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IMBSIR 80-2073.3

Guidelines for Exchangeable APT Data Packages

APT Postprocessor Specifications

Prepared for the

Air Force Logistics Command

Sacramento Air Logistics Center

PRAM Office

Bradford M. Smith

June 1980

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!

: 100

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80-2073.3

I 1980

ATIONAL BUREAU

09 STANDARDS

LIBRARY

SEP 1 9 1980

Automation Technology Program

NBSIR 80-2073.3

ON

GUIDELINES FOR EXCHANGEABLE APT DATA PACKAGES

APT Postprocessor Specifications

Bradford M. Smith

June 1980

Prepared for the

Air Force Logistics Command

Sacramento Air Logistics Center

PRAM Office

U.S. DEPARTMENT OF COMMERCE, Philip M. Klutznick, Secretary

Luther H. Hodges, Jr., Deputy Secretary

Jordan J. Baruch, Assistant Secretary for Productivity. Technology, and Innovation

NATIONAL BUREAU OF STANDARDS, Ernest Ambler. Director
%
TABLE OF CONTENTS

INTRODUCTION -------- - - - - 3

SYSTEM REQUIREMENTS ---------- 5

FUNCTIONAL REQUIREMENTS 7

DOCUMENTATION REQUIREMENTS ------- 8

POSTPROCESSOR PROGRAM TAPE ------- 10

SOFTWARE VALIDATION ---------- 11

POSTPROCESSOR MACHINING TEST ------ 11

REFERENCES 12

- 1 -
PREFACE

This report documents work done at the National Bureau of Standards for the Air Force Logistics Command under Military Interdepartmental Purchase Request FD 2040 78 60013 from the Producibility. Reliability, Attainability and Maintenance Office at Sacramento Air Logistics Center. The Project Manager at Sacramento

was Mr. Cleon Binyon, and software modifications were under the

direction of Mr. Malcolm Allen at Ogden A i r Log i s t i c s Center.
INTRODUCTION

This document sets forth minimum specifications for the procurement of APT Pos tprocessor s for numerical controlled (NC) machine

tools in the Air Force Logistics Command (AFLC). The objective

is to obtain software which maximizes the productivity of the NC

equipment within the AFLC environment. This involves providing

the ability to quickly and easily exchange part programs among

different NC machine tools. Such portability of APT part program

data is achieved through a careful standardization of postprocessor language syntax and semantics, based upon ANSI X3. 37-1980,

with the burden being placed on the postprocessor to satisfy the

intent of the part programmer at all times. It is the purpose of

this specification to provide software which functions correctly,

which fully exercises all machine tool capabilities, and which is

well documented. To this end, these specifications will address

the following topics:

1. SYSTEM REQUIREMENTS

The computer system interface requirements for postprocessor operation. The coding and blocking of the output punch

file which subsequently is used to generate the NC machine

control media.

2. FUNCTIONAL REQUIREMENTS

The syntax of APT postprocessor language to be used and the

semantics, the desired functions to be performed at the NC

machine tool for each postprocessor language statement.

Error conditions to be detected by the postprocessor and

highlighted on the output listing.

3. DOCUMENTATION REQUIREMENTS

Documentation for computer programmer and part programmer.

Instructions for manual programming and for postprocessor

implementation .

4. POSTPROCESSOR PROGRAM TAPE

The form in which the software shall be delivered to the

using activity.

5. SOFTWARE VALIDATION

The methods by which the postprocessor is to be tested for

conformance with this specification.

6. POSTPROCESSOR MACHINING TEST

The methods by which the postprocessor output tape is to be

tested for properly exercising machine tool functions.

- 3 -
TABLE 1 MAJOR and MINOR WORD INTEGER CODES

MAJOR WORDS MINOR WORDS

AIR 10 11 ALL 5 1 MODE 1003

BREAK 16 ATANGL 1 NEUTRL 302

CLAMP 1 060 ~ AUTO 88 NODRAG 278

CLRSRF 1057 BORE 82 OFF 72

COOLNT 1030 BOTH 83 OMIT 172 * CUTCOM 1007 CCLW 59 ON 71

CYCLE 1054 CIRCUL 75 OPTION 144

DELAY 10 10 CL W 60 PARAB 77

END 1 CSINK 256 RADIUS 23

FEDRAT 1009 DEEP 153 RAIL 93

GOHOME 14 ~ DIAMTR 205 RANGE 145

INSERT 1046 DRAG 278 RAPFED 127 * LEADER 1013 DRILL 163 RAPOUT 189 #

LINTOL 1 068 ~ DWELL 1058 RAPTO 280

LOAD 1075 FACE 81 REAM 167

MACHIN 10 15 FEDTO 28 1 REAR 149 * MCHTOL 1016 FLOOD 89 REV 97

OPSKIP 1012 FRONT 148 * RIGHT 24

OPSTOP 3 HEAD 1002 ROTREF 68

ORIGIN 1 024 ~ HIGH 62 RPM 78

PARTNO 1045 HOMEPT 154 * SADDLE 150

PIVOTZ 10 17 IN CR 66 SIDE 94

PPRINT 1044 IPM 73 SFM 1 1 5 RAPID 5 IPR 74 STEP 92

RETRCT 7 KEYLCK 282 * TABLE 177

REWIND 1006 LEFT 8 TAP 168

ROTATE 1066 LINEAR 76 TAPKUL 91 * SELECT 1 07 4 # LOCK 1 1 4 TLANGL 156

SEQNO 10 19 LOW 63 TLCHG 147 * SET 1087 MAIN 93

~ TLSET 155 #

SPINDL 1031 MANOP 248 ~ TOOL 240 #

STOP 2 MANUAL 158 X AX I

S

84

TMARK 1005 MAX RPM 79 XYPLAN 33

TRANS 1037 MEDIUM 61 YAXIS 85

MILL 151 YZ PL AN 37

MIST 90 Z AX IS 86

ZXPLAN 4 1

NOTES:

* Extension to ANSI X3 . 37-1980 Standard APT vocabulary

Integer Code differs with ANSI X3-37-1980

// Integer Code not assigned by ANSI X3.37-1 980

- 4 -
SYSTEM REQUIREMENTS

The APT system and its postprocessor s are resident on an IBM

360/65 computer operating under OS/MVT release 21. 8F with

RJE/HASP version 3.2. The part programs are input to the IBM 360

thru a Systems Engineering Laboratories Model 32/55 computer

which emulates a standard IBM HASP interleaving work station.

The postprocessor shall be compatible with the IBM System/360 APT Numerical Control Processor (360-CN-10X) Version

4, Mod 3. This general processor is used by all AFLC installations for generating Numerical Control Part Programs.

The postprocessor load module shall execute in a region size

not to exceed 256 K bytes. This 256 K includes a 48 K APT

processor control region leaving a net postprocessor region

size of 208 K bytes. Overlays are acceptable.

Input to the APT Postprocessor shall be tool position data

on the APT Center Line (CL) file. Format and structure of

this file are given in the System/360 APT Numerical Control

Processor Operations Manual. Integer coding of APT postprocessor major and minor words shall conform to Table 1 .

The FORTRAN language shall be used to the maximum extent

possible. The compiler used by AFLC is IBM 360 FORTRAN IV

Level H. Programming techniques which exploit undefined or

non-standard features of FORTRAN, or exploit unique features

of a particular compiler are not acceptable.

No modification of the APT processor may be made by the

postprocessor during its execution. The postprocessor writer is encouraged to use the APT general processor utility

routines for performing system functions such as reading CL

records. Use of these routines shall be documented as

external requirements in the Computer Programmer’s Guide.

The machine control tape shall be output from the postprocessor as an 80 character card image NC Output file with

card columns 1 thru 72 containing machine tool coding and

columns 73 thru 80 containing an optional card sequence

number

.

NOTE: Certain commercial equipment is identified is this report

to adequately specify the software procedure. In no case does

this identification imply recommendation or endorsement by the

National Bureau of Standards, nor does it imply that the equipment is necessarily the best available for the purpose.

- 5 -
Starting information on the NC Output file, triggered by the

PARTNO statement, shall be the contents of the PARTNO statement in man-readable form followed by 24 to 36 inches of

leader. The punch codes comprising the man-readable section

shall not use channel 8 of the tape.

Final information on the NC Output file, triggered by the

FINI statement, shall be a Rewind command (M30) plus an End

of Block command followed by 24 to 36 inches of leader.

The End of Block Character (EOB) output by the postprocessor

shall be a dollar sign ($) or hollerith 11-3-8 punch. The

End of Record (EOR), tape mark (TM), and Rewind Stop (RS)

code characters shall be a pound sign (//) or hollerith 3-8

punch

.

The text output of the postprocessor shall be in a format

for printing on 132 column paper (11 x 14-7/8 inches). Each

page of the listing shall contain a heading consisting of

the contents of the PARTNO statement, the machine tool name,

the postprocessor name and a consecutive page number.

Each control block generated by the postprocessor shall be

printed on a separate line of the text output listing. Information shall include:

Section 1 statement number

Section 3 CLDATA record number

Control tape block number

End of motion machine coordinates

Feedrate in IPM/CSS

Spindle speed in RPM/CSS

Elapsed machine run and dwell times

Accumulated control tape footage

The diagnostic comments on the text output shall contain a meaningful description of the errors involved. The total

number of errors and warnings shall be printed at the end of

the postprocessor listing.

- 6 -
FUNCTIONAL REQUIREMENTS

The purpose of an APT postprocessor is to interpret the tool position data from the APT general processor and to direct the

operation of the selected NC machine tool. Tool position data

resulting from an APT part program is expressed on the Center

Line (CL) file containing cutter path, feedrate along that path

and auxiliary commands to be executed at certain positions. The

CL data represents the part programmer’s intent for the machining

operation. Each APT postprocessor shall satisfy this intent at

all times. Elements of this task are:

Every legal APT CL record shall be acceptable to the postprocessor without fatal error. Detailed syntax of these

records is to be found in American National Standards Institute document X 3.37 - 1980 on APT.

The postprocessor shall insure that CL records produce the

functional response at the machine tool as specified in the

AFLC APT Part Programmer's Manual.

Where the required operations cannot be accomplished by exercising automatic functions of the machine or the controller, the postprocessor shall accomplish the operation by alternative means, calling for operator assistance if necessary.

Any deviation from the functions in the AFLC Part

Programmer's Manual and any language extensions shall be

thoroughly documented in the Part Programmer's Guide supplied with the postprocessor

.

The postprocessor may ignore any legal APT CL record if a warning diagnostic is issued on the printed output and if

such handling is described in both the Part Programmer's and

the Computer Programmer's Guides.

APT CL records which appear to be illegal or undefined shall

be flagged with a diagnostic message indicating the source

statement at fault.

The postprocessor shall guard against any commands that

would cause damage to the cutter, machine, or workpiece.

The postprocessor shall recognize commands which exceed the

limitations of machine or controller and, if possible, output suitable action. If not possible, the postprocessor

shall issue diagnostic messages to the programmer identifying the source statement at fault.

The postprocessor shall provide for adequate validation of

input data and for orderly recovery when an unknown or undefined combination of input parameters occurs.

- 7 -
DOCUMENTATION REQUIREMENTS

Text and graphic documentation shall be provided to fully

describe the implementation, operation, use and maintenance of

the postprocessor software over the life of the machine tool.

Four particular forms of documentation are required; a Computer

Programmer's Guide, a Part Programmer's Guide, a Guide for Manual

Programming and an Implement er ' s Guide. Three copies of the documentation shall be furnished and delivered concurrently with

the postprocessor.

Computer Programmer's Guide

The Computer Programmer's Guide shall describe the operation,

modification and maintenance of the software. It shall contain

as a minimum the following information:

Narrative of the general organization of the postprocessor.

Narrative of the purpose and general flow of each subroutine

including the purpose and coding of all arguments.

The purpose, content and function of any overlays.

The function and usage of all data arrays including the

operation and coding of all intermediate data buffers.

Identification of all error diagnostic messages and their

originating subroutine.

The function and possible states of each flag variable including references to where it is set and where it is used.

Identification of machine tool and controller constants used

by the program. Explain the use of each parameter and the

method by which its value is calculated. Indicate how they

may be changed and what portions of the program are affected

by a change.

The assignment of COMMON variable blocks and the definition

and use of each variable name within the COMMON area.

Examples of all built in debugging aids used to localize

software problems.

Description of methods used to compute functions such as:

Acceleration-Deceleration

Tool axis orientation

Coordinate system transformations

Coded feedrate numbers

Coded spindle speeds

- 8 -
Part Programmer's Guide

The Part Programmer's Guide shall describe all special rules

which shall be followed by a part programmer in using the postprocessor. The guide shall act as a supplement to the AFLC APT

Part Programmer's Manual in specifying additional information as identified below:

Examples of common programming practice and interpretation

of typical output listings.

Usage of all machine dependent APT language commands such as MACHIN, ORIGIN and INSERT.

Illustrations of the physical axes of the machine tool including maximun departures and collision avoidance zones.

Listings of all part programmer error diagnostics and their

probable cause.

Descriptions of all default values assumed by the postprocessor . Limitations and restrictions on part programming techniques

or on input data values.

Usage of any APT language extensions not elsewhere documented, particularly those which are unusual or differ from ANSI

Standard, APT Encyclopedia or APT Dictionary usage.

Identification of applicable reference documents such as the

Manuf acturer ' s machine tool description and the control system description.

Guide for Manual Programming

The Manual Programmer's Guide shall describe all information

necessary to code the NC tape manually. It shall contain as a minimum a description of the following:

tape format and coding

preparatory and auxiliary functions

critical machine limits

coding procedure and precedence

data calculations

- 9 -
Impl eme n t er ' s Guide

The Impl ement er ' s Guide shall describe all information necessary

to implement the postprocessor. It shall contain as a minimum

the following information:

Narrative of the implementation on the target APT system.

Installation steps including the job control language necessary to execute each step.

Execution procedures including the necessary job control

language . Unique design characteristics of the postprocessor.

Procedures for modifying or changing postprocessor routines.

POSTPROCESSOR PROGRAM TAPE

The pos tprocessor shall be delivered on a magnetic tape with the

following physical characteristics

9 Track

Non-1 abeled

.

800 BPI.

Blocked 80 X 800.

As a minimum the postprocessor tape shall contain two files:

Postprocessor Source Code.

APT Test Part Program.

This program shall include coding designed to exercise the

postprocessor’s ability to call all pos tprocessor

subroutines, and to generate the NC output data necessary to

adequately test the machine's capability to perform the general operating characteristics, auxiliary functions, and

miscellaneous functions specified in the purchase description as well as the functions associated with any attachments or accessories.
SOFTWARE VALIDATION

The postprocessor program tape and the postprocessor documentation described above shall be furnished to the using activity who

will in turn forward the package to Hill Air Force Base for computer and compiler compatibility testing.

Hill AFB will refer to the Postprocessor Implementer ' s Guide to

compile the Postprocessor Source Code. Of specific interest will

be the compatibility of the postprocessor with the user's computer system specified herein. The source program shall be able to

be read from the Postprocessor Program Tape and be successfully

compiled without generating errors or causing system failure.

Hill AFB will compile the APT Test Part Program included on the

program tape and use the CL data generated to test the capability

of the postprocessor to successfully produce a text listing and

NC output tape without causing system failure or generating unresolvable diagnostics. Both the listing and the NC output tape

generated shall conform to the specifications herein.

If the Software Validation Tests are successful. Hill AFB will

forward the program tape to the using activity for use in the

Postprocessor Machining Test. All postprocessor errors or system

failures will be reported to the manufacturer and shall be

corrected by the manufacturer before the Postprocessor Machining

Test

.

POSTPROCESSOR MACHINING TEST

A machining test using the NC output tape defined in the Software

Validation section shall be demonstrated on the NC machine after

its installation at the using activity. The test shall demonstrate the ability of the NC system and machine to perform the

machining operations required herein. The NC output tape together with the part produced by the tape shall form a component of

the final acceptance of the postprocessor and the machine tool.

The material for the test part and the type of tooling used may

be of the supplier's choice. The spindle speeds and the

feedrates used shall be based on optimum cutting conditions. All

tools and materials required for the test shall be furnished by

the manuf ac tur er

.
REFERENCES

The following references may be used for additional information.

1. System/360 APT Numerical Control Processor Systems Manual

GY20-0080-2

.

2. System/360 APT Numerical Control Processor Operations Manual GH20-0331-6.

3. Guidelines for Exchangeable APT Data Packages

Final Report - NBS Report NBSIR 80-2073-1

! 4. Guidelines for Exchangeable APT Data Packages

Part Programmer's Manual - NBS Report NBSIR 80-2073-2

- 12 -
HBS-114A (REV. »-7»)

U.S. DEPT. OF COMM.

BIBLIOGRAPHIC DATA

SHEET

1. PUBLICATION OR REPORT NO. NBSIR 80-2073.3

TcwawTWflHon No. Z. fteciptent's Accession No.

4. TITLE AND SUBTITLE

Air Force Logistics Command

Guidelines for Exchangeable APT Data Packages

APT Postprocessor Specifications

5. Publication Date June 1980

7. AUTHOR(S) 8. Performing Organ. Report No. Mr. Bradford M. Smith

9. PERFORMING ORGANIZATION NAME AND ADDRESS

NATIONAL BUREAU OF STANDARDS

DEPARTMENT OF COMMERCE

WASHINGTON, DC 20234

Ifcfa^/Task/Work Unit No.

11. Contract/Grant No.

12. SPONSORING ORGANIZATION NAME AND COMPLETE ADDRESS (Street, city, state, zip)

Air Force Logistics Center

McClellan Air Force Base

California 95652

13. Type of Report & Period Covered Final

IP

15. supplementary NOTES This is a companion document to Air Force Logistics Command

Guidelines for Exchangeable APT Data Packages, Final Report

n Document describes a computer program; SF-185, FIPS Software Summary, is attached.

IS. ABSTRACT (A 200-word or less tactual summary of moat significant information. If document includes a significant bibliography or

literature survey, mention it here.) A method of APT programming and postprocessor design has been developed which permits more efficient data preparation for numerical control (NC) machine tools and

then allows this data to be quickly and easily exchanged among different NC

machines. This is accomplished through rigorous specification of the APT postprocessor language based upon new ANSI standards for APT plus a comprehensive

definition of the maching functions which should result from the use of each APT

language statement. Individual postprocessors are modified to process each statement in the same manner. This document sets forth minimum specifications for the

procurement of APT Postprocessors consistent with the standardized postprocessing

language concept. It is expected that these specifications will be used in future

machine tool procurements. The concept was successfully demonstrated in production

by processing a single APT data package on three different milling-drilling type

machine tools. A 23% increase in NC manufacturing efficiency j.s projected.

17. KEY WORDS (six to twelve entries; alphabetical order; capitalize only the first letter of the first key word unless a proper name;

separated by semicolons)

APT; Automation; Computer aided manufacturing; NC machining; NC programming;

Numerical Control; Part programming. Software specifications

18. AVAILABILITY [x

1 Unlimited

I | For Official Distribution. Do Not Release to NTIS

I I Order From Sup. of Doc., U.S. Government Printing Office, Washington, DC

20402, SD Stock No. SN003-003-

fXl Order From National Technical Information Service (NTIS), Springfield,

vAj. 22161

, y,$, Distribution Only

19. SECURITY CLASS

(THIS REPORT)

UNCLASSIFIED

20. SECURITY CLASS

(THIS PAGE)

UNCLASSIFIED

21. NO. OF

PRINTED PAGES

14

22. Price

$5.00

USCOMM-DC
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