Programming Gryphon stepper motor.
The title of the editing window is Gryphon or Gryphon [n],
in this case, where n is a number given in sequence to
the Gryphon robots that are declared for the cell.
The on-line state is true if the software detects that the
robot is connected correctly to host computer through
the RJ45 serial form of interface. The connection is
checked continuously but the state may be switched,
using the Run menu selection.
Gryphon is a conventional robot, emulating the
movement of the human arm and hand, and having axes
for rotation about the effective waist and axes for rotation
about the shoulder, elbow and wrist in the forward plane.
A program consists of a tabular statement of numerical
entries for the movement of each axis of the robot,
headed in columns by Axis 0 to Axis 4 and the Gripper,
Axis 5. Since the wrist has two effective axes, for
rotation and elevation, there are two columns with these
headings, and they may be used as alternatives to co-
ordinate the entries in Axis 3 and Axis 4, the motor axes
which drive the differential gear drive train at the wrist.
The equivalent labelled push buttons on the Teach
Pendant have effective, but indirect, entry to these two
columns in the Pendant mode of programming.
The gripper entry is either 0 or 1, indicating open or
closed for the Pneumatic actuated gripper. A further
column has been introduced allowing the speed of
movement of the robot axis to be set, using numbers in
the range 0 to 3, with 0 indicating the lowest speed. The
speed may be separately selected for each line of
program, if so desired, and it is effective for all the axes
on the line .
When the Walli application is first entered, a New
program is requested, or when the Gryphon is first
declared as a Device in the Cell Definition Window, the
window is empty of program except for an initial line of
code containing "seed" values for each axis.
When the robot is off-line, these are nominally in the
mid-range of encoder position values for each axis. The
range of values for each axis is determined by the
resolution and gearing of the encoders used in the
position feedback paths on Gryphon (12000 steps per
revolution for axes 0,1 and 2 ; 2000 for axes 3 and 4)
and on the range of permitted movement on each axis
( 270, 170 and 300 degrees, respectively for axes 0,1
and 2 ; 170 and 290 degrees, respectively for wrist pitch
and roll). If the robot is on-line, they will be the current
feedback data values from each axis and the graphics
windows will show movement to adopt these values for
the robots initial position.
At the bottom of the tabulation in the edit window a
separate line labelled Now, indicates the data values
from the encoders, for the current cursor line, at all
times, if the system is on-line. If the power to the motors
is turned off, these values represent the position of the
robot axes which may be used in lead-by-nose
programming, moving the axes by hand. With power on,
any changes to the axes values will be shown as
changing values, following the robot as it moves. If the
system is switched off-line, the values in this bottom row
will be those of the current cursor line, i.e. the demands
to the robot axes through the servo gates to each
WALLI for WINDOWS. Revision A
The program is developed by adding lines of code, using
the Insert command, which copies the values for each
axis on the current cursor line to the line below and then
moves the cursor down to the new line. This strategy for
the command is important in avoiding any unwanted and
hazardous movements of the robot, particularly when
programming on-line.
The On-Line state for the Keyboard Control mode of
program entry, is the default condition in which data
entered or edited in any of the rows and columns from
the keyboard, results in movement of the robot axis that
heads the column, and the graphics will follow the
movement as it occurs. The cursor keys are used in the
normal way to move between row and column positions.
The values entered are notional four digit numbers, in
the range 0 to 9950 ( maximum for axis 2), but they may
be truncated by using the return key, tab key or one of
the cursor keys. The numbers represent the range of
movement between end stops, but the scaling between
numbers and degrees of rotation are not necessarily the
same for each axis. The editor will correct attempts to
enter values out of the range for each axis, as indicated
for the axis that currently has the cursor and is being
edited, by numbers at the top and bottom of the vertical
scroll at the right of the program matrix, or tabulation.
The slider and arrows on this vertical scroll bar may also
be used to change the axis value at the current cursor
position using the mouse pointer as an alternative to the
keyboard. Keyboard entry is restored by selecting any of
the table positions with the mouse.
The following editing commands and modes of
programming may be selected from the Windows menu
bar, using the Edit and Teachmode menus. The short
cut keys for the edit commands are indicated against
each item of the menu. The lists repeat those that have
been given and discussed in detail under the appropriate
headings previously, but here they are specific to what
obtains for the Gryphon robot.
Editing Commands
Insert ~ Inserting code into the window
Delete ~ Deleting a line of code
Clear ~ Clearing the window of code
Auto Line Number ~ Assign consecutive line
numbers (default)
Modes of Robot Programming
Keyboard ~ Direct entry of Axis data
from Keyboard
Lead By Nose ~ Axis data taken from Robot,
power off
Simulator(Actual) ~ Axis data taken from
simulator positions
Simulator(Combined) ~ Ditto
Teledictor(Actual) ~ Ditto
Teledictor(Combined) ~ Ditto
Pendant ~ Axis data taken by moving the robot
under push button control
Cartesian ~ XYZ Co-ordinate data entered from
Keyboard to extract the Inverse
USE of WALLI page 28
 Kinematic solution for the required
axes data
Note: The Simulator mode provides point-to-point
control and the Teledictor mode provides continuous
control, both using the Simulator device.
The technique of programming is always best illustrated
by example and for this purpose a number of programs
for Gryphon have been included in the directory of
demonstration files on the distribution disc, DEMODIR
which will have been transferred to a WALLI3 sub-
directory in the software installation process.
The Gryphon programs are distinguished by a file
extension [ .gry ], which is the system imposed extension
for programs saved from the Gryphon edit window. The
project programs, i.e. those that define a workcell and
which all have the file extension [ .wal ], that have been
written specifically as examples for Gryphon are
identified by the initial letter incorporated into the DEMO
name with a number, as in DEMO_G1.wal.
The illustration is taken from the Gryphon program,
DEMO_G1, and is at the point of naming the third
section of the Robot program as “Accepted”, a reference
in the last line of the Main workcell program. The
program is attempting a similar exercise as that which is
used to illustrate Mentor programming and is repeated
for the Neptune to illustrate by direct comparison, the
differences between the use of these three conventional
robots.
Clip 46 : Naming a block of Gryphon code.
The program has been written with the robot in the Not-
Connected state and with Auto-line numbers permitted
initially. This accounts for the number 3 that is high-
lighted with the intention of editing in the robot program,
and the number 1 as the first line label in the Main
workcell program. At this point the Auto-line numbering
option has been turned off, to continue writing the cell
program, which does however use the numeric label in
the GOTO statement.
The line numbers for the robot program have then been
blanked out, except for the start line of each robot
manoeuvre, all three of which start from the same robot
position, with the gripper poised high above the surface
of the conveyor.
WALLI for WINDOWS. Revision A
The numeric labels for these manoeuvres have then
been changed to names which are meaningful, to pickup
a part from the conveyor after it has been measured in
the width gauge, and then either dropping it into a bin for
the accepted parts or a bin for rejected parts, according
to size. Number 3 is the last of the numeric labels to be
retained and it will become synonymous with Accepted
within the software.
The fact that the three robot manoeuvres all start from
the same position, allows the complete program to be
obeyed as a sequence when the robot edit window has
the screen focus, without wild excursions of the arm from
the end of one block to the beginning of the next.
Demonstration programs, Xxxx.gry ~ DEMO_G[n].wal
are on file and more detailed descriptions are given
under the heading Demonstration Programs, at the end
of the Use of Walli section of the Walli for Windows
Manual.
Programming Neptune
The two Neptune robots differ in that Neptune II has a
control system using 12 bit ADC’s in the feedback loops,
as compared to 8 bit ADC’s used for Neptune I.
Neptune II also has an additional axis at the wrist, for
yaw. These differences are apparent in the edit window
which is presented for either robot, when it is first
declared as a component device for the workcell from
the Cell menu, and has then been allocated an address
on the parallel Turbo interface to the host computer.
The motive power for Neptune is water hydraulics in the
form of linear actuators which have been used for all
axes movement. It is not possible to have a mechanical
arrangement for the wrist, therefore, which allows the
intersection of the axes for pitch, yaw and roll to be co-
incident with the fore arm link axis, as it is for the other
two conventional robots, Mentor and Gryphon. The pitch
axis does pass through the fore arm link axis, as a
horizontal right angled intersection, but is displaced from
the link axis. Both the yaw axis, in the case of Neptune
II, and the roll axis are necessarily offset from the pitch
axis also, along the extension of the fore arm link axis for
yaw, and both along and above the link axis for roll.
These offsets are important in programming Neptune, in
particular for the resulting Cartesian co-ordinates of the
gripper when manoeuvring workpieces within a work cell.
As compared to both Mentor and Gryphon, it is not
possible to program the separate wrist axes for an
effective pitch and roll, either.
Gripper action for Neptune is shown in the graphics and
the XYZ co-ordinate window as either open or closed,
even though the control values are given in the same
range as for the other axes movements. Values above
30 are considered as closed or shut for Neptune I, above
480 for Neptune II. A feedback potentiometer for the
movement of the gripper may be fitted, if specified
however, and in this configuration the gripper action is
proportionally controlled. The feedback data may be
used to derive a measurement to gauge the workpiece.
When Neptune is first declared or when a New program
is requested for the existing workcell, the edit window is
USE of WALLI page 29
empty of code except for a initial line of seed values for
each axis. If the system is off-line, these will be the mid
range values for the bit size of the ADC’s used, 128 for
Neptune I and 2048 for Neptune II. If the system is on-
line, they will be the position feed back values of each
axis of the robot. The program is developed by adding
lines of code, using the Insert command to copy the
current line to the line below ready for editing axis by
axis, so avoiding any hazardous movements when the
robot is on-line.
The program may be written either on or off-line, in the
latter case only the principal and default mode of
programming through the keyboard obtains. On-line, the
simulator may be used to enter program either in the
point-to-point mode or in the continuously recorded
Teledictor mode.
The following editing commands and modes of
programming may be selected from the Windows menu
bar, using the Edit and Teachmode menus. The short
cut keys for the edit commands are given against each
item in the menu. The lists repeat those that have been
given and discussed in detail under the appropriate
headings previously, but here they are specific to what
obtains for the Neptune robot.
Editing Commands
Insert ~ Inserting code into the window
Delete ~ Deleting a line of code
Clear ~ Clearing the window of code
Auto Line Number ~ Assign consecutive line
numbers (default)
Modes of Robot Programming
Keyboard ~ Direct entry of Axis data from Keyboard
Simulator ~ Axis data taken from simulator
positions
Teledictor ~ Ditto
Lead By Nose control may be fitted to Neptune II as an
option to provide a further mode of programming. With
this the robot may be moved into position by pressing
touch sensors which are attached to the robot arm, at
the extremity of each link.
Note: The Simulator mode provides point-to-point
control and the Teledictor mode provides continuous
control, both using the Simulator device.
The writing of a program is best illustrated by example
and the illustration here is taken from the Neptune
program, DEMO_N1, where the robot is obeying tasks
similar to the Mentor robot in DEMO_M1. This is to
allow direct comparison of the similarities and differences
between programming the robots.
WALLI for WINDOWS. Revision A
Clip 47 : Naming a block of Neptune code.
The illustration shows the program preparation at the
point of naming the third section of the Robot program
as “Accepted”, a reference in the last line of the Main
workcell program, the Cell Definition having been stated
previously.
The program has been written with the robot in the Not-
Connected state and with Auto-line numbers permitted
initially. This accounts for the number 3 that is high-
lighted with the intention of editing in the robot program,
and the number 1 as the first line label in the Main
workcell program. At this point the Auto-line numbering
option has been turned off, to continue writing the cell
program, which does however use the numeric label in
the GOTO statement.
The line numbers for the robot program have then been
blanked out, except for the start line of each robot
manoeuvre, all three of which start from the same robot
position, with the gripper poised high above the surface
of the conveyor.
The numeric labels for these manoeuvres have then
been changed to names which are meaningful, to pickup
a part from the conveyor after it has been measured in
the width gauge, and the either dropping it into a bin for
the accepted parts or a bin for rejected parts, according
to size. Number 3 is the last of the numeric labels to be
retained and it will become synonymous with Accepted
within the software.
The fact that the three robot manoeuvres all start from
the same position, allows the complete program to be
obeyed as a sequence when the robot edit window has
the screen focus, without wild excursions of the arm from
the end of one block to the beginning of the next.
Demonstration programs, Xxxx.nep ~ DEMO_N[n].wal
are on file and more detailed descriptions are given
under the heading Demonstration Programs, at the end
of the Use of Walli section of the Walli for Windows
Manual.
USE of WALLI page 30
 PROGRAMMING SCARA ROBOTS
The two SCARA robots, Serpent I and Serpent II, are
compliant in their horizontal plane of operation about the
three principal vertical revolute axes. Compliance is
introduced through the backlash specification for the
gearboxes driving each axis. The two versions differ
only in the length of the two moving arm components,
the links between the three revolute axes, otherwise they
are the same in operation and require the same
programming technique. The cylinder of influence for
Serpent II is greater by virtue of the increased arm
length, allowing greater reach within the workcell, but
with reduced spatial resolution. The corollary to this, is
that for the same X and Y co-ordinates from the axis of
the vertical mounting column, different axis positions will
in general be required, one version to the other.
As with the conventional robots, the program is written in
terms of the rotation of the robot axes, three in the
SCARA form. The vertical movement of the prismatic
axis carrying the gripper, which is co-incident with the
wrist revolute axis, is either up or down, although the
range of movement may be set using the mechanical
stops.
Similarly, the height of the complete arm on the vertical
column may be adjusted to suit the geometry of the
workcell, as may also the rotation or orientation about
the axis of the column. The adjustment may be made by
releasing the clamps holding the main axis block to the
column. If such adjustments are made, they should be
documented with the program, since the program
reference is to the factory set positions.
Wrist axis movement is co-ordinated, that is the spatial
alignment of its cylinder of rotation is maintained
irrespective of the rotations of the main and fore axes, at
the equivalent shoulder and elbow positions,
respectively. This is achieved through toothed belt
drives over an odd number of pulleys from the wrist axis
motor, mounted in the main axis block which is clamped
to the vertical column. Co-ordination of the wrist axis
has greater significance when either of the two finger
grippers are fitted, rather than the suction gripper. When
the finger grippers are used, allowance must be made
for the extent of finger movement when placing or
picking up a workpiece. With either finger or suction
type gripper, co-ordination allows the workpiece to be
presented in the same orientation at the point of delivery
as it had at the pick up point.
A program consists of a series of data entries into
column position in lines of a tabulation which is
presented in the robot’s own edit window, whenever it is
declared as part of the workcell complement. The
entries represent the positions through which the robot
will move in each of its axes, in the sequence obeyed
line by line of the tabulation. This is either for the whole
program or in parts, normally referred to as robot
subroutines, under control of the Main workcell program.
The columns for data entries are for the three revolute
axes, the Z translation of the prismatic axis at the wrist
and for the gripper closure, both of the latter being on or
off statements, entered by 1 or 0 respectively, for
up/down and closed/open. Vertical movement of the
prismatic axis at the wrist is factory set to 100mm. For
WALLI for WINDOWS. Revision A
the new EC version of Serpent, there is a sixth column
for speed of rotation about the axes under program
control, in the range 0 to 3, which may be made only by
keyboard entry. The speed selected controls all axes in
the program line with the one statement, from slow at 0
to fast at 3, with two intermediate speed values, all of
which are relative and not strictly determinate.
The program may be created on-line or off and
connected or otherwise, and by the same variety of
methods available for the conventional robots, with
keyboard entry being the principal and default mode of
programming. The alternative modes may be selected
from the Teachmode menu.
Lead-by-nose control disables the normal drive to the
revolute axes, and enables the push button switches
which are suitably positioned at the outer end of the two
arm links, so that finger pressure on the switch has the
effect of power-steering the inboard axis in the required
direction.
Both Pendant control and Simulator control are provided
for program data entry and in the case of the simulator,
the Teledictor variation for continuously recorded
movement is also provided. Speed control for the
Pendant mode of entry is provided in the form of a
single button which slows all axes rotation for inching into
position, when held down. This is not the same speed
control as may be set from the keyboard, for the speed
of axes response during the running of the program.
Such speed statements may be edited subsequently into
a program originally created under all three alternative
point-to-point modes of programming.
The compliance on the three revolute axes is not simply
a result of the backlash in the gearboxes, but this
provides the space for a controlled freedom of
movement. The net result is that the Serpent EC version
in particular, has a positional accuracy on a par with the
other robots that have a digital control system. The
graphics and the statement of the spatial co-ordinate
position of the end of the gripper, which accompany the
Serpent edit window on screen, may be considered as
statements derived with the same degree of precision. It
should be re-emphasised that they are also statements
made with respect to the factory set positions of the
main axis block on the vertical column, and for the range
of movement of the prismatic wrist axis, Z, in the
specification.
Programming Serpent
When the Serpent is first declared from the Cell menu as
a device in the Cell Definition window and connected to
the host using the appropriate interface, RJ45 for the EC
version, the edit window that is placed on top of the top
left hand stack is initially empty of program except for
seed values for each axis on the first line. If the robot is
off-line or not connected, the seed values are those to
align the arm with the X spatial axis, as may be seen in
the graphics of the robot plan, with the gripper raised
and open. If the robot is on-line, these are either the
current position if it is a previous version of Serpent
connected through the parallel Turbo interface, or it will
be the position adopted after the zeroing manoeuvre for
USE of WALLI page 31
the new EC version, which must be connected through
the RJ45 serial interface.
The control system for Serpent has been upgraded in
the EC version to use encoder feedback in place of
potentiometer feedback through ADC’s. The new largely
digital control system requires the zero count positions
for the incremental encoders on each axis to be
established when power is applied and before control
can be assumed. This is done by driving the axis to its
end stop, backing off slightly to set the zero position and
then manoeuvring the arm to a safe position for
subsequent movement. The user has a choice of which
end stops to use for the two inner revolute axes,
clockwise or anti-clockwise, so that the zeroing can take
place without collisions with other cell components. The
on-line state is then judged to be true if the software
detects that the robot is connected correctly to the host
processor through the required RJ45 serial interface.
The on-line state is checked continuously thereafter, but
it may be switched using the Run menu selection, as for
the previous analogue control system.
The number range that may be used in the program for
each revolute axis is different for the analog and digital
control systems, being determined by the bit value range
from the ADC’s and the encoder resolution and gearing,
respectively, each representing the same angular
movement for the axis.
The number range is disposed symmetrically about the Y
spatial axis alignment for the main and wrist axis, giving
a total of 450° rotation at the wrist. The fore arm axis is
not disposed symmetrically, allowing a greater inner
reach on the one side, in the counter clockwise sense,
and this is apparent in the mechanical design of the arm
at the elbow joint. Both the aligned values and the
maximum values may be observed from, respectively,
the seed values for each axis when off-line and the value
heading the scroll bar to the right of the tabulation, when
each column is given the edit focus using the cursor
keys.
At the bottom of the edit window, the separate line
labelled Now and highlighted with a different background
colour, indicates the data values from the encoders or
ADC’s for the current cursor line, at all times if the robot
is on-line. The graphics windows will show animated
movement to reflect these values as changes occur. In
the lead-by-nose programming mode, these values are
the positions of the axes that will be entered as the
program values on the current line, when the downward
cursor key is pressed. If the robot is off-line, the Now
values repeat the values of the current cursor line and
are therefore the demands to the control system, rather
than the feedback values.
The program is developed by adding lines of code using
the Insert command to copy the values from the current
line to a line inserted below and move the cursor down
ready for editing axis by axis, a process which avoids
unwanted and hazardous movement of the robot,
particularly when on-line.
On-line and under keyboard control is the default
programming or teach mode from which the data
entered or edited in any of the rows or columns results in
movement of the column axis once the entry is
completed by the return, cursor or tab key. The cursor
WALLI for WINDOWS. Revision A
keys are used in the normal way to move between line or
row and column or axis positions in the tabulation.
The edit commands and modes of programming may be
selected from the Windows menu bar and are the same
as for the conventional robots and repeated here to be
specific to what obtains to the Serpent robot. The short-
cut keys for the edit commands are indicated for each
item in the menu and these may be found to be more
convenient to use, once learnt.
Editing Commands
Insert ~ Inserting code into the window
Delete ~ Deleting a line of code
Clear ~ Clearing the window of code
Auto Line Number ~ Assign consecutive line
numbers (default)
Modes of Robot Programming
Keyboard ~ Direct entry of Axis data from
Keyboard
Lead By Nose~ Axis data taken from Robot,
power off
Simulator ~ Axis data taken from
simulator positions
Teledictor ~ Ditto
Pendant ~ Axis data taken by moving the robot
under push button control,
EC version only
Cartesian ~ XYZ Co-ordinate data entered from
Keyboard to extract the Inverse
Kinematic solution for the required
axes data
Note: The Simulator mode provides point-to-point
control and the Teledictor mode provides continuous
control, both using the Simulator device.
Clip 48 : Sample program for Serpent.
The technique of programming is best illustrated by
example and here the illustration is taken from the
Serpent project, DEMO_W2, which uses the Serpent
robot to pick up workpieces from a conveyor, load them
onto a Mill table and unload them when the drilling
program has been completed. It is an exercise similar to
that which has been used for illustrating the
programming of conventional robots, but here the arm is
moving in a horizontal plane and it has been put into the
USE of WALLI page 32
context of a more extensive workcell project by involving
the Mill.
The program has been prepared in the not-connected
state and is at the point where the first section of
Serpent code is being named Rejected, a manoeuvre
called as a robot subroutine to separate the parts that
have been gauged outside the size specified.
The arrangement of Conveyor, Mill and Serpent in the
workcell, which determines the movements required for
the Serpent, is as illustrated for Table W2 in the Walli for
Windows brochure. The position for zeroing the control
system encoder counters has been chosen with the main
axis fully clockwise and the fore axis fully counter
clockwise.
PROGRAMMING RECTILINEAR ROBOTS
Rectilinear robots are the simplest form to program since
by definition, they move in the co-ordinate system which
is normally used to express the dimensions of the
workcell. For Kestrel, the program statements are in
absolute metric units of measurement from the zero
point, in the front left hand corner of the frame which
corresponds to the bottom left hand corner of the robot
plan view presented in conjunction with the robot edit
window.
The zero point in X and Y is within the dimensions of the
frame since of necessity the frame and axes slides have
structural width, and it is offset at 200 and 140mm in X
and Y, respectively, from the outside corner.
The zero for the Z co-ordinate is taken in the normal
sense close to table height but the initial zero point for
the Z axis at its highest position of 150mm, clear of most
other cell components. Movement to position is usually
with the gripper at its highest point at a Z axis value of
150mm and the placement or effective movement in the
Z axis is done by reducing the value of the co-ordinate
onto the workpiece. This is the safest way to avoid
collisions and as a result any program move that has all
three axes changing is obeyed in two parts with the Z
movement last if the gripper is being lowered or first if it
is being raised.
When extended legs are fitted, the zero for the Z co-
ordinate is some 90mm above table height.
As with the conventional robots, the program is written
as a tabular statement, in this case for the X, Y and Z
positions, but also including columns for the wrist
revolute axis, giving two full rotations or 720° in absolute
units, for the gripper action and for the required speed of
axis movement. The latter is expressed as a relative
number in the range 0 to 3, as for the other robots with a
similar digital control system.
The tabular statement for the program is presented in
the Robots own edit window, whenever it is declared as
part of the workcell complement. The entries that are
made represent the positions through which the robot will
move in each of its axes in a sequence obeyed line by
line, for the whole program, or in parts usually referred to
as robot subroutines, and under control of the Main
workcell program. The program may be created on or
WALLI for WINDOWS. Revision A
off-line and in either the default keyboard mode of
control, or under Pendant control. Pendant control in
this case describes the functionality normally associated
with a pendant device, but in the case of Kestrel, the
pendant control panel is mounted on the robot frame.
Kestrel’s digital control system with encoder feedback,
allows placement to a precision of 0.01mm in the X and
Y co-ordinates, with a repeatability of 0.1mm.
Programming Kestrel
When Kestrel is first declared as a device from the Cell
menu, and then connected to an RJ45 serial interface,
the edit window that is placed on top of the top right
hand stack is initially empty of program code except for
an initial line of seed values. These seed values are of
the initialised position, the position where the count
values for the encoder feed back positions have been
established, and are the same statement whether on or
off-line. Earlier versions of Kestrel for a parallel interface
are not supported by Walli3.
The program is developed by adding lines of code using
the Insert command to copy the values from the current
cursor line into a new line below, ready for editing axis by
axis, so avoiding hazardous movements in the process.
Keyboard mode of entry is the default programming
mode but the pendant form of point-to-point control has
a particular application when fine tuning the program for
precision placements.
The edit commands and modes of programming that
may be selected for Kestrel from the Windows menu bar
are as follows. The short-cut keys for the edit
commands are included with each menu item and are
more convenient once learnt.
Editing Commands
Insert ~ Inserting code into the window
Delete ~ Deleting a line of code
Clear ~ Clearing the window of code
Auto Line Number ~ Assign consecutive line
numbers (default)
Modes of Robot Programming
Keyboard ~ Direct entry of Axis data from
Keyboard
Pendant ~ Axis data taken by moving the robot
under push button control
Programming is best illustrated by example and here the
illustration is taken from the Kestrel project, DEMO_W3,
which uses the Kestrel robot to pick up workpieces from
a conveyor, load them onto a Mill table and unload them
when the drilling program has been completed and
replacing them onto the conveyor from where they fall
into a bin. The project bares comparison with the
exercise used to illustrate programming for the Serpent
SCARA robot. The essential differences are only in the
choice of robot and the spatial arrangement of the Cell
components.
The program has been prepared off-line and not-
USE of WALLI page 33
connected to the robot and is at the point where the third
section of Kestrel code is being named Unload_m.
The arrangement of Conveyor, Mill and Kestrel in the
workcell, is as illustrated for Table W3 in the Walli for
Windows brochure, taking only the top right hand part of
the workcell assembly shown. When using Kestrel in a
cell, the emphasis is more on the closeness with which
components may be grouped to be within the work
envelope inside the frame, rather than the positioning of
the components which determine the robot movements.
The Kestrel is shown on extended legs, with the front
right leg standing in the base tray of the Mill and there is
then sufficient room to place the conveyor inside the left
hand edge of the frame, running from rear to front, in this
case.
The Table W3 illustration also shows another conveyor
at right angles, on which the gauges are mounted, and
the Kestrel has the added task of transferring parts from
one conveyor to the other. The gauges would present
hazards to working within the Kestrels envelope, so if
only one conveyor is to be used, it would best be of
sufficient length to accommodate the gauges outside the
frame.
Clip 49 : Sample program for Kestrel.
WALLI for WINDOWS. Revision A
PROGRAMMING CNC DEVICES
General Information to Support Programming
Both CNC devices, the Cyber Mill and the Cyber Lathe,
are powered by variable reluctance stepper motors
coupled through worm and nut drives to each of the
principal axes, three in the case of the mill for X,Y and Z,
where Z is the depth cut, and two for the lathe bed
traverse in X and Z. Permanent-magnet DC motors
provide the cutting power in both cases and small DC
motors are used to drive the vice jaws on the Mill and the
chuck and tool changer on the Lathe.
The stepper motor resolution and the pitch of the worm
drive combine to give a mechanical resolution of
0.0075mm in half step mode of operation, allowing very
smooth contours to be cut. The variable reluctance
motors also allow high slewing speeds to be achieved
between control points in the machining program.
The two devices have essentially similar control systems,
employing the same processor cum interface control
board, in communication via a serial RJ45 interface
board in the host computer. The serial link is such that
up to eight devices may be daisy-chained to the one
RJ45 board, providing the end connection is correctly
terminated, and an Expander Box for the RJ45 link, may
be used to expand the logic and analog signal facilities
for the workcell beyond those provided by the Mill and
Lathe.
The requirement to use the RJ45 serial interface board is
built into the Walli3 software, and each addition to the
chain will be allocated a sequential number by default, as
seen in the Device Address Selection dialogue box which
is displayed when a device is declared for the Workcell.
Earlier versions of the Mill, which used the parallel
interface and a different control system, are not
supported by the Walli3 software.
Both devices also use the same power supply and DC
motor drive board and individual control boards for each
of the stepper motors. Load current regulation control is
provided for the stepper motors to ensure a good
speed~torque characteristic. The DC cutter motors are
switch mode regulated, using sampled measurement of
back EMF to provide a wide range speed control system,
in which the speed is set by the voltage output from a
DAC on the processor control board.
Manual control for movement along the principal axes
and for the speed of the cutter motor, is provided from a
group of push button switches mounted on the
electronics cabinet which forms the rear of the safety
enclosure. Two buttons are provided for each axis, and
there main purpose is for inching or jogging the cutter
into position and setting offsets from the “home” position,
as determined by the control system from the limit micro-
switches on each axis. The functionality of the manual
push buttons is replicated and enhanced by the Walli3
software, in a dialogue box accessed from the Control
Panel selection in the Options menu.
USE of WALLI page 34

Clip 50 : On-screen control panel for Cyber Mill.
A high-current power switch is also provided for instantly
stopping the cutter motor, and may be considered as the
emergency switch.
It has a secondary use in that its state is connected back
into the processor control board to enable un-interrupted
running of the control program, signalling to the
processor to continue after a programmed stop for a tool
change, say, when for safety reasons it would be
advisable to switch off the power supply to the motor.
Cutting Tools
The laminated plastics samples for engraving that are
supplied with the Mill are made from a very suitable
material for cutting at these low power capabilities, and a
brand new ball-nosed cutter will cut into it very cleanly.
A standard quality cutter will lose it’s edge very quickly,
however, resulting in ragged edges to the cuts. Although
initially more expensive, the use of carbide cutters is
strongly recommended if any quantity of work is to be
undertaken.
The machineable Acetal plastics samples supplied with
the Lathe is best cut with carbide cutters also, in this
case the inserts for the tool holder.
Workcell Interface
As with all other devices in the Walli range, both the
Cyber Mill and Lathe are equipped with an interface to
the workcell, providing eight latched digital outputs and
eight digital inputs, all at TTL level and with a 20mA drive
capability on the output.
The interface takes the usual form of colour coded
sockets in two columns below the bank of manual push
button switches, using the convention of blue for input,
yellow for output, with Digital ground, black and +5V, red.
An analog interface is not provided, however.
PROGRAMMING THE CYBER MILL
WALLI for WINDOWS. Revision A
The tabulation used in the CNC program editor follows
examples from the literature, with column headings as
the Address Characters defined in the BS 3635
Specification. Minor variations from the definition include
the use of T for tool size and the use of D for dwell time.
All variants of the convention used for circular
interpolation assume that the last programmed move
brought the cutting tool to the start point for the arc.
The convention used here assumes that a clock-wise
path is obeyed by a G02 code and the end point for the
arc may be defined either relative to the start point in
incremental terms for X and Y or in absolute terms from
the X, Y datum, but the centre of the arc is always in
incremental terms I and J. The alternative of the datum
point in X, Y for I and J. is not used, and as a
consequence, I and J are always positive in a strict
observance of the convention. The Walli3 editor for CNC
programs, however, does not reject the use of negative
numbers for I and J, since they are a help when reading
the code, nor does it require the irrational change to
using diameters when in the absolute mode, i.e. double
the X ordinate.
Before writing a program, the examples on the
distribution disc should be examined and perhaps run to
give a degree of confidence and understanding of the
ISO programming conventions.
Edit Screen
The edit screen for the Cyber Mill is presented on top of
the stack of device and cell definition windows, when the
mill is first declared as part of the cell from the cell menu
or whenever selected thereafter, from the windows menu
devices option. It is initially empty of code except for a
start line with default values for F, S and T.
Clip 51 : Initial edit screen for Cyber Mill.
The meaning of the column heading Address Characters
are as follows :-
N Line number
G Preparatory function, generally relating to the
cutter
X,Y,Z Co-ordinates of the next position to move to
I,J Incremental co-ordinates of the centre of a
circular arc
F Feed rate for the move
USE of WALLI page 35
 S Spindle speed
T Tool diameter
D Dwell time in seconds
M Miscellaneous functions
Rem Remarks field
All dimensions may be specified in millimetres or inches
using the G70 and G71 codes, respectively.
Entries may be made into any of the column positions
and edited by over-typing as appropriate, using the
keyboard cursor and tab keys to move between fields
and the Ctrl+I, Ctrl+D combinations to insert and delete
lines or rows, respectively.
Auto-line numbers are imposed and the choice greyed-
out as an option in the Edit menu. Line numbers are
given in single increments.
Programs previously written in the G&M code format
may be loaded into the edit window from the Load
selection in the File menu. Programs in other formats
may also be loaded using the Import selection from the
File menu,
Clip 52 : Expanded list of file types to import to the Mill.
The Import file types as shown in Clip 52 include HPGL,
NC Drill, Gerber and ASCII, making the distinction in the
latter case between programs in G&M code written in the
edit window and those written with a conventional text
editor, when the address character must be stated for
every entry.
Clip 53 : Dialogue for NC Drill post-processor.
In the example shown in Clip 52, when the NC Drill file,
gauge.ht0 is selected for loading, the dialogue for the NC
Drill Post-processor will be displayed as in Clip 53, listing
the drill sizes to be used for the various depth of cut and
feed rates. The dimensions of the blank may be set and
also the load point. The five check boxes are for
alternatives in the mode of operation.
WALLI for WINDOWS. Revision A
When the setting have been accepted using the OK
button, the post-processing stage is entered with a
horizontal bar display to indicate progress, and at the
end the save file dialogue box is presented.
Clip 54 : Save dialogue for post-processed Cyber Mill
file.
Once the file has been saved as required, the processed
file is revealed, written in G and M codes in the Mill edit
window, ready for program execution either to cut
material or to check beforehand, by simulation off-line in
the Mill graphics window.
Clip 55 : Drill file post-processed code for Mill.
ISO Format Programming the Mill
Many good books have been written on CNC
programming and this section of the manual should be
read in conjunction with one of them, particularly one
that is based on the use of the ISO G and M Codes.
From the large range of standard preparatory and
miscellaneous function codes (G and M Codes), the
ones that are accepted within Walli3 form a sub-set that
demonstrate the basics of CNC machining on a mill
which is capable of doing useful work, either as a stand
alone device, or as part of an integrated multi-robot and
CNC workcell. Four other non-standard but permissible
G codes, are also included in the sub-set.
The cutting program is written on the host computer in
ISO format, using a separate edit window for each of the
CNC devices declared in the Cell Definitions Window.
The CNC editor accepts the most widely used G and M
codes that are relevant to the machines operation, in a
conventional tabular statement. After saving to file, this
tabular text statement is then compiled as a CNC
program suitable for transmission to the control
processor in the Mill device, where it is run under
supervisory control from the Workcell program.
ISO PREPARATORY AND MISCELLANEOUS
CODES SUPPORTED FOR THE MILL
Standard G Codes
USE of WALLI page 36
G00 Rapid Positioning Point-to-Point
This is used when moving the cutter between
the end of one cut and the start of the next. It
should never be used when the cutter is in
contact with the work-piece.
G01 Linear Interpolation
This takes the cutter along a straight line from
the last programmed position to the position
defined by this coded line. Interpolation is
confined to the X-Y plane, and if Z is defined,
the Z movement will precede the interpolation
between end points.
G02 Circular Interpolation Arc, Clockwise
This takes the cutter in a circular arc of up to
90º in a clockwise direction from the last
programmed position to the position defined by
this coded line. The centre of the arc is defined
by the I and J incremental parameters for the X
and Y co-ordinates, respectively.
G03 Circular Interpolation Arc, Counter-Clockwise
This takes the cutter in a circular arc of up to
90º in a counter-clockwise direction from the
last programmed position to the position
defined by this coded line. The centre of the arc
is defined by the I and J incremental
parameters for the X and Y co-ordinates,
respectively.
G04 Dwell
This defines a wait period, the value of which is
set in the D or Dwell field, in seconds.
G05 End Subroutine
Used to mark the end of a section of code
intended to be obeyed as a subroutine and
declared by the corresponding Subroutine Start
code, G28. When the G05 code is obeyed, the
program sequence is returned to the line
following the call to the subroutine.
G06 End Loop
Marks the end of a Loop Cycle sequence.
G28 Subroutine Start
The code which is entered as the first line of a
block intended as a subroutine to the main G
and M code program. The code is
accompanied by a statement in the X field,
which is the subroutines numerical label or
name.
G36 Face Milling Cycle
This is a non-standardised fixed cycle for
skimming the face of a blank. X and Y define
the area to be skimmed and the cut proceeds in
the positive directions from the start point.
Since the tool has a defined diameter, the start
WALLI for WINDOWS. Revision A
point for the cycle, as defined by the previous
move, must accommodate the half diameter
with an inscribed position at the top left-hand
corner of the area defined.
G65 Call Subroutine
The code used to call a subroutine from the
main part of a G and M code program. The
code is accompanied by a statement in the X
field, which is the numerical label or name of
the subroutine, as declared with the Subroutine
Start code.
G70 Imperial
Sets the imperial inch as the unit for all
subsequent dimension entries.
G71 Metric
Sets the milli-metre as the unit for all
subsequent dimension entries.
G73 Loop Cycle
Marks the beginning of a sequence of
commands that will be repeated the number of
times entered as an integer in the X column.
When obeyed in the incremental mode, loops
typically allow a cutting sequence to be
repeated at equal intervals along the X and Y
axes.
G81 Drilling Cycle
This is the standardised fixed cycle for drilling
holes.
G82 Drilling Cycle with Dwell
This adds a wait period to the drilling cycle to
improve the finish at the bottom of the cut.
G83 Peck Cycle with Dwell
An intermittent feed cycle with both a wait
period to improve the finish at the bottom of the
cut, and to avoid the drill flute becoming
clogged, the drilling is interrupted after the
penetration defined in the I parameter field,
defaulting to 3mm, and lifted clear of the hole.
The start position for the drilling operation is
determined by the previous moves.
G90 Absolute programming
After specifying absolute programming each
subsequent X,Y and Z dimension entered is
interpreted as the co-ordinate from the zero
datum. The default position for the zero datum
is the Home position established by the control
systems use of the limit switches on each axis,
which is with the cutter fully retracted from the
work piece and with the table fully forward and
fully to the right. The cutter is then over, and its
cutting axis passes through, the rear left corner
of the vice.
The zero datum may be altered by applying
USE of WALLI page 37
 offsets, using the manual controls or their
equivalents in the CNC Mill Jog dialogue box,
accessed from the Options menu, or by
program using the G92 code.
G91 Incremental programming
After specifying incremental programming, each
subsequent X,Y and Z dimension entered is
interpreted as the distance from the last
programmed position to the one currently
defined in the coded line. As a consequence,
the dimensions may be either positive or
negative.
Note: Both G90 and G91 are single entries on a line.
G92 Shift Zero Datum
This allows a program statement in the X,Y and
Z fields of an offset from the machine datum, or
home position, to some other zero datum which
will thereafter be the zero reference for the
X,Y,Z program co-ordinates.
Note: The home position is returned to automatically, at
the start of the program execution.
Non-Standard G Codes
G38 Pause for Input
This allows the Mill to act autonomously on
logic inputs, rather than through the Workcell
control. The X and Y fields are used for logic
inputs going low and going high, respectively,
the entry being the numbered input in the range
1 to 8.
G39 Set output
This allows the Mill to autonomously drive logic
outputs. The X and Y fields are again used, as
for inputs.
G98 Configure Engrave ( used with Engrave Text
code, G99 )
The two codes are used as a pair, usually in
numerical order although this need not be the
case, and they may be split, such as within a
loop cycle to engrave at different places.
The text is centred at the current position and
may be orientated in the four 90° positions by
specifying a number 1 to 4 in the X field of the
G98 code statement. Each orientation may be
mirrored for reverse engraving, using the
numbers 5 to 8.
One of 19 fonts may be selected by number in
the Y field. The fonts are comparable to those
available from the normal choice in AutoSketch.
The maximum number of characters is
specified in the Z field, with zero indicating an
unlimited number.
WALLI for WINDOWS. Revision A
If text for engraving is not stated in the
Remarks field of the G99 code, default text may
be specified in the Remarks field of the G98
code, to appear in a dialogue box for
confirmation at run time. If the default is also
left blank, a blank dialogue box will be
presented.
G99 Engrave Text ( used with Configure Engrave
code, G98 )
The dimensions of the text are given in the X
and Y fields of the G99 code statement but, if X
is not specified, the spacing and character
width will be as defined in the font.
The Z field specifies the depth of cut, usually
set to 1mm, say, if a 2mm ball ended engraving
tool is used.
The text to be engraved is stated in the
Remarks field, but if this is left blank, a dialogue
box for the text is presented at run time, which
contains the default text, if this has been
specified by the G98 code, or it will be blank
ready for a run time entry.
Miscellaneous Functions
Note: Because of the modal character of many of the
preparatory functions, that is they stay in operation until
changed or cancelled, it is advisable to have a G code
on all lines that have an M code, to cancel the previous
G code, even if this is a null dwell, G04 with zero dwell
time. M codes are executed before G codes.
M00 Program Stop
This stops the program waiting for the motor
current to be switched off and then on again. It
is useful for tool changes and when setting the
Z axis offset. While in the stopped state, the
Monitor LED will flash rapidly and the continue
may be selected from Control Panel dialogue.
M02 End of Program
End of program is an implied function which is
obeyed automatically at the end of program
execution. However, the M02 code may be
used in program, either to truncate further
execution or to force a stop during program
development, say.
M03 Spindle Clock-Wise (CW)
This switches on the cutter motor in the clock-
wise direction, the normal direction for cutting.
The speed of the motor should be specified in
the same line, otherwise a speed previously
specified, set manually or through the Jog
Feedrate button in the CNC Mill Control Panel
dialogue box, will be used. Suitable speeds are
in the range zero to 4500rpm selected by
number in the range 0 - 9.
M04 Spindle Counter Clock-Wise (CCW)
USE of WALLI page 38

This reverses the spindle motor direction from
that normally used for cutting.
M05 Spindle Off
This stops the cutter motor.
M08 Turns the air blast on to remove swarf.
M09 Turns the air blast off.
M68 Clamp Work-Piece
This switches on the small electric motors to
close the index positioning device and the jaw
of the vice, in a sequence, to clamp the work-
piece.
M69 Unclamp Work-Piece
This reverses the closing sequence, to return
the jaws and index positioning device to the
fully open position.
Graphical Presentation - Mill
A graphical execution, without cutting the work-piece,
may be selected by placing the Mill or Lathe off-line from
the Run menu. This presents a new window as an
overlay to the Main program window stack area, in which
the work-piece is shown to the size set from the Size
dialogue box, accessed from the menu bar when the
graphic has the screen focus.
The cutting path is drawn to dimension in a position
programmed in relation to the top left hand corner,
irrespective of the actual size work-piece. The right
hand information window stack areas are not used for
the graphical execution, since they are reserved for
graphics more appropriate to the programming and set-
up phase for the robots and workcell.
The simple illustration used here is from the first
example program for the Mill, DEMO_CM1.
Different colours are used to show the depth of cut and
this is summarised in a display box when the Key option
is selected from the menu bar to the graphics window.
The colours which correspond to the numbers given for
depth of cut ( Z axis value if the datum is not set ) and
tool diameter, will change as the execution progresses.
WALLI for WINDOWS. Revision A
Clip 56 : Graphic simulation of a simple Mill program.
The programs written with the editor produce G&M code
format files and to these, the colours are allocated in
order from the list ascribed to the HP pen Carousel for
HPGL files. As a result, there is compatibility with when
the program is produced from AutoCAD and imported in
HPGL format, when the colours will be as allocated for
the different depths of cut in the AutoCAD drawing.
Use of the Pen Adapter
The Draw selection which may be made from the Run
menu when the Mill is on-line, has the effect of inhibiting
all cutter motor operations and limiting the movement of
the Z axis to a narrow range, between the pen just above
the paper and lowered fractionally to touching the paper,
ready to draw.
These modifications to the cutter operation ensure that
the pen is not damaged. A drawing block to which the
paper should be carefully fixed so that it lays flat, is used
in place of the work-piece and the pen is adjusted to
touch the surface of the paper using the manual control.
The path of the cutter may be confirmed to be correct
using the graphical simulation before cutting a complex
shape, but more precisely by drawing with a pen in the
chuck of the spindle motor. Using the pen in the
development stage of a program also saves spoiling
expensive material.
The pen supplied with the mill is a disposable plotter pen
(Staedler Marsplot 32HP03K-9, as used for Hewlett
Packard plotters 7221, 7225, 7470, 7475, 7550 and
9872, which also is available from Farnell Electronic
Components under their part number 176-187).
Setting-up the Mill
Push the pen fully into the adapter, fit the adapter into
the full depth of the spindle motor chuck and then
remove the cover for the pen.
Lay a sheet of A4 paper, trimmed to size over the
drawing holder block, wrap the edges tightly underneath
and secure the paper with the two plastic binding clips
provided.
Open the vice, using the control from the dialogue box
and place the drawing holder on the Mill table. Finally
close the vice to clamp the drawing holder into the
correct position.
It is advisable to temporarily disconnect the motor for the
index device, by pulling out the jack plug, otherwise there
is a tendency to bow the drawing holder as the vice
closes.
Running the Program for Drawing
After Homing, the pen will be brought down to a position
just above the paper. Using the manual control buttons
for the Z axis, move the pen fractionally down to be just
in contact with the paper. Switch the Motor Power off
and then on again.
USE of WALLI page 39
 PROGRAMMING the CYBER LATHE
The program will now run with the pen at the two
alternative heights, just above the paper and in contact The tabulation used in the CNC program editor follows
whilst drawing. Whereas in the Graphics Simulation the example from the literature, with column headings the
different depths of cut are drawn in different colours, the Address Characters defined in the BS 3635 and ISO
one pen is used for all depths of cuts in the drawing. For 646 Specifications. There are omissions in keeping with
complex machining, the interpretation of the drawing the relative simplicity of the machine, notably the J
may well be aided by the graphics. parameter for circular interpolation, parallel to the Y axis
which is also irrelevant, and the U, V and W parameters
When the program is completed, the pen will be raised for subsidiary movement of the tool carrier parallel to the
well clear of the paper so that the drawing holder may be X,Y and Z axes, respectively. There are also minor
removed from the vice. At this point, the jack plug variations, notably using D for dwell time.
connection to the motor for the index device should be
re-inserted. All variants of the convention used for circular
interpolation assume that the last programmed move
Note: Replace the cap onto the pen as soon as the brought the cutting tool to the start point for the arc.
drawing is complete, to prevent it from drying out.
The convention used here assumes that a clock-wise
Engraving Text path is obeyed by a G02 code and the end point for the
arc may be defined either relative to the start point in
The use of these non-standard codes is best illustrated incremental terms for X and Z or in absolute terms from
by example, such as in the tabulated below, which is the X, Z datum, but the centre of the arc is always in
taken from the program, g_keyfob.ncm, and which incremental terms I and K.
specifies the text "fred", of maximum height 9.00 mm
engraved to a depth of 1mm. The alternative of the datum point in X, Z for I and K. is
not used, and as a consequence, I and K are always
The width of text is not specified in the X field, so the text positive in a strict observance of the convention. The
will be engraved with a spacing and character width un- Walli3 editor for CNC programs, however, does not
scaled from the font description. reject the use of negative numbers for I and K, since
they are a help when reading the code, nor does it
Example require the irrational change to using diameters when in
the absolute mode, i.e. double the X ordinate.
N G X Y Z Remarks
n 00 25.00 25.00 19.00 Centre of text Before writing a program, the examples on the
n+1 01 20.00 distribution disc should be examined and perhaps run to
n+2 98 1 1 0 normal 0°, font 1 give a degree of confidence and understanding of the
n+3 99 9.00 1.00 fred , 9mm high ISO programming conventions.
n+4 00 0.00 0.00 0.00

The default text in the Remarks field of the G98 code
has not been specified either, since in this case, the
engraved text is specified.
Edit Screen
The edit window for the CNC Cyber Lathe is initially
empty of program, except for a single semi-blank line
giving default values in the F, S, T and D fields. It is
presented on top of the stack of device and cell definition
windows when the lathe is first declared as part of the
cell and thereafter whenever selected from the windows
menu device option. “Home” indicates maximum values.

Clip 57 : Initial edit screen for the Cyber Lathe.

The program is developed by adding lines of code, using

the Insert command, which adds additional blank lines at
the cursor position, or by the normal use of the Enter or
Return key to complete the line. Alternatively programs
may be loaded from file or imported for post processing.

The meaning of the column heading Address Characters

are as follows :-

WALLI for WINDOWS. Revision A USE of WALLI page 40


N Line number
G Preparatory function, generally relating to the
cutter
X,ZCo-ordinates of the next position to move to
I,K Incremental co-ordinates of the centre of a
circular arc
F Feed rate for the move
S Spindle speed
T Tool selection, 1 normal and end face
2 reverse taper and faces
3 thread cutting
4 boring
D Dwell time in seconds
M Miscellaneous functions
Rem Remarks
All dimensions may be specified in milli-meters or inches
using the G70 and G71 codes, respectively.
Entries may be made into any of the column positions
and edited by over-typing as appropriate, using the
keyboard cursor and tab keys to move between fields
and the Ctrl+I, Ctrl+D combinations to insert and delete
lines or rows, respectively. Auto-line numbers are
imposed and this selection is greyed-out in the Edit
menu, giving line numbers in single increments.
Programs previously written in the G&M Code format
may be loaded into the edit window from the Load
selection in the File menu. Programs in other formats
may also be loaded using the Import selection from the
File menu.
Clip 58 : Import file types for the Cyber Lathe.
The Import file types include HPGL, DXF and ASCII,
making the distinction in the latter case between
programs in G&M Code written in the edit window and
those written with a conventional text editor, when the
address character must be stated for every field entry.
Files imported into Walli, detailing components for
manufacture on the Cyber Lathe, invoke the interpreter
provided by the G25 code for Profile Cutting, to translate
the half section outline into code which will both remove
the stock material and provide the finishing cuts.
The HPGL type files with extension [.prt], [.prn] and [.plt],
such as may be produced from the AutoSketch and
CorelDRAW packages, and which are types supported
by any Windows vector drawing package, may be
successfully imported and post processed into the G & M
Codes for the Lathe.
The resultant file from any source, is large by
comparison with those written directly in the G & M
Codes, or processed from DXF type files, produced as
WALLI for WINDOWS. Revision A
standard from the AutoCAD, AutoSketch and similar
CAD packages and potentially by selection from the
CorelDRAW package. Any curved sections of the outline
will in general be represented by a sequence of short
straight lines, which together produce a curved path for
the tool.
The technique can never-the-less, provide a convincing
demonstration, and will be reverted to in any case when
processing DXF type files where there are features of
the design that cannot be directly translated to circular
interpolations, as in forming an ogival cone.
The drawing should be made with reference to the top
left-hand corner of the page that has been defined, to
correspond to the lathe datum, on the turning axis at the
top and against the outer face of the chuck jaws on the
left.
The drawing will typically be a half section in a single
colour and with only one radial or X co-ordinate for each
Z axis position, i.e. a monotonic form. The code that is
produced will require edits for any threaded portions or if
there is the need to bore into the end face, using the
G33 and G83 codes, respectively.
The post processor uses the outer limits of the drawing
to scale it to the stock size of the work piece and this is
set within the dialogue box presented by the Setup
menu, when the graphical execution window has the
screen focus.
ISO Format Programming the Lathe
The turning program is written on the host computer in
ISO format, using a separate edit window for each of the
CNC machines declared in the Cell Definitions Window.
The CNC editor for the Lathe will accept the most widely
used G and M codes which are relevant to the machines
operation, in a conventional tabular statement. This
tabular text statement may be saved to file before it is
compiled as a CNC program suitable for transmission
to the control processor in the Lathe device where it may
be run under supervisory control from the workcell
program.
From the large range of standard preparatory and
miscellaneous function codes that are defined, the ones
that are accepted within Walli3 form a sub-set that
demonstrate the basics of CNC machining on a lathe
which is capable of doing useful work, either as a stand
alone device or as part of an integrated multi-robot/CNC
workcell.
Some non-standard but permissible G codes have also
been implemented, notably for profile cutting, G25, and
also to permit logic access from the workcell, G38 and
G39.
Most of these do not require special comment except to
refer to the convention that is used in circular
interpolation, as previously stated.
ISO PREPARATORY AND MISCELLANEOUS
CODES SUPPORTED FOR THE LATHE
Standard G Codes
USE of WALLI page 41

G00 Rapid Positioning Point-to-Point
This is used when moving the cutting tool
between the end of one cutting sequence and
the start of the next. It should never be used
when the tool is in contact with the work-piece,
except directly away from the material, i.e.
normally in the X or Z direction.
G01 Linear Interpolation
This takes the tool along a straight line from the
last defined position to the position defined by
the current line. It is the usual code for cutting
operations, having made a previous move to
insert the tool into the surface of the material to
an appropriate depth of cut.
G02 Circular Interpolation Arc, Clockwise
This takes the tool in a circular arc of up to 90º
in a clockwise direction from the last defined
position to the position defined by the current
line with the G02 code. The centre of the arc is
defined by the I and K incremental parameters
for the X and Z co-ordinates, respectively.
As a single cut, it will produce a concave
circular segment with the tool moving away
from the chuck, but the bulk of material would
need to have been removed beforehand.
G03 Circular Interpolation Arc, Counter-Clockwise
This takes the tool in a circular arc of up to 90º
in a counter-clockwise direction from the last
defined position to the position defined by the
current line. The centre of the arc is defined by
the I and K incremental parameters for the X
and Z co-ordinates, respectively.
As a single cut, it will produce a convex circular
segment with the tool moving away from the
chuck, but the bulk of material would need to
have been removed beforehand.
G04 Dwell
This defines a wait period, the value of which is
set in the D or Dwell field in seconds.
G05 End Subroutine
Used to mark the end of a section of code
intended to be obeyed as a subroutine and
declared by the corresponding Subroutine Start
code, G28.
When the G05 code is obeyed, the program
sequence is returned to the line following the
call to the subroutine.
G06 End Loop
Marks the end of a Loop Cycle sequence.
G28 Subroutine Start
The code which is entered as the first line of a
WALLI for WINDOWS. Revision A
block intended as a subroutine to the main G
and M code program.
The code is accompanied by a statement in the
X field, which is the subroutines numerical label
or name.
G33 Thread Cutting
Three standard thread forms may be cut, for
Metric (M4 to M30), BSP (1/8 to 7/8) and BA (0
to 3).
The X field specifies the external radius of the
thread and the Z field its length.
The I field parameter is the depth of thread for
the standard thread form. It may be found
necessary to make adjustments to this
parameter for a fit to the inner thread form of
the corresponding nut or similar internally
threaded part. The K field specifies the thread
pitch.
Threads are always cut in the negative Z
direction, to give a right-hand-thread, and the
tool change to the 60 degree thread cutting
tool, is done automatically, although it may be
programmed as part of the preparatory move to
the position to start the thread cutting.
G65 Call Subroutine
The code used to call a subroutine from the
main part of a G and M code program.
The code is accompanied by a statement in the
X field, which is the numerical label or name of
the subroutine, as declared with the Subroutine
Start code.
G70 Imperial
Sets the imperial inch as the unit for all
subsequent dimension entries.
G71 Metric
Sets the milli-metre as the unit for all
subsequent dimension entries.
G73 Loop Cycle
Marks the beginning of a sequence of
commands that will be repeated the number of
times entered as an integer in the X column.
When obeyed in the incremental mode, it
typically defines a cutting sequence to remove
a section of stock material from the workpiece.
G83 Peck Cycle with Dwell ( Boring )
This is an intermittent feed cycle with a wait
period to improve the finish at the bottom of the
cut, by definition, but principally to avoid the
build-up of swaf during the boring process, here
the sequence is interrupted after the
penetration defined in the I parameter field,
USE of WALLI page 42
 defaulting to 3mm, and the drill withdrawn clear
of the hole.
The start position on the Z axis for the drilling
operation is determined by the previous moves.
G90 Absolute programming
After specifying absolute programming each
subsequent X and Z dimension entered is
interpreted as the co-ordinate from the zero
datum which is set in the alignment procedure
for a tool position on the turning, or Z axis, and
close to the outer surface of the chuck jaws.
The zero datum may be altered by program
using the G92 code so that a subroutine, say,
written in absolute code, may be recalled at a
different start position along the Z axis.
G91 Incremental programming
After specifying incremental programming, each
subsequent X and Z dimension entered is
interpreted as the distance from the last defined
position to the one currently defined in the
coded line. As a consequence, the dimensions
may be either positive or negative.
Note: Both G90 and G91 are single entries on a line.
G92 Shift Zero Datum
After specifying absolute programming each
subsequent X and Z dimension entered is
interpreted as the co-ordinate from the zero
datum which is set in the alignment procedure
for a tool position on the turning, or Z axis, and
close to the outer surface of the chuck jaws.
The zero datum may be altered by program
using the G92 code so that a subroutine, say,
written in absolute code, may be recalled at a
different start position along the Z axis.
This code allows a program statement in the X
and Z fields of an offset from the machine
datum, to some other zero datum which will
thereafter be the zero reference for the X and Z
absolute program co-ordinates for program
execution. This feature is provided by the
code, but it is not a normal requirement in lathe
operation.
Note: The aligned position is re-established
automatically, at the start of program execution.
Non-Standard G Codes
G25 Profile Cutting
Profile Cutting further extends the concept of
Canned Cycles and Wizards used in CNC
programming, to give direct access to an
interpreter which generates code to complete
the machining of a part from a definition of its
WALLI for WINDOWS. Revision A
outline.
The machining is done in a series of continuous
tool passes which reduce the stock of the
workpiece, working from end to end, rather than
in sections of length for specific detail, i.e. along
the profile.
The outline definition is derived by the
interpreter from inspection of a G and M code
program which either has been written directly
in code, and may include sections derived by
the use of Wizards, or has been generated by
post-processing a design imported from a
Drawing or CAD Package.
The interpreter makes its own decisions for tool
changes, using the default Tool 1 where
possible, and makes the "best attempt" at
shapes which cannot be achieved on the lathe,
or could be considered illegal, multi-valued or
not monotonic.
The G25 code must be the first code statement
of a program. This is ensured automatically by
the import post-processors but it requires a
simple edit for written programs.
When the program is run in the normal way, the
interpreted code is not presented but held in
memory to be obeyed for the graphical
simulation and compiled for execution, if the
lathe is on-line. The original code is retained
within the edit window and on file.
G38 Pause for Input
This allows the Lathe to respond autonomously
to logic inputs, rather than through the Workcell
control program. The X and Z fields are used
for logic inputs going low and going high,
respectively, the entry being the numbered
input in the range 1 to 8.
It is the non-preferred method of logic control
since the connection is not listed in the Cell
Definition.
G39 Set output
This allows the Lathe to autonomously drive
logic outputs. The X and Z fields are again
used, as for inputs. It is the non-preferred
method of logic control since the connection is
not listed in the Cell Definition.
Miscellaneous Functions
Note: Because of the modal character of many of the
preparatory functions, that is they stay in operation until
changed or cancelled, it is advisable to have a G code
on all lines that have an M code, to cancel the previous
G code, even if this is a null dwell, G04 with zero dwell
time. M codes are executed before G codes.
M00 Program Pause
USE of WALLI page 43
 This halts the program waiting for the motor
current to be switched off and then on again. It
is useful for introducing manual tool changes or
to allow a build-up of swaf to be removed.
While in the paused state, the Monitor LED
mounted on the control processor board
between the RJ45 connectors, will flash more
rapidly. The program continue may be selected
from the Control Panel dialogue box.
M02 End of Program
End of program is an implied function which is
obeyed automatically at the end of program
execution. The M02 code may be used in
program, either to truncate further execution or
to force a stop during program development,
say. It should be used also to mark the end of
the main program, before the code statements
for subroutines. It will be inserted automatically
if the Segment wizard is used to generate the
subroutines.
M03 Spindle On
This switches on the Lathe spindle motor. The
speed of the motor should be specified in the
same line, otherwise the default speed, a speed
previously specified, set manually or through
the screen dialogue box replica of the manual
control panel, will be used.
Spindle speeds are in the range zero to
2000rpm selected by number in the range 0 - 9,
at notional intervals of 200rpm.
M05 Spindle Off
This stops the Lathe spindle motor.
M68 Close Chuck
This selects a low speed, low power mode for
the lathe spindle motor drive, switches on two
small electric motors in the appropriate direction
to enter the chuck key and to close the jaws of
the chuck by rotating the key, in a sequence to
clamp the work-piece in the chuck which is
completed by withdrawing the chuck key,.
M69 Open Chuck
This reverses the direction of the key rotation in the
closing sequence, to return the chuck jaws to the fully
open position.
Graphical Presentation - Lathe
A graphical execution of the program without cutting the
work-piece, may be selected by placing the Lathe off-line
from the Run menu before starting the program
sequence. Whether on-line or off-line, the selection
presents a new window overlaying the screen space
occupied by the Workcell widow stack, in which the
work-piece is shown in a plan view of the Lathe work
area and to a size set from the Size dialogue box. The
dialogue is accessed from Setup, one of two items
displayed on the Menu bar when the graphics window
has the screen focus, the other item providing Options
for the graphics display.
WALLI for WINDOWS. Revision A
Clip 59 : Graphic execution of King chess piece program.
Once started, control of the graphical execution is
transferred to the row of pads at the bottom of the
window, to step, start / pause or abort. In the same row
there is a status display showing the current position of
the cutting tool, in X and Z co-ordinates together with the
current depth of cut, calculated orthogonal to the local
surface of the work-piece. A check box is also provided,
labelled Turbo, and this suppresses all changes in the
graphical presentation until re-checked, allowing rapid
progress through sections of program during program
development.
In normal program execution, the graphic depicts an
outline the selected tool as it moves, both when clear of
the surface and as it reduces the stock outline of the
work-piece to the finished profile form.
This simulation is particularly useful in detecting un-
intentional contact of the tool with the work-piece, as
shown by an overlap of the outlines, and may indicate
the need to change the tool for work on reverse faces,
for example. The current depth of cut is also shown
graphically as a line of varying thickness, following the
tool, but diagonally opposite to it on the workpiece, along
the upper part of the profile.
The Options menu item allows the graphical display of
the depth of cut to be shown or not, and also whether
the tool is shown or not, both options allowing the speed
of execution to be increased. The status display of the
running X and Z co-ordinates may be similarly
suppressed, as may the facility to pause the execution
on error.
Errors are detected for depths of cut that are calculated
to be in excess of that set in the Size dialogue box, or for
violations of the workspace such as attempting to move
the tool beyond the limits of travel on both axes.
Suppressing any of these alternative has the effect of
speeding the graphical execution.
Once graphical simulation has checked the program for
errors, it may be compiled by running on-line, when the
USE of WALLI page 44
compiled code is passed to the Lathe control computer arc and radius, all in three related groups which change
for autonomous execution except from possible position according to the quadrant selected, so as to re-
intervention from the Workcell program. enforce their meaning and the direction of cut.

Note :
The size of workpiece set in the Size dialogue
box does not include the length of billet held in
the chuck, an extra nominal 15mm, depending
on the zero set in the X - Z alignment. The
default size for the billet is the maximum
allowed, or 15mm radius and 60mm long. The
default depth of cut is 0.5mm.

If the billet size is not set to that assumed in the

program, the graphical representation is likely
to show a block of material left un-attached, if it
is too long, or the outline will not be complete, if
it is too short.

USING WIZARDS IN CNC PROGRAMS

Wizards provide on screen assistance in the entry of

parameters for some of the G and M codes that may be
used in programs for the Cyber Mill and Lathe.

In particular, assistance is given for determining the field

parameters for the two Circular Interpolation codes, G02
As few as five of the seven parameters are required to
and G03, where the start and end points are stated in
define the arc, as discussed in the General Notes and
the X and Y(Z) fields in the preceding and current line,
Student Exercises section of the Manual. A particular
respectively, and for which the centre of the circle is
coding requirement is met by entering only sufficient
stated as an offset from the start position in the I and
parameters for the definition, allowing a calculation from
J(K) fields of the current line. A full explanation of the
different design criteria, depending on what is known and
geometry involved, and the methods of calculating the
what is not known of the geometry.
parameters, is to be found in the General Notes and
Student Exercises section of the Manual for both the Mill
Any shortfall in the parameters will be flagged by an
and the Lathe, where the apparent differences arise from
error message when the calculation is entered by
the axes convention for CNC machines.
selecting the OK pad, and so will be any attempt to use
parameters which contravene the geometric constraints
Assistance is also given for the Lathe only, in stating the
imposed by the code convention, i.e. segments which
parameters required for thread cutting, using the G33
exceed 90 degrees of arc or which pass through
code, and in generating code to remove whole sections
quadrant boundaries.
of material, such as when roughing-out the required
shape.
If the calculation is successful, the dialogue box is
removed from the screen and the end point and offset
The wizards that may be selected from the Wizards
values are inserted into the current cursor line of the
menu are :-
program window, using the appropriate code for
interpolation in the clockwise or counter-clockwise
Arc For the Mill
direction.
Segment For the Lathe
Thread For the Lathe
The user is referred to the notes mentioned above, for a
full understanding of the geometry and for further
Arc Wizard explanation of any error messages that may be
displayed if the calculation cannot be completed
The graphical dialogue box which is displayed when the correctly.
Arc wizard is selected from the menu bar, while the Mill
has the screen focus, provides assistance in calculating Segment Wizard
the geometry of circular interpolation and provides the
code required to cut a sector of arc in the surface of the
The Segment wizard for the Lathe provides assistance
workpiece.
with the programming of the circular interpolation codes
for sectors of arc, in the same way that is provided by
The graphical presentation shows a full quadrant of arc,
the Arc wizard for the Mill. However, in the nature of
which may be any one of four going clockwise and four
work on a lathe, the bulk of stock material must be
counter-clockwise, as selected from the group of pads to
removed in the roughing-out stage, before a profile
the right.
circular cut can be made. As a consequence, the output
from the use of the wizard is by default a section of code
Within the graph area, there are entry boxes for the
to remove the stock down to the finished arc and this is
parameters which are required to define the segment of
indicated by concentric arcs in the quadrant shown in
arc, the start and end positions in X and Y, the centre of
the graphics.

WALLI for WINDOWS. Revision A USE of WALLI page 45

If sufficient parameters which obey the convention have
been inserted into the entry boxes, the code is
composed as a subroutine appended to the end of the
program and a subroutine call is inserted at the current
line.
This method of implementing of the roughing-out
process by generating blocks of code in the form of
subroutines, has been extended within the Segment
wizard to include the other standard roughing cuts
required in lathe work, to face-off, remove cylindrical
sections and to cut tapers.
These may be selected using the pads on the right of the
main graph area, below those for the segments of arc.
The graphic changes from depicting concentric arcs to
indicate the successive cuts for a taper, for the facing
operation or for the simple turning operation to remove
cylindrical sections of material. The graphic which is
reproduced here, has Help File "hot spots" to assist in
explaining its use.
Segments of Arc
The graphic presented when one of the circular segment
pads is selected, is of a full quadrant of arc, any one of
four going clockwise and four counter-clockwise, and
showing a solid segment with concentric arcs as the
default condition, indicating that stock material will be
removed down to the finishing cut defined by the arc.
Within the graph area, there are entry boxes for the
parameters which define the required segment, the start
and end positions of the finished arc in X and Z, the
centre of arc and the radius. The boxes are in three
related groups which change position according to the
quadrant selected, so as to re-enforce their meaning and
to indicate the direction of cut.
As few as five of the seven parameters may be required
to define the arc, as discussed in the General Notes and
Student Exercises section of the manual. A particular
coding requirement is met by entering only sufficient
parameters for the definition, allowing a calculation from
different design criteria, depending on what is known and
what is not known of the geometry.
WALLI for WINDOWS. Revision A
Any shortfall in the parameters will be flagged by an
error message when the calculation is entered using the
OK pad and so will any attempt to use parameters which
contravene the geometric constraints imposed by the
code convention, i.e. segments which exceed 90
degrees of arc or which pass through quadrant
boundaries.
The user is referred to the notes mentioned above, for a
full understanding of the geometry and for further
explanation of any error messages that may be
displayed if the calculation cannot be completed
correctly.
If the geometry can be calculated successfully, the
Wizard dialogue box is removed from the screen but the
code inserted is dependent on the selections made in the
checkboxes for Generate Roughing and Incremental
Code. The alternatives are :-
Generate Roughing in Incremental Code
Generate Roughing in Absolute Code
Generate Arc in Incremental Code
Generate Arc in Absolute Code
For the first two of these, the code will be in the form of a
numbered subroutine appended to the end of the
program with an appropriate subroutine call at the
current cursor line. The subroutine code will be in either
absolute or incremental form as an overall statement,
although the active code may be in incremental form,
from a calculated absolute reference.
The last two will produce a single line of code to cut a
circular profile in absolute or incremental form. If a
change of mode is implied by the selection, a line with
the G90 or G91 code will be inserted also.
Cutting tapers
The graphical presentation shows a 45 degree taper, but
the actual slope of the taper which is to be cut is
determined by the X and Z parameters entered for the
start and end points of the finished conical shape. Both
leading and reverse tapers may be cut, with the tool path
towards or away from the turning axis, as indicated on
the selection pads. The face resulting from a reverse
USE of WALLI page 46
taper will always be true, i.e. at right angles to the turning
axis.
The code is generated as a subroutine placed at the end
of the program with cuts progressing to the finished
taper in increments determined by the depth of cut that
has been selected. It may be generated in incremental
or absolute mode.
Cylindrical and Face Cuts
The subroutine code generated for the alternatives for
both of these roughing-out procedures is in the form of a
loop cycle with the loop number calculated from the
amount of material to be removed. This is determined
from the start and end parameters, and from the depth
of cut. The active code is always generated in
incremental mode even if bracketed by mode changes.
Thread Wizard
The thread wizard relieves the programmer from the
need to interpret the standard thread definitions into the
parameter fields of the G33 code.
Three standard thread forms may be cut, for Metric (M4
to M30), BSP (1/8 to 7/8) and BA (0 to 3).
The thread type is selected by Name from the dialogue
box, which also has entries for the radius, length of
thread, pitch/lead and height/depth of thread, some of
which are generated directly by the thread definition.
A line of code is generated at the current cursor position,
with the remarks field containing the type identification of
the selected thread, such as M4.
The depth of thread for the standard thread form is
stated in the I parameter field. It may be found
necessary to make adjustments to this parameter for a
suitable fit to the inner thread form of the corresponding
nut or similar internally threaded part.
Threads are always cut in the negative Z direction, to
give a right-hand-thread. A tool change to the 60 degree
thread cutting tool, is invoked automatically by the G33
code but it is necessary to program the position of the
tool for the start of thread cutting at the right hand edge
of the outer diameter cylindrical section, before the code.
PROGRAMMING the WORKCELL
A correct statement must be made in the Cell Definition
widow of all the devices and sub-devices that are to be
WALLI for WINDOWS. Revision A
addressed in the workcell program, including the
connections between them. This would be a statement
of the content of the workcell as supplied for a turn-key
system but for any system, it may edited to be a subset
of the equipment or amended to account for any
subsequent additions. If the statement is incorrect or
incomplete, warning messages will be displayed when
attempting to program the device or sub-device which is
in error. For the most part, however, the syntax of a
program command will be restricted to exclude devices
and sub-devices that have not been declared.
EDITING THE CELL DEFINITION WINDOW
The window presents the current list of the Devices and
Sub-Devices that have been declared as the equipment
contents of the workcell. The Devices are grouped at
the head of the list, followed by the Sub-Devices.
Against each of the devices there is a statement of its
connection to an appropriate interface into the host
computer and against each of the sub-devices there is a
summary of the intended connections to the devices. As
such the window presents the Wiring List for the
workcell.
Without any entry, the window will be correspondingly
blank, but entries may be made via the Cell menu at any
time during program development, but most
appropriately while the Cell definition window has the
screen focus on top of the stack of device edit windows.
The range of equipment that may be used to build a
workcell comprises Devices such as robots, CNC
machines and any necessary expander boxes, and Sub-
Devices, such as conveyors and index tables. Up to
eight devices may be allocated to each interface card
and any number of sub-devices may be specified for
use in any one workcell, limited only by the workcell
connections available from the devices. The program to
co-ordinate the control of all of these is written into the
"Main" Walli program and its Walli Subroutines.
Although the Cell Definition Window may not be edited
directly as text from the keyboard, it is allowed the
screen focus so that the cursor may be moved to an
appropriate entry, to allow the editing of connections and
deletions via the corresponding amendment to the Cell
menu, or by pressing the return key, which gives direct
access to the same edit dialogue boxes.
Clip 63 : Editing dialogue for the Cell Definition window.
The current contents of the Cell Definitions window is
saved as part of the project file but it may be saved
separately so that it may be recalled as the cell
statement for all new projects that use the particular
USE of WALLI page 47
equipment complement, as for a turn-key or
demonstration system.
Adding Robots, CNC Machines and Expanders
Selecting any of the possible devices from the upper half
of the Cell menu has the effect of opening a selection
dialogue box through which the Device's address on the
interface connecting to the ISA Bus in the host
computer, may be allocated.
Clip 64 : Device Address Selection dialogue for Mentor.
The type and content of the Device Address Selection
box and the choice of address, depends on the device
being added. There are two alternative types of
interface and if both are relevant, as for Mentor in Clip
64, the choice will be presented. Here both the parallel
Turbo Board and the Serial RJ45 alternative are
presented for adding a second Mentor, the first Mentor
has already been allocated to A4, which is greyed out.
When adding the new version of the Serpent, the
Gryphon or CNC devices, the Turbo Board selection will
be absent, since these devices may only use the RJ45
board. Conversely, only the Turbo Board selection will
be presented for the Neptune which may only be
connected through the parallel interface.
Unless the interfaces are installed in the host, and there
may be more than one of each type, the edit windows for
the devices will indicate not-connected, appended to the
title bar.
ISA Bus Interface Connection Alternatives ~
Parallel Turbo Board
The Device Address Selection dialogue box presents a
double row of four radio buttons, labelled A4 to A7 and
AW to AZ, respectively. These correspond to the
decoded address lines to the device from the Turbo
Board, itself connected to the Host processors ISA
address and data bus. Any selection which is made by
choosing the radio buttons must therefore correspond to
the address selection on the device, which is made by
physical links to the logic rails.
The connection is on eight parallel lines and those
devices that require wider data word transfer, such as
the Serpent or Neptune at 12 bits, do so using two eight
bit phrases, by effectively taking two of the eight devices
that the board will support.
WALLI for WINDOWS. Revision A
Note :
A4 to A7 and AW to AZ are alternative "phrases"
from the address decode, which require
alternative decode PROMS in the device
interface, and of these, A4 to A7 is standard.
ISA Bus Interface Connection Alternatives ~
RJ45 Serial Board
The Device Address Selection dialogue box presents a
double row of four radio buttons, labelled Device 1 to 8.
These correspond to the decoded address lines to the
devices from the RJ45 Serial Board, itself connected to
the Host processors ISA address and data bus. The
address and data information is relayed to the devices
on four twisted pair transmission lines connected as a
daisy chain between devices and correctly terminated at
the last in the chain. Any selection which is made by
choosing one of the radio buttons must therefore
correspond to the address selection on the
corresponding RJ45 device interface, which is made by
physical links to the logic rails between pins on a header
connection adjacent to the pair of inter-linked RJ45
sockets.
When the selection has been made, the appropriate
editing window for the device is displayed overlaying the
stack of existing device edit windows and with the screen
focus, ready for data entry.
The device that has been added will also be listed in the
Cell Definition window, along with all other devices and
sub-devices that have been declared.
Note :
The Expander Box does not have an editing
window but, depending on the version, it may be
connected to either type of interface.
Adding Sub-Devices
When any of the possible Sub-Devices in the middle
section of the Cell menus selected, a dialogue box is
presented in which the connections may be established
between the sub-device and any of the devices that have
been declared.
The contents of the dialogue box depends on the type of
sub-device that has been selected and only those items
that are relevant are included.
The illustration in Clip 65 shows the potential addition of
a digital Height Gauge to the declarations for
DEMO_M1.wal. The workcell interface can
accommodate this within the extended output drive
capability of the latest version of Mentor.
Once the connections for the sub-device are completed,
a summary is attached to the list of the declared Sub-
Devices in the Cell Definition window.
USE of WALLI page 48

Clip 65 : Addition of a digital height gauge to existing cell.
The drop-down list of Devices from which the connection
may be made in each of the ‘Connected To’ boxes,
includes only those that have been declared (or
selected) for the workcell, and which are currently listed
in the Cell Definition window. The connections required
and their relevance will be from the following items :-
Connections
Start To ~ Conveyor, Index Table,
Parts Dispenser
Stop To ~ Conveyor, Index Table
Increment To ~ Conveyor, Index Table
When these selection are made, a drop-down list for the
Output selection appears, with all the possible numbered
logical outputs from the device.
Serial To ~ Conveyor, Index Table
When the Serial From selection is made, a drop-down
list for the Output selection appears, with all the possible
latched logical outputs from the device. The connection
is used to send data in serial format, at 9600 Baud,
emulating RS232 transmission on the single logic line
with an earth return. Note that outputs are not latched
on early Mentors and Neptune but for the digital control
system devices and the Mentor SB board, all are
latched.
Zero To ~ Index Table
Free To ~ Parts Dispenser
When these selections are made, a drop-down list for
the Input selection appears, with all the possible
numbered digital inputs to the device. When the choice
is made, the logical state of the input will be displayed,
providing an interface connection has been made to the
Host computer, and the system is On-Line.
Mounted On ~ Parts Dispenser
This is a Mechanical connection between Sub-devices,
and only those Sub-Devices on which the Parts
Dispenser can be physically mounted, and which have
been declared, appear in the drop-down list.
Open/Up To ~ Analog Width and Height Gauges
Close/Down To ~ Analog Width and Height Gauges
When these selections are made, a drop-down list for
the Output selection appears, with all the possible
numbered logical outputs from the device.
Potentiometer To ~ Analog Width and Height Gauges
WALLI for WINDOWS. Revision A
When the Potentiometer To selection is made, a drop-
down list of the possible analogue data input
connections to the device is presented for choice.
Providing an interface has been installed into the Host
computer and the system is On-Line, the value of the
input from the Potentiometer will be displayed.
Start To ~ Digital Width and Height Gauges
Read To ~ Digital Width and Height Gauges
When these selections are made, a drop-down list for
the Output selection appears, with all the possible
numbered logical outputs from the device.
Out To ~ Digital Width and Height Gauges
When this selection is made, a drop-down list for the
Input selection appears, with all the possible numbered
digital inputs to the device. The Read To and Out To
selections for each gauge must be to the same device
since the data from the gauge is transmitted in serial
format on the Out line and the transmission sequence is
initiated on the Read line.
Output ~ Sensor
When the Output selection is made, a drop-down list for
the Input selection appears, with all the possible
numbered digital inputs to the device. The logical state of
the input line will be displayed providing the device is
connected to an interface installed into the Host
computer, and the system is On-Line.
Note :
It is the users responsibility to ensure the validity
and logic of all the cell connections, in particular
that the signal line connections are accounted
and not duplicated, unless intentionally.
Test Buttons
The following buttons are provided as appropriate in the
dialogue box to test the connections. They will only have
an observable effect if the system is On-Line and have
significance if the connections have been wired between
the device and sub-device.
Start ~ Sends a single Pulse to the conveyor
or index table
Stop ~ Sends a single Pulse to the conveyor
or index table
Increment ~ Moves the conveyor or index table a
chosen Increment
Part Dispense ~ Starts the sequence to dispense a part
onto the moving conveyor
Gauge ~Initiates a Gauge measurement cycle
and displays the value in the status box
Calibrate ~Initiates the sequence to move the
Digital Gauge rack between its limits to
determine the stroke available
OK ~Enters the connections made.
Cancel ~Discards any changes that have been
made to the connections since they
were last entered.
Deleting Devices and Sub-Devices
The Device or Sub-Device to be deleted may only be
USE of WALLI page 49
identified and included in the bottom part of the Cell
menu, by moving the cursor onto the appropriate entry in
the Cell Definition window.
Clip 66 : Deleting an item from the Cell.
A dialogue box is presented when Delete is selected
from the Cell menu, as the usual safe guard to confirm
the deletion, as in Clip 66.
Once deletion has been confirmed, the entry is removed
from the list of Devices and Sub-Devices in the Cell
Definition window. If a device is deleted, it may be
necessary to re-allocate any connections to its workcell
interface, in the Cell Definition window and within the
context of the Main workcell program or its sub-routines.
Editing Sub-Devices
The Sub-device for which the connections need to be
edited, may only be identified and included in the bottom
part of the Cell menu, if the cursor is moved to the
appropriate entry in the Cell Definition window.
Once selected, the same dialogue box for the device
connections as that entered from the corresponding Add
Sub-Device selection, is re-entered and any changes
may be made.
PROGRAMMING THE WORKCELL
The Workcell program co-ordinates the movement of
robotic devices and other sub-devices, into a meaningful
and productive automated workcell activity. The workcell
may contain a number of robots and computer
numerically controlled machines, together with a range of
associated transport and measurement sub-devices,
such as conveyors and gauges.
When the application is entered, or when a new project
is selected from the Edit menu, the window is headed by
the title "Main", declaring the name of the workcell
program that will exist for any Walli project. It does not
exist for stand-alone installations, when the programs
are named and loaded with a device related file
extension into the appropriate device edit window.
This main part of the project program may be
supplemented by a number of subroutines, added from
the Edit menu, all of which will be presented in a
separate window similar to the Main window, except for
the titles given them by the programmer.
Each subroutine window may be given the screen focus
subsequently and called to the top of the workcell
program stack, using the side menu which is appended
to the Walli item in the Window menu.
WALLI for WINDOWS. Revision A
In its initial state, the contents of the window is blank,
with the cursor on a blank entry against line 1, in the left
hand column. The blank right hand column in the line
may then be used to enter any of the commands
available in Walli3 as the first line of a program to control
the activity within the workcell. The commands are listed
for reference in the cue card to the right of the workcell
window and all have explanations and examples in the
Help files. Any subsequent lines are introduced using
the Insert edit command at the cursor position or by
using the return key for consecutive lines.
Clip 67 : Entering Walli workcell program commands.
The Walli Commands are entered using two letter
mnemonics, in upper or lower case, and the remainder
of the syntax and data fields are presented from the
application software, and completed as the entry
proceeds. At the completion of all the syntactic entries
or when the line is terminated with the return key, the
line statement is tidied into the form shown in the upper
lines of the illustration. Once entered, the commands
may be deleted, displaced, re-numbered or named using
the edit facilities. The contents of any of the data fields
in a command may be changed while the command is
being entered, using the Tab key to move forward
between parameter fields and Shift+Tab, backwards.
A completed command line may be edited by moving the
cursor highlight to the line and pressing the return key.
The full syntax of the line is restored in expanded form
and any of the fields may be edited in the normal way
using the Tab key to move between parameter fields.
Clip 68 : Editing a Walli command.
The Walli subroutines and their separate named copies
of the workcell window, may be added or deleted using
the Edit menu, when any of the edit windows has the
screen focus, but excluding the Cell Definition window.
One principal use of such Walli subroutines would be in
workcells which contain more than one robotic or CNC
device, allocating the control of each robot or CNC
machine and its associated sub-devices to an
appropriately named Walli subroutine, which may be
called from the Main workcell program which co-
ordinates the overall cell activity.
USE of WALLI page 50
In this use of Walli subroutines, they would be termed [a]
parallel subroutines, in that they are intended to be
obeyed concurrently, that is with the host computer's CH Calibrate Height gauge [n]
operating system providing pseudo parallel operation. GH Gauge Height [n]
IH If Height gauge[n] is between[d] and [D] then
The other principal use of parallel Walli subroutines is to goto[a]
set-up timing loops, to time-out activity in the workcell,
preventing "locked" conditions and allowing orderly DP Dispense Part [n]
recovery.
ID If Digital sensor [n] is [on/off] then goto [a]
Expanding the idea of parallel subroutines further, the IS If analog Sensor is between [d] and [D] then goto
Walli commands for RS232 communication allow a [a]
number of host computers to control divisions of a larger WD Wait until Digital sensor [n] is [on/off]
workcell, with the communicating processors in
concurrent control of their respective workcell segments. Counters and Flags

CO COunter [n] [+ / - / = ] [m]

AC Add Counter [n] into counter [n]
CC Copy Counter [n] into counter [n]
IC If Counter [n] [ = / < / > ] [m] then goto [a]

SF Set Flag [n]

RF Reset Flag [n]
CF Copy Flag [n] into flag [n]
WF Wait until Flag [n] is [set/reset]
IF If Flag [n] is [set/reset] then goto [a]
Clip 69 : Serial communication commands as Help topic.
WA Wait [n] seconds
COMMAND SUMMARY Program Control Statements
The two letter mnemonic is given first, followed by the FO FOr [A] = [n] to [m]
syntax in which the mnemonic letters are repeated in NE NExt [A]
upper case. See Appendix 2 for a full expansion of the GO GOto [a]
syntax.
GS Goto Subroutine [a]
Computer Controlled Devices ~ Robots and CNC RS Return from Subroutine
Machines
SS Start parallel Subroutine [a]
MO MOve [rob n] through position [a/A] to position [b] ES End parallel Subroutine [a]
IA If [rob n] axis [m] is between [d] and[D] then goto [a]
EL ELse
SP Start [CNC n] Program [file] EI End If
CP Continue [CNC n] Program
IP If [CNC n] program has Paused then goto [a] Miscellaneous Statements
IE If [CNC n] program has Ended then goto [a]
WP Wait until [CNC n] program has Paused DM Display Message [text]
WE Wait until [CNC n] program has Ended RE REmark [text]
PR PRint [text]
JX Jog [CNC n] X axis [d]mm and continue program
JY Jog [CNC n] Y axis [d]mm and continue program TR TRace [on/off]
JZ Jog [CNC n] Z axis [d]mm and continue program
SL Start Log file to [text] row [n]
SO Set [dev n] Output [n] LO LOg [counter/flag/sensor/gauge n] to column [m]
RO Reset [dev n] Output [n] LF Log [rob n] Feedback starting at column [m]
Peripherals or Sub-Devices ~ Indirectly Controlled via CR Configure Rs232 port [n] [text]
Devices or Expander Boxes WR Write to RS232 port [n] [data]
OR Output to RS232 port [n] [file]
SC Start Conveyor [n] FR Flush RS232 port [n]
HC Halt Conveyor [n] IR If Rs232 port [n] = [text] then goto [a]
MC Move Conveyor [n] [d] mm
ST Start index Table [n]
HT Halt index Table [n]
MT Move index Table [n] through [d] degrees

CW Calibrate Width gauge [n]

GW Gauge Width [n]
IW If Width gauge[n] is between[d] and [D] then goto

WALLI for WINDOWS. Revision A USE of WALLI page 51