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5 Steps to ActiveEdge
5 steps to installing your Zenith Loop with
ActiveEdge tools
Why do I want a Zenith solution?
● Reduce labour costs
● Eliminate scrap
● Fully automated, 24 hour production through lights-out manufacturing
● Micron accurate adjustments & compensations
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5 Steps to ActiveEdge
Step 1 — Machine Control Wiring
ActiveEdge supports Siemens, Fanuc and Mazak machine controls, which covers most CNCs.
We need to have exclusive access to a block of 100 user variables and access to one input and one
output on your CNC, connected to the ActiveEdge Interface using AEI-CABLE01, which is shown in the
below image.
See information and images below for examples of the wiring required for each of the typical
machine types:
Siemens
TYPICAL SIEMENS X132 PANEL WIRING FOR RIGIBORE AEI
BLACK [X124] 0V
RED [X124] +24V
PINK [X124] +24V (This can be doubled with red)
ORANGE [X132] DI 0 Input
WHITE [X132] DI/DO 11
M + M1 MUST BE LINKED
Using this wiring configuration, your inputs and
outputs are as follows:
$A_OUT[1] =1
$A_OUT[1] =0
$A_IN[1] =1
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5 Steps to ActiveEdge
Fanuc
TYPICAL FANUC XT4 I/O PANEL WIRING FOR RIGIBORE AEI
ActiveEdge connections for wire harness AEI-CABLE01
BLACK [33] 0VRED [03] +24E (Red & Pink can be doubled up)PINK [03] +24EORANGE [01] X04.0WHITE [35] Y02.6
Using this wiring configuration on a Fanuc I/O, your inputs and outputs are as follows:
CNC input = #1015
CNC output = ON: M105
CNC output = OFF: M115
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5 Steps to ActiveEdge
Mazak
TYPICAL MAZAK MAZATROL PANEL WIRING FOR RIGIBORE AEI
BLACK [XT155] – 1M = 0V
RED [X155]— 2L+ = +24V
PINK [X155]— 2L+ = +24V (This can be doubled with red)
ORANGE [X155]— = 3155 (Input)
WHITE [X155]— = 12485 (Output)
Using this wiring configuration for the Mazak I/O, your inputs and outputs are as follows:
CNC input = #1030
CNC output = ON: M418
CNC output = OFF: M419
If your machine has these connections available (or similar), and you have taken note of the 100 user
variables and inputs and outputs you can assign to ActiveEdge processes, then move onto the next
step (there is a checklist in step 3 where you can fill out this information)! Please note your
compensations will only be as accurate as your measuring probe, please contact Rigibore if you need
suggestions for suitable measuring probes in your Zenith loop.
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5 Steps to ActiveEdge
Step 2 — Networking & Software Setup
Now your tools are designed and we know your machine is compatible, this is a good time to
consider how you would like to connect your AEI to the network. While it is highly recommended
that you connect your Zenith loop to your factory network, it is possible to install it on a separate
(ad-hoc) network if required.
The free software “ActiveNet” allows you to monitor every step, check tool statuses, battery levels,
and keep your ActiveEdge firmware and cartridge library up to date. ActiveNet is available as a free
download for Windows PCs from the Rigibore website.
ActiveEdge can support tools with up to 7 cartridges. In the screenshot you can see multiple tabs,
each one represents an ActiveEdge Interface which may correspond to each manufacturing line. Each
ActiveEdge Interface can support an unlimited number of ActiveEdge tools.
The AEI or “ActiveEdge Interface” can connect to your network in one of two ways:
● DHCP - This setting is very easy to connect to ActiveNet, just plug your AEI into the network
with an ethernet cable, open ActiveNet > AEI Management > Add Interface and enter the
AEI’s specific number and press “Get IP”, for example “AEI02159”. ActiveNet will fetch the IP
automatically (using DNS) and open a new tab in the software, the light will go green when it
is connected.
● Static IP - This method is a little more complicated but is often the preferred option if you
want to give your AEI a permanent address in your network that no other device can take.
This option makes a permanent address for the AEI and will connect regardless if you turn it
off and on again.
You will need to ask IT for a specific IP address that can be allocated to your AEI, the AEI will
then be set up prior to delivery to look for the IP address that has been provided by your IT
department.
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5 Steps to ActiveEdge
Step 3 — Checklist
In this section we provide a checklist to ensure that all aspects required for a smooth installation
have been completed.
1. Has Rigibore been provided with 100 user variables and I /O configuration ?
You can choose any block of user variables as long as it is available exclusively for Rigibore
use, this is essential for the system to make micron accurate compensations.
Please fill in the table below:
Control system (Siemens, Mazak or Fanuc)
Block of 100 user variables (eg Siemens RAE,R,GD, GUD) exam RAE 100 -> RAE 200
Inputs & Outputs exam $A_IN[1] input,$A_OUT[1]=1 output on $A_OUT[1]=0 outputoff
2. Has the tool design been finalised and the drawing signed off?
You’ve now designed your tools in RADS, or had your tools designed in house. The design has
been finalised at Rigibore, there is a mutual agreement on the complete design.
3. Has Rigibore been provided with your network preferences?
DCHP or Static IP, please ask your IT department which network settings would be preferable.
Please tick the relevant tables below and provide relevant information, if applicable:
DCHP (easy to connect, simply connect viaethernet cable and search for AEI on ActiveNet,it will grab a IP automatically)
Static IP (this requires pre-configuration atRigibore, we will tell your AEI to look for a IPaddress that your IT department has specified)
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5 Steps to ActiveEdge
Step 4 — Connection Testing
With the checklist complete and following a completed purchase order, we can now start
manufacturing your custom tools. This can usually take up to 8 weeks so to make good use of the
time, we will send you a few things straight away to get started;
Your customised programs and subprograms also known as macros which can be included in your
main production program. These must be placed in the appropriate folders.
AE-Cable-01
This connects your Machine’s I/O & power to the ActiveEdge AEI
AE-TESTBOX
This is sent on loan to be returned, along with a test script for your machine to test if the cable has
been fitted correctly before your tools arrive.
Plug the AE-CABLE-01 into your machine as
described in Step 1 and as you have recorded in
Step 4.
Plug the AE-TESTBOX into AE-CABLE-01 and run
Program 8536. If the AE-TESTBOX LED lights
up, everything is connected correctly.
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5 Steps to ActiveEdge
Step 5 — Calibration
1) Set your antenna within a reasonable distance from your ActiveEdge tool.
2) Connect the antenna into the jack on the right of the AEI and the network cable into the jack
on the left.
Then connecting AE-CABLE-01 into the AEI completes all your connection requirements.
One final step to take before you're ready to go. The AEI needs to create a timing profile for the
messages sent between the AEI and the machine control.
This process takes around 7 minutes in total to complete. Now you have your programs and
subprograms sitting in the correct folders, look for the program “8500” and execute this program, it
will take around 5 minutes to complete.
Once complete it will drop a new file “8510” into your AEI, you can access this file by opening
ActiveNet, connecting to your AEI and looking in the AEI system folder, found in the AEI management
drop down menu. Do not delete or edit any of the files in the AEI system folder!
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5 Steps to ActiveEdge
Put the 8510 file onto a memory stick and copy the file onto your machine control in the relevant
folder.
And now your Zenith loop is up and running! You can now use our macros in your main production
program for micron accurate compensations!
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