Loading and proving computer control programs
Overview
This standard identifies the competences you need to load and prove computer control programs, such as computer numerically controlled (CNC) machine tools, co-ordinate measuring machines (CMM), programmable logic control (PLC), and robotic applications, in accordance with approved procedures. You will be required to obtain the correct component program, which may be on various types of media or downloaded from a remote computer. You will need to check the program for currency, and load it correctly into the machine controller, checking for faults or error messages and dealing with these, as appropriate to your level of responsibility. You will also be required to adjust the equipment and program, following proving/editing procedures, to achieve the specification. You must ensure that any edited programs are saved and backed up, safely and correctly.
Your responsibilities will require you to comply with organisational policy and procedures for obtaining, loading and proving the programs, and to report any problems with these activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying computer control program loading and proving techniques and procedures. You will understand the computer control equipment used in the process, and its application, and will know about the programming, editing and proving process, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the machine controller is set up to carry out its activities to the required specification.
You will understand the safety precautions required when working on the computer equipment and its associated accessories/equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety legislation and other relevant regulations, directives and guidelines
- use the correct control program and ensure it is correctly loaded into the machine controller
- follow the correct procedures for calling up the program and dealing with any error messages or faults
- confirm program integrity
- adjust the equipment and program operating parameters to optimise the outcomes to be achieved
- load and correctly set-up all associated equipment
- check that all safety mechanisms are in place and that the equipment is set correctly for the required operations
- produce and maintain records in accordance with organisational requirements
- deal promptly and effectively with problems within your control and report those that cannot be solved
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken when loading and proving computer control operating programs
- how to start and stop the equipment in normal and emergency situations
- the importance of wearing the appropriate protective clothing and equipment (PPE) and of keeping the work area clean and tidy
- how to handle and store program media, safely and correctly, away from contaminants and sources of corruption
- the computer coding language used in operating programs
- the function keys and operating system of the computer control system being operated
- how to load, execute, edit and exit programs correctly
- how to set machine datums for each machine axis being used
- how to deal with error messages and faults on the program or computer controlled equipment
- how to place the controller into the correct operating mode, and access the program edit facility, in order to enter data (such as tool datums, positions, lengths, offsets and radius compensation)
- the use of tooling magazines and carousels, and how to identify the tooling in relationship to the operating program
- how to conduct trial runs (using single block run, dry run and override controls)
- the items that you need to check before allowing the equipment to operate in full program run mode
- the application/output of the program being proved
- the numbering system and codes used for identification of control input and outputs
- how to search the program within the controller for specific elements
- programming techniques and codes used (such as interlocking, timers, counters, sub-routines)
- how to force contacts
on' andoff' to check if peripherals are operating correctly - the techniques involved in editing, entering and removing contacts from lines of logic and, where applicable, the procedure to be followed for
on-and `off-line' programming - how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS or ISO standards) in relation to work undertaken
- how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
- factors which affect the feeds and speeds that can be used, and why they may need to be adjusted from the program setting (such as condition of material, workholding method, tooling used, tolerance and finish to be achieved)
typical problems that can occur with the loading and editing of the operating program, and what to do if they occur
the extent of your own responsibility, and whom you should report to if you have problems that you cannot resolve
Scope/range
Ensure that you apply all of the following checks and practices during the programming activities:
- the correct operating program is obtained and checked for currency and validity
- the machine controller is prepared, ready to accept the operating program
- the program is loaded into the controller, safely and correctly
- program media is stored safely and correctly, away from contaminants or sources of corruption
Load and prove programs for one of the following types of computer control equipment:
- CNC machine tools
- industrial robots
- co-ordinate measuring machines
- PLC equipment
Obtain and load programs stored on one of the following mediums:
- remote or networked computer terminal
- machine controller
- personal computers
- tape (such as punched or magnetic)
- handheld programmers
- disk
- other specific media
Operate the controller using six of the following, as applicable to the equipment type:
- use single step/single block run mode of operation
- graphic displays
- full dry run
- search facilities
- program save/store facilities
- edit facilities
- program override controls (speed, feed, tool data)
- data input facilities
- data output peripherals (such as printers)
- speed and acceleration parameters
Confirm that the equipment and program operates safely and correctly by carrying out the following, as applicable to the type of equipment used:
either carry out all of the following:
- check that datums for each axis are set in relation to the equipment/component and tooling used
- ensure that start-up positions are safe and correctly set
- ensure that tooling information is correctly entered into the machine controller (such as type, number, position)
- check that tooling change positions are safe and clear of the workpiece and other devices (such as clamps, jigs and fixtures)
- ensure that the correct tooling is selected at the appropriate points in the program
- check that tooling/operational paths are executed safely and correctly
- ensure that all operations are carried out to the program co-ordinates
- save edited programs
- produce back-up copies of completed programs
- ensure that any alterations to programs are communicated fully to the appropriate personnel
or carry out all of the following:
11. force contacts on' andoff' and check for correct operation of peripherals
12. edit, enter and remove contacts from lines of logic, where appropriate
13. check counter and timer settings
14. save edited programs
15. produce back-ups of completed programs
16. ensure that any alterations to programs are communicated fully to the appropriate personnel
or carry out all of the following:
17. confirm that the robot operates within the defined operating environment/envelope/cell layout
18. ensure that start-up positions are safe and correctly set
19. check that intrusion monitoring systems are operating correctly (where appropriate)
20. check that robot operations are executed safely and correctly
21. monitor and review cycle times
22. ensure that all operations are carried out to program co-ordinates
23. save edited programs
24. produce back-ups of completed programs
25. ensure that any alterations to programs are communicated fully to the appropriate personnel
Produce and maintain appropriate records of program proving activities, using two of the following methods:
- written or typed report
- electronic mail
- computer record
- verbal report
- specific company form