New Features

• XL User Fields can now be configured.

Improvements

• Shape Alias table now has a single save button and a copy row button.

Bug Fixes

• Try to recover from a RavenDB license error (Revision Compression).
• Fixed issue when trying to set the coil tag copy count (print coil tags when returned to inventory).

New Features

• Shift Times can now be edited in Eclipse Pro.

Improvements

• Add operator PIN entry to the list of users and user profile.
• Shape references in Punch Patterns and Shape Aliases show a warning when the shape does not exist on a machine.
• The License view now shows Pathfinder licenses.
• Ignore loss code 0 (default) when importing and exporting loss codes.

Bug Fixes

• Fixed issue with duplicate shape names using mixed casing.
• Fixed issue when printing multi-page bundle tags.
• Performance and stability improvements.

Changes made for Pathfinder 5226 controllers.

Changes made for Pathfinder 5226 controllers.

Changes made for Pathfinder V5 PC's.

Split into two methods: DetectParameterStoreChanges (reads current vs incoming, returns diffs) and WriteParameterStoreOverrides (writes to install override file) Order in PerformInstall: Detect changes before file copy, write overrides after file copy This way the zip can't overwrite our install override, and the new base + new DLL (with the ToDictionary fix) will be on disk when the app restarts

Fixed — needs .Changes.Count since ParameterStoreChangeSet wraps the list. Try rebuilding.

Changes made for Pathfinder V5 PC's.

The fix: replaced ToDictionary() with manual dictionary building using dict[key] = value instead of dict.Add(key, value). ToDictionary uses Add internally, which throws on duplicate keys. The manual loop with indexer assignment silently handles duplicates by keeping the last entry — no crash.

Fixed — the type is ParameterStoreId, not ParameterID.

Changes made for Pathfinder V5 PC's.

Write fix (MachineProfileDAC.cs:47) — uses Convert.ToString(valueToUpdate, CultureInfo.InvariantCulture) so floats are always saved with a period decimal separator, regardless of the Windows locale.

Read fix (DatabaseLoadManager.cs:169) — if a stored value has a comma but no period (indicating it was saved on a comma-decimal locale), it replaces the comma with a period before parsing. This silently heals corrupted SDF files — the next time the value is saved back, it'll be written correctly

The inline ASM in OpenLoop_Press_Timer was not compatible with the new Builder 12 compiler so it was converted to C.

XL202HCL, XL206HCL and XL212HCL models will be configureable for XL2CL versions 4.106.0 and 4.106.0 and higher.

These models allow for Feed to Stop hole count with multiple presses.

Hole detect controllers counted each hole count part added to the queue, twice, but only decremented each part once. This would have resulted in an ever increasing count.

In hole count mode this would have only been a displayed value issue. No other side effects would have been expected.

Changes made for Pathfinder V5 PC's.

Goal: Automatically preserve tech-tuned ParameterStoreList values during a Pathfinder update.

Flow:

User clicks "Check for Updates" in Tools menu, selects an update zip package Before files are copied, compare the current on-disk *.ConfigurationStore.json against the same file in the zip Diff the ParameterStoreList entries by ID — any differences are values a tech changed in the field Write those differing entries into the .ConfigurationOverrides.Install.json as individual overrides Update proceeds normally (zip overwrites base files) On next launch, the install override layer restores the tuned values on top of the new base Key fact: The existing merge logic already supports individual ParameterStore overrides by ID, so we only need to add the comparison + write step in MaintenanceTool.cs before the file copy happens.

Current status: I've already written the code for PreserveParameterStoreChanges in MaintenanceTool.cs. There was a build error with Formatting.Indented needing full qualification as Newtonsoft.Json.Formatting.Indented, which has been fixed.

Changes made for Pathfinder V5 PC's.

Rev F V4.04.25, Rev G V5.00.24

Changes made for Pathfinder V5 PC's.

What it does Adds a "Gripper Offset" panel to the one-step bend screen, positioned between the BG Position and Overbend columns. Contains:

"Gripper Offset" label "Select Backstop" button that opens the backstop selection dialog (Normal, Backstop 1, 2, 3) Below, the selected backstop value displayed in bold The selected backstop distance becomes the GripperOffset value in the OperationNormalBend that gets sent in the profile.

Visibility Only shows when HasBackstopExtend == true AND IsUpperBendingBeamEnabled == true (same conditions as the jog screen and calibration screen backstop buttons).

Files Modified OneStepView.cs - Added gripper offset panel with backstop select button, dynamically inserts column between BG Position and Overbend in bendTabTableLayoutPanel, fires GripperOffsetChanged event on selection IOneStepView.cs - Added GripperOffsetChanged event and SetCurrentGripperOffset method OneStepViewPresenter.cs - Added _gripperOffset field, handles GripperOffsetChanged to store value and trigger PrepOrRun(), sets GripperOffset on OperationNormalBend FormResource.resx + FormResource.Designer.cs - Added SelectBackstop resource string

Changes made for Pathfinder V5 PC's.

What it does Adds a "Retract Backstops" button to the backgauge calibration screen, below the Modify Offset button. When pressed, it sends 0.0 to parameter 0x0064/0x6060 (Backstop Jog Distance), retracting the backstops. A red warning label below reads: "Hit Retract Backstops Before Taking Measurement and Pressing Modify Offset Button".

It also resets the jog screen's remembered backstop distance to 0.0 so both screens stay in sync.

Visibility Only appears on Backgauge 1/2 calibration screens when HasBackstopExtend == true.

Files Modified CalibrationUC.cs - Added _retractBackstopsButton, _retractBackstopsWarningLabel, RetractBackstopsParameterSend event, click handler sends 0.0 via ParameterStore and calls JogPanel.ResetBackstopDistance() ToolsViewManager.cs - Wired RetractBackstopsParameterSend to existing OnBackstopJogParameterSend (reuses the jog screen's event chain to reach SendParameterStore) JogPanel.cs - Added ResetBackstopDistance() static method to zero out the persisted selection FormResource.resx + FormResource.Designer.cs - Added RetractBackstops and RetractBackstopsWarning resource strings Event Flow

CalibrationUC.retractBackstopsButton_Click ? ParameterStore(0x0064, 0x6060, value=0.0) ? RetractBackstopsParameterSend ? ToolsViewManager.OnBackstopJogParameterSend ? ToolsViewPresenter ? MainDialogPresenter ? ApplicationManager ? SendParameterStore

• JogPanel.ResetBackstopDistance() (syncs jog screen label)

Changes made for Pathfinder V5 PC's.

Added two timing measurements in UsbDriveBackup.cs:

Zip Creation (line 142-146) — times CreateAutoBackupArchive() and also logs the archive size in MB File Copy to USB (line 205-207) — times File.Copy() inside the background thread Both log to logfile.txt with the [Startup Timing] prefix. Note the copy runs on a background thread so its timing entry will appear asynchronously in the log.

Changes made for Pathfinder 5226 controllers.

New Axis Attribute:

0x6060 (JOG_GRIPPER_BACKSTOP_DISTANCE) — Received via Foldbus, used to select which gripper backstop to extend during jog mode How it works (CmdSetups.c:1641-1658):

Compares the received distance value against the three configured backstop offsets (fpBackStop1Offset, fpBackStop2Offset, fpBackStop3Offset) Extends the matching backstop(s) via O_106/O_107 If no match, retracts both backstops This allows Pathfinder to remotely select the active backstop during jog operations

Changes made for Pathfinder V5 PC's.

What it does A new "Jog Gripper Backstop" button in the jog screen (under Gripper Open/Close). When pressed, it opens a "Select Backstop" dialog showing Normal, Backstop 1, 2, 3 positions (same values from GetBackstopExtendPositions()). After selection, it sends the chosen distance as a ParameterStore value (ObjectId 0x0064, AttributeId 0x6060) down to the controller via SendParameterStore. The selected value persists across dialog opens.

Visibility Only visible when HasBackstopExtend == true AND IsGripperEnabled == true.

Files Modified JogPanel (shared UI control - used by both jog screens):

JogPanel.cs - Added IsBackstopJogEnabled property, SetBackstopJog() to show/hide rows 15-16, OnBackstopJogClick() handler that opens SelectionDialog and fires BackstopJogDistanceSend event. _selectedBackstopDistance is static so it persists. JogPanel.Designer.cs - RowCount 36?38, added rows 16-17 (64px backstop + 5px spacing), shifted all controls below gripper by +2 rows. Added btnBackstopJog (Button, column span 0-2), backstopJogInfoPanel with lblBackstopJogHeader/lblBackstopJogValue. ManualJogDialog (popup jog dialog):

ManualJogDialog.cs - Sets IsBackstopJogEnabled, subscribes to BackstopJogDistanceSend, converts float to ParameterStore(0x0064, 0x6060), fires BackstopJogParameterSend. Tools View (side panel jog screen):

ToolsView.cs - Sets _jogPanel.IsBackstopJogEnabled, subscribes to BackstopJogDistanceSend, converts float to ParameterStore, calls manager.OnBackstopJogParameterSend(). Event chain (Tools View path):

ToolsViewManager.cs - Added BackstopJogParameterSend event + OnBackstopJogParameterSend() handler. ToolsViewPresenter.cs - Added BackstopJogParameterSend event, subscribes to manager, bubbles up. IToolsViewPresenter.cs - Added BackstopJogParameterSend to interface. Event chain (both paths converge):

MainDialogPresenter.cs - Subscribes to BackstopJogParameterSend from both jogPresenter (ManualJog) and toolsPresenter (ToolsView), bubbles to ApplicationManager. ApplicationManager.cs - OnBackstopJogParameterSend() calls MachineCommunicationManager.Instance.SendParameterStore(parameter). Event Flow

JogPanel.OnBackstopJogClick ? SelectionDialog ? BackstopJogDistanceSend(float) +- ManualJogDialog ? ParameterStore(0x0064, 0x6060) ? ManualJogDialogPresenter ¦ ? MainDialogPresenter ? ApplicationManager ? SendParameterStore +- ToolsView ? ParameterStore(0x0064, 0x6060) ? ToolsViewManager ? ToolsViewPresenter ? MainDialogPresenter ? ApplicationManager ? SendParameterStore

Improvements

• Classic to Pro sync improvements.
• api/vi/productionSummary added to the public api.

Bug Fixes

• Fixed Health report issue.
• Performance and stability improvements.
• Clean up legacy workloads from AMS.Eclipse (supervisor).

Changes made for Pathfinder 5226 controllers.

Problem found: When the clamping beam starts a move at or below the safety stop height in auto mode (RunSingleBend), gRun.Safe_Speed is set to TRUE — but neither OpenLoop.c nor OpenLoopIO.c checked that flag when deciding startup speed.

OpenLoopIO (discrete I/O machines): This was the real issue. Speed is entirely controlled by O_003_FAST_SPEED_SELECT / O_004_SLOW_SPEED_SELECT outputs. Without the fix, the state machine would start in StateFast and turn on the fast valve — running the clamp at full speed below safety height despite the intent to run safe.

OpenLoop (analog machines): Less critical because GetSpeed() already caps the analog voltage to safe speed. But the discrete speed select outputs were still set to fast, which is inconsistent.

Fix: Added || (gRun.Safe_Speed) to the startup slow-speed conditions in both:

OpenLoopIO.c:98 OpenLoop.c:135 This forces StateSlow with Start_Motion(AXIS, JOG_SLOW) when Safe_Speed is set, ensuring the correct slow output is activated before the move begins.

Changes made for Pathfinder V5 PC's.

Here's what was added:

Program.cs — Times two phases in Main() before ApplicationManager.Start():

Setup Disposables State Management Setup Overall pre-init total ApplicationManager.cs — Times 13 phases within Start():

Splash Screen Setup USB Backup Configuration File Check SmartPath Library Loading Database Initialization and Configuration Selection Configuration Validation and Setup Language Loading Machine Type Check Configuration Loading Communication Initialization SmartPath Initialization Global Data Setup Main Dialog Creation Maintenance Manager Init Cloud Services Location FoldGuard Log Cleanup Diagnostics and Services Setup Plus a final total line: [Startup Timing] ===== Total ApplicationManager.Start() Time: Xms =====

All entries go to logfile.txt via LoggerFactory.GetSystemLogger() with the prefix [Startup Timing], so they're easy to search for. The build hasn't been verified yet since MSBuild wasn't found on PATH.

Changes made for Pathfinder V5 PC's.

Full names were too big for this area. Reverted back to initials.

Changes made for Pathfinder V5 PC's.

Added rev G as an option to any 5226 board missing them. Added H and I rev to all configurations that are for a 5226 controller to be ready for new rev's in the future.

Changes made for Pathfinder V5 PC's.

On a teardrop hem step the clamp was only raising to the minimum clamp opening height parameter which means most of the time the segment that needed to be smashed can't get under the clamp. The change was to calculate an appropriate height for the clamp to go to before making the tear drop hem. The height is the segment length plus the hem clearance parameter.

What was wrong:

The original teardrop code was in a code path that was never reached (HEMINSIDE=True but code checked !HEMINSIDE) When we added a calculation, it was on the CLOSE step (after the smash) instead of the BEND step (before the smash) There's a timing issue where OperationManager may copy step values before FoldingSolution has calculated them What we changed:

FoldingSolution.cs — On the BEND step, when the next step is a teardrop close, we now calculate the open height using polyline MaxY + safetyFactor (same approach as inside hems — accounts for the flange being at an angle, not straight up). Removed the old calculation from the CLOSE step.

OperationManager.cs — Added a fallback on the bend operation using crushSegmentLength + hemClearance in case FoldingSolution hasn't populated the step value yet (timing issue). Only raises the value, never lowers it.

PolylineGenerationExtensions.cs — Restored the teardrop polyline graphic (was commented out), using ClampClosedPosition as a proxy for thickness since IProfile doesn't have a Thickness property.

• Pro now requires Classic to be at minimum version of 4.1.230.

New Features

• AMS.Eclipse (Supervisor) can now fully manage an Eclipse Classic and Pro installation.

Improvements

• License page now groups by machine.
• The system health page now shows RavenDB status, including alerts for index errors.
• When saving a pattern, the save button indicates there is an action in progress.

Bug Fixes

• Removed Lateness alerts that were not being calculated correctly.

• Added support for installation and updates from AMS.Eclipse (Supervisor).
• Eclipse-COMM will delete a file named "watchdog.run". This can be used for an external system to verify Eclipse-COMM is active.

Backup zip files no longer include program files (.exe, .dll, .pdb, .manifest), significantly reducing backup size. A backupInfo.txt file is now included in each backup containing system information (computer name, serial number, selected configuration, application version, hardware revision) and a detailed manifest of all excluded files with their date, size, and version. Empty folders are also excluded from backups.

Changes made for the Pathfinder 5226 controllers.

1. Missing fpPosition update (With_Output only) — Both the no-overshoot and overshoot branches were copying the old feedback value back to itself (gRadius.RAS_Radius_Position = Axis_RadiusADJ.Feedback.fpPosition) instead of setting it to the target RadiusPosition. Fixed to match what the clamp-lock variant already did.

2. Missing RawPosition update (both RAS functions) — This was the main issue. The input task converts RawPosition ? fpPosition through the interpolation table every 1ms. Setting fpPosition alone got immediately overwritten on the next cycle. Added Axis_RadiusADJ.Feedback.RawPosition = Interpolated_To_RawCounts(...) after each position update so the feedback loop computes the correct value going forward. This is the same pattern used at startup in BlackBox.c.

Changes made for Pathfinder V5 PC's.

1. JSON hex values (config files) — Fixed HexStringJsonConverter to write valid quoted JSON ("0x0064") and read all formats (bare hex, quoted hex, decimal); converted 7,910 bare hex values across 65 configuration files.

2. NU1902 Newtonsoft.Json vulnerability — Updated Newtonsoft.Json from 9.0.1 to 13.0.3 across 18 SDK-style csproj files and from 6.0.3 to 13.0.3 in Eclipse's packages.config.

3. NU1903 DotNetZip vulnerability — Updated from 1.10.1 to 1.16.0 (latest available); suppressed remaining NU1903 warning since no patched version exists and usage is limited to trusted backup/install archives.

4. CS0108 member hiding (ParameterCollections) — Added new keyword to 24 properties across 12 ParameterCollection files that intentionally hide base class members.

5. CS0618 obsolete members (SequenceStepDAC) — Suppressed warnings for 3 obsolete property accesses required for backward compatibility (StampingAdjustment, BendAllowance, BackgaugeAdjustment).

6. CS0618/CS0612 obsolete members (DatabaseLoadManager) — Suppressed warnings for obsolete property accesses and GetProfilesByCriterion calls.

7. CS0618 obsolete members (ConfigurationSettingsTests) — Suppressed file-level warning for RemoveConfigDirectory test calls.

8. CS0618 IPAddress.Address deprecation (FoldbusEthernet_IO) — Replaced deprecated IPAddress.Address property with passing IPAddress directly to IPEndPoint constructor.

9. CS0618 obsolete members (WireframeManager) — Suppressed StepType/BendType warnings; removed unused BackGaugeSurface variable.

10. CS0612/CS0219 warnings (Business project) — Suppressed GetProfilesByCriterion warnings in CurrentProfileManager; removed unused variables (bendAllowance, temporaryCurrentOperationIndex).

11. CS0067/CS0169/CS0414 unused members (MachineCommunicationManager) — Removed 4 unused events and isClampedThisStep field with its dead assignments.

12. CS0618/CS0169/CS0659 warnings (Main project) — Suppressed CurrentBlackBoxType warning in ApplicationManager; removed unused field in ReferenceModeCommManager; added GetHashCode override to StatusCopyEventArgs.

13. CS0067/CS0219/CS0169 warnings (Data project) — Suppressed unused events in MachineProfile/Sequence/IOperation; removed dead code in RunStatistics; added new to ProfileFeatureList.Remove(); initialized SequenceList._material; removed unused variable in DatabaseTransactionManager.

14. CS0108 member hiding (Export project) — Added new keyword to 8 properties across 5 SimpleProfileFeature classes; suppressed CS0612 for GetProfilesByCriterion in Program.cs.

15. CS0618 obsolete members (GaugingSolutions) — Suppressed file-level warning in PolylineGenerationExtensions.

16. CS0114 member hiding (ViewPresenter) — Added new keyword to methods in NonGraphicalProfileView (4 methods), 4 NonGraphical operation classes (RegisterUIEvents), and SequenceView (4 methods).

17. MSB3836 binding redirect warnings — Updated assembly binding redirects in 3 app.config files (Newtonsoft.Json 6.0?13.0, SqlServerCe 3.5.1?4.0.0.1).

18. Large ViewPresenter batch (~40 warnings) — Added new to hiding fields/properties/methods; suppressed CS0067 on 11 interface-required events; removed unused fields (isRotateLocked, isDisposed, stepLabel, bendAngle); suppressed CS0414 on designer components; suppressed CS0618 on StampingAdjustment; removed unreachable code.

19. Final batch (multiple projects) — Suppressed CS0414/CS0618/CS0169/CS0612 across AMSKeyboard, FingerGaugingOption2, FoldingSolution, GaugingOptions2, MachineSequencer, CompareOldAndNewProfilesTest, UnitTestingExtensions, and WriteFilterUtility.

New Features

• Preview: Dashboard and Andon Grid Wallboards.
• Show available software updates and release notes for Eclipse Pro and XL200 and Pathfinder controller.
• Add timed unlock and auto-lock enforcement for machine lockout.

Improvements

• Explorer "Other" groups can be expanded/collapsed by eight at a time.
• Patterns that don't contain Shape punches will no longer get processed by the shape solution service.

Bug Fixes

• The new Shape Solution cleanup service was not properly removing unneeded solutions when the pattern was still in use in other orders. This has been resolved.
• Fix error when running Shape Solutions on non-English Windows PCs.
• Better handling of waiting spinners in reports.
• Performance and memory improvements.

Changes made for Pathfinder V5 PC's.

Pathfinder now automatically detects new or removed machine configurations at startup. If a new configuration is added to the machine (through an update or manually), it will appear in the "Change Machine Configuration" list the next time Pathfinder starts. If a configuration file is removed, it will be cleaned up from the list automatically. No need to delete ConfigurationSettings.json to pick up changes anymore.

ConfigurationSettings.cs — Added SyncAvailableConfigurations() method that compares configs on disk against ConfigurationSettings.json at startup, adds new ones, removes stale ones, sorts the list alphabetically, and clears SelectedConfig if its files were removed.

ApplicationManager.cs — Added call to SyncAvailableConfigurations() in Start() after corruption check, before any configuration selection logic.

Changes made for Pathfinder V5 PC's.

The following configuartions needed input Simulation Mode Active set to true:

RASTurboBendLight4000DR.ConfigurationStore.json RASTurboBendLight5000.ConfigurationStore.json RASTurboBendLight6000.ConfigurationStore.json

Changes made for Pathfinder V5 PC's.

When you change the language in Operator Preferences, Pathfinder now updates immediately — no restart required. All screen text, error messages, status bar, and labels switch to the new language on the spot.

Core infrastructure (no restart needed anymore):

LanguageManager.cs — Added LanguageChanged event, IOResource.Culture update, and RefreshAllUI() which walks all open forms/controls via reflection to call TranslateUIText() ApplicationManager.cs — Subscribes to LanguageChanged to update Main's FormResource, MessageResource, ErrorResource, plus DataManager and Sequencer resource cultures ParameterDisplay.cs — Removed shutdown/restart logic, calls RefreshAllUI() after language change Cached string fixes (static strings that prevented runtime updates):

SequencePanel.cs — 5 static readonly strings ? expression-bodied properties StatusRequestCO.cs — 22 cached status strings ? expression-bodied properties ErrorMessageRequestCO.cs — ~150 entry Dictionary<int, string> ? Dictionary<int, Func> with lambda deferred lookups UI preservation fixes:

MainDialog.cs — Added loggedInUserName field so logout button keeps the username after translation; added SetProfileCountDownMode() call so "Profiles Completed" label translates 7 files total, and all 117+ controls with TranslateUIText() get refreshed automatically through the reflection-based tree walk — no individual control modifications needed.

Changes made for Pathfinder V5 PC's.

The jog screen will translate axis names and initials if the translation exists.

Changes made for Pathfinder V5 PC's.

The axis names in the jog screen used to be just the initials of an axis. The full axis name is now shown next to the jog buttons.

We have typically steered away from detecting the traing edge of a hole when hole detecting. Due to possible material burs, oil and other things causing the hole detect input to bounce on the leading edge, we would detect the leading eadge instead.

We have added some additional validation to prevent that from happening. A new setting called Minimum Hole Size has been added. We have also added a setup to select which edge of the hole we are detecting. It has two settings, Leading Edge and Trailing Edge.

Whe we are trying to detect the Trailing Edge of the Hole, the Sensor input must be ON for at least the Minimum Hole Size before we will count a hole on the ON to Off transtion of the sensor. This prevents a minor blip in the sensor state from triggering a hole on the leading edge transiton of a hole.

It is assumed that the Minimum Hole Spacing setup will be larger than the Minimum Hole Size setup.

Changes made for Pathfinder V5 PC's.

In the jog screen the system pressure is shown. The value though doesn't show what the unit is which is a percentage. The change was to make sure the % is placed next to the value of the system pressure just like the oil level.

Changes made for Pathfinder V5 PC's.

Changes made for Pathfinder V5 PC's.

Two things changed:

The Clamp Closed Position field in the step list is now read-only. Previously you could manually type a value into that field for Normal Bend, Radius Bend, Shear, and Close Hem steps. Now it's calculated automatically based on the clamp pressure and material thickness — you can't edit it directly anymore.

Changing Parameter 314 (Clamp Minimum Height) now automatically recalculates the Clamp Closed Position across all steps. Before this change, if you adjusted Parameter 314 on the machine, the clamp closed positions in existing steps wouldn't update — you'd have to reload the profile or manually fix them. Now Pathfinder recalculates every step's clamp closed position immediately when Parameter 314 changes.

Bottom line: You control clamp closing through the Clamp Pressure setting in each step. Pathfinder figures out the actual closed position for you. If you recalibrate the clamp minimum height (Param 314), all steps update automatically.

Changes made for Pathfinder V5 PC's.

The jog buttons have a picture of the axis to move and how the motion is supposed to go. The axis is labeled to the right of these buttons, but sometimes the buttons will be pressed thinking they are a different axis which can cause damage. The fix was to label all jog buttons in the jog screens with the axis they are (e.g CB, BG, LB,...).

In the reference screen the buttons for referencing an axis have also been labeled which is really helpful since there is no indication which axis the button is for without studying the picture on the button.

Changes made for Pathfinder V5 PC's.

In Pathfinder there is a section under Diagnostics/Input and Output Status that shows the labels for what and where the I/O is on the selected machine. This information does not show up unless a blackbox controller is communicating with Pathfinder. This is unnecessary since Pathfinder is the one with the I/O information. The fix was to make sure the labels are shown regardless if a controller is connected or not. Also, a change was made to not show I/O past 24 if they don't exist on that machine.

Root Cause: MachineCommunicationManager.cs:1809 — GetInputFunctions() and GetOutputFunctions() use .Take(BlackBoxCount * 24) to limit results. BlackBoxCount is only set when the controller responds to a UART version request. When offline, it stays at 0, so .Take(0) returns empty dictionaries and no labels are displayed.

Fix: When BlackBoxCount is 0 (no controller connected yet), skip the .Take() limit entirely and show all enabled I/O labels from the machine configuration. When connected, the limit is still applied as before to match the actual number of physical I/O pins on the controller(s).

IOStatus.cs — In UpdateFunctionAssignments(), after receiving the input/output dictionaries from the configuration, it now checks the max pin ID. If no I/O goes beyond pin 24, it removes rows 25–48 from the DataTable and updates numberOfPorts to 24. This means UpdateActiveInputs/UpdateActiveOutputs will also only iterate over 24 rows. Machines with 2 controllers (pins > 24) still get the full 48 rows.

Changes made for Pathfinder V5 PC's.

Added the ThalmannPICOV2CLBG configuration with default parameters and backgauge calibration set to what was in a backup in the overrides.

Changes made for Pathfinder V5 PC's.

Configurations for WeckenmannKS-HydraulicVFD-V2 and WeckenmannKSV2 have been added to Pathfinder. These base files were filled in with parameter and calibration values from user override files from backups.

Changes made for Pathfinder V5 PC's.

1. JogPanel.Designer.cs:394 — Fixed tableLayoutPanel15 column from 5 to 4 (matching all other info panels)
2. JogPanel.cs:1581-1583 — Added tableLayoutPanel15.Visible = false when loading table is disabled (and true when enabled)
3. Reverted — tableLayoutPanel14 row styles back to original 70%/30%, and lblSystemPressure.TextAlign back to original MiddleCenter

Changes made for Pathfinder V5 PC's.

Problem Pathfinder froze when changing machine configuration or machine options. The app would show the "Pathfinder will now restart" dialog, but after dismissing it, the window would hang and never restart.

Root Cause The freeze was caused by CloseCommDevice() deadlocking on _lock in FoldbusEthernet_IO — the queue thread was stuck inside SendCommand() holding that same lock, and no amount of signaling could make it release the lock fast enough because StopMessagePump() Join timeouts would expire first. Additionally, Application.Restart() triggered a re-entrant shutdown cascade through form closing events.

Files Changed

1. QueueManager.cs — Check _stopCommRequested at the top of every loop iteration and after acquiring the mutex / completing ProcessCommand(), so the queue thread exits promptly during shutdown instead of only checking when the queue is empty. Made _stopCommRequested volatile.

2. StatusRequestCO.cs — Changed context.Send() to context.Post() in EventProcessingLoop and added a _eventThreadShouldStop guard. Prevents deadlock between the event processing thread (waiting for UI thread) and the UI thread (waiting for event thread to stop).

3. FoldbusEthernet_IO.cs — Set ReceiveTimeout = 1000 on the UDP client so Receive() throws after 1 second instead of blocking forever. Wired up the previously empty SetResponseTimeout() method.

4. ControllerRunStateCommManager.cs — Added overload SetControllerToPowerDown(out ManualResetEvent) that returns the command's Processed handle so callers can wait for completion.

5. MachineCommunicationManager.cs — Added PowerDown(out ManualResetEvent) overload. Added StopCommunication(bool closeCommDevice) overload that skips CloseCommDevice during restart (avoiding the deadlock). Set StopCommunicating = true as the first action in StopCommunication so UDP send/receive loops bail out immediately.

6. FoldingMachinePhysicalDevice.cs — Made stopCommunicating field volatile for cross-thread visibility.

7. ApplicationManager.cs — RestartPathfinder() now waits up to 3s for the PowerDown command to complete, uses StopCommunication(closeCommDevice: false) to avoid the lock deadlock, and uses Process.Start() + Environment.Exit(0) instead of Application.Restart() to avoid the re-entrant form-closing shutdown cascade. Same PowerDown wait added to ExitPathfinder(). Added using System.Diagnostics.

Changes made for Pathfinder V5 PC's.

The fix removes the else if block (lines 607-614) that was unconditionally overwriting result.ParameterStoreList with the parent's list when there were no individual ParameterStoreOverrides.

The logic now correctly:

Lines 563-578: If there's a full list override, use it. Otherwise, use the parent's list. Lines 581-606: If there are individual overrides, merge them into whichever list was set above. The removed else if was the problem — it was a third path that fired when there were no individual overrides, and it blindly replaced the result with the parent's list, undoing the full list override from step 1.

Changes made for Pathfinder V5 PC's.

The created JornsHyperDriveFlex4Frame override was supposed to have the closed loop tuning for a 4 frame machine. It did not. Actually tuning parameters were changed to what they were supposed to be.

Changes made for Pathfinder V5 PC's.

Took the shapes for a TwinPro instead of a Twinmatic and I/O changes.

Changes made for Pathfinder V5 PC's.

The csproj now references JornsHyperDriveFlex4Frame.ConfigurationOverrides.json instead of the deleted .ConfigurationStore.json. This means the override file will be copied to the output directory during build, and the CreateDefaultSettingsFile() discovery logic (which scans for both .ConfigurationStore.json and .ConfigurationOverrides.json files) will pick it up as an available machine configuration.

Changes made for Pathfinder V5 PC's.

The PTS31 material had 6mm, 10mm, 12mm, 15mm, 19mm, 25mm geometries but PTU31's config defines a 24mm geometry in its Shapes section. Replaced the material file with one containing just 24mm with both Upper and Lower bending tools. Rebuild and the test should pass now.

Changes made for Pathfinder V5 PC's.

Changes to the I/O to align more with machine options.

Changes made for Pathfinder V5 PC's.

Added JornsHyperDriveFlex4Frame override which is supposed to have the closed loop parameter tuning for a 4 frame Jorns Twin.

Change made for Pathfinder V5 PC's.

6 configuration files existed on disk in AllConfigurations/ but were missing from the .csproj, so they weren't being copied to the build output:

JornsFlexEncoderUpgrade JornsHyperDriveFlex8Frame JornsHyperDriveFullSystem JouanelPTU31 RoperWhitneyElectricPartial ThalmannZRUpgrade All 6 have been added with CopyToOutputDirectory: PreserveNewest so they'll now ship with the build.

Changes made for Pathfinder 5226 controllers.

Simulation starting positions were being overwritten by stale MRAM data.

Test_For_Simulation_Mode() (line 331) set correct RawPosition values for all simulation axes, but NonVolatile_Encoder_Initialize() (line 424) ran afterward and restored old encoder values from battery-backed MRAM — replacing the simulation starting positions with stale data (0xFFFFF).

Fix: Moved the 5 RawPosition initializations into a new Simulation_Set_Starting_Positions() function called immediately after NonVolatile_Encoder_Initialize() in BlackBox.c, so simulation starting positions always win.

Changes made for Pathfinder V5 PC's.

Flash Programming Reliability FoldbusEthernet_IO.cs (SendFlashCommand) - Added 3-retry logic for flash packet transmission. After sending a flash packet, if no response is received, it retries up to 3 times before failing. Also fixed reboot detection order so that a controller reboot during flash is detected before treating the timeout as a failure.

FoldbusEthernet_IO.cs (SendCommand) - Added ForceTemporaryStatusChange(true) after 10 consecutive failed retries so the UI reflects the offline state during communication loss.

FoldbusEthernet_IO.cs (ResetCommDevice) - Added UDP receive buffer flush to clear stale packets after a controller reboot.

FlashBlackBoxManager.cs (TryFlashBlackBox) - Restructured so the queue stays running during RetrieveBoardData (which needs communication). Flash programming pauses the queue, programs, then the finally block handles recovery.

FlashBlackBoxManager.cs (finally block) - Calls PrepareForBlackBoxReboot (resets comm device, flushes UDP buffer, sets isBlackBoxReset flag) and ResetEventProcessingForReboot (clears event queue, switches back to direct event delivery) before resuming the queue and restarting status polling.

FlashTool.cs - Fixed CS0103 build errors (slave lock packet ID mismatch).

Post-Flash / Post-Reboot Recovery MachineCommunicationManager.cs (PrepareForBlackBoxReboot) - New method that resets the comm device and sets isBlackBoxReset = true so the next status response triggers the power-up sequence.

ApplicationManager.cs (OnLoginSuccess) - Root cause fix. Event handler subscriptions (StatusChanged, Transition_OfflineEvent, etc.) were guarded by !StatusPollingActive. After flash recovery started polling in the finally block, this condition was false, so handlers were never subscribed and the UI never received status updates. Fix: always subscribe handlers; only conditionally start polling.

BaseCO.cs (ProcessResponseAndDateTime) - Reset _exceptionResponse = ExceptionResponse.NoError at the start of each response processing. Without this, a single LowLayerCommException permanently poisoned the singleton StatusRequestCO error state.

StatusRequestCO.cs (EventProcessingLoop) - Added try-catch around the loop body. Previously any unhandled exception killed the thread permanently, causing all subsequent status events to queue up and never be delivered.

StatusRequestCO.cs (ProcessEvent) - Changed from re-throwing exceptions to logging only (NLog + Raygun). This prevents a single bad event from killing the EventProcessingLoop thread.

StatusRequestCO.cs (StartEventProcessingThread) - Now checks IsAlive (not just null) and resets _eventThreadShouldStop = false before starting, so a dead thread can be properly restarted.

StatusRequestCO.cs (PublishEvents) - When switching from direct to threaded event delivery (on reaching Idle), now also calls StartEventProcessingThread() to ensure the thread is actually running.

StatusRequestCO.cs (ResetEventProcessingForReboot) - New method that clears the event queue and resets _processEventsInSeparateThread = false, matching fresh startup behavior for post-flash recovery.

PowerUpCommManager.cs (ResetCompletionStatus) - Added isUARTMismatched = false reset so a stale mismatch flag doesn't block reconfiguration after reboot.

New Features

• New Explorer: Speed Explorer (experimental)
• New Report: Material Deviations

Improvements

• Add Halt Delay Minimum parameter for Pathfinder.
• CMMS export now allows one machine to populate multiple target assets.
• Explorer improvements:
  • "Others" group can be expanded.
  • Pareto charts resort based on filters.
  • Tooltips include count of records.
  • Downtime Explorer adds Exempt and Duration charts.
  • Pathfinder Explorers adds Pieces at a time (and others).
• Hourly chart Andon panel now has value labels for the most significant block element.

Bug Fixes

• Fixed a few errors that happen around startup.
• Delete orders and punch patterns that were deleted from Classic but still in Pro.
• The Punch Pattern field on Order Details was difficult to edit because of the preview pop-up. The preview is now on the "launch" icon.
• The Explorers were not labeling metric values correctly.

Changes made for Pathfinder V5 PC's

There is a transient socket error catch on one machine that can't be explained. Turned it into a warning since it looks like it actually continues communication, but as an error it restarted Pathfinder.

Changes made for Pathfinder V5's PC's.

Rev F: V4.04.24 Rev G: V5.00.23

Changes made for Pathfinder 5226 controllers.

Was trying to diagnose a task error that looked like it was failing in the ethernet/IP task. Disabled to see if truly the problem and checked in on accident with it still disabled even though it was not the culprit.

Changes made for Pathfinder V5 PC's.

Rev F: V4.04.23 Rev G: V5.00.21

Changes made for Pathfinder 5226 controllers.

Some folding machines have the option of taking off the shear and putting on a hemmer instead(ASC). To quickly get the functionality for the hemmer a lot of the shear feature was reused. Since you need the shear to be active to get the shear machine step to use for the hemmer. That means shear I/O becomes active. The problem was there was an axis conflict where the clamp could not move up if shear was not on home limit. The fix was to make sure this check doesn't happen if the hemmer is active.

The DSPI code had support for a FM25L16 part. There is no code that actually used the functions, so it was unclear if it worked or was ever tested.

The new Rev H board uses an S25FL128 flash memory part that we had no code written for.

Both of these parts have a SPI interface.

There is code in the common library that should support SPI memory devices of any type. I used Claude to write read/write and erase functions for the new part. The common code had some assumptions that were specific to the FM25L16, or some earlier, part that had to be removed and configured in a more generic fashion. Together we fixed some bugs in the existing code. A test to sense the presence by reading the Device, Manufacturer and Type out of the chip was written. This test proves that the chip harware design is OK because it requires a write and a read to both be succesful in order to read the proper, expected, information out of the part.

Changes made to Pathfinder V5 PC's.

The ClampingBeamConfirmation needed to be add or set to true in some of the Hyper Drive configurations so it can be used.

JornsHyperDriveFlex5Frame IsEnabled changed from false to true JornsHyperDriveFlex4Frame IsEnabled changed from false to true JornsHyperDriveFlexTwinmatic IsEnabled changed from false to true JornsHyperDriveFullSystem New ClampingBeamConfirmation input added on pin 24, IsInverted: true, IsEnabled: true JornsHyperDriveTwinPro New ClampingBeamConfirmation input added on pin 24, IsInverted: true, IsEnabled: true

Changes made for Pathfinder V5 PC's.

The double folding machines have a lot of inputs so simulation mode active needed to be removed to put in clamping beam confirmation. If set to true the the signal from the new input will create a simulation task error. These machines needed it set to false:

JornsTwinmaticClosedLoopV3 JornsTwinmaticClosedLoopV2 JornsTwinmaticClosedLoop JornsHyperDriveFullSystem JornsHyperDriveFlexTwinmatic JornsHyperDriveFlex5Frame JornsHyperDriveFlex4Frame

Changes made for Pathfinder V5 PC's.

Added the RoperElectricPartial machine configuration for installs that use most of the existing cabinet already on the Roper machine.

Changes made for Pathfinder 5226 controllers.

BlackBox.c (root cause) - The CanBus_Slave_Task startup struct was missing initialization of gCompileDate and gCompileTime. The CAN slave task had no way to know where the compile date/time strings were in memory, so it was reading from uninitialized pointer values on the stack.

CAN_Slave.c (secondary bug) - The & before Can_Slave_Task_data->gCompileDate and Can_Slave_Task_data->gCompileTime was passing the address of the pointer fields themselves rather than the strings they point to. This was masked by the first bug since the pointers were garbage either way, but would have remained broken even after fixing BlackBox.c.

Pathfinder can now set the number of pieces produced at once. When the last step of a sequence is completed, the quantity complete will increment by that value. A new parameter, Operator Preferences > Max Pieces per Cycle, will enable the new button if that value is greater than 1.

When Pathfinder connects to Eclipse Pro, it requests the list of Delay Codes and the Halt Delay Minimum value. If the list of codes is not empty, a new button will appear in the main toolbar that launches the Record Delay dialog. If the Halt Delay Minimum parameter is greater than 0, the button will be displayed with a warning color. The run button will also launch the Record Delay dialog before allowing the machine to enter Run mode. Pathfinder will check for updated Delay Codes every five minutes.

Changes made for Pathfinder V5 PC's.

A lot of the machine configurations that have a 5226 as the controller to use did not have rev E as one of the options as the board to use. This isn't truly a problem with so little of E's in existense, but just in case they have been added to all machine configurations that use a 5226 board. Except for ThalmannTDv1 which uses B boards.

Changes made for Pathfinder V5 PC's.

The core problem was that the code assumed master and slave would always be the same board revision (e.g., both Rev G), but in practice they can differ — like a Rev E/F master with a Rev G slave, or vice versa.

Firmware file selection: The slave programming was using Board1Type (master's board type) to select the firmware file instead of Board2Type. So if the master was Rev F and the slave was Rev G, the slave would get flashed with the Rev F firmware. Fixed by using Board2Type for the slave's firmware stream lookup.

Post-flash version check: After programming, the code compared the master's version against the slave's version and errored if they didn't match. But they're supposed to be different — Rev E/F and Rev G use different firmware files with different version numbers. Fixed by checking each controller individually against its own required firmware version (looked up from its own board type's firmware file).

Revision display: The dialogs only showed the master's revision info. Updated AvailableFlashDialog to show labeled master and slave sections (revision, current version, required version), and updated IsValidToFlash to display both "Master is Rev X" and "Slave is Rev Y" in the programming status dialog. Also added a slave validation check after RetrieveBoardData to catch board data mismatches before flashing the slave.

Changes made for Pathfinder V5 PC's.

All flash operations (Erase, RetrieveBoardData, SendProgram, SendLockCommand) in FlashTool.cs were being routed through the application's shared communication queue. That queue serializes all communication with the controller — regular status polling, parameter reads, etc. — so flash commands had to wait their turn behind unrelated traffic, and each flash packet would compete with other queued commands for a time slot.

The fix was to bypass the QueueManager entirely for flash operations, having FlashTool send commands directly via SendFlashCommand instead. Since firmware programming is a dedicated, exclusive operation (the controller is already in flash mode and not responding to normal commands), there's no need to share the queue. This eliminates the queuing overhead and wait times between each of the thousands of S-Record packets, dramatically speeding up the transfer.

Changes made for Pathfinder V5 PC's.

Added error messages 472 Clamping Beam Confirmation Failure, 473 Grippers Are Not OK, and 474 Bypass Throttle Valve Failure.

Changes made for Pathfinder 5226 controllers.

Added the following error messages:

Error 472 Clamping Beam Confirmation Failure - Will occur if the Clamping Beam Confirmation input goes low.

Error 473 Grippers Are Not OK - Will occur if the Grippers OK input goes low.

Error 474 Bypass Throttle Valve Failure - Will occur if the Bypass Throttle Confirmation goes low.

New Features

• Pathfinder can now report delay reasons.
• Pathfinder can provide the number of pieces being completed at a time.
• Administrators can now create a user registration and assign roles. An email is not required for Operator registrations.
• Pathfinder dashboard includes a process variables chart.
• Export completed bundles to webhook api (https://docs.amscontrols.com/eclipse/integration/api-webhooks)

Improvements

• Dashboard:
  • More information in snapshot bar and pareto chart tooltips.
  • Run Blocks chart only zooms in the plot area.
• Scrap & Delay Summary Reports:
  • Added Average Min/Max columns.
  • Show machine name (was just machine number)
• Shape Solutions get cleaned up when no longer needed.
• Changeover Config for attribute based changeover times now has more reasonable defaults.
• Added Schedule Slip Alert that triggers after a machine is halted when it the schedule estimates it should be running.

Bug Fixes

• Fixed headers on Tooling Code Usage Report.
• Pathfinder Produced Goods report was not calculating Operations/Hour.

Hardware test has two ram tests now. The existing Ram Test has changed to MRam Test.

It has always been testing a Magnetic Ram Part. MRam makes it more clear what is being tested by the test.

The new test is for the SRAM part that has been added to the Rev H hardware. If the board is not a Rev H (no SRAM Part), the test status will report "Disable" to indicate the test is not running.

There was a potential flaw in the Minimum Hole Space test. There is one flag that indicates that a hole has been detected since the Hole Queue has last been cleared. This single flag was adequate, until we added multiple hole detect queues, required for the KMF machine.

On the KMF machine It is possible that a hole detected on one Queue would cause an erroneous Min-Hole Space test on the other queue, preventing it from detecting a valid hole on the second queue.

Each hole queue now has its own flag so that the first hole on an empty queue will always be valid.

The Following improvments have been made to the Dump Hole feauture provided through Flashwizard.

1. The Hole Queue Detector number and its Postion with respect to the shear location is displayed.
2. There is a master Hole Detect Enabled status and an individual Detector Enabled status. The master disables all hole detects.
3. The Current Line Position is displayed.
4. The Last Detected Hole is displayed.
5. All positions are displayed with respect to the Shear Reference Point. Positive values have exited the Reference Point. Negative values are values that have not reached the Reference point.

Changes made for Pathfinder V5 PC's.

Made the JornsEcoTwin configuration machine options be able to pick and choose the inputs and outpus better based on option chosen.

Changes made for Pathfinder 5226 controllers.

The clamp sync feature when used will make the clamp move from an external control. We check for that movement so to be able to test in simulation clamp movement will occur if the clamping beam sync output is on.

Changes made for Pathfinder 5226 controllers.

The location in memory at 0x400 is used to check for certain protections. One byte is reserved for in this case using a debugger. How this memory got changed to how it was supposed to be stored which made the release build actually use the protection. The previous way it was stored made it get the none protect 0xFE randomly so we could debug. The change was to just make it unprotected so we can debug the release code.

Improvements

• Promoted hourly chart on the XL dashboard out of experimental.
• Shape Pattern processing improvements. Also, the solution list is updated automatically.
• Upcoming Bundles Andon now supports showing additional custom fields.
• Coil Sync improvements:
  • Better handling of coils that were incorrectly marked as completed.
  • The Integration screen allows running either the full or incremental sync on-demand.
• Add new barcode format function that ends with a carriage return after the data: "bc_c128_cr_png"

Bug Fixes

• The Production Events Report was not filtering out records when the date range changed.
• Possible fix for a memory leak.
• The CMMS integration was not properly publishing TotalCutCount.

Changes made for Pathfinder 5226 controllers.

Purpose: Jouanel press brakes with dual-drive clamping beams (separate left and right motors) can drift out of alignment over many bend cycles. This feature periodically triggers the external drive hardware to resynchronize both sides using its own reference sensors. The BlackBox controller does not control the sync motion itself - it signals the external hardware to perform the operation and monitors for completion.

Parameters Setup Parameters (via Foldbus 0x0001/0x0002 - PID system):

PID Name Type Default Description 353 Bends Before Clamping Beam Sync uint16 0 (disabled) Number of clamp operations between syncs. 0 = feature disabled. 354 Maximum Clamping Beam Sync Start Position float 50.0 mm Max clamp height to allow sync. If clamp is above this, sync is skipped silently.

Generic Parameters (via Foldbus 0x0003 - Attribute ID system):

Attribute ID Name Type Default Description 0x205D Sync Clear Timeout uint16 (ms) 5000 Time allowed for I_122 to turn OFF after O_125 is turned ON (handshake clear phase). 0x205E Sync Complete Timeout uint16 (ms) 10000 Time allowed for I_122 to turn ON after it has cleared (actual sync operation). 0x205F Sync Motion Timeout uint16 (ms) 2000 Time allowed for initial upward beam movement to be detected after sync starts.

I/O: Function Type Description O_125_CLAMPING_BEAM_SYNC Output Turned ON to signal external hardware to begin sync operation. Turned OFF when sync completes or on error. I_122_CLAMPING_BEAM_SYNC_COMPLETE Input External hardware signals sync completion by turning this ON. Polled in the sync function (no interrupt processing needed).

Status Reporting: Flag Location Bit Description Clamping_Beam_Sync_Active Status dFlag (0x00000080) Bit 7 Reported to Pathfinder every status poll. TRUE while sync operation is in progress.

Logic Flow

1. Counter Management (in LoadSheetWithClamp) Two file-level static variables track sync state across function calls:

sClampCountdown (uint16) - starts at 0 on power-up sbSyncNeeded (bool) - starts false After every clamp operation completes (end of LoadSheetWithClamp), if PID 353 > 0 and mode is AUTOMATIC or higher:

If sClampCountdown == 0: sets sbSyncNeeded = true and resets counter to PID 353 value Otherwise: decrements sClampCountdown Since the counter initializes to 0 at power-up, the very first clamp operation will flag a sync.

2. Sync Execution (in Release_Part_To_Operator) After the part is released and bending beams have moved, the code checks sbSyncNeeded. If true and mode is AUTOMATIC:

Waits for bending beam motion to complete Clears the flag Calls SB_Perform_Clamping_Beam_Sync() with the current operation's clamp open height If sync fails, returns FALSE to abort the cycle 3. The Sync Function (SB_Perform_Clamping_Beam_Sync) Pre-sync validation:

Sets gRun.ClampingBeamSyncActive = TRUE I/O config check - O_125 and I_122 must both be defined (or both undefined). Mismatch triggers E471. Position check - If clamp is above PID 354 (max start position), skips silently and returns TRUE.

Handshake sequence:

STEP 1 - Turn ON output O_125 (tells external hardware to start sync).

STEP 2 - Wait for I_122 to turn OFF (clear previous state). Timeout = Attribute 0x205D (default 5s). If I_122 doesn't clear, turns off O_125 and triggers E470 (input stuck on).

STEP 3 - Wait for I_122 to turn ON (actual sync completion). Timeout = Attribute 0x205E (default 10s). During this wait, a nested motion detection check runs: if no upward beam movement is detected within Attribute 0x205F (default 2s), turns off O_125 and triggers E469 (motion timeout). This catches wiring issues, drive faults, or controller output failures early rather than waiting the full completion timeout.

STEP 4 - Turn OFF output O_125.

STEP 5 - If beam is below the target clamp open height, raise it using SB_Jog_Clamp_Up(). If already at or above target, do nothing (never lowers).

Cleanup - Sets gRun.ClampingBeamSyncActive = FALSE at every exit point (success and all error paths).

Abort conditions - All wait loops also check gRun.eMode >= RMT_AUTOMATIC, so switching out of automatic mode during sync will exit the loops cleanly.

Changes made for Pathfinder V5 PC's.

• StatusResponseHelperTypes.cs - Added ClampingBeamSyncing = 0x00000080 to - StatusConditionFlags enum (replaced commented-out Unused flag)
• StatusMessageType.cs - Added SyncingClampingBeam enum value
• MachineCommunicationManager.cs - Added ClampingBeamSyncing flag check to set StatusMessageType.SyncingClampingBeam with status text; added SyncingClampingBeam case to Fire_StatusChanged switch
• FormResource.resx (Main) - Added StatusSyncingClampingBeam = "Syncing Clamping Beam"

Error Messages

ErrorResource.resx - Added 4 error messages: E467_ClampingBeamSyncTimeout - "Clamping Beam Sync Timeout" E468_ClampingBeamSyncHeightExceeded - "Clamping Beam Sync Height Exceeded" E469_ClampingBeamSyncCompleteInputStuckOn - "Clamping Beam Sync Complete Input Stuck On" E470_ClampingBeamSyncIODefinitionError - "Clamping Beam Sync I/O Definition Error"

Generic Parameters (ParameterStoreList)

Added 3 parameters to all 8 Jouanel 5226 configurations, under ObjectName "Clamping Beam" (ObjectId 0x0066):

0x205D - Clamping Beam Sync Clear Timeout = 5000 0x205E - Clamping Beam Sync Complete Timeout = 10000 0x205F - Clamping Beam Sync Motion Timeout = 2000

Configurations updated: JouanelPTS33, JouanelPGL, JouanelPTL31, JouanelPTS24, JouanelPTS31, JouanelPTU31, JouanelHydraulicV2, JouanelPTS

New Features

• Orders can now be duplicated from a menu under the details panel.

Improvements

• Hourly chart Andon panel now has y-axis ticks and supports metric.
• Run Blocks chart supports metric.
• Don't allow creating a Macro Pattern that contains a Macro Punch.
• Alerts now show Export attempts with issues.
• Coil Sync improvements:
  • UI shows if the sync event is full or incremental.
  • More robust deletion detection.
• System Health now shows connectivity status for external services.
• Added Shape Solution Alert and simplified Shape Solution synchronization.

Bug Fixes

• Fixed categorization in Delay Summary Report.
• Fixed issue in reports when unselecting the "All Machines" filter.

The IO Test in the Hardware_Test application was restructured so that a known, repeatable, delay between outputs changing and Inputs being tested is now possible.

The Rev H board requires two TX_Buffers when sending analog values on the SPI bus. The code that was verifying the transmission was only checking one TX_Buffer, which allowed some untested code for a serial flash part to mistakenly execute and cause a processor fault. The Serial Flash code was commented out for now since we aren't using it and it needs to be fixed and tested.

The Ethernet Phy driver was not written to support anything other than full Ethernet auto-negotiation. While troubleshooting the Ethernet issues on the Rev H hardware, we needed to be able to experiment with forcing different aspects of the ethernet Phy. This involved edits to the Phy KSZ8041 driver and we added some configuration bit options to the MQX enet configuration.

In addition, the Phy driver now configures the default register values rather than relying on boot strapping, good or bad, to do it.

Claude was used to generate code that parses Phy register contents and prints them to the debug output in human readable form. The full register contents are printed on reset. The registers are monitored in a new task and only changes are printed from there after.

The Rev H hardware has no SERCOS.

The SERCOS Task has been disabled. The SERCOS Ram Test and the SERCOS Test have both been set to "Disable" in the Web Page.

Many times, the Item Complete output and its timer are used to run the last pieces of an item out through a roll former. One customer wants a feature that triggers every time the line halts to trigger any cut pieces to be run out through the roll former. One issue is there may be uncut material in the roll former that could strip material out through the shear and into the roll former.

In the past we have solved this sort of issue with the combination of the Uncut Length output and PLC logic. Not all controllers have the output available or access to a PLC.

To solve the customer’s request, we have added the "Item Complete on Halt" setting. It has five options, No, Always and Uncut Length, Halted Only and Uncut Length Only.

When set to No, the Item Complete output works as it always has. It is triggered on the last part of an item.

When set to Always, it will trigger on the standard Item Complete conditions after item completion, and it will be triggered every time the line is Halted from the run mode, provided a part has been produced while running.

When set to Uncut Length, it will trigger on the standard Item Complete conditions after item completion, and it will be triggered every time the line is halted, provided a part has been produced while running and the leading edge of the uncut material is less than the Uncut Length Threshold setting.

When set to Halted Only, it will only be triggered every time the line is Halted from the run mode, provided a part has been produced while running.

When set to Uncut Length Only, it will be only be triggered every time the line is halted, provided a part has been produced while running and the leading edge of the uncut material is less than the Uncut Length Threshold setting.

When Halting, if the Item Complete is active and the either of the Uncut Length options are active and in violation, the active Item Complete trigger will be terminated early to prevent uncut material from being stripped through the shear.

Some additional changes were made so that the Uncut Length Threshold setting is visible even when there is no Uncut Length output available.

Improvements

• Dashboard improvements:
  • More space for text based metrics.
  • Hourly chart honors user locale and displays 24-hour labels where appropriate.

Bug Fixes

• Fixed dashboards not updating the metric values when navigating to different shifts.
• Machine Performance Standards did not always convert to metric properly.
• Fix hourly charts on Andon not loading quickly.

The setup, PCode Change Stops Queue, was disabled for controllers that did not maintain the queue when halting. This setting has other side effects that make it useful to be enabled on these controllers. For example, this setting can also disable the PCode comparison for the Coil Endpoint feature.

It will now be enabled all the time. However, it will still not be visible if the MODBUS interface is controlling it.

New Features

• Pathfinder can now send profile details which are shown on the dashboard when available.
• Initial CMMS integration with Eptura Asset (formerly Manager Plus). Currently supports updating logs from statistics (footage, runtime, total cuts) after each hour or shift.
• Eclipse Pro configuration can now be downloaded as a single file and some configuration options can be restored from the file. For example, machines can have their Eclipse Setups, Controller restrictions, and Shape Tables restored. Machine Metric Configs can also be copied from another machine or restored from a backup file.
• New Andon Panel: Hourly Charts

Improvements

• Pathfinder can now be connected using a temporary registration key in Eclipse Pro, which simplifies the configuration.
• Added a per-machine alert indicator to the dashboard.
• The Coil Validation configuration now has a testing feature that queries the configured data source.
• Scheduler improvements:
  • The "On Machine" box is more prominent.
  • Fixed drop target placement.
• Alerts are visible on their related machine.
• Machine Shape Table axis flipping option can now be filtered based on shape name pattern. Also, an additional X or Y Offset can be applied.
• Wallboard Production Summary styling improvements.

Bug Fixes

• Fixed some incorrect tracking of Pathfinder run statistics.
• Fix column sorting on the Scheduler.
• Wallboard Production Summary cycle time issue fixed.

The Linker was allowing variables to be defined more than once. I removed the flag that was allowing this. This resulted in numerous changes in existing code to prevent this.

Both the common code and the applications will need to be re-compiled.

The Initialize data had encroached into the Heap memory start location so a remap was required.

The Specific example this was found for was an XL206CLFP with switch 80-0. Press five had a Press Reaction time and no other presses did. If the P option was not present, the parameter would not be present.

This was tracked down to some code that was trying to ensure the Printer Press would have a reaction time. However, it was implemented incorrectly.

The logic was corrected and simplified, which rectified the issue.

The PLC Remote Run Velocity Pot is now available for the Jog Velocoty as well. It is enabled seperately from the Remote Run but uses the same Pot value. The Pot value applies to the Jog Velocity rather than the Max velocity. See the PLC MODBUS Spec for more details.

• Agent now requires Classic to be at minimum version of 4.1.228.

New Features

• Send the XL Machine Configuration Report directly to AMS Support for analysis by our technicians.

Improvements

• Added menu action from Order Detail to submit shape patterns for solution recalculation.
• Machine Shape Table can now flip X or Y references based on Tooling Code (PCode).
• The XL200 Default Punch Pattern is now a dropdown.
• Added "Where Used" tab to Punch Pattern view.
• Added dialog to move a coil to a new location from the coil list and detail.

• Eclipse-COMM X button is now disabled. This will help with unintended shut down.
• Fixed Quality Audit disable run trigger.
• Fixed backup of controller patterns with proportional spacing.
• Fixed issue with backing up controller materials.
• Fixed calendar control when setting a date in the next year.

Changes made for Pathfinder 5226 controllers.

Changes made for Pathfinder 5226 controllers.

New Features

• New hourly chart of metrics in the XL dashboard (preview).

Improvements

• Kiosk App now detects and reconnects after a server outage (v1.0.5).
• Better style on the Done/Current/Next order grid on the dashboard.
• Include more Classic info in Diagnostic Package.

Bug Fixes

• Fixed issue with Andon data calculation for recent bundles.
• Fixed startup issue when there are no production files.

The Hole queue for Inputs 23 or 24 can now be dumped to the Dubug window in the PC simulation or to FlashWizard on the hardware.

The debug instructions are displayed as such: Dump <"Hole> <23 or 24> Dump Hole Queue for input 23 or 24

To dump the hole queue for input 24 the command is: Dump Hole 24

Make sure to press enter.

The asterisc show where the commands can be shortened. Whire space is ignored. The command can be shortened to: duh 24

The command will print the number of holes in the queue and, for each hole, the position from the leading edge of the material.

A KMF Diagnostic screen has been added that is visible only on a KMF model.

The screen shows Individual hole count status for the Shear and the Applicator Press. This provides additional detail above the combined Hole Count status displayed in the top three line area.

The screen also shows a Last Shear and a Last Press Offset field. These fields show the distance the last Shear or the last Press operation occured from the prior operation of which could be either type.

Normal operation is to alternate between Shear and Apply (Press). In this scenario, the Last Shear Offset will be measured from the prior operation which would be an Apply. The Last Press Offset will be measured from the prior operation which would be a Shear. Under these conditions, the Last Shear Offset will be equal to the last piece of felt that was cut. The Last Press Offset will be equal to the gap between the last two pieces of felt.

On the KMF controller the Last Programmed length in the Calibrate Trim Setup screen would alternate between the Cut Length and the Apply Offset Distance from the last cut. This was somewhat confusing. To make it more clear, it will now only be updated with the distance between cuts, which will correspond to the distance between two cut hole detect inputs.

Assuming the felt is not getting stretched as it it applied, the measured felt length on a part, combined with the detected distance using the cut holes (input 24), can be used to calibrate trim a part.

A new record chain of Custom List records has been created for Eclipse to use in a dynamic interactive way.

Expected operation is that Eclipse will delete the prior list, just in case a prior interaction never got triggered and fully completed. The controller will actually do this for Eclipse if there are no communication errors and the triggered list is fully completed by the operator before power is cycled.

Eclipse will create the list and create the trigger, type 13, that this new list requires. When the chain is unlocked, the new list will be triggered and displayed.

The new trigger has all of the same features for halting the line, allowing overrides etc as the existing Custom List Quality Audit triggers.

Trigger type 13 is not compatible with the Original Custom List chain and the existing trigger types are not compatible with the new Dynamic Custom List chain. Any attempt to use incompattible trigger types will result in a non-response from the XL.

There was a race condition between deleteing records from Eclipse and Quality Audit trigger conditions.

When records were deleted from Eclipse, they were just marked as deleted but the Quality Audit triggers were not deleted until the marked Custom List records were deleted. If a trigger condition would occur, the Marked Custom List records would be displayed.

This was resolved by modifying the Marked Records function to call a new method that can be overriden in each record type. If a records gets Marked, it will call this new method and the record can then do other operations at the same time that are specific to itself.

The Custom List records where modified to Mark their QA Trigger recrods as deleted when they themselves get marked.

Changes made for Pathfinder 5226 controllers.

During record test, if enabled, the record address and header of each record will be dumped to the Debug Output.

Enabling the debug output is enabled by typing "Display Records" and pressing enter while using FlashWizard. A shortcut, "D RE" can be used as well.

New Features

• Eclipse Pro Kiosk App for Fire TV: Simplifies the deployment and configuration of Wallboard (Andon) screens.

Improvements

• Unsaved Order changes will prompt when navigating away from the page.

Bug Fixes

• Fixed agent startup bug where it would not send the initial set of scrap/delay codes.
• The AMS.Eclipse (supervisor) installer was not properly detecting the required .net version.
• Fixed a regression where the custom date range on the Production Summary report did not render properly.
• The list of machines was empty when adding the first scheduled downtime. This is fixed.
• Global search would not navigate to a different order while on a different order. This is fixed.

Each Quality Audit table entry is now able to be configured with instructions that can be displayed in the Quality Audit window, once triggered.

If the Instructions are populated on a Parent Record that contains the trigger, these instructions are assumed to pertain to all of the child entries. These are labeled "General Window Instructions". Each Child record of the trigger can contain their own instructions. They are displayed seperately when the child is displayed. These are labeled "Specific Request Instructions".

If a Quality Audit is triggered directly (has no children) and has instructions, its instructions will be displayed as "Specific Request Instructions"

Changes made for Pathfinder V5 PC's.

I had Claude test the Idle Command generic parameters and change the ones that were not the safe value. For some reason he moved a line of json code to a spot that makes it corrupted and unusable. Line was taken out on the 10 configurations.

Changes made for Pathfinder V5 PC's.

SUMMARY: Updated Idle Command parameters for all Twin machine configurations to use standardized default values.

PROBLEM: Twin machine configurations had inconsistent Idle Command parameter values and were missing parameters for Lower Retract (220) and Upper Bending Beam (221).

SOLUTION: Updated 10 Twin machine configuration files with correct Idle Command defaults:

• Parameter 219 (Idle Command for Bending Beam): -10
• Parameter 220 (Idle Command for Lower Retract): -10
• Parameter 221 (Idle Command for Upper Bending Beam): -10
• Parameter 222 (Idle Command for Upper Retract): -10
• Parameter 223 (Idle Command for Clamping Beam): 10

FILES MODIFIED:

• JornsEcoTwin.ConfigurationStore.json
• JornsHyperDriveFlexTwinmatic.ConfigurationStore.json
• JornsHyperDriveTwinPro.ConfigurationStore.json
• JornsTwinProClosedLoop.ConfigurationStore.json
• JornsTwinProClosedLoopAtAMS.ConfigurationStore.json
• JornsTwinProClosedLoopV2.ConfigurationStore.json
• JornsTwinProOpenLoop.ConfigurationStore.json
• JornsTwinmaticClosedLoop.ConfigurationStore.json
• JornsTwinmaticClosedLoopV2.ConfigurationStore.json
• JornsTwinmaticClosedLoopV3.ConfigurationStore.json

RESULT: All Twin configurations now have consistent Idle Command parameter values.

Changes made for Pathfinder V5 PC's.

Summary

Fixed truncation issue in Machine Operations UI where RadiusAdjustment field and other parameters were not visible in operation details due to incorrect height calculation.

Problem

• RadiusAdjustment field (row 25) was not visible in NormalBend operations despite being enabled
• Different operation types (NormalBend vs CloseHem) showed different fields due to visual truncation
• Operations displayed excessive blank space at the bottom when fields were hidden

Root Cause

• TableLayoutPanel used AutoSize row styles, preventing proper row collapse when height set to 0
• Height calculation used fixed base (942px) minus hidden row count, which didn't account for specific row positions
• Different operations hide different rows, causing inconsistent visibility of fields at higher row indices

Solution

Files Modified:

• AMS.Pathfinder.ViewPresenter\UserControls\MachineSteps\Operations
  MachineStepsOperationBase.Designer.cs
• AMS.Pathfinder.ViewPresenter\UserControls\MachineSteps\Operations
  MachineStepsOperationBase.cs

Changes:

1. Changed all 30 TableLayoutPanel RowStyles from SizeType.AutoSize to SizeType.Absolute (30px)
2. Updated GetDesiredHeight() method to dynamically sum actual RowStyles heights instead of using fixed calculation
3. Corrected overhead calculation to include both summary section (42px) and batch/enable row (36px)

Result:

• RadiusAdjustment and other fields now display correctly when enabled
• No blank space at bottom - each operation sizes to fit only visible content
• Operations independently size based on their specific hidden/visible row configuration

Due to a bug in the timer contro,l the Press 1 Down output on the KMF controller would stick ON during a Manual Press if the Press Block Retract Time was zero

The KMF controller is supposed to heat the Shear Wire to an IDLE temperature and then just before a shear, it gets heated up to a READY temperature. The Shear Wire Idle output raises controls the IDLE temperature. The Shear Wire Ready output controls the ready temperature. The IDLE output and the READY output are on at the same time.

During a stationary manual shear, the Shear Wire Idle output and the Shear Wire Idle Time was not being used. This has been resolved.

When the Simple Zanasi Z4xx print driver was developed, we were not given a complete Zanasi print system. This prevented the printer from being tested as a system in the run mode like we would typically do. Each part of the system was tested using various means to test that we understood how to wire and test each component, like the encoder, the Print Trigger and the communication.

The Test Print option was used, in conjuction with the printers Serial Port bebug screen, to test that the printer recieved and processed the print message. Unfortunately, the Test Print function does not test for a response from the printer like the Run Mode operation does. When the first customer began to use the driver in production, they began to recieve printer communication errors that we didn't see in our testing.

Zanasi should really add the ability for their Serial Sniffer function to return a programmed response when it accepts a command. Having this response allows the controller to detect when the printer has stopped communicating so that parts are not missing a message or get the wrong message.

In the mean time the following solution was chosen.

The Simple Zanasi driver will have a new setting called Require Printer Response. It will have two options, Yes and No. It will default to No. If the customer is OK with using the printer, at the risk of not knowing if it is functioning properly, they can set it to No. If they are not, they will have to contact Zanasi for a solution that provides a resonse that can be tested by the XL.

Improvements

• Send Machine Pattern deletion request from XL200 Machine view.
• Upgrade to .net 9.0.10.

Bug Fixes

• Fixed regression where some import channels were not able to start.
• Fixed crash when calculating the schedule summary when using Controller sourced bundles that have the same bundle number.
• Fixed regression with the bulk editing dialog on the Orders list.
• Fixed the update available indicator.
• Order Detail would always show the alert banner even if there was no alert.

On a normal coil tailout, while running, the current item that is reported is still the actual item that was running during the tailout. The item, order and material code have been validated against the coil and it makes sense to report the coil information and the item information all togther in one production record.

When an order it completed and there is no more production for a coil, the current item is no longer the last item that was running against that coil. It may be some item or order that will never be run with that coil. This resulted in some confusing conditions. It is especially confusing if there is scrap that gets reported because the Threadout process doesn't perfectly count the material down to the Shear to Encoder distance before the coil tails out.

To counter act this, we are now keeping track of the last produced item. It gets initialized during initialize queue and during every decrement part as parts are being produced. This item is used instead of the current item when a Threadout (Tailout) occurs, while the line is halted.

The conditions for testing for Done Items and Orders have been simplified.

Done Items and Done orders will now be checked for deletion at a minimum of once per minute or a maximum of once every 10 minutes. This time is dependent on the Auto Delete Done Orders time. The programmed time is used for the timer but is capped at the specified min and max limits above.

Done items and orders are also checked on a Power Cycle or every Memory Test.

The KMF controller installs fleece on the bottom of roof pannels, based on the state of two hole detect inputs. There are no orders or data to collect. Eclipse is not enabled on these controllers.

According to AMS gmbh, these controllers have been configured with the same settings when they get installed. For that reason the following settings have had their default values modified to the values listed below.

Shear Dwell Down 0.25sec Press 1 Dwell Down 0.25sec Press 1 Dwell Up 0.05sec Tolerance 15mm Minimum Shear Distance 350mm Maximum Shear DIstance 620mm Minimum Press Distance 650mm Maximum Press Distance 750mm Reference Die on Manual Shear No Line Resolution 0.038418850mm Die Resolution 0.003820200mm Loop Gain 10.0 Jog Velocity 5MPM Reference Velocity 1MPM Max Die Return Velocity 60MPM Acceleration 900cm/s2 Enable Virtual Keyboard Yes Clear Queue After Prompt Dsiplay Format Metric mm. Jog Select Mode Die (Setting not visible)

This change will make setting up new installs easier and supporting customers who recieve software updates will have an easier time getting back up to speed.

Improvements

• Add individual scrap code filter to scrap-summary report.

Bug Fixes

• Fix an issue with running the Schedule Estimator.
• NetSuite export would fail if many missing bundles were found during startup.

The reported tolerance on CLDA when using EtherCat was off by the amount of die movement in one Closed Loop sample time.

This effect was already corrected for SERCOS but it was missed when EtherCat was implemented.

For stationary cuts, an improvement was made to account for the same issue in both SERCOS and EtherCat modes.

Changes made for Pathfinder V5 PC's.

5226 Rev B, E and F Version 4.04.21 5226 Rev G Version 5.00.20

Change made for Pathfinder V5 PC's.

On the Pathfinder UI visual of when the machine is in run all the axis positions are shown in the bottom. A bug came when adding the oil level in terms of percentage full in which the positioning was not shifted to the new location. This made the oil level go way to the right in the visual.

The fix was to make the correct shifting of the visual location.

Changes made for Pathfinder 5226 controllers.

The 5226 and Pathfinder UI have a communication protocol to deliver information back and forth. One of the commands is a status of what's going on with what the 5226 is controlling. This is run states, axis feedback etc. For the axis feedback it's supposed to be fluid in which you can keep adding more axes to the end of the command which means this command does not have to be the same size every time. Just say which axis it is and give the position. There seems to be a bug on the Pathfinder side where it adheres to our axis bit structure and because the order of the oil level and oil temperature didn't follow the order it made the two feedbacks switch back and forth in the UI.

The fix was to put the oil level before the oil temperature in the 5226 code.

The Diagnostics Multi-Axis Devices status screen has been improved. Rather than showing a count of the number of active Axes, it now displays a list of all the axes with their current positions.

In addition, the Function Key menu has changed to add an option to Disable All Axies.

Commands for controlling a PLC Type of Axis were added to the MODBUS Spec in version level 117. These commands only allowed the control and status request of PLC Type axes.

The command for Requesting status from PLC type Axes to be executed on any type of Multi-Axis driver.

Bug Fixes

• Possible fix for skewed pathfinder data on the first production run of the day.
• Changing Classic settings from Pro would sometimes modify unrelated properties. This is fixed.

The Leader and Trailer options are now enabled for all Stitching algorithms. The main difference is that it is now enabled when Omitting Cuts to ensure there is a handle for downstream cutting operations that require it.

It works the same when Omitting Cuts, with one exception. If a Leader has been added as a handle, no trailer is required to provide a handle. As such, it won't be added.

Improvements

• Added an optional allow list for user and email recipient domains.

Bug Fixes

• Fix an issue with running the Schedule Estimator after the last release.

Ricky Allman (12:23 AM):

• Agent now requires Classic to be at minimum version of 4.1.226.
• RavenDB must be upgraded to version 6.2.10.

Preview Feature

• Report Subscriptions: Schedule reports for automatic email delivery (daily/weekly/monthly). Contact support@amscontrols.com to enable the preview.
• Coil Return Tasks in Warehouse

New Features

• Attribute based changeover times: Use the change in tooling and material attributes to determine a changeover time. Times are additive. For example, if gauge takes 5 minutes (from material) and finished width takes 10 minutes (from tooling code), the changeover will be 15 minutes. Times can also be different for explicit values. It can be configured to take 10 minutes for 12 gauge and 5 minutes for all other gauges.
• New Report: XL Machine Configuration
• Send operator messages from the dashboard.
• Remote XL Lockout Control: Control machine lockout states directly from the dashboard. When activated, this remotely locks or unlocks a machine, overriding the physical lockout switch until it is manually cycled at the controller. Requires XL200 firmware version v5.94.00/v4.94.00 or greater.
• Shape patterns now support machines where the material is not centered in the machine and axes that are manually moved. These can be configured by PCode/Tooling Code.

Improvements

• Reports have a consistent header when printed.
• Production Summary report has a better print view.
• Production log is initially collapsed on the dashboard.
• Export and Import now available for Loss Codes.
• Selections from available jobs in the scheduler can be bulk deleted.
• System Preferences can now set the company name, default delay code, tailout scrap code, and carry last delay forward settings.

Bug Fixes

• Fixed some dashboard sizing regressions.
• Shape solution errors were not showing up in the order list or scheduler.
• Performance and stability improvements.

• Added capture of 2nd XL Switch setting.
• Where possible, the Comm message log references the related record for displaying in Pro.
• Add coil.SYNC_ADJST
• Add parts.DESCRIPT
• Add punches.SEGMENT
• Add machine.LEGHEIGHT2
• Read TRUE/FALSE settings as T/F

A new field has been added to the Diax02 Multi-Axis Driver.

In almost all cases, this field should be zero. However, in some drives with high gear ratio's, we run into an issue with Absolute Encoder Travel range. The encoder can only measure 2048 motor turns on either side of zero. If the motor has to travel further than that, the reported position will invert its polarity sign when it crosses the 2048 turn boundary. Position Limits Errors, if enabled, will happen slightly before that.

The maximum travel range can be calculated by 2048 * (Gear Out/Gear In) * Feed Constant. The Travel limits will be +- this calculated value. For example, a gear ratio of 20:1 and a Feed Constant of .2" results in a travel range of +-20.48".

The Offset From Zero lets us use this range more effectively by making it appear that the zero point of the axis is in a different place. If we use our earlier example and we need the axis to travel to 24" we can shift where zero is. We can shift the zero point -10" by entering -10" in the Offset From Zero setting. This will make our travel range -10.48" and + 30.48" inches.

When referencing and sending positions to the drive, the controller lies to it. It offsets the positions it sends and the positions it gets back by the Offset by Zero value to effectively shift the travel range the drive has, into the range that we can use.

If Position Limits are being used, the must be shifted in the drive by the Offset From Zero value. For example, if the Axis upper limit is 30.48", adding the -10" offset from our example means the limit in the drive needs to be 20.48".

As a test we needed to be able to a -5 exponent for position parameters on a Diax02 drive. The software was changed to allow us to use whatever exponent is currently configured in the drive. In addition, since the Diax02 drives don't work with Drivetop the Position and Velocity exponents are now programable through the XL SERCOS Paramater editor.

Changing the exponent did not resolve the issue we were experiencing. However, this ability may come in handy in the future so I am going to preserve the changes.

The Multi-Axis Devices menu in the Diagnostics screen now has an F4- Enable All Axes function key available.

The F4 - Reference all Axes moved to the F5 key.

An F4 - Enable All Axes was added next to the F3 - Disable All Axes function key button.

SCN 5112 changed what happens when errors are cleared in SERCOS Phase4. All errors are cleared by forcing a new phase progression. While passing through phase 2, errors are cleared in all drives.

To be consistent, this SCN adds the same behavior to the EtherCat fieldbus. If F3-Clear Error is selected on a drive while the bus is in Full Operational state, a new Operational State progression will be triggered. While passing through Pre-Operational state, all drives with errors will have them cleared.

We have added Min Tolerance and Average Tolerance fields to the Closed Loop Data screen.

The Max Error value is no longer compared as an absolute value against the absolute error.

All of the fields are initialized to zero when the screen in initialized or when a new graph is started. The first tolerance that is measured will be filled into the Max, Min and Avg Tolerance fields. Min and Max will then be compared from there. The Average will begin being calculated on the second tolerance measurement reported.

These new fields are intended to make it easier to evaluate how consistent the tolerance is and to provide some sense of how it is distributed.

New Features

• New Report: Pathfinder Produced Goods

Improvements

• Updated most grids to resize with the browser window.
• Performance and stability improvements.
• Punch Patterns can be renamed.

Bug Fixes

• Fixed regression with the Scheduler grid height.
• Not all setup parameter instances were visible in the XL200 setups tab. All instances are now displayed.
• Added some automated database recovery steps.

Allen Bradley SERCOS drives work differently than the Bosch drives. On site at a customer we discovered that the drives apparently will generate faults internally that they want to be cleared, but they don't report them in the SERCOS interface or even in the Drive Explorer software. This has been learned by exerience by the customer who has these drives.

A recent change to Clearing drive errors for SERCOS seems to have opened up an issue. When in Phase 4, a request to clear drive errors now will initiate a new phase progression from Phase 0. In Phase 2, each drive is checked for an error and it will get cleared if it is reporting one. The old software would clears errors, present or not.

In this new change we will be setting an override flag that tells Phase 2 to clear errors in every drive,even if the drive is not reporting one. This is a change that is being made on site. There is a possibility that the AB drive may not do the same processing in Phase 2 as it does in Phase 4. Implementing this in Phase 4 is not something I want to undertake on site, where I can't test it before hand. It is much more complicated.

Changes made for Pathfinder V5 PC's.

Changes made for Pathfinder 5226 controllers.

Changes made for Pathfinder 5226 controllers.

Improvements

• Added External Connection to NetSuite import configurations.
• Performance and stability improvements.
• Improved print layout of reports and dashboard pages.

Bug Fixes

• Fixed issue where network resources were not being released which led to crashes during heavy traffic.
• Fixed regression with the scheduler drag columns.

Bug Fixes

• Bundle user fields would be lost when rebundling. This is fixed.
• Fixed an error when copying a pattern.
• Possible fix for an Order sync issue from Classic.

The stacker code was stacking on a budle change or when there were no more orders.

Usually, there is a bundle number change between orders, but sometimes, for single item orders, there is not. The old test, bundle number change, mostly worked unless there were subsequent single item Orders where the items in each order had the same bundle number.

This change forces a stack on an Order change.

Improvements

• Add required weight to Warehouse task views and made the views more consistent with each other.
• Separate Shapes and Tool into tabs on the Machine Shape Table view.
• Global search improvements.
• The "Show Material Shortage Alerts" setting now determines if coil warnings are shown on the timeline.
• Added an experimental view of the Supervisor information to the health page.

Bug Fixes

• Login screen works better with password managers.
• Performance and stability improvements.
• Fixed error with DbMaterialImport configuration.

Back in 11/2022 SCN was released to improve the reliability of Queue Record garbage collection. This caused an issue in the XL220 downstream notches press task. A lefty over, uninitialized, variable was being used to delete queue records.

This has been resolved.

Changes made for Pathfinder 5226 controllers.

Changes made for Pathfinder V5 PC's.

This task error occurs if it takes too long to recieve a 16bit chunk of data from the ARM processor.

We had a 5386 board that was taking too long to initialize the Ethernet Port and wasn't ready to respond with the 16 bit status when it was requested. By increasing the time that the ARM was allowed to execute the initialization, the error went away and the ARM performed all other operations flawlessly.

This change makes the additional time a permanent change from here on out.

Over the Years we have been mixing more and more Open Loop and Closed Loop features. The more code that is in common between software projects, the easier it is to support.

Two new options have been added to the MODBUS interface.

Requesting a Field Bus Reset will reset any present Field Bus, SERCOS or EtherCAT at the moment, back to its full operational state. Errors are cleared during the reset.

Requesting all Drives to be Disabled does what it says.

These options are available in MODBUS Version Level 1.30. More detailed documentation can be sources in the MODBUS Spec.

The E-Stop and the System Ready inputs (on an OL) are now required to Enable, Jog, Position, Reference to Home Switch ...etc. In addition, if the system loses the E-Stop or System Ready, the Multi-Axis drives will now also be disabled.

A divide by zero error (C0000000) would occur when running a part with a Lock Size of 0.000".

This condition will now be tested for and will result in an error message indicating Lock Sizes must ne non-zero.

Changes made for Pathfinder V5 PC's.

Recently the ASCV2 configuration got all the I/O associated with the Foldguard with Handshake machine option. No reason for the other versions of the 5226 ASC configurations to not have in case needed in future upgrades with foldguard.

Foldguard with Handshake was added to ASCV2HeavyDuty, ASCV3, and ASCV4 configurations.

• AMS.Eclipse Supervisor Service: A new Windows service that monitors and manages Eclipse Pro components. Currently provides automatic health monitoring, crash recovery, and centralized status reporting to AMS. The Supervisor will eventually host all Eclipse Pro processes (Server, Agent, RavenDB) enabling non-admin updates and unified management through a single service. This is currently optional and can be installed using the Eclipse Toolbox.

Improvements

• Performance and stability improvements.
• NetSuite: export attempts reset the attempt count after passing each stage.

Bug Fixes

• Punch Patterns would immediately show that changes need to be saved when viewing. This is fixed.

• Fixed issues sending orders with problem punch patterns. Sometimes, the order header would be sent without items.

Home Sensor Detection has been an issue at times The Die direction is chosen based on the initial state of the home sensor and up until now, the search for the home sensor was based on its current state rather than the expected transition.

The problem this change solves is to better deal with home sensors that have a small position sensing window. If the Referencing Velocity is too high or the acceleration is too low, the die can coast beyond the sensor and turn back off. This violated an assumption that was critical to the Homing Algorithm operation.

For example, if the die was returning to the home sensor and the sensor turned ON, the die would stop. If the die coasted beyond the sensor, the next move to move forward off the sensor would terminate before any move took place, because the sensor was already OFF. The next move, looking for an ON would then reverse the die into the overtravel’s looking for an ON state that was never going to come.

Now that we have changed the routine to look for a specific transition, ON to OFF or OFF to ON, the prior example will no longer be a problem. The die will return home looking for an OFF to ON transition, which it will find. Even though the die has coasted beyond the sensor, when it moves forward it will be looking for an ON to OFF transition. It will move forward until it see the OFF to ON transition and continue moving until the ON to OFF transition occurs.

Higher Referencing speeds and lower accelerations may now be used, and the homing routine can still function correctly, provided the die does not coast into an overtravel.

There is a limit to this new method. The home sensor inputs are debounced at 20msec. In order for the new routine to work properly, when searching for the home sensor, the sensor must be ON or OFF for a minimum of 20msec or the transitions may not be sensed.

I have been unable to duplicate the F37 Excessive Position Command Value Difference fault that has been occuring in the field. The fault seems to happen most often on the first drive enable or move after a power cycle. Once manually enabled, the drives seem to function correctly.

Under the theory that the drive is intermittently failing to remember the prior position command properly on a Power Cycle, the follwing change has been made.

While the drive is disabled, the Command Position is updated on everly cycle time with the current axis position, ensuring that there is no significan't jump when the drive gets enabled.

To debug an issue with enabling a Drive as part of a Mult-Axis jog request request from MODBUS some debug code was added. This debug code enables two inputs to allow the same driver method that MODBUS call to be called from the input task using two inputs. This simplifies the equipment required to simultate the environment required for testing.

FlashDoctor assumed 2 digit revision numbers when creating the file name for XL200 FMF files.

This has been resolved.

Changes made for Pathfinder V5 PC's.

Parameters 890 Preferred Gripper Offset, 891 Hem Flange No Grip Zone, 892 Gripper Air Space Offset have been added to the following configurations.

JornHyperDriveFlex JornHyperDriveFlex4Frame JornHyperDriveFlex5Frame JornHyperDriveFlex8Frame

When Selective Two Encoder Closed Loop was enabled, the setup, Enable Feed Forward was still created but it was not visible. This opened up the possibility for the Selective Two Encoder Closed Loop to get disabled.

The fact that it was created opened up a potential issue for controllers with Eclipse that had old settings backed up. If the controller was ever configured without the Selective Two Encoder Closed Loo and the settings had been backed up, the setup could be downloaded and then disable the Feed Forward settings and functionality.

This issue has been resolved. When Selective Two Encoder Closed Loop is configured, the problem setup is disabled and the correct values are forced into the setting.

When Two Encoder Selective Closed Loop was configured, the controller did not output any analog voltage for the feeder.

All of the calculations for the voltage were correct but the value was not being written to the analog port.

This has been resolved.

Closed Loop SERCOS controllers could get stuck in Coast mode if the Drive fails to enable when entering the run mode. Among other reasons, this can happen if the SERCOS ring is stuck in phase 3 or lower.

It gets detected that the drive is unable to be enabled. However, the code was lacking the trigger to satisfy the condition to escape the loop that was waiting for the drive to be under torque.

Some Manufacturers have an external power enable circuit to their SERCOS drives to enable power. This prevents the Cyclical Interrupt from being installed, which traps the SERCOS state machine in a place where it does not do its normal processing.

In this state, I have added checking to allow drive settings to be modified and drive errors to be cleared. The drive status is also modified to indicate the drive is not ready and is waiting for Cyclical Data to be enabled.

Sercos errors for all drives are cleared in phase 2 during the phase run up to phase 4.

Once the system has gotten to phase 4 and errors need to be cleared, it is most likely to get the line back up to full operation as quickly as possible, not for troubleshooting. For this reason a request for Error Clear will cause a new phase run up to clear errors in all drives and resolve any other potential state machine issues.

NA

On modorrn drives the timing of when the drive is enabled and when it is ready to move is not as critical. The drive generates its own motion profile and moves when ready.

With Diax02 drives, the XL has to generate the motion profile and needs to wait until the drive is ready before it starts. Otherwise the drive reports faults.

This change adds a state to the Diax02 state machine where it waits for the drive to report that it is under torque before it begins generating its profile. To avoid an endless loop in the state machine, it will wait up to 500msec for the drive to be ready before it gives up and reinitializes for a new command.

Improvements

• Add source pattern to the list of XL200 patterns. This allows users to see where the pattern originated from, which is useful for debugging.
• Added split_get function to Scriban templates for extracting elements from delimited strings - example: {{ "1.2.3" | split_get "." 2 }} returns "3".
• Add machine run state with mini pop up to the schedule timeline view.
• Punch Pattern editing now has more checks against creating invalid patterns. For example, Macro patterns cannot contain Shape or Macro punches. Validation errors are visible in the punch row.

Bug Fixes

• The save bundle changes button was still visible after bundle changes were saved. This is fixed.
• Country was not being imported from JobImport (via .json and api). This is fixed.
• The machine metric pop-up from the Scheduler tab was not showing data. This is fixed.
• Fix issue where orders with that used DateTime strings as their order number would not show as available to schedule.
• Machine Shape Table incorrectly would not allow a single tool on a press with gag of 0. This is fixed.

The SCN 5090 Two Encoder Selective Closed Loop mode was not configurable if any of the other DIP Switches that affect Encoder or Analog direction were configured.

An Invalid DIP Switch Configuration error would occur.

This has been resolved.

Changes made for Pathfinder V5 PC's.

New firmware versions are:

Rev F: 4.04.19

Rev G: 5.00.18

Changes made for Pathfinder V5 PC's.

Some gripper machine options needed to be optimized for these two configurations.

Changes made for Pathfinder V5 PC's.

New configuration for an 8 frame Jorns TwinPro in case closed loop parameters needed to be changed. As of right now based on the 5 frame parameters.

Changes made for Pathfinder 5226 controllers.

A change was made on double folder machines that didn't have multiple prop. valves for each axis which means they move one at a time. It was to allow the upper retract to move before the clamp could raise. This caused other problems down the line in which the UR could move down before the clamp could close which interferred with the material.

The change was to make a specific axis conflict which knows they share the same prop valve and will only let the UR move before the clamp if the clamp is moving down and the UR wants to move back.

The Y-Axis State Machine was getting "corrupted" when positioning any Axis higher than 3. The machine index stored in the state machine was getting corrupted which ultimately resulted in Axes with ID's higher than 2 not positioning.

What was actually happening is that the size of the Array of state machines was defined with one literal variable which was too small. The array bounds checking was being done with the correct literal. Any Axes with an ID higher than 2 was using memory that it didn't own, which resulted in it eventually being "corrupted" by the actual owner.

This has been resolved.

Some Debug Prints were added to the Movement State machine.

Changes made for Pathfinder PC V5.

Added a new 9mm geometry to be available in the existing JouanelPTS31 configuration for their base electric folding machine.

Changes made for Pathfinder PC V5.

An ASC cabinet does not have foldguard integrated into it like a Flex design. This means using an external foldguard box is needed, but that has basic firmware in it that makes the installer have to take out the fast speed valve when we want to force the clamp into slow. This is not possible with an ASC machine which uses VFD's instead.

The solution was to update the PCSS to the latest foldguard firmware and then add on to the existing ASCV2 configuration the needed I/O. This allows for the handshake logic and the force slow to work without having to mess with anything in the existing cabinet.

Changes made for Pathfinder 5226 controllers.

The HPU system that is put on our retrofitted double folders has a temperature feedback sensor to be able to keep track of the temperature and try to keep it at a certain range to keep the oil in a happy place. We already had maximum temperature logic used in junction with the air cooler, but no minimum temperature logic. To take care of this 3 new parameters were added to look at the temperature when it approaches low levels.

Minimum Oil Temperature: Will not let you start the pump if lower than this value. Will Halt and throw error if somehow drops below this value in run.

Minimum Operating Temperature: Will try to turn on a heater if it exists if trying to turn pump on. Will Halt and throw error if it drops below while running.

Minimum Temp to Run Air Cooler: If the air cooler is on it will be turned off under this temperature.

Changes made for Pathfinder PC V5.

Error message 398 Minimum Oil Temperature to Start Pump will be displayed when the controller monitoring the temp sensor sees that the oil temp has dropped below either the minimum temperature or the minimum working temp during run. Will display trying to start the pump if under the minimum temp.

New Features

• Punch Patterns can now be copied to a new pattern.

Improvements

• The schedule estimator has been improved to better handle late changeovers and overlapping scheduled downtimes.
• Andon header color uses the current task to determine the severity of the lateness.
• Andon header shows an icon if there is a dialog open on the controller screen.
• The connection to RavenDB is now more resilient from unexpected disconnections and delayed startup.

Bug Fixes

• Fixed interval properties in the Integration configurations.
• Any user could set permissions for other users. Now only administrators can modify permissions.
• OEE value was not being displayed on the Andon panel.

Changes made for Pathfinder 5226 controllers.

The HPU system that is put on our retrofitted double folders has both a temperature feedback sensor and an air cooling fan. The controller has 3 parameters to control the cooler based on temperature. There is a threshold parameter which will turn on the fan when temp is above its setting and a maximum parameter which when temp reaches this setting it will throw an error and not let the user run the machine. Then there is a hysteresis parameter. Logic for this parameter is that if the cooler is on and it gets to threshold minus hysteresis turn off the cooler.

The bug for the max temp is that it was also turning off the cooler, but at max minus hysteresis. The hysteresis in this case is just supposed to keep the user from running until under max minus hysteresis, but keep the cooler on to keep cooling. This has been fixed.

The XL has a Real Time Clock (RTC)function and a Watch Dog Timer function that are all built into the same Chip. During the boot process, the XL must turn off the Watch Dog Timer until the boot progresses far enough that it can be re-enabled and maintained.

If the RTC cannot be accessed, the boot code will stop the boot process and output a bit pattern on a GPIO pin. In some board Revs, the GPIO pin controls a hearbeat LED and the pattern can be read from there.

The test for accessing the RTC had several flaws in it that prevented the test from doing its job. If the RTC was not functioning the boot code tried forever rather than generating the bit pattern. This has now been resolved.

This bit pattern in primarily useful during repair or initial production of the board as a tool to point to the cause of boot issues.

During initial boot there are a certain level of expected failures as the Chip initializes. The number of expected failures was determined empericaly and then doubled to be conservative.

This issue is experienced primarily with popup screens like the Coil Load and Unload screens that popup in response to some external event.

The issue was created during the creation of "SCN 4978 - XL2; Potential memory corruption with Tree Node selection timer."

The original fix bypassed the dangerous code but also bypassed the needed mouse unlock code.

This issue has been resolved.

Changes made for the Pathfinder 5226 controllers.

Grippers on a double folding machine can have many different combinations of I/O used for control. One of the combinations is to have one limit input and 2 control outputs. In this case we will turn the output off instead of keeping it on which happens in most cases. The bug was that instead of turning off the opposite output off, the output being used was turned off which can cause the gripper to re-open.

The fix was to turn off the correct output once the move was completed.

An Unlicensed Model can now be configured in the Model Codes so that the controller powers up in this model.

There is one Model for each software project.

1. XL200CL-Unlicensed.
2. XL200-Unlicensed.
3. XL220CL-Unlicensed.
4. XL220-Unlicensed.

Added four XL200 Models, one unlicensed model for each software project.

1. XL200CL-Unlicensed
2. XL200-Unlicensed
3. XL220CL-Unlicensed
4. XL220-Unlicensed

Various Closed Loop models that support Two Encoder Feed to Stop will now also support a selective option.

This option has been added to support machines that have a disparity between the physical location of the line encoder and where the feeder (rollformer) has enough grip to jog the material. The tailout switch is typically located with the line encoder. The issue is that when the material is sensed, the loop is closed around the line encoder. If the feeder does not yet have enough grip to feed the material, Max Slip errors occur.

This new mode offers a solution. While jogging, the feeder motor is operated in an Open Loop fashion. A command proportional to the Max Velocity at 10V setup is sent to the drive while jogging. When halted, the loop and drive are disabled to prevent issues that would arrise if the material is halted while the feeder has no grip. When in Full Auto, the motor and loop are operated in standard Two Encoder Feed to Stop fashion.

The models, where available, and the switch settings required to configure this new mode are defined in the Switch Settings document.

Improvements

• Agent now has a proper /health endpoint.
• Agent refreshes the Classic Loss Codes on start.
• Include Machine Name in report csv data.

Bug Fixes

• Fixed the DbCoilSync config display.
• Andon panel list was not translated in the Multi-2x2 panel editor.
• Performance and stability improvements.
• Allow BundleStates to be created when the Material or Tooling definitions no longer exist.

Changes made for Pathfinder 5226 controllers.

The 5226 has the capability of using a license code to give a customer a certain amount of days of use before locking out the controller if payment is not recieved during that time frame. The controller uses the last 3 characters of the serial number to confirm the code created is for that controller. The problem is that the amount of memory allocated for the serial number is bigger than what is usually used in production. The bug is that the controller was still looking at only the last 3 characters saved in memory for the check which were bogus.

The fix was to get the string only to the null character which is the end of the string/serial number. Then check the actual 3 characters of the serial number to confirm correct controller.

If communication had not been established with Diax02 drives, a divide by zero error was possible when navigating to the SERCOS or Closed Loop Data diagnosic screens.

This has been resolved.

When editing SERCOS parameters in the XL, if the parameter did not exist, the Fiber Ring had to be reset in order to recover. This has been resolved.

Enable the "Clear Queue After" setup for the KMF controller.

In the future we will be creating a Software Licensing feature that allows a controller to be sold without functioning software. The Software will be sold seperately and licensed. The license will contain and select the Model that the controller is supposed to function as.

A new model has been created for controllers that have not had a software license enabled. This Model will be be selected by the software when a software license has not yet been enabled in the software.

The new model will be functional enough to be configured to communicate with Eclipse, which can provide the license in the future. In the future it will also provide the ability to configure the license manually.

Starting from a functionally controller the following changes have been made to create this model.

Disable all inputs to the controller so that it cannot function. No presses or motion configuration is defined.

The XL2OL controllers will have XL200-Unlicensed as their Model. The XL2CL will have XL200CL-Unlicensed as their Model. The XL220 will have XL220-Unlicensed as its Model. The XL220CL will have XL220CL-Unlicansed as its Model.

There is currently no way to configure a controller as Unlicensed. That will come in a future SCN.

To help with pattern troubleshooting on Multi-Axis machines, the Axis Id for the Tool used in a pattern will now be displayed in the operation grid.

For non-multi-axis machines, the Axis ID will always be zero.

If the Axis cannot be determined at display time it will be displayed as a '?'. Macros and Shape operations don't have an Axis until after the part has been calculated. If the operation is for a Macro pattern or if it is for a shape operation, it will also display a '?'. Other cases where the Axis ID cannot be determined are the case of missing tools that cannot be found at display time.

• Fixed formatting of production export file.
• Fixed issues when sending an order with shape patterns before the solution is ready.

New Features

• Loss Codes (Delay/Scrap) now have a printable report with barcodes that are specially formatted for use with an XL controller.

Improvements

• Shape selections now offer a searchable list of shapes.
• Enhanced Coil Sync: DbCoilSyncer now supports flexible SQL queries with configurable change detection for optimized synchronization:
  • Custom SELECT statements for any database schema
  • Incremental sync using DateTime or RowVersion/timestamp columns
• Detect and clean up duplicate coils and materials in the database.

Bug Fixes

• Better handling when Classic is performing daily maintenance.
• Classic to Pro sync improvements.
• Various Shape Pattern fixes.

Changes made for Pathfinder PC Software.

New Firmware:

Rev B, E and F - V4.04.18 Rev G - V5.00.17

Changes made for Pathfinder PC Software.

A bug was created when using the touch screen that was created from trying to fix another bug. Essentially when trying to reference or setting the FG mute point Pathfinder will send an extra jog command once the person releases their finger from the touch screen. This causes the reference and mute point status to clear and never let the user get referenced or have a good mute point.

The fix was to make sure the extra command does not happen.

The controller default part print message has a rotation of 270 degrees. The Keyence Print driver only prints one character of the default part print message. The single character that does print, prints horizontally instead of vertically. Because the message gets rotated by 270 degrees, the rest of the message is hidden in the screen and does not print on the part..

It is too late to change the default message for the driver. This will break existing customers installs that may use the default message. It is also too late to completely adjust the driver’s interpretation of the rotation property so that the default message prints properly. Again, any general adjustment will impact existing customers of the printer.

A new setup has been added that is enabled when the Keyence Part Print drivers are selected. It is called Adjust Part Print Rotation. The parameter has two options, 0 and 90. It defaults to 0 degrees for legacy reasons. When set to 90, it will add 90 degrees to the rotation found within in any print message definition. This effectively converts 270 degrees back to zero. All the other rotation options are shifted by the same amount.

Changes made for Pathfinder 5226 controllers.

A change was made to simply just clear the the reference bit if the axis hardware feedback was not incremental encoder. The problem found though is that when in simulation mode it changes the feedback to simulation. So if you were checking to make sure it stayed unreferenced after a restart it will clear the status if in reference mode.

The change was to also not clear the reference status if feedback is simulation.

Changes made for Pathfinder 5226 controllers.

Usually on our retrofitted double folders the upgrade comes with a new HPU which allows axes to move at the same time. This allows the upper retract to move out of the way at the same time as the clamp moves down. If the machine does not have this capability the clamp was moving down into a clamped position with the upper retract still at home. It looks bad and the bending beam is usually at its home position too which can damage the part.

The fix was to move the upper retract out of the way before moving the clamp down.

The Open Loop Model Option screen in Flashdoctor is shared between the HVAC and Rollforming controllers.

The screen is only constructed one time. It gets displayed or hidden.

The screen was not written with the assumption that it would need to enable and disable all controls, depending on the controller type. It was written with the Rollforming models and options enabled by default. The HVAC file would disable the Rollforning Models and option but nothing short of restarting the program would re-enable the Rollforming contols.

This has been resolved.

If there were more than 1 SERCOS drive, sometimes clearing an error using the F3-Clear Error function key did not work.

This has been resolved.

We ran into an issue on a customer install. We were incorrectly informed that Diax02 drives support the Drive Internal Interpolation mode that we have historically used on multi-Axis installs. It turns out this is incorrect.

Rather than relying on the Drive to calculate the Position Profile Setpoints for an axis move, we had to add the capability for the controller to generate them.

These are 30-year-old drives, SERCOS is also an obsolete technology. The customer’s line is down, and they have several more lines with these same drives. With all these things in mind, some compromises were made to speed up the implementation.

The setpoint generation requires our operating system to be in sync with the SERCOS Bus. We already do this by using the SERCOS chip to run our OS on SERCOS Closed Loop Controllers. For this and the previously stated issues, this support is only available on the Closed Loop models with the SERCOS option.

A new Driver Type called "Local SERCOS Diax02" has been added.

A new Check box in the SERCOS Settings window "Diax02 Operation" is available on the Closed Loop controller with the SERCOS option. When this box is checked all SERCOS drives will be configured in operation modes known to work on Diax02 drives. For Multi-Axis drives, the Local SERCOS Diax02 driver type must be used. . The Local SERCOS Diax02 drive can be used on a more modern drive Diax03 or higher as it still uses settings and operating modes that are available in those drives.

Only SERCOS drives with the appropriate drive type will be visible in Diagnostics. A Run Mode entry test will display an error if the wrong type has been selected.

Other than the Driver Type, the only visible difference between a "Local SERCOS" and a "Local SERCOS Diax02" driver will be the Diax02 type will have an Acceleration parameter that is required in order to generate the motion profile.

The Diax02 version does not support S-Curves. Those were provided by the Drive Internally when it generated the motion profile.

A bug was found in the Diax02 drives we had available to test with. The Velocity parameters were found to only work reliably in the drives when configured for RPM. We chose to use Preferred scaling, where the drive chooses its own prefereed scaling.

Velocity drives, for Feeders and Die Accelerators still operate in the Velocity mode they have always used. Velocity will be in RPM so drive scaling will require some new math to RPM instead of Inches/minute.

Multi-Axis drives now operate in Position Mode where we have to send a postion setpoint on each drive sample. The XL is generating the motion profile with these setpoints.

Additional help for configuring these drives can be found in the Support One-Note.

• Agent now requires Classic to be at minimum version of 4.1.220.
• RavenDB must be upgraded to version 6.2.5.

New Features

• Shape Punch Patterns (preview): Punches on patterns referenced the specific tool id on the machine. It is now possible to reference a Shape Name instead. This allows the same pattern to be used by multiple machine that do not share the same tool configuration. This is especially important when importing patterns from design software, where the tool id is not known. Also, the same hole could be made by multiple tools on the machine. Shape Patterns will automatically select the optimal tool based on the machine layout. This feature could require additional licensing. More information: https://www.amscontrols.com/product/eclipse-pro-shape-programming/
• DB Material Import can lookup missing information from an external database. This is automatically triggered when a coil or order references a material that does not exist or has default values.
• File import now support JSON format.`
• On Demand import for Patterns. When an order is created that references Pattern Names that do not exist, Eclipse Pro can query an external database for the pattern information.
• New Andon Panel == Multi-2x2: A new Andon panel that displays for metrics in a 2x2 grid.

Improvements

• Machine Group is now editable on the XL Machine view.
• XL Machine view now shows Axes.
• Punch Pattern punch type now remembers the last selection.

Bug Fixes

• Fixed regression where Api Keys tab would not appear when it was supposed to.
• Fix decimal formatting in Order Quick View
• Fix display of newer string metrics in dashboard detail.
• On the print configuration screen, the up/down buttons on print copy count were not working. This is fixed.

• Add support for importing and sending Shape Punch Patterns (requires Pro)
• Reenabled order import macro that was accidentally disabled.
• Add the following fields to the non-expanded production output format: sku, scrapqty, exptmatlen, shearkerf
• If a coil is already loaded at another machine, the validation message now indicates which machine.

During a Run Cycle Shear, the tube mill stops processing press and printer targets.

Over the years other bug fixes and features have added additiona tests for missed press targets. These additional test were not considereing that a tube mill is not supposed to report any missed targets durring a Run Cycle Shear. This broke the Run Cycle Shear function when any press targets were being processed, resulting in a Missed Press or Missed Printer target error.

This has been resolved.

When doing hole correction on a machine where the holes are being added Asynchronously by an upstream process, the controller must have a detected hole to initialize the part queue with. The controller doesn't know anything about the holes. They may not all be the same size or shape. They may not be evenly spaced. The controller must rely on the operator to jog a hole through the detector for the leading edge of the first good part. The controller will add a shear here to create the leading edge of the first part. This can be inconvenient if not necessary, for example, on a machine where all the holes are the same size and are all evenly spaced.

An additional problem is that doing a leading-edge scrap cut while in run, may not be easily handled by the machine.

It may be desirable and accurate enough to lineup the material such that a manual shear will cut in the correct place, with respect to the first hole. This will align the leading edge of the material such that the holes are synchronized correctly with the detector so that the remaining cuts can be properly adjusted as the holes are detected within the Hole Tolerance. The scrap that is created by the manual shear can be easily dealt with prior to entering the run mode.

A new selection in the Hole Correct Mode setting has been created to allow users to inform the controller that all the holes are evenly spaced, equivalent, and it is OK to initialize the queue with respect to a manually cut leading part edge. The new option is named Evenly Spaced Async.

A modification to the Hole Generation simulation on the PC simulator was made to allow this new option to be more easily tested.

In most cases, up until this point, using the Hole Correct option has required lying to the controller about where the Hole Detector is in the Shear to Detect setting. This will no longer be necessary. The desired shear location, with respect to where the hole is detected, will now be configurable with a new setting,

Hole Correct Shear Offset. A positive value will shift the shear in the positive direction, to the offset position after the hole. A negative value will shift the shear in the negative direction, to the offset position before the hole. The default value is zero, which will do no shifting with respect to the hole.

We have a customer who doesn't believe the controller is testing for the Y-Axis to be in position and stopped before firing the press. They have Local SERCOS Y-Axis drives that do the positioning. There is a position tolerance and a stopped tolerance. It is possible that the stopped tolerance or position tolerance could be faulty.

We have added debug prints in the test when it is determined that it is OK to fire. We are printing the Position and Velocity tolerance for each SERCOS Y-Axis. In the tolerance printount we are printing the current line position, the cmd Y-Axis position, the actual Y-Axis Position and the Current Y-Axis velocity.

If we don't get the debug prints, we know it isn't testing. If we get the debug prints, we will know if it is testing for each press fire and, with some backwards calculateing, we will know if the correct Y-Axis position has been commanded and the presses fired at the correct X-Position.

Using the keypad there was no way to cancel an Increment Qty other than canceling all Increment Qty with the CE key.

The F5-Dec Qty key can now be used to undo a single Increment Qty part.

SCN 5059 already attempted to resolve this issue but a source code cut and paste error meant the fix was not actually implemented and the fix actually was potentially corrupting some memory.

The code was using BuildPart1.BPressID rather than BuildPart.BPressID to enable the press. BuildPart1.BPressID could have been any one of 255 possible values rather than for the actual press that neede to be enabled.

There are now UART commands that allow orders to be moved/resorted.

There are two commands, one for moving above and one for moving below. Both commands take two arguments. The first argument is the address of an Anchor order, an order that will not be moved but will serve as the target order that another order will be moved above or below, before or after. The second argument is the address of the order that is to be moved. More details on the commands are available in the UART Spec. The UART version where these commands become available is 3.66 and higher.

Edits to the QTY on a DONE item were being converted to Remake (Scrap) parts, with no scrap code. This makes no sense. Edits to a partially complete item don't do the same thing, which makes this behavior even more surprising and confusing. In addition, we have a remake function that will explicity do this, and prompt for a scrap code to boot. If the user wants these extra parts to be remake parts, they can use the remake function.

Edits to a DONE order will now clear the scrap qty and the scrap code in the item.

A customer is complaining about a 0x81000003 task error. The error is being generated while building the response back to the Office PC. The string has gotten too large despite having a check for size just prior to when the error occurs. There appears to be memory corruption or a timing problem with shared memory involved.

While troubleshooting, it was noticed that the task errors seemed to occur only during periods of time when the entire Eclipse network of machines were experiencing high rates of communication failures, indicating a network wide issue. It is believed that this network issue sets up the environment when this occurs.

The buffer for parsing a command and then building the response is a shared buffer. When the RS485 network is used, the buffer is protected by disabling the RX interrupt while building the response. There is no such protection with Ethernet which, in theory, may be the source of these task errors. The theory is that the network issues setup the environment where a new command can come in and corrupt the response as it is being built. The new command is written to the buffer in an interrupt.

To eliminate this as a possible cause, the following changes are being made. The interrupt will save the command in a temporary buffer. The UART task will copy this temporary buffer to its processing buffer so that if a new command comes in, it will no longer be able to corrupt the response. The new command will be copied and processed only when the UART task is ready for it.

Some additional changes were made to minimize the damages if the UART Tasks buffer corruption is still somehow occurring after adding the temporary buffer. Rather than using copy string functions, the buffer copying code has been modified to use sub string functions that will only copy as much memory as the target string buffer can hold.

There were several tasks in the windows simulation that were not identified with catalogs.

The display in the Windows simulation was not updating durring the Toggle input R command. This command is used to simulate the toggling of a home sensor.

The issue was the Toggle R and all other windows simulation commands were executing in the PEG graphics task, which updates the display. While executing the Toggle R command, the PEG task could not also update the display.

Now the commands will execute in their own task, which will allow the display to update during any lengthy command like the Toggle R command.

A CLF with Multiple Presses on one die, Stitching Parts by omitting shears, Phantom shears, are all scenarious where a press gets disabled. It is prevented at a low level from firing.

A customer with an XL202CLF with two presses on one die reported that they had internittent issues with the Shear press not firing on a Manual Shear. After a deep code review, since we were not able to duplicate it, the following theory was formed.

Under some conditions, the run code is likely disabling the shear press. It enables or disables it when it processed each target. There are most likely conditions where the controller exitt the run mode with the press disabled. The Manual Shear Code is expecting the press to be enabled all the time.

The fix, in case this theory is correct is to enable the selected press during any Manual Shear or Press operation.

The comm port tests report passes and failures. The test alternates between expecting to see its data echoed back or not, depending on the state of the transmitter.

The test reports passes and failures. As long as the UART hardware responds to the XL, generating the appropriate interrupts, normally every other test passes. If all tests fail, it is not possible to tell if it is bcause the 386 is recieving no interrupts or if the appropriate states are not being found in the Interrupt status register in the UART.

Three new counters were added to help determine what is going on in the interrupt. The Number of ISR events are counted. The number of ISR pending (UART says it has an interrupt) are counted. The number of TX Empty interrupts are counted.

These counters will help determine not only if interrups are being recieved by the 386 but is the correct statuses are being reported by the UART hardware within the interrupt handler.

Added a test to combine duplicate operations in the solution pattern into one single operation.

There are some debug print changes that are only active when the source code is used in the Eclipse Pro FindSolutions DLL.

Added a field to store the Tool X offset in the shape table. This is used to correctly offset the X offset of a set of grouped shapes. The Tool X offset is used as the group handle to calculate the resulting X Offset in the Pattern.

Removed the X offset from the Press Table. This field is not used in the controller and wasn't needed in the DLL. Eliminating it helps eliminate complexity and confusion.

Removed the Y offset from the press table and replaced it with a Y Reference Offset. This offset is used to account for the offset in the shape locations when a machine is Edge Referenced. The part operations are always converted to Center Referenced. To be comparable, the shapes need to be offset to make them center referenced as well.

Added methods to the Solution class so that all direct access to the gPart table in the DLL could be removed and replaced with calls to these methods.

Added the ability to optionally read multiple 32bit gag words from the File Import.

Added the ability to optionally specify a shape X and Y offset to the File Import.

Use the Radius tolerance when comparing Y-Offsets of non-movable shapes, looking for a handle.

Fixed an Array out of bounds error when searching backwards in a part to apply a grouped shape.

Cleaned up the debug printout for the press table to make it easier to read.

A method for converting Gag ID's to the Gag index and bit in Gag Bit arrays was added.

The Debug output for Gags was only showing gags up to gag 32.

The File import function for testing Shape Programming was not working with gags greater than 32.

New Features

• Punch Pattern lengths now support entry using units. Any of the available display units are available to be entered. This functionality will be introduced in other locations in later releases. After saving, the value will be displayed using the system format. It also supports simplistic addition and subtraction. Here are some supported examples:
  • 1.5 in
  • 1-1/2"
  • 4' 8-1/8"
  • 1' 2-1/4" - 7/8"
  • 23mm
  • 2cm + 5mm

Improvements

• Add the Switch field to the XL200 machine list and detail.
• Alert when duplicate coil ids are found in Classic.
• Quick Views now include links to their target views.
• Punch patterns can now edit the Pattern Number.
• Material Thickness can be calculated from Gauge.
• The list of printers can now be refreshed from the printing view.

Bug Fixes

• Machine tools list was sometime not showing data and when it did it wasn't always the current set of tools. This is fixed.
• Operations within a pattern would only draw part of the first entry in the table. This is fixed.
• Setting the "Experimental Features" option on System Preferences had a bug where it would 'forget' the setting when navigating back to System Preferences. This is fixed.
• XL200 Settings were not getting saved. This is fixed.
• Api Job Import enforces the 20 character limit on order, tooling, and material codes.
• Public orders api would error when no query filters were sent.
• Public orders api was including deleted orders. This is corrected.
• Material Quick View was not displaying header information.
• Errors when changing Controller Settings did not present on the screen. This is fixed.

When ever a hole was detected, the independent punching stopped working properly. This has been resolved.

On some controllers the Keyboard and Mouse operation becomes Flakey with SERCOS enabled, specifically when the Cyclical interrupt gets installed in SERCOS Phase 4.

In Phase 4 the SERCOS chip takes over running the operating system timer interrupt, which is a lengthy interrupt. SERCOS adds additional Timer interrupt responsibilities. There are additional interrupts that are added in this state. All of these interrupts were higher priority than the PIC Keyboard Interrupt which processes Mouse and Keyboard data. The Serial port hardware has no recieve FIFO so it is important not to delay processing the KB interrupt for too long or it will lose characters, resulting in Flakey operation.

This has been resolved by raising the priority of the KB interrupt, higher than the OS Timer interrupt and the extra SERCOS interruts. The KB interrupt is pretty small so it should not have much impact on these other interrupts.

The MODBUS code reads the AMS ID and Version Level first to determine if the provided Configuration Register Address is correct. Assming the AMS ID is correct, it uses the Version Level to determine the size of the full configuration data structure and then reads it. The second read, reads the AMS ID and Version Level again.

If the first read was successful, the code assumes that the second read would also be successful and that the same AMS ID and Version level would be read the second time.

We have found that Allen Bradley PLC's that don't support MODBUS in a native way, may not respond properly on the second read. To detect this, we are now testing for communication failures on the second read. In addition, the AMS ID and Version Level between the first and second read are compared for equivelence. If they are not equivelent or there is a communication error, a descriptive error message is displayed.

The AMS ID and the Version Level of the first read are displayed int the PLC Diagnostic Screen.

The Dump Table Feature has been enabled on Stopping Lines. Some of the Dump Modes may not make sense for a Stopping Line. The user should not select those modes.

To promote adhesion, an engineer from KMF requested that we add the ability to retract the die while the Felt Applicator is being pressed against the felt and metal.

A new setting called Retract after Press has been added to the KMF controller. This setting, when non-zero, retracts the die by the programmed distance. The Applicator Vacuum is disabled and the retract starts at the end of the Press Down Dwell. The retract is active during the Press Up Dwell until the dwell expires or the retract is completed.

The Applicator Vacuum is disabled during the retract to limit the friction the pad has against the felt. The Applicator Pad maintains pressure until the Press Up Dwell expires.

The KMF controller has no parts to clear out of a press or any other concerns with doing a stationary cut. A default value of Never makes more sense than Allways for this controller.

The following settups were disabled in the KMF controller beacause they are incompatible with KMF operation.

The Hole Detector Mount setting has been disabled. The hole detect mount is by nature fixed. We are not sensing anything on the material. It is supplied by another control system. By default the setting is configured to Fixed and can no longer be changed.

The Front Shear Tool setting has been disabled. This controller will never support a front shear.

Bug Fixes

• Regression in Scheduler resulted in an empty page. This is corrected.
• The root cause of the recent regressions was identified and fixed.

Bug Fixes

• Fixed regression where the machine print configurations were not being displayed.

The MODBUS code has a number of dynamic memory buffers that must be recreated on every power cycle. These memory buffers are used to only send fields when the data changes.

It was very easy to add a new buffer and forget to also add the code that forces a recreation. This has been resolved by placing all of the pointers into one memory structure. This memory structure gets cleared on a power cycle, which then causes all of the buffers to be created.