1. January 2014

2. The new OPENcontrol family
OPENcontrol – Control Units OverView
Configurations
Software architecture
HW Platforms
HMI solutions
Modular Operator Panel OPENconsole
Compact Panel
Monitors and PanelPC
Hand helded console TOP5
OPENcontrol family devices
OPENrio and other I/Os
OPENdrive
Utilities

3. OPENcontrol line
The new family of Hi-Tech Numerical Controls Osai Prima Electro Numerical control

4. OPENcontrol: Synthesis of the Motion Control
The OPENcontrol comes up with the purpose to combine into a family of products the Prima Electro experience within the Motion Control market
The OPENcontrol integrates the features developed for Laser Cutting Machines Controls for Prima Industrie Group and the general purpose market oriented features
Osai Prima Electro Numerical control

5. The new line of OPEN products
Software
Functionalities
Hardware
Computing Power

6. Scalability at all levels…
Performance Scalability
Functional Scalability
Hardware
Software

7. Migration from OSAI CNC to OPENcontrol
SyncMotion
OPEN-10
OPEN-20
10/Series
OPEN-10
Major integration of the Motion Control software
Same interpolators used by CNC version
Immediate and transparent migration on higher level products (OPEN20 and 30)
Besides SyncMotion features, OPEN10 allows to have:
Major integration within the development and setup tools of the PLC environment, field bus, HMI and motion control
A richer and powerful Motion Control library
“Ethernet based” field bus to interface axes and I/O
OPEN-30
OPEN-20, OPEN-30
CNC Solutions dedicated respectively to the applications for the 2D and 3D machines
Continuity with the 10 Series development environments (WinPLUS, WinNBI)
OSAI Prima Electro standard local or remote HMI (WinNBI)
New Real Time operating system WindowsCE
New openings for the communication on Ethernet Based standard field bus

8. System overview – HW configurations

9. System overview – OPENcontrol Stand Alone
CNC + Monitor
Drives and I/Os can be on the same fieldbus
I/O fieldbus
Drive fieldbus
OPENcontrol
Drives
Modular I/O
Dashed lines for OPTIONAL modules
Monitor
DVI/VGA
USB
MTB panel
Keyboard
Windows CE real time O.S.
Dual Operating System option (WinCE + WES2009)

10. System overview – OPENcontrol Multi Platform
CNC + Industrial PC (or Panel PC)
Drives and I/Os can be on the same fieldbus
DVI/VGA
Monitor
Keyboard
MTB panel
Industrial PC
TCP/IP over Ethernet
Modular I/O
Drive fieldbus
Drives
OPENcontrol
Dashed lines for OPTIONAL modules
USB
I/O fieldbus

11. System overview – SW architecture

12. Development Tools - WinPLUS
SoftPLC: WinPLUS
Development environment and machine logic debug through a tool within the Windows IEC environment
Windows development environment based on IEC which can be programmed in IL, LD, ST, FB, SFC
Integrated machine logic environment
Multi-tasking real-time execution
Max 250 tasks, 10 priority levels
Cyclic task with min. scheduling of 250 µSec.
User event-driven tasks
Event tasks associated to M, S, T functions
On-line debugging (tracing, breakpoint etc.)
[Continuity with 10/Series and SyncMotion]

13. Development Tools - WinNBI
HMI & Configuration: WinNBI
“Configurable Network Based Interface”
Standard user screen panels
Screen panels customization based on graphical obejcts
DLL Available for the development of custom graphical interfaces
[Continuity with 10/Series and SyncMotion]

14. WinNBI - End User applications
PathView
System History
Boot Controller
ProcessController
standard layouts
File Browser
MachinePlot
Digicad
Table Editor

15. WinNBI - OEM applications
O-Scope
ODM
Security

16. WinNBI applications availability
Windows XP/7
Windows CE
End User applications
BootController
CNC boot manager
ProcessController
CNC main and auxiliary screens manager and builder
SystemHistory
System journal
TableEditor
Table data manager (Offset, Tool, Origins…)
MachinePlot -
2D/3D graphical drawing of the tool trajectory
FileBrowser
File manager (CNC and PC)
PathView
3D graphical tool for digitising with spline
DigiCAD
OEM applications
ODM
Configurator and run-time
Security
SW Installation, backup, restore. License manager
TimeMonitor
PLC and System task timing graphical monitor
O-Scope
Oscilloscope for many system parameters
Available
Option
Not available

17. Conversational Editors
Conversational Editor for 3 axes milling machines
SawCAD
SketchCAD
Running on PC and on CNC (Windows CE)

18. Conversational Editor – Milling Machines
Face milling
Round Pocketing
Square/Rectangular Pocketing
Round Boss
Square/Rectangular Boss
Straight/Linear/Radial Slotting
Hexagon Boss Milling
Triangular Pocket Milling
OD Helical Milling
ID Helical Milling
OD Thread Milling
ID Thread Milling
Drilling
All drilling patterns include the ability to include standard drilling cycles:
Spot Drilling
Peck Drilling
Deep Hole Peck Drilling
C’Sink with Dwell
Normal Tapping
Reverse Tapping
Boring Cycle w/Rapid Extraction
Boring Cycle w/Extraction at a Feedrate
Custom Drill Cycle Creation
Drilling Patterns include:
Bolt Circle Pattern
Line-At-An-Angle Pattern
Grid Pattern
User defined locations
Machinist Toolbox for reference to shop floor formulas such as :
IN-MM conversion
RPM-SFM Conversion
Drill Point Length Calculations
Feedrate Conversions
Tap Drill Reference Chart
Screw Dimensioning Chart
Speed / Feed Database
Tapping Calculator
Straight Line Engraving
Full HELP Manuals accessed via F key
Program Text Editor specifically designed for G code editing with the following features :
Re-Sequence programs with N numbers
Remove N numbers
Add / Remove Spaces
Search / Replace
Paint / Highlight with user defined paint pallet
Mark / Cut / Copy Text
Rotate existing G code programs
Non-Traditional Machining
Conversational-To-G-Code Programming Assistant (KipwarePA® )
SketchPad allowing users the ability to draw the desired toolpath.
DXF to SketchPad Converter for importing DXF files into the SketchPad.

19. SawCAD for stone market
Profondità nel piano
Distanza di rallentamento
Ra ggi o
Distanza di rallentamento/2
P 0
P 1

20. SketchCAD for stone market

21. SW architecture - real-time modules

22. SW architecture - HMI and Communication
OPENcontrol real-time module
Remote PC
Ethernet
DCOM
proxy
WinNBI
COM client
Utilities
WinPLUS
COM client
COM client
PC Hardware

23. SW architecture - Dual Operating System
OPENcontrol real-time module
Windows XP
Windows CE
Ethernet
DCOM
proxy
WinNBI
COM client
Utilities
WinPLUS
PC Hardware
Virtual Network

24. CNC SW key features Axes Management
Coordinated, Auxiliary, Pseudo and Spindle axes
Linear and Rotary Axes
Rollover Axes
Diametral Axes
Gantry Axes (Split)
Dual Axes
Master/Slave axes
Dynamic follower axes
Special Features
Multi-Axis Electronic Cam
Bidirectional axis calibration
Cross Compensation
Volumetric Compensation
Virtualization
Programming on Rotated Plane
Polar Coordinates
Cylindrical Coordinates
Non orthogonal axes management
Axes Motion
Linear, Circular, Helical and Spline Interpolation
Motion Modality (RAMP parameters)
Independent acceleration/deceleration parameters for
Linear Ramp
S Ramp
Trapezoidal Ramp
S Ramp with Jerk limitation
Point to Point and various Continuous Mode
Axis motion filters programming
Velocity Feed Forward (VFF)
Zero Shift
Constant or Variable Pitch Threading (G33)
Multi-start threading
Multi Block Retrace
Memory Search (Restart)
Look-ahead
3D Axes Motion
Circular 3D interpolation
Tangential axis control
Tool Centre Point (TCP)
TCP for Double Twist and Prismatic Heads with 2 or 3 rotary axes.
TCP for non standard kinematics
TCP with Spline (High Speed Machine)
Tool Direction axis movement
TCP on rotated planes
Selection by program of active kinematics
Various
Unit of measure change
Shared Axes
Axis Migration
Parametric (macro) language
Machining canned cycles
Probing cycles
Part-program subroutines
XML macro interpreter

25. CNC Control Unit HW platforms

26. “Typical” hardware/software configurations
OPEN-10
OPEN-20
OPEN-30 XS
Atom N GHz • o M
Celeron M 1.5 GHz L
Pentium M 1.8 GHz XL
Core 2 Duo

27. OPENcontrol OPEN-XS – Modularity concept
Factory Ethernet
Sigma-5 SD
Digital BUS
Mechatrolink III
EtherCAT option
(CANopen option)
ATOM N GHz
1 LAN
USB (3)
4 RS232 (1 as RS232/RS422/RS485)
Windows CE
Dual Operating System option (WinCE + WES2009)
Mechatrolink III
VGA
EtherCAT
CANopen
fieldbus
OPENrio modular I/O
Optional CANopen devices

28. OPENcontrol OPEN-XS – Modularity concept
Factory Ethernet
Digital DRIVES
EtherCAT
Digital BUS
EtherCAT (SoE + Coe)
CANopen option
ATOM N GHz
1 LAN
USB (3)
4 RS232 (1 as RS232/RS422/RS485)
Windows CE
Dual Operating System option (WinCE + WES2009)
VGA
OPENrio
modular I/O
CANopen
fieldbus
Optional CANopen devices

29. OPENcontrol OPEN-XS – Modularity concept
Factory Ethernet
Drives with analog interface
EtherCAT
Analog
A432 module
4 Analog axes
2 Analog output
1 Analog output (Spindle)
1 ABZ 5V Encoder input (handwheel)
4 Analog Input
32 Digital Input
32 Digital Output
A664 module
6 Analog axes
64 Digital Input
64 Digital Output
VGA
CANopen
fieldbus
Optional
Modular I/O
Optional CANopen devices

30. OPENcontrol OPEN-XS – Modularity concept
Factory Ethernet
Drives with Pulse & Direction interface
EtherCAT
P&D
P432 module
4 P&D axes
1 Analog output (Spindle)
1 ABZ 5V Encoder input (handwheel)
4 Analog Input
32 Digital Input
32 Digital Output
P664 module
6 P&D axes
64 Digital Input
64 Digital Output
VGA
CANopen
fieldbus
Optional
Modular I/O
Optional CANopen devices

31. OPENcontrol OPEN-XS – Modularity concept
Integrated CNC
(Monitor + Control Panel + Control Unit)
Control Unit
EtherCAT
Mechatrolink III
CANopen

32. OPENcontrol OPEN-M and OPEN-L
Axis Board OS-Wire / Mechatrolink I/II
Os-Wire
Mechatrolink I/II
CANopen or Profibus
2 analog input 12 bit
1 analog output 16 bit
1 Encoder channel
3 Fast Out + 1 Out (SPEPN)
4 Fast In (o 3 In + Touch-Probe)
Axis Board EtherCAT / Mechatrolink III
EtherCAT (2 channels)
Mechatrolink III
CANopen
ETN Hermes
2 analog input 12 bit
1 analog output 16 bit
1 Encoder channel
3 Fast Out + 1 Out (SPEPN)
4 Fast In (or 3 In + Touch-Probe)
Axis Board Sercos III
Sercos III (2 channels)
CANopen or Profibus
ETN Hermes
2 analog input 12 bit
1 analog output 16 bit
1 Encoder channel
3 Fast Out + 1 Out (SPEPN)
4 Fast In (o 3 In + Touch-Probe)
Auxiliary Board EtherCAT
EtherCAT
Celeron M 1.5 GHz / Pentium M 1.8 GHz
2 GB RAM
2 LAN 10/100/1000
4 USB v2.0
4 RS232 (1 as RS232/RS422/RS485)
2 slots PCI
1 GB or 4 GB Compact Flash
32 GB SSD SATA option
1 or 2 Axes modules
3 different axes boards for fieldbusses flexible management (see above)
HMI
VGA Monitor on WinCE
VGA Monitor on WES2009 side in case of Dual Operating System
Remote PC connected via LAN
Windows CE
Dual Operating System option (WinCE + WES2009)

33. OPENcontrol OPEN-XL – Dual Core – Dual O.S.
Axis Board OS-Wire / Mechatrolink I/II
Os-Wire
Mechatrolink I/II
CANopen or Profibus
2 analog input 12 bit
1 analog output 16 bit
1 Encoder channel
3 Fast Out + 1 Out (SPEPN)
4 Fast In (o 3 In + Touch-Probe)
Axis Board EtherCAT / Mechatrolink III
EtherCAT (2 channels)
Mechatrolink III
CANopen
ETN Hermes
2 analog input 12 bit
1 analog output 16 bit
1 Encoder channel
3 Fast Out + 1 Out (SPEPN)
4 Fast In (or 3 In + Touch-Probe)
Axis Board Sercos III
Sercos III (2 channels)
CANopen or Profibus
ETN Hermes
2 analog input 12 bit
1 analog output 16 bit
1 Encoder channel
3 Fast Out + 1 Out (SPEPN)
4 Fast In (o 3 In + Touch-Probe)
Auxiliary Board EtherCAT
EtherCAT
Core 2 Duo 2.26 GHz
2 GB RAM
2 LAN 10/100/1000
4 USB v2.0
4 RS232 (1 as RS232/RS422/RS485)
2 slot PCI
1 GB or 4 GB Compact Flash
32 GB SSD SATA option
1 or 2 Axes modules
3 different axes boards for fieldbusses flexible management (see above)
HMI
VGA Monitor on WES2009 side in case of Dual Operating System
Remote PC connected via LAN
Dual Operating System (WinCE + WES 2009)

34. OPENcontrol: data table…
Hardware
Versions
Microrack black box
Microrack with VGA monitor
Microrack with front-end PC
PanelPC (integrated TFT)
Digital interfaces for the axes control
Mechatrolink III, Mechatrolink II & I, EtherCAT,
OS-Wire, CANopen, (SERCOSIII)
Analog axes
YES (bridge solution, with integrated I/Os)
Pulse & Direction axes
I/O
Field bus expansion modules.(RIO or bridge)
Execution periods (servo loop, block processing, etc.)
250µs over fast digital busses
5ms over CANopen
Communication
Ethernet network
TCP/IP
HMI
Software Suite
WinNBI
Supported languages
Up to 23 for the O.S.
Any language for WinNBI, 5 predefined
Built in diagnostic tools (servo tuning, trace functions, machine logic display, etc.)
WinNBI advanced tools
(ODM, O-scope, servo monitor, alarm history, …)
Programming
Standard G-code programming NO
YES
XML
Interpolation from program
YES, Advanced CNC interpolation
Interpolation from logic
Linear /Circular /Helicoidal, start/stop on event etc.

35. OPENcontrol: …data table
Group of axes
12 axes per interpolator
40 interpolators
1 interpolator per process
Up to 24 processes
Handling of different reference system
By logic, max 32
User Tables, 100 available
Absolute/Incremental programming
YES
Bidiretional axis calibration
Cross compensation
Volumetric compensation
Tool Center Point NO
Spline
Polynomial interpolation
Axes
Number of axes
Up to 64
Number of analog axes
4 or 6 axes (bridge solution)
Analogue spindle management
Absolute position transducers

36. Dual Operating as offline real CNC environment
Offline OPENcontrol CNC
Windows XP + Virtualization SW + Windows CE on desktop/laptop PC
The same software used on the real CNC
Part Program development and testing
Machine Logic development and testing

37. PRIMAlogic – Entry level GMC
OPEN-10
OPEN-20
OPEN-30
PRIMAlogic
ARM MHz • - XS
Atom N GHz o M
Celeron M 1.5 GHz L
Pentium M 1.8 GHz XL
Core 2 Duo

38. PRIMAlogic: Entry level GMC
Compact SoftPLC
Axes control through CANopen bus
Windows CE real-time Operative System
The same F.B. libraries used for OPENcontrol
The same development/debug/tuning tool used for OPENcontrol
OSAI Prima Electro standard remote HMI (WinNBI)
Immediate and transparent scalabity on higher level products (OPEN10, 20 and 30)

39. PRIMAlogic: entry level GMC
Same architecture and
same development environments
used for OPENcontrol
Windows CE
PLC IEC
HMI: LCD 4 rows of 40 alphanumerical characters
WinNBI (only remote)
CPU ARM MHz
Communication:
Ethernet
RS485/USB
CANopen
Modbus
Digital and analog local I/O

40. PRIMAlogic: entry level GMC
Same architecture and
same development environments
used for OPENcontrol
16 Digital Input
4 Digital output
4 n.o. single contact relay Output
2 Switch relay Output
2 Frequency/counter Input
4 Analog Input
(also for pressure sensor management)
(also for temperature sensor management)
4 x 12 bit analog Output

41. HMI solutions

42. OPENconsole - Modular Operator Panel
Display
Main panel
Secondary panel
Keyboard

43. OPENconsole - Design

44. OPENconsole - Display Panel
Models
Industrial Monitor 17”
Industrial Monitor 19”
Features
Element for
stand alone monitor
USB port
Resolution 1280 x 1024
Touch Screen Option
IP65 front protection level
19 “ rack size
24V Power Supply
4/3 format
VGA/(DVI) connection (till 20 meters)
USB and VGA(DVI) extender option (till 20 meters or till 80 meters versions)

45. OPENconsole – Main MTB Panel
Features
EtherCAT fieldbus
Emergency push-button
Drive ON , Drive OFF
CNC ON/OFF
Jog +, Jog -
Cycle, Reset, Hold
Auto mode, Manual mode, mode lock key
Feed (configurable)

46. OPENconsole – Secondary MTB Panel
Wires connection with Main Panel for easy maintenance and I/O save
Features
7 elements (keys, push-buttons, lamps etc.) as required by OEM
Simple connection to main MTB panel

47. OPENconsole – Keyboard and Pointing Device
Features
101 keys US keyboard
Touch Pad or Track Ball
Ergonomic positioning
USB port

48. OPENconsole Compact, all-in-one Operator Panel
Models
15” Monitor (1024 x 768)
15” OPEN-XS integrated
Features
Single, light, flat frame
Panel mounting
IP65 front protection level
“Bubble keys” keyboards
Standard QWERTY 100 keys keyboard
OEM Control Panel standard keys
OEM Control Panel custom keys
Configurable Feed knobs
USB port
Touch pad
Touch Screen option
Emergency push button (option)
2 Electro-mechanical push-button (option)

49. Monitor Monitor 10,4” Monitor15” Monitor17” Monitor19” Display
Monitor 10,4”
Monitor15”
Monitor17”
Monitor19”
Display
10,4” TFT (1024x768)
15” TFT (1024x768)
17” TFT (1280x1024)
19” TFT (1280x1024)
Touch Screen
Resistive (optional)
Mounting
Open Frame / with Frame
Open Frame
Power Supply
24V

50. Panel PC Panel PC 10,4” Panel PC 15” CPU ATOM N270 – 1.60 GHz
Panel PC 10,4”
Panel PC 15”
CPU
ATOM N270 – 1.60 GHz
Touch Screen
Resistive
Display
10,4” TFT (1024x768)
15” TFT (1024x768)
RAM
1 GB - 2 GB
Mass Storage
Compact Flash 8 GB – 16 GB / SSD 32 GB – 64 GB
Serial line
1x COM RS232 – 1x COM RS232/422/485
USB
2 x
Audio
1 x Mic IN - 1x Spk OUT
Video
1x VGA
Ethernet
1x 10/100/1000
Expansion
PCI 104 OS
Windows Embedded Standard 2009
Power Supply
24 V
Frame
Alluminum
Mounting
Open Frame / With Frame

51. TOP5 - Remote Programming Console
Windows CE
Communication:
Ethernet TCP/IP
USB
Safety:
Emergency stop push-button
Double push-button (left and right) with double contact for dead man and live man
HMI:
TFT 6.4” graphical display with touch-screen
Local WinNBI
Local keyboard with customizable keys
Keyboard with dedicated keys
Jog
Hold
Run
Selection of the operative modalities

52. Devices

53. YASKAWA Sigma-5 SD Sigma-5 SD Combined spindle & servo system
Modular Multiaxes Drive
MECHATROLINK-III high-speed networking (100 Mbps Ethernet)
multiaxes high speed synchronisation
Overload 350% for 3 – 5 sec, high peak torque
fast acceleration, no amplifier oversizing
High encoder resolution, 20 bit => counts per revolution
Easy tuning, advanced autotuning, one parameter tuning
Energy savings
power regenerative converter completely recovers braking energy back to the mains supply
Up to 10 modules (that is ot the number of axes.)

54. YASKAWA Sigma-5 SD

55. YASKAWA Sigma-5 SD – Energy saving

56. YASKAWA Sigma-5 SD – spindle motor range

57. YASKAWA Sigma-5 SD – servo motor range

58. OS-Wire/CAN drives range extension
OPENdrive – OD600
OS-Wire/CAN drives range extension
NEW
OPENdrive – OD600
- Power Supply
From 230V -10% to 480V + 10%
- Soft Start circuit
- STO (Safe Torque Off)
OD600-OSW (OS-Wire)
OD600-CAN (CANopen)

59. OPENrio – EtherCAT I/O module
Modules
EtherCAT BUS coupler
16 Digital Input opto-isolated (2 x 24V power supply, 1 GND)
16 Digital Output 250 mA (2 x 24V power supply, 1 GND)
8 Digital In + 8 Digital Out
2 Analog In + 2 Analog Out
4 Analog In
4 Digital Out 2 Amp
4 Relays Out
Multi I/O (4 Din, 4 fast Dout ON/OFF or PWM, 1 Ain, 1 Aout)
EtherCAT repeater
Flex strip connection between modules
Dimensions: 19 mm x mm x 86.5mm

60. RIO – OS-Wire/CANopen I/O module
Modules
OS-Wire and CANopen BUS coupler
8 config. Input/Output
16 Digital Input
16 Digital Output
8 Digital Input + 8 config. Input/Output
4 Analog Input + 4 Analog Output (+/- 10V or 20mA)
4 Analog Input (+/- 10V or 20mA)
4 Output relais
8 Digital Output 2A
4 up/down counter
2 incremental encoder
4 Input self tuning PT100/PT1000

61. Compact I/O – OS-Wire Compact Module OS-Wire BUS 24 Digital Input
24 Digital Output
16 configurable Input/Output
Mini-Compact Module
CANopen BUS
16 Digital Input
16 configurable Input/Output

62. Bridge OS-Wire Bridge Module OS-Wire BUS 3 Analog axes interface
3 D/A converter
3 Encoder input
Touch Probe Input
3 Digital Input
3 Digital Output

63. OPEN-XS + Compact Operator Panel
TURNKEY solution
OPEN-XS + Compact Operator Panel
CNC
OPEN-XS with analog bridge
HMI
Compact Op. Panel 10.4" (1024x768)
I/O
Local on Bridge
Drive
VFD400
Motor
OS3 Motor

64. Utilities

65. Point to Point Remote Service (WinCE-WinXP/7)
CNC
Engineering
Gateway
Engineering PC
Customer
Gateway
Internet connection must be available through LAN
Public IP
Client Windows 7
Server Windows CE
Internet
Any VNC SW
UltraVNC
TightVNC
RealVNC
Embedded Remote Desktop
EfonVNC(free open source software)
VNC: Virtual Network Computing

66. Point to Point Remote Service (WinXP/7-WinXP/7)PC
Customer
Gateway
Engineering PC
Engineering
Gateway
Mobile Connection
Public IP
CNC
Internet
Server Windows XP/7
Client Windows XP/7
TeamViewer client
TeamViewer server

67. Remote Service possible structurePC
Engineering
Gateway
Customer
Gateway
Public IP
CNC
Internet
Router
Engineering PC

68. All OSAI products on the same network
PC “office”
WinMedia
Top5
P30L
Ethernet TCP/IP
Netbios over Ethernet
Open-M
Open-L
PRIMAlogic
Open-XS
Open-XL
SyncLogic
SyncMotion
10/Series
OS-Wire
Modbus

69. Q&A
Thanks