Maestro Editor - Manual CNC - Description

Maestro CNC
User manual
Rew. 23 of 06-21-2021

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SUMMARY
1 DESCRIPTION OF THE SOFTWARE...............................................................................................................14
1.1 INSTALLATION..............................................................................................................................................14
1.1.1 PC minimum requirements ...................................................................................................................14
2 OPERATOR INTERFACE .................................................................................................................................15
3 PROJECT ..........................................................................................................................................................16
3.1 PROJECT MANAGEMENT ...............................................................................................................................17
3.1.1 Project default .......................................................................................................................................18
3.1.1.1 Default: "Project name”............................................................................................................................... 18
3.1.1.2 Default “Project folder”................................................................................................................................ 18
3.1.1.3 Save the configuration parameters ............................................................................................................. 19
3.1.1.4 Restore the configuration parameters......................................................................................................... 20
3.1.1.5 Operating environment ............................................................................................................................... 21
3.1.2 New project setting ...............................................................................................................................23
3.1.3 Open an existing project .......................................................................................................................23
3.1.4 Import Pgm/Xxl .....................................................................................................................................24
3.1.5 Import 3D template ...............................................................................................................................27
3.1.6 Import from STL ....................................................................................................................................27
3.1.7 Import Image.........................................................................................................................................28
3.1.8 Project check.........................................................................................................................................29
3.1.9 End project............................................................................................................................................30
3.1.10 Save Project .....................................................................................................................................31
3.1.11 Project Graphic display.....................................................................................................................32
3.1.11.1 What you see of the project ........................................................................................................................ 32
3.1.11.2 Where to see the project............................................................................................................................. 33
3.1.11.2.1 Zoom..................................................................................................................................................... 34
3.1.11.2.2 Pan ....................................................................................................................................................... 34
3.1.11.2.3 Orbit...................................................................................................................................................... 34
3.1.11.3 How to see the project ................................................................................................................................ 35
3.1.12 Transformation of DXF list to PGMX ................................................................................................36
3.2 WORKPIECE ................................................................................................................................................39
3.2.1 Rough workpiece ..................................................................................................................................39
3.2.2 Finalised workpiece ..............................................................................................................................39
3.2.2.1 Parallelepiped shaped workpiece ............................................................................................................... 39
3.2.2.2 Extruded workpiece .................................................................................................................................... 40
3.2.2.2.1 New geometry creation for extruded ...................................................................................................... 40
3.2.2.2.2 Geometry importing for extruded from another workpiece ..................................................................... 41
3.2.2.2.3 Geometry importing for extruded from dxf.............................................................................................. 41
3.2.3 Change workpiece shape .....................................................................................................................41
3.2.4 Change workpiece dimensions.............................................................................................................41
3.2.5 Import the workpiece.............................................................................................................................42
3.2.6 workpiece Removal...............................................................................................................................42
3.3 WORKING PLANES........................................................................................................................................43
3.3.1 Standard Faces.....................................................................................................................................44
3.3.2 Parallel Plane........................................................................................................................................45
3.3.3 Inclined Plane .......................................................................................................................................46
3.3.4 Plane from surface area........................................................................................................................47
3.3.5 Work plane tree.....................................................................................................................................48
3.3.5.1 Work plane selection................................................................................................................................... 48
3.3.5.2 Properties and plane modification............................................................................................................... 49
3.3.5.3 Plane removal............................................................................................................................................. 49
3.3.5.4 Displaying working processes on planes .................................................................................................... 50
3.4 GEOMETRIES...............................................................................................................................................51
3.4.1 Enter new 2D geometries .....................................................................................................................51
3.4.1.1 Type a new point......................................................................................................................................... 52
3.4.1.2 Type an existing point by using the Osnap ................................................................................................. 53
3.4.1.3 Point............................................................................................................................................................ 54
3.4.1.4 Line............................................................................................................................................................. 55
3.4.1.5 Arc .............................................................................................................................................................. 56

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3.4.1.6 Circle........................................................................................................................................................... 58
3.4.1.7 Polyline ....................................................................................................................................................... 60
3.4.1.8 Rectangle.................................................................................................................................................... 61
3.4.1.9 Buttonhole................................................................................................................................................... 62
3.4.1.10 Loop line ..................................................................................................................................................... 63
3.4.1.11 Smooth ....................................................................................................................................................... 64
3.4.1.12 Offset .......................................................................................................................................................... 65
3.4.1.13 Text............................................................................................................................................................. 66
3.4.2 Inserting blocking profile .......................................................................................................................67
3.4.3 Enter new surfaces ...............................................................................................................................68
3.4.3.1 Flat surface................................................................................................................................................. 69
3.4.3.2 Linear extrusion .......................................................................................................................................... 70
3.4.3.3 Revolution................................................................................................................................................... 70
3.4.3.4 Mesh lined .................................................................................................................................................. 71
3.4.3.5 Mesh corner................................................................................................................................................ 71
3.4.3.6 Section surface ........................................................................................................................................... 71
3.4.3.7 Sweeping.................................................................................................................................................... 72
3.4.4 Insertion of solids ..................................................................................................................................73
3.4.4.1 Parallelepiped ............................................................................................................................................. 73
3.4.4.2 Sphere ........................................................................................................................................................ 74
3.4.4.3 Cylinder....................................................................................................................................................... 74
3.4.4.4 Cone ........................................................................................................................................................... 75
3.4.4.5 Pyramid....................................................................................................................................................... 75
3.4.5 Enter new 3D curves.............................................................................................................................76
3.4.5.1 3D arc ......................................................................................................................................................... 76
3.4.5.2 3D composite line ....................................................................................................................................... 77
3.4.5.3 Projection.................................................................................................................................................... 77
3.4.5.4 Normal surface projection........................................................................................................................... 78
3.4.5.5 Wrapping .................................................................................................................................................... 78
3.4.5.6 Extract surface edges ................................................................................................................................. 78
3.4.6 2D geometry imported from DXF..........................................................................................................79
3.4.6.1 Recognition of horizontal holes................................................................................................................... 81
3.4.6.2 2D geometries advanced import from DXF................................................................................................. 82
3.4.6.2.1 Import 2D geometries from DXF for machining...................................................................................... 84
3.4.6.2.2 Import 2D geometries from DXF for edge banding................................................................................. 91
3.4.7 Export 2D geometry in DXF..................................................................................................................95
3.4.8 Geometry selection ...............................................................................................................................96
3.4.9 Contextual Menu of graphic area..........................................................................................................97
3.4.10 Geometry removal ............................................................................................................................98
3.4.11 Geometry properties.........................................................................................................................98
3.4.12 Change existing geometries.............................................................................................................99
3.4.12.1 Cut .............................................................................................................................................................. 99
3.4.12.2 Extend......................................................................................................................................................... 99
3.4.12.3 Invert......................................................................................................................................................... 100
3.4.12.4 Initial point................................................................................................................................................. 100
3.4.12.5 Join ........................................................................................................................................................... 100
3.4.12.6 Explode..................................................................................................................................................... 101
3.4.12.7 Split geometry........................................................................................................................................... 101
3.4.12.8 Editing geometries with the mouse ........................................................................................................... 101
3.4.12.9 Simplifying a polyline (smoothing)............................................................................................................. 102
3.4.12.10 Change surfaces.................................................................................................................................. 104
3.4.12.10.1 Extend surfaces ................................................................................................................................ 104
3.4.12.10.2 Intersection between surfaces .......................................................................................................... 104
3.4.12.10.3 Cut surface ....................................................................................................................................... 105
3.4.12.11 Fillet between surfaces ........................................................................................................................ 105
3.4.12.12 Adapt piece to surfaces........................................................................................................................ 106
3.4.12.12.1 Automatic counterprofile creation...................................................................................................... 106
3.4.12.12.2 3D model sectioning ......................................................................................................................... 106
3.4.13 Move and/or copy the existing geometries.....................................................................................108
3.4.13.1 Move......................................................................................................................................................... 109
3.4.13.2 Rotate ....................................................................................................................................................... 110
3.4.13.2.1 3D machining axis rotation.................................................................................................................. 110
3.4.13.3 Mirror ........................................................................................................................................................ 111
3.4.13.4 Oppose ..................................................................................................................................................... 112
3.4.13.5 Cut ............................................................................................................................................................ 113
3.4.13.6 Copy ......................................................................................................................................................... 113
3.4.13.7 Paste......................................................................................................................................................... 113

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3.4.14 Dimensioning..................................................................................................................................114
3.5 WORKING PROCESSES...............................................................................................................................115
3.5.1 Boring..................................................................................................................................................116
3.5.1.1 Bore position............................................................................................................................................. 116
3.5.1.2 Bore structure ........................................................................................................................................... 117
3.5.1.2.1 Data entry for countersunk holes ......................................................................................................... 118
3.5.1.3 Boring mode ............................................................................................................................................. 118
3.5.1.4 Boring technology ..................................................................................................................................... 118
3.5.1.4.1 Drilling speed ....................................................................................................................................... 119
3.5.1.5 Drilling deduced from the surface ............................................................................................................. 120
3.5.2 Speed profiles .....................................................................................................................................121
3.5.2.1 General data............................................................................................................................................. 121
3.5.2.2 First entry (initial phase)............................................................................................................................ 122
3.5.2.3 Feed (intermediate phase)........................................................................................................................ 123
3.5.2.4 Exit (final phase) ....................................................................................................................................... 124
3.5.2.5 Second entry (countersink phase) ............................................................................................................ 125
3.5.2.6 Return....................................................................................................................................................... 126
3.5.2.7 Change speed profiles.............................................................................................................................. 127
3.5.2.8 Using the speed profiles ........................................................................................................................... 128
3.5.2.8.1 Table of profiles default........................................................................................................................ 129
3.5.3 Inclined drilling ....................................................................................................................................130
3.5.3.1 Position of the inclined hole ...................................................................................................................... 130
3.5.3.2 Shape of the inclined hole......................................................................................................................... 130
3.5.3.3 Inclined drilling mode ................................................................................................................................ 131
3.5.3.4 Inclined drilling technology........................................................................................................................ 131
3.5.3.5 Drilling deduced from the surface ............................................................................................................. 131
3.5.4 Automatic drilling deduced from the surfaces.....................................................................................131
3.5.5 Milling..................................................................................................................................................133
3.5.5.1 Miling position ........................................................................................................................................... 133
3.5.5.2 Milling form ............................................................................................................................................... 136
3.5.5.3 Milling modes............................................................................................................................................ 136
3.5.5.4 Milling technology ..................................................................................................................................... 137
3.5.6 Slanted routing....................................................................................................................................138
3.5.6.1 Tilting routing position............................................................................................................................... 138
3.5.6.2 Tilting routing shape.................................................................................................................................. 138
3.5.6.3 Tilting routing mode .................................................................................................................................. 139
3.5.6.4 Tilting routing technology.......................................................................................................................... 139
3.5.7 Chamfering..........................................................................................................................................140
3.5.7.1 Chamfering position.................................................................................................................................. 140
3.5.7.2 Slotting shape ........................................................................................................................................... 140
3.5.7.3 Chamfering mode ..................................................................................................................................... 141
3.5.7.4 Chamfering technology............................................................................................................................. 141
3.5.8 3D routing............................................................................................................................................142
3.5.8.1 3D routing position.................................................................................................................................... 142
3.5.8.2 3D routing shape....................................................................................................................................... 142
3.5.8.3 3D routing mode ....................................................................................................................................... 142
3.5.8.4 3D routing technology............................................................................................................................... 142
3.5.9 Scoring................................................................................................................................................143
3.5.9.1 Scoring position ........................................................................................................................................ 143
3.5.9.2 Scoring shape........................................................................................................................................... 143
3.5.9.3 Scoring execution mode. .......................................................................................................................... 143
3.5.9.4 Scoring technology ................................................................................................................................... 144
3.5.10 Channel ..........................................................................................................................................145
3.5.10.1 Channel position ....................................................................................................................................... 145
3.5.10.2 Channel structure...................................................................................................................................... 146
3.5.10.3 Channel execution mode .......................................................................................................................... 146
3.5.10.4 Channel technology .................................................................................................................................. 146
3.5.10.5 Channel deduced from surface................................................................................................................. 146
3.5.10.6 Channel wider than disc thickness............................................................................................................ 147
3.5.11 Blade cut.........................................................................................................................................149
3.5.11.1 Cut position............................................................................................................................................... 150
3.5.11.2 Cut structure ............................................................................................................................................. 151
3.5.11.3 Cut mode .................................................................................................................................................. 151
3.5.11.4 Cut technology.......................................................................................................................................... 151
3.5.11.5 Cut deduced from the surface................................................................................................................... 151
3.5.12 Contouring ......................................................................................................................................152
3.5.12.1 Contouring position................................................................................................................................... 152

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3.5.12.2 Contouring structure ................................................................................................................................. 153
3.5.12.3 Contouring modes..................................................................................................................................... 153
3.5.12.4 Contouring technology.............................................................................................................................. 153
3.5.13 Emptying.........................................................................................................................................154
3.5.13.1 Emptying position...................................................................................................................................... 154
3.5.13.2 Emptying structure.................................................................................................................................... 155
3.5.13.3 Emptying mode......................................................................................................................................... 155
3.5.13.4 Emptying technology................................................................................................................................. 155
3.5.13.5 Recognition of pocket milling from 3D model............................................................................................ 156
3.5.14 Work on the lower face...................................................................................................................156
3.5.15 Technological data (shared by the machining operations).............................................................157
3.5.16 Approach/Retraction (shared by the machining operations) ..........................................................157
3.5.17 Advanced data (common to machinings) .......................................................................................159
3.5.18 Machine data (shared by the machining operations) .....................................................................161
3.5.18.1 Jerk........................................................................................................................................................... 161
3.5.18.2 Jerk3D ...................................................................................................................................................... 162
3.5.18.3 Main hood................................................................................................................................................. 162
3.5.18.4 Power hood............................................................................................................................................... 162
3.5.18.5 Additional hood ......................................................................................................................................... 162
3.5.18.6 Rotating axes brakes ................................................................................................................................ 163
3.5.18.7 5-axes head unrolling................................................................................................................................ 163
3.5.18.8 Electronic feeler ........................................................................................................................................ 163
3.5.18.9 NC speed adjustment ............................................................................................................................... 165
3.5.18.10 Tool blower .......................................................................................................................................... 165
3.5.18.11 Mechanical hold-down ......................................................................................................................... 165
3.5.19 Edge banding process....................................................................................................................166
3.5.19.1 Edge banding............................................................................................................................................ 166
3.5.19.1.1 Technological Data ............................................................................................................................. 167
3.5.19.1.2 Approach/Retraction Data................................................................................................................... 170
3.5.19.1.3 Edge banding advanced data ............................................................................................................. 171
3.5.19.1.4 Machine Data...................................................................................................................................... 171
3.5.19.2 End trimming............................................................................................................................................. 172
3.5.19.3 Trimming................................................................................................................................................... 174
3.5.19.4 Scraping.................................................................................................................................................... 175
3.5.19.5 Shaving..................................................................................................................................................... 176
3.5.19.6 Anti-Adhesive............................................................................................................................................ 177
3.5.19.7 Polishing ................................................................................................................................................... 178
3.5.19.8 Edge Banding default settings .................................................................................................................. 179
3.5.19.8.1 Edge banding Default ......................................................................................................................... 179
3.5.19.8.2 End trimming default........................................................................................................................... 183
3.5.19.8.3 Trimming default ................................................................................................................................. 183
3.5.19.8.4 Scraping default.................................................................................................................................. 184
3.5.19.8.5 Shaving default ................................................................................................................................... 184
3.5.19.8.6 Anti-adhesive and Polishing................................................................................................................ 185
3.5.20 Attributes.........................................................................................................................................185
3.5.20.1 Depth ........................................................................................................................................................ 186
3.5.20.2 Speed ....................................................................................................................................................... 187
3.5.20.3 Microjoints................................................................................................................................................. 190
3.5.20.4 Start work.................................................................................................................................................. 195
3.5.20.5 End work................................................................................................................................................... 196
3.5.20.6 Edge banding attributes............................................................................................................................ 197
3.5.20.6.1 Head rotation ...................................................................................................................................... 197
3.5.20.6.2 Rotation X ........................................................................................................................................... 200
3.5.20.6.3 Ruller stop........................................................................................................................................... 202
3.5.20.6.4 Edge rollers opening........................................................................................................................... 203
3.5.20.6.5 Edge rollers closure ............................................................................................................................ 203
3.5.20.6.6 Lamp on.............................................................................................................................................. 203
3.5.20.6.7 Edge supply ........................................................................................................................................ 205
3.5.20.7 Delete attributes........................................................................................................................................ 206
3.5.21 Working process tree......................................................................................................................207
3.5.21.1 Object selection ........................................................................................................................................ 207
3.5.21.2 Multiple selection ...................................................................................................................................... 207
3.5.21.3 Working process ordering......................................................................................................................... 208
3.5.21.4 Working process display........................................................................................................................... 208
3.5.21.5 Contextual menu....................................................................................................................................... 209
3.5.21.6 Group of machinings................................................................................................................................. 210
3.5.21.7 Group of machinings explosion................................................................................................................. 210

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3.5.22 Working process selection..............................................................................................................211
3.5.23 Contextual menu for working processes ........................................................................................211
3.5.24 Working process removal ...............................................................................................................211
3.5.25 Working process properties............................................................................................................211
3.5.26 Working process modification.........................................................................................................212
3.5.27 Move and/or copy existing working processes...............................................................................212
3.5.28 Machining technologies ..................................................................................................................213
3.5.28.1 Create Technology.................................................................................................................................... 213
3.5.28.2 Copy technology ....................................................................................................................................... 215
3.5.28.3 Apply technology....................................................................................................................................... 216
3.5.29 Geometry technologies...................................................................................................................216
3.5.29.1 Create Technology.................................................................................................................................... 216
3.5.29.2 View technology........................................................................................................................................ 219
3.5.29.3 Apply technology....................................................................................................................................... 220
3.5.29.3.1 Apply Technology Report.................................................................................................................... 220
3.6 3D MACHINING...........................................................................................................................................221
3.6.1 Roughing.............................................................................................................................................222
3.6.2 Finishing..............................................................................................................................................229
3.6.2.1 Finishing strategies................................................................................................................................... 230
3.6.2.2 Tool strategies .......................................................................................................................................... 232
3.6.3 Swarfing ..............................................................................................................................................233
3.6.4 Routing on surface..............................................................................................................................236
3.6.5 3D pocketing .......................................................................................................................................237
3.6.6 Tool path wrap ....................................................................................................................................238
3.7 MACRO AND SUBPROGRAMS ......................................................................................................................239
3.7.1 Creating machining-macros (.xsp)......................................................................................................239
3.7.1.1 Creazione della struttura base della macro ( wizard); ............................................................................... 239
3.7.1.1.1 General parameters ............................................................................................................................. 240
3.7.1.1.2 Image selection.................................................................................................................................... 242
3.7.1.1.3 Parameters .......................................................................................................................................... 243
3.7.1.1.4 Groups ................................................................................................................................................. 244
3.7.1.1.5 Languages ........................................................................................................................................... 245
3.7.1.1.6 Macro Management ............................................................................................................................. 247
3.7.1.2 Implementation of the functions in the macro. .......................................................................................... 248
3.7.2 Create Subprograms (.xsp).................................................................................................................248
3.7.2.1 Create project ........................................................................................................................................... 248
3.7.2.2 Define the parameters .............................................................................................................................. 249
3.7.2.3 Save the sub-program .............................................................................................................................. 250
3.7.2.4 Open an existing sub-program.................................................................................................................. 252
3.7.3 Use of .XSP Apps and subprograms ..................................................................................................253
3.7.3.1 Modify Macros .......................................................................................................................................... 253
3.7.3.2 Import Script (.xcs).................................................................................................................................... 254
3.8 NC FUNCTIONS..........................................................................................................................................256
3.8.1 Enter an ISO instruction......................................................................................................................257
3.8.2 Machine parking..................................................................................................................................258
3.8.3 Null operation......................................................................................................................................259
3.8.4 Workpiece probing ..............................................................................................................................260
3.8.4.1 Probing with side position correction......................................................................................................... 260
3.8.4.2 Probing with tool length correction............................................................................................................ 261
3.8.4.3 Probing with workpiece roto-translation .................................................................................................... 262
3.8.5 Display an operator message .............................................................................................................263
3.8.6 Table cleaning.....................................................................................................................................264
3.8.7 DY check.............................................................................................................................................266
3.8.7.1 Automatic DY control ................................................................................................................................ 267
3.9 WORKING STEPS .......................................................................................................................................268
3.9.1 Working step tree................................................................................................................................268
3.9.2 Inserting a working step......................................................................................................................269
3.9.3 Removal of a working step..................................................................................................................269
3.9.4 Working step properties ......................................................................................................................270
3.9.5 Modifying the workpiece position in one step .....................................................................................270
3.9.6 Moving working processes from one step to another one ..................................................................271
3.9.7 Add workpiece name to working process name .................................................................................272
3.9.8 Sub-programs Activation/Deactivation................................................................................................273
3.10 WORKPIECES LAYOUT IN MACHINE ..............................................................................................................274

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3.10.1 Choice of work area, references and devices ................................................................................275
3.10.1.1 Work area selection .................................................................................................................................. 275
3.10.1.2 References Selection................................................................................................................................ 276
3.10.1.3 Type of blocking selection......................................................................................................................... 276
3.10.2 Dynamic work areas .......................................................................................................................277
3.10.2.1 Function enable ........................................................................................................................................ 277
3.10.2.2 Manual programming of the area length ................................................................................................... 277
3.10.2.3 Automatic programming of the area length............................................................................................... 278
3.10.2.4 Reset the area length................................................................................................................................ 278
3.10.3 Adding pieces on the machine plane..............................................................................................279
3.10.4 Workpieces positioning...................................................................................................................280
3.10.5 Separation of workpieces ...............................................................................................................281
3.10.6 Elimination of pieces from the machine plane................................................................................284
3.11 DEFINITION OF THE BLOCKING SYSTEM........................................................................................................285
3.11.1 Workpiece blocking with clamps.....................................................................................................285
3.11.1.1 Type of clamp ........................................................................................................................................... 285
3.11.1.1.1 Clamps with round plate ..................................................................................................................... 286
3.11.1.1.2 Clamps with rectangular plate............................................................................................................. 286
3.11.1.1.3 Clamps with reference stops............................................................................................................... 286
3.11.1.1.4 Horizontal clamps ............................................................................................................................... 287
3.11.1.2 Type of clamp selection ............................................................................................................................ 288
3.11.1.3 Clamps positioning on the bars................................................................................................................. 288
3.11.1.4 Saving plane layout................................................................................................................................... 289
3.11.1.5 Reusing the plane layout .......................................................................................................................... 289
3.11.1.6 Saving of different table settings............................................................................................................... 289
3.11.1.7 Blocking states of clamps ......................................................................................................................... 290
3.11.1.7.1 Blocking state change......................................................................................................................... 290
3.11.1.7.2 Blocking state display ......................................................................................................................... 291
3.11.1.8 Clamps positioning on workpiece.............................................................................................................. 292
3.11.1.8.1 Manual clamps positioning.................................................................................................................. 293
3.11.1.8.2 Manual clamps' positioning with blocking profile................................................................................. 293
3.11.1.8.3 Automatic clamps' positioning with blocking profile............................................................................. 295
3.11.1.8.4 Positioning terminals outside the work area........................................................................................ 296
3.11.1.8.5 Enables the positioning of the clamps on the piece edge ................................................................... 297
3.11.1.9 Initial setup creation.................................................................................................................................. 298
3.11.1.10 Final setup creation.............................................................................................................................. 298
3.11.1.11 Cycles generation for clamps exchange .............................................................................................. 299
3.11.1.12 Cycles elimination for clamps exchange .............................................................................................. 299
3.11.2 Workpiece blocking with suction cups............................................................................................300
3.11.2.1 Type of suction cups................................................................................................................................. 300
3.11.2.2 Select the type of suction cup ................................................................................................................... 300
3.11.2.3 Suction cups positioning on the bars ........................................................................................................ 301
3.11.2.4 Positioning suction cups under the piece.................................................................................................. 301
3.11.2.4.1 Manual suction cups positioning ......................................................................................................... 301
3.11.2.4.2 Automatic suction cups positioning..................................................................................................... 302
3.11.3 Easier Load.....................................................................................................................................304
3.11.3.1 Easier Load Insertion................................................................................................................................ 304
3.11.3.1.1 Automatic facilitated loading ............................................................................................................... 304
3.11.3.1.2 Manual facilitated loading ................................................................................................................... 305
3.11.3.1.3 Preset of easier load........................................................................................................................... 307
3.11.3.1.4 Preset of easier load creation/change................................................................................................. 307
3.11.3.1.5 Preset of easier load use .................................................................................................................... 308
3.11.3.2 Easier load elimination.............................................................................................................................. 309
3.11.4 Work top automatic setup...............................................................................................................310
3.11.5 Restoring the plan...........................................................................................................................311
3.11.6 Collisions check..............................................................................................................................311
3.12 DEFINITION OF WORKPIECES MACHINED CONTEMPORANEOUSLY...................................................................313
3.12.1 Number of workpieces machined contemporaneously...................................................................313
3.13 PROJECT OPTIMIZATION .............................................................................................................................314
3.13.1 Standard projects optimisation .......................................................................................................315
3.13.1.1 Guided Optimization ................................................................................................................................. 315
3.13.1.2 Automatic optimization.............................................................................................................................. 317
3.13.2 Nesting projects optimisation..........................................................................................................318
3.13.2.1 Nesting Guided Optimisation .................................................................................................................... 318
3.13.2.1.1 Basic Guided Optimisation.................................................................................................................. 319
3.13.2.1.2 Advanced Guided Optimisation........................................................................................................... 322
3.13.2.2 Nesting Automatic Optimisation................................................................................................................ 325

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3.13.2.3 Edge banding optimization........................................................................................................................ 326
3.13.2.3.1 Rotations optimization......................................................................................................................... 327
3.13.2.3.2 Lamps optimization............................................................................................................................. 327
3.13.2.3.3 Stop roller optimization ....................................................................................................................... 328
3.13.2.3.4 Edge banding parameters optimization............................................................................................... 328
3.13.2.3.5 Autostart optimization ......................................................................................................................... 329
3.13.2.3.6 Trimmer rotations optimization............................................................................................................ 329
3.13.2.3.7 Anti-adhesive and Polishing optimisation............................................................................................ 330
3.14 AUTOMATIC PARTS ARRANGEMENT AND OPTIMIZATION.................................................................................331
3.14.1 Add Project .....................................................................................................................................332
3.14.2 Pgmx editor.....................................................................................................................................332
3.14.3 Saving and opening .wpx files........................................................................................................333
3.14.4 Optimisation criteria........................................................................................................................333
3.14.5 Optimisation....................................................................................................................................334
3.14.5.1 Generated .mixx file.................................................................................................................................. 334
3.14.5.2 Generated .pgmx files............................................................................................................................... 334
3.15 TOOL MAGAZINE OPTIMISATION...................................................................................................................335
3.16 SIMULATION ..............................................................................................................................................342
3.16.1 Tool path simulation .......................................................................................................................342
3.16.1.1 Display only one machining ...................................................................................................................... 342
3.16.1.2 Display all the machinings ........................................................................................................................ 343
3.16.2 Machining simulation ......................................................................................................................344
3.16.3 Simulation in machine (optional) ....................................................................................................345
3.16.3.1 Enable the Proview simulator in Maestro.................................................................................................. 345
3.16.3.2 The simulation environment...................................................................................................................... 345
3.16.3.3 Simulation example................................................................................................................................... 347
3.17 PRINT .......................................................................................................................................................349
3.17.1 Print current view............................................................................................................................349
3.17.2 Print compound views ....................................................................................................................349
3.18 MATHEMATICAL FUNCTIONS........................................................................................................................351
4 PROJECT MANAGEMENT FOR CX ..............................................................................................................352
4.1 LOADING PANELS ON CX............................................................................................................................352
4.2 UNLOADING PANELS ON CX........................................................................................................................354
4.2.1 Unload to the right (V70).....................................................................................................................355
4.2.2 Unload to the right complete (V72) .....................................................................................................357
4.2.3 Unloading to the left (V71) ..................................................................................................................358
4.2.4 Unload to the left complete (V73) .......................................................................................................359
4.3 OPTIMISATION FOR CX PROGRAMS.............................................................................................................360
4.3.1 Machining clustering ...........................................................................................................................360
4.3.2 Clamps-machining distances setting ..................................................................................................361
4.3.3 Type of optimisation algorithm............................................................................................................362
4.3.4 Clamps options ...................................................................................................................................362
4.3.5 Pressers options .................................................................................................................................363
4.3.6 Tracing ................................................................................................................................................366
4.3.7 Panel anti-fall ......................................................................................................................................366
4.3.8 Aligner.................................................................................................................................................369
4.3.9 Processing with optimiser ...................................................................................................................369
4.4 LAYOUT FOR CX PROGRAMS ......................................................................................................................370
5 PROJECT MANAGEMENT FOR UX ..............................................................................................................371
5.1 CREATE PROJECT ......................................................................................................................................371
5.1.1 One piece mirror .................................................................................................................................371
5.1.2 Creating the Double Dual Project .......................................................................................................373
5.1.3 Creating the Double Dual Project .......................................................................................................374
5.1.4 Creating the Single Project .................................................................................................................375
5.1.5 Optimization of the project by Maestro ...............................................................................................376
5.2 TYPES OF DRAIN........................................................................................................................................377
5.3 TOEKICK...................................................................................................................................................378
5.3.1 Flag for ToeKick management on UX.................................................................................................378
5.4 TOOL PROGRAMMING RULES ......................................................................................................................380
5.4.1 Flat bit .................................................................................................................................................380
5.4.2 Launch tip............................................................................................................................................381

9
5.4.3 Smooth flat tip .....................................................................................................................................382
5.4.4 Countersunk spear tip.........................................................................................................................383
5.4.5 Blitz Tip ...............................................................................................................................................383
5.5 UX OPTIONS .............................................................................................................................................385
6 PROJECT MANAGEMENT FOR HE-POD TABLE........................................................................................388
7 PROJECT MANAGEMENT FOR PWX100.....................................................................................................391
7.1 MASTER SETTINGS ....................................................................................................................................391
7.2 OPTIMIZATION CONSTRAINTS......................................................................................................................392
7.2.1 Generic Constraints ............................................................................................................................393
7.2.2 Piece positioning restrictions ..............................................................................................................394
7.2.3 Heads rotation restrictions ..................................................................................................................394
7.2.4 Tables position restrictions .................................................................................................................395
7.3 OPTIMIZING EXECUTION .............................................................................................................................396
7.4 OPTIMIZATION RESULTS .............................................................................................................................396
7.5 POWERSET TOOLING OPTIMIZER................................................................................................................397
7.5.1 Operating requirements ......................................................................................................................397
7.5.2 Optimization Wizard............................................................................................................................398
7.5.2.1 Page1: Parameters.................................................................................................................................. 399
7.5.2.2 Page2: Execution..................................................................................................................................... 401
7.5.2.3 Page3: Results ........................................................................................................................................ 402
8 NESTING PROJECT MANAGEMENT............................................................................................................406
8.1 DEFAULTS FOR “NESTING PROJECTS”.........................................................................................................407
8.1.1 Default Folder for “Nesting Projects” ..................................................................................................407
8.1.2 Default Nesting Parameters................................................................................................................408
8.2 CREATING A NEW NESTING PROJECT..........................................................................................................410
8.2.1 Nesting Parameters ............................................................................................................................411
8.2.1.1 Type of Nesting......................................................................................................................................... 411
8.2.1.1.1 Rectangular Nesting............................................................................................................................. 412
8.2.1.1.2 Free Form Nesting ............................................................................................................................... 412
8.2.1.1.3 Tubular Nesting.................................................................................................................................... 412
8.2.1.1.4 Manual Nesting .................................................................................................................................... 412
8.2.1.2 Part sequencing........................................................................................................................................ 413
8.2.1.2.1 Insertion in sequence by Area.............................................................................................................. 413
8.2.1.2.2 Insertion in sequence by Perimeter...................................................................................................... 413
8.2.1.3 Minimum distance between two nested parts ........................................................................................... 413
8.2.1.4 Spoil board thickness................................................................................................................................ 413
8.2.1.5 Enable cutting outside the sheet............................................................................................................... 413
8.2.1.6 Enables the possibility of nesting the parts in the holes of other parts...................................................... 413
8.2.1.7 Maximum part size and area..................................................................................................................... 414
8.2.2 Nesting Sheets....................................................................................................................................414
8.2.2.1 Adding a sheet to the list........................................................................................................................... 416
8.2.2.1.1 Meanings of sheet data........................................................................................................................ 416
8.2.2.2 Deleting a sheet from the list .................................................................................................................... 417
8.2.2.3 Copying sheet data................................................................................................................................... 417
8.2.2.4 Pasting sheet data .................................................................................................................................... 417
8.2.2.5 Editing sheet data ..................................................................................................................................... 417
8.2.2.6 Enable the use of materials magazine management ................................................................................ 417
8.2.3 Nesting parts.......................................................................................................................................418
8.2.3.1 Enter workpiece in the list......................................................................................................................... 419
8.2.3.1.1 Meanings of workpiece data ................................................................................................................ 419
8.2.3.1.2 Inserting pieces from .CSV files ........................................................................................................... 421
8.2.3.1.3 Definition of CSV columns of parts....................................................................................................... 422
8.2.3.2 Deleting a workpiece from the list ............................................................................................................. 423
8.2.3.3 Copying workpiece data............................................................................................................................ 423
8.2.3.4 Pasting workpiece data............................................................................................................................. 423
8.2.3.5 Editing workpiece data.............................................................................................................................. 423
8.2.4 Nesting Cut .........................................................................................................................................425
8.2.4.1 Manual Cut ............................................................................................................................................... 425
8.2.4.2 Automatic Cut ........................................................................................................................................... 426
8.2.4.2.1 Head for Nesting cut ............................................................................................................................ 427
8.2.4.2.2 Tool for Nesting cut.............................................................................................................................. 427
8.2.4.2.3 Cutting technology ............................................................................................................................... 427
8.2.4.2.4 Scoring................................................................................................................................................. 428

10
8.2.4.2.5 Machine functions ................................................................................................................................ 428
8.2.5 Creating parametric NSTX programmes from parametric PGMX files. ..............................................428
8.2.6 Nesting optimisation............................................................................................................................430
8.2.7 Nesting remainders and scrap............................................................................................................431
8.2.8 Nesting labelling..................................................................................................................................433
8.2.8.1 Move labels............................................................................................................................................... 435
8.2.8.2 Delete labels............................................................................................................................................. 436
8.2.8.3 Enter labels............................................................................................................................................... 436
8.2.9 Loading, unloading and Nesting cleaning...........................................................................................437
8.2.9.1 Load.......................................................................................................................................................... 437
8.2.9.2 Unpacking and cleaning............................................................................................................................ 438
8.2.10 Manual Nesting completion ............................................................................................................439
8.2.10.1 Manual positioning of the parts on the sheet ............................................................................................ 439
8.2.10.1.1 Create new part .................................................................................................................................. 439
8.2.10.1.2 Insert new part .................................................................................................................................... 439
8.2.10.1.3 Insert existing part............................................................................................................................... 440
8.2.10.1.4 Part rotation ........................................................................................................................................ 441
8.2.10.1.5 Reposition part.................................................................................................................................... 441
8.2.10.1.6 Associate machinings ......................................................................................................................... 441
8.2.10.1.7 Part deletion........................................................................................................................................ 441
8.3 OPENING AN EXISTING NESTING PROJECT ..................................................................................................442
8.4 CLOSING A NESTING PROJECT ...................................................................................................................442
8.5 SAVING A NESTING PROJECT .....................................................................................................................442
8.6 NESTING PROCESSING...............................................................................................................................443
8.6.1 Conditions to be complied with in Nesting ..........................................................................................443
8.6.2 Recurring strategies in Nesting...........................................................................................................444
8.6.2.1 Positioning small workpieces at the center ............................................................................................... 444
8.6.2.2 Contouring outside the sheet .................................................................................................................... 445
8.7 OPTIMIZING NESTING MACHINING................................................................................................................445
8.8 LABELLING PIECES IN MACHINE ...................................................................................................................446
8.8.1 Automatic labelling of pieces in machine............................................................................................446
8.8.2 Manual labelling of pieces in machine ................................................................................................446
8.8.2.1 Manual labelling of pieces with LabelPrinterManager............................................................................... 447
8.8.3 Nesting .nstrptx report file...................................................................................................................448
8.9 NESTING REPORT ......................................................................................................................................449
8.9.1 General statistics ................................................................................................................................449
8.9.2 Materials..............................................................................................................................................450
8.9.3 Pieces summary .................................................................................................................................450
8.9.4 Sheets and pieces matrices mapping.................................................................................................450
8.9.5 Cutting diagrams.................................................................................................................................451
9 MANAGING THE BEAMS AND WALLS PROJECT......................................................................................453
9.1 GENERAL INFORMATION .............................................................................................................................453
9.1.1 Machining wooden beams and walls and BTL standard ....................................................................453
9.2 WORKFLOW...............................................................................................................................................453
9.2.1 Creating a project for beams and walls ..............................................................................................454
9.2.1.1 Beam rotation ........................................................................................................................................... 456
9.2.1.2 Inserting a machining................................................................................................................................ 457
9.2.1.3 Machining strategies................................................................................................................................. 458
9.2.1.4 Machining and beams cut-copy-paste ...................................................................................................... 460
9.2.1.5 Local parameters ...................................................................................................................................... 460
9.2.2 Opening a project from a BTL file .......................................................................................................461
9.2.3 Processing a project for beams or walls .............................................................................................462
9.2.3.1 Resolving messages generated during processing .................................................................................. 464
9.2.3.1.1 Error due to the tool ............................................................................................................................. 464
9.2.3.1.2 Error: Geometry not allowed ................................................................................................................ 465
9.2.3.1.3 Post processor alarms ......................................................................................................................... 465
9.2.3.1.4 Error: No valid clamping....................................................................................................................... 466
9.2.4 Tool paths ...........................................................................................................................................467
9.2.4.1 Display tool paths of the macros............................................................................................................... 469
9.2.5 Simulation and validation....................................................................................................................470
9.2.6 Nesting for beams...............................................................................................................................472
9.3 NESTING FOR WALLS..................................................................................................................................474
9.3.1 Outline cuts .........................................................................................................................................475

11
9.4 COMPLETE PROJECT..................................................................................................................................476
10 MATERIALS MAGAZINE MANAGEMENT ....................................................................................................477
10.1 ADD NEW SHEETS ......................................................................................................................................478
10.1.1 Default dimensions for Nesting sheets...........................................................................................478
10.2 DELETE EXISTING SHEETS ..........................................................................................................................479
10.3 CUT EXISTING SHEETS ...............................................................................................................................479
10.4 COPY EXISTING SHEETS .............................................................................................................................479
10.5 PASTE CUT OR COPIED SHEETS ..................................................................................................................480
10.5.1 Copy-Paste Cells............................................................................................................................480
10.6 SHEET ROTATION.......................................................................................................................................480
10.7 IMPORT MATERIALS MAGAZINE....................................................................................................................481
10.8 EXPORT MATERIALS MAGAZINE ...................................................................................................................482
10.9 SAVE MATERIALS MAGAZINE .......................................................................................................................482
10.10 UNLOAD MATERIALS ..............................................................................................................................482
10.11 LOAD REMAINDERS................................................................................................................................483
11 LABELS DATABASE MANAGEMENT WITH LABELEDITOR .....................................................................484
11.1 CREATE LABEL ..........................................................................................................................................484
11.2 OPEN LABEL..............................................................................................................................................486
11.3 CLOSE LABEL ............................................................................................................................................487
11.4 SAVE LABEL...............................................................................................................................................487
11.5 PRINT LABEL..............................................................................................................................................488
11.5.1 Print label on Zebra printer .............................................................................................................488
11.5.2 Print label on office printer..............................................................................................................488
11.6 TOOLS ......................................................................................................................................................489
11.6.1 Zoom...............................................................................................................................................489
11.6.2 Pan .................................................................................................................................................489
11.7 DRAWING OBJECTS MANAGEMENT ..............................................................................................................489
11.7.1 Add object.......................................................................................................................................489
11.7.2 Delete object...................................................................................................................................490
11.7.3 Copy object.....................................................................................................................................490
11.7.4 Paste object....................................................................................................................................490
11.8 DRAWING OBJECTS....................................................................................................................................491
11.8.1 Horizontal line.................................................................................................................................491
11.8.2 Vertical line .....................................................................................................................................492
11.8.3 Rectangle........................................................................................................................................493
11.8.4 Image..............................................................................................................................................494
11.8.4.1 Fixed......................................................................................................................................................... 495
11.8.4.2 Parametric ................................................................................................................................................ 495
11.8.5 Text.................................................................................................................................................496
11.8.5.1 Fixed......................................................................................................................................................... 498
11.8.5.2 Parametric ................................................................................................................................................ 498
11.8.5.3 Date .......................................................................................................................................................... 499
11.8.5.4 Time.......................................................................................................................................................... 500
11.8.6 Barcode ..........................................................................................................................................501
11.8.6.1 Unidimensional ......................................................................................................................................... 501
11.8.6.1.1 Code 39 .............................................................................................................................................. 501
11.8.6.1.2 Code 93 .............................................................................................................................................. 503
11.8.6.1.3 Code 128 ............................................................................................................................................ 505
11.8.6.2 Two-dimensional....................................................................................................................................... 507
11.8.6.2.1 Aztec................................................................................................................................................... 507
11.8.6.2.2 Datamatrix .......................................................................................................................................... 509
11.8.6.2.3 QR ...................................................................................................................................................... 511
11.8.6.2.4 PDF417............................................................................................................................................... 513
11.9 OPTIONS ...................................................................................................................................................515
11.9.1 Files ................................................................................................................................................516
11.9.2 Parameters .....................................................................................................................................516
11.9.2.1 Geometries ............................................................................................................................................... 516
11.9.2.2 Zebra ........................................................................................................................................................ 516
11.9.2.3 Page layout............................................................................................................................................... 517
11.9.3 Language........................................................................................................................................518
11.10 ZEBRA PRINTER.....................................................................................................................................519

12
11.10.1 Installation.......................................................................................................................................519
11.10.2 Calibration.......................................................................................................................................527
11.10.3 Download font.................................................................................................................................529
11.10.4 Memory...........................................................................................................................................533
11.11 AT AUTOMATIC PRINTER ........................................................................................................................537
11.11.1 Notes ..............................................................................................................................................537
12 TOOL DATA-BASE.........................................................................................................................................538
12.1 DEFAULT FOR TOOL DATA-BASE.................................................................................................................539
12.1.1 Default "Name Tool Data-Base "....................................................................................................539
12.1.2 Default "Folder for tool Data-Base" ................................................................................................539
12.1.3 Default "Folder for Import/Export toll Data-Base"...........................................................................539
12.2 TOOL DATA -BASE CREATION .....................................................................................................................540
12.3 TOOL DATA-BASE OPENING.........................................................................................................................540
12.4 CLOSING TOOL DATA-BASE.........................................................................................................................541
12.5 SAVING TOOL DATA-BASE ...........................................................................................................................542
12.6 TOOL DATA-BASE IMPORT FROM XILOG .......................................................................................................543
12.7 TOOL DATA-BASE EXPORT TO XILOG ...........................................................................................................544
12.8 ACTIVATE TOOL DATA-BASE ......................................................................................................................545
12.9 TOOLS ......................................................................................................................................................546
12.9.1 Tool introduction .............................................................................................................................546
12.9.1.1 Bits............................................................................................................................................................ 549
12.9.1.1.1 Tools wear .......................................................................................................................................... 551
12.9.1.2 Milling cutters............................................................................................................................................ 552
12.9.1.2.1 Shaped Cutter..................................................................................................................................... 552
12.9.1.2.2 Sanders .............................................................................................................................................. 554
12.9.1.2.3 Edge scraper....................................................................................................................................... 555
12.9.1.2.4 Glue scraper ....................................................................................................................................... 556
12.9.1.2.5 Trimmers............................................................................................................................................. 557
12.9.1.3 Blades....................................................................................................................................................... 558
12.9.1.4 Mortises .................................................................................................................................................... 559
12.9.1.5 Contact tools............................................................................................................................................. 560
12.9.1.5.1 Probes ................................................................................................................................................ 560
12.9.1.5.2 Pressure rollers................................................................................................................................... 561
12.9.1.6 Special tools ............................................................................................................................................. 562
12.9.1.6.1 Manipulators ....................................................................................................................................... 562
12.9.1.6.2 Blowers ............................................................................................................................................... 563
12.9.1.6.3 Anti-adhesive ...................................................................................................................................... 563
12.9.1.6.4 Polishing ............................................................................................................................................. 565
12.9.1.7 Heads ....................................................................................................................................................... 566
12.9.1.7.1 Weldon................................................................................................................................................ 569
12.9.1.7.2 General Head...................................................................................................................................... 570
12.9.1.8 Aggregates tools....................................................................................................................................... 571
12.9.2 Modifying tolls.................................................................................................................................572
12.9.3 Tool removal...................................................................................................................................572
12.10 VIRTUAL TOOLS.....................................................................................................................................572
13 TOOL EQUIPMENT.........................................................................................................................................575
13.1 TOOL EQUIPMENT DEFAULT........................................................................................................................576
13.2 TOOL EQUIPMENT CREATION......................................................................................................................577
13.3 OPEN TOOL EQUIPMENT ............................................................................................................................577
13.4 CLOSE TOOL EQUIPMENT...........................................................................................................................577
13.5 SAVE TOOL EQUIPMENT.............................................................................................................................578
13.6 TOOL EQUIPMENT ACTIVATION....................................................................................................................579
13.7 TOOL EQUIPMENT EDITOR ..........................................................................................................................580
13.7.1 Configuration selection ...................................................................................................................580
13.7.2 Tools database selection................................................................................................................580
13.7.3 Machine Selection ..........................................................................................................................581
13.7.4 Operator Group Selection...............................................................................................................581
13.7.5 Association Tool-Spindle ................................................................................................................582
13.7.6 Tool removal from the spindle ........................................................................................................582
13.7.7 Viewing Tool Information ................................................................................................................583
13.7.8 Spindle information display.............................................................................................................583
13.7.9 Displaying Equipment.....................................................................................................................584

13
13.8 PRINT FIXTURING DATA ..............................................................................................................................585
13.9 COMPARING TOOLING ................................................................................................................................587
13.10 TOOLS WEAR ........................................................................................................................................591
13.10.1 Tool wear display............................................................................................................................591
13.10.2 Tool wear update............................................................................................................................592
13.10.3 Reset wear......................................................................................................................................592
13.10.4 Wear report.....................................................................................................................................592
14 EDGES DATABASE(EDGEMANAGER) ........................................................................................................595
14.1 EDGES DATABASE DEFAULT.......................................................................................................................596
14.1.1 “Edges Database Name” Default....................................................................................................596
14.1.2 “Edges Database Folder” Default...................................................................................................596
14.1.3 Automatic Export of the Edges Database in Ext. format ...............................................................597
14.2 EDGES DATABASE CREATION.....................................................................................................................598
14.3 OPEN EDGES DATABASE............................................................................................................................598
14.4 CLOSE EDGES DATABASE ..........................................................................................................................598
14.5 SAVE EDGES DATABASE ............................................................................................................................599
14.6 ACTIVATE EDGES DATABASE......................................................................................................................600
14.7 EDGES ......................................................................................................................................................601
14.7.1 Entering Edges ...............................................................................................................................601
14.7.1.1 Edge name ............................................................................................................................................... 602
14.7.1.2 Edge data ................................................................................................................................................. 602
14.7.1.3 Machining Technological Data.................................................................................................................. 602
14.8 TECHNOLOGIES MANAGER .........................................................................................................................603
14.8.1 Name ..............................................................................................................................................604
14.8.2 Speed .............................................................................................................................................604
14.8.3 Edge heating lamps........................................................................................................................605
14.8.4 Edge dispensing .............................................................................................................................605
14.8.5 Roller stop optimization ..................................................................................................................606
14.8.6 Stoptime of the edge bander in infeed and outfeed to the profile ..................................................606
14.8.7 Edge in closure compensation .......................................................................................................607
14.8.8 Edge banding early-late..................................................................................................................607
15 POST-PROCESSOR .......................................................................................................................................608
15.1 CREATE .XXL AND .PGM FILES.....................................................................................................................608
15.1.1 Xilog installation..............................................................................................................................608
15.1.2 Set output folder .............................................................................................................................609
15.1.3 Execution Post-Processor ..............................................................................................................610
15.2 CREATE .EPL FILES ....................................................................................................................................611
15.3 XXL/PGM EDITOR.....................................................................................................................................612
16 APPENDIX.......................................................................................................................................................613
16.1 SIZES USED BY MAESTRO ..........................................................................................................................613

14
1 Description of the software
The software described in this manual allows the definition of workpieces and the related
machining operations so that they can be machined on numeric control machining centers.
The setting of all workpieces occurs in a three-dimensional CAD environment very useful for the
user in order to check immediately his schedule.
Working processes are divided in two different steps: firstly, by setting the geometries, secondly
by applying machine tools like in a CAM system.
After setting workpiece and working processes, all of the information will be passed to the
machine, which will carry out the machining.
1.1 Installation
1.1.1 PC minimum requirements
The software requires the following minimum requirements for installation:
- Operating system: Windows XP Professional (SP2), Windows Vista, Windows 7 or
Windows 10
- Framework DotNet Framework 4.7.2
- Patch -vc_redist_2017x86 (Microsoft Visual C++ 2017 redistributable x86)
- Processor: Intel compatible, minimum 2GHz;
recommended multicore processor
- Memory: minimum 1GB
recommended 2GB
- Space on disc: 5GB
- Graphical board: OpenGL compatible
The following minimum PC requirements are needed for the "Maestro3D" option for machining
surface or with a machine with "edge banding unit":
- Operating system: Windows XP Professional (SP2), Windows Vista or Windows 7
- Processor: Intel® I5 - 3.2 GHz
- Memory: 4GB (8GB recommended for 64bit operating systems)
- Free space: 30 GB (recommended HD with 7200 rpm)
- Graphic board: specific (e.g. NVIDIA GFORCE, ATI)
Note: a graphic board integrated in the motherboard could compromise the
performance of the application: not recommended
- Monitor Screen resolution 1024x768 colour 32-bit

15
2 Operator interface
Maestro interface is structured as follows:
There are six areas:
Menu
Trees
Parameters
Graphics
Current command
Status bar
Following chapters describe all commands included in the menus.

16
3 Project
Project refers an object that can contain the definition of one or more workpieces with 2D
geometries and associated machining.
The project contains all the information needed to define a machining process.
This process will be illustrated in the following chapters:
1) Project management
2) Workpiece
3) Worktables
4) 2D geometries
5) Machining operations
6) 3D machining
7) Macro and Subprograms
8) NC functions
9) Work phases
10)Workpiece setup in machine
11)Blocking system
12)Workpieces to be machined contemporaneously
13)Projects optimisation
14)Mathematical functions

17
3.1 Project management
The "Project" file - with a .pgmx size- must contain at least one workpiece and it might include -
but not necessarily- also working processes.
It is a compressed file including:
tool.tlgx Data Base Tools
progetto.xml Instructions to set the geometry.
progetto.epl Clamp/suction pad definition
A project can be:
Created
Started
Ended
Saved
By using these icons in the Menu area:

18
3.1.1 Project default
You may change project defaults by clicking on the icon "Options" in the folder "Tools".
3.1.1.1 Default: "Project name”
If you wish to modify the default name of a new project:
Click on the icon "Options"
Fill the field "Project name" .
3.1.1.2 Default “Project folder”
If you wish to change the name of the folder where projects are started/saved:
Click on the icon "Options"
Fill the field "Project folder".

19
3.1.1.3 Save the configuration parameters
As well as the default settings described above, there are many other configurations possible in
the “Options” session, described below.
If a new Maestro Release is installed all the configuration parameters set will be overwritten.
This is why we recommend saving all the configurations set with the “Backup” key in the “Tools”
folder.
After having selected the command, the following menu will be displayed, to select which
parameters to save.
Press “Cancel” to end the operation.
Press “Save” to save a .settingsx file with all the configuration information.

20
3.1.1.4 Restore the configuration parameters
To restore the previously saved configuration parameters use the “Restore” command in the
“Tools” folder.
After having selected the command, the following menu will be displayed, to select the type of
restore desired.
Press “Open” to display the following confirmation window.
Press “OK” to select the previously saved .settingsx file and then restore the parameters that
will take place after closing Maestro.

21
3.1.1.5 Operating environment
The work environment is the set of all the data necessary to work on a given machine.
The work environment includes configuration, tools, virtual tools, set-up, edges, machine
parameters, options, etc., related to the current machine.
You will be able to create an individual work environment for each configuration file (.cfgx) which
will have the same name as the configuration.
To do so, use the commands in the Machines tab, Work
environment where we find:
- Save, which allows you to create and update work
environments based on the files active at that
moment
- A selector, to select the work environment to use.
Saving a work environment generates a .settingsx file in a
configurable Maestro CNC options folder.
Selecting a work environment using the appropriate selector opens a window asking which files
of the environment you want to load.
Proceeding with the operation, Maestro CNC loads all the files selected from the work
environment and updates itself accordingly.

22
If you change information relating to the environment when working with an active work
environment, you will be notified of the change when the application is closed or when the
environment is changed and you will be asked whether to save or discard the changes made.
When changing the configuration from the CFGX file selector and there is a work environment
associated with it, the user will be offered the option to load the environment or to make the
configuration change only.
When Maestro CNC is started, the work environment for the configuration set as default in the
application preferences will be automatically loaded. If Maestro is not present, it will continue to
function as in the past without the work environment, which can always be saved later.
The advantage of using work environments is that they allow you to change all the files involved
in the configuration of a specific machine with a single operation, thus speeding up the transition
from one machine to another when creating projects.

23
3.1.2 New project setting
If you wish to set up a new project,.click on the icon "Create project"
The name of such new project will be definedas described in paragraph
3.1.1.1 Default “Project name”
Since a project must include at least one workpiece, whenever you create a new Project, you
activate the option
“Create Workpiece”.
If a project was already been started, following option would automatically start.
“Closing project”
3.1.3 Open an existing project
If you wish to open an existing project, click on the icon "Open".
The resulting window shows you the list where you may select a pgmx file.
The default folder will be defined as described in paragraph
3.1.1.2. Default ”Project folder”
Please select a pgmx file and click on "Open".
Or click twice on the pgmx file.
For a project that has already been started, following option would be automatically performed:

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3.1.4 Import Pgm/Xxl
This function is used to convert a .pgm or .xxl file into a project.
To import a .pgm or .xxl file click on the “Import Pgm/Xxl” icon in the
“Import” menu.
You will be asked to close any open project as the Import Pgm/Xxl
function is equivalent to opening an existing project.
A window will be displayed from which you can select a file with
extension .pgm or .xxl.
The default folder will be the one defined, as described in section
15.1.2 Post-Processor Options which describes the “Output folder”
Then select an .xxl file and then press “Open”.
A window will appear for entering the import options in order to make the import independent of
the configuration currently active in Maestro CNC.4
The options entered must be consistent with those for which the imported PGM file was created.
First we find the reference stop setting and the notation of the working depth, which can be
either SCM or Morbidelli. In the "Work environment" group we find the machine type, which can
be "Machining centre", ''CX'' or ''UX'', the selector of the tool file to be used and the type of tool
notation used in the PGM.
Proceeding with the import, the operation continues as before, with the only difference that at
the end of the operation the created PGMX is automatically saved with the same name as the
imported PGM.
Any unrecognised instructions will be displayed in a “XXL errors found” screen with the line
number of their location in the input life.

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If there are no errors the “Parameters found” screen is displayed with a list of the known
parameters in the file to import.
The following keys are found on the bottom:
To proceed click on “OK” and the input file will be imported as if it were an existing project.
To interrupt the import click on “Cancel”
For a list of the instructions click on “Help”.

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3.1.5 Import 3D template
It is possible to import a 3D model using the IGES formats (* .igs, *. Iges) or the STEP (* .stp, *.
Step) formats using the "Import 3D model" command in the "Home-Import" menu.
After selecting the command, simply select the file to be imported.
If the model is imported when there is no part in the project, a new part will be created with the
minimum dimensions needed to contain the imported model.
If the 3D model consists of an assembly of various solids, each one of the pieces will be
recognised as part and therefore the whole model will be converted in multi-part project. All the
parts will be automatically tilted so that the largest dimensions is along axis X and the smallest
along axis Z.
3.1.6 Import from STL
An STL can be imported by using the "Import from STL" command in the "Home-Import" menu.
After selecting the command, simply select the file to be imported.
The formats handled ate *.stl or *.dxf files.
If the STL is imported when there is no part in the project, a new part will be created with the
minimum dimensions needed to contain the imported model.

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3.1.7 Import Image
You can import an image and turn it into three-dimensional geometry
using the "Import image as a surface" command in the "Home-Import" menu.
After selecting the command, you can select a file to be
imported with the following formats:
After selection, the following dialog box
will appear so you can manage the
following characteristics of the surface that
will be generated:
- Dimensions (X, Y)
- Maximum and minimum size of Z
- Distance of the surface from part edge
The generated surface will be lower for
darker pixels and higher for light pixels.
This rule can be reversed by checking the
"Invert grey scale" item
With the "Detail reduction" potentiometer,
you can soften the surface by blurring the
grey tone of the image.

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3.1.8 Project check
After having created a project you can check if it is correct with the "Project check" command in
the "Machines-Post" menu.
The checks carried out inform the operator whether the project created can be executed in the
machine.
As well as the Maestro checks, other checks are carried out that will subsequently be used to
guarantee that the program can be executed in the machine, but without guarantees of anti-
collisions.
The result of the check could be negative. In this case the following message appears:
In this case the operator must correct the error in the project before executing it in the machine.
If the result is positive, the following message appears:
As shown in the message is correct from an execution point of view, but this function doesn't
check any collision errors.
The collision errors between heads and pieces and between heads and clamping devices can
be in part detected with the “Collisions check” function in Maestro (see chapter ) or completely
by the “ProView” optional package.

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3.1.9 End project
If you wish to end a project click on the icon "Close".
If your project is saved, following question will appear:
If your project has not yet been saved, following question will be displayed:
If you click on "Yes”, following option will be automatically performed in order to save your
project: "Automatic Saving"

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3.1.10 Save Project
If you wish to save an open project, click on the icon "Save"
If the project was already named, no question would be asked.
If the project was already created, the option "Save with name" would be performed.
You can specify the project name in the box "File name".
then click on "Save".

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3.1.11 Project Graphic display
The project is displayed in the mein are at the centre of the screen.
it is a three-dimensional representation.
The operator can choose what, where and how to see interesting project workpieces.
3.1.11.1 What you see of the project
In order to select the working processes to display among all those included in a sole project,
you can use the commands available:
- In the plane tree (see paragraph 3.3.5.4 )
- in the working process tree (see paragraph 3.5.21.4 )
- in the menu of the step tree:
Or use the "Display" "Options" menu "Opaque View" control."
The command "Dim" displays only the working processes of the active plane.
If one or more working processes of the active plane have been switched off with the tree menu,
these will no be displayed.

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3.1.11.2 Where to see the project
If you wish to see the project, it is possible to set the point from which you display it.
The main references to this purposes are the "Standard faces".
Immediate commands are available to see the different faces.
In the menu "Home" sub-menu "Views"
Clicking on the commands with the Face names, you will only display the face related to the
seleced view.
In the same menu, you can also see three commands related to three isometric views.
After selecting one out of ten views, you can zoom, size, shift or rotate the project view by using
the menu "Surfing" to the right of the menu "Views".

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3.1.11.2.1 Zoom
The main icon of the Zoom displays the whole screen.
The icon "Zoom" allows you to zoom through a rectangle. You can select it by clicking on the left
button of the mouse.
The icon "Zoom +" allows you to size the view whenever you click with the left button of the
mouse.
You can use this option also by rotating the mouse roller forward.
The icon "Zoom" allows you to size the view when you click with the left button of the mouse.
You can select this option by rotating the roller backwards.
The icon "Dynamic Zoom" allows you to zoom by cliking with the left button of the mouse on the
area to be zoomed and then to move in order to zoom/size the view.
You can select this option by rotating the roller backwards and forwards.
The commands "Zoom +", "Zoom -" and "dynamic Zoom" can be disabled if you click on the
"Esc key".
3.1.11.2.2 Pan
Pan allows you to shift the view by keeping the left button of the mpuse pressed and then to
shift with the mouse.
You can disable the command with the button "Esc" or by modyfing the command.
The same function is always available if you press the central button of the mouse and then you
move with the mouse.
3.1.11.2.3 Orbit
This option allows you to rotate the view by keeping the left button pressed and then move with
the mouse.
You can disable the command with the button "Esc" or by modifying the command.
This option is also available if you press the button "Ctrl", the central button of the mouse while
moving the mouse.

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3.1.11.3 How to see the project
All project elements can be displayed in different ways.
In order to choose the way to see such elements, the commands of this menu allow you to
produce the different representations that have been shown.

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The command CAMCAM allows you to display the tool path and the side of correction.
Here you can see a workpiece with a profiling and two tenonings in Shading representation
(25%)
The same workpiece in CAM representation shows you:
- the basic geometries of the profile
- paths in tool centre
- the circle with the arrow that indicates the initial point of the working process and the direction
The command "Redraw" upgrades the whole graphic area.
3.1.12 Transformation of DXF list to PGMX
The Project generation command in the Tools
menu opens a wizard that transforms advanced
DXF files into programmes.

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Clicking on the command opens
the first wizard window to
generate projects from DXF:
In this window you must set:
- the configuration
- the tools
- the edges if the machine is an
edge bander
- the folder where the projects
will be saved.
Pressing the Next button takes you to the second window.
In this section you must select
the DXF files from which you
want to create the projects.
You can select either the
individual files or the folder
containing them.
Pressing the Next button takes you to the section to actually generate the projects.

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This section contains a
summary of the selected
DXF files
By pressing the Generate button, the projects are generated and saved in the previously
selected folder.
Errors are generated in project creation are displayed on the screen and reported in a log file
that has the same name as the initial DXF file.

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3.2 Workpiece
Workpieces must be defined as "Finalised workpiece" and optionally also as "Rough workpiece
". You may insert more workpieces in one project.
3.2.1 Rough workpiece
Function implemented only in “Script” mode (see MSL manual)
3.2.2 Finalised workpiece
The finalised workpiece can have several geometric shapes:
3.2.2.1 Parallelepiped shaped workpiece
If you wish to set a parallelepiped shaped workpiece click on the menu "Create workpiece".
Introduce the values in the menu on the right.
You can change your field values after creating the workpiece.
Setting workpiece quantity is useful when
the parts are to be imported into Nesting.
When the parts are imported they already
contain the quantity information
Name of the
workpiece
Dimensions
Position

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3.2.2.2 Extruded workpiece
A closed geometry, that can be obtained in 3 ways, is required to make the extruded workpiece:
1) Creating a new geometry
2) Importing geometry from another workpiece
3) Importing geometry from dxf
Click on "Select Geometry" then on an available closed geometry
Click on "Apply" to create the "Extruded Piece" contained by a parallelepiped representing its
clearance.
The various fields' values can also be changed after the piece is created.
3.2.2.2.1 New geometry creation for extruded
Use the "Draw" menu controls (see paragraph 3.4) to create a new closed geometry.
Workpiece name
Extruded height
Select Geometry
Import geometry from a workpiece
Import geometry from Dxf file

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3.2.2.2.2 Geometry importing for extruded from another workpiece
Use the "Import geometry from a workpiece" control to have the closed geometry belonging to a
project piece. Select a project from those in the memory.
If the selected project only has one piece, its closed geometry will appear.
If the selected project has more than one piece, select the piece which geometry is to be
imported. The closed geometry of the selected piece will appear.
3.2.2.2.3 Geometry importing for extruded from dxf
Use the "Import geometry from Dxf file" control to have the closed geometry contained in a Dxf
file. From the memory select a Dxf file containing a closed geometry.
3.2.3 Change workpiece shape
The piece can be re-defined from rectangular to extruded also after it has been created.
To change a rectangular piece into an extruded piece use the same procedure described fro the
creation phase.
If switching from an extruded piece to a rectangular piece, the dimensions of the piece will be
the ones that inscribe the previous extruded piece.
3.2.4 Change workpiece dimensions
If three-dimensional geometries have been imported or completed for an existing project, the
part dimensions can be automatically updated to contain the selected geometries.
The function is activated using the "Fit part to surfaces" command in the "Draw-Modify
Surfaces" menu
After selecting the surface (s), the X, Y, Z super-material to be
added is requested in terms of the margins of the selected area
(s).

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3.2.5 Import the workpiece
You may also import a workpiece to another project.
To this purpose you can use the command "Import workpiece” of the menu "Home" "Importa".
The resulting window shows you the list of projects where you can select the workpiece to be
imported.
After clicking on the icon "Open", the list of workpieces in the selected project will be showed:
You can select one or more workpieces to import and click on the icon "Open".
In the tree of our project the selected workpieces will be added.
3.2.6 workpiece Removal
The workpiece can be removed from the working processes.
(see paragraph3.5.21 )
In order to remove a workpiece:
- select the workpiece to remove from the tree of the working processes.
- click on the command "Remove” in the tree commands or in the context menu of the
workpiece
the workpiece removal implies also that all related workings processes are removed as well.

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3.3 Working planes
The "working plane" is a plane with Cartesian axis where you can add shapes of plane
geometry like line, arc, circle and so on (see paragraph 3.4)
The work tops are created in four ways:
- automatically during the creation of a new workpiece (Standard Faces)
- by creating a plane in parallel with an existing plane (Parallel Plane)
- by setting the rotations around axis Z and around axis X (Inclined Plane)
- Cut with blade (Generated work top)
In case of Parallel and Inclined Planes you can also modify - after the creation - any value in the
window - the name of the plane as well.
With regard to all standard faces, all fields remain unvaried.

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3.3.1 Standard Faces
A workpiece has six faces in which six working planes called "Standard Faces" have been
created when a new workpiece is created.
Names and positions of the "Standard Faces" are as follows:
Upper Face Lower Face
Left Face Right face
Front Face Back Face

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3.3.2 Parallel Plane
A parallel plane is a new plane in parallel with an existing plane in the project.
There are two possibilities in order to create a parallel plane:
by using the tree of planes
By clicking - with the right button of the mouse - on the selected face, the resulting menu allows
you to create a "New parallel plane"
by using the menu “Draw” “Inclined Plane” “Parallel Plane”
In both cases a window will be displayed:
By setting following options "Distance from the plane” and "Apply" (apply), a new parallel Plane
will be created.
Note: with positive value it is created on the workpiece, with negative it is created inside the
workpiece.

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3.3.3 Inclined Plane
An inclined plane is a general plane created by the user with origin and inclination.
Two possibilities apply for every plane:
by using the plane tree
By clicking - with the right button of the mouse - on "Workpiece", the heading "New plane” will
appear.
by using the menu "Draw" "Inclined Planes" "Generic"

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In both cases a window will be displayed:
The definition of Inclined Plane starts with the threesome related to the workpiece placed at the
lower corner on the left.
By setting X values as origin, Y origin and Z origin, the origin of the new plane is established.
By setting the rotating angles of Z-axis and X-axis, you also set the plane direction.
You must also take into account that both rotation angles are sequential, that is to say: only
after the rotation around the Z-axis, the rotation around the new X-axis position will be
performed.
3.3.4 Plane from surface area
It is possible to create a coplanar plane to a surface using the "From surface" command in the
"Draw-inclined planes" menu.
Once the command has been selected, you simply select a surface and a coplanar user plane
to the selected surface will be set up.
Obviously the surface must be exclusively flat.

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3.3.5 Work plane tree
The work plane tree collects all planes set for a certain project.
This tree - a workpiece from displaying existing planes- allows you to:
- activate an existing plane
- display and change the properties of existing planes
- remove a plane
- create parallel planes (see paragraph 3.3.2)
- create an inclined plane (see paragraph 3.3.3)
Buttons with light bulbs (on or off) allow you to display or switch off the working processes (see
paragraph 3.5.21.4)
3.3.5.1 Work plane selection
The work plane selection will identify the active plane, that is to say, the plane where the two-
dimensional geometry will be drawn.
In order to reactivate an existing plane, click - with the left button of your mouse- on the name of
the plane in the tree.
If you wish to know the active plane, check the plane highlighted in light blue.
Properties
Display
Switch off
Remove

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3.3.5.2 Properties and plane modification
In order to see or modify the properties of a plane you can activate a plane then click on the
button "Properties” or click with the right button on the name of that plane and on the heading
"Properties" of the plane menu.
On the right side of your screen the menu will show you all current properties of the plane.
If you wish to modify the plane, click on "Apply" in order to change its values.
3.3.5.3 Plane removal
If you wish to remove a plane click with the right button on the plane name, then click on
"Remove" of the plane menu.
You can delete only the Parallel Planes or Inclined Planes.
You are not allowed to delete the Standard Faces.

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3.3.5.4 Displaying working processes on planes
You are free to decide to display -or not- the working processes on the plane tree.
To the left side of every work plane there is the icon which stands for the face type. To the left of
the icon there is the symbol which represents an "eye".
By clicking with the left button on the eye, you change its status from open to closed.
If the eye is open, it means that all plane working processes will be displayed.
If the eye is closed, it means that all working processes will not be displayed.
In this example, you see a project in which the “Upper Face” is
active but all working processes on the same "Upper Face"
have been switched off.
If you wish to switch all working processes off you can:
1) close all eyes to the left of the planes.
2) close the eye to the left of the workpiece
3) or click on the light bulb that is off.
If you wish to display all working processes you can:
1) open all eyes to the left of the planes
2) open the eye to the left of the workpiece
3) or click on the light bulb that is on.
The selection on the tree has an immediate impact on the graphic area.

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3.4 Geometries
3.4.1 Enter new 2D geometries
The 2D geometry is used in order to set the profile of an extruded workpiece as well as to set a
profile (open or closed) of a working process
Before introducing any two-dimensional geometric element, you must set and activate a working
plane.
The icons about the commands to insert the basic geometries are diplayed in the menu "Draw"
"Geometries"
All commands to create 2D geometry can be interrupted if you select a new command or click
on "Esc key".

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3.4.1.1 Type a new point
Every command aimed at introducing a new geometric shape has to identify one or more points
by the operator.
Firstly, it is important to explain the meaning of "type a new point".
"Type a new point" means that the operator creates a new point or sets an existing one within
the project.
The point can be created with Cartesian Coordinates (X, Y) or with Polar Coordinates (Lenght,
Angle).
If you wish to type a new point with Cartesian Coordinates (X; Y) you can:
- move the mouse (X and Y coordinates are upgraded).
- click with the left button of the mouse or press Enter key.
Or:
- type the value of the X coordinate
- move your mouse (Y coordinate is upgraded)
- press Enter key.
Or:
- type the value of the Y coordinate
- move the mouse (X coordinate is upgraded)
- press Enter key.
Or:
- type the value of the X coordinate
- type the value of the Y coordinate
- press Enter key.
In order to type a new point with Polar Coordinates (Length, Angle) you can:
- move the mouse (values corresponding to Length and Angle are upgraded)
Or:
- type the Length value
- move the mouse (the Angle value is upgraded)
- press Enter key.
Or:
- type the Angle value
- move the mouse (the Length value is upgraded)
- press Enter key.
Or:
- type the Length value
- type the Angle value
- press Enter key.

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3.4.1.2 Type an existing point by using the Osnap
In order to type a point, it is often desirable to use the points of the shapes that are already on
our plane.
To this purpose, the Osnap (Object Snap) in the following
menu are a useful support.
For an existing point:
- click on one command Osnap
- move the mouse (a red cross appears on the geometry)
Final It is linked to the final point of any graphic shape.
In a polyline it is linked to the final point of every entity that is contained in its
structure.
Intersection It is linked to the intersection of two entities.
Middle It is linked to the middle point of any entity (also a circle)
Centre It is linked to the centre of arcs and circles.
Quadrant It is linked to the X and Y points of maximum and minimum in the circles.
Perpendicular  It is linked to the point perpendicularly projected to a segment.
Tangent  It is linked to the tangent point of an arc or a circle.
Parallel It is linked to the point projected on the parallel to a segment.
Point  It is linked to an entity "Point”.
Horizontal  It keeps the Y coordinate of the previous point.
Vertical  It keeps the X coordinate of the previous point.
Near  It is linked to the point nearer to the point of the mouse.

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3.4.1.3 Point
It introduces a geometric element: "Point”
In order to introduce a point:
- click on the command "Point"
- type a point
In the graphic area the point is represented with this symbol:
Point properties

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3.4.1.4 Line
It inserts a line
A line can be inserted in two ways:
1) Line for 2 points
2) Length and angle line
In order to introduce a line for 2 points:
- click on the command "Line”
- type the initial point of that line
- type the final point of that line
In order to introduce a Line with a certain length and a certain angle.
- clcik on the command "Line length and angle”
- type the initial point of that line
- type the final point of the line (with Polar Coordinates)
Line properties

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3.4.1.5 Arc
It inserts an arc.
An arc can be inserted in 5 ways:
1) Arc for 3 points
2) Centre data arc and 2 Points
3) Arc given radius
4) Arc given centre
5) Continous tangent arc
In order to insert an Arc for 3 points:
- click on the command "Arc"
- type the initial point of the arc
- type the intermediate point of the arc
- type the final point of the arc
In order to insert an Arc whose centre radius initial and final angle are known:
- click on the command "Arc Centre and 2 Points"
- type the point of the arc centre
- insert the radius value and press Enter key
- insert the value of the initial angle and press Enter key
or move the mouse (the radius value is upgraded) click on the left button of the mouse
(also the initial angle is captured)
- Insert the angle value at the centre of the arc
or move the mouse (the angle value in the centre is upgraded) click on the left button of
the mouse
This command has two options at disposal:
- Sequence (Single/Multiple)
- Input (radius/Diameter)
that can be changed by the dynamic menu
The multiple sequence allows you to insert a further concentric arc to the previous one.
In order to insert an Arc whose final point and radius are known:
- click on the command "Arc given radius"
or move the mouse (the value of the radius is upgraded) click on the left button of the
mouse
- Direction (clockwise-anticlockwise)
- Arc length (Shorter/Longer)

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In order to insert an Arc whose centre and final point are known:
- click on the command "Arco dato centro" (arc given centre)
- type the point of the arc centre
This command has following option at disposal:
Direction (clockwise-anticlockwise)
In order to insert a tangent Arc in the previous element in a continuous manner:
- click on the command “Continuous tangent arc”
- select a geometric element
- click on the left button of the mouse
This command has three options:
- Type of feature (Arc/Line)
- Tangency (Direct
Inverse
Shorter length
Longer length)
that can be changed from the dynamic menu
The multiple sequence allows you to make tangent elements with the previous one.
The direct tangency does not create a sharp edge
The inverse tangency creates a sharp edge
The length options create the workpiece of Shorter or Longer arc.
Arc properties

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3.4.1.6 Circle
It introduces a circle:
A circle can be inserted in 3 ways:
1) Circle for 3 points
2) Circle given radius
3) Circle given diameter
In order to insert a Circle for 3 points:
- click on the command "Circle”
- type the initial point of the circle
- type the intermediate point of the circle
- type the final point of the circle
In order to insert a Circle whose centre and radius are known:
- click on the command "Circle given radius"
- type the point at the centre of the circle
or move the mouse (the value of the radius is upgraded) click on the left button of the
mouse
The multiple sequence allos to insert a further concentric circle to the previous one.
In order to insert a Circle whose centre and diameter are known:
- click on the command "Circle given diameter"
- type the point at the centre of the circle
- insert the value of the diameter and press Enter key
or move the mouse (the value of the diameter is upgraded) click on the left button of the
mouse
The multiple sequence allows to insert a further concentric circle to the previous one.
It is the same command used for the circle given radius, in which the default "Input" has been
turn into "Diameter"

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3.4.1.7 Polyline
It introduces a polyline that is a continuous sequence of arcs and/or open or closed segments.
It can be drawn using the commands for the input of lines and arcs.
In order to insert a polyline:
- click on the command "Polyline"
- follow the instructions related to the command set in the option "Mode”
- Closed (option that can be ticked off)
- Mode (Line given 2 Points
Arc given 3 Points
Arc given radius
Arc given Centre
Continuous tangent arc
Continuous tangent line)
that can be changed from the dynamic menu
End: it is an option that allows you to make an open or closed polyline
Modus describes the command to use in order to describe the next geometric element.
The six commands in the menu modus have been described in the previous paragraph about
lines and arcs.
Polyline properties are made of several tables that stand for the properties of all elements in the
structure (Lines or Arcs).
You can surf the tables by clicking on the left/right arrows.
If the field "Length” appears, the element described is a Line.
If the field "Radius” appears, the element described is an Arc.
Polyline properties

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3.4.1.8 Rectangle
It introduces a rectangle that is performed with a closed polyline made of 4 lines.
The rectangle can be inserted in two ways:
1) By inserting 2 vertex:
2) Typing the dimensions
In order to insert a rectangle given 2 vertex:
- click on the command "Rectangle 2 points”
- type the point of the first vertex
- type the point of the second vertex
In order to insert a rectangle by typing the dimensions
- click on the command "Rectangle dimensions”
- type the central point of the rectangle
- Insert the Width value and press Enter key
or move the mouse (the Width value is upgraded) click on the left button of the mouse.
- Insert the length value and press Enter key
or move the mouse (the Length value is upgraded) click on the left button of the mouse.
- Insert the Angle value and press Enter key
or move the mouse (the Angle value is upgraded) click on the left button of the mouse
Rectangle properties

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3.4.1.9 Buttonhole
It inserts a buttonhole performed with a closed polyline of 4 elements two lines and two arcs.
Arcs have a diameter like their width and a breadth of 180°.
In order to insert a buttonhole:
- by clicking on "Buttonhole”
- type the central point of the buttonhole
- Please insert the Width value and press Enter key
or move the mouse (the Width value is upgraded) click the left button of the mouse.
- Please insert the length value and press Enter key
or move the mouse (the Length value is upgraded) click on the left button of the mouse.
- Please insert the Angle value and press Enter key
or move the mouse (the Angle value is upgraded) click on the left button of the mouse
Buttonhole line
properties

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3.4.1.10 Loop line
It inserts an arc of circle or a tangent circle to 2 existing entity.
In order to insert a loop line:
- click on the command "Loop line"
- type the radius value
- move with the mouse (a loop line next to the cursor)
Or:
- select the first geometry
Or:
- click on the option "Quadrante" (quadrant)
- select the second geometry
- Cut/Widen (both
First
Second
Nothing)
- Quadrant
- Type (Usual
Inverted
Circle)
Cut/Widen serves as option to widen or cut the selected elements
Quadrant serves to insert the loop line in the third mode (2 geometries and the quadrant)
Type establishes the type of desired loop line.
The properties of the loop line are the same of the Arc.

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3.4.1.11 Smooth
It inserts a segment that smooths 2 existing entities.
The smooth can be set in 4 modes (see option "Type")
In order to insert a Smooth:
- click on the command "Smooth"
- type the values to set the smooth
- move with the mouse (a smooth will appear next to the cursor)
Or:
- move with the mouse (a smooth will appear net to the cursor)
Or:
- click on the option "Quadrante" (quadrant)
- select the second geometry
- move with the mouse (a smooth will appear net to the cursor)
- Cut/Widen (both
First
Second
Nothing)
- Quadrant
- Type (1 Distance
2 Distances
Length/Angle
Length)
The Cut/Widen option serves as option to widen or cut the selected elements
The Quadrant option aims at introducing the smooth in the third mode (2 geometries and the
quadrant)
The Type option establishes how to insert the data about the loop line
The values inserted in 1 Distance or 2 Distances are measured along the selected geometries.
The length represents the length of the new smooth segment inserted.
The smooth properties are the same of a Line.

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3.4.1.12 Offset
It creates one or more geometries that have a steady value compared to an existing selected
geometry.
The new entities will look like the selected ones.
In case of a polyline, the new entities will always be considered as polylines but the number of
elements in their structure can be higher or lower than the elements of the selected polyline.
In order to creare an Offset geometry:
- click on the command "Offset"
- select one or more geometric elements
- insert your offset value
- set the number of repetitions
- select the reference point to establish where to create the offset
- Repetitions
- Preview
The option "Repetitions" allows you to create one or more offset geometries
The option Preview - if it is marked - allows you to see - in Preview- the geometries that will be
created by moving the mouse.
It is possible to set off the initial and final tracts of an open break, when they are inferior to a
certain length because of the offset.
To do this you put the flag on the parameter
"Enable elimination of the outer tracts of the open curve" visible in the path:
Tools-Options-Parameters-geometries.
By ticking the parameter, the second parameter will also appear:
"Minimum length below which to delete traits"

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3.4.1.13 Text
It inserts a text made of many polylines (one or more for every character)
The text can be inserted in several fonts and heights.
In order to insert a text:
- click on the command "Text"
- select the reference plane
- selected the desired character
- select the desired style
- insert the text
- type the height
- type a precision
- select the desired alignment
- type the position in X and Y of the text
- Click on the button "Apply"

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3.4.2 Inserting blocking profile
The blocking profile consists of a geometry that indicates the part of the piece to be blocked by
the clamps.
To insert a blocking profile, you must first create a geometry with the
instructions seen in the chapter "Geometries" and then use the "Blocking
profile" command in the "Operations" menu.
The following rules must be respected:
- the clamps are always to be positioned to the right of the geometry
created.
- create the blocking profile in the correct work phase.
If, for example, you have to work an element to be blocked with the clamps to be profiled on
both sides, you must make a project with two work phases (Setup and Swap), with the blocking
profile to be inserted in each phase.
After selecting the command, this dialogue window appears:
where you can select the geometry and set a minimum
clamping.
Minimum clamping means the minimum quantity of wood that can be clamped during the
clamping phases with the clamps.
In the "Minimum clamping" field, you can enter a negative value or the name of a previously-set
parameter.
If, in generating the geometry, considerable points of the workpiece were used, the profile is
completely parametric.

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3.4.3 Enter new surfaces
Maestro provides functions to create new surfaces. To access the commands enter the “Draw”
area of the application menu and press “Surfaces”.
The methods available and their main features are described below.

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3.4.3.1 Flat surface
To create a flat surface click on “Flat surface”.
Then proceed as follows:
- select a closed 2D curve;

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3.4.3.2 Linear extrusion
To create an extrusion surface click on “Linear Extrusion”.
- select a geometry on a plane;
- enter the geometry extrusion length.
The geometry to select can be on any project plane, on the workpiece faces and created by the
user (e.g. tilting plane). The length must be entered after having selected the geometry. The
extrusion is performed along the axis z direction with the Cartesian reference system local to the
plane. The sign determines the extrusion direction along the direction.
The created surface can be closed by two other
surfaces by checking the corresponding flags,
provided the section is closed
3.4.3.3 Revolution
To create an extrusion surface click on “Revolution”.
- select a geometry on a plane;
- select a revolution axis;
- enter a revolution angle.
The geometry selected can be on any project plane.
The revolution axis must be a linear geometry not at right angles to the plane on which the
revolution geometry is drawn.
The revolution angle value determines the rotation quantity around the axis, whilst the sign
determines the clockwise/counterclockwise direction, usually clockwise.
The created surface can be closed by two other
surfaces by checking the corresponding flag,
provided that:
- the section is closed
- the angle is less than 360 °

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3.4.3.4 Mesh lined
To create a surface with mesh lined click on “Mesh lined”.
- select a first geometry on a plane;
- select a second geometry on a plane.
The geometries selected cannot be closed geometries.
The surface is created by connecting the points of the first geometry with the points of the
second, with lines. Usually the start point of the first geometry is connected to the start point of
the second, the same applies to the end points. As this approach can create surfaces that
collapse in the middle, if the directions of the curves used are in conflict, the algorithm inverts
the start point and end point of one of the two geometries.
3.4.3.5 Mesh corner
To create a surface with mesh corner click on “Mesh corner”.
- Select the first corner geometry;
- Select the second corner geometry;
- Select the third corner geometry;
- Select the fourth corner geometry.
The corner geometries must have matching points, so that the total contour, formed by the four
elements, is closed.
3.4.3.6 Section surface
To create a surface that joins multiple curves that will form the sections
of the super surface, click on "Surface from Sections".
The function has the following requests:
The selection of three curves is mandatory while the selection of additional curves is optional.

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3.4.3.7 Sweeping
This function helps create a set of surfaces that form a tube with a
constant section following a trajectory.
The input will consist of two curves.
The extrusion curve must have no edges and it is advisable that the first section forms an angle
of 90 ° with respect to the plane in which the profile curve has been created.
Generation occurs by making the initial points of the two curves coincide.
It is possible to plug the tube by ticking the related items "Closing surface"
Esempio :

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3.4.4 Insertion of solids
Solids are inserted using the "Draw - Solids" menu.
The solids created are a set of multiple surfaces.
3.4.4.1 Parallelepiped
This function allows you to create a parallelepiped consisting of 6
surfaces.
Example:

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3.4.4.2 Sphere
This function allows you to create a sphere or a portion of a sphere made
up of one or more surfaces.
Example:
3.4.4.3 Cylinder
This function enables users to create a cylinder or a cylinder portion formed
by one or more surfaces.
Example:

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3.4.4.4 Cone
This function enables you to create a cone or cone portion formed by one
or more surfaces.
Example:
3.4.4.5 Pyramid
This feature means you can create a pyramid having a closed, unjoined
geometry as a base.It will be made up of one or more surfaces.
The vertex of the pyramid will be the projection in height at the centre of
gravity of the base
Example:

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3.4.5 Enter new 3D curves
Maestro provides functions to create 3D curves. To access the commands enter the “Draw”
area of the application menu and press “3D Curves”.
3.4.5.1 3D arc
To create an arc in the space click on “3D arc”.
- Select the start point
- Select the intermediate point
- Select the end point
This will result in an arc that lies on the plane through the 3 points described.
Note that:
- The points can be entered by combining the mouse and keyboard.
- The arc generated is shown in red to distinguish it from an arc that has been defined on a
plane

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3.4.5.2 3D composite line
To create a break in the space click on “3D composite line”.
- Select the start point
- Select a series of subsequent
points
To complete the composite line press “Esc”.
Note that the line is not part of the active plane.
3.4.5.3 Projection
To create a 3D curve by projecting a geometry on a surface, click on
"Projection".
- select the geometry to project;
- select the target surface.

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3.4.5.4 Normal surface projection
To create a 3D curve by projecting a curve normally on a
surface, click on "Normal surface projection".
The selected curve will normally be projected onto the surface by generating a 3D curve
3.4.5.5 Wrapping
To create a 3D curve by wrapping a geometry on a surface, click on
"Wrapping".
- select the wrapping geometry;
- select the target surface.
3.4.5.6 Extract surface edges
To get the 3D curves that make up the surface perimeter, click
on "Extract Surface Edges".
The function does the following:
After selecting the surface, the 3D curves that form the surface perimeter are generated.

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3.4.6 2D geometry imported from DXF
It is possible to import 2D geometry from an existing DXF file.
To do this, there must be a project with at least one workpiece defined.
To import a DXF file use the “Import dxf” command in the
“Home” “Import” menu.
After selecting the command, the dialogue box appears which allows you to select a “.dxf” file
from the PC disk.
The “DXF program (*.dxf)” filter is already set in the “File type:” box.

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Once you have selected the file, the
menu shown here appears:
In the menu you can see the name of the
dxf file which is being imported in the
“File Name” field.
You can select:
- the Layers present in the dxf file
- the face on which you want to import the
geometric entities present in the
selected Layers
Use the “Cancel” key to interrupt the
operation.
Use the “Apply” key to begin importing the
dxf file.
At the end of the import
operation this window appears:
(Do you want to see the import report?)
Select “No” to conclude the operation.
Select “Yes” and another window opens,
showing the dxf import operation report.
In the report, for each
layer you can see how
many and which entities
were imported and how
many and which entities
were not imported and the
reason why.

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The report file is also saved in the “Maestro/Report/DXF” folder in XML format.
The name with which it is saved has the prefix “DxfImpor” followed by the date and time.
Example: “DxfImport_20110920_085538.xml”.
The following Dxf versions are supported:
12, 13, 14, 2000, 2004, 2007, 2010, 2013
With the restriction that in Maestro only the 2D geometries will be imported.
The geometries that can be imported are:
-DxfLine
-DxfCircle
-DxfArc
-DxfPolyline2D
-DxfLwPolyline
-DxfPoint
-DxfText
-DxfEllipse
-Spline 2D
Note: The following geometries cannot be imported:
1) SPLINE3D
2) POLYLINE3D
In Autocad 2004 ellipses can be exported as polylines using the “PELLIPSE” variable. This
would allow it to be imported into the packet.
3.4.6.1 Recognition of horizontal holes
When importing a DXF, the horizontal holes are often exported as rectangles with one side
adjacent to the edge of the workpiece. These geometries can be recognised as horizontal
holes: by selecting a rectangular geometry (instead of a circle or point) based on the side of the
adjacent panel edge, the originating plane is deduced; the dimensions of the rectangle are used
to reconstruct the depth and diameter of the hole; the hole is conventionally applied to a Z equal
to half the thickness of the workpiece.

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3.4.6.2 2D geometries advanced import from DXF
In order to associate machining operations to the geometries the CAD designer must structure
the project and the drawing of the geometries in a certain way.
First of all the CAD designed must know the dimensions of the workpiece being produced and
know which machinings must be applied to the geometries to draw. This information is needed
to structure the project correctly.
The CAD project must be structured in layers, as follows:
1. Possess a layer dedicated to the definition of the piece;
2. Possess a layer to describe the surface, for each surface on which you wish to draw the
geometries.
3. Possess a layer to describe processing, for each processing of geometries on a surface.
The following rules apply especially to create layers:
1. All layers that are to be interpreted and managed by "advanced import" must have their
names beginning with the key: XLY.
2. The XLY key is followed by a set of key values. If the values are alphanumeric, they must
start and end with the separator character $.
3. The keys allowed in the layer name are:
- P: work plane (E.g.: XLYP1 is the layer referred to the upper plane). The values
allowed are: 1, 2, 3, 4, 5, 6 for standard planes (1=upper plane, 2=r plane, 3=l
plane, 4= front plane , 5= rear plane, 6=lower plane), and values from 7 upwards
for the user planes.
- T: technology and processing (E.G.: XLYP1T$FORA1$ geometries on the upper
surface and technology application FORA1 to the geometries). The value of these
keys is alphanumeric and represents the name of the technology (technology file
name without an extension). The values must correspond to the technologies that
will be used in Maestro.
- H: piece height. Valid key only for the layer that defines the piece: it is only allowed
if the surface is P1 and there are no associated technologies (E.G.: XLYP1H18).
The value of this key cannot be alphanumeric.
- OX: coordinate X of the plane origin. Key valid only for user planes and not for
standard planes: all planes of greater index equal to 7 are allowed and no
technologies must be associated (E.g.: XLYP7OX100). The value of this key
cannot be alphanumerical.
- OY: coordinate Y of the plane origin. Key valid only for user planes and not for
technologies must be associated (E.g.: XLYP7OY100). The value of this key
- OZ: coordinate Z of the plane origin. Key valid only for user planes and not for
technologies must be associated (E.g.: XLYP7OZ100). The value of this key
- RX: rotation angle expressed in degrees, of the reference system integral to the
plane around its X axis. Key valid only for user planes and not for standard planes:
all planes of greater index equal to 7 are allowed and no technologies must be
associated (E.g.: XLYP7RX45). The value of this key cannot be alphanumerical.

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- RZ: rotation angle expressed in degrees, of the plane reference system around the
Z axis of the absolute reference system. Key valid only for user planes and not for
technologies must be associated (E.g.: XLYP7RZ45). The value of this key cannot
be alphanumerical.
4. The layer name must not contain spaces, unless within the separator characters.
5. The piece definition (dimensions DX, DY and DZ) is carried out by means of a layer that
contains a rectangle whose dimensions define DX and DY. The thickness of the piece
(DZ) is defined in the layer name by means of the H key followed by the corresponding
value. Only one layer must contain this information.
You can import a workpiece of any shape (extruded) during the import of an advanced
DXF (workpiece and geometry on a layer with a technology name). The geometry can be
of any shape as long as it is closed. This geometry will be considered the profile of the
extruded workpiece, while the rectangle that encloses it will be that of the theoretical
workpiece whose rectangular faces can still be described in the usual way.
The closed geometry can contain one or more closed geometries that will be associated
with the same number of holes inside the workpiece.
6. For correct positioning of the geometrical entity, you must have a reference for each
surface used. Therefore, each surface containing one or more entities must have a layer
name like
XLYP<layer name>
containing a rectangle having dimensions equivalent to those of the associated surface.
The entity contained on it will then be positioned in the DXF project in relation to the said
rectangle. If one or more layers refer to a surface, which has not been supplied with a
layer description, processing contained therein will be rejected with an error message for
the user. The layer associated with the upper surface must always exist since it is
conventionally committed to describe the dimensions of the piece, therefore, it is the only
layer that contains the "H" key. The geometry contained in this layer will describe the
upper surface of the piece and, if necessary, the lower surface (should this not be
described).
7. The definition of the layer for a user plane follows different rules to the standard planes.
The layer is defined by drawing the rectangle that describes the plane in any position of
the DXF project. The geometries inside the rectangle must be drawn with local reference
at the rectangle origin, that is in relation to the origin of the plane being created.
8. The sequence used to define the technological layers (ES XLYP1T$FORA1$) defines the
sequence with which the machining operations must be created inside the project. For
example, in order to create 3 layers, one routing, one trimming and one drilling, to obtain
the following type of machining:
1- Trimming
2- Drilling
3- Routing
the layers must be defined in the following order
XLYP1T$Contornatura$
XLYP1T$Foratura$
XLYP1T$Fresatura$

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VALID EXAMPLES:
XLYP1H18
XLYP3
XLYP1T$FORA1$
XLYP3T$FRESA LAMA$
XLYP2T$FORA LAT5$
NON-VALID EXAMPLES
P1H18 (initial XLY key missing)
XLYP1H18T$FORA1$ (H specified in combination with a technology)
XLYP1 T$FORA1$ (presence of a space besides the separators $)
XLYP1TFORA1 (no separators $ with alphanumeric type values FORA1)
Moreover, geometries must be made by keeping the characteristics of processing and the tool
path in mind:
- If processing envisages the use of a tool compensation, for example the use of left
correction, this restricts the CAD designer in drawing the geometries. For example,
making closed geometries in a clockwise and anticlockwise direction; the first case of
processing will be carried out externally from the geometry profile whilst the second will
be inside it. Similarly, the designer will have to keep the direction in mind also for open
geometries since processing an AB segment will be different from that of a segment
covering the opposite direction (segment BA).
3.4.6.2.1 Import 2D geometries from DXF for machining
By way of an example, here is a project to make a plank of wood composed of three pieces. For
each piece, it is necessary to define a .dxf file, which describes the associated geometries for
each individual piece and its relative processing. Below is a representation of the plank and
parts it is composed of.
In the example, we assume that the geometries refer to the upper surface of all pieces taken
into consideration and that each side of the geometry needs to be processed with a different
technology than the others. In detail, for each piece, assuming we have to firstly execute
contouring of all the geometries and then execute the required processing for each of their
sides. The upper side of the geometry requires milling processing by means of a tool having a
convex shape whilst the lower one requires a concave shape.

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Instead, processing associated with the sides of the geometries enable the finish of the side, if
this corresponds to an external side of the plank, or shaping it as a junction to the adjacent
piece if this is the side of the junction.
For contouring operations, TECH0.tchx technology is assumed to be available, while milling with
a convex tool is for TECH2.tchx technology and a concave tool is for TECH3.tchx technology.
To make a junction, TECH1.tchx and TECH5.techx technologies are assumed to be available,
which correspond to milling the left and right side of the junction. The finish is instead obtained
by means of TECH4.tchx technology. For all technologies taken into consideration, it is
assumed that tool correction is on the left.
To import a DXF, you must use an "Importa dxf" control from the menu
"Home" "Importa".
After having selected the control, a dialogue window will appear that enables you to select a
".dxf" file from the PC's disc.
Below are the layers created for each piece with the relative geometries and associated
processing.

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PIECE A:
Layer Technology Operation
XLYP1H30 - Piece definition and upper
surface
XLYP1T$TECH0$ TECH0.tchx Contouring
XLYP1T$TECH1$ TECH1.tchx Left Junction
XLYP1T$TECH2$ TECH2.tchx Convex milling tool

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XLYP1T$TECH3$ TECH3.tchx Concave milling tool
XLYP1T$TECH4$ TECH4.tchx Finish
PIECE B:
surface

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XLYP1T$TECH5$ TECH5.tchx Right Junction
XLYP1T$TECH1$ TECH1.tchx Left Junction

89
PIECE C:
surface
XLYP1T$TECH5$ TECH5.tchx Right Junction

90
XLYP1T$TECH4$ TECH4.tchx Finish

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3.4.6.2.2 Import 2D geometries from DXF for edge banding
The edge banding process can be defined starting from a project structured with the
specifications defined at the beginning of the chapter, introducing layers that identify the edge
banding machining operations.
In particular a layer associated to an edge banding technology must be defined as specified in
item 1, with the same structure and syntax (e.g. XLYP1T$BORDATURA$).
The difference in this case is in the way the geometries to which the edge bandings are
associated and the machining operations defined in the technological process are defined. As
opposed to earlier where the entire technology is applied to each geometry, in this case one or
more machining operations specified in the technology can be applied to each geometry
section, with the start and end points being the ends of the geometry. Independently of whether
the geometry being machined is closed or open, to perform a specific machining on a section,
the total geometry must not be drawn as a single curve (e.g. polyline) but as a set of more or
less elementary curves (e.g. segments, arcs, polylines) and a colour associated to each section
with the RGB code. This code must be the same colour code of the machining in the
technology. In this way the system will create a single geometry as a combination of all the
defined geometries and apply the associated machining operations to each section. The order
in which the geometries are drawn is used to define the machining sequence of the edge
banding process.
The drawing of the geometries must be produced so that the direction is always clockwise.
Figure 1 shows a practical example.
Figure 1.
The final geometry must be a rectangle, to which the edge banding process is applied.

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The resulting sequence must be as follows:
1- Routing the whole rectangle
2- Edge banding upper side with edge B1
3- Upper side end trimming
4- Edge banding lower side with edge B1
5- Lower side end trimming
6- Edge banding right side with edge B1
7- Right side end trimming
8- Edge banding left side with edge B2
9- Left side end trimming
10- Trimming upper-right-lower side with trimmer RE1
11- Trimming right side with trimmer RE2
12- Scraping upper-right-lower side with scraper RA1
13- Scraping left side with scraper RA2
14- Shaving the 4 corners
To obtain the sequence the 4 lines are drawn to form a clockwise rectangle and a colour is
associated to each line, as shown in figure 1.
The application of the technology associated to the layer, follows two fundamental rules:
1- Technological process
2- Order of the geometries and colour associated to the geometry
This means that during the application phase, if present in the technology, the routing is
automatically applied to the whole geometry obtained by joining the 4 sections that must have
matching start and end points. The routing is applied with start in the middle of the first side.
Immediately after the routing the edges present, that will be applied by following the order with
which the geometries have been drawn, are analysed.
With the reference to the example, the geometries that must be edge banded must be drawn in
the following order:
1- Red upper segment
2- Red lower segment
3- Red right segment
4- Yellow left segment
In this way, during the import phase, if in the technology a red edge banding and a yellow edge
banding are found, the 4 edge bandings will be applied by following the sequence with which
the geometries have been drawn and the single requested edge banding technologies.
The upper side will be edge banded first with edge B1, the lower side second with edge B1, the
right side third with edge B1 and the left side fourth with edge B2.
Once the edge bandings have been inserted it checks if there is, for each section that has a
colour, an end trimming technology with the same colour.
If there is the end trimming associated to the colour will be applied to each edge banding
section.
The same applies for the trimming, for each geometry section with a colour it checks if there is
the relative trimming technology, but in the application phase the trimmings with the same tool
are joined together, if possible, in a single trimming operation.

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In the example, as the upper-lower-right side are red, they are given the same trimming,
therefore a single trimming with trimmer RE1 is created.
The yellow left side is trimmed with trimmer RE2.
The same applies for the edge scraping and glue scraping operations.
The shavings are managed automatically, during the application the applicability of the shaving
for each edge banding is checked and where possible it is applied.
To obtain the rectangle edge banded with 2 edges, B1 on the upper-right-lower and B2 on the
left, we have had to create the rectangle with 4 section in the correct sequence and associate to
each section the edge banding colour present in the technology.

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The example in figure 2 shows a case with sections not edge banded.
Figure 2.
In this case the upper section of the panel must not be edge banded. This is achieved by
drawing the section, but the transparent RGB is associated as the colour.
As opposed to the example of figure 1 this achieves:
1- Routing the whole rectangle
2- Edge banding right side with edge B1
3- Right side end trimming
4- Edge banding left side with edge B2
5- Left side end trimming
6- Edge banding lower side with edge B3
7- Lower side end trimming
8- Trimming right side with trimmer RE1
9- Trimming left side with trimmer RE2
10- Trimming lower side with trimmer RE3
11- Scraping right side with scraper RA1
12- Scraping left side with scraper RA2
13- Scraping lower side with scraper RA3
14- Shaving the 4 corners
Similarly to example 1 the first machining applied is the routing of the whole panel, starting from
the geometry start point.
Followed by the edge banding of the right with edge B1 (red), left with edge B2 (yellow), and
lower with edge B3 (blue).
Followed by the end trimming associated toe the single edge bandings.
Followed by the trimming of the right with trimmer RE1 (red), left with trimmer RE2 (yellow), and
lower with trimmer RE3 (blue).
Followed by the scraping of the right with scraper RA1 (red), left with scraper RA2 (yellow), and
lower with scraper RA3 (blue).
The shavings are applied automatically.

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3.4.7 Export 2D geometry in DXF
The 2D geometries in a project can be exported in a DXF file.
To do this use the "Export dxf" command in the "Home" menu.
After selecting the command, the following screen will appear:
here you can select the piece or pieces in the project whose geometry you want to export.
By selecting the “Export dimensions” options any quotas in the project will be exported along
with the 2D geometries.
Click on “Apply” to select a folder where to the save the dxf.
If the current project has been saved, a folder with the name of the project will be created,
containing a dxf file for each piece selected.
If the project has not been saved, the folder with the name of the project will not be created and
the dxf files will be saved directly in the folder selected.
The dxf generated will contain the geometry created along with the geometric contour of all the
sides of the piece.

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3.4.8 Geometry selection
Once all geometric entities or working processes have been inserted, it is often necessary to
select them in order to carry out several operations
You can select a single entity by clicking with the left button of the mouse on the desired entity.
The selection is clearly visible because it is red-coloured.
In order to select more than one entity you can press - like for the single selection - "Shift".
In order to make a quicker multiple selection, this is a suitable method:
- press the left button of the mouse
- move the mouse (a rectangle is drawn)
- release the left button of the mouse
At this point all entities included in the rectangle will be selected and red-coloured.

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3.4.9 Contextual Menu of graphic area
After selecting one or more geometric entities or working processes, if you click with the right
button of the mouse, one of these two menus will appear with the commands related to the
selected geometric elements.
The first menu will appear if you select two or more elements.
The second one if you select one geometric element.
The third if you select only one working process.
It is possible to display "Properties" only for one entity.
If there is no geometric entity among the selected elements, the commands "invert”, "Join” and
"Explode” are inhibited.
In case of one working process, it is possible to display the "Properties" of the working process
or the "Properties" of the geometry concerning the working process.

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3.4.10 Geometry removal
After selecting one or more geometric entities, you can delete:
- by clicking with the button "Canc"
- or clicking on the command "Remove" of the menu "Home" "Clipboard"
- or on the command "Remove" if the contextual Menu.
3.4.11 Geometry properties
Every geometric feature has several properties.
In order to display the properties of one element:
- Select the object (red-coloured)
- click on the command "Geometric properties of the contextual menu”
- The resulting table will show you the geometric data.
The tables displayed for every entity have been reported in the paragraphs related to the
geometry inserting commands.
By marking the field "absolute Coordinates”, the data will not refer to the faces on which the
geometry has been built but to the three-dimensional "Zero" of the Project.
By changing the values in the fields of properties it is possible to modify the geometry.
This function cannot currently be applied to the 3D surfaces and curves.

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3.4.12 Change existing geometries
Icons related to commands to modify basic geometries are to be found in the menu "Draw"
"Modify".
All commands of geometry modification are interrupted by selecting a new command or
pressing the button "Esc".
The “Cut”, “Extend”, “Start point”, “Join, “Explode” commands cannot be applied to the 3D
surfaces and curves. To change surfaces, see the relevant paragraph.
3.4.12.1 Cut
It removes a workpiece of a geometric entity intersected by other entities.
If an entity is not intersected by any line, it will be completely deleted.
In order to remove a workpiece of geometric entity:
- Click on the command "Cut”
- move the mouse (the entity workpiece to delete is green-coloured, in bold)
3.4.12.2 Extend
It extends the geometry of a geometrical entity until it intersects with other entities.
To extend a geometrical entity:
- click on "Extend"
- select the entity to be extended
- select an entity that intersects the entity to be extended
(the entity to be extended becomes blue and thick representing the new shape it will
have, while moving the mouse on the many entities).

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3.4.12.3 Invert
It inverts the initial point with the final one of any geometric entity.
The command is available in the menu "Draw” “Modify” as well as in the “Contextual menu).
In order to invert the direction of one or more geometries:
- Select one or more geometric entities
- click on the command "Invert”
The inversion is evident when the symbol linked with the geometric initial point has changed.
The “Invert” command, if applied to surfaces, inverts the normal of the surface.
3.4.12.4 Initial point
It changes the initial point of a closed geometry (circle or polyline).
In order to modify the initial point of a closed geometry:
- click on the command "Initial point”
- move the mouse
- click with the left button of the mouse (for a new initial point )
The representation of the initial point is performed with an arrow that detects the position and
the direction.
3.4.12.5 Join
It creates a polyline by combining geometric entity with coinciding vertex.
The command is available in the menu "Draw” “Modify” as well as in the "Contextual menu”.
In order to combine one or more geometries with coinciding vertex:
- Select one or more geometric entities
- click on the command "Join"
One or more polylines can be combined only with the entities that have coinciding vertex.
In case of more entities with coinciding vertex, the entities inserted in the polyline will follow the
selection order.
The direction of the new polylines is casual

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3.4.12.6 Explode
This command explodes a polyline in all basic geometric elements in its structure.
In order to explode one or more polylines:
- select one or more polylines
- click on the command "Explode”
The direction of the single entities will be the one inside the polyline.
3.4.12.7 Split geometry
By selecting a 2D geometry of the arc,
segment or polyline type, it is possible to break
it at a point, creating two parts via the Split
geometry command in the Draw Edit menu.
The first part of the geometry will go from the
start point of the geometry (geometries always
have a start point and an end point, coincident
for closed geometries) to the point selected
with the mouse; the second part of the
geometry will go from the selected point to the
end point. If machining is associated with the
geometry to be split, splitting is not permitted and a message notifies the user of this if splitting
is attempted.
3.4.12.8 Editing geometries with the mouse
You can modify any geometry by using the mouse directly rather than through tables (recalling
properties and changing values of coordinates, radii, etc.).
The command is activated by the
CAD tool button for geometry modification.
If no geometry is selected at the start, the desired geometry selection is requested. Once the selection
has been made, grip points appear on the specified geometry that can be used for manual modification
of the geometry itself:

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More precisely, grips are associated with the segments (visible as a thickened segment in a different
colour) and at the vertices or significant points of the curves:
 for linear segments, the ends of the curve are shown for repositioning;
 for the segments of the arc of a circle, in addition to the ends, the centre of the arc can be
modified (by moving the original circle) or the quadrant point to 0° to modify its radius, keeping
the centre and the ends stationary;
 similarly, for the segments of an ellipse, the major and minor semi-axes of the ellipse and its
inclination can be modified;
 for circles (and ellipses), it is possible to move their centre (and therefore the entire curve) and
modify their radius (or semi-axes and inclination);
 for polylines, it is possible to move the vertices in common to two adjacent segments (by
stretching them both) or the centre of an arc (by changing its radius of curvature).
Osnaps can also be used to carry out controlled movements.
3.4.12.9 Simplifying a polyline (smoothing)
A very common occurrence when importing geometries from DXF files is to end up with
polylines made up of hundreds or thousands of very small segments. Machining of these curves
creates a variety of problems for the machines and the result is almost never satisfactory.
Furthermore, the presence of so many segments can lead to slowdowns in the calculations
required for their management.
The Simplify polyline command allows you to eliminate a considerable number of segments,
reducing the discrepancy between the original curve and the simplified curve.
The command is found in the Draw Edit menu or
in the context menu of the drawing area, (after
selecting the curve to simplify)
The parameters governing simplification are those relating to
the geometries in the appropriate section of the Maestro CNC

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options (maximum chord error and discontinuity of the maximum tangent, in degrees).
You can also simplify all the polylines imported from DXF using a special check box on the
relevant import page:
By activating this check box, all the imported polylines will be simplified, reducing the complexity
of the curves and avoiding having to do this manually at a later time for each curve.

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3.4.12.10 Change surfaces
To change a surface click on “Change surfaces”.
There are two commands to change the surfaces:
- Extend surface;
- Intersection between surfaces.
- Cut surface
- Fillet between surfaces
- Chamfer between surfaces.
3.4.12.10.1 Extend surfaces
To extend the surface proceed as follows:
- select the surface to extend;
- enter the extension length values.
The surface extension occurs in tangency and it generates a new surface that replaces the
original one.
3.4.12.10.2 Intersection between surfaces
The surfaces intersection procedure is performed as follows:
- select the first surface;
- select the second surface.

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3.4.12.10.3 Cut surface
The surface cutting procedure requires:
- selecting the surface to be cut;
- selecting one or more curves.
The permitted curves must be:
- Closed (if inside the surface)
- Open but with the initial and final points on the edge of the surface
The result will be to divide the original surface into two or more surfaces.
3.4.12.11 Fillet between surfaces
You can modify two or more contiguous surfaces (i.e. with one shared side) using the fitting
between surfaces command contained in the set of tools for modifying surfaces:
This command provides for the selection of two or more contiguous surfaces (if this is not the
case, an error message is displayed) and the radius of curvature to be given to the fitting
between them: if the radius is compatible with the selected surfaces, they will be modified
accordingly and a rounded surface will be inserted between them to fit them to each other:

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3.4.12.12 Adapt piece to surfaces
3.4.12.12.1 Automatic counterprofile creation
To create a counterprofile of a solid model, use the
Create counterprofile from surfaces command in the
Draw Edit Fit workpiece to surfaces menu
As a first step, you are requested to select the surfaces of the solid model to make the
counterprofile. Once the surfaces have been selected, the Z value required to sink the 3D model
into the counterprofile is requested. Note that while the Z value is specified, the preview of the
counterprofile shape is shown in real time above the 3D model. Once the Z dimension is
confirmed, a new workpiece is created within the same project with the surfaces and
dimensions required to build the counterprofile (this typically requires one flush milling and one
or more finishing), plus some geometries that identify the contour of the cavity in which the 3D
model will be housed once it is turned and inserted in the counterprofile: these geometries can
be used for milling needed to insert a gasket to seal the workpiece. A third workpiece is
generated with the initial 3D model, upside down, at the Z dimension it will assume once
inserted in the counterprofile: the machining of this workpiece will complete the underlying part
of the initial workpiece.
3.4.12.12.2 3D model sectioning
This command allows you to create portions of a 3D model (consisting of surfaces), sectioning it
along a predetermined direction.
To launch the command, press the appropriate button in the group relating to management of a
workpiece associated with a 3D model:
Draw Edit Fit workpiece to surfaces 3D model sectioning

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After selecting the surfaces of the model, the command requests the maximum size of the
section along the preselected axis.
The options allow for selection of the axis to cut (X, Y or Z): in this way, based on the maximum
acceptable size, theoretical section planes will be created and displayed showing the points
where the 3D model will be cut.
Each portion of the divided model will be inserted into a new workpiece: each workpiece created
will be added to the current project and its dimensions will be automatically adapted to the
surfaces.
Two other options are also available: the first allows you to create closing surfaces in
correspondence with the section points of the model, as long as this is made up of contiguous
surfaces so that the section curves are closed (some may be internal to the others). For user
convenience, the edge of this closing surface is added to the face where it is located.
A final option allows the sectioning command to add reference points on the faces originating
from the sectioning cuts as a suggestion for pin hole positioning: this guarantees absolute
correspondence in the drilling of two counterpoints on two opposite faces, even if the
workpieces to which they belong are of different sizes.

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3.4.13 Move and/or copy the existing geometries
The icons on the commands to move, rotate, mirror or copy the existing geometries are to be
found in the menu "Draw” “Modify”
All commands of geometry modification are interrupted by selecting a new command or
pressing the button "Esc".
Further recurring commands are to be found in the menu "Home" "Clipboard".
The “Mirror” and “Oppose” commands are not valid for 3D surfaces and curve geometries.

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3.4.13.1 Move
Move one or more entities from one point to another one.
In order to move one or more entities:
- select one or more entities
- click on the command "Move”
- type the reference point
- type the final point
Or:
- click on the command "Move”
- type the final point
- Create a copy
- Coordinates (Relative/Absolute)
The option "Create a copy” allows you to make a copy out of the source text.
The option Multiple Sequence allows you to keep on moving the element by typing further final
points.
The option "Absolute Coordinates" allows you to stop the select geometries at a certain level
starting from a zero level of the work plane.

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3.4.13.2 Rotate
Rotate one or more entities.
The command is available in the menu "Draw"”Modify” as well as in the "Contextual menu”.
In order to rotate one or more entities:
- click on the command "Rotate”
Or:
- click on the command "Rotate”
If you rotate two-dimensional elements:
- set an angle (typing the point or inserting the value)
If you rotate three-dimensional elements i :
- Select an axis or a vector or define a vector by entering two points
- set an angle (typing the point or inserting the value)
- Single Sequence
- Multiple Sequence)
The Multiple Sequence option allows you to continue rotating the selected items by making a
copy each time you set a new angle.
3.4.13.2.1 3D machining axis rotation
The rotation command is also applicable to 3D flush milling, finishing, 3D milling and inclined
hole machining. If one of these machining types is selected, the command sets itself to 3D
mode and requests an axis (instead of a point) around which to rotate the machining.
If ''Single sequence'' mode is enabled, only the 3D drillings can be rotated around the axis, as
they are not associated with surfaces; if "Multiple sequence" mode is enabled, each time the
Enter key is pressed, multiple copies of the selected 3D machining will be created, each rotated
(cumulatively) around the selected axis (with the same rotation modes as a surface around an
axis) by an amount equal to the specified angle.

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3.4.13.3 Mirror
It mirrors one or more entities compared to the axis of the centre line in the work face.
The command is available in the menu "Draw" "Modify" as well as in the "Contextual menu”.
This command works only in case of standard faces.
In order to mirror one or more entities:
- click on the command "Mirror”
- select the mirror mode in the menu
- click on the button "Apply"
This commands has five options:
- Mirror in X
- Mirror in Y
- Mirror in X/Y
- Keep in the source form
- Invert the working process
The option "Mirror in X” mirrors the geometry compared to the Y-axis of the centre line in the
active face.
The option "Mirror in Y” mirrors the geometry compared to the X-axis in the middle of the active
face.
The option "Mirror X/Y" mirrors the geometry compared to the X and Y axis in the middle of the
active face (this mode is like a rotation of 180°)
The option "keep the source geometry" allows you to make a copy out of the source geometry.
The option "Invert working process” allows you to invert the direction of the working process if
the command "Mirror” is used to mirror a working process.

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3.4.13.4 Oppose
It copies one or more entities on the standard face opposite to the active one.
The command is available in the menu "Draw" "Modify" as well as in the "Contextual menu”.
This command works only in case of standard faces.
In order to copy one or more entities on the opposite standard face:
- click on the command "Oppose”
- click on the button "Apply"
- Keep in the source form
- Invert the working process
The option "keep the source geometry" allows you to make a copy out of the source geometry).
The option "Invert the working process” allows you to invert the working direction if the
command "Oppose" is used for a working process.

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3.4.13.5 Cut
It cuts one or more geometric elements or working processes in order to put them in the buffer
for the option "paste”.
The command is available in the menu "Home" "Clipboard" as well as the "Contextual menu”
and works only for elements of the active face.
In order to cut one or more entities from the active face.
- click on the command "Cut” or press "Ctrl-x"
- type one reference point.
As a result of the geometry of the selected working process it will disappear from the display.
3.4.13.6 Copy
It copies one or more geometric elements or working processes in order to put them in the
buffer of the option "Paste)
The command is available in the menu "Home" "Clipboard" as well as the "Contextual menu"
and works only for the elements of the active face.
In order to copy one or more entities from the active face:
- click on the command "Copy” or press "Ctrl-c".
You do not notice any effect but the previously selected geometry will be available to be copied
through the option "Paste”
3.4.13.7 Paste
It pastes one or more geometric elements or working processes that have previously been
selected from the option "Cut” or "Copy”
The command is available in the menu "Home" "Clipboard" as well as the "Contextual menu”
In order to paste one or more entities on the active face:
- click on the command "Paste” or press "Ctrl-v"

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3.4.14 Dimensioning
This function is used to enter only linear or angular quotas.
To enter a dimensioning use the "Linear dimensioning" or "Angular dimensioning" commands
on the "Change" menu.
After having selected the dimensioning command, a dialogue menu will appear asking you to
enter the selections to enter the dimensioning requested.
By default the dimensionings are lost, if you want to save one or more quotas on the project,
select the "Permanent" option before entering each quota.

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3.5 Working processes
The commands in order to insert the working processes are to be found in the menu
"Operations”
Every working process must be carried out combining a tool with a 2D geometry.
As a result, it is necessary to activate a Tool- Data-Base (see paragraph 12.8)
In order to set any working process, it is useful to keep this structure in mind:
1) Set the position in which you carry out the working process (Pos)
2) Set the Geometric Shape of the working process (Geo)
3) Set the Work mode (Mode)
4) Set the technology adopted (tool, speed and so on).

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3.5.1 Boring
In order to bore, you can:
- click on the command "Boring”
- select one or more 2D elements
Or:
- click on the command "Boring”
The selection of 2D elements can be single or multiple as the
option for boring will make bores connecting them with the
points or the circles.
3.5.1.1 Bore position
If, among the selected elements, there are points and/or
circles, the bore position is automatically set.
If no point or circle has been selected, you can set the
position of a new point in this way:
- select the reference face
- select the reference edge on the face
- fill the field X Coordinate in
- fill the field Y Coordinate in
The reference edge on the face allows programming the hole with
X and Y coordinates that are related to the user-selected
reference point. In the case of pwx100 machines, if you want to
draw holes with coordinates relative to the mechanical zero of the
machine, for the upper face holes you must select the left upper
edge.

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It is possible to set a set of matrix bores by using the sub-menu "Repetitions”
to this purpose, the nearby menu fields must be filled in.
Rotat. 1 represents the angle to set the lines
Rotat. 2 stands for the angle to set the columns compared to the
lines
By clicking on the button "Preview", you obtain a
representative table that displays the bore position as
described above.
3.5.1.2 Bore structure
In order to set the bore structure, Diameter, Depth and bore Type must be set in the menu.
In field "Depth" you will insert the value corresponding to the
thickness of the workpiece in case the option "Passer-by” is
selected.
If the "boring" operation has been performed by selecting a
circle rather than a point, the field "Bore diameter” will be filled
with the value of the circle diameter.
In this case, if you wish to change the diameter, you can
unmark the heading "Keep circle diameter” and set a new
diameter.
The field "Extra depth is filled with the extent through which the bore must go beyond the
thickness of such workpiece (this heading will appear only if the option "Passer-by" has been
selected")
The type of bore must be specified when it is not linked to a drilling tool and in this case, in order
to choose the tool, you need this information.
The hole types are as follows:
- Hole with flat bottom
- Hole with tapered bottom
- Counterbored hole in top part and with tapered bottom
- Blitz hole (with two diameters)
Select the types from the "Type of hole" field

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3.5.1.2.1 Data entry for countersunk holes
When creating a countersunk hole, it is very useful to specify the depth of the countersink;
however, it is difficult to directly measure this depth and verify
whether a hole has been made precisely or not.
For this reason, next to the Countersink depth value, the
Countersink diameter has now been inserted (text field in
read-only, non-editable) which shows the expected diameter of
the countersink for the hole being made.
The reported countersink diameter is automatically calculated
based on the specified countersink depth, its diameter and
assuming the countersink is at 45°. This value can be easily
measured with a gauge and allows you to directly check the
accuracy of the hole once it has been made in the machine.
3.5.1.3 Boring mode
In order to set how to structure the bore, you use the sub-menu "Strategy”
The bore can be performed in a single or a multiple rub.
The following can be set with multi-pass:
- the "Number of passes" required to make the hole.
- The "Pass depth" visible when selecting "Enable
pass depth" field.
3.5.1.4 Boring technology
In this step, you set all technical aspects related to tools,
spindles and machines at disposal.
See the following chapters:
3.5.15 Technological data (shared by the machining operations)
3.5.17 Advanced data (common to machining)
3.5.18 Machine data (shared by the machining operations)
A speed profile can be set by selecting it from the drop down
menu of the “Technological data – Speed profiles" section (the
description of the speed profile can be found in chapter
3.5.2Speed profiles)

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3.5.1.4.1 Drilling speed
The drilling feed speed can be set in the tool definition section (chapter Errore. L'origine
riferimento non è stata trovata.)
The section where the drilling speed can be set is from the safety quota to the hole end. This
section is partly outside the wood and partly inside.
If the“Feed” field of the “Machining parameters” is not filled the hole is drilled at the
"Downstroke speed →Standard"
If the“Feed” field of the “Machining parameters” is filled the hole is drilled at the slowest
speed between the speed set and the "Feed speed → Maximum”
Examples:
Tool data set:
Example 1
Value not set:
Feed equal to the Standard downstroke speed 5 m/min
Example 2
Value set at 9 m/min:
Feed 9 m/min (as it is slower than the Maximum feed speed
parameter 10 m/min)
Example 3
Value set at 12 m/min:
Feed 10 m/min (as it is faster than the Maximum feed speed
parameter 10 m/min)
Note: there are no controls for the minimum programmed speed, except for entering
negative values when editing in Maestro CNC, that is:
the error is signalled with a red box and the datum cannot be
validated/saved.

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3.5.1.5 Drilling deduced from the surface
If a cylindrical surface is selected which refers to a hole, all the geometric parameters of the
dialog boxes will be automatically filled.
In the case of multiple selection of coaxial surfaces of suitable shape and position, the system
can recognize flared or counterbored holes.
The user can still modify the precompiled fields.
If a through hole is recognized, if possible a lance point will be used and a depth determined to
guarantee the through hole.
The condition in which the hole is made is that the hole axis is orthogonal to one of the six
planes of the part or to a previously created user plane.

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3.5.2 Speed profiles
When drilling there is the risk of damaging the material being machined.
To prevent this you can vary the tool insertion speed during the whole drilling phase (initial
phase, intermediate phase, final phase and countersink phase).
To set the parameters go to "Tools - Speed
profiles - Create profile". A window will
appear to create various speed profiles.
The following window will appear
to set the various parameters in the specific sessions.
3.5.2.1 General data
This section is used to enter:
- Profile name
- Gain to apply to the Jerk

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3.5.2.2 First entry (initial phase)
This section is used to set the speed during the entry of the tool in the panel being drilled. You
can also set from when it has to have this speed (Early, e.g.: From 0.5 mm from the piece) to
when the entry phase ends (Late, e.g.: From 1 mm from the piece).
Click on “Add” (on the bottom left of the “Technological data”sector) to add the speed that it
must have during the phase based on the different tool diameters.

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3.5.2.3 Feed (intermediate phase)
This section is used to set the speed of the tool in the next phase and before the final phase
(this is the intermediate phase). Various speeds can be selected based on the tool diameter.

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3.5.2.4 Exit (final phase)
This section is used to set the speed during the exit of the tool from the object being drilled. You
can also set from when it has to change this speed (Early, e.g.: From 0.5 mm from the piece) to
when the exit phase ends (Late, e.g.: From 1 mm from the piece). The speed can be selected
based on the tool diameter.

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3.5.2.5 Second entry (countersink phase)
This section is used to set the speed during the entry of the countersink/blading in the panel
being machined. You can also set from when it has to have this speed (Early, e.g.: From 0.5
mm from the piece) to when the countersink phase ends (Late, e.g.: From 1 mm from the
piece). The speed can be selected based on the tool diameter.

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3.5.2.6 Return
This section is used to set the speed of the tool path section from the machining end to the
safety quota to remove the tool from the piece.
The speed can be selected based on the tool diameter.

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3.5.2.7 Change speed profiles
To check or change the parameters go to
"Tools - Speed profiles - Display profile".
A window will appear with the list of all the profiles created up to then.
Right click on the profile to select the following items:
- Properties
- Copy
- Delete
Select Properties to open the section 3.5.2 Speed profiles
Select Copy to create a copy of the speed profile
Select Delete to delete the selected speed profile

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3.5.2.8 Using the speed profiles
The speed profiles created can be used in two ways:
the first method consists of setting a profile created directly in the drilling properties. (See
chapter 3.5.1.4 Boring technology)
the second method consists of creating a “Table of profiles” (that can be set as preset),
To create a table of profiles go to
"Tools - Table of profiles - Create
profile".
- Create profile". A window appears
to create various tables of profiles.
By creating a table of profiles you can set the profile (created previously) based on the tool and
table used to work.

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3.5.2.8.1 Table of profiles default
To set a table of profiles as default go to “Tools– Options – Preferences – Files of the table of
the drilling technology and select one of the previously created Table of profiles.

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3.5.3 Inclined drilling
To insert one or more holes we can:
- click on the "Drilling" command
Or:
- click on the "Drilling" command
The 2D elements selected can be single or multiple because the
"Inclined drilling" function will produce holes by associating them
only with the points or circles.
3.5.3.1 Position of the inclined hole
If the selected elements have points and / or circles, the position
of the holes is determined automatically.
If no point or circle has been selected, the position of a new point
can be defined by entering the coordinates X, Y, Z
3.5.3.2 Shape of the inclined hole
To define the shape of the hole, the Diameter, Depth, Angles A and B Type of hole must be set
in the menu.
If drilling was done by selecting a circle instead of a point, the "Hole diameter" field will
represent the value of the circle diameter.
The Type of hole must be specified when no tool is associated with the drilling, and in this case,
this information is needed to make the automatic tool selection.
The types of hole are the following:
- Hole with flat bottom
- Hole with conical bottom
- Flared hole in the upper part and with a conical bottom
- Counterbored hole (Blitz)
The types can be selected from the "Hole type" field
The angles A and B are used to determine hole inclination.

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3.5.3.3 Inclined drilling mode
The same applies to drilling
3.5.3.4 Inclined drilling technology
The same applies to drilling
3.5.3.5 Drilling deduced from the surface
If a cylindrical surface is selected which refers to a hole, all the geometric parameters of the
dialog boxes will be automatically filled.
In the case of multiple selection of coaxial surfaces of suitable shape and position, the system
can recognize flared or counterbored holes.
The user can still modify the precompiled fields.
3.5.4 Automatic drilling deduced from the surfaces
This function recognizes all the inclined holes and holes present in the selected surfaces.
To use this function, use the "Automatic
hole recognition" command in the
"Operations-3D Machining" menu
The operating mode is similar to that described in drilling and inclined drilling with the following
additional functions:
"Create User Plan for 3D Drilling" Creates a plane
for each recognized inclined hole.
"Fast surface analysis" will only recognize
cylindrical holes and involves a low processing
time.By removing the check to this parameter, also countersunk and counterbored holes will be
recognized at the cost of longer processing time.
Once the surfaces to be analysed have been selected, the maximum diameter below which the
surfaces are recognized as holes must be set.
The generated holes will start from the work plane closer to the hole geometry.
It is advisable to check the correct assignment of the tools which will perform inclined drilling.
If more than one hole has been generated on the same user plane, it is advisable to check that
they can be implemented by switching to the safety level from the user's plane, otherwise the
programming must be corrected.

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"Circular pocket milling for too large holes"
The automatic hole recognition command requires the maximum diameter for which a cylindrical
cavity is recognised as a hole. This new option has been introduced to indicate whether or not
you want any cylindrical cavities with a diameter greater than the maximum allowed to be
recognised as circular pocket milling.
By activating this check box, all holes with a diameter greater than the set value will be
converted into circular pocket milling applied to the most appropriate plane. The tool will be
selected from the cylindrical cutters on the basis of the diameter and a message invites the user
to view the tool together with the various technological default parameters. If an appropriate tool
cannot be identified for one or more circular pocket millings, these are still created but a
message indicates the absence of a tool and invites the user to specify a suitable tool.

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3.5.5 Milling
In order to insert one or more milling operations you can:
- click on the command "Milling”
Or:
- click on the command "Milling”
The selection of 2D elements can be single or multiple
because the function "Milling" will perform milling operations
connecting them with lines, polylines, arcs and circles.
3.5.5.1 Miling position
If there is any line and/or polyline and/or arc and/or circle
among the selected elements, the milling position is
automatically set.
The real position of every milling is affected by the used tool
correction and the super-material.
In the following tables it is possible to understand how the different combination of options work.
The light blue line stands for the "2D geometry" and the red line represents the tool path in the
tool centre.
By marking "Correction C.N.”, it implies that the coordinates of the 2Dgeometry are passed and
the effective path (red line) will be calculated by the CN.
If you mark "Cad correction”, the coordinates of the red line are directly transferred to the CN
and this latest will not make any correction.

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Behaviours with left, central and right corrections without any correction in length and without
any super-material.
Behaviours with left, central and right corrections in length and without any super-material.

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Behaviours with left, central and right correction without any correction in length and with super-
material.
Behaviours with left, central and right corrections in length and with super-material.

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3.5.5.2 Milling form
In order to set he milling form you have to set Length and Depth in the menu.
The field Width is automatically filled when a tool is
connected with the milling.
thickness of the workpiece in case the option "Passer-by is
selected.
The field "Extra depth" sets the extent of the milling to cross
the workpiece. (This heading will appear only the option
"Passer-by" has been selected)
The field "Indivisible processing" (currently used only for CX machines) ensures that such
machining is not performed in one or more stages for those automatically generated when using
CX
If an error is generated during the optimisation phase, the operator must replace the machining
operation with the selection with two or more machining operations that produce the same
operation.
3.5.5.3 Milling modes
In order to set how to perform the milling, you use the sub-menus "Strategy" and
"Approach/Removal".
The milling can be performed only in one or more rubs.
In case of "multi-rub", you must choose between One- way or
two- ways strategy.
In the "one-way strategy", you have to establish if the rise
between two rubs must occur:
- at a safety level on the workpiece
- or in the workpiece
Use the "Tools" "Options" "Parameters" "Machining" menus to
modify these two parameters.

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For the one-way strategy as well as for the two ways strategy,
the heading "Enable multi-rub” must be marked and the values
"Rub depth” and depth "Last rub.”
If you leave the Pass depth parameter at zero and set only the
Last pass parameter, a first pass will be made at the set depth
minus the value set in Last Pass, and a second, last pass will
be made at the final depth.
Both numerical values and user parameters can be entered in
the fields relating to the two parameters.
For uni-directional strategy with multiple passes you can
extend the multiple passes to input and output sections by
placing the flag on “Enable input”
Another modification to the milling mode can be set by the menu "Advanced data" through the
parameter "Invert".(See 3.5.17 Advanced data (common to machining)
By marking this parameter, the working process can be performed starting from the final point of
the selected 2D geometry.(See 3.5.16 Approach/Retraction (shared by the machining
operations))
3.5.5.4 Milling technology

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3.5.6 Slanted routing
To enter one or more tilting routing proceed as follows:
- click on “Tilting routing”
Or:
- click on “Slanted routing”
The 2D elements selection can be single or multiple.
3.5.6.1 Tilting routing position
The position of the tilting routing is determined automatically by the geometry selected.
The tool correction is available only if the tool is perpendicular to the right or left and the Angle A
is equal to 0.
To use the tool correction see chapter 3.5.5.1 Routing position.
3.5.6.2 Tilting routing shape
To define the tilting routing shape set the parameters in the menu:
The “Width” is set automatically based on the diameter of the tool
selected (cannot be edited).
The “Depth” is the position Z in relation to the plane selected.
The “Angle A” indicates the tool rotation in relation to axis X
The “Angle B” indicates the tool rotation in relation to axis Z.
The “Tools position” can be set in the 5 modes visible in the menu.
Bear in mind that the positions are considered before the setting of
the “Angle A” parameter.
By selecting “Parallel axis X” the tool axis will be parallel to axis X,
angle B will rotate the tool in the X-Z plane.
After having selected this mode, setting Angle A the tool axis will
no longer be parallel to axis x.
During the whole tilting routing in this mode the tool will always
maintain the same setup.
Selecting “Perpendicular to the right” the tool will enter from the

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right in relation to the first geometrical entity of the trajectory.
The setup will be maintained for the whole machining operation.
Selecting “Perpendicular to the left” the tool will enter from the left in relation to the first
geometrical entity of the trajectory.
Selecting “Parallel start point” the tool will position itself with an inclination of Angle B set in the
plane of the first geometrical entity of the trajectory.
Selecting “Parallel trajectory” the tool will position itself with an inclination of Angle B set in the
plane of the first geometrical entity of the trajectory.
The setup will be recalculated in the same for each subsequent geometrical entity of the whole
machining operation.
3.5.6.3 Tilting routing mode
To define how the tilting routing is performed use the “Approach/Retraction” submenu.
See the use of the parameters of the “Approach/Retraction” menu in paragraph 3.5.16
Approach/Retraction (shared by the machining operations)
The arc approach and retraction are disabled.
3.5.6.4 Tilting routing technology

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3.5.7 Chamfering
To enter one or more chamfering proceed as follows:
- click on “Chamfering”
Or:
- click on “Chamfering”
The 2D elements selection can be single or multiple.
3.5.7.1 Chamfering position
The position of the chamfering is determined automatically by
the geometry selected.
3.5.7.2 Slotting shape
To define the slotting shape set:
The position of the tool in relation to the geometry (see “Tool position” icons).
The chamfer width quota measured on the plane selected.
The chamfer height (quota measured at right angles to the plane selected).
The chamfer angle is determined automatically after setting the width and height.
The “Extra depth” field is used to move the tool beyond the height set.

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3.5.7.3 Chamfering mode
To define how the chamfering is performed use the “Approach/Retraction” submenu.
See the use of the parameters of the “Approach/Retraction” menu in paragraph 3.5.16
3.5.7.4 Chamfering technology

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3.5.8 3D routing
To enter a 3D routing click on “3D routing” in the “Routing” menu.
The geometry cannot be selected, but entered by points.
The tool inclination can be associated to each programmed point.
3.5.8.1 3D routing position
The 3D routing position is determined by all the points entered during the machining definition.
The tool correction is not available.
3.5.8.2 3D routing shape
The 3D routing shape can be a segment or a broken line of
various segments.
To define the 3D routing shape set the coordinates of the
various points of the broken line.
The “Angle Q” indicates the tool rotation in relation to axis Z.
The “Angle R” indicates the tool rotation in relation to axis X
The tool will maintain the same setup for the whole machining
of the defined section.
To enter other sections use the “Enter point” key.
To see the points entered use the right and left arrows to
navigate in the broken line.
To delete a point use "Z".
3.5.8.3 3D routing mode
The “Approach/Retraction” mode cannot be used.
3.5.8.4 3D routing technology

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3.5.9 Scoring
The scoring is used to create a machining identical to the geometry in the project, even if it has
sharp edges.
To do this use only conical or trimming-conical tools.
Another limit is that it can only be applied to a closed geometry.
Another limit is that the maximum scoring depth will be equal to the
height of the conical part of the tool.
To enter a scoring use the "Scoring" command in the "Routing sub
menu.
3.5.9.1 Scoring position
The scoring position is determined implicitly by the position of
the geometry selected.
3.5.9.2 Scoring shape
The scoring shape is determined by the geometry selected and
by the value set in the "Offset" field that lets you create a
machining with a parallel geometry greater or smaller than the
original one.
3.5.9.3 Scoring execution mode.
The scoring processing can be divided in three parts:
- Internal trimming
- Corner Cleaning
- Pocketing
The internal trimming, selected with the "Profile only", performs
a machining inside the geometry selected at the maximum
depth equal to the one set.
If two sides of the geometry are very close the depth will be
reduced progressively to follow the shape of the geometry
being machined.
In other words the machining is performed with a dynamic
diameter correction.
By selecting the Pocketing option, all the area inside the
geometry selected will be machined with the depth set.
The "Only corner cleaning" option is used to machine the parts
remained filleted by a previous machining with a trimming-
conical tool.

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Selecting this item will display the request for the smaller diameter of the trimming-conical tool
used in the previous machining.
The machining will clean only the parts that will were left filleted.
Using the "Complete machining" option will perform the internal profiling and pocketing phases
at the same time.
See the use of the parameters of the “Approach/Retraction” menu in the paragraph 3.5.16
3.5.9.4 Scoring technology
3.5.17 Advanced data (common to machinings)

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3.5.10 Channel
The channel is a milling process with one limit and some added-values compared to the general
milling process.
The limit is due to the fact that the channel can be applied only for a line.
The added-values will be showed in the menu explanation.
In order to insert one or more channels, we can:
- Click on the command "Channel”
Or:
- Click on the command "Channel”
The selection of 2D elements can be single or multiple because the function "Channel" will
perform milling cutters associated with the lines.
3.5.10.1 Channel position
if there is any line among the selected elements, the channel
position is automatically set.
If no line has been selected, the position of a new line can be
set in this way:
- select the reference face
- fill the X field initial point
- fill the Y field initial point
- fill the X field final point
- fill the Y field final point
The real position of every milling is affected by the used tool
correction and the super-material.
In the tables in paragraph 3.5.5.1(milling position) it is
possible to understand how the different combinations of
options work.

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We can also change the channel position by using the
parameter "Enable edge” in the sub-menu "Advanced data".
By using this function, the selected segment will be stretched
until it crosses the panel edges.
You can also have a channel extension if you activate the
paramters "Extra initial distance” and "Extra final distance”.
3.5.10.2 Channel structure
In order to set the channel structure, Length and Depth
must be set in the menu.
The field Width is automatically filled when a tool is
connected with the channel.
selected.
It si possible to set a "Final Depth (associated with the final
point of the geometry) different from the one associated with
the final point).
Enter the channel's inclination value, varying from 0° to
180° (not included) in the "Angle °" field. (90° =
perpendicular channel to face)
3.5.10.3 Channel execution mode
The channel execution mode looks like the milling mode
(see paragraph 3.5.5.3).
3.5.10.4 Channel technology
3.5.10.5 Channel deduced from surface
If a flat surface is selected, all the geometric parameters of the dialog boxes will be
automatically filled.
The user can modify the precompiled fields and must insert the blade to be used.

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3.5.10.6 Channel wider than disc thickness
A channel with a width greater than the thickness of the disc can be created using the "Parallel
passes" pass generating strategy
Example:
1) A channel is created in any plane by defining all the dimensions
2) Select a blade tool:
3) The Parallel passes strategy is set,
unlocking the box to set the channel width:
4) The desired channel width can be set

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5) Proceed to define the other processing parameters:
- By enabling Length correction in the Tool correction section, Maestro also
takes into account the size of the disk radius for the length of the channel.
- Cutting direction in the Parallel passes section''
o From left to right: the path starts from the left of the longitudinal symmetry
of the channel and moves to the right
o From right to left: the opposite direction

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3.5.11 Blade cut
In order to insert one or more blade cuts you can:
- click on the command "Blade cut”
Or:
- click on the command "Blade cut”
The selection of 2D elements can be single or multiple because the option "Blade cut" will
performs cuts associated with the lines.

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3.5.11.1 Cut position
Blade cuts can be performed only on lines on the upper
face.
If there are lines among the selected elements, the cuts
position is automatically set.
If no line has been selected, the position for a new line can be
set in this way:
- Fill the X field initial point
- Fill the Y field initial point
- Fill the X field final point
- Fill the Y field final point
- fill the Inclination field
The real position of every cut is affected by the used tool
correction and by the super-material.
In the tables in paragraph 3.5.5.1(milling position) it is
possible to understand how the different combinations of
options work.
We can modify the cut position using the sub-menu
"Advanced data”
The parameter "Enable edge” extends the selected segment
until the cross of the panel edges.
You can extend it using the parameters "Extra initial dist." and
"Extra final dist."
By using the parameter "Lower reference” the selected
geometry will lie on the lower face.
This working process generates also a work plane on one of the
two surfaces caused by the cut.
The surface will be created on the new external face of the
workpiece, so you must specify the material placement after the
cut using the parameters "To the right of the geometry" "To the left
of the geometry".

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3.5.11.2 Cut structure
In order to set the structure of the blade cut, Length and
Extra Depth must be set in the menu.
The field Width is automatically filled when the blade is
associated with the cut.
The Depth (whose field is not present) will correspond to the
thickness of the workpiece.
The field "Extra depth” indicates the extent of the cut
overcoming the thickness of the workpiece.
3.5.11.3 Cut mode
Use the following as cutting mode:
- The "invert" function
- The "Cutting" Strategy
See "Advanced Data" menu in paragraph 3.5.5.3 (Milling mode) for use of "Invert" parameter
The "Cutting" strategy foresees incision for equal length to the
selected geometry, without cutting the workpiece at
"Incision depth", increased by the "Outlet distance".
The blade descends at programmed depth at end of first
incision, simultaneously moving outside the cut equally to
"Side movement" height. The cut will be completed by
returning to initial point.
Note: Side movement accepts values from -0.5 to +0.5m included.
3.5.11.4 Cut technology
3.5.11.5 Cut deduced from the surface
If a flat surface is selected, all the geometric parameters of the dialog boxes will be
automatically filled.
The user can modify the precompiled fields and must insert the blade to be used.

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3.5.12 Contouring
The contouring is a milling that can apply the external contour of the workpiece or the
geometries.
In order to perform the contouring to the external
workpiece:
- click on the command "Contouring"
The resulting menu will show you the parameter of the
selected "workpiece".
By inserting the workpiece contouring, a closed polyline will be
created on the upper face, that overlaps with the external
profile of the workpiece.
In order to insert one or more geometric contouring, you can:
- click on the parameter "Geometry"
Or:
The selection of 2D elements can be single or multiple
because the contouring will perform millings associated only
with closed polylines or with circles.
3.5.12.1 Contouring position
The contouring position is automatically set by the selected geometry.
If the contouring is set to the geometry, then it is possible to choose the "Eternal" "Internal"
"Side" from the menu where you can set it.

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3.5.12.2 Contouring structure
In order to set the contouring structure, you must set Length and Depth in the menu.
The field Length is automatically filled when you associate a tool
to the contouring.
selected.
The field "Extra depth" sets the contouring extent to go
beyond the workpiece (This heading will appear only if the
option "Passer-by" has been selected)
The contouring leaves extra material for subsequent
machining thanks to the "Excess-material" field.
3.5.12.3 Contouring modes
See the use of the parameter “Invert” of the menu Advanced data in the paragraph 3.5.17
Advanced data (common to machining)
See the use of menu parameters "Approach/Removal” in paragraph 3.5.16 Approach/Retraction
(shared by the machining operations)
3.5.12.4 Contouring technology

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3.5.13 Emptying
In order to insert one or more empty workpieces you can:
- click on the command "Emptying"
Or:
- click on the command "Emptying"
The selection of 2D elements can be single or multiple since the
option "Emptying" will carry out working processes
associated with closed polylines or with circles.
For "gripper" machines (CXS and CXHP), embroidery work is carried out within the same
stapling phase and is not automatically broken.
So if an emptying that is X in size X above the stroke X of the CXS clamp or the pitch between
CXHP clamps is programmed, Master does not optimize the program by communicating this
error:
In this case it is up to the operator to break the pockets in multiple overlapping pockets and
reduced X size
3.5.13.1 Emptying position
The emptying position is automatically set by the selected geometry.

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3.5.13.2 Emptying structure
In order to set the emptying structure, you have to set Length Cut and Depth in the menu.
The field Length cut is automatically filled when you
associate a tool with the emptying.
selected.
The field "Extra depth" indicates the extent of the emptiness on
the workpiece ( This heading will appear only if the option
"Passer-by" has been selected).
3.5.13.3 Emptying mode
In order to set how to perform the milling, you use the sub-menus "Strategy" and
"Approach/Removal.
The strategy "Parallel to the contour" aims at making a set of
polylines to a certain offset from the selected polyline.
The space among polylines is calculated according to the
tool-diameter and the parameter Overload. (%).
For a multi-rub management, see paragraph 3.5.5.3 (milling
modes)
See the use of menu parameters "Approach/Removal” in paragraph 3.5.16 Approach/Retraction
(shared by the machining operations)
3.5.13.4 Emptying technology

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3.5.13.5 Recognition of pocket milling from 3D model
It is possible to recognise a pocket milling starting from the selection of a flat surface that
represents the bottom of the intended pocket. As when selecting a closed curve to make a
pocket, it is possible to select a flat surface parallel to an existing plane (from among the
standard planes or those created by the user). If a plane parallel to the selected surface is not
found, an error message is given, otherwise the external profile of the surface is constructed on
the fly and used for the pocket milling. The distance of the surface from the parallel plane is
considered the depth of the intended milling. If the flat surface is to have slots, you are asked if
you want to take these into consideration: if so, the contour geometries of the slots will also be
built and the pocket milling will take them into account, otherwise these will be ignored and the
pocket milling will be done in passes parallel to the pocket contour only.
3.5.14 Work on the lower face
You must have a Weldon head to perform work on the lower part of the workpiece.
The head should be configured correctly following the instructions in the chapter 12.9.1.7.1.
Using the Weldon head requires you to program the machining exclusively on the lower face of
the workpiece.
When working with the Weldon head, an "Angle" field will
appear, indicating the orientation (around the Z axis) that will
have to be headed during machining.
This angle will be calculated beforehand by Master who will
achieve the approach to machining from the side closer to the
machining itself.

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This chapter describes those parameters common to most machinings in order to group the
description.
The "Technological Data" session is used to:
Select the head for the machining.
Selecting "Automatic" the system will determine which head to use
for the machining.
Select the tool for the machining.
Set the feed speed during the machining.
Set the number of spindle RPMs.
For pwx100 machines in the "Technological Data" section you can:
Select the head for the machining. Selecting "Automatic" the system
will determine which head to use for the machining.
Select the Head Group you want to use to do the work. Selecting
"Automatic" the system will determine which head to use for the
machining. To select a heads group, you must select the machine
with which to perform the machining.
Select the head for the machining. Selecting "Automatic" the system
will determine which head to use for the machining. To select a
head, select the group of heads with which to work.
Select the Spindle with which to do the work. To select a spindle,
select a head and activate the "Spindle Selection"
Set the feed speed during the machining. Please note that the
actual speed used in the machine may differ from the one shown
here, depending on the machining couplings operated by the
optimizer by the technology profiles associated with the machine.
Set the number of spindle RPMs.
3.5.16 Approach/Retraction (shared by the
machining operations)

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In the menu "Approach/Removal" you set the in-and-out mode from the milling path.
For the entry as well as for the exit, you can choose the line or
arc geometry.
The length of these paths is set by "Radius multipl." that, in
case of a milling cutter of 10 radius and a multiplier of 1.2, a
length line of 12 will be added to our path or a radius ray of 12
with a width of 90° and tangent to the initial/final point or the 2D
geometry.
These additional properties can be performed by the machine:
- in case of security level (on level)
- while the point of approach in reached (in fall)
- while the point of removal is reached (in rise)
The surmount is the workpiece worked along the first object of
the polyline.
if this value is higher than the length of the first polyline
element, the working process would end in the last workpiece
of the element.

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3.5.17 Advanced data (common to machinings)
This chapter describes those parameters common to most machinings in order to group the
description.
The "Advanced Data" menu is used to:
Invert the machining, starting from the final point of the
geometry selected.
Enter a condition that determines whether the machining must
or must not be executed.
Set the start point automatically at:
- In the middle of the first section
- In the middle of the longest section
Enter a comment.
Enter a "Safety quota" for the tool before executing the
machining.
Set the execution priority.
This parameter allows you to group project machining while maintaining the technological
sequence during optimization.
Optimization is done in these cases:
1. When you plan to machine 2 or more workpieces on the surfaces
2. When processing a workpiece on CX machines
When machining multiple workpieces on the surface, the Master Trainer Optimizer may change
the technology sequence.
To maintain the desired technological sequence, you must define the operational priority for all
the jobs which need to remain related by inserting positive and increasing values.
If a Priority value is lower than or equal to the previous one, the batch will be interrupted.
When working on the CX machine, machining associated with increasing Priority values will be
performed at the same stage.
Such method is due to accuracy problems with CX machines when the piece is moved from one
stage to the other.
Machinings consisting of more tool paths: for example, a counterboard hole made with two
different tools might be imprecise if machining consists of two stages.
"Execution priority" mode requires the insertion of a growing value in all machinings that need to
be performed in the same stage.
When the value is equal to zero or to another value that is lower than the last one entered, the
series of machinings to be performed in the same stage is interrupted.

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Example of pgmx
- Hole Execution priority = 1
When this program is optimised, holes 1,2,5 shall be executed in the same stage, and holes
3,4,6 shall be executed in the same stage too although this is different from the first one.
You want to prevent hole 1 from being in a different stage compared to holes 2 and 5.
For pwx100 machines in the "Advanced Data" menu, you can:
Set the Processing Priority of the Processing with reference to the following rules:
- Priority 0: Workmanship is not priority over other workmanship, its execution can take
place before, after, or at the same time as other workings, regardless of the priority value
of the latter.
- Priorities 1 to N: Work must be done after all jobs have a priority value other than zero
and lower than the one set for machining, but before all those with a value other than
zero and higher than working priority value. If two jobs have the same priority value, this
does not imply their execution at the same time, but only the use of the same sorting rule
for both.
Set the "reference point" of the machining. This parameter
allows you to specify the reference point that will be
considered for machining machining machining offset after
panel measurement. For each machining you can specify the
reference point by choosing between the four edges of the workpiece or the center point of the
workpiece.
If the user does not specify any reference, during the optimization phase the machining will be
assigned the default reference for the work face. Below is the table of default references, used
for pwx100 machines with upper left stop of the workpiece:
Work face Default reference
Upper Upper left
Left Lower left
Right Lower right
Front Lower left
Rear Lower right
Lower Lower left

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This chapter describes all the "Machine functions" that can be found in most machining
operations to group the description.
The machine functions available depend on the machine configuration, therefore instead of
describing them together they will be described individually.
This session will probably have a certain amount of dynamism, as it manages devices in the
machine that in the future may be removed or new ones may be added.
The machine functions currently available are:
1) Jerk
2) Jerk3D
3) Main hood
4) Additional hood
5) Rotating axes brakes
6) 5-axes head unrolling
7) Electronic feeler
8) NC speed adjustment
9) Tool blower
10)Mechanical hold-down
3.5.18.1 Jerk
This parameter affects the machine behaviour during the bi-
dimensional machining operations.
The "Adjustment" parameter is set with a value that is significant
from -2 to +5.
With the -2 value the machine will be slow but the machined pieces
will have a good finish.
With the 5 value the machine will be fast but the machined pieces
will not have a good finish.
Selecting the "Spline interpolation" parameter the finish will improve when the machining has
been described with some "Splines" as the edge will be rounded.

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3.5.18.2 Jerk3D
This parameter affects the machine behaviour during the three-
dimensional machining operations.
One of the items from the drop down menu at the side can be
selected.
Selecting "Roughing" the finish will be less accurate
Selecting one of the 3 Finishes the finish will improve.
Generally, as various factors can affect the finish, it is advisable to
perform tests in the machine until the desired finish is achieved.
3.5.18.3 Main hood
This parameter is used to position the main hood of the machining
unit in 5 positions that can be selected from the drop down menu at
the side.
Selecting the "Automatic" option the hood will position itself so that it
skims the surface of the piece.
It will position itself at a value which is the tool length minus the
useful length.
3.5.18.4 Power hood
If you have a machine with a power hood, you will see the following
menu:
Checking Select enables the hood, otherwise it will remain raised.
Checking Automatic causes Maestro to automatically calculate the
position of the hood.
If you do not check Automatic, the hood will position itself in the
preset position.
Auto adaptive will only appear if your machine has this feature.
Checking Auto adaptive allows you to move the hood upwards or downwards dynamically along
the machining path.
The Offset centring value represents permitted hood deviation from the programmed position.
3.5.18.5 Additional hood

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This parameter is used to position the additional hood of the
machining unit in 5 or 8 positions that can be selected from the drop
down menu at the side.
The number of positions displayed depends on the machine
configuration.
3.5.18.6 Rotating axes brakes
The braking of the rotating axes is used in order to improve the
finish of the machined piece.
Braking the rotating axes reduces the vibrations due to the fact that
the motor maintains the rotating axis constantly in position.
The axes that can be braked can be selected from the drop down
menu and depend on the machine configuration.
3.5.18.7 5-axes head unrolling
This function is used when wanting to continue
machining rotating always clockwise or counterclockwise
with the machining unit.
The machine, in order to execute the machining
requested once it reaches the axis limit switch, must
reposition the axis on the opposite limit switch.
to do this:
- the tool must be removed from the piece
- the head rises in Z
- the axis goes to the opposite limit switch (in jargon it
"unrolls")
- the head drops back down in Z
- the tool must return to the machining.
The mode in which the tool will restart the machining can be selected in the drop down menu.
For entries in "Tangency" there will be an arc entry whose radius will be equal to the tool radius
multiplied by the value set in the "Multiplier" field.
3.5.18.8 Electronic feeler
The electronic feeler is a device that changes the tool Z position
based on the irregularities of the panel being machined.

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The management is performed with the following parameters:
- Offset is the distance between tool and feeler
- Compression refers to the compression of the feeler springs
- Gain is a factor that combined with the feed speed delays the Z movements of the tool in
relation to when the feeler has found a change in the Z position of the piece.
The compression and gain values can be set after carrying a few tests on the pieces being
machined.

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3.5.18.9 NC speed adjustment
The NC speed adjustment, also referred to as "Adaptive cut" allows the NC to change the feed
speed when an excessive cutting stress is detected.
This method could result in non-homogeneous finishes on the piece.
To enable this function click the "Select" field.
3.5.18.10 Tool blower
The following types of blowing options can be enabled:
- Air (air is blown on the tool)
- Air and oil (air and oil are blown on the tool)
- Head (a pneumatic option is enabled on the head)
- Air tank (air is blown on the tool from the lubricant/coolant)
- Air and oil tank (air and oil are blown on the tool from the
lubricant/coolant)
3.5.18.11 Mechanical hold-down
The mechanical hold-down presses the panel on the machine table to guarantee a precise
machining operation.
To enable this function click the "Select" field.

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3.5.19 Edge banding process
Edge banding a panel is a process that includes the following operations:
- Edge banding
- End trimming
- Trimming
- Edge scraping
- Glue scraping
- Shaving
The edge banding process consists of applying the edge to a panel, whilst the end trimming,
trimming, scraping (edge/glue) and shaving operations all complete the process, but are only
found with the edge banding process.
3.5.19.1 Edge banding
The edge banding operation applies an edge to the panel contour.
The edge banding process is created by selecting the Edge banding button in the "Operations"
menu.
Clicking on the button opens the Edge banding window:
Press the Select Geometry button in the window to select a
geometry on which to apply the machining. Please note that
the geometries must lie on the upper plane of the panel and
the edge banding cannot be applied to a point.
Pressing the select geometry button also activates the
“Select Machining Start Point and End Point” command,
which is used to select the start and end point of the edge
banding. You can also specify the routing parameters that
can be applied before the edge banding automatically.

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3.5.19.1.1 Technological Data
The edge banding technological data define the following:
- the type of edge banding; whether the edge is loaded
automatically or manually
- the type of edge to apply; when an edge is selected,
its machining parameters and the feed speed in
particular, will be displayed automatically.

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Enabling the routing in automatic with the relative router
parameters, two types of machining operations will be
generated: one routing and one edge banding, totally
separate so that they can easily be changed in the future.

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Selecting an edge banding operation in the machining tree creates the panel displaying the
machining data.

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3.5.19.1.2 Approach/Retraction Data
The approach data are:
 Speed from magazine to first approach point
 Speed along approach section
 Speed in last approach section, when the head enters
with an arc on the trajectory.
Downstroke point:
 Coordinate polars of down point: distance and angle.
 Edge banding head inclination in the down section
Approach point:
 Coordinate polars of entry point: distance and angle.
 Edge banding head inclination in the entry section
The retraction data are:
 Speed along retraction section
- Stop time: any stop time in the last retraction section.
Closuret point:
 Coordinate polars of exit point: distance and angle.
 Edge banding head inclination in the exit section

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3.5.19.1.3 Edge banding advanced data
This data is found in the technical specifications of the edge assigned to the edge banding.
Edge Dispensing
 Infeed edge: quantity of edge to insert in infeed to the
profile.
 Total Edge: extra quantity of edge to insert in relation to
the profile calculation
 Safety edge: quantity of edge dispensed to avoid
having the edge in tension during the unwinding
Closure data
 Cut correction: quantity of edge in excess in relation to
the trajectory being edge banded.
End trimmer
- if selected it enables the edge cut by the edge bander
end trimmer blade (always active for closed edge
banding)
Multi edge banding
- if selected it assigns the multi edge banding state to the
edge banding (with a previous edge banding operation)
Lamps
Flat that enables the edge heating lamps in the approach
section
3.5.19.1.4 Machine Data
Machine functions:
- Autostart: if enabled it can be Active or the Stand-by
function after machining.
Head rotation direction, which can be:
- Optimized
- Counterclockwise
- Clockwise
The selection must be made based on the type of machining
being carried out, the type of approach and the type of
geometry being edge banded.

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3.5.19.2 End trimming
The end trimming operation is linked to the edge banding
operation on open profiles. End trimming is not available on
other operations.
End trimming is a cut with a blade performed with a special
tool called end trimmer, which removes the excess edge from
the panel.
Selecting an end trimming operation in the machining tree
creates the panel displaying the machining data.
End trimming data
 X, Y coordinates of the end
trimming point
 Extra depth of the machining
 Angle: end trimmer blade
angle
Tool correction
 Machining allowance:
machining movement in
relation to the point given by
the end trimming
coordinates.
Strategy: this is the machining
mode
- Cut with Blade Centre
- Cut with Blade Periphery

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- Advanced Data
- Safety quota: machining safety quota.

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3.5.19.3 Trimming
The trimming, performed with the trimming tool, removes the excess edge from the profile.
The trimming operation is linked to the edge banding operation. Trimming is not available on
other operations.
Selecting a trimming operation in the machining tree creates the panel displaying the machining
data.

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3.5.19.4 Scraping
Scraping, performed with the scraping tool, scrapes the excess glue or edge from the profile
after the trimming operation.
The scraping operation is linked to the edge banding operation. Scraping is not available on
other operations.
Selecting a scraping operation in the machining tree creates the panel displaying the machining
data.

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3.5.19.5 Shaving
Shaving is linked to the edge banding operation and it removes any irregularities from an edge
at the external angles of an edge banded panel.
It is performed with a double diameter cutter and it is in short a routing operation and the
technological information of this machining operation are the same as those for general routing.

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3.5.19.6 Anti-Adhesive
Anti-adhesive processing is part of the edge banding process which serves to apply an anti-
adhesive liquid on the upper and lower surfaces of the panel prior to edge banding to prevent
adhesion of glue present on the excess edges during pressing.
The process uses the Anti-adhesive tool, and can be created
automatically during the creation of a new edge banding or
through the Anti-adhesive processing command visible in the Edge
banding group, only if the Anti-adhesive tool is present in the
Maestro tool database.
The processing start and end point can be moved by modifying
the Advance and Delay data in the Anti-adhesive expander.
Similarly, the entry or exit angle of the tool can be changed by
modifying its value in Approach and Withdrawal.

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3.5.19.7 Polishing
Polishing is part of the edge banding process which serves to polish the surface of the edge
with a polishing liquid to remove any glue residues or to polish the roundings produced by the
edge scraper.
The process is carried out using the Polishing tool with the Brushing machining command
visible in the Edge banding group, only if the Polishing tool is present in the Maestro tool
database.
The processing start and end point can be moved by modifying
the Advance and Delay data in the Anti-adhesive panel.
Similarly, the entry or exit angle of the tool can be changed by
modifying its value in Approach and Withdrawal.
Polishing is carried out with two tools: an upper copying tool that
processes the upper part of the panel in the direction of the edge
banding and a lower copying one that processes the lower part
of the panel in the opposite direction of the edge banding. The
tools are selected in the machining panel via the tool selection
vertical drop-down menu.
The two processes are entered in the Maestro process tree at
the end of all edge banding processes.

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3.5.19.8 Edge Banding default settings
The default settings can be set for all the edge banding operations.
Go to: tools, options.
Select parameters, machining to display all the edge banding machining operations and the
properties for each operation that can be entered as default and that will be displayed
automatically during the edge banding machining.
3.5.19.8.1 Edge banding Default

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Edge banding approach
Edge banding retraction

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Edge banding advanced data
Edge banding automatic routing

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3.5.19.8.2 End trimming default
3.5.19.8.3 Trimming default

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3.5.19.8.4 Scraping default
3.5.19.8.5 Shaving default

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3.5.19.8.6 Anti-adhesive and Polishing
The Maestro options window is used to define the approach and withdrawal options for the two
processes.
3.5.20 Attributes
Various attributes can be assigned to the
machining operation created.
The attributes are assigned in the menu of the
same name:

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3.5.20.1 Depth
The depth is used to change the machining
depth along a section of machining.
Select the Depth icon and then select the
machining geometry for which the machining depth must be changed.
For composite lines it is important to select the exact geometry section where the depth attribute
must be entered.
Then select the point along the section
selected.
The positioning can be done by moving the
mouse or by entering the section percentage.
Then enter the depth value.
A cone symbol, that represents a machining depth change, will
be displayed.
For composite lines the depth will remain constant with the
machining depth for all the geometry sections before the
section containing the attribute. Then the depth will change until
the point with the attribute and then it will remain constant until the
end of the composite line or until the next depth attribute.

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To change the depth attribute
parameters again simply select the
cone symbol and change the
Depth or Position values that will be
displayed in the window.
3.5.20.2 Speed
Select the Speed icon and then select the
machining geometry for which the machining
speed must be changed for just a section or
completely.

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Once selected a marker will be displayed highlighting the percentage of the section where the
speed will be changed.
After the section percentage has been entered, left click on the mouse to enter the new speed.

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Once completed, a triangle-shaped marker, proportional to the speed, will be displayed to
highlight the machining speed change.

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3.5.20.3 Microjoints
Cut pieces can be inserted between the different microjoints' contouring to keep the contoured
workpieces linked, avoiding movements.
Passing contouring is the necessary condition for inserting a microjoint.
The Microjoints button is in the Operations-
Attributes menu.
Click on it to display an initial phase for entering the microjoints dimensions:
Particularly length and thickness
Length = microjoint dimension (bridge)
Thickness = bridge height

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Insert the initial point (use the snap function) once the dimensions are confirmed through the
send key.

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Insert the final point at the end.
The figure shows an example of microjoints made in the medium point of rectangular figures'
longer side.
System intercepts all passing contouring machining upon final point confirmation, in this case
inserting 10x1 mm microjoints in all detected intersection points.

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Yellow parallelepipeds graphically represent the microjoints.
The passing machining part shown in figure is interrupted by the 1 mm re-ascent for a 10 mm
section, to then return to being passing.

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The microjoints' dimensions can be individually modified. The specific dimensions of the
selected microjoint appear on right by clicking on the microjoint.
The dimensions can be modified and confirmed with the Apply key.
N.B. Microjoints are not only restricted to nesting function but are also managed in the individual
program.

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3.5.20.4 Start work
This attribute is used to set the machining start
point.
Select the “Start work” icon and then select the
machining geometry for which the start point must be
changed.
For composite lines it is important to select the
exact geometry section where the new start point must
be entered.
Then select the point along the section selected.
mouse or by entering the section percentage.
The machining start will be moved to the
requested point.
For composite lines any geometry sections before the
section where the new machining start has been
entered, will be ignored.

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3.5.20.5 End work
This attribute is used to set the machining end
point.
Select the “End work” icon and then select the
machining geometry for which the end point must be
changed.
For composite lines it is important to select the
exact geometry section where the machining must
end.
Then select the point along the section
selected.
mouse or by entering the section
percentage.
The machining end will be moved to the requested
point.
For composite lines any geometry sections after the
section where the new machining end has been
entered, will be ignored.

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3.5.20.6 Edge banding attributes
Due to the special nature of the machining and the considerable number of attributes necessary
for the edge banding we have created a group of attributes used solely for edge banding.
3.5.20.6.1 Head rotation
The edge banding head rotation is used to
tilt the edge banding head as necessary.
The operation is similar to the speed change in a specific point.
Select a machining operation where the rotation is to be applied and enter the percentage
where the change must take place.
Enter the rotation angle in relation to the vertical line.

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An arrow will be displayed indicating the rotation change.

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If selected the edge bander head will be displayed tilted by the angle entered previously.

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3.5.20.6.2 Rotation X
The “Rotation X” attribute is used to
change the tilting of the trimmer in a
specific point of the trimming operation.
Select the “Rotation X” icon and then select the geometry of a
trimming operation.
If the machining operation selected is not trimming, the following message will be displayed:
Then select the point along the section selected.
The positioning can be done by moving the mouse
or by entering the section percentage.
Then enter the rotation angle of the trimmer, bearing
in mind that 0° refers to the trimmer at right angles
to the geometry and that the value entered can be positive
or negative.

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An arrow symbol will be displayed tilted at the
angle set.
If the trimmer dxf has been entered in the
fixturing rows, the trimmer image will
appear on the profile.
To change the Rotation X
attribute parameters again
simply select the arrow symbol and
change the Angle or Position
values that will be displayed in the
window.

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3.5.20.6.3 Ruller stop
The edge banding head roller stop is used
to stop the roller as needed to help the
gluing of the edge to the panel in specific
conditions in terms of shape and type of
edge used.
Select a machining operation where the roller stop is to be applied and enter the percentage
Enter the time, expressed in seconds.

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A symbol will be displayed indicating the time change.
3.5.20.6.4 Edge rollers opening
3.5.20.6.5 Edge rollers closure
3.5.20.6.6 Lamp on
This attribute is used to switch on the edge
heating lamps at a specific point to heat the
edge and increase its flexibility so that it
follows the geometry better.
Select a machining operation where the lamp switch on is to be applied and enter the
percentage where the change must take place.

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Enter the lamps power percentage.
A symbol will be displayed indicating the lamp switch on change.

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3.5.20.6.7 Edge supply
This attribute is used to increase the
length of edge during the edge banding to
avoid unusual bends and improve the
application on the geometry being
followed.
Select a machining operation where the extra length is to be applied and enter the percentage
Enter the measurement in millimetres of extra edge to be available at the head side.

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A symbol will be displayed indicating the extra edge length change.
3.5.20.7 Delete attributes
To delete any type of attribute simply select the attribute to delete and right click on the mouse.
The following menu will be displayed:
Only the attribute selected, or all the attributes of the same type on the same geometry, can be
deleted.

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3.5.21 Working process tree
The working process tree represents the workpiece and all working processes set in a certain
project.
3.5.21.1 Object selection
You can perform the object selection on the tree by clicking with the left button of the mouse on
any displayed element.
It is possible to select the workpiece or a working workpiece and it is not possible to select more
than one object.
When an object is selected, the name is written in white on a blue background.
The selected object in the tree will be marked also in the graphic area.
3.5.21.2 Multiple selection
After having selected a single machining you can make a multiple selection in two ways:
- Keep the "CTRL" key pressed and left-click on another machining, which will be added to
the one already selected.
- Keep the "Shift" key pressed and left-click on another machining so that all the
machinings between the first and second machining selected will be added to the
previous ones.
Properties
Display
Switch off
Remove
Move on working process
Move down the working
process

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3.5.21.3 Working process ordering
The working process tree shows us the working processes in our project as well as their
sequence. so you could benefit from ordering the working process sequence.
In order to move a working process in the tree:
- select the working process
- use the command "Move on the working process, arrow upwards”
- or "Arrow downwards”
This option is inhibited by the working process tree when the project has more than one step
(see paragraph 3.9.6 )
3.5.21.4 Working process display
On the working process tree you can display or not the different working processes.
To the left of every working process name, you can see the icon that represents the type of
working process and to the left of the icon there is the symbol that stands for an eye.
By clicking with the left button on the eye, you change its status from open to closed.
The open eye means that the working process will be displayed.
The closed eye means that the working process will not be displayed.
In this example you can see a project where the Emptying has
been selected and the Milling and the Countouring have
been switched off.
If you wish to switch all working processes off you can:
1) close all eyes to the left of the working processes.
2) close the eye to the left of the workpiece
3) or click on the light bulb that is off.
If you wish to display all working processes you can:
1) open all eyes to the left of the working processes.
2) open the eye to the left of the workpiece
3) or click on the light bulb that is on.
The selection on the tree has an immediate impact on the graphic area.

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3.5.21.5 Contextual menu
After selecting any object of the tree, by clicking with the right button of the mouse, a contextual
menu will show us what kind of operations we can carry out with the selected object:
Contextual Menu workpiece
Contextual Menu Working process
Context menu for the multiple selection

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3.5.21.6 Group of machinings
After having selected more than one machining you can group them by clicking on "Create
group" in the menu.
In the tree there will be a new node that contains the previously selected machinings.
3.5.21.7 Group of machinings explosion
A group of machinings can be exploded, restoring the original machinings in the group with the
"Explode" command in the menu.

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3.5.22 Working process selection
The working process selection in the graphic area occurs in the same way as the geometry
selection (see paragraph 3.4.8)
you can also select a single working process from the working tree (see paragraph 3.5.21.1)
3.5.23 Contextual menu for working processes
The contextual menu for working processes is available:
- In the graphic area (see paragraph3.4.9 )
- and in the working process tree (see paragraph 3.5.21.5 )
3.5.24 Working process removal
After selecting one or more working process you can remove them:
- by clicking with the button "Canc"
- or clicking on the command "Remove" of the menu "Home" "Clipboard"
- or on the command "Remove" if the contextual Menu.
This menu will appear:
You can choose if you wish to:
- remove only the working process
- remove Geometry and Working process
3.5.25 Working process properties
If you wish to know an existing working process properties, the dialogue menu during the
working process inserting will be showed.

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3.5.26 Working process modification
After selecting one working process (on the screen or in the tree) it is possible to modify the
parameter values in the dialogue menu.
3.5.27 Move and/or copy existing working processes
The options used to move or modify working processes are:
- Move
- Rotate
- Mirror
- Oppose
- Cut
- Copy
- Paste
these same options are also used for the geometries (see paragraph 3.4.13)

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3.5.28 Machining technologies
The technologies differ from the machining in that they do not have an associated geometry.
As the technological information is often much more than the geometrical information it is useful
to save them in order to apply them to other geometries.
3.5.28.1 Create Technology
To create a technology do a project with a single
machining and save it as technology.
You will be asked to save the technology file with the
.tchx extension.
To reuse these files they must be located in the
“Technologies” sub-folder of the Maestro
installation folder.
The screen below will appear, to enter the
technology name and the sub-unit name where it appears in the Maestro menu.
After having selected “Next”, the second screen where the bitmap can be entered, is displayed.

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If the technology being saved is an edge banding process, the machining can be grouped with
colours (as shown in the figure).
These groupings do not affect the interactive use, but they apply during the DXF import phase.
The segments with the same colours in the technology will be associated to the relative
machinings. (see chapter 3.4.6.2.2)
The technology is saved by pressing “End”.

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3.5.28.2 Copy technology
As well as imply copying the machining, you can copy all the technological information of a
machining and apply them to new 2D geometries.
(Equivalent to copying the whole machining, except for the geometry).
To do this use the “Technology” command in the “Operations” “Technologies” menu.
The following menu is displayed after clicking on Technology:
The dropper shape cursor reminds you that you are selecting an existing technology.
To select a technology to copy on other 2D geometries, simply select an existing machining in
the project.
As soon as a machining is selected the cursor becomes a syringe.
And the “Select geometry” item appears in the menu.
The previously selected technology will be applied to all the geometries selected.
To apply the technology to just one part of the geometry selected, check the “Partial machining”
item in the menu.
In this case, after having selected the geometry the menu asks to “select start point” and then
“select end point”, the technology will be applied only to the part of the geometry from the start
point to the end point.

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3.5.28.3 Apply technology
A previously saved existing technology can be applied (see chapter 1.2.11.1 Create
Technology) to one or more geometries.
In fact all the technologies created will appear in the “Technologies” menu:
To apply a technology to one or more geometries select the desired technology from the
technologies menu.
The geometry selection menu is displayed and the cursor
changes to the syringe symbol.
Select a geometry to apply the previously selected geometry.
To apply the technology to just one part of the geometry selected, check the “Partial machining”
item in the menu.
3.5.29 Geometry technologies
This command allows you to automatically apply machining on circle-type geometries in a
project. There are three types of machining: Drilling, Milling, Pocket milling.
The command is located in the tools tab
Selecting the Geometry technology button
opens a drop-down menu containing two
commands
- Create technology
- Display technology.
3.5.29.1 Create Technology

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The Create technology command opens a window that allows you to create the geometry
technology
The window contains several sections: on the left there is a button indicating the type of
geometry, in our case Circle; on the right, in sequence, is the name you want to assign to the
technology, 3 expanders for Drilling, Pocket milling and Milling; at the bottom are the two Finish
and Close buttons.
Each expander has two buttons, one button that adds the necessary data to a job and the ICS
that allows you to delete a job from the list.
The data required for drilling operations are:
diameter or a minimum and a maximum diameter, selecting one type excludes the other;
machining depth;
hole type (flat or conical);
finally, selecting the use of an existing technology enables the drop-down menu on the right
which lists all the technologies present in Maestro; in this case, only the fields relating to
diameter are modifiable.

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The data necessary for pocket milling and milling operations are:
diameter;
machining depth;
type of tool (list of milling tools found in the tool database defined in the Maestro options).
Finally, selecting the use of an existing technology enables the drop-down menu on the right
that lists all the technologies present in Maestro; in this case, only the field relating to diameter
is modifiable.
Attention: if a tool database has not been selected in the Maestro options, the tool list remains
empty.

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Once the machining operations (at least one) have been defined, the technology can be saved
by pressing the Finish button. Alternatively, the command can be terminated without saving by
pressing the Close button.
3.5.29.2 View technology
The View technology command opens a window listing all the technologies created up to that
moment. These can be selected using the mouse or through the Select/Deselect all box.
Activating the contextual menu on the selection (right
mouse button) displays a number of commands:
- Properties
- Copy
- Delete

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3.5.29.3 Apply technology
The Apply Technology command is enabled only if there is an active project in Maestro with at
least one workpiece and at least one geometry.
The command opens a window listing all the Geometry Technologies present in Maestro
Once the technology has been selected, it will apply to all compatible geometries without
machining present in the project. However, you can apply the machining to a subset of
geometries: in this case they must be previously selected in the graphic and in the Apply
Technology window to enable the “Apply only to selected geometries” option.
3.5.29.3.1 Apply Technology Report
If an error occurs during the application of a technology, a
dialogue box appears asking whether or not to display the
report of the applied technology.
If you choose to view the report, a window will open
listing the number of features that have not been
processed by the technology and the reason for
any technology errors.

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3.6 3D machining
This function is used to create 3D machining operations of surfaces and curve machining on
surfaces.
These operations are executed only if the surfaces are within the workpiece volume.

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3.6.1 Roughing
This command is used to rough a surface and it can be applied to one or more surfaces at the
same time with a single tool path to remove as much material as possible from the unfinished
workpiece.
to perform the surface roughing, proceed as follows:
- click on “Roughing”
The specifications of the 3D roughing will be displayed on the
right.
The roughing parameters have the same properties of any
other machining operation (tolerance, machining allowance
and extra depth).
The main properties are the machining strategies:
- terraces
- bidirectional
- unidirectional
The tool strategy defines the tool movements in relation to the
surface:
- 3-axes management with vertical tool
- 3-axes management with tilting tool
By combining the various strategies you can achieve roughing operations on different surfaces:

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- terraces roughing, 3-axes vertical tool

224
- terraces roughing, 3-axes tilting tool

225
- bidirectional, 3-axes vertical tool

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- bidirectional, 3-axes tilting tool

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- unidirectional, 3-axes vertical tool

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- unidirectional, 3-axes tilting tool

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3.6.2 Finishing
The “Finishing” command is used to machine one or more surfaces.
It is located in the “Operations” “3D machining” menu.
After having selected the command the menu at the side will be
displayed.
The surface can be selected after having clicked on “Select
geometry”.
A tolerance and a machining allowance in relation to the surface
can be set.
There are 5 finishing strategies that will be illustrated with 6
examples.
The Superimposition represents the percentage with which the
tool passes again on the previous machining.
The pass direction indicates an angle in relation to the X axis
(0° along X – 90° along Y).
There are 4 tool strategies that will be illustrated with 4
examples.

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3.6.2.1 Finishing strategies
Six examples will be illustrated for the five finishing strategies available. The first two will have
the same strategy with two right angle pass directions.
All the examples use the “normal to surface” tool strategy and the tool strategies will be
described below.

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3.6.3 Swarfing
Command used to create surface machining with tool side. It can be applied to two curves, an
upper one and a lower one, or directly to one or more surfaces.
N.B.
To perform the machining directly on the surface, firstly select the surface and then click on
“Swarfing”. Now the surface is recognised automatically and you can proceed with the direct
creation of the machining operation.
Once the “Swarfing” 3D machining is open the machining menu
will be displayed, to select the various options.
You will also be asked to select the upper curve and then the
lower curve to create the surface in which the machining must be
generated.

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Also in this case by combining the various strategies you can achieve machining operations with
different results.
Tool strategy
Synchronise curves
Tools strategy
Minimum distance

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Tool strategy
Perpendicular to the
lower curve

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3.6.4 Routing on surface
The “Routing on surface” command is used to perform the machining of a 3D curve that lies on
a surface.
After having selected the command the menu at the side will be
displayed.
A precision tolerance can also be set.
A depth can be set; with “0” the tool will skim the surface.
The tool strategies are three of the five described for the
“Finishing”.
To proceed with the machining select a 3D curve and then select a surface.
The following commands will be displayed:
Example:

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3.6.5 3D pocketing
The "Emptying 3D" command allows you to create a pocket by selecting the surfaces that
delimit it.
To perform the processing, select the following surfaces:
The bottom surface is mandatory, the side ones are optional
because if you select only the bottom one would be
completely cleaned.
Any upper surface will only be used when the bottom surface
is not parallel to the upper level, in this case one of the
following can be specified
emptying strategies which are (from left to right):
- Offset from bottom of the pocketing
- Adaptive offset from the start to the bottom of the pocketing
- Offset from the start of the pocketing
The Offset from the bottom runs parallel passes to the bottom
of the pocket.
The Offset from the beginning of the pocketing executes
passes parallel to the upper surface.
The Adaptive Offset performs variable shape passes
between the bottom of the pocket and the upper surface.
The remaining parameters are analogous to those present in
roughing machining.

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3.6.6 Tool path wrap
The “Tool path wrap” command is used to apply a tool path of a drilling, routing or pocketing on
a surface.
The original tool path will be wrapped on a surface and the tool orientation will be perpendicular
to the surface.
To proceed with the machining select a machining tool path and then select a surface.
The following commands will be displayed:
The original machining will be transformed in a 3D routing with the same specifications.
Example of a pocketing transported to the surface:

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3.7 Macro and Subprograms
3.7.1 Creating machining-macros (.xsp)
The “.XSP” Macro are a sequence of instructions used to add geometries or machining
operations to a project.
The macros can be launched more than once in the same project and the names associated to
them will be transcribed in the workpiece machining tree, as if they were elementary machining
operations.
The Maestro installation package contains various “.XSP” macros that can be used as outline to
create new macros.
The macro creation procedure can be described in two phases:
1. Creation of the macro basic structure ( wizard);
2. Implementation of the functions in the macro.
3.7.1.1 Creazione della struttura base della macro ( wizard);
During the planning phase the user must decide which parameters to supply as input variables
for the macro. The workpiece dimension parameters are passed to the macro with the wizard,
clearly for the user and therefore do not have to be parameterized. The remaining parameters
must be entered manually by the user, with the wizard as described in the subsequent
procedures.
To start the macro creation wizard select Tools in the Maestro menu bar, and press Macro
Management and select Create macro.

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The wizard window is displayed on the screen, used by the user to access four different areas:
general parameters, image selection, parameters, units and languages.
3.7.1.1.1 General parameters
In this section, in the first field the user must associated an identification name to the macro,
whilst in the remaining fields a short function description, a category, unit and sub-unit type
identifier can be entered.
These last fields can be used to organize the macro properties hierarchically, in order to retrieve
them more easily when required, from the Maestro menu. In particular there are two options for
the category: “Operations” and “Macro”. The first category enters the macros in the ”Operations”
tab , whilst the second in the “Macro” tab, in the Maestro menu. If there is no Macro tab, it is
created the first time a macro of this category is created. Based on the category chosen
groupings and sub-groupings can be created with the following fields

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For example the general parameters for the Slot macro are:
These parameters define the Slot macro as a “Standard” macro, of the “Apps - Generic -
Machinings - Pocketing” sub-unit.
The user can check that the macro is placed in Maestro, in the specified sub-unit.

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3.7.1.1.2 Image selection
This section is used to associate different types of images to the macro:
• 16x16 pixel image: visible in the Maestro menu on the left of the macro (used when small
bitmaps are required);
• 32x32 pixel image: visible in the Maestro menu on the left of the macro (used when large
bitmaps are required);
• 200x154 pixel image: visible with the macro parameters.
The following formats are supported: .bmp or . jpg or .png
In general it is good practice for the16x16 and 32x32 images to provide a general idea of the
macro function, whilst the 200x154 image must provide the detailed meaning of the macro input
parameters. See the example below:

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3.7.1.1.3 Parameters
This section is used by the user to describe the macro input parameters. Usually the input
parameters for a macro are divided in:
1. geometric parameters;
2. technological parameters (tool, strategy, etc…).
To add an input parameter, right click on the mouse and select Add in the menu.
The following fields can be defined for each parameter in the table:
 Name parameter identification name (name of the variable used for the macro input
parameter);
 Type of parameter: defines the type of parameter (selected from: machining head, tool,
user and worktable);
 Type of value: defines the type of value in the parameter (selected from: Boolean,
decimal, integer, string);
 Physical unit: defines the unit of measurement associated to the parameter value (length,
speed or dimensional size);
 Null value: specifies if a null value can be assigned to the parameter;
 Default value: used to set a default value for the parameter;
 Multiple values: defines a restricted group of elements and ties the parameter value to
this group (if activated the group elements must be defined in terms of key/value);
 Visibility: allows the visibility of the parameter in the interactive use of the macro (in the
Maestro expander);

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 Group: defines the group of the parameter;
 Image: used to associate a descriptive image to the parameter.
3.7.1.1.4 Groups
In this section the user can decide how to group together the parameters entered in the
previous section, so that they appear in the desired group in the macro configuration menu.

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For example for the Slot macro, the pass feed parameter
(AvPas) is defined in the AvPasGroup group and
corresponds in the Maestro expander to the “Mode”
category of the image on the right
3.7.1.1.5 Languages
In this section the user can translate the descriptive information of the macros in the desired
languages. In particular, in the Parameters tab, the user must associate to every previously
entered parameter, the name that will be associated to the parameter and that will be displayed
in the Maestro editor. Or he can also enter a brief description of the parameter use. These
operations must be repeated by the user for every language that the macro will be available in.
Similarly in the Groups tab the group ID created can be translated and a brief description in the
relative language can be associated.

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In the Messages tab various error message can be translated, according to the key/message
layout. To recall the desired message when there is the corresponding error condition, use the
Print scripting instruction. This function uses as input parameter the key associated to the
message, preceded by the special character @ (the @ character is used to identify and
interpret the string that follows as a message key).
In the Documentation tab, any documents in the relevant language can be associated to be
available in the macro.
The flag can be enabled to help in the compilation and to copy the instructions from another
language, in order not to have to start from zero for each new language introduced.
Once the wizard procedure is finished (End key), the macro is created and saved in the Macros
folder of Maestro, that is usually found with this path C:Program FilesScm
GroupMaestroMacros.
With the completion of this first phase the basic structure of the macro is created, but no
function has been implemented inside it The wizard has in fact created in the .xsp file of the
macro a source file with extension .cs, with the parameters and values supplied by the user, but
the user has not described the behaviour in the execution of the file.
At this point the user must define the macro behaviour with the MSL scripting language.
Maestro must be restarted to proceed with this second phase (implementation of a macro). Now
this file can be accessed and the desired specifications can be implemented and edit the macro
created as the described in the next section.

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3.7.1.1.6 Macro Management
To access the macro management function select Tools in the Maestro menu bar, and press
Macro Management and select Display macro.
N.B.: SCM provides in the interface a set of macros specifically for various woodworking
technological sectors (window frames, doors, shutters, furniture, etc.).
These macros, except for those for UX machines, do not support the mirroring, rotation and
tipping operations.
If these operations are used in projects containing the macros, their correct operation is not
guaranteed".
A window is displayed containing all the macros of Maestro and the ones created by the user.
Move on the desired macro and right click on the mouse to access the menu.
The flag in the list, on the left of each macro, allows the macro to be viewed or blocked from the
Maestro interactive menu. This does not mean that the macro will be deleted, but just that it will
be visible from the menu. At any time the user can access the complete list of all the macros
and change the display status of the ones that he is interested in.

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Select Edit to change the .cs file of the macro.
As the ideal solution to editing the macro is using Visual Studio 2010 or a later version, we
recommend using this tool, where possible. If the user does not have this tool, a free version
called Express can be downloaded at the website: www.microsoft.com/visualstudio/.
See the MSL manual for the structure and content of the .cs file.
Select Check: to check if the macro is correct. In this case the macro is checked for any file and
parameters creation errors. The result of the check will be displayed on the screen.
Select Properties: to open the wizard graphic interface again. At this point the basic structure of
the macro can be changed by adding parameters or changing existing parameters.
Select Delete: to delete the macro. Note that deleting a macro also affects the programs that
use the macro deleted. As the macro no longer exists, these programs can no longer be
changed.
Select Edit: To open the source code (extension. Cs) associated with the selected macro.
3.7.1.2 Implementation of the functions in the macro.
See the MSL manual.
3.7.2 Create Subprograms (.xsp)
The subprograms are used to enter recurring 2D geometries or machining operations in the
project.
The subprogram is created as follows:
1) Create project
2) Define the parameters
3) Save the subprogram
3.7.2.1 Create project
The creation of a subprogram starts by defining any project.

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3.7.2.2 Define the parameters
If you insert a workpiece in the project, parameters dx1, dy1, dz1 will be available in the
workpiece dimensions.
By inserting a second workpiece in the project, also dx2, dy2, dz2 will be also included.
The list of parameters available in the project is to be found in the interface down on the left.
By using the command "Create a new variable", it is possible to insert new parameters.
By using the command "Variable Properties", the same window used for the creation will
appear:
By using the command "Delete variable", it will be possible to delete the variables created by
the user but not those which have been automatically created (dx1, dy1, dz1).
All parameters available in the project can be used in every field that accepts a number in order
to create 2D geometries as well as to set working processes.
In order to use a parameter, it is sufficient to write it in place of such number, or you can also
write the formula with more parameters and mathematic operators.
Parameters can also be exported with the sub-program as input data (see paragraph 3.7.2.3
"Saving the sub-program").
Create a new
variable
Variable
properties
Delete variable

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3.7.2.3 Save the sub-program
After the project setting, you can save the 2D geometries and the working processes as sub-
program in order to reuse them for further projects.
Subprograms can be performed only for projects with one workpiece.
In order to save a sub-program, use the command
"Save as sub-program" in the menu "Home" "Save".
The resulting window will allow you to save the .xsp subprogram.
The default folder for saving programs is the Maestro set up sub-folder "Macros".
You can also save sub-programs in another folder but if you wish to use them, you must save
them also in the default folder.
After naming the sub-program and clicking on "Save", following window will be showed:

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Fields included in "Display properties" serve as indicators for the menu where the sub-program
will be saved.
If you click on "Next", on the resulting window - almost like the previous one- you will be asked
to list the names of the bitmap to link with the subprogram. (Optional)
If you click on "Next", the resulting window will allow you to establish those variables to be
exported.
If you click on "End", the saving process will end.
You can check the saving process :
- in the menu "Operations" (written in the field "Tab Name")
- since the sub-menu "Forme" has been created (written in the field "Group Name").
- and it contains the sub-program "esagono" (field " Macro Name”)

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3.7.2.4 Open an existing sub-program
If you wish to open an existing sub-program, click on the icon "Open".
The resulting window shows you the list where you may select a pgmx file.
Select "File type" "Sub-program (*xsp)".
Select the folder "Macros".
Select a xsp file and then click on "Open".
Or click twice on the xsp file.
For a project that has already been started, following option would be automatically performed:

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3.7.3 Use of .XSP Apps and subprograms
The .XSP Apps can be used when a project is already open in the Maestro editor, or when
creating a workpiece program with the MSL scripting language (see next chapter).
To use the Asola Apps in a project, it is in:
OperationsAppsGenericMachiningPocketsAsola
After having clicked on “Asola” the various parameters can be changed, and the macro applied
by clicking “Apply”
The effect of the macro can be seen in the machining tree and in the Maestro graphic area.
In the tree the name of the macro (Slot) can be seen, and in the graphic area the geometry and
the machining described in the Slot.cs function.
3.7.3.1 Modify Macros

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Macros allow the operations of Cut, Copy, Paste, Move, Rotate, Mirror, Oppose in a similar way
as for a geometry or a machining.
Some Macros contain processes that do not permit this type of operation, for example 3D
processes.
The modification operations for Macros attributable to one plane only (e.g. Hinge) related to that
plane. Modification operations for Macros attributable to different planes relate either to the
reference plane or the plane associated with the Macro in the plane tree.
3.7.3.2 Import Script (.xcs)
To use a workpiece program in .XCS format in the Maestro interactive environment, use the
“Import script” command in the submenu “Import” of the “Home” menu.
The following will be displayed where a .xcs. file to import can be selected.
After having confirmed the selection of the .xcs file with “Open” the script is interpreted and the
workpiece will appear and any machining described inside it.

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Bear in mind that a script file (.xcs) can contain all the workpiece information and the relative
machining, including the names of the tools associated to the machining, but it does not contain
the “.tlgx” tools database file.
To achieve the desired workpiece correctly when the script was produced, before executing the
“Import script” command, the “.tlgx” file, containing all the tools used in the script functions, must
be prepared and rendered active.
To activate the .tlgx see the “Activating the tools database” chapter of the Maestro manual.

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3.8 NC functions
Used to define and make the machine perform operations different from the machining
operations.
The following NC functions can be entered in a program:
1. Enter an ISO instruction: CreateIso
2. Machine parking: CreatePark
3. Null operation: CreateNullOperation
4. Workpiece probing: CreateWorkPieceProbing
5. Display an operator message CreateMessage
6. Table cleaning
7. DY check
The functions are in the Machines – NC functions menu.
The icons of the available CN functions are visualised according to the machine set-up,
therefore they are all visible at all times.

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3.8.1 Enter an ISO instruction
To enter an ISO instruction in the machining tree select the “ISO” command in the “NC
functions” menu.
The following dialogue window is displayed:
Maestro will not check the syntax of the instructions entered by
the user.
Any syntax error in the ISO instruction will be performed on the
Machine Panel.
The Flag on the Xiso option lets you report the Iso instruction
written.
If the Xiso flag is not selected in the post phase the “ISO” prefix is
added to the instruction.
Examples:
Machining Tree Dialogue window Post generated
;**********************************
.OP1 ;G0 X0 Y0
;**********************************
G0 X0 Y0
;**********************************
.OP1 ;G0 X0 Y0
;**********************************
ISO "G0" X0 Y0

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3.8.2 Machine parking
The machine parking functions moves the upright in the parking zone to access the workpieces
positioned in the machine in the unload phase.
To enter a parking instruction in the machining tree select the “Parking” command in the “NC
functions” menu.
The parking is available in the following modes:
- No stop
- Stop with start wait
- Stop with release and start wait
The modes can be selected from the “Stop” drop down menu.
Example of parking with start wait
;**********************************
. OP1 ;Parking
;**********************************
PARK S=1

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3.8.3 Null operation
The “Null operation” function does not perform machining operations on the workpiece but it can
be used to park the machine in a desired point and perform a tool change.
To enter a null operation instruction in the machining tree select the “Null operation” command
in the “NC functions” menu.
The following parameters can be entered in the dialogue menu:
X final (position X to position the machine)
Y final (position Y to position the machine)
Reference (Relative or Absolute)
Speed (movement speed)
Electrospindle (Off or On)
The “Tools information” and “Heads data” fields must be filled in
only if you want to change a tool.

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3.8.4 Workpiece probing
The workpiece probing is an operation that is used for precise machining operations, even on
workpieces that are irregular or positioned incorrectly.
There are three workpiece probing modes:
1) Probing with side position correction
2) Probing with tool length correction
3) Probing with workpiece roto-translation
3.8.4.1 Probing with side position correction
The probing with face position correction is performed with a probing tool.
The effect generated after the probing is to redefine the position of the working face so that all
the machining operations on that face are precise.
The function is disabled each time the face is changed.
To enter a face position correction probing instruction in the machining tree select the “Probing”
command in the “NC functions” menu.
References (field used to select the work face).
X (X probing position)
Y (Y probing position)
Head return (can be performed to three different positions):
- Parking quota
- Probing quota
- Skimming quota
The “Tools information” filed is used to select the probing tool.
The “Heads data” field is used to select the head used for the
probing.

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3.8.4.2 Probing with tool length correction
The probing with tool length correction is performed with a pneumatic probe fitted on the
spindle.
The effect generated after the probing is to redefine the tool length so that all the machining
operations performed with that tool on that face are precise.
On long workpieces, even when working on the same face with the same tool, it is preferable to
perform various probing operations in different positions in case the workpiece is warped.
The function is disabled each time the tool or the face are changed.
To enter a tool length correction probing
instruction in the machining tree select the
“Special probing” command from the “Probing”
menu in the “NC functions” menu.
References (field used to select the work face).
X (X probing position)
Y (Y probing position)
Speed (probing speed)
The “Tool information” field is used to select the tool whose length
will be corrected and that will be used for the subsequent
machining operations.

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3.8.4.3 Probing with workpiece roto-translation
The probing with workpiece roto-translation is performed with a probing tool.
The effect generated after the probing is to redefine the position and angular orientation of the
workpiece so that all the machining operations performed with that tool on that face are precise.
The function remains active for the whole workpiece program.
To enter a probing with workpiece roto-translation
instruction in the machining tree select the
“Workpiece rotation translation probing” command
from the “Probing” menu in the “NC functions”
menu.
First quota side X (first probing position X)
Second quota side X (second probing position X)
Side Y quota (third probing position Y)
Quota Z (position Z of all the probings)
The “Tools information” filed is used to select the probing tool.
The “Heads data” field is used to select the head used for the
probing.

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3.8.5 Display an operator message
The display an operator message function is similar to the parking functions and allows the
operator to view a message and restart the program without moving the machine.
To enter a message for the operator in the machining tree select the “Print message” command
The message can appear in the following ways:
- No stop
- Stop with start wait
- Stop with release and start wait
The modes can be selected from the “Stop” drop down menu.
The “Input enable” and “Input variable” variables are not
managed.
The “Operator message” field can be filled with the message that
will be displayed for the operator during the program execution.

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3.8.6 Table cleaning
The table cleaning NC function enables a cleaning cycle of the machine table with the extraction
hood.
To enter a message for the operator in the machining tree select the “Table cleaning” command
Hood enable: determines the extraction hood enable or
disable.
- Hood position:
o for the motor—driven hood the value indicates
a position in millimetres
o for the pneumatic hood the value indicates one
of the possible positions
- Cleaning speed: speed for the cleaning cycle: 25
metres per minute, default
- Cleaning start X quota: position along the X axis
where the cleaning cycle starts in relation to the
workpiece origin (optional parameter, necessary for
Ergon type machines)
- Cleaning end X quota: position along the X axis where the cleaning cycle ends in relation
to the workpiece origin (optional parameter, necessary for Ergon type machines)
In the machining tree it will be displayed as follows:
Examples:
1) All the programmed parameters and the motor-
driven hood
Dialogue window Post Generated
;**********************************************************
.OP1 ;Table cleaning
;**********************************************************
XHOODPLANE a=1 s=25.000 Q=100.000 l=50.000 L=600.000

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2) All the programmed parameters and pneumatic hood in position 1
;**********************************************************
;**********************************************************
XHOODPLANE a=0 s=25.000 Q=1.000 l=50.000 L=600.000
3) no programmed parameter
;**********************************************************
;**********************************************************
XHOODPLANE a=0 s=25.000

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3.8.7 DY check
CN function "DY check" is meant for CX machines and allows measuring the piece in Y right
after the loading stage.
If the dimensions of the piece in Y are not consistent, the machine shall signal an error.
In order to set the DY check of a panel, select control
"DY check" from the "C.N. functions" menu.
CN function "DY check" only has the parameter "Distance"
that represents the distance from the right edge of the piece
whose dimension needs to be checked.
By clicking on the function "DY check" allows adding such
function to the machinings tree.
Its position is not relevant in that during the "Optimisation"
stage this will always comes first.
If you try to set another "DY check", the following message will appear:

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3.8.7.1 Automatic DY control
In the Cyflex S, the Y dimension control of the panel is fundamental, because in these types of
machines there is the aligner. If a piece is inserted with a different DY from the one specified in
the program, there is a risk of collision between the machining operations and the aligner.
Maestro has been fitted with an automatic Y dimension control of the panel, with a specific
parameter in the options:
This option is displayed only when CX S is selected as the type of machine and is disabled by
default, to save the current behaviour.
When the function is activated, the possibility of specifying the distance from the right edge of
the panel is enabled. This distance is the one that will be used in all the NC functions to control
the dimension of the piece entered automatically.
During the optimisation of a program, check if the option is active: if it is, if the pgmx does not
already contain the piece dimension control NC function, it will be entered automatically with the
distance specified in the options. If the user has already entered his personal control, it will be
saved so as not to change the distance value already entered.
With other types of machines, such as the CX HP, the option, even if enabled, has not effect.

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3.9 Working steps
A working step describes the positioning of one or more workpieces and which working
processes must be performed if they are in the positions described.
When you create a new project, the step "Setup" is automatically created.
3.9.1 Working step tree
The working step tree represents all working steps set for a certain project.
Through this tree it is possible to:
- Insert a working step
- Removete a wokring step
- See the step properties
- Add working processes
- Move the working processes from one step to another one.
- Display or switch off the working processes
- Add the workpiece name to the working process name.
Add
workpiece
name
Display
Properties
Switch off
Remove
Move on working process
process

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3.9.2 Inserting a working step
In order to insert a new working step, you use the command "New step” in the contextual menu
of the step tree.
After selecting the command, the menu to the right will show you where you can insert the name
of the "Working step".
3.9.3 Removal of a working step
In order to remove a working step, you use the button with the red cross or the command
"Remove" in the contextual menu of the step tree.
The initial "Setup" cannot be removed.
Remove

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3.9.4 Working step properties
In order to display a working step, you use the button "Properties" or the command "Property" in
the step contextual menu.
After selecting such command, the menu to the right will show you the name of the "Working
step" and the workpiece positioning in that step.
3.9.5 Modifying the workpiece position in one step
It is possible to modify the workpiece position in a certain
step by using the command "Properties" in the contextual
menu of the step tree.
By clicking on the arrows to the left of the workpiece name, the
menu will show the current position of the machine
workpiece.
You can change the workpiece position in the selected step by
modifying the values to the right of the parameters.
- X origin
- Y origin
- Z origin
By clicking on the button "Apply"
Properties

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3.9.6 Moving working processes from one step to another one
In order to move the working processes from one step to another one, you use the buttons with
the blue arrows on the tree.
In the image above, if you click on the button with the arrow downwards, the Contouring will be
shifted on the Milling but it will remain the same during the step "Setup".
By using the arrow downwards, the Countering will always occur before the boring, but will shift
from "Setup" to "Working step"
Move up working process
process

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3.9.7 Add workpiece name to working process name
If you look at the step tree, we see what kind of working processes are performed in every step
but we do not know to which workpiece they belong.
In order to obtain this information, you use the button "Add workpiece name".
Project example with 2 workpieces and 2 steps:
As you see in the step tree, you cannot understand to which workpieces the working processes
belong. By using the command "Add workpiece name", the step tree will appear in this way:
The working processes are not modified, but you see only a temporary representation that can
be restored by clicking on "Add workpiece name".
Add
workpiece
name

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3.9.8 Sub-programs Activation/Deactivation
Use the "Tools – Sub-programs management" control to activate or deactivate the "Macros"
folder Sub-programs.
The following window appears once the "Sub-programs management" control is clicked:
From where the available sub-programs can be activated or deactivated.

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3.10 Workpieces layout in machine
Arrange the workpieces in machine based on its work top, blocking devices and workpieces to
be machined.
"Setup" is a detached session from the project environment.
Use the following to access "Setup":
The "Setup" control in the "Machines"
menu.
Or the "Workpieces layout" in the context menu of the
phases' shaft.
The menu appears when right-clicking the mouse on a
phase name.
"Setup" shows the following menu:
Some controls will not be active due to different work top configuration or setup.
The various controls are described below following a work trail and not in order of position on
menu.

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3.10.1 Choice of work area, references and devices
The machine has a work top divided by areas having various references and different blocking
devices.
They are selected through "Machine parameters" control in the "Setup" menu.
The following menu appears after selection:
3.10.1.1 Work area selection
Use the right drop-down menu showing the available areas in a given machine configuration to
select the work area.

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3.10.1.2 References Selection
Use the "Mechanical options" sub-menu to select the workpieces' references:
3.10.1.3 Type of blocking selection
Use the "Blocking" sub-menu to select the type of blocking:

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3.10.2 Dynamic work areas
The dynamic areas can be used to increase or decrease the length of the area of a half-table, allowing
the project to have a different work area compared to the physical one specified in the configuration.
This work mode avoids the use of an area that uses the entire table for projects that have a piece
encumbrance and machinings longer than the length of a half-table, but that can be machined using only
the bars. This means that in the machine you can still use the pendulum work mode, without having to
interrupt it to load a project on the entire table.
3.10.2.1 Function enable
To use the dynamic areas, first of all the configuration must be able to support them. In the "Work areas"
node the "Setup for use of the dynamic areas" flag has been added, which is disabled by default. The
new Maestro version that supports this function is therefore compatible with the old configurations, that
are therefore not enabled for use of the dynamic areas.
When this item is selected the Machine Parameters of the project show another options: "Enable the use
of dynamic areas". This is used to specify that the current project can use this function.
The other conditions for using the dynamic areas are:
● programming a half-table (e.g. AB or DC);
● no central bars or disabled.
If one or more of the conditions are not met, the user will be warned when he tries to use the commands
for the calculation or the area length setting.
3.10.2.2 Manual programming of the area length
In the Setup environment, press the "Set length" of the "Dynamic areas" group to manually set the area
length. The length must guarantee that all the bars of the current half-table are inside the limits of the
area.
The minimum length that can be set is therefore equal to the encumbrance of the bars parked added to
the value of the "Margin in relation to the parked bars" option of the "Worktable" sheet of the Maestro
options. The margin has been introduced to provide a minimum of space for the movement of the bars.
The maximum length that can be set is calculated, with the same considerations, in relation to the bars
of the half-table not used.

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The figure below shows the limits described, indicating with D the margin specified in the options.
If the user enters a value outside these limits, Maestro signals an error.
If the user has moved one or more bars, the minimum limit changes and becomes equal to the
encumbrance of the most external bar increased by the tool-support safety distance. In this case the
error will indicate this value as the limit and not the absolute minimum.
With the manual programming, once the length of the area has been specified, the user must position
the bars or launch the automatic setup.
3.10.2.3 Automatic programming of the area length
In the Setup environment, press the "Calculate length" of the "Dynamic areas" group to automatically
calculate the area length.
This operation requires that the table is setup with at least one clamp or suction cup because, having to
calculate the encumbrance of the machinings, depends on the type of support used.
For a given project the automatic calculation of the length of the area returns a value equal to the
encumbrance of all the pieces and the respective machinings added to the value of the "Safety margin in
the area calculation" of the "Worktable" sheet of the Maestro options. The margin has been added to
allow the user to specify a free area of the table to eventually use for parking the bars in standby.
If the encumbrance of the pieces and the machinings is longer than the maximum length that can be set
for the area, the user is warned with a message that signals the need to set a work area for the whole
table.
3.10.2.4 Reset the area length
In the Setup environment pressing the "Reset area" button of the "Dynamic areas" group, resets the
length of the area in the configuration, to return the project to the default settings.
The reset is also performed automatically after certain events, such as the changing the area and
enabling the central bars.

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3.10.3 Adding pieces on the machine plane
It is possible to add a piece on the machine plane by selecting it from an existing project.The
starting project can also be empty.
The mode is as follows:
- Select a project using the "Browser" folder that allows you to search for it on your PC.
- Select one of the pieces in the project
- Set a distance to maintain with respect to existing pieces
Add the new piece using the mouse

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3.10.4 Workpieces positioning
Use the right-hand window to position the workpieces on the
machine's work top:
The workpieces' position can be modified by changing the
"source" values and clicking on "Apply".
(Also see paragraphs 3.9.5)
The pieces can also be positioned using the "Select piece" and "Move piece" commands
The "Select piece" command is necessary because the default of Arrange is to select suckers
or clamps.
Once the piece has been selected, to move the piece, use the "Move piece" command available
in the layout menu or in the context menu
In this case, the selected piece will move with the mouse respecting the set offset.
The movement will also be made on the locking devices fixing the workpiece to the table unless
they are constrained by other workpieces that must remain stationary.
Example:

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If the bars involved are shared with other workpieces, the movement of the latter will also be
suggested (only in X) to keep locking consistent for the workpieces involved:
3.10.5 Separation of workpieces
The Workpiece Separation Optimizer command in the Optimizer Machines menu is used to
separate workpieces (or parts) arranged on the work table:
This command allows the workpieces present on the table to be moved away from each other,
in X and Y, and creates a new phase for this separation in which the separated workpieces are
locked with the same fasteners (suction cups) in the same starting positions.

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The data for this command is requested by an input window:
The first section contains the offsets in X and Y to offset all the workpieces from the current area
stop (the distance between the workpieces will be with respect to this).
The second section contains the amount of displacement in X and Y to be applied to each
workpiece to move it away from the adjacent workpieces on the right or left and above or below
respectively.
The third section refers to the option of generating a third phase in which the workpieces are
brought back towards the stop. If checked, the phase will be generated and the workpieces will
be moved with respect to their initial position by the value specified in the text field below.
Some remarks:
 the function is applied to single phase projects containing two or more workpieces locked
by suction cups;
 the through machining such as contouring, pocket milling, milling and blade cutting,
which are potentially responsible for the detachment of the workpieces from each other,
will be left in the initial phase (the phase created by the user with the workpieces in the
cutting position);
 all the other machining processes are moved to the second phase to be carried out on
separate workpieces;
 when the Apply button is pressed, if there are workpieces without suction cups
underneath or there are suction cups between two workpieces, an error message is
given and the command is not executed;
 if locking of the workpieces in the initial phase is not repeatable for the separated
workpieces after separation (for exceeded limit switches or for collisions between bars or

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suction cups), a message warning of incomplete solution is shown, leaving the user to
choose whether to proceed and save the separation result or whether to abort the
command;
 if two adjacent workpieces in X share bars with another workpiece (above or below them,
in Y), these cannot be physically separated from each other and so they will not be
separated in X;
 the project obtained by separating the workpieces will be saved with the name of the
current project with the added suffix ''Sep''.

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3.10.6 Elimination of pieces from the machine plane
The pieces can be removed using the "Select piece" and "Delete" commands
- Select the "Select piece" command
- Select the piece (the piece will assume a green outline)
- Select the "Delete" command
The confirmation message will appear before being deleted:
You can also select the piece (turning it green) click the right mouse button (the context menu
appears) and select "Delete piece"

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3.11 Definition of the blocking system
There are two types of blocking systems on the work centres:
1. Clamps blocking
2. Suction cups blocking
3.11.1 Workpiece blocking with clamps
Workpiece blocking using clamps normally happens to block window or door elements.
Select the devices via "Pressure switches" or "Vacuum gauges + Pressure switches", as
described in chapter 3.10.1.3.
Note: If working with machines not having motorised work top it is not necessary to position the
clamps.
3.11.1.1 Type of clamp
The types of clamps currently available are:
1. Clamps with round plate
2. Clamps with rectangular plate
3. Clamps with reference stops
4. Horizontal clamps
The first three types of clamp block the workpiece along axis Z.
The horizontal clamps block the workpiece along axis Y.
A code is used to identify the various types of clamps.
The code consists of a maximum of 4 separate fields. The first two are the same for all types of
clamps.
The code of the first two fields is:
Hzzz-U
Where
- zzz is the clamp work height (50/110)
- U is the type of use (M/A)(Manual/Automatic)
The remaining optional fields of the clamp code will be described in the following chapters.

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3.11.1.1.1 Clamps with round plate
For these clamps the third code field describes the plate diameter.
The code for this type of clamp is:
Hzzz-U-ddd
Where ddd can currently have a value of 145 or 185.
Examples:
H50-M-145 Clamp height 50mm manual with 145mm diameter
H110-A-185 Clamp height 110mm automatic with 185mm diameter
3.11.1.1.2 Clamps with rectangular plate
For these clamps the third code field describes the plate rectangular
dimension.
Hzzz-U-bbbxyyy
Where bbb and yyy are the length and width of the clamp plate
rectangle.
Currently there is only 165X165
Examples:
H50-M-165x165 Clamp height 50mm manual with square plate 165x165mm
H110-A-165x165 Clamp height 110mm automatic with square plate 165x165mm
3.11.1.1.3 Clamps with reference stops
For these clamps the third code field describes the plate rectangular
dimension and the fourth field the reference stop thickness.
Hzzz-U-bbbxyyy-Scc
Where bbb and yyy are the length and width of the clamp plate
rectangle. Currently there is only 165x165.
cc is the thickness of the reference stop on which the workpiece rests (values currently
available: 10,20,25,30)
Examples:
H50-M-165x165-S10 Clamp height 50mm manual with square plate 165x165mm and
10mm stop.
H110-A-165x165-S30 Clamp height 110mm automatic with square plate 165x165mm and
30mm stop.

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3.11.1.1.4 Horizontal clamps
This type of clamp blocks the workpieces horizontally along axis Y and
is only managed manually.
For these clamps the third code field describes the rectangular
dimension of the whole clamp.
Hzzz-U-bbbxyyy
Where bbb and yyy are the length and width of the whole clamp. Currently there is only
150x294.
There is no parameter indicating whether it is an horizontal clamp.
At the moment it can only be seen by the dimension of the rectangle 150x294.
Example:
H50-M-150x294 Clamp height 50mm manual with rectangular plate 150x294mm
H110-M-150x294 Clamp height 110mm manual with rectangular plate 150x294mm

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3.11.1.2 Type of clamp selection
Use the bottom-left list of available clamps to select the type of
clamp:
The top-left window shows the clamps' preview:
3.11.1.3 Clamps positioning on the bars
Select the clamp to be used and drag it onto the manual bar or onto the motorised bars' plates.
Assemble the clamps on all plates in case of motorised bars. Do this using the context control
and right-click the mouse on the clamp to be used.
In certain cases there may be collisions during the assembly. This is because Maestro
considers the total space of the machine elements (plate plus camp) in the collision control
between mobile elements. To overcome this issue simply move the plates from each other
before applying the clamp.

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3.11.1.4 Saving plane layout
Once the plane has been set up with clamps or suction cups, it is possible to save the plane
layout so that it can be used on other occasions.
To save, the command
"Save plane arrangement" command is used
A .eplx file will be created in its Eplx folder
3.11.1.5 Reusing the plane layout
To re-use the previously saved plane configuration, set the name to:
Tools-Options-Preferences File of the default work plane positioning
After setting the field with the name of the eplx file, every time you enter the "Layout" session,
the previously saved setup will appear.
3.11.1.6 Saving of different table settings
Arrange offers the option to save the media arrangement in
EPLX file. There is now also the option to recall these
arrangements quickly and easily.
Click on the "Tables" button and a drop-down menu appears
with all the tables saved at that moment:
Selecting an arrangement applies it to the current project.

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3.11.1.7 Blocking states of clamps
Each clamp can have 3 blocking states:
1) Open
2) Closed
3) Closed on the piece
The clamps state can change in every phase to manage the machining process.
3.11.1.7.1 Blocking state change
To change the blocking state of a clamp:
- select a clamp
(it becomes light green)
(a window appears on
right)
- right-click the mouse (a context menu appears)
- select the wanted state entry by left-clicking the
mouse
- or click on right arrow of the state
- select the wanted state entry by left-clicking the
mouse
- click on "Apply"

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3.11.1.7.2 Blocking state display
The blocking state is displayed through the "Clamp Data" – "State"
menu, but this only shows the selected clamp's state.
Use the "Setup" menu's "Blocking states" control
to see the overall clamps states.
The clamps are displayed as follows:
- Open (green with symbol "-")
- Closed (yellow with symbol "X")
- Closed on workpiece (red with symbol "+")
Tick "Display the clamps' blocking states" in the "Options" menu's "Work top" "Parameters" to
ensure the blocking state is always active when accessing "Setup".

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3.11.1.8 Clamps positioning on workpiece
One or more workpieces having one or more work phases can be blocked on the machine's
work top.
Every phase must contain information on position and states of clamps for machining
workpieces with machines having motorised work top (not essential for machines with manual
work top).
The clamps can be positioned:
1) Fully manually
2) Manually using the blocking profile
3) Automatically using the blocking profile
Once the clamp has been fitted, it can be moved in three ways:
- Click on the clamp and drag it keeping the mouse button pressed;
- Enter the precise coordinates where the clamp must
be positioned in the screen on the right displayed after
clicking on the clamp (figure 8);
- Enter the size of the movement to perform and clicking
on the arrows on the right displayed after clicking on
the clamp (figure 9).
The clamp movement is restricted by an anti-collision control that does not allow movements if it
detects collision between the clamp and other machine elements on the plane.
The following functions can be used by the operator during the positioning.
This ribbon button is used to block the movement of the bars
to guarantee the positioning of the supports in Y without worrying about the movement
in X.
This ribbon button is used to block the movement of the supports
to guarantee the positioning of the supports in X without worrying about the movement
in Y.

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When a bar has a clamp closed on the workpiece, the movement of the bar is not allowed.
Therefore the movement in X is inhibited when trying to move the bar and when moving a
different support from the one blocked.
If there is only one clamp closed on the workpiece along the bar, its movement also moves the
bar in X.
When a clamp is moved by dragging, its blocking state changes to closed. This function has
been implemented to comply with standard clamps.
3.11.1.8.1 Manual clamps positioning
This positioning only has the screen viewing aid.
Position by dragging one clamp in the wanted position at a time.
Then change clamp state in “Closed on workpiece” (see paragraph 3.11.1.7)
Ensure the workpiece does not touch the clamps' rod.
3.11.1.8.2 Manual clamps' positioning with blocking profile
The blocking profile is a polyline that can only currently be realised from "Script": writing an
external file to be imported in Maestro.
As well as polyline geometry, the blocking profile also has a dimensional feature indicating
minimum pincering.
Different blockings can be made using the "Pincering
rules" in the "Setup" menu, with a piece having a
blocking profile.
- Load distance
- Minimum pincering
- Maximum pincering
- Maximum pincering without recoveries

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1) The "Load distance" rule is normally used to position the clamps that must internally
block a door to be profiled.
The clamp's axis sticks to an axis that becomes blue when a clamp nears the blocking
profile using the "Load distance" rule.
This guarantees the clamp remains at a distance from the blocking profile.
The clamp's state is automatically taken to "Open" when left on the blue axis.
Use the "Tools" "Options" control to modify the parameter establishing the clamp's
distance from the blocking profile (Load Distance (DCA)). The following screen appears:
The "Load distance (DCA)" parameter is found in the "Options" "Parameters" "Work top"
folder.
2) The "Minimum pincering" rule is normally used to position the clamps that must block the
workpiece, pincering minimum wood section.
The clamp's axis sticks to an axis that becomes red when a clamp nears the blocking
profile using the "Minimum pincering" rule.
This guarantees the clamp pincers the blocking profile for minimum established height.
The clamp's state is automatically taken to "Closed on workpiece" when left on the red
axis.
The minimum pincering dimension is written as blocking profile feature.
3) The "Maximum pincering" rule is normally used to position the clamps that must block the
workpiece, pincering maximum wood section.
The clamp's axis sticks to an axis that becomes green when a clamp nears the blocking
profile using the "Minimum pincering" rule.
This guarantees the clamp pincers the blocking profile for maximum established height.
The clamp's state is automatically taken to "Closed on workpiece" when left on the green
axis.
The maximum pincering dimension depends on type of clamp and "Rod-workpiece
distance" parameter found in the "Options" "Parameters" "Work top" folder.
4) The "Maximum pincering without recoveries" rule is normally used to position the clamps
that must block the workpiece, pincering maximum wood section, guaranteeing exchange
of clamps without recoveries to speed-up the cycle.
This rules only remains active for horizontal, without arcs, blocking profiles.
The clamp's axis sticks to an axis that becomes blue when a clamp nears the blocking
profile using the "Maximum pincering without recoveries" rule.
This guarantees the clamp pincers the blocking profile for maximum established height.
The clamp's state is automatically taken to "Closed on workpiece" when left on the blue
axis.

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The pincering dimension depends on type of clamp, workpiece width, "Safety distance in
Y" parameter found in the Bars' "Property" window configuration and on "Rod-workpiece
distance" parameter found in "Options" "Parameters" "Work top" folder.
Notes:
- The "Load distance" rule deactivates the others and vice-versa
- The maximum pincering rules exclude one another
- "Minimum pincering" rule can be activated together with a maximum pincering rule. This
enables clamp positioning in the area between the red and green axes or between the
red and blue axes.
3.11.1.8.3 Automatic clamps' positioning with blocking profile
Use the "Automatic setup" control in the "Setup" menu's "Work top
setup" sub-menu to automatically position the clamps on the
blocking profile.
The clamps are automatically positioned on the blocking profiles of all
workpieces in all phases without adding further information, after
clicking on the function control.
Note: This function saves time compared to manual positioning.

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3.11.1.8.4 Positioning terminals outside the work area
When you have a machine that has reference stops inside the work area, you may need to
place the clamps outside the work area.
This feature is enabled by ticking the entry:
Allows the positioning of the supports outside the area
the item is located by selecting:
Tools-Options-Parameters-Work Plan-Automatic Positioning Terminals
Enabling functionality allows you to get this set up, allowing you to have more work space
available:

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3.11.1.8.5 Enables the positioning of the clamps on the piece edge
When working a particularly tedious material, it may damage the special high-pressure part that
is created when the automatic positioner of the terminals places them on the edges of the
workpiece.
the axes can be moved with the mobile control panel.
Enables the positioning of the clamps on the piece edge
the item is located by selecting:
Tools-Options-Parameters-Work Plan-Automatic Positioning Terminals
Example that could crash the edges (With the flag selected)
Example that does not damage the edges (Without the flag selected)

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3.11.1.9 Initial setup creation
An "Initial phase" is required for loading the workpieces to complete the project.
Use the "Initial setup" control in the "Setup" menu's "Work top setup"
sub-menu to do this.
A new "Initial Setup" phase, indicated in the first project phase with
regard to clamps' positions (the clamps blocking the workpiece will
have the "Open" state), is created after having selected the control.
The initial setup phase must be manually completed if preparing initial setup for a closed
structure workpiece, requiring internal blocking (door profiling).
Use the "Load distance" rule to position the clamps inside the door for loading. (see chapter
3.11.1.8.2 point 1)
Note: the "Initial Setup" phase can be eliminated like any other
phase.
To do this, you can also use the "Cancel initial set up" command in
the "Plan recovery" menu
3.11.1.10 Final setup creation
Unlike initial setup, this function is compulsory. It is used if clamps must be moved to remove
the workpiece (internally blocked door) at program end.
Use the "Final setup" control in the "Setup" menu's "Work top setup" sub-menu to create a final
setup phase.
A new "Final Setup" phase is created, identical to "Initial Setup", after having selected the
control.
The function will not be successful if an initial phase is not already present.
Note: the "Final Setup" phase can be eliminated like any other
phase.
To do this, you can also use the "Cancel final set up" command in the
"Plan recovery" menu

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3.11.1.11 Cycles generation for clamps exchange
Establish the clamps' sequence of movements to change from one project phase to another,
once the clamps have been positioned in the various blocking phases.
This is done automatically using the "Cycles generate" control in the "Setup" menu's "Work top
setup" sub-menu.
A cycles structure, a set of phases to manage the clamps' exchange, is created after having
selected the control.
The following is a structure example:
The cycles names are composed of initials identifying the
clamps, followed by a letter expressing a change.
Examples:
- B1M1O  (O) Opening of clamp 1 (M1) of bar 1(B1)
- B1M1Y  (Y) Long Y movement of clamp 1 (M1) of bar
1(B1)
- B1M1B  (B) Blocking on workpiece of clamp 1 (M1)
of bar 1(B1)
3.11.1.12 Cycles elimination for clamps exchange
The already created cycles must be eliminated if modifying one or more positions of the clamps
in any phase.
Use the "Cycles cancel" control in the "Setup" menu's "Plan
recovery " sub-menu to eliminate all cycles.
This happens automatically if re-using the "Cycles generate"
control.

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3.11.2 Workpiece blocking with suction cups
The workpiece blocking with suction cups is usually used when machining panels.
To select the devices proceed as described in the chapter 3.10.1.3 and select “Vacuostats”
3.11.2.1 Type of suction cups
The types of suctions clamps currently available are:
1. Standard suction cups
2. HePod suction cups
3.11.2.2 Select the type of suction cup
To select the type of suction cup use the list of suction cups available
on the bottom left:
The suction cup preview is shown in the top right window:
The codes of the suction cups is similar to the clamps (see chapter 3.11.1.1)

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3.11.2.3 Suction cups positioning on the bars
Once the suction cup has been selected it can be dragged on the manual bar or on the plates of
the motor driven bars.
On the motor driven bars the suction cups can be installed on all the plates using the command
that appears by right clicking on the suction cup that you want to use.
If you want to install them on just certain bases, use the Mount command on selection, that lets
you use one suction cup and install it on all the bases that will be touched afterwards.
The layout of the table is saved and reused in the same way as described for the clamps (see
chapter 3.11.1.4)
3.11.2.4 Positioning suction cups under the piece
The suction cups can be positioned under the piece in two ways:
- Manual positioning
- Automatic positioning
3.11.2.4.1 Manual suction cups positioning
This type of positioning has not help apart from the visual one on the screen.
To position drag one suction cup at the time in the desired position.
For the manual positioning of the suction cups proceed in the same way as the manual
positioning of the clamps (see chapter 3.11.1.8.1)
The table setup defined manually can also
be used for the automatic positioning by
selecting the “Keep the current set-up”
option in the worktable options.

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3.11.2.4.2 Automatic suction cups positioning
A piece can be blocked automatically with the suction cups by
using the Automatic setup function in the Table setup menu.
If some suction cups have already been entered and the “Keep
the current set-up” option has not been selected, the automatic positioning will give this
message :
Press "Yes" to display the following screen used to define which suction cups to use and how to
position them during the blockage.

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Click on Apply to allow the algorithm to automatically position the suction cups, taking into
account the piece, machinings, suction cups being used and the relative positioning.
See below for a blockage example:
If the table is setup with He-Pod suction cups or if the "Keep the current setup" option has been
selected (see chapter 3.11.2.4.1) the screen with the list of suction cups available is not
displayed, but it proceeds with the automatic positioning, taking into account only the blocking
devices on the machine table.
For the management of the He-Pod table see chapter 6.

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3.11.3 Easier Load
The "Easier Load" function can be used to machine workpieces in a different position to that
loaded.
3.11.3.1 Easier Load Insertion
Use the "Easier Load" control in the "Setup" menu's "Work top
setup" sub-menu to make loading easier.
The following screen appears after the control is selected:
The Assisted Loading Mode area allows for selecting Automatic mode or the Manual mode.
3.11.3.1.1 Automatic facilitated loading
Selecting this mode disables the area for the input of the loading and unloading deltas as these
will be automatically calculated on the basis of the dimensions of the machining and of the
clamps present on the table.

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By clicking Apply, if the dimensions of the machining allow it, facilitated loading and unloading
phases will be created as in the manual mode and the workpieces will be machined in positions
that avoid collisions.
The function manages a maximum of 4 workpieces arranged in two columns and 2 work
phases.
3.11.3.1.2 Manual facilitated loading
Selecting this mode enables the area for the input of the loading and unloading deltas: on the
left you can see the names of the workpieces in the project; you can specify the "Loading Y
Delta" and "Unloading Y Delta" on the right for each workpiece.
The names of workpieces in the project appear on left.
Specify the "Load Y Delta" and the "Unload Y Delta" for each workpiece on right.
The "Load Y Delta" indicates the distance the workpiece must be placed at compared to loading
initial position.
The "Unload Y Delta" indicates the distance the workpiece must be re-positioned at compared
to positioned defined with initial "Load Y Delta".
Two new phases are created by clicking on "Apply": "Load phase" and "Unload phase".
- "Load phase" is identical to old "Setup" phase (without machining).
- The new "Setup" phase is like the old "Setup" phase plus "Load Y Delta".
- The new "Swap" phase is like the old "Swap" phase plus "Load Y Delta".
- The "Unload phase" is identical to the new "Swap" phase less "Unload Y Delta" (without
machining).
Example:

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3.11.3.1.3 Preset of easier load
It may be necessary to use different easier load heights based on type of workpieces to be
machined.
A range of "Presets" can be created to memorise the load and unload heights of the various
workpieces to be machined.
3.11.3.1.4 Preset of easier load creation/change
Use the "Modify Presets" control in the "Easier load" screen to create or modify a new "Easier
load preset".
The following screen appears after command is given:
The following screen appears by clicking on "New":
For entering a new preset name.
"Preset" field shows existing presets: for selecting the name of a preset to be modified.

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All screen fields can be modified with a visible preset.
Click on "Add" to also insert a new workpiece.
Click on "Save" to memorise the made modifications.
3.11.3.1.5 Preset of easier load use
Select preset name from "Preset" box to associate those memorised to current project.
Note: Visible presets are only those having the same number of workpieces of those of the
current project.
The "Preset name" field is filled with names of workpieces described in preset and the "Y Delta"
fields with relative values memorised in preset, once this is associated.
The workpieces' names are automatically associated if those memorised in preset and those in
the current project coincide. If not, use the arrows right of the workpiece names to correctly
associate them.
With "Apply", the "Easier load" function continues creating new phases as previously described.

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3.11.3.2 Easier load elimination
Restore original phases if wanting to perform easier load again at different heights to those
previously set. Eliminating the two "Load phase" and "Unload phase" added phases would be
insufficient.
This is done using the "Delete easier loading" function in the
"Setup" menu's "Plan recovery" sub-menu.

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3.11.4 Work top automatic setup
This chapter describes many phases that can be automatically performed in sequence, without
operator interaction.
This is done by directly clicking on the "Setup" menu's "Work top setup" control.
Note the "Work top setup" icon is the same used as sub-menu for the previously seen individual
functions.
The following screen appears after "Work top setup" command is given:
The following functions are performed in sequence once all is ticked and "Apply" is clicked:
- Automatic setup (see chapter 3.11.1.8.3)
- Easier load (see chapter 3.11.3.1)
- Initial setup (see chapter 3.11.1.9)
- Final setup (see chapter 3.11.1.10)
- Cycles generate (see chapter 3.11.1.11)
The project is enriched by the creation of all individual functions' phases, except "Final Setup"
phase created only if required (for doors blocking).

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3.11.5 Restoring the plan
This function is used when you want to eliminate all those phases or cycles that were
automatically created with the "Plan set-up" function.
By clicking on the "Plan recovery" command in the "Setup"
menu, all the operations visible in the drop-down menu will
be performed automatically:
- Delete cycles
- Cancel final set up
- Cancel initial set up
- Clear facilitated load
The order of the cancellation operations is the exact reverse of the order of creation.
3.11.6 Collisions check
After the clamps or suction cups blocking systems have been added to the project, it is probable
that the tools and machining units can come into collision with these devices.
This can be checked with the "Collisions check" option in the
"Setup-Checks" menu.
If a collision is detected, the following message appears:
To have more information on the message displayed, you can
see the areas inhibited to the blocking systems with the "Show
collision areas" command.

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An image similar to the one below will appear:
The area with the red border is the area inhibited to the positioning of the suction cups as the
machining is through.
To resolve the problem move the suction cups and repeat the check.
When there are no more collisions the following message is displayed:
N.B.: The fact that the previous message appears does not guarantee that there won't be
collisions during the machining in the machine, as the Maestro "Collisions check" command
checks only the machinings and blocking devices defined. In this context not all the elements
that could create collisions are defined.
To have a greater level of certainty of avoiding collisions during machining, perform the program
simulation with the optional ProView package.

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3.12 Definition of workpieces machined
contemporaneously
In order to machine various workpieces define the following:
1. Number of workpieces to machine contemporaneously on the table
2. Whether to minimize the tool changes in the program
3.12.1 Number of workpieces machined contemporaneously
The number of workpieces to machine contemporaneously on the table depends on the
dimension of the workpieces and the dimension of the machine table.
To enter various workpieces on the machine table you must create a project with various
workpieces and display the position in machine with the “Arrange” function.

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3.13 Project optimization
This option allows you to minimise the number of tool changes and the paths related to the
transfer from one working process to another one.
Starting from a saved project, a new project will be created, with a working processes structure
according to the modes indicated.
The project name will be "NameProjectOriginalOpt.pgmx".
After the process, the source project will be closed and the optimised project will be opened.
In order to optimise a project, use commands "Guided optimization" or "Automatic Optimization"
in the menu "Machines" "Optimizator".
After applying the optimization modes described in following paragraphs, the file
"NameProjectOriginalOpt.pgmx". will be created.
If the optimised file was already been created, following message would appear:
By choosing "No", the optimization will end without saving any optimised file.
If you choose "Yes", following message will appear:
By choosing "Cancel", the optimization process will end.
By choosing "OK", the source project will be closed and the optimized project will open.

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3.13.1 Standard projects optimisation
The mode for project optimisation can be:
Guided
Automatic
3.13.1.1 Guided Optimization
This mode allows you to restructure the working process ordering in every step before
optimizing the project.
By using "guided Optimization", following menu will open:
You can decide the optimization on one step or all steps by using the area "Working steps".
This workpiece of the menu will appear only if working processes on almost two steps exist.
In the area "Working processes", all working processes in the step or in the selected steps will
be displayed. You can change the working process ordering with the arrows.
In the area "Tools", all tools in the selected type of working process will be selected. It is
possible if you change the tool ordering with the arrows.
If you select the check "Sub-programs optimization", all working processes in the sub-programs
will be drawn, following the same structure of the previuos project. In order to avoid losing the
ordering operations, following message will appear:

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If you select the check "Optimization tool path", apart from tool change minimization, also the
whole tool path is minimised among the different working processes.
After the selection, you can:
- Click on the command "Cancel" to avoid the optimization
- click on the command "Restore"
- Click on the command "Apply"
The command "restore" could restore the working tree as it was in the source project, so
following message would appear:
With the command "Apply", the optimization for the tool change would be carried out without
keeping the technological sequence on all working processes in the selected step.

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3.13.1.2 Automatic optimization
By using the command "Automatic Optimization", following menu is open:
If you do not insert any check, the optimization for tool change is carried out on all project
working processes without changing the technological sequence.
Tools change and overall tool path among the various machining are minimised if "Optimisation
enable" is checked.
If you select the check "Optimization tool path", apart from tool change minimization, also the
whole tool path is minimised among the different working processes.
IIf you select "sub-program optimization", before starting the process, all working processes in
the sub-programs will be drawn. The working tree of the source project will be modified.
After the selection, you can:
- Click on the command "Cancel" to avoid the optimization
- Click on the command "Apply"

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3.13.2 Nesting projects optimisation
The mode for Nesting project optimisation can be:
Guided
Automatic
3.13.2.1 Nesting Guided Optimisation
Guided optimisation is divided in another two modes:
Basic Guided Optimisation
Advanced Guided Optimisation

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3.13.2.1.1 Basic Guided Optimisation
Before optimising the project, this allows manually re-organising the machining order within
each phase.
The following menu opens using the "Basic Guided Optimisation" control:

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Basic optimisation is by machining sequence and a tool order can be indicated for every
machining (the order can be manually modified for both Machining and Tools menus using the
"UP" and "DOWN").
Enable tool path optimisation to:
- access the Optimisation type drop-down menu for specifying the tool path to be
optimised according to Generic mode, X Long (optimises path according to movement
along axis X), Y Long (optimises path according to movement along axis Y).
- Enable/disable the "Execute boring first" option.
- Enable/disable the First cut the small pieces option
The generic optimisation allows the inversion of
the machining tool path, by selecting the relative
parameter.
The optimisation along X allows the sheet to be virtually cut in horizontal strips that will have a Y
dimension equal to the dimension of the sheet divided by the number of "Lines" set.

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The final result will be that the machinings after the
optimisation will follow the progress displayed.
The optimisation along Y allows the sheet to be
virtually cut in vertical strips that will have a Y
dimension equal to the dimension of the sheet
divided by the number of "Columns" set.
The final result will be that the machinings after the
optimisation will follow the progress displayed.
The guided optimisation window is closed using the "cancel" control
Initial condition, highlighting the following message, is restored using the "Restore" control
Optimisation for tool change is made with "Apply" control.

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3.13.2.1.2 Advanced Guided Optimisation
Machining order is manually re-organised, creating groups containing different machining,
through this mode.
The following menu opens by selecting this optimisation mode:
The machining section changes compared to basic optimisation: a button is present for groups'
creation/removal.
A group is a set of machining (list on left) associated for managing its order priority compared to
overall machining.

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The following menu opens by selecting the Add/Remove Groups button:
A group can be created containing machining in the list on right, using the arrow towards right
button from the machining list on left.
Enter the group's name in top-left box.
This group is added to the list (scrolled via the drop-down menu) using the Apply button.

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Advanced optimisation of all groups, following priority given during forming of the individual
groups, is made by selecting "All".
All machining in Milling (with order established in the same group), then all incisions and finally
the Cuts are performed in this case (above figure).

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3.13.2.2 Nesting Automatic Optimisation
The following menu opens using the "Automatic Optimisation" control:
Tools change optimisation is performed on all project machining without altering the
technological sequence if no check is inserted.
Tools change and overall tool path among the various machining are minimised if "Optimisation
enable" is checked.
For a detailed description of the type of optmisation process see 3.13.2.1.1
After the wanted selection is made:
- click on the "Cancel" control to miss optimisation
- click on the "Apply" control to proceed with optimisation.

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3.13.2.3 Edge banding optimization
Once all the edge banding machinings have been created, they can be optimized by accessing
machines, optimizer and select Edge Banding Optimizer.
At this point a table will be displayed to select the various operations to optimize.

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3.13.2.3.1 Rotations optimization
Select this optimization option to optimize the
rotations of the edge banding head for the
collisions check and to optimize the gluing
between edge and panel.
3.13.2.3.2 Lamps optimization
switch on of the lamps used to heat the
edge, especially for geometries that include
arcs.

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3.13.2.3.3 Stop roller optimization
Select this optimization option to optimize
the roller stop of the edge banding head,
especially for geometries that include arcs.
3.13.2.3.4 Edge banding parameters optimization
Select this optimization option to optimize
the edge dispensing parameters and the
infeed and outfeed wait times by using the
technology data of the edge used for the
edge banding.

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3.13.2.3.5 Autostart optimization
Select this optimization option to disable
Autostart machine instruction for the first
edge banding and enable it for the
subsequent edge banding operations.
3.13.2.3.6 Trimmer rotations optimization
trimmer rotations to avoid collisions with the
edge, especially when the trimmer
changes direction.
N.B.:
The edge banding optimization will cancel all the attributes entered
previously during the creation phase, replacing them with the
optimized attributes.

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3.13.2.3.7 Anti-adhesive and Polishing optimisation
The Anti-adhesive and Polishing tools can be inclined along their path to avoid any collisions in
a similar way to trimming. It is therefore necessary to optimise the machining using the Optimize
Edge banding command and selecting the Finish-> Rotation Optimization field
This is particularly important when working with profiles where collisions can occur during
machining.

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3.14 Automatic parts arrangement and optimization
This function enables users to automatically place several pieces on the plane and to optimize
the blocking and processing sequences
The premise is that a .eplx file has been previously saved defining how the plane is set up (see
chapter 3.11.1.5)
To activate the function, use the command
"Project-Pieces layout"
The following screen will appear:

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3.14.1 Add Project
With this command, you add a project to the list of projects to be optimized.
The project must have a single piece inside.
The "Add" command is used
A list of pieces to be placed on the plane will appear:
3.14.2 Pgmx editor
By selecting a pgmx from the list, it will become blue so you can:
- Remove the pgmx with the key
- Move it to the top of the list with the key
- Move it down in the list with the key
- Change the quantity in the "Repetitions" box
- Select one or two adjacent sides in the "Reference" field of the piece which must obligatorily
be into abutment.
The optimizer to decrease the generated pgmx could also rotate some pieces by 180 °.
- Select any mirroring in the "Mirroring" field

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3.14.3 Saving and opening .wpx files
Files with the .wpx extension contain a list of projects to be optimized and blocked on the
machine floor.
The wpx file is saved using the command
The save will create a file with the .wpx extension in the selected folder
To open an existing .wpx file, use the command
3.14.4 Optimisation criteria
The optimisation criteria determine from which part of the plane the pieces will start to be
positioned.
To this end, the "Departure areas" and "Starting area" drop-down menus are used.
The areas where you can position pieces are
those read from the configuration:
The front areas are those near the operator, while those to the rear are those away from the
operator.By clicking on ABCD, the following screen appears:
Where you can select or deselect the desired row of areas
The selection of the "Left half-plane" or "Right half-plane" will make the wizard choose the
"pendulum" mode to calculate the area of the optimised programs.
Selecting the "Whole Plane" will generate all programs in the AD area.

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3.14.5 Optimisation
Piece layout optimisation is done with the button
The processing result will consist of:
-A .mixx file containing the list of generated pgmx
- many pgmx files containing one or more pieces
3.14.5.1 Generated .mixx file
The generated .mixx file can be positioned and renamed using the field:
The .mixx file will contain a list of all the .pgmx files generated during processing
3.14.5.2 Generated .pgmx files
The generated .pgmx file can be placed in the desired folder using the field:
Each generated .pgmx file will respect the set criteria.

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3.15 Tool magazine optimisation
This feature allows you to automatically determine an optimal arrangement for the tools inside
the fixed-place magazines on board the machine in order to consider the actual profile of each
tool and not just the minimum cylinder that contains it. This way you can clearly compact many
more tools in the magazines, because you analyse the effective interpenetration between two
profiles, which allows you to find arrangements that require fewer free positions to be absolutely
sure that two tools will not conflict. Just to give a clearer understanding, optimisation for
interpenetration permits results such as the following:
a simple arrangement for cylindrical dimensions would have involved an empty position
between one tool and the other, as both tool types shown protrude with respect to the cylinder
associated with magazine position (grey rectangle):
Optimisation is a general utility tool and particularly useful in frame machining, which requires a
large number of bulky tools with complex and irregular profiles.
The function can accessed through the "Magazine optimization" button, located in the upper bar
in the Machines Tab and in the 'Tools' group.
The graphical interface looks like this:

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Broadly speaking, it is a matter of specifying a certain machine configuration (Maestro can also
be used in the office and not only on the machine to perform this type of processing on different
machines) and the tools that you want to have in the magazines to then execute the algorithm
which will process the input and return the result essentially as a tool - magazine position list.
Going into a little more detail, in practice the optimisation will rarely be performed from a start
point of completely empty magazines. For this reason, a magazine status should loaded through
a specific file. By uploading files of this type, a 'snapshot' of all the magazines is imported from
which a new optimisation can begin. The result of the optimisation is rendered both in a
printable document and through a graphical preview, with immediate feedback on tool
interpenetration, as well as potential conflicts (if there are any errors). Finally, it is important to
highlight how, in addition to the 'final snapshot', optimisation will also determine the sequence of
all tool transfers, starting from the initial state and ending at the aforementioned final
arrangement. This is the overall picture, so let's see in detail how this is achieved.
In the left column there are widgets to specify the input of the algorithm, the central area is
dedicated to the output, i.e. the graphical preview of magazine status resulting from
optimisation. The buttons at the bottom will be described later.
As mentioned, all input to the optimiser is provided through the graphical controls in the left
column. Starting from the bottom, let's look at the options in detail.
Tools pane. A list of all the tools related to the selected tool file (.tlgx) is shown. Each time this
selection changes, the list is updated.

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The Select tools from pgmx/mixx button allows you to select programme files of the type
indicated to automatically select the tools of the enabled machining present. The selection can
also be repeated, as the previous selections only have the effect of checking the related tools in
the list.
To reset or select all tools use the Select/deselect all check mark at the bottom.
Then we have the following line of controls, placed beneath the programme selection button:
The leftmost selection check allows you to filter the tools in the list based on their
selected/unselected status. The text box allows you to filter this list based on text segments
contained in the tool name or description. The two Open and Save buttons allow you to open a
file containing the tool list in the order indicated and with the previously saved selection status,
and to save the current selection. Please note that the order in which the tools are shown in the
list is important in establishing their priority. The closer a tool is to the top of the list, the higher
its priority. This order can be changed by means of drag&drop on an individual tool selected
with the mouse and dragged to the desired position in the list. When dragging is active, a label
appears next to the cursor containing the name of the tool, as shown in the image.
ATTENTION: drag&drop works only when the selected tools view check is disabled, since the
check represents a filter on the tools list and the order to assign priority makes sense only on
the list as a whole, and not a part of it.

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Higher up we have the Configuration pane, where you simply go to select the desired machine
configuration using the appropriate Combo. The available magazines will be updated with each
new selection. It is not possible to make enabling/disabling selections on the individual
magazines, therefore these will always be enabled and greyed out.
Last but not least is the Parameters pane, where you choose the behaviour logics you want for
the optimizer. More specifically, this
Optimisation strategy allows for a choice between the two opposing approaches, priority and
compacting.
The Compacting strateg places the selected tools to minimise the overall space occupied,
without taking into account the withdrawal time of each individual magazine and how much a
given tool is used within a given job to be processed (pgmx/mixx). The aim is to maximise the
storage space offered by the magazines, thereby avoiding tool exclusion. This is particularly
advantageous when the price to pay for higher average picking times is not such to justify
manual loading/unloading of tools by the operator if these magazines are frequently
reconfigured according to the type of programmes to be executed. For example, it may be
useful to perform this type of optimisation for the first time with empty magazines, without being
guided by a particular series of panels for machining. In this case, the optimiser will be free to
find the most compact solution to store as many tools as possible in the machine arranged in
the various magazines
On the other hand, the Priority strategy places the first tools that appear in the list in the
magazines with the shortest picking time (parameter can be set in the machine configuration).
This is at the cost of fragmenting magazine allocation, not fully utilising capacity and perhaps
leaving some positions free in favour of housing higher priority tools. Therefore, the percentage
of use of a given tool in a given job, the linear metres of machining to be carried out, the
frequency of use etc., are all reflected in one parameter: the order of the tool in the list. This
operation is not currently automatic, and how well the order specified by the operator reflects all
the parameters indicated above depends on the success of optimisation in obtaining the lowest
possible cycle times.
Two further parameters can be entered in this pane
Safety distance (mm): the minimum distance to be maintained between two tools, in millimeters.
It goes without saying that the success of the optimiser in maximising tool interpenetration is

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much higher when the profiles are represented more accurately. We know that this is not always
possible for a number of reasons. For example, it is not always possible to obtain the CAD
drawing with which the tool maker designed the tools. Using this parameter, it is possible to
compensate for any representation defects, without the risk of tool collision during handling
and/or in the housing.
Maximum time: this is the indicative maximum execution time that you want to grant to the
optimiser to find a solution. Longer times will give the algorithm greater possibilities to explore
the space of all possible configurations. Therefore, and particularly when the magazines are
sufficiently full, the differences in the quality of the solution compared to optimisation performed
with shorter times will be appreciable.
Let's move on to describe the meaning of the buttons located in the lower interface area.
Starting from the left, we have:
1. Import status: allows you to import a current magazine status from a special file with the
extension tsdx, generated using Maestro Active.
2. Start optimization: starts the algorithm. The other buttons are disabled during processing,
while this button changes name to “End Optimization”, thus allowing abort.
3. Print: at the end of the optimisation it will be possible to generate a document containing
the results. This command opens the preview, which can then be printed.
4. Export tool transfers: as mentioned, at the end of each optimisation a sequence of tool
transfers will be generated to move from the initial state to the final arrangement. This
command allows the sequence to be exported to a file for uploading into Maestro Active,
from which it can be automatically executed on the machine.
5. Reset Results: Performs a reset to start a new optimisation from a clean state.
Once the machine configuration, tool order preference, optimisation parameters and, where
relevant, the initial state have been selected, optimisation can be performed by pressing the
Start optimization button.
During processing, a progress bar will appear at the bottom of the central graphical area, from
which you can see the optimisation phase in progress. Once complete, the graphical area will
be populated with as many tabs as there are magazines, plus an additional Tools out of
magazine tab, where any tools that the optimiser was unable to place will be listed. On each tab
relating to a magazine, a graphical representation of the profile of the tools in their respective
positions will be shown schematically (i.e. without taking into account the actual geometry of the
magazine) (see example in image).

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It will therefore be possible to generate a detailed document where a tool-position list will be
generated for each magazine, accompanied by the graphical representation that can also be
seen on the screen, plus a list of tool transfers to be carried out to move from the initial state to
the final state produced by the optimizer. The following image shows an example of such a list.

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3.16 Simulation
After having created or opened a project you can see the simulation of the machinings with the
specific menu:
There are three simulation modes:
1. Tool path simulation
2. Machining simulation
3. Simulation in machine (optional)
3.16.1 Tool path simulation
This display mode shows the path of the tool in one or more machining operations.
3.16.1.1 Display only one machining
To display the tool path of a
single machining use the context
menu that appears by right-
clicking on the machining that
you want to view. The menu
displayed at the side appears.

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After having selected the command the following player is displayed:
The “Previous machining” and “Next machining” buttons are not available when the command is
launched from the context menu of a single machining operation.
Click on “Start/Resume display" to display the tool path, scrolling the tool with the geometry
described in the .tlgx file.
The machining speed can be changed with the “Speed potentiometer”.
When the tool path is displayed the menu changes as follows:
“Interrupt display” suspends the display and the “Start/Resume display” button will be available.
3.16.1.2 Display all the machinings
To display the tool path of all the machinings click on the "Tool
path" button in the "Simulation" menu.
The display mode is the same as the one used to display a
single machining, except that during the simulation you can switch between machinings by
clicking "Previous machining" and "Next machining", which are active in this option.
End display
Previous machining
Start / Resume viewing
Potentiometer speed
Further processing
Sospendi visualizzazione

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Clicking on one of these buttons you can display the previous or next machining, even if the
current display has not finished.
If you are using a project with various pieces, the display will show all the machinings of the
current piece only.
3.16.2 Machining simulation
This display mode shows the machinings realistically.
If the tools have been defined as shaped tools, you can see the correct tool and the machining
that will remove the material removed by the actual machining.
To display the tool path of all the machinings click on the
"Machinings simulation" button in the "Simulation" menu.
The commands to display the single machinings are identical
to those used to display all the machinings.
The screen displayed will be as follows:
At the end of the machining, if all the tools have been defined correctly, you will be able to see
the piece that will be produced during the actual machinings exactly.

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3.16.3 Simulation in machine (optional)
This type of display, as well as seeing the single machining or the single piece machined, allows
you to see the model of the machine with all the clamping devices, whilst it is machining one or
more pieces on the table.
This function (ProView) is an optional module that previously could only be used out of the
Maestro interface, lets you simulate the execution in the machine of the program loaded in
Maestro. This means that the simulation in Maestro is always of a single pgmx program at the
time.
It is important to note that the machine displayed in simulation will be only the one compatible
with the Maestro configuration for the machine serial number purchased by the customer.
3.16.3.1 Enable the Proview simulator in Maestro
In order to use the simulator in Maestro it must be enabled in Maestro with the options. If the
optional module is active, the Simulation node in the parameters tree is displayed in the options.
By selecting the Enable the use of the simulator, the simulator will be available next time
Maestro is started, the two Proview and Numeric Control folders will indicate where the two
applications are located.
The pages also display certain values necessary for the correct start of the simulator, that
generally do not need to be changed.
3.16.3.2 The simulation environment

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Once the use of the simulator has been enabled (3.15.3.1) the next time Maestro is started the
Simulation button will be visible in the Machinings simulation group. Press it to access the
simulation environment.
The window that appears contains at the tip a series of commands used to manage the
simulation, the graphic area shows the machine and on the right there is a panel that contains,
in the upper part, the messages from Maestro Active during the execution of the simulation and,
in the lower part, the program execution time.
The following commands are available to manage the simulation.
The first group of Program buttons contains the table Setup commands (if necessary, e.g for a
bars table) and program Reload.

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The Program simulation group performs the piece simulation: Start starts the simulation, Pause
pauses the execution and Stop stops the execution of the program and unloads the piece from
the table. If you want to keep the piece on the table at the end of the program execution, press
the Show piece button before the program execution. In this way the program is interrupted just
before unloading the piece, that will be executed by pressing Stop.
The Speed multiplier group increases and decreases the program execution speed by pressing
Decrease and Increase, the multiplication factor is from 1 to 10.
The MDI group has only one button used to execute the Start, when the machine is in the MDI
state.
Finally the Close button in the Close group, stops any program simulation in progress and
closes the simulation environment, going back to the Maestro planning environment.
The title bar contains a button highlighted in the figure with a red rectangle that is pressed to
display the Maestro Active window.
3.16.3.3 Simulation example
To simulate a program it must be saved in Maestro and the machine supports for its execution
must be defined. Therefore you must access the Setup environment and setup the project.
It is also good practice to carry out a Project check to resolve all errors that could interrupt the
program execution.
As a simulation example lets take a program loaded on a machine with bars table. Accessing
the simulation the pgmx is loaded and the table is setup.
The Setup button flashes indicating that the table must be setup, the Start and Pause buttons
are in fact disabled.
At the end of the setup the Start and Pause buttons are enabled, indicating that the program is
ready to be executed.
During the program execution any instructions that require pressing the Start button (e.g Park
or XMSG), are displayed in the messages panel:

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If the program ends and it has repetitions equal to 1, to be executed again it must be reloaded.
In this case the Reload button is enabled. If on the other hand the program has repetitions
greater than 1, to re-execute it again, simply press Setup and Start again.
NB:
You may need to access in MDI mode to restart the execution of a simulation, for example if the
head in the machine has remained low on the table.
At the next Start you will be informed of this type of error:
In this case you must stop the program by pressing Stop. Open Maestro Active by pressing the
button in the title bar,
access in MDI in Maestro Active, release the head (M80 instruction), go back to Maestro to
press Start in MDI. At this point the head rises in the simulator. After having exited the MDI
environment of Maestro Active the simulation is ready to be executed again.

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3.17 Print
This function is used to print the current view or multiple views.
To print press "Print" in the "Home" menu.
3.17.1 Print current view
To print the current view click on the command in the "Print
current view" drop down menu.
The interface used to set the print options is displayed.
The print will be of the screen displayed.
3.17.2 Print compound views
To print the five orthogonal views of the project click on the
command in the "Print compound views" drop down menu.
After having given the command, the following screen will
appear, to select the display mode of the views.

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By selecting "Rotate the references to keep the views aligned", the view will be as follows:
By not selecting "Rotate the references to keep the views aligned", the view will be as follows:
The interface used to set the print options is displayed afterwards.
The print will be of the two images laid out as shown in the example.

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3.18 Mathematical functions
Maestro features the following mathematical functions:
Abs(value) (Absolute value)
Acos(value) (Arcsine)
Asin(value) (Arcsine)
Atan(value) (Arctangent)
Tan(value) (Tangent in degrees)
Tanh(value) (Hyperbolic tangent in degrees)
Cos(value) (Cosine in degrees)
Cosh(value) (Hyperbolic cosine in degrees)
Sin(value) (Sine in degrees)
Sinh(value) (Hyperbolic sine in degrees)
Exp(value) (Exponential)
Ceiling(value) (Round up)
RU(value) (Round up)
Floor(value) (Round down)
RD(value) (Round down)
Log(value) (Natural logarithm)
Log(value, newBase) (Basic logarithm newBase)
Max(val1; val2) (Maximum)
Min(val1; val2) (Minimum)
Pow(x; y) (Raise x to the y power)
Round(value) (Rounding off)
Sqrt(value) (Square root)
- (Subtraction 600-400 = 200)
+ (Addition 600+400 == 1000)
/ (Division 400/200 = 200)
% (Remaining division (417% 100 = 17)
* (Multiplication 400*2 = 800)
() (Round brackets)
> (Greater dx1>200)
< (Lower dx1<200)
>= (Greater equal dx1>=200)
<= (Lower equal dx1<= 200)
<> (Different 200 != 300)
= (Equal 200 == 200)
^ (Power 2^2=2*2= 4, 2^3=2*2*2=8)
(Value1)AND(Value2) (Operator AND (dx1>600)AND(dy1>400)
(Value1)OR(Value2) (Operator OR (dx1>600)OR(dy1>400))
(Value1)XOR(Value2) (OR exclusive (dx1>600)XOR(dy1>400))
NOT(Value) (Negation NOT(dx1>1600))
IF(Condition;Value1; Value2) (Condition IF (Condition == true) (Value1)
else (Value2)
The functions listed can be used in the parameter or variable fields of the context menus.

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4 Project Management for CX
CX machines have a different table compared to classic routers provided with a multifunctional
table or a bars one; this is why the tools disposition on the machine needs to be treated
separately.
4.1 Loading panels on CX.
The panels to be machined in CX must be loaded manually, positioning them on the left side of
the machine and moving them against the reference stop on the right.
The workpiece can be loaded from the right using a CX220.
To load the workpiece from the right, the machine must be fitted with the relative stops.
Specifically, in addition to the stop for loading from the left, it must be equipped with a stop for
loading large workpieces from the right and one for loading small workpieces from the right.

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The use of one or the other is decided on the basis of the length of the workpiece and the
following
Maestro options parameter:
Workpieces shorter than this value are loaded on the outermost stop.
In the programme you can specify loading from the right through the work area in
Maestro machine parameters.

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The “Standard right” area allows loading from the right without X mirroring the
machining, while the "Mirror right" area allows the same type of loading with
mirroring of the machining.
This window indicates the areas with user-comprehensible names. Below are
the associations between these names and the names of the areas in configuration:
Mirror B
Mirror right C
Standard J
Standard right K
During configuration it was therefore necessary to add the new areas ''K'' and ''C'',
corresponding to ''J'' and ''B'' but referring to loading from the right.
4.2 Unloading panels on CX.
The panels are unloaded from the machine automatically, but the side and unloading mode can
be selected.
The selection is made on the "Machine parameters" - "Hold-down device"
The options in the drop down menu are:
- Unload to the right
- Unload to the left
- Unload to the right complete
- Unload to the left complete

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4.2.1 Unload to the right (V70)
The unload to the right differs whether you are using a CX S or a CX HP.
The unload to the right for the CX S moves the centre of the clamps to the "Right release
quota", however the tail of the panel could remain the work zone when:
- the clamp reaches the positive limit switch
- the panel head reaches the "Maximum unload to the right quota"
The "Right release quota" parameter for the CX S can be changed in the session:
"Tools-Options-Parameters-Work table-CX -Work table" selecting "CX S"
Whilst the "Maximum unload to the right quota" must be set in Xilog
load zone unload zone
work zone
Shaft 1
Right release
quota
Panel
Clamp
Maximum unload to the right quota

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The right discharge for the CX HP is carried out by bringing both clamps to their right limit
switch, opening the right clamp before moving. In this case, the "Right junction level" is not
considered: if the clamps have enough running to bring the panel beyond that height, the
movement is carried out without limitation. The only constraint is given by the parameter
"Maximum discharge level on the right", which represents the limit beyond which the head of the
panel cannot be carried.
The "Right release quota" and "Maximum unload to the right quota" parameters for the CX HP
are changed in the session:
"Tools-Options-Parameters-Work table-CX -Work table" selecting "CX HP"
With this type of unloading, no ribbing is performed: the left clamp remains at the same
coordinate used to perform the last machining, resulting in different unloading positions
depending on the machining and optimization performed. To ensure that the panel is moved to
a fixed coordinate, you must use "Full right unloading".
work zone
Shaft 1
Right release
quota
Panel
Clamp
Maximum unload to the right quota

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4.2.2 Unload to the right complete (V72)
For the CX S, this unloading mode involves, like the V70, bringing the centre of the clamps to
the "Right junction level", with the only difference being that before unloading the clamp will be
repositioned to avoid the panel remaining in the machining area. In practice, you will bring the
centre of the clamp to the "Panel tail clamp position" level (this level can only be modified by
Xilog).
As for CX HP, with this unloading mode, the tail of the workpiece is moved to the "Right junction
level", taking into account also the "Minimum portion of the part to be unloaded". To ensure that
the desired position can be reached, reinsets may be made before the panel is unloaded. As in
the V70 mode, even in this case, do not take the head of the panel beyond the "Maximum right
unloading level".
Minimum portion of piece for
unloading
Panel
Clamp
Panel tail clamp
position
Panel
Clamp

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4.2.3 Unloading to the left (V71)
The unload to the left has a slightly different mode whether you are using a CX S or a CX HP.
The unload to the left for the CX S is executed by trying to move the panel head to the "Offset X
stop", however the panel head could remain in the work zone as no re-clamping is performed
The "Offset X stop" parameter is a configuration parameter, changed in Xilog.
Left side unloading for the CX HP is carried by bringing both clamps to their left hand limit
switch, opening the left clamp before moving. In this case, the "Offset unloading stop" is not
considered: if the clamps have enough running to bring the panel beyond that height, movement
is carried out without limitation. The only constraint is given by the parameter "Maximum left
unloading level", which represents the limit beyond which the head of the panel can not be
carried.
work zone
Shaft 1
Offset X
stop
Panel
Clamp
Piece
alignme
nt stop
work zone
Shaft 1
Offset X
stop
Panel
Clamp
Maximum unload to the left quota
Piece
alignme
nt stop
Stop unload
offset

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The "Stop unload offset" and "Maximum unload to the left quota" parameters for the CX HP are
changed in the session:
"Tools-Options-Parameters-Work table-CX -Work table" selecting "CX HP"
With this type of unloading no ribbing is made: the right clamp remains at the same coordinate
used to perform the last machining, resulting in different unloading positions depending on the
machining and optimization performed. To ensure that the panel is moved to a fixed coordinate,
you must use "Full left unloading".
4.2.4 Unload to the left complete (V73)
This unloading mode is only available for CX HP. With it the workpiece head is moved to match
the "Stop unloading offset", also taking into account the "Minimum portion of the workpiece for
unloading". To ensure that the desired position can be reached, reinsets may be made before
the panel is unloaded. As in the V70 mode, even in this case, do not move the head of the
panel beyond the "Maximum left unloading level".
Minimum portion of piece for
unloading
Panel
Clamp

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4.3 Optimisation for CX programs
The operator does not have to launch the optimisation, because when the pgmx is called from
the machine panel, the optimisation process will be launched automatically.
Before the program is optimised proceed with the following:
- Cluster the machining operations
- Set the clamps-machining operations distances
4.3.1 Machining clustering
The machining process on CX machines requires one or more clampings to machine a piece
completely.
For precision requirements it may be useful to cluster the same type of machining operations
and clearly the machining times will increase in relation to the greater number of clampings.
The machining clustering is managed with the following dialogue window
"Tools-Options-Parameters-Work table-CX-Machining-Machining clusters"
The mode requires you to move up or down the four types of machining operations:
- Horizontal boring
- Vertical boring
- Routing
- Cuts with blade
changing their order.
When a type of operation is the last in the cluster and you click on "Arrow down”, it will be
moved in the cluster below, that if it does not exit it would be created.
The maximum number of clusters that can be created are 4, but it is reduced to 3, when
selecting "Enable the management of all borings as horizontal boring".

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4.3.2 Clamps-machining distances setting
To set the distances between the clamps and machining use the session:
"Tools-Options-Parameters-Work table-CX-Machining-Distance from machinings"
For each type of machining operation you can set a distance from the clamp:
- Unlimited
- Percentage
- Absolute
The setting can be made whether the piece is blocked with a one clamp or with two clamps
(only for CX HP).

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4.3.3 Type of optimisation algorithm
The type of algorithm used to process the project can be selected in the menu:
"Tools-Options-Parameters-Work table-CX-Optimiser"
The following "Clustering algorithm" can be selected:
- Automatic
- Clustering
- Linear
- Sequential
To display a report of the phases generated select the "Display optimisation statistics" at the
end of the optimisation.
4.3.4 Clamps options
With the session:
"Tools-Options-Parameters-Work table-CX-Optimiser-Clamps"

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to set the clamps intervention mode.
Clamp-stop minimum distance
This is the distance to be respected between the edge of
the stop and the edge of the gripper closest to it. It allows
you to position the gripper far enough away from the edge
of the workpiece to allow you to make holes without re-
gripping. When set to 0, this limit is not taken into
consideration and the gripper can also withdraw from the
workpiece during loading.
Use only one end of the clamp to block the piece
Machines equipped with a shaped gripper allow for the
workpiece to be locked with only one of the two ends
(see image to the side for meaning of ''end''). If this
option is disabled, the entire gripper must be wholly
above the workpiece.
In the Clamp grip percentage on piece field enter a
high value (max 100%) to block a piece very well or a
lower value when the clamping is less significant.
The Minimum piece dimensions indicate the
minimum piece that will be processed by the optimiser.
The Flag on Use only one clamp on long pieces is
used only on CX HP adding also the value in the
"Maximum piece length" field.
The longer pieces will be blocked, if possible, with 2
clamps.
Selecting one or more types of machining operations means that during that type of machining
only clamp will be used.
This is to have less interruptions during the machining.
4.3.5 Pressers options
With section:
Tools-Options-Parameters-Work Table-CyFlex/Uniflex Optimizer-Pressers presser intervention
modes can be set.
For CyFlex HP/Cyflex HP2

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to set the pressers intervention mode.
"Minimum length" and "Minimum with" are the minimum piece dimensions, below which the
presser can move down also with one wheel.
"Minimum height" is the thickness below which the presser can move down in the lower part of
the panel.
This is to prevent collisions between the presser and the panel support rollers.
Selecting "Use pressers for horizontal boring", with the value in the "Maximum height for
pressers obligatory downstroke" field, forces the downstroke of the pressers for all horizontal
boring operations that are at a lower Y quota than the one specified.
In the absence of the option, the presser is not lowered.
Selecting "Clamp close to boring without pressers", with the value in the "Maximum clamp
distance" field, forces the presence of the clamp at a shorter or equal distance to the one set
when the pressers cannot operate.
This mode is used to achieve a greater machining precision.
For CyflexHP2 only
Minimum distance between the edge of the workpiece and the centre of the presser wheel
entered to determine whether a presser wheel is above the workpiece and follows the entire
movement made by the presser during machining.
The presser is considered on the workpiece only if this distance is respected.
For all other Cyflex models, the check is carried out on the entire wheel size.
Check that the pressers do not cross existing machinings
The heads for lateral drilling (front, rear, left and right face) are equipped with a presser that
descends to press the panel on the table during machining. This is important for the quality of
the machining, otherwise there is a risk that the hole is at an inaccurate Z coordinate. During
drilling, the presser, which is equipped with wheels, slides over the workpiece and thus follows
the movement of the tool.
If other machining has been carried out before panel drilling, the presser could fall inside these
and break during sliding. However, if the size of these machinings is not large, they may not
interfere with presser sliding even where present. This is why activating the option also enables
the section relating to minimum thicknesses and diameters of machining: if these are not
exceeded, the relative machinings are not taken into account for verification.

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When machining that could break the presser is detected, an error is generated and
optimisation is interrupted.

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4.3.6 Tracing
With the session:
"Tools-Options-Parameters-Work table-CX-Optimiser-Tracing"
to set the maximum difference for the panel to be optimised. Set the value in the "Margin for
feeler" field.
For CyflexHP2 only
Distance from the touch probe in X
This parameter is applicable to the CX220 only. This machine is equipped with a special probe
head which allows probing in all three directions. The head has 3 pads which detect the panel
mechanically along the 3 directions.
The probe is integral with head 1 and, in the probing phase, is pneumatically translated
downwards (minus Z direction) like a drilling machine spindle.
There are two sensors for probing in X: one for the left face and one for the right face.
The options parameter relates to the descent of the head for probing in X: it represents the
distance between the touch probe pressed and the edge of the workpiece to be probed.
4.3.7Panel anti-fall
The anti-fall is made by avoiding opening the clamp or clamps that block the panel at the end of
the discharge procedure. This behavior is conditioned by:
 using a CX HP;
 to the left exhaust, complete and not.
The anti-fall feature can be enabled in the Maestro options or in the project's machine
parameters.

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The section on the CX HP Options page has added the visible section in the following figure:
Through CheckBox, you can enable anti-fall functionality, which will become effective if at least
two of the following conditions are met:
 Panel length <Minimum piece length value
 Panel width <Minimum piece width value
 Panel height> Maximum workpiece height value
Values set in Options will be active for all projects that will be optimized by Maestro.
When using a configuration for a CX HP in machine parameters, the entry "Use panel anti-fall
functionality" appears in the figure below:
Through CheckBox, you can enable anti-fall functionality, which will only become effective for
the current project.
When activated by machine parameters, it has a higher priority and the anti-fall is applied
regardless of the value in the Options.

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4.3.8 Aligner
With the session:
"Tools-Options-Parameters-Work table-CX-Optimiser-Aligner"
to set the aligner intervention mode. (Only for CX S)
In the "Boring tolerance" field you can set the minimum material thickness, below which the
aligner will not operate.
This parameter is used to prevent that a through machining operation in the high part of the
panel can be damaged by the pressure of the aligner.
4.3.9 Processing with optimiser
This procedure provides the pgmx program with all the stages required by CX to handle and
work the piece.
Optimisation can be started through the "Optimisation" control from the
"Machines" menu.
The result can be viewed in the "Arrange" section.

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4.4 Layout for CX programs
The "Layout" for CX is used to see the piece in all the phases from loading to unloading.
The procedure can be executed to check the work phases that have been produced.
To access the Layout environment use the "Layout" command in the
"Machines" menu.
The "Layout" environment for a pgmx of a CX machine appears as follows:
on the left there is the phases tree and in the centre of the screen there is the machine and the
piece moved by the clamps:
Move though the phases tree to see the piece moved by the clamps in the machine.

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5 Project Management for UX
5.1 Create project
The UX machine allows the machining of a single piece or two superimposed pieces with the
same dimensions in X and Y. In the latter case, it is required to construct a project containing
both pieces, suitably positioned on the plane.
To facilitate the implementation of the project, a tool was created using the
"UX" command in the "Home-Project" command:
Three different types of projects will be possible:
Auto Double
Double
- Single
5.1.1One piece mirror
In the paragraphs that will follow, when it comes to mirroring the workpiece, reference will be
made to the combined operation of mirror machining and rollover of the workpiece. Both will be
referenced to the Y coordinate: it is not permitted in the UX to mirror or reverse over the X, due
to a loss of precision, since the reference is on the side supporting the pliers.
The mirror operation, as shown in the following pictures, works by overturning the workings
leaving them on the same plane they belong to, except for those on the front and rear faces,
which are exchanged:
This type of operation, if you want to do it manually, can
be done through the "Specchia - Y" command of the
workpiece context menu:

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The tilting operation has no effect on the view of the
workpiece in the Maestro CAD environment, but only in the
Available. In practice, this is done by setting the roll over in
the positioning properties of the workpiece.
By using these commands and appropriately setting the positions of the pieces in Z, you can
manually construct, if you want to do so, the types of projects described below.

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5.1.2Creating the Double Dual Project
A Double Dual design contains two identical pieces, importing the same piece twice. The panel
in the top position is oriented as by the original program, and the bottom panel can be mirrored.
If it were, the machining of both pieces would be aligned, allowing them to be executed at the
same time by the upper and lower heads.
Entering the name of the project to be uploaded to its field will also automatically fill in the name
of the file to be created.
Mirroring is only allowed for the lower part and is selected by default because it represents the
most common operating mode.
Selecting "Create Project" will create the project with the pieces at the appropriate locations,
while selecting "Optimize" will be produced directly the optimized file, with the work phases.

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5.1.3Creating the Double Dual Project
This type of project is useful for creating a program with two different and overlapping pieces.
By entering the names of the projects to be uploaded in their respective fields, the name of the
file to be created will also be automatically filled in.
The mirror can be applied to both pieces, to give the operator maximum freedom of use.
Selecting "Create Project" will create the project with the pieces at the appropriate locations,
while selecting "Optimize" will be produced directly the optimized file, with the work phases.

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5.1.4Creating the Single Project
The single project is the simplest one, that is, the one that contains the only piece to be
optimized.
Entering the name of the project to be uploaded to its field will also automatically fill in the name
of the file to be created.
It is possible to apply the mirror to the workpiece to be optimized.
Selecting "Create Project" will create the project with the piece in the right position, selecting
"Optimize" will produce the optimized file directly with the work steps.

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5.1.5Optimization of the project by Maestro
The optimization project can be created or opened directly into Master, without going through
the tool just described. To optimize the current design, simply press the "Optimizer" button on
the "Machines" tab of the ribbon.

377
5.2 Types of drain
As the following image shows, there are 4 types of discharge:
1. exhaust to full right
2. exhaust to full left
3. discharge to the right with touch probe
4. full left exhaust with touch
The drain on the left carries the panel at the loading position, ie with the head over the bars.
The drain on the right leads instead the tail of the panel at the junction to the right, as indicated
in the Teacher options.
exhaust left exhaust right
The "touch probe" modes enable the touch probe, which verifies the actual size of the panel.

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5.3 ToeKick
ToeKick machining can be built in two different ways.
When it does not produce shrinkage, ie when it is not passing or when it is made with jumper, it
does not need special intervention: it is like any other milling work and can be done at the
discretion of the optimizer at any point in the process.
When it generates fracture, as it can not fall inside the machine, damaging the same, the
ToeKick is executed as the last work and the clamp is put from the optimizer to block both the
piece and the sludge. In this case, it is absolutely necessary that the macro is constructed with
machining in the tool center.
Obviously in this chapter you are referring to the ToeKick on the back of the piece, that is, those
in contact with the pliers. Front ToeKicks can not generate friction, because the machine does
not have the elements needed to drain residues outside the work plane.
The right ToeKick scrap is unloaded by bringing the workpiece to the position indicated in the
Master options ("Right ToeKick Shredding Quota Discharge"), while the Left ToeKick residue is
dropped into the unloading position of the workpiece. In both cases, you are expected to
confirm that the sprayer has been dropped, so as not to damage the machine. These
expectations can also be disabled by turning off the corresponding check in the machine
parameter window:
5.3.1 Flag for ToeKick management on UX
Three types of ToeKick are defined:
Wide ToeKick
This ToeKick type that allows the gripper to block both
the workpiece and the swarf. Swarf is discharged
through ad hoc cycles that allow it to fall outside the
head area.

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Narrow ToeKick
This ToeKick type does not allow the gripper to hold
the swarf. Swarf falls into the machine at the end of its
machining and the gripper is placed to the side.
ToeKick with pocketing
This ToeKick type does not leave swarf and requires
the gripper to be positioned to the side.
Pocket milling must be done via an inside out
strategy, otherwise project optimisation will return an
error.
The wide ToeKick, single or multiple, is always locked with the gripper between the workpiece
and the swarf, unless it is associated with a ToeKick with pocketing, e.g. to finish previously
machined sides. In this case, the presence of multiple machining processes for ToeKick
production is recognised and the gripper is placed to the side.
Narrow ToeKick machining, which generates swarf that falls into the machine, is only permitted
if the following option field is active:

380
Otherwise, project optimisation will return an error.
ToeKick with pocketing is always recognised and machined, regardless of the value of the
options field: this relates only to narrow ToeKick.
If there are several ToeKicks on a short
workpiece, the workpiece is held with two
grippers and the right ToeKick is machined
first, followed by the left one. During machining
of the latter, the right gripper must have at least
one entire end above the workpiece; otherwise,
the workpiece is locked with a single gripper.
In the event that the workpiece is even shorter
and held with only one gripper, the ToeKicks
are optimised if they ensure that, during left
ToeKick machining, the entire gripper is above
the workpiece. Otherwise, an error is returned
during project optimisation.
5.4 Tool programming rules
To allow the correct behavior of the optimizer, you must follow some rules while building the
tools.
5.4.1Flat bit
If the diameter of the spindle is greater than the useful one, the diameter of the anti-collision
must be equal to it and the other diameters must be the same as the one useful. The tool will be
considered as a diameter equal to that useful for its entire length, then with a diameter equal to
that of anti-collision.

381
In the case of a greater useful diameter than the spindle, all tool diameters must be equal to the
tool diameter.
5.4.2Launch tip
The same rules as the flat tip apply.

382
5.4.3Smooth flat tip
The useful diameter is that of the first part of the tip.
The maximum diameter of the counter must correspond to the total diameter of the tool.
The anti-collision diameter is equal to the spindle diameter and is used beyond the total length.
If the counterfoil diameter is larger than that of the spindle, the anti-collision diameter must be
equal to ace.

383
5.4.4Countersunk spear tip
The same rules as the flat tip apply.
5.4.5Blitz Tip
The same rules apply as for the countersunk tips, except that the "Blitz Maximum Countersink
Diameter" is used instead of the "Maximum Countersink Diameter".

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5.5 UX Options
This chapter contains information for the correct installation of machine parts that make up the
UX. For other options, please refer to the CX section of the Maestro manual.
Piece-stop minimum distance
The stops against which the right side of the workpiece rests during loading, lowered to bring
the panel into the work area, can be raised while the programme is running, provided that the
workpiece does not collide with them. This option is used to have a tolerance for comparing the
size of the workpiece with that of the stops.
Maximum workpiece width for discharge of scrap with a gripper
The unloading of the panel can be done by bringing the workpiece to the unloading position with
both grippers, or with a single gripper, the one closest to the head, which pushes the workpiece
out of the work area (this choice is made, when necessary, to avoid a re-punching). However,
the latter technique cannot be used when the workpiece is wider than a certain threshold,
otherwise it will rotate during unloading. Authorization is used to specify access rights.
Waste portion of the right ToeKick scrap
It represents the X coordinate to which the workpiece head is carried to unload the residual
ToeKick machining residue, when it is made without jumpers.
Movement for discharging the right Toekick waste
It's the movement made to drop the residue of ToeKick's machining, when it is made without
jumpers.

386
Left clamp initial minimum grip percentage
Indicates the portion (percentage) of the length of the left clamp that should lock the workpiece
during loading. This parameter must not be reduced beyond default, otherwise the clamp will
collide with the workpiece alignment devices.
Use only one end of the clamp to block the piece
Given the shaped shape of the clamp with two ends that can hold the workpiece, this option
indicates whether only one of the two ends can be used for clamping. Obviously, if the
workpiece is held by a single clamp, this option is automatically excluded, regardless of its
value.
Distance from front edge to use the comb.
Indicates the distance of spindle 1 from the front edge of the workpiece to force the use of the
comb for clamping the workpiece during machining.
Minimum portion of the piece for the presser
When the edge of one of the pressers is less than this threshold from the edge of the workpiece,
the presser is not lowered. The expertise may be carried out in-house or externally.
Check that the pressers do not cross existing machinings
Check that the pressers associated with front and rear holes do not cross existing machinings
and break.
This inspection shall only cover work carried out with tools of a diameter or thickness greater
than those indicated.

387
When a presser is found to fall into a machining operation, the workpiece optimization is
interrupted and the following error is displayed:
To solve the problem, as indicated by the same error message, it is sufficient to modify the
order of execution of the machining operations, in order to perform the horizontal drilling before
the incriminated machining operations (for example, in the following image, the milling
damaged the presser). This order is changed in the Maestro options:
If executing horizontal drillings on the clamps side and the piece clamping is not optimal, the
"Horizontal drilling" field in the "Distance from machining" section can be changed from
"unlimited" to "Absolute" and setting a value. The value is for the distance between the
machining and the closest clamp when the machining is overhanging.

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6 Project management for He-Pod table
The He-Pod suction cups are devices used to block the pieces that also manage the work
phases, lifting only the pieces that have to be machined and leaving the scraps or pieces that
don't have to be machined low.
There are specific commands to manage the He-Pod suction cups to lower or
raise the individual devices or those under a specific piece.
Example of lowered piece:
Example of raised piece:
As you can see all the suction cups under the piece are raised

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A project consisting of one or more pieces arranged on a table setup (at least partially) with He-
Pod suction cups, can be optimised to use the uniqueness of these supports and, at the same
time, to sort the machinings based on a reference production process (edgebanding). This is all
done by trying to reduce the number of tool changes and movements (raising/lowering) of the
pieces as much as possible.
To optimise a He-Pod project, launch the “HEPOD table optimisation” command in the
“Machines" menu.
If the project is the result of an automatic or manual nesting, each part in the sheet is converted
in an extruded piece positioned on the machine table.
The He-Pod table optimiser, once launched with the button, sorts the machinings as follows:
 If there are machinings associated to the scraps (linked to manual nesting), these are
executed first, to avoid ruining the pieces, once removed.
 Subsequently, in a phase with pieced low (or, for nesting, with sheet lowered), all the
through trimming is performed (which are machinings usually responsible for removing
the pieces) and eventually (there is an option to request it), all the vertical drillings (on
the upper plane of each piece).
 Then it completes the edgebanding process machinings:
o If routings are associated to an edgebanding, they are executed first, piece by
piece, to reduce the path of the routing head in passing from one piece to the
next. A raising phase (with eventual lowering of the previous piece) is created for
each piece, where the edge cleaning routing is performed.
o For all the edgebanding/end trimming units associated to the same piece a phase
with the raising of the piece is created. The passes from one piece to the next
are executed by trying to minimise the movements of the edgebanding unit.
o All the trimming, scraping and radius cutting machinings of the edges are, to
reduce the number of tool changes, executed in this order or grouped based on
the tool and/or aggregate involved. If these machinings include, with the same
tool, various pieces, it will pass from one to the other (with the same number of
raising/lowering phases) before changing tool or aggregate. Obviously the
passes from one piece to the next are executed by trying to minimise the
movements of the unit involved.
o The blowing (cold or hot) machinings are also divided in phases, based on the
order in which the edgebandings associated to them are sorted.
 Then all the routing and cutting machinings are carried out, sorting them based on the
tool involved and the position of the pieces on the machine tables, in order to reduce
the tool changes and movements to a minimum.

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 Finally all the vertical drillings (if not executed in the first phase) and horizontal drillings
are carried out.
 If machinings associated to an edgebanding process have been found, to optimise them,
the user will be asked whether he or she wants to perform the optimisation of the
edgebanding machinings (edgebander rotations, trimmer, etc.).
The final project can therefore include many phases, based on the number of pieces on the
machine table, the presence or not of edgebanding machinings and the use of various tools in
the same type of machining operation.

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7 Project management for pwx100
This chapter describes Maestro's capabilities for optimizing part design for pwx100 machines.
7.1 Master Settings
In order to successfully create and optimize a pwx100 program, you must
on your PC, you have installed the Albatros software environment and that Maestro is
configured to work with pwx100 machines.
In the Master Options in the Folders section, you must select the path where the Albatros
installation resides.
In the Master Options in the Preferences section, you must select your pwx100 machine
configuration (. cfgx file). This selection is essential for the correct operation of the machine
program (interaction with PowerInterface).

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7.2 Optimization constraints
Before optimizing a program, it is necessary to set the program-specific optimization constraints.
To access the commands enter the “Draw” area of the application menu and press “Surfaces”.
Having selected a pwx100 machine configuration, the parameters shown to the user will be as
follows:

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7.2.1Generic Constraints
The generic constraints are described below.
Execution mode
Allows you to specify different optimization modes for the execution of the workpiece on the
machine. You can choose from the following options:
- Direct - Normal: the project is optimized without undergoing mirroring transformations.
The optimizer produces a single sequence of execution steps. All panels associated with
the project will be processed in this sequence.
- Direct - MirrorX: the project is optimized after being mirrored in X. . The optimizer
produces a single sequence of execution steps. All panels associated with the project will
be processed in this sequence.
- Multiple - MirrorX: the project is optimized after being mirrored in X. The optimizer
produces two sequences of execution steps, one for the executng the unmirrored project
and one for the mirrored project. The panels associated with the project will be machined
by alternating the use of the sequence obtained for the unmirrored project, then the one
obtained for the mirrored project.
- Multiple – Normal:the project is optimised without mirroring transformation. The optimiser
produces two sequences of execution steps, one for the outward panel and one for the
return path panel. The final outward execution status will be the initial state of the return
execution. The panels associated with the project will be machined by alternating the
direct sequence, then the return sequence.
- Multiple - MirrorX: the project is optimized after being mirrored in X. The optimizer
produces two sequences of execution steps, one for the execution of the outward and
one for the execution of the panel in return path. The final outward execution status will
be the initial state of the return execution. The panels associated with the project will be
machined by alternating the direct sequence, then the return sequence.
For multiple execution modes, it is also possible to specify by flag whether the return path
generated by the optimizer should be a simple backward execution of the outward path or may
differ from it. In the first case, during production, it will be necessary to check the quality of only
one panel, because in both paths the machining operations will be carried out by exactly the
same tools. In the second case, it will be necessary to check the quality of two panels, because
the optimizer could choose a return path that does not use the same tools, but which is more
advantageous in terms of execution times.
Odd/Even enable
Significant functionality only in the case of a line composed of several machines. In the case of
enabling, each machine in the line must be able to work independently the panel in its entirety
and the optimizer must find a complete solution for each machine in the line. In the case of
disabled functions, the optimizer can use all the machines in the line for the complete execution
of a panel, dividing the machining operations between the machines.
Execute profiles after all the holes
Through this parameter it is possible to constrain the optimizer to perform all the machining
operations that allow a profile (milled/lamated) following the execution of all drilling operations.
Allow boring to router unit
This parameter can be used to constrain the optimizer to use or not the milling unit to drill holes.

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Allow boring without countersink with countersink drill
Through this parameter it is possible to constrain the optimizer to use or not the countersink
drills to make holes that do not allow fading (using the tip part without flaring).
Towing speed
This parameter allows you to set the towing speed (m/min) to be used for the panel. The towing
speed is not related to the line speed, but only affects the transport inside the machine.
Sequence delay for panel clamping and unclamping
Parameter that allows you to set the sequence delay (sec/100) to be used for panel locking and
unlocking.
Acc. /rip speed. pane
Parameter that allows you to set the speed of approach and repositioning of the panel (m/min).
7.2.2Piece positioning restrictions
Through this section it is possible to condition the optimizer's choices for the search of the
workpiece stop positions in the machine. The parameters of interest are described below.
Position search mode
Allows you to specify the search criteria for the stop positions of the panel in the machine,
choosing between:
- Extended automatic search: the optimizer determines the panel stop positions
independently, performing an accurate search for all possible stop positions.
- Limited automatic search: the optimizer determines panel stop positions independently,
making a quick search for all possible stop positions in a limited search range.
- Manual search: the optimizer determines panel stop positions in an assisted manner,
using the search range indicated by the user. For each machine, the user must specify
the minimum and maximum stop position that the machine panel can take on. In case of
coincident values, the optimizer will position the panel at the value indicated, allowing
only one positioning of the panel in the machine.
Allow repositionings on the machine
This parameter can be used to constrain the optimizer to search for solutions that allow
repositioning of the workpiece in the machine or not.
7.2.3Heads rotation restrictions
Through this section it is possible to condition the optimization choices for the search of the
rotation status of the heads present in the machine.
Allow different rotation positions for the heads of the same unit
If the parameter is enabled, the optimizer can assign a different rotation status to the heads of
the same group. For example, considering a group of two heads, in the case of parameter
enabled, the optimizer can choose whether to rotate one of the two heads or both or none of

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them, while in the case of a disabled the optimizer can only choose to rotate both heads or not
rotate them both.
Allow heads rotation between successive stops
If the parameter is enabled, the optimizer can decide to change the rotation status of the heads
between one machining step and the next, within the machining of the same panel. If not
enabled, the optimizer assumes that the rotation states of the heads in the first step are such for
the entire panel machining time.
Heads rotation search mode
Allows you to specify the search criteria for head rotations, choosing between:
- Automatic search: The optimizer determines the rotation of the heads autonomously.
- Manual search:The optimizer uses user set head rotations. For each machine, the user
must specify the rotation status assumed by the heads of each group.
7.2.4Tables position restrictions
Through this section it is possible to condition the optimizer's choices for the search of the
workpiece stop positions in the machine.
Positioning search mode
For each machine, you can choose the positioning search mode by choosing between the
following:
- Automatic search: The optimizer determines the positions of the planes autonomously.
- Manual search: The optimizer uses the positions of the planes set by the user. For each
machine, the user must specify the minimum and maximum stop position that the
machine panel can take on. However, the optimizer will check the feasibility of the
workpiece and analyse possible collisions.

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7.3 Optimizing execution
In order to optimize a pwx100 program, a pwx100 machine configuration must be activated in
the Machines section of the interface, a valid tool database and tooling must be selected.
Before performing optimization, it is good practice to set the specific program optimization
constraints (terms described in the previous chapter). Optimizer execution is carried out by
pressing the "Optimizer" button in the Machines tab.
7.4 Optimization results
Once the optimization has been completed, the user is informed of the result of the optimization
operation.
In the case of a program that cannot be optimized, the user is informed of the error found.
In the case of an optimisable program, a short report is sent to the user with an indication of the
number of positions in the machine needed to execute the panel, the number of steps (higher)
and the time taken in optimization phase.
Subsequently, the user is led to choose whether to use the data found during the optimization
process as new optimization constraints for the source program. This operation allows you to
modify the source program in order to obtain a "pre-optimized" program whose optimization in
the machine is faster.
Depending on the type of execution chosen in the optimization constraints, the successful
optimization results in the generation of one or more optimized programs. For modes that allow
only one execution sequence, only one optimized program is generated, while for modes that
allow multiple execution sequences, e. g. multiple modes, an optimized program is generated
for each obtained sequence.
It is important to note that optimized programs are not machine-executable programs. Their task
is only to provide the user with a tool to evaluate the execution sequences obtained by the
optimizer before running the source program on the machine.

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7.5 PowerSet Tooling Optimizer
The PowerSet Tool Optimizer is a Master CAD/CAM tool which allows users to create, evaluate
or integrate pwx100 machine tooling.
7.5.1Operating requirements
To be able to use the instrument, you need to have:
 the installation of the Albatros environment, with the machine/equipment parameters of
interest;
 the configuration of machinery/equipment of interest (. cfgx file);
 tool database (. tlgx file);
 the mix of programs of interest (mixx file and related. pgmx files);
 a hardware key enabled to run the tooling optimizer;
In addition, if the integration or verification of a tooling is required, it is necessary to have the
sample tooling (. atrx file).
To allow Maestro to interact properly with Albatros, ensure that the pathway where the Albatros
installation resides is correct n the Maestro options.

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As a rule, any changes in the Albatros parameter are saved at each optimization and the
machine configuration files are updated accordingly. This ensures that optimization is always
done with recent machine data. If you want to disable this sequence (recommended choice for
debugging), disable the machine configuration update in
Tools→Options→Parameters→Optimization.
7.5.2Optimization Wizard
In order to display the PowerSet tool optimizer button, you must have the selection of a pwx100
machine configuration enabled. To access the tool, click on the PowerSet button in the Tools
tab.
This opens a wizard consisting of three pages: parameters, execution, results. Each page is
representative of a step in the optimizer execution flow and guides the user through the correct
sequence of steps.

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7.5.2.1 Page1: Parameters
On this page, the user must set the parameters of interest for the optimizer execution.
Analysis criteria
PowerSet provides three different types of analysis:
 Create new tooling:An analysis procedure is started that analyses all the programs in the
execution list which, starting from empty tooling, creates a tooling configuration to
execute all the programs as quickly as possible.
 Integrates existing tooling: an analysis procedure of all the programs in the operating list
which, starting from a loaded tooling, integrates the current composition, without
replacing the drills already present, to minimise the programme execution time
 Checking existing toolingan analysis procedure of all the programs in the operating list
which, using the tooling loaded, produces a report with the execution times and the
number of stops obtained for the programs. The loaded tooling is not changed.
Toolings

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This section appears only if one of the analysis criteria that requires starting equipment is
selected. In this case, the user must choose the reference. atrx file for analysis.
Programs mix
In this section, the user must choose the reference. mixx file for analysis. This file will contain
the list of execution programs to be considered for optimization. Remember that for the correct
functioning of the tooling optimizer, the file. mixx created as a folder import must be at the same
level as the import folder. This is necessary to allow the optimizer to access the source
programs with which it was created.
Tools database
the list of tools available for tooling.
Machine configuration
the representation of the machine/plant to be used for analysis.
Optimisation options
This section describes the common tooling optimiser settings for the programs in the list.
Research mode: the user can choose between a full run mode, and a fast one. The full mode
provides accurate, but time-consuming analysis. Fast mode performs less accurate analysis,
with shorter run times
Allows drilling in milling unit: you can specify whether or not to use the milling unit for drilling.
Allows users to make holes without cuts with flaring tool: you can use flaring tips to make holes
without cuts, using the part of the tip before the countersink.
These options command any settings in the individual list programs. In addition, the tool
optimizer takes into account individual programs in the list:
 always automatically search for panel positioning in the machine;
 panel re-positioning in the machine is always possible;
 always automatically search for the head rotation statuses;
 always automatically search for plane positions.
Constraints set on the individual program machining operations are respected by the tool
optimizer.
Once the parameters have been compiled, the user can start the optimization run by pressing
the Run button. The second page of the wizard is displayed as follows

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7.5.2.2 Page2: Execution
On this page, the user can view the progress status of the execution through a progress bar
with completion percentage. The user is also provided with the elapsed execution time and an
estimate of the remaining run time.
Optimization can be stopped by pressing the Stop button.
This action stops the current operation with loss of processed data.
If the user does not interrupt the execution, the results page is loaded when the analysis is
complete.

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7.5.2.3 Page3: Results
This page displays the configuration result of the tool optimizer.
The central part of the page displays the general information about the analysis outcome,
including:
 outcome of execution (positive/negative)
 time required to perform optimization;
 Number of mix projects which are feasible;
 number of mix projects that are not feasible;
 total number of spindles in configuration;
 total number of spindles equipped;
 total number of spindles used for programme machining;
 individual project implementation reports.

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If the number of spindles used is less than that of the equipped spindles, a display will give the
user the possibility of choosing whether to consider the full setup or setup without tools unused
in the mix.
The choice of a setup with only the spindles used can be useful to identify any spindles with
tools that are not useful for the mix execution. These spindles, if considered unfit, can be
equipped with new tools in future optimizations of integration of the existing tooling.
If the result outcome highlighted the presence of unfeasible projects, it is possible to verify the
reason for their unfeasibility in the project report. Using the drop-down menu, the user can
choose to display the report of all projects, feasible projects or only those unfeasible ones.
You can save the report by copying the text content in the displayed pane.
In the lower part of the page, there are three buttons which allow you to respectively:
 Access the tool list;
 Access data from optimized projects;
 save the tooling.
Tools specifications
By pressing this button, you can print the list of tools in the tool kit, including information on
quantity, general tool characteristics and position on head (spindle number). For more details on
the tooling specifications, please refer to the description of the tool printing functionality in the
ToolEquipmentManager.
Optimised projects

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By pressing this button, it is possible to access the cyclical optimization data of the mix
programs, obtained by using the optimised tooling.
A table is presented at the top of the window, in which each line contains the optimization data
of a mix program. For each program, the general program information and the optimization data
obtained from the tooling are presented.
Below is a list of the main information provided for each item in the table:
 programme name;
 workpiece size;
 number of workpiece repetitions (quantity);
 optimization mode for execution on machine;
 Number of steps per quantity 1;
 execution time for quantity 1;
 productivity (pieces/minute);
 setup time considered (for change of workpiece);
 lot execution time (full quantity);
 panel positioning in the machine;
 Number of steps in the machine for quantity 1;
 run time in the machine for quantity 1.
This table can be saved in the electronic excel format, by pressing the export button.

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If the user needs to transfer the cyclical information obtained to a source program, he can
enable the program update by checking the "Enable update" box for the line of interest. If
instead you want to select/deselect the update of all programs, you can use the cumulative box
at the end of the table. The information transfer operation is activated by pressing the PGMX
update button.
This operation has the effect of inserting optimization constraints in the source project, such as
panel stop positions and the rotation status of the heads. The resulting program can thus be
optimized in the machine with shorter processing times, as thought pre-optimised.
Save tooling
By pressing this button, you can save the tooling generated by the optimizer.

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8 Nesting Project Management
“Nesting” is a technique which allows the best arrangement of workpieces on a panel to be
found, so as to minimize waste when the workpieces are produced.
A “Nesting Project” is a project including the definition of one or more workpieces to be
produced, definition of the rough panel with all of the workpieces positioned, and the information
describing methods for positioning the workpieces on the panel.
Hereinafter the “rough panel” is referred to simply as the “Sheet”.
The “Nesting Project” file has a (.nstx) extension and is a compressed file containing:
pezzo1.pgmx Workpiece 1 design
pezzo2.pgmx Workpiece 2 design
pezzon.pgmx Workpiece n design
foglio1.pgmx Nesting Arrangement on sheet 1
foglio2.pgmx Nesting Arrangement on sheet 2
foglion.pgmx Nesting Arrangement on sheet n
Progetto Nesting.xml information for positioning workpieces on panel
A Nesting Project can be:
Created
Opened
Closed
Saved
Using these icons present in the menu area:

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8.1 Defaults for “Nesting Projects”
It is possible to change the Defaults relating to Nesting Projects by clicking on the “Options” icon
in the “Tools” tab.
8.1.1 Default Folder for “Nesting Projects”
To change the name of the folder in which the Nesting Projects are saved:
Click on the “Options” icon and the following window opens:
In which you can change the “Nesting Projects Folder” field.

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8.1.2 Default Nesting Parameters
To change the value of the Nesting Parameters:
- Click on the “Options” icon and after the “Options” window opens
- Click on “+” to the left of “Parameters”
- Click on the “Nesting” item
The following window opens:
Where you can set:
Sheet:
- the size of the sheet that is normally used
- Margin dimensions of the sheet to be unused
Parameters
- the thickness of the martyr panel
- Choosing to export a pgmx for each nesting scheme
- Choosing to convert the nesting project to a .mixx file
Parts
- the angle of rotation of the parts to fit them into the Free Form nesting

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Microjoints
- Length and Thickness of the bridges to use to keep the ties together
Machine parameters
- Work area where to place the sheet
- Distance to X and Y of the sheet from the origin of the workspace
Cutting
- The tool to use by default for FreeForm or Rectangle cutting
- The tool to be used by default for tubular cutting
Distinta csv
- The separator character to be used between the various fields of the csv file
Remainders
- The number of decimals to be written in the code assigned to the rest of the reusable
sheet
Material Storage
- The use of FlexStore strorage in Maestro must be enabled by selecting Enable Flexstore
Storage use. This way, when a Nesting is created and saved in Maestro, an output folder
with the same name as the Nesting project is created, which produces the data
necessary for communication with the storage, such as picking data, labelling data, and
panel loading/unloading data.
Once you have set the values you can:
- store them by clicking the "Apply" button
- cancel the changes by clicking the "Cancel" button

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8.2 Creating a new Nesting Project
To create a new Nesting project, a tool Database must have been
activated (see sec. 12.8), then click on the “Nesting” icon.
If there is a project already open, the
“Close Project” function is automatically activated.
Select the “Nesting” command and you will be asked for information grouped into three parts of
a dialogue box, in this sequence:
1) Parameters
2) Sheets
3) Parts Parts (not available for Manual Nesting)
4) Cutting
5) Parts (not available for Manual Nesting)
6) Remainders and scrap (not available for Tubular Nesting)
7) Labelling (not available for Tubular Nesting)
8) Loading unloading and cleaning (not available for Tubular Nesting)
The following buttons will be available on the bottom right of each session:
They can either be enabled or disabled.
“Back”, goes back to the previous dialogue box
“Next”, goes to the next dialogue box
"Finish" starts processing the Nesting
"Close" cancels the Nesting operation

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8.2.1 Nesting Parameters
Nesting parameters are collected in the following dialogue box:
8.2.1.1 Type of Nesting
There are two possible types of Nesting:
1) Rectangular
2) Free Form
3) Tubular
4) Manual
Select one or the other by clicking in the related radio button.

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8.2.1.1.1 Rectangular Nesting
Rectangular Nesting allows only rectangular workpieces, which may even be rotated anti-
clockwise through 90°, to be positioned on the sheet.
This type of nesting has a relatively low processing time, since it has a lot fewer degrees of
freedom than Free Form Nesting.
8.2.1.1.2 Free Form Nesting
Free Form Nesting allows workpieces having any shape and arranged at any angles to be
positioned on the sheet.
This type of nesting has longer processing times than Rectangular Nesting because it involves
many more degrees of freedom.
8.2.1.1.3 Tubular Nesting
The Tubular Nesting is used to machine pieces from an unfinished bar.
In this case the pieces must have the same section as the bar.
8.2.1.1.4 Manual Nesting
This mode does not allow for a nesting project with automatic pieces positioning and relative
optimisation.
At the end of the Wizard phase there won't be a complete nesting project, but the user will have
to manually position the parts on the sheets and then optimise the program. (see 8.2.10 Manual
Nesting completion)

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8.2.1.2 Part sequencing
Part sequencing allows definition of the sequence in which the workpieces must be arranged on
the sheet.
Possible alternatives:
1) By Area
2) By Perimeter
which can be selected from the drop-down menu.
8.2.1.2.1 Insertion in sequence by Area
In this mode, the arrangement of the parts on the sheet is done starting with the workpiece
which has the largest area and ending with the workpiece which has the smallest area.
8.2.1.2.2 Insertion in sequence by Perimeter
In this mode, the arrangement of the parts on the sheet is done starting with the workpiece
which has the longest perimeter and ending with the workpiece which has the shortest
perimeter.
8.2.1.3 Minimum distance between two nested parts
This value represents the distance remaining between a workpiece and the tool machining the
adjacent workpiece.
8.2.1.4 Spoil board thickness
For setting the size of the panel placed beneath the rough sheet to be machined.
The default value of the spoil board thickness can be changed by setting the "Spoilboard
thickness" in the session; Tools-Options-Parameters-Nesting-Parameters
8.2.1.5 Enable cutting outside the sheet
Tick this box and separation of the workpieces at the border of the sheet can be carried out
even outside of the sheet.
8.2.1.6 Enables the possibility of nesting the parts in the holes of other
parts
Selecting this option allows a piece to be obtained from the scrap contained inside another
larger part.

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8.2.1.7 Maximum part size and area.
These define the specifications of a small workpiece. The workpiece is considered ''small'' if it
has one of two dimensions (length or width) less than the maximum value indicated and if the
area of the workpiece is less than the maximum value indicated. Values equal to 0 do not
enable the definition of small workpieces.
8.2.2 Nesting Sheets
In this session you can set the dimensions of the rough sheets to be used for Nesting
machining.
The following dialogue box appears:
The sheet displayed, when creating a new nesting project, will have the previously defined
default dimensions. (see 10.1.1)
Use the “Back” command to return to the “Parameters” dialogue box
Use the “Forward” command to go to the “Parts” dialogue box
Use the “Close” command to cancel the Nesting operation.
In this context you can:
1) Add a sheet to the list
2) Delete a sheet from the list
3) Copy sheet data
4) Paste sheet data
5) Edit sheet data
6) Enable the use of materials magazine management

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Right click with the mouse in the Sheets area and the following
context menu appears:

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8.2.2.1 Adding a sheet to the list
To add another sheet to the list:
- Left click with the mouse on the “Insert” item in the context menu.
- Or click on "Add" in the dialogue box
Or select a cell or the line of a sheet and press the “Ins” key
A new sheet will appear with the previously defined default dimensions. (see 10.1.1)
8.2.2.1.1 Meanings of sheet data
Each sheet contains the following data:
- Name  Sheet name
- Length  Sheet length
- Width  Sheet width
- Thickness  Sheet thickness
- Material  Sheet material
- Quantity  Quantity of sheets available
- Vertex  Starting position for positioning workpieces
(selectable from menu)
o Top left
o Top right
o Bottom left
o Bottom right
- Direction  Direction in which the workpieces will be positioned
o X
o Y
- Grain  Direction of the sheet grain
o X
o Y
o None
- Left margin  Size of left margin in which workpieces cannot be positioned
- Right margin  Size of right margin in which pieces cannot be positioned
- Top margin  Size of top margin in which workpieces cannot be positioned
- Bottom margin  Size of bottom margin in which workpieces cannot be positioned
N.B.: The Vertex and Direction parameters are not available for the rectangular nesting.

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8.2.2.2 Deleting a sheet from the list
To delete a sheet from the list:
- Right click on the number to the left of the sheet you want to delete.
- Left click on the “Del” item in the context menu.
- Or click on "Delete" in the dialogue box
- Or press the “Del” key
8.2.2.3 Copying sheet data
To copy the data from a sheet:
- Highlight the cells of the sheet to be copied
- Left click on the “Copy Ctrl+C” item
- Or simultaneously press the “Ctrl” and “C” keys
The selected data will be placed in a temporary memory so that it can be pasted.
8.2.2.4 Pasting sheet data
To paste the data previously copied from one sheet to another sheet:
- Right click on the number to the left of the sheet you want to paste the data to.
- Left click on the “Paste Ctrl+V” item in the context menu.
- Or simultaneously press the “Ctrl” and “V” keys
8.2.2.5 Editing sheet data
To edit the sheet data:
- Double click with the left mouse button on the data item to be edited
- Enter the new data item
- Press “Enter” or left click on another data item
Note: Some data items have preset values. In this case, the new value must not be typed in, but
selected from a drop-down menu which can be displayed by clicking on the arrow to the right of
the value or on the value itself.
8.2.2.6 Enable the use of materials magazine management
By selecting this parameter the current sheets will be replaced with the ones previously defined
in the materials magazine (see 10.9)

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8.2.3 Nesting parts
This session is for setting the list of workpieces to be machined.
This session is not available for the Manual Nesting.
Parts to be entered in a Nesting project must be .pgmx type programs that must contain just one
workpiece and one phase.
Non-rectangular shaped parts for nesting (Free form) should be created as "Extrusion" pieces
and not as "Rectangular", otherwise the whole parallelepiped that encloses the non-rectangular
piece would be considered as piece.
In this way the Nesting algorythm can slot the parts more efficiently.
In this context you can:
1) Add a workpiece to the list
2) Delete a workpiece from the list
3) Copy workpiece data
4) Paste workpiece data
5) Edit workpiece data
Right click with the mouse in the Parts area and the following
context menu appears:

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8.2.3.1 Enter workpiece in the list
To add a workpieces to the list:
- Left click on the “Insert” item in the context menu.
- Or click on "Add" in the dialogue box
- Or select a cell or the line of a workpiece and press the “Ins” key
The files that can be added can have the following extensions:
The dxf files can be only geometric or advanced dxf.
The workpiece is added at the end of the list.
8.2.3.1.1 Meanings of workpiece data
Each workpiece contains the following data:
- File  Workpiece file name
- Name  Workpiece name
- Length  Workpiece length
- Width  Workpiece width
- Thickness  Workpiece thickness
- Material  Workpiece material
- Quantity  Quantity of workpieces to be machined
- Extra quantity  Quantity of workpieces to be machined if space remains on
the sheet after machining the required quantity of workpieces
- Angle  The angular increase used for tests when positioning
the workpiece during Nesting processing
- Rotation  Workpiece 90° rotation (tick to select)
- Grain  Direction of workpiece grain
o X
o Y
o None
- Priority  Priority for insertion of workpiece on sheet
(the workpiece with the highest value is inserted first)
- Distance from edge Distance from edges in workpiece positioning
- Mirroring  Entering mirrored parts in these modes:
o None
o Original then mirrored
o Half parts available
o All parts
- Field1 - Fieldxx  Parameters available for the labels composition.

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Notes:
- The parameters Angle, Priority and Distance from edge are only available in Free Form
Nesting and Tubular Nesting
- The Rotation parameter is only available in Rectangular Nesting.
- The "Original then mirrored" mirroring mode tries to create mirrored pieces after having
processed all the non-mirrored pieces.
- The "Half parts available" mirroring mode creates the nesting by producing half mirrored
and half non-mirrored pieces.
- The "All parts" mirroring mode creates the nesting by producing all the pieces mirrored.
- The number of fields displayed us set in the labelling options. (see 11.8.4.2)

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8.2.3.1.2 Inserting pieces from .CSV files
To insert multiple pieces at once, you can use a list of pgmx stored in a .Csv file
The list must consist of a line for each piece containing the following data:
Piece Code; (Ex: ARM21FSX;)
Type Piece; Not used, it can be "Blank" (Ex: F1
Description; Not used, it can be "Blank" (Ex: Left side;)
Amount; (Ex: 1;)
Extra Quantity; (Ex: 0;)
Length; (Ex: 1818;)
Width; (Ex: 478;)
Thickness; (Ex: 18;)
Material; (Ex: WALNUT;)
Grain; (0 = none 1 = long X 2 = Long Y) (Ex: 1;)
Pgmx file name, (Ex: Fianco_sinistro.pgmx;)
Field1; Optional labeling fields (Ex: UserField1;)
Field fields are those set in the labeling options (see chapter 11.8.4.2)
Example :
ARM21FSX;F1;Fianco_sinistro;1;0;1818;478;18;NOCE;1;Fianco_sinistro.pgmx
ARM21FDX;F2;Fianco_destro;1;0;1818;478;18;NOCE;1;Fianco_destro.pgmx
ARM21CP1;T;Coperchio;1;0;864;479;18;NOCE;1;Coperchio.pgmx
ARM21BS;B;Fondo;1;0;864;479;18;NOCE;1;Fondo.pgmx
ARM21RPA;V;Divisorio_orizzontale;1;0;864;467;18;VANIGLIA;1;Divisorio_orizzontale.pgmx
ARM21SCH1;S;Schiena;1;0;1722;882;3;NAT;1;Schiena.pgmx
ARM21AZ2;Z2;Zoccolo_frontale;1;0;864;80;18;NOCE;1;Zoccolo_frontale.pgmx
ARM21AZ4;Z4;Zoccolo_posteriore;1;0;864;80;18;NOCE;1;Zoccolo_posteriore.pgmx
After selecting "Add" you select the filter "Bill CSV (* .csv), then
select the list containing the parts to be inserted.
The result that is obtained is the following:

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8.2.3.1.3 Definition of CSV columns of parts
Rotation and other parameters can also be specified as a parameter in CSV file definition for
Nesting parts.
To do this, we must be able to define the meaning of the individual CSV columns instead of
using the fixed position format.
The Tools ribbon includes a group for Nesting which contains the button for CSV Nesting
management
The button opens a View in which the column position for each CSV field should be defined.
The View must show the columns to be defined and the parameters for each column.
Practical example:

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The associated CSV format will be
Parte1.pgmx;1600;3;User1;User7;A=100;B=200
By doing this you can define the position of the user parameters in the CSV (in the example
Parameter 1 and Parameter 2), and the parameter and the value must be explicitly indicated in
the corresponding CSV position.
This will then be solved by the module that imports the CSV into Nesting which understands
from the position that it is a parameter and from the value (example A = 100) parses to extract
the name of the parameter and the associated value.
8.2.3.2 Deleting a workpiece from the list
To delete a workpiece from the list:
- Right click on the number to the left of the workpiece to be deleted.
- Left click on the “Del” item in the context menu.
- Or click on "Delete" in the dialogue box
- Or press the “Del” key.
8.2.3.3 Copying workpiece data
To copy workpiece data:
- Highlight the cells of the workpiece to be copied
- Or simultaneously press the “Ctrl” and “C” keys
The selected data will be placed in a temporary memory so that it can be pasted.
8.2.3.4 Pasting workpiece data
To paste the data previously copied from one workpiece to another:
- Right click on the number to the left of the workpiece you want to paste the data to.
- Left click on the “Paste Ctrl+V” item in the context menu.
- Or simultaneously press the “Ctrl” and “V” keys
Note: The data will not be pasted: File and Name
8.2.3.5 Editing workpiece data
To edit workpiece data:
- Double click with the left mouse button on the data item to be edited
- Enter the new data item
- Press “Enter” or left click on another data item

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Note :
- Note: Some data items have preset values. In this case, the new value must not be typed
in, but selected from a drop-down menu which can be displayed by clicking on the arrow
to the right of the value or on the value itself.
- The File and Name data cannot be changed.

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8.2.4Nesting Cut
In this session the user defines the way in which the pieces will be separated.
The separation modes are:
1) Manual Cut
2) Automatic Cut
8.2.4.1 Manual Cut
This mode is used when the pieces in the nesting already have external trimming machining
operations that effectively separate the pieces from each other.
It can also be used when the user does not want to do the separation during the nesting.
This session is accessed when the following parameter is not selected:
"Enable the automatic cutting of the parts"
The only thing that must be specified is the "Maximum cutting width"
During the nesting calculation the pieces will be placed at the specified distance.

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8.2.4.2 Automatic Cut
This mode is used when the pieces in the nesting do not have external trimming machining
operations that can separate the pieces from each other.
This session is accessed when the following parameter is selected:
"Enable the automatic cutting of the parts"
Here you can:
1) Head
2) Tool
3) Cutting technology
4) Scoring
5) Machine functions

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8.2.4.2.1 Head for Nesting cut
The head or heads used for the cuts can be selected.
By default the head is selected automatically, but removing the "Automatic" option lets you
choose one or more heads compatible with the machine configuration.
8.2.4.2.2 Tool for Nesting cut
A tool can be selected from the current tooling to be used to separate the Nesting pieces.
The default tools can also be set by filling in the relative fields in the visible cutting session in
"Tools-Options-Parameters-Nesting":
8.2.4.2.3 Cutting technology
In this session the following can be set:
- Cutting speed
- Cutting depth correction
the value is the distance between the tool and the lower face of the piece.
The following can be entered:
- a positive value (to drop with the tool below the lower face of the piece)
- zero (to drop with the tool level with the lower face)
- a negative value (to remain with the tool higher than the lower face of the piece, without
detaching the piece from any scrap)
In the first two cases the piece is separated, whilst in the third case, the piece remains
joined.
- Enable CAD compensation
Select this parameter for the CAD correction
- Automatic start point
For each piece in the nesting, the machining start point
can be forced in the following points:
- Cutting direction
For each piece in the nesting, the cutting direction can be
forced in the following points:

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Selecting geometry the cutting direction will be the one in the piece geometry
- Automatic cut of the holes of the parts
Selecting this parameter the holes of the parts that inside do not receive any machining
will also be machined
8.2.4.2.4 Scoring
This function is used to machine the piece without detaching it from the sheet, leaving a
minimum thickness of material that will be removed with the final pass.
The aim is to reduce the cutting stress in the final pass so that when the piece is separated from
the sheet it does not move
The following parameters are used for this:
The first sets the thickness of the material that keeps the piece joined to the sheet.
The second links the scoring to the size of the pieces, as the movement problem is found only
with small parts.
8.2.4.2.5 Machine functions
The following machine functions can be set:
8.2.5 Creating parametric NSTX programmes from parametric
PGMX files.
In Nesting, it is possible to insert parametric parts, i.e. parts for which the machinings are
associated with parameters other than the dimensions of the part itself.
Under part data within the Nesting Wizard, you can open a View to modify the parameters.

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The View shows the available parameters and allows modification
This way, the Nested part will first be parametrically updated based on the values provided.

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8.2.6Nesting optimisation
This session can be used to set the same parameters that are set for the guided or automatic
optimisation (see 3.13.2.1.1)
The information is written in this sheet so that the nesting document is also optimised.

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8.2.7Nesting remainders and scrap
This session is used to manage the remainders and scrap machining.
The remainder, unlike the scrap, is a portion of sheet that could be returned to the materials
magazine (see 10)
The tool used to machine the remainders can be selected.
The default tool is the one set in the cutting session displayed in "Tools-Options-Parameters-
Nesting".
The pieces with both dimensions larger than the one set in "Minimum sheet dimension to
consider as remainder" will be considered "Remainders".
The type of remainder can be "Rectangular" or "Single cut", so that a portion of sheet will be
separated from the pieces machined with an open routing.

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The scrap can be either be shred or cut by setting the parameters in the "Scrap management"
table.
The tool used to machine the scrap can be selected.
The minimum area above which the scrap will be cut and not shred can be set.
For the shredding the overlap of the passes can be set.
The "Remaining material in relation to the profile" parameter is used to complete the shredding
of the scrap that would leave small parts at the edges.
Setting a value equal to "-tool radius" the scrap is trimmed with the tool centre so that the scrap
is completely shred.
Selecting "Enable the scrap pre-cut" ensures that the scrap being cut does not, falling, ruin the
finished pieces.
Therefore the pre-cut detaches the scrap or the remainder at a safety distance from the finished
pieces so that the pieces are not damaged. It can be set in the "Pre-cut distance from the scrap
profile" parameter.

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8.2.8 Nesting labelling
This session defines the type of label to use for all the parts in the sheet.
The following dialogue window will be displayed:
Use “Back” to go back to the “Parts” dialogue window
Use "Finish" to start the processing (active if at least one piece has been added)
Use "Close" to cancel the nesting operation.
In this context you can select the label model that will be applied to all the pieces in the sheet.
The name of the label that appears by default is the one specified in the labelling options.
Note:
The label model is the same for each piece, but if the parametric label type has been selected,
the data of each label can be different for each piece.

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Click on "Finish" to see the layout of the pieces on the sheet and of the labels positioned on
each piece.
The labels positioning depends on the options that have been set:
With the "Forced label positioning" selected the label will always be positioned in the middle of
the piece.
Deselecting the "Forced label positioning" will position the label inside the piece and out of the
machining on the piece, respecting the "Label safety margin".
If there is no solution the label is not positioned.
If the result is not satisfactory you can:
- Move labels
- Delete labels
- Enter labels

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8.2.8.1 Move labels
The labels can be moved with the "Move label" command in the
"Drawing" menu.
Click on "Move label" to display the context menu that is
used to specify the new position. A rectangular block
appears with the dimension of the label being positioned.
If the label is positioned out of the piece the following message is displayed:
If the label is positioned on a different piece from the previous one the following message is
displayed:
- Click on "Ok" to move the label
- Click on "Cancel" or on the red cross and the label will not be moved
To exit the command press "Esc".

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8.2.8.2 Delete labels
To delete a label use the context menu, similarly to any other
element.
To activate the context menu, right click with the mouse on the
label to be deleted and then click on "Delete" in the menu.
Or select the label to delete and press "Canc".
8.2.8.3 Enter labels
To enter a new label on the nesting pieces use the "Add label"
command in the "Drawing" menu.
Click on "Add label" to display the context menu that
asks you to select the label application point. A
rectangular block appears with the dimension of the
label being positioned.
If the label is positioned out of the piece the following message is displayed:
If the label is positioned on a piece that already has a label the following message will appear:
To exit the command press "Esc".

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8.2.9 Loading, unloading and Nesting cleaning
This session defines the loading, unloading and cleaning modes of the machine table.
8.2.9.1 Load
The sheet can be loaded as follows:
the sheet alignment method moves the sheet as far as a photocell or a mechanical stop.

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The suction cups used for the pickup and alignment are managed by the parameter:
number of suction cups for alignment and it has the following options:
The following parameters can be set:
- Number of panels to be loaded.
N.B.: If the quantity is greater than 1 the automatic labelling is not available, and certain
functions such as "Scoring" (Onion Skin) cannot be used because they are incompatible with
the multiple loading.
- Elevator table position offset
- Unloader position offset
The piece presser can be enabled.
8.2.9.2 Unpacking and cleaning
The following parameters can be set:
- Piece pickup quota for unloading start
- Type of table cleaning with one of the following options
- Cleaning start quota with one of the following options
- Unloader position offset
The unloading function can be executed only for the last nesting sheet.

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8.2.10 Manual Nesting completion
At the end of the Manual Nesting Wizard the project will have to be completed with: - Manual
positioning of the parts on the sheet
- Program optimisation
8.2.10.1 Manual positioning of the parts on the sheet
The parts on the sheet can be managed with the parts menu which allows the following
operations
Create new part
Insert new part
Insert existing part
Part rotation
8.2.10.1.1 Create new part
To create a new part use the "Create part" command
This command assumes that there is a geometry on the sheet
(imported or just created)
Select the geometry
Decide the type of part to be created:
Part
Remainder
Scrap
Click on Apply to create the desired part.
8.2.10.1.2 Insert new part
To enter a new part use the "Insert from geometry" command
This command, unlike the "Create part" command, can be used to:
- create more than part from a single geometry
- position the parts in different positions
- rotate the parts being inserted (see 8.2.10.1.4 Part rotation)

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8.2.10.1.3 Insert existing part
To insert an existing part use the "Insert part" command that can
also be found in the context menu that will appear by right clicking
on the mouse on the sheet where the pieces are to be positioned.
Click on "Insert part" to display the part on the sheet, along with the fields of the X Y position
and the orientation angle.
To move the part on the sheet you can:
- enter the values in the X Y fields
- move the mouse
To rotate the parts see the next section
The part insertion can be repeated: the same part and angle used previously will be maintained.
To interrupt the parts insertion press the "Esc" key.

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8.2.10.1.4 Part rotation
To rotate a part:
- enter a value in the angle field
- keep the Ctrl key pressed whilst rotating the mouse wheel
In this case the rotation will be of 1°
- keep Shift+Ctrl pressed whilst rotating the mouse wheel
In this case the rotation will be of 5°
When the parts comes out of the sheet or collides with another part during the rotation it will turn
orange.
8.2.10.1.5 Reposition part
Clicking on Reposition part allows you to modify the
position and/or the angle of rotation of a part already
positioned on the workpiece, through the same
operation as the Insert part command.
8.2.10.1.6 Associate machinings
Clicking on Associate machinings allows you to
associate one or more machinings to a part present
on the nesting sheet. In this way, the machinings will
follow the part during any movements/rotations or will
be deleted if the part is deleted.
8.2.10.1.7 Part deletion
To delete a part use the "Delete part" command
One or more parts can be selected for deletion.

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8.3 Opening an existing Nesting Project
To open an existing Nesting Project, click on the “Open”
icon.
A window appears in which you can select a file.
Change the “File type” (whose default setting is: “Project (*.pgmx) ) to Nesting (*.nstx).
Then select a .nstx file, followed by the “Open” key.
Or double click on the .nstx file.
If there is a project already open, the “Close Project” function is automatically activated.
To change the data of a Nesting project with the Wizard use the “Create”
– “Project” - “Nesting” command.
8.4 Closing a Nesting Project
Nesting project closing is the same as for a normal project
(see sec. 3.1.9)
8.5 Saving a Nesting Project
Nesting project saving is the same as for a normal project
(see sec. 3.1.10 )

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8.6 Nesting Processing
Nesting project processing takes place when you click on the “Finish” command in the “Parts”
dialogue box (see sec. 8.2.3 ).
You access the “Parts” dialogue box both when a Nesting project has been created and when
an existing Nesting project is opened, since all of the data entered at the creation stage was
saved in the .nstx file.
After giving the “Finish” command, Nesting
processing beings and it ends with a report message
which summarizes the result:
Click on “OK” and the project graphics appear,
showing all of the workpieces positioned on the sheet.
8.6.1 Conditions to be complied with in Nesting
If the data relating to:
- Thickness
- Material
- Grain
is not compatible between the workpieces and the sheets, Nesting processing is not
successfully completed and the following message appears:

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8.6.2 Recurring strategies in Nesting
8.6.2.1 Positioning small workpieces at the center
A recurring technique in Nesting is that of positioning small workpieces at the center of the
panel to overcome hold-down problems.
To do this:
- assign small workpieces a priority value higher than that of larger workpieces
- for the small workpieces set a “Distance from edge” value which places them at the
center.
Example :
The result obtained is as follows:

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8.6.2.2 Contouring outside the sheet
To increase the number of workpieces which can be obtained from a sheet, you can use the
technique of producing workpiece contours which are on the edges of the sheet outside of the
sheet.
To do this, simple put a tick by the “Enable cutting outside the sheet” parameter (see sec.
8.2.1.5 )
Example :
8.7 Optimizing Nesting machining
After Nesting processing and before the workpieces are machined on the machine, it is a good
idea to optimize the Nesting project produced.
(see sec. 3.13 Optimizing Projects)

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8.8 Labelling pieces in machine
The pieces in the machine can be labelled in two ways, based on the labeller available.
8.8.1Automatic labelling of pieces in machine
This type of labelling requires a labeller that can perform the following:
- Read the label data (what to print and where to position)
- Print labels
- Peel labels from support
- Position the label on the nesting panel before machining.
After the machining all the machined pieces separated by the sheet will have their own label
attached.
To use this mode, the following parameters in the "Labelling options" must be set:
- Select the "Automatic labelling" parameter
- Set the "Label height and width"
- Select the labeller position:
- Front (operator side labeller)
- Rear (opposite operator side labeller)
8.8.2Manual labelling of pieces in machine
This type of labelling requires a labeller that can perform the following:
- Read the label data (what to print)
- Print labels
It also requires an operator to attach the labels on the various machined pieces.
This type of labelling is used if there is no automatic labeller, but it can also be used with the
automatic labeller to attach damaged labels or labels not attached automatically.

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8.8.2.1 Manual labelling of pieces with LabelPrinterManager
This application is used to print labels relative to one or all the pieces in the nesting sheet
machined by the machine.
The interface is as follows:
It allows the operator to:
- Open a project
- Print one or all the labels in the open project
A project can be opened with the "Open" command and any project.
It can also be opened automatically with the "Refresh" command.
This mode lets you open in sequence all the projects executed from the PanelMac.
The programs executed are copied in an exchange folder with the prefix consisting of 5 digits to
maintain the memory of the sequence of machined pieces.
This exchange folder must be configured in the LabelPrinterManager options at "Path of folder
for automatic projects reading".
Each time that "Refresh" is pressed:
- The next project in the exchange folder can be viewed
- One or more labels of the project open can be printed
- The project is deleted from the exchange folder after printing.
When there are no more projects in the exchange folder, the following message will be
displayed:

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One or more labels can be printed with the "Print selection"
command.
This command is used to select one ore more pieces and print the
relative labels.
To print all the labels in the project use the "Print all" command.
This command does not require any selection.
After each label is printed the colour of the piece whose label has been printed changes.
The "Reset state" command is used to visually reset the state of the print, as if nothing had
been printed.
8.8.3Nesting .nstrptx report file
Each time a Nesting file is saved, in the MaestroReportNesting folder, a name file is
automatically saved equal to the name of the .nstx file and with extension .nstrptx.
The report file can be read with an external software to extract the information on sheets that
have been nested and which and how many parts have been entered in the sheet.
One of the various uses, for example, is to print labels to glue to each workpiece of the sheet.
The Nesting report file is a text file where each line contains the information of the part that is
nested in the sheet.
Each line consists of elements defined by an identification key in square brackets "[]" performed
by the symbol "=" as separator between key and value.
Each value ends with the separator ";".
Example:
[Key1]=Value1;[Key2]=Value2;[Key3]=Value3;[Key4]=Value4;
The following keys are present in a line:
[SheetName] : Name of the sheet
[PartName] : Name of the part
[PartFileName] : Name of the file containing the part
[PartLength] : Length of the part
[PartWidth] : Width of the part
[PartDepth] : Depth of the part
[PartQuantity] : Part quantity in the sheet
[PartMaterial] : Material of the part
This is the .nstrptx report of the previous example :
[SheetName]=sheet;[PartName]= Pz500x200;[PartFileName]=drilled workpiece 500x200.pgmx;
[PartLength]=500;[PartWidth]=200;[PartDepth]=18;[PartQuantity]=3;[PartMaterial]=MDF;
[SheetName]=sheet;[PartName]= Pz450x180;[PartFileName]=routed workpiece 450x180.pgmx;
[PartLength]=450;[PartWidth]=180;[PartDepth]=18;[PartQuantity]=3;[PartMaterial]=MDF;

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8.9 Nesting report
Once the Nesting project processing has been completed the
statistics can be viewed by pressing "Nesting Report" in the
"Tools" menu.
Click on the command to display the following window where you can select the data that you
want to examine.
For each topic a sheet will be created in an .xls file containing the relative data.
8.9.1General statistics
The general statistics report contains the following values:

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8.9.2Materials
The materials report contains the following values:
8.9.3Pieces summary
The pieces summary report contains the following values:
8.9.4Sheets and pieces matrices mapping
The mapping report contains the following values:

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8.9.5Cutting diagrams
The cutting diagrams report contains a sheet for each sheet processed.
In this example 2 sheets have been used to execute the nesting of 200 circular pieces:
Sheet 1

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9 Managing the beams and walls project
9.1 General information
9.1.1 Machining wooden beams and walls and BTL standard
The “design2machine” consortium, that brings together the leading CAD software houses of the
wooden building sector, has been set up to standardise the exchange of data between CAD
architectonic projects and automatic cutting centres.
The various types of machining operations have been grouped in parametric families (macro)
and encoded in the BTL standard, which has been sponsored and maintained by the leading
architectonic CAD software houses (CADWORK, SEMA, HSBCAD and DIETRICH’S).
The document that defines the standard can be downloaded free of charge from the BTL
consortium website www.design2machine.com.
The free “BTLviewer” program, used to graphically view the geometry of the pieces in a BTL
project, can also be downloaded from the site.
The viewer allows the operator to check, if there are any doubts about the translation process to
the machine, whether any fault is generated in the process before the creation of the BTL file
(CAD programme) or after the creation of the BTL file (Maestro CNC).
Various versions of the BTL protocol are regularly released by the consortium. A specification
document for each version can be found on the consortium’s website.
Each macro of the BTL standard has a code that identifies it and a name.
Refer to the BTL standard manual, available to download from the website, for the list of macros
available.
The Maestro Beam&Wall software is compatible with the BTL 10.4, 10.5 and 10.6 version.
9.2 Workflow
See below for the optimal workflow:
1) Reading and first processing of the project in BTL format on the programming/simulation
station
2) Adjustment of the tools fixturing
3) Changes to working strategies and/or rotation of certain pieces, to overcome
technological manufacturing restrictions of the project
4) Transfer of the project on the simulator and preliminary execution of the project (at
increased speed)
5) Analysis of the pieces that the simulator indicates as having faults and changes to the
strategies to resolve the faults
6) Transfer of the pieces with faults on the simulator and execution of such pieces
7) Transfer of the project in the machine and project execution.

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9.2.1 Creating a project for beams and walls
To create a new project for beams and walls click on “Project” on the“Home” menu
In the right of the screen a dialogue window will appear to enter the details of the single beam.
To add a new beam click on "Piece" of the "Home" menu.
The two beams inserted in the project can be seen in the project tree:
EL0 and EL1 represent the progressive numbers of the beams in the project
Whilst Beam1 and Beam2 are the name assigned to the elements EL0 and EL1
In the dialogue windows of each piece you can enter the following data:
Piece dimension (DX, DY, DZ)
Element number
Quantity
Name
Description
Notes
Click on "Apply" to enter the new piece in the project tree.
Further parameters in the ADV dialogue window:

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The "Increase tool length" and "Increase clamp length" parameters
are used to manage the machining of short pieces.
These two parameters are used to machine short pieces with machining along the beam, in
other words machining processes that require a clamp exchange to be completed. Let’s take for
example a 1000 mm long piece that contains a sloping machining along its whole length. In this
case the software automatically divides the machining to work one part with the clamp gripping
the piece, and then completes the machining with the grip on the other clamp. On short and
particularly elaborate pieces this solution may not be sufficient. The machine assumes that it is
working on an unfinished piece whose length is the same as the finished piece.
To resolve this type of problem the production sequence can be organised in order to have the
whole length of the bar behind the piece. This situation can be used as additional support to the
piece to complete the machining along the beam without having to change the clamp gripping.
Certain data must be set to tell the software by how much to increase this ‘virtual’ length of the
piece.
"Increase tool length" indicates the dimension of the piece of bar that will be worked by the tool
beyond the actual length of the piece. This parameter will therefore move the position of the
next piece on the bar, that would otherwise be placed above on this reject part.
"Increase clamp length" increases the ‘virtual’ length of the piece, in order to provide a support
for the clamp.
The "Round" option selected indicates a circular section.
This will possible only if the DY and DZ fields have the same value.
The "Round" option selected inhibits the "Blockhouse" function
In the "Material" parameters you can enter the name of the material and the relative quality
degree
The Blockhouse tab contains the following options:
"Enable block house offset": enables the block house type piece, with tapping
"Face": sets the tapping side
“Offset”: sets the tapping height
The “Curvature” tab contains the following options:
- Enable curvature
- Face (Machining face)
- Arc point 1 (P01 parameter of BTL manual)

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- Curvature dimension (P04 parameter of BTL manual)
N.B.: The Arc point 3 value is inhibited as it is considered always in the centre of the beam
9.2.1.1 Beam rotation
Select a beam of the project to perform certain rotations to determine the orientation during
machining.
Select one of the four rotations present in the menu that opens by right-clicking on the mouse.
The following rotations are possible:
- Head tail rotation (180°rotation around axis Z)
- 90° left rotation (90° rotation around axis X)
- 90° right rotation (-90° rotation around axis X)
- 180° rotation (180° rotation around axis X)

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9.2.1.2 Inserting a machining
All the machining operations to carry out on the beams must be made by using the standard
macros supplied by Maestro CNC.
The list of macros is displayed in the "Macro" menu
The names of the macros are those of the standard BTL.
To enter a macro in the beam, simply select it in the menu and it will be placed in queue of the
machining tree for the beam selected (shown on the left).
In the right of the screen there is the dialogue window used to enter the parameters requested
by the macro.
The buttons in the rotation section are used to position the
macro correctly on the beam.
The BTL section contains the standard BTL parameters.
The ADV parameters are further optional parameters used
to define the various machining operations. Generally
this tab contains the forcing parameters for the type of
machining and type of tool.
the description field appears in the machining tree.
Click on "Apply" to confirm all the parameters entered.
The macro entered can be enabled or disabled by clicking on "IF that
precedes the name. (See on the right for the example with the macro
disabled).

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9.2.1.3 Machining strategies
Each macro defines a beam material removal operation.
The material removal can be made with different tools and with different strategies, therefore
there are various strategic options available based on the macro used.
For example, the following head joint machining can be
performed with the 030 macro:
If can be made with these approach strategies:
The icons easily indicate the type of tool and relative
orientation to use.
Once the strategy has been selected in the "Face"
menu, you can define which faces should be open
and which ones must be clean.
Passing the mouse pointer over the icons, will
highlight the face being set on the 3D graphic.

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In the “Options” menu you can define further details
that complete the strategy selected, tools, depth,
approach face, etc.
The options in this tap can vary based on the
strategy selected.
Click on "Apply" to confirm all the strategic choices
made for the macro selected.

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9.2.1.4 Machining and beams cut-copy-paste
All the macros can be cut or copied and then pasted, using the context menu displayed by right-
clicking on one or more macros.
The same operations cam be performed for one or more beams.
A mixed beams and machining selection is not possible.
9.2.1.5 Local parameters
The local parameters are the parameters that belong to the beam and are used to change a
certain machining process.
These parameters can be changed by clicking on
"Local options".
The changed local parameters are displayed in the
"Local options" window, on the bottom right.

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9.2.2 Opening a project from a BTL file
To import a new project click on Open in the "Home-File" menu.
The presence of the suitable configuration lets you automatically select the files with the .qldx or
.btl extensions.
After having opened the file, the following screen appears:
The box on the left is called the elements tree, while the one on the right displays the model of
the element selected.
The elements tree contains all the pieces of the project.
The example also shows the five macros in the first element.

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9.2.3 Processing a project for beams or walls
The elements, in order to be machined by the machining centre, need to be processed.
To select the elements go to the tree and use the mouse with the "Ctrl" and "Shift" keys to make
multiple selections.
The programs can be processed for all the elements with the "Post" key in the "Machines"
menu.
Or click on the "Post” line in the drop down context menu that appears by right-clicking on the
mouse after a single or multiple selection.
Based on the size of the project the time needed to create the following varies:
- the geometries of the joints in the single beams
- the machinings for each geometry
- the necessary anti-collision checks during the machining process
the tool paths generated will be generated starting from the head to the tail
The machinings must be grouped in 4 stages: precut, pre-detach from bar, detach from bar
and post-detach from bar. To perform this type of grouping Maestro CNC will take into account
the position and priority dictated by the machine.
Subsequently you will be able to manually change the order created automatically (see "Tool
path" chapter).
At the end of the processing process the result of the creation must be checked to identify the
indications that the Maestro CNC applies directly on the elements.

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The elements tree will show three icons on the left of each element that indicate the result of the
processing.
Each icon contains three small rectangles that indicate the result of the processing in the
following order:
- Geometric result
- Post result
- Anti-collision result
Each rectangle displays the result with the following colours:
- Green (OK)
- Blue (Additional info)
- Yellow (Attention)
- Red (Error)
In more detail:
- The blue icon indicates that certain machining operations in the element contain an
information message for the operator, the machining is therefore true to the geometry
and there is no need for the user intervention.
- The yellow icon indicates that certain machining operations in the element contain a
warning message. In this case the machining could have been changed in relation to the
defined geometry and the result could be different. In this case the type of problem can
be analysed and act accordingly to resolve it.
- The red icon indicates that certain machining operations in the element contain an error
message. In this case, the machining could have been changed or it may even be
missing and the result could be different from the defined geometry. In this case to the
type of problem can be analysed and act accordingly to resolve it.
Seeing as the machining contained on a piece can present various types of message, the
element icon usually displays the most serious machining operation.

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9.2.3.1 Resolving messages generated during processing
After the processing you can analyse the situation of the whole project.
Obviously we don't recommend starting the machining if there are blocking messages
highlighted in red in the elements tree and in more detail in the machining operations tree,
because the machining with errors will not be executed.
To resolve the problems highlighted during the processing, proceed as follows:
- "open" the piece and analyse the machining messages.
- Select the machining with the error message
- Display the message in the machining
- Resolve the problem indicated in the message
9.2.3.1.1 Error due to the tool
The example shows that there are three beams with
the red icon for the geometric aspect.
These three beams cannot be machined until the
problems are resolved.
We have displayed the list of macros for the third beam
and seen that the macro responsible for the error is the
macro 4-040-3
Selecting the macro we can see the 3D graph in the
middle of the screen and the error message in the top
right menu.
To resolve the problem in this case you must select and use the correct tool.

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9.2.3.1.2 Error: Geometry not allowed
This example contains a manufacture with an error message (red M).
Maestro CNC warns us that it cannot create a valid geometry due to the combination of
parameters from the BTL project to the translation algorithm (e.g. in the BTL certain parameters
define the rotations and intersection of the faces being processed and for certain combinations
of parameters there may not be geometrically possible solutions).
SOLUTION: There is no solution that can be implements on Maestro CNC, eventually
check in the CAD software.
9.2.3.1.3 Post processor alarms
In this example there are post processor warnings (Maestro CNC module that transforms the
tool paths calculated in an ISO machine program that can interpreted by the machine CNC).
The second message warns us that a collision is being generated between machine parts and
piece.
SOLUTION: to resolve the problem we can try changing the work strategy.
The strategy suggested is probably not the best.

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9.2.3.1.4 Error: No valid clamping
In this case the post processor warns that it has not found a solution for the clamps
In this case even if the message has the yellow icon, it is is still a blocking message.
Possible SOLUTIONS:
- If the problem was due to the piece being short a special type of cut can be forced, to
leave the piece attached to the bar during the machining of the plane and use the length
of the bar to help the clamping.
- If the problem was due to the piece transport, it can resolved by rotating the beam.

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9.2.4 Tool paths
Each macro in the beam could have one or more tool
paths.
All the tools paths of all the macros can be displayed in the
"Paths" tree on the right side of the screen:
The list shown groups together all the tool paths present in
all the macros in the beam.
Above the list there are a series of buttons used to change
or display certain things of the project processed
automatically:
The two arrows are used to move a certain machining
operation above or below the others.
The image with the blade is used to assign to a
machining performed with the blade the property of
detaching the piece from the bar.
The image with the two tables is used to invert the
worktable. The effect is to switch the position between
the tool and the machining unit.
(Function only available for the blade cuts)
The image with the “X” deletes a tool path.
The image with the eye displays all the tool paths
present in the piece selected.
The image with the eye and tool displays all the
tool paths created with the same tool.
The image with the eye and the tick displays only
the tool path selected.

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Let's see in sequence three images for the three display buttons:
Display all
Display tool
Display selected
On the left of each path there is a rectangle with the "P" in the middle that indicates the
presence of a message displayed on the bottom left of the screen:
All changes made in this section will be sagged by clicking "Apply", but they will be lost if the
project is precessed once again.

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9.2.4.1 Display tool paths of the macros
After processing the piece, the tool paths generated will be shown in the piece graphic window
as 3D lines that contain the position of the tool tip during the machining. The tool tip is usually
identified as the centre of the tool diameter in the furthest position from the tool taper. For
example in a blade tool, the tool tip is the centre of the blade circumference.
The default tool path graph is always displayed.
The tool path graph can be hidden using the drop down menu in the Display-Options tab.
Possible choices are:
- Hide all tool paths
- Hide tool paths not selected

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9.2.5 Simulation and validation
To validate the project execute a simulation of the machining operations to make sure that there
are no collisions between the various machine devices and the pieces being machined.
To see the simulation of the machinings, launch the “ProView” application.
After having launched “ProView” you can see:
- The simulation of a single beam of the
project, by clicking on "Check" of the context
menu
- The simulation of all the elements
processed in the project, by clicking on
"Check project" in the Machines menu.
In both cases the machine model is displayed
We can see of the single piece or all the pieces will be processed correctly by the machine.

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The simulation process requires a time proportional to the size of the project. During the
simulation all the movements performed by the machining centre are reproduced and even
though the movements can be speeded up, some time is still required. However there is no
need to focus your attention on the simulator during its operation: any faults found will be
documented with freeze frames and included in the "Check" tab.
During the check process the rectangles on the right are temporarily blue.
At the end of the simulation we can see:
On the left of the screen the element or the elements in the project tree will also include the third
rectangle that will indicate the result.
In this case the "Yellow" colour indicates that there is an alarm displayed in the right of the
screen in the "Check" section. In this case the message is "NDX=1".
If the colour was "Red" the machine on the right will be shown with two elements in collision
highlighted in red.
To proceed with the project processing we must disable the element with the collision problem,
or resolve the problem and simulate the element or elements with the collision again.

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9.2.6 Nesting for beams
To execute the nesting for beams enter one or more bars in the project tree.
To do this use the "Bar" command in the "Home" menu.
We can enter the name and dimension of the bar in the right of the screen.
After having entered the bars, launch a nesting algorithm by clicking on "Optimiser" in the
"Machines" menu.

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After having launched the optimiser an image similar to the one below will be displayed:
Where:
- on the left there is the tree changed with the various beams grouped as daughters of the
bar that they will be extracted from.
- In the central part of the screen there is the bar containing all the beams that will be
produced.
- In the right we can enter an overlap between the beams if there is a common tilting cut
for two adjacent beams.

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9.3 Nesting for walls
To execute the nesting for wooden walls, enter pieces inside another piece that will be the panel
from which the various walls will be extracted.
To create this structure in the project tree, use the "Nested piece" command, after having
selected a piece already present in the project tree.
In the example in the previous image, you can see that the pieces nested EL514 and EL547 will
be extracted from the panel EL5.
As well as in the tree we can see it also in the central screen:

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9.3.1 Outline cuts
The outlines cuts are cuts used to separate a wall from others and that also determine their
dimensions.
These outline cuts must be inserted as machinings of the nested piece,
In the example on the left there is the outline machinings tree that correspond to the red
geometries visible in the main screen.
The coordinates of each outline point can be entered in
the relative dialogue window:
In the division cuts generated with the “outline”there is the
tool change if there are blades with a diameter of 500mm
and 600mm. The change is completely automatic, if the
thickness is greater than the maximum blade depth, the
600 mm blade will be selected to machine the upper face,
whilst the 500 mm blade will be used for machining with
approach on the lower face.

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9.4 Complete project
If all the beams of a project have been processed by a specific software to design roofs, each
beam has, as well as the machining information, the assembly information to be assembled with
other beams.
In this case the whole roof project can be displayed with the "Complete project" option in the
"Tools" menu.

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10 Materials magazine management
the materials magazine consists of a set of unfinished pieces used to produce the finished
pieces.
The materials magazine is used mainly for nesting machining operations, but it may also be
used in the future for other types of machining operations.
To access the "Materials magazine" application click on
"Materials magazine" icon in the "Tools" menu.
The materials magazine interface looks like this:
The buttons on the bottom left can be used to:
- add new sheets
- delete existing sheets
- cut existing sheets
- copy existing sheets
- paste cut or copied sheets
- rotate the sheet
- import a materials magazine
- export a materials magazine
The materials magazine displayed when accessing this session is the last one that was saved.
For the meaning of the sheet data see 8.2.2.1.1

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10.1 Add new sheets
To add new sheets use the "Add" button
Click on "Add" to add a new sheet in queue to the current materials magazine.
The name field will be "Sheet" for the first sheet entered "Sheet(1)" for the second sheet entered
and so on.
The "Length, Width and Thickness" dimensions will be the default settings of the Nesting
parameters.
The "Quantity" will be set as 1 and the sheet will have the "Enable" flag.
If the quantity is set as "-1" the sheet will be considered of unlimited quantity.
10.1.1 Default dimensions for Nesting sheets
To set the default dimensions of a new Nesting sheet fill in the relative fields in the "Sheet" table
displayed with:
"Tools-Options-Parameters-Nesting"

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10.2 Delete existing sheets
To delete existing sheets, select one or more sheets (turning them blue) and then
click on "Delete".
10.3 Cut existing sheets
To cut existing sheets, select one or more sheets (turning them blue) and then click
on "Cut".
10.4 Copy existing sheets
To copy existing sheets, select one or more sheets (turning them blue) and then
click on "Copy".

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10.5 Paste cut or copied sheets
To paste previously cut or copied sheets, select the sheet below which they are to
be pasted and then click on "Paste".
10.5.1 Copy-Paste Cells
To copy and paste cells between sheets:
- select one or more adjoining sheets from the same sheet
- press Ctrl-C (copy cells)
- select the equivalent cells in a different sheet
- press CTRL-V (paste cells)
10.6 Sheet rotation
Rotating the sheet switches the length value with the width value of the sheet.
To rotate existing sheets, select one or more sheets (turning them blue) and then click
on "Rotate material".
The rotation not only switches the length with the width but also switches any grain from X to Y
or from Y to X.

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10.7 Import materials magazine
This operation is used to import a text file with the .csv extension containing the information on
the sheets in the magazine.
To import a materials magazine click on "Import materials magazine".
Only a .csv file, that contains all the necessary information, must be selected.
Example of .csv file:
Name Piece;Length;Width;Thickness;Material;Quantity;Grain;Enable;
Remainder;LeftCollar;RightCollar;UpperCollar;LowerCollar;
Sheet;500;400;18;Mdf;5;None;1;0;10;20;30;40;
Sheet 1;500;500;18;Walnut;4;X;0;0;10;20;30;40;
Sheet 2;500;600;18;Mahogany;3;Y;1;1;10;20;30;40;
Sheet 3;3200;1600;18;Oak;3;None;1;1;10;20;30;40;
Sheet 4;3200;1600;18;Cherry;3;None;1;1;10;20;30;40;
Sheet 5;3200;1600;18;Ebony;3;None;1;1;10;20;30;40;
Once the file has been
selected a message with the
following options will appear:
This is the result of selecting "No" (the magazine has been replaced)
Selecting "Yes" (the magazine is updated adding sheets to the existing ones).
Sheets with the same name and dimensions will be added together.

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10.8 Export materials magazine
This operation is used to export the current materials magazine in text files with the.csv
extension formatted identically to the .csv file used as import.
To export the current materials magazine in .csv format, click on "Export
materials magazine".
10.9 Save materials magazine
To save the materials magazine click on "Save".
The last magazine saved will be the one active when the "Materials magazine" session is
opened once again.
The file containing the information of the materials magazine will be saved in the folder specified
in the "Materials magazine folder" field in the session:
Tools-Options-Folders.
The name of the file is always the same: "MaterialStore.mstx" and is written in a format that
cannot be edited.
10.10 Unload materials
Once the nesting has been processed with the "Enable the use of materials magazine
management" in the "Sheets" session (see 8.2.2.6) the materials used in the nesting machining
can be unloaded.
To do this use the "unload materials" function in the "Tools-
Options".
The sheets unloading
will be confirmed with
the following
message:
The function will
update the quantity of sheets used in the materials magazine.

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10.11 Load remainders
Once the nesting has been processed with the "Enable materials magazine management use"
in the "Sheets" session (see 8.2.2.6) the remainders produced during the nesting machining can
be loaded.
To do this use the "unload materials" function in the "Tools-
Options".
The remainders loading
will be confirmed with the
following message:
The function will insert the remainders in the materials magazine.

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11 Labels database management with LabelEditor
The labels database contains all the information needed to define the labels used to label the
pieces generated with the nesting.
LabelEditor can be launched from the installation directory, by clicking on “LabelEditor.exe”.
The LabelEditor interface looks as follows:
11.1 Create label
To create a new label use the “New” command in the “Home”
menu “File”.

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A list with the label attributes is displayed. The
characteristic label data are:
- Width width
- Height height
- Top margin  upper edge
- Right margin  right edge
- Left margin  left edge
- Bottom margin  lower edge
The measurements are expressed in the unit of measurement set in the options.
To create the label press "Apply". To restore the initial values press "Cancel". Select a label to
display its attributes. They can be changed and the changes rendered effective by pressing
"Apply". Any graphic objects are maintained.

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11.2 Open label
To open an existing label use the “Open” command in the
“Home” menu “File”.
The default path used to open the labels is defined in the “Options”  “File”.
A label can also be opened in the office button. The ones saved recently will appear in the list to
be opened directly, without being searched.

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11.3 Close label
To close the current label use the “Close” command in the
“Home” menu “File”.
A label can also be closed from the office button.
11.4 Save label
To save the current label use the “Save” command in the
“Home” menu “File”. If it is a label without a name yet, specify
the label path and name.
To save the label with another name use the “Save with name”
command in the “Home” menu “File”.

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A label can also be saved from the office button.
11.5 Print label
11.5.1 Print label on Zebra printer
To print the current label on the printer use the “Print zebra” command in the “Home”
menu“File”.
11.5.2 Print label on office printer
To print the current label on the printer
based on the matrix diagram defined in the
options, use the "Print office" command in
the “Home” menu“File”.

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11.6 Tools
11.6.1 Zoom
Zooms in and out of the label display with the “Zoom” command in the
“Home” menu  “Navigation”. It can also be executed with the mouse
scroll when the mouse is positioned inside the label.
11.6.2 Pan
Once the label is selected, keep the left mouse key pressed to move the label with the mouse.
11.7 Drawing objects management
11.7.1 Add object
The following objects can be added to the label:
- Geometries
o Horizontal line
o Vertical line
o Rectangle
- Elements
o Image
o Text
o Barcode 1D
 Code 39
 Code 93
 Code 128
o Barcode 2D
 Aztec
 Datamatrix
 QR
 PDF417

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11.7.2 Delete object
Use the “Cancel” command in the “Home” menu  “Clipboard” to
delete the element selected. The command is also available on the
keyboard with the "Canc" key.
11.7.3 Copy object
Use the “Copy” command in the “Home” menu  “Clipboard” to copy the
element selected. The command is also available on the keyboard with
the “Ctrl”+”c” combination.
11.7.4 Paste object
Use the “paste” command in the “Home” menu  “Clipboard” to paste the
previously copied element. The command is also available on the
keyboard with the “Ctrl”+”v” combination.

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11.8 Drawing objects
11.8.1 Horizontal line
Use the “Horizontal line” command in the “Home” menu  “Geometries” to create a horizontal
line.
A list with the horizontal line attributes is displayed. The
characteristic data of the horizontal line are:
- X1  initial X coordinate
- X2  final X coordinate
- Y  Y coordinate
- Thickness  line thickness
X1 must have a lower value than X2.
The thickness must have a higher value or the same
value as the minimum value set in “Options”
”Parameters”.
The measurements are expressed in the unit of
measurement set in the options.
Press "Apply" to add the horizontal line to the label. To restore the initial values press "Cancel".
Select the horizontal line graphic object in the label to display its list of attributes. They can be
changed and the changes rendered effective by pressing "Apply". The element can be moved
also by selecting it and dragging it with the mouse. The element can be resized also by
selecting and dragging the end points with the mouse.

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11.8.2 Vertical line
Use the “Vertical line” command in the “Home” menu  “Geometries” to create a vertical line.
A list with the vertical line attributes is displayed. The
characteristic data of the horizontal line are:
- X  X coordinate
- Y1  initial Y coordinate
- Y2  final Y coordinate
Y1 must have a lower value than Y2.
Press "Apply" to add the vertical line to the label. To restore the initial values press "Cancel".
Select the vertical line graphic object in the label to display its list of attributes. They can be

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11.8.3 Rectangle
Use the “Rectangle” command in the “Home” menu “Geometries” to create a rectangle.
A list with the rectangle attributes is displayed. The
characteristic data of the rectangle are:
- X1  initial X coordinate
- X2  final X coordinate
- Y1  initial Y coordinate
- Y2  final Y coordinate
X1 must have a lower value than X2.
Y1 must have a lower value than Y2.
Press "Apply" to add the rectangle to the label. To restore the initial values press "Cancel".
Select the rectangle graphic object in the label to display its list of attributes. They can be

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11.8.4 Image
Use the “Image” command in the “Home” menu “Elements” to create an image.
A list with the image attributes is displayed. The
characteristic data of the image are:
- Type: fixed, parametric
- X  initial X coordinate
- Y  initial Y coordinate
- Path  image file name defined with the
complete path
- Width  image width
- Height  image height
Press "Apply" to add the image to the label. To restore the initial values press "Cancel". Select
the image graphic object in the label to display its list of attributes. They can be changed and
the changes rendered effective by pressing "Apply". The element can be moved also by
selecting it and dragging it with the mouse. The element can be resized also by selecting and
dragging the end points with the mouse.

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11.8.4.1 Fixed
If the image is "Fixed" it means that the image is displayed in the label as it will be printed.
11.8.4.2 Parametric
In this case an additional "Parameter" attribute is displayed in the list of image attributes.
If the image is "Parametric" it means that an empty
image is displayed in the label. The content of the image
is filled during printing with the piece data from the
nesting based on the type of parameter:
- Piece  the piece image is loaded
- FieldN (1<=N<=20)  parametric field, the image
corresponding to the index N parameter value is
loaded (file path)

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11.8.5 Text
Use the “Text” command in the “Home” menu “Elements” to create a text.
A list with the text attributes is displayed. The
characteristic data of the text are:
- Type: fixed, parametric, date or time
- Rotation  text rotation angle
- Text  text
- Windows font  displays Windows font
- Zebra font  displays Zebra font
- Font  name of the font
- Measurement  font dimension (if Windows font it
is expressed in point, if Zebra font it is a
multiplicative factor of the base dimension of the
font selected)
The other measurements are expressed in the unit of
measurement defined in the options.
Press "Apply" to add the text to the label. To restore the initial values press "Cancel". Select the
horizontal line graphic object in the label to display its list of attributes. They can be changed
and the changes rendered effective by pressing "Apply". The element can be moved also by
selecting it and dragging it with the mouse.

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A Windows font or a Zebra font can be used for a text. The Zebra fonts are: ZebraA, ZebraB
(only upper case characters), ZebraD, ZebraE, ZebraF, ZebraH (only upper case characters)
and are fonts that reside in the printers. In the label the Zebra fonts are displayed with a grey
background to distinguish them from the Windows font.
As they are not available as system fonts the zebra font text is displayed accurately in terms of
space but not in style of font. This means that prints with zebra font texts on a zebra printer use
texts with similar fonts and with the same space. Prints on an office printer, which has no zebra
font, uses texts with the same font and with the same space. Unicode characters cannot be
printed with the zebra font.
The Windows fonts are those contained in the "WindowsFonts" system folder and, the ones
that are used in the label texts, to be printed correctly, must have been previously downloaded
in the printer memory with a Zebra utility. Once downloaded in the printer a file with the "FNT"
extension is allocated to the downloaded font. In the printer, by default there is already the font
Windows Swiss721 whose file is called “TT0003M_.FNT”. To use it in the “WindowsFonts”
folder there must be the font “Swiss721 BT” (file called “tt0003m_0.ttf”). All this information must
be set in the options of the zebra printer parameters. With the font Swiss721 unicode characters
can be printed (e.g. texts in Greek, Russian, Turkish), to print Chinese; Japanese or Korean
texts other fonts are required. They can be downloaded in “WindowsFonts” and in the printer
memory (Simplified Chinese - ANMDS.TTF, Traditional Chinese - ANMDT.TTF, Japanese -
ANMDJ.TTF, Korean - ANMDK.TTF).

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11.8.5.1 Fixed
If the text is "Fixed" it means that the text is displayed in the label as it will be printed.
11.8.5.2 Parametric
In this case an additional "Parameter" attribute is
displayed in the list of text attributes.
If the text is "Parametric" it means that a temporary text is
displayed in the label. The content of the text is filled
during printing with the piece data from the nesting based
on the type of parameter:
- Name  the name is loaded
- Dimension X the width is loaded
- Dimension Y  the height is loaded
- Dimension Z  the thickness if loaded
- Material  the material is loaded
- Program side 1  the side 1 machining program
code is loaded
code is loaded
code is loaded
code is loaded
- FieldN (1<=N<=20)  parametric field, the index
N parameter value is loaded

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11.8.5.3 Date
In this case an additional "Date" attribute is displayed in the list of text attributes.
If the text is "Date" it means that a temporary text is
during printing with the current system date with the
format selected:
- dd/mn/yyyy
- yyyy/mn/dd
- ddmnyyyy
- yyyymndd

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11.8.5.4 Time
In this case an additional "Time" attribute is displayed in the list of text attributes.
If the text is "Time" it means that a temporary text is
during printing with the current system time with the format
selected:
- hh.mm.ss (24h)
- hh:mm:ss (24h)
- hh.mm.ss XX  XX assumes the “AM” or “PM”
value (12h)
- hh:mm:ss XX  XX assumes the “AM” or “PM”
value (12h)

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11.8.6 Barcode
11.8.6.1 Unidimensional
11.8.6.1.1 Code 39
Use the “Code 39” command in the “Home” menu 
“Elements”  “Barcode 1D” to create a code 39.
A list with the code 39 attributes is displayed. The
characteristic data of the code 39 are:
- Type: fixed, parametric, date or time (same as
for the "Text" element)
- Rotation  code 39 rotation angle
- Text  text
- Display text  displays the text under the code
- Bars height  height of the bars
- Narrow bar  width of the bar expressed in
points
- bars ratio  ratio between the bars
The code 39 is used to encode the first 128 symbols ASCII.

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Press "Apply" to add the code 39 to the label. To restore the initial values press "Cancel". Select
the code 39 graphic object in the label to display its list of attributes. They can be changed and

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11.8.6.1.2 Code 93
- Text  text
points
The code 93 is used to encode the first 128 symbols ASCII.

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Press "Apply" to add the code 93 to the label. To restore the initial values press "Cancel". Select
the code 93 graphic object in the label to display its list of attributes. They can be changed and

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11.8.6.1.3 Code 128
- Text  text
points
The code 128 with automatic alphabet selection is
used to encode the first 128 symbols ASCII.

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Press "Apply" to add the code 128 to the label. To restore the initial values press "Cancel".
Select the code 128 graphic object in the label to display its list of attributes. They can be

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11.8.6.2 Two-dimensional
11.8.6.2.1 Aztec
Use the “Aztec” command in the “Home” menu 
“Elements”  “Barcode 2D” to create an Aztec code.
A list with the Aztec code attributes is displayed. The
characteristic data of the Aztec code are:
- Rotation  Aztec code rotation angle
- Text  text
- Measurement  adimensional code
measurement (the value must be between 1 and
10)
- Codes table  page of the codes used to
encode the text
The Aztec code is used to encode a maximum of 3832 digits or 3067 characters or 1914 bytes.

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Press "Apply" to add the Aztec code to the label. To restore the initial values press "Cancel".
Select the Aztec code graphic object in the label to display the list of attributes. They can be

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11.8.6.2.2 Datamatrix
Use the “Datamatrix” command in the “Home”
menu “Elements”  “Barcode 1D”to create a
Datamatrix code.
A list with the Datamatrix code attributes is displayed.
The characteristic data of the Datamatrix code are:
- Rotation  Datamatrix code rotation angle
- Text  text
measurement (the value must be between 1
and 50)
encode the text
The Datamatrix code is used to encode a maximum of 2335 alphanumerical characters.

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Press "Apply" to add the Datamatrix code to the label. To restore the initial values press
"Cancel". Select the Datamatrix code graphic object in the label to display the list of attributes.
They can be changed and the changes rendered effective by pressing "Apply". The element can
be moved also by selecting it and dragging it with the mouse. The element can be resized also
by selecting and dragging the end points with the mouse.

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11.8.6.2.3 QR
Use the “QR” command in the “Home” menu
“Elements”  “Barcode 2D” to create a QR code.
A list with the QR code attributes is displayed. The
characteristic data of the QR code are:
- Text  text
measurement (the value must be between 1
and 100)
- Error correction  level of errors correction
- Encoding  type of encoding
The QR code is used encode a maximum of 7089
digits or 4296 alphanumerical characters or 2953 bytes or 1817 Kanji/kana characters.

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Press "Apply" to add the QR code to the label. To restore the initial values press "Cancel".
Select the QR code graphic object in the label to display the list of attributes. They can be

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11.8.6.2.4 PDF417
Use the “PDF417” command in the “Home”
menu “Elements”  “Barcode 2D” to create a
PDF417 code.
A list with the PDF417 code attributes is displayed.
The characteristic data of the PDF417 code are:
- Text  text
- Measurement Y  adimensional code vertical
measurement
- Measurement X  adimensional code
horizontal measurement
encode the text
- Lines number  number of lines (the value
must be between 3 and 90)
- Columns number  number of columns (the
value must be between 1 and 30)
The PDF417 code is used to encode a maximum of 2710 digits or 1850 characters.

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Press "Apply" to add the PDF417 code to the label. To restore the initial values press "Cancel".
Select the PDF417 code graphic object in the label to display the list of attributes. They can be

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11.9 Options
Use the “Options” command in the “Tools” menu 
“Options”.
The “Files”, “Parameters” and “Language” sheets are displayed in the window.

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11.9.1 Files
In the "Files" sheet you can specify:
- The default path from which to open and save the labels
- The default name to associate to a new label
11.9.2 Parameters
11.9.2.1 Geometries
- Minimum thickness  minimum thickness of the horizontal lines, vertical lines, rectangles
The measurement is expressed in the unit of measurement set in the options.
11.9.2.2 Zebra
Zebra printer parameters
- Resolution  print density expressed in dpi (dots per inch), the printers of the GC420
family (GC420d and GC420t models) have resolutions equal to 203

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- Flash memory  printer rom memory used to save the fonts
- Font in memory  fonts that have been downloaded in the printer with the reference
names (up to 3 fonts)
- Print other texts as images if the option is enabled, the texts whose fonts have
NOT been downloaded in the zebra printer with the relative procedure, are printed
as images but it is NOT guaranteed that the print will match the image preview. If
the option is disabled the texts whose fonts have NOT been downloaded in the
zebra printer with the relative procedure will NOT be printed
- Correction X  correction factor in X in the label calibration (a positive value corresponds
to a movement to the right, the measurement is expressed in the unit of measurement
set in the options).
- Correction Y  correction factor in Y in the label calibration (a positive value corresponds
to a movement downwards, the measurement is expressed in the unit of measurement
set in the options)
11.9.2.3 Page layout
These parameters indicate how to layout the labels matrix in the sheet to print in the office
printer (in the final labels positioning in the sheet take into account the top and left margins of
the printer).
- Lines  number of lines of labels in the sheet being printed
- Columns  number of columns of labels in the sheet being printed
- Horizontal space  horizontal gap between labels
- Vertical space  vertical gap between labels
- Office printer  printer selection (if there is no value, at the first printing operation you
will be asked to select a printer and the one selected will become the value of the
parameter also for the subsequent times)

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11.9.3 Language
The language of the application and the unit of measurement to use (millimetres or inches) are
set in the "Language" sheet. The unit of measurement selected will be used for all the
measurements of the label and the objects.

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11.10 Zebra printer
11.10.1 Installation
The Zebra printer must be a printer of the GC420 family (GC420d or GC420t model).
The following window is displayed with the automatic start from the CD ROM. If not manually
execute the “RunCD.exe” from the CD.
Select the printer model.

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In the menu on the left select “Install printer” and in the menu on the right “Execute Zebra Setup
Utilities”.

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Select the printer/computer connection mode and press “Next”.
Press “Manual Install”.

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Press “Next”.
Press “Printer installation”.

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In the list on the right select the printer model and press “Next”.
In the list select the printer/computer connection port and press “Next”.

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Deselect the additional installation options suggested and press “End”.
Wait.

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11.10.2 Calibration
Once the zebra printer is installed on the PC, you must carry out the calibration in order to
calibrate the labels correctly.
In the “Zebra Setup Utilities” program press “Open Printer Tools”.

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In the window displayed, in the “Action” sheet, select “Calibrate media” and press “Send”.
Wait for the printer to complete the operation.

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11.10.3 Download font
To use fonts to print labels they must be converted and downloaded in the Zebra printer
memory.
In the program Zebra Setup Utilities, select the program “Download Fonts and Graphics”:
In the drop down menu “Slot for memory board” select “Flash”, which corresponds to the printer
memory device used to save the type of character.
Now create a new configuration file for the memory sheet. Select a new icon. You can create a
new file or select an existing one in the local hard disc. For example, create a new configuration
file for the "Arial" memory sheet:

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You can enter a description for the memory sheet configuration file and select the size of the
paper. This depends on the type of character selected and it must be sufficient to contain it. It
can be selected in the interval from 256Kbyte to 131072Kbyte.

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Then select “Fonts”  “New” then select to load all characters.
Select the type of character and then click on "Select".
In the font data preview click on "OK":

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Now you can download the font in the printer memory:
You must agree with the licence contract for the type of character to download it in the printer.
If there is the "Insufficient free space in the memory board to download" error, go back to
“Paper”  “Memory sheet information” and increase the size before repeating the procedure.

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11.10.4 Memory
The Zebra printer is fitted with two memories: one eprom "E" flash memory used to contain the
fonts and a ram "R" memory to temporarily save the graphic objects. It may be useful to poll the
content of the Zebra printer memories.
In the program “Zebra Setup Utilities”, select the program “Open Communication With Printer”:
In the window displayed you can write the poll commands in the top box and the results are
shown in the bottom box. To display the fonts saved in the flash memory “E” type the command
“^XA^HWE:*:*^XZ” and press “Send To Printer”.

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To delete a font saved in the ram memory “E”, for example the “Arial” font, type the
“^XA^IDE:ARI000.FNT ^XZ” command and press “Send To Printer”.

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To display the graphic objects saved in the ram memory “R” type the command
“^XA^HWR:*:*^XZ” and press “Send To Printer”.

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To delete all the graphic objects saved in the ram memory “R” type the command
“^XA^IDR:*.GRF^XZ” and press “Send To Printer”.

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11.11 AT automatic printer
11.11.1 Notes
For the AT automatic printer use the labels editor supplied with the labeller software. To
generate the correct label position use the Maestro "Label editor" to create an empty label with
the same dimensions of the label that will be applied by the automatic labeller and select it
during nesting.
The maximum number of parametric fields that can be used with the AT automatic printer is 14.

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12 Tool Data-Base
The tool data-base includes all necessary information to choose the tools for the working
processes as it has been established.
In order to manage the tool data-base you use the “ToolManager.exe” , launched by clicking on
hte icon "Tools" of the menu "Machines".
Tool Manager can be also launched from the installation directory by clicking on the file
“ToolManager.exe” .
The Tool Manager Interface is shown as follows:

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12.1 Default for tool Data-Base
It is possible to change the Data-Base defaults by clicking on the menu "Options" in the folder
"Tools"
12.1.1 Default "Name Tool Data-Base "
In order to modify the default name of a new tool Data-Base:
Click on the icon "Opzioni"
Fill the field "Name of the default tool file".
12.1.2 Default "Folder for tool Data-Base"
In order to modify the folder name where toll data-base are open/saved:
Fill the field "Path of the Tlgx export directory"
12.1.3 Default "Folder for Import/Export toll Data-Base"
In order to modify the default name in which tool Data-Base are imported exported:
Fill the field "Path of the Xilog Bin directory".

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12.2 Tool Data -Base creation
In order to create a tool data-base, you use the command " in the menu “Home” “File”.
The data-base will be empty but strctured with following categories:
12.3 Tool data-base opening
In order to open a tool data base, click on the icon "Open".
A window will appear where you can select a Tlgx file.
The default folder will be definedas described in paragraph
12.1.2. Default "Folder for tool Data-Base"
Then select a Tlgx file and the button open
Or click twice on the Tlgx file.
If a tool data-base has been already open, the option "Tool data-base closing" would be
automatically performed.

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12.4 Closing tool data-base
In order to close an open tool data-base, click on the icon "Close".
If the tool data-base has not yet been saved, following question will appear:
By clicking on "Yes", the option "Saving tool data-base" will be automatically performed.

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12.5 Saving tool data-base
In order to save an open tool data-base, click on the icon "Save"
If the tool data-base had already been named, no question would be made.
If the project was already created, the option "Save con nome" would be performed.
The default folder proposed for the saving is set as described in paragraph 12.1.2.. Default
"Folder for tool Data-Base"
You can specify the data-base name in the folder "File Name".
then click on "Save".

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12.6 Tool data-base import from Xilog
In order to import a tool data-base from Xilog, use the command "import" in the menu "Home"
"Conversion".
The default folder proposed to import a tlg file is set as in paragraph 12.1.3 Default Folder
Import/Export tool Data-Base.
You can also specify the tool data-base Xilog (tlg) in the fiedl "File name:"
then click on "Open".

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12.7 Tool data-base export to Xilog
In order to export a tool data-base to Xilog (tlg) in the menu "Home" "Conversion".
select the file. Tlgx to be exported from the dialogue window and click on the button "Open".
Following message will appear to confirm the export:

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12.8 Activate Tool Data-Base
In order to insert any working process on a sole project, you have to select a tool data-base to
be activated since the working processes are described by combining a tool and a 2D geometry.
In order to activate a tool data-base, use the menu "Machines" "Tools".
By clicking on the button "Tools"; a list of available data-base will appear in the "default" folder.
The tool data-base marked on the left is the active one.
In order to activate another one, select it with the left button of the mouse.
You find the information about the tool data-base is to be found also in the lower workpiece to
the right of Maestro interface.

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12.9 Tools
The tools are the object used for working processes.
In order to use them, you need to know all geometric and technological information of every
tool.
The information collected must be inserted in a toll Data-Base
12.9.1 Tool introduction
In order to insert a new tool in the data-base, you use one of the commands in the following
menu:
The interface that appears is the following:
The image is divided into four zones:

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- In the left area, you can see a picture of the tool
- In the upper central area, you can see the picture of the type of tool
- In the lower central area, you can import an image or a drawing of the tool
- In the area to the right, you can enter the tool data.
An image or a drawing of the tool can be added by clicking in the
lower central area where the following image is initially seen:
In the area to the right, rather, the tool data is entered:
- The data at the top is the "General data" and is common to all tool types
- The subsequent data varies according to the type of tool.
After selecting the command about
the tool you have to fill the fields in
the menu "General Data".
These data are common for all
tools, for every category will be
necessary to insert the data related
to the tool type.
The code used during machining must be entered in "Name" field.
We recommend using the historical code used on Xilog “E001” “E002” …. Etc. for congruence,
even if not essential.
The main mill features can be reported in the description field to immediately understand which
tool it is about.
The tool producer code or one chosen by the customer can be entered in the Code field.
The quantity represents the number of identical tools that are available. This figure is important
when setting up a boring machine
The remaining main data three values represent mill's clearance.
The "Type of taper" represents the part of the tool that lies between the spindle and the actual
tool.
The geometric data of the tool is always accompanied by a dynamic image that varies upon
moving the mouse over the various fields to be filled out order to render the value that must be
entered more comprehensible.

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The image shown in the left area is updated according to the values
set each time the "Apply" button is clicked
The image is made up of four significant elements. From top to
bottom are:
- The type of attack (cone HSH of black color)
- The part of the non-cutting tool (tang of gray color)
- The part of the cutting tool (ocher tool)
- A dashed circle that represents the programming diameter that will
follow the machining geometry
This circle in the end mills will always be in the lower part of the
milling cutter while in the shaped milling cutters it will be possible to
find in any position and not necessarily coinciding with an edge of
the milling cutter.

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12.9.1.1 Bits
Bits drill are divided into following categories:
Lance Bit Flared Bit Lance Bit Plain Bit Flat bit
Flared Flared Blitz
In order to insert a Bit in the data-base, click on the command related to the wished head in the
menu "Boring bits" and fill all fields in order to describe the point shape and use properties
(speed, rotation number and so on)
See description and dynamic bitmaps appearing on some values when going over them with the
mouse for individual parameters' meaning.

550
NOTE:
For the lance tools the boring cycle is affected by the panel thickness and the angle set in the
relative "Tool angle (degrees)" field.
Set the correct angle to achieve a correct boring cycle.
As an alternative to the tip angle, the height of the cone can be inserted.

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12.9.1.1.1 Tools wear
For all tools, the wear condition can only be seen if there is a quantity of 1.
To do so, set:
"Maximum number of uses" for tips
"Nominal distance (mm)' for cutters or blades
Panel Mac will record the number of uses for drills and the path taken for blades and cutters.
The data identified will be entered into the effective use field and percentage wear field.
The wear range will be green, yellow or red depending on the state of wear.

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12.9.1.2 Milling cutters
Cutters are divided into following categories:
Cylinder cutter Spheric Cutter Toroidal Cutter Conical Cutter Shaped Cutter
In order to insert a cutter in the data-base, click on the cutter type in the menu"Milling cutters"
and fill all fields to describe the cutter shape and use properties (speed, rotation number and so
on).
In this category, there are also cutters with specialised uses:
- Sanders
- Edge scraper
- Glue scraper
- Trimmers
12.9.1.2.1 Shaped Cutter
Shaped cutters allow you to create a detailed cutter profile which is described in the Tool
Profiles section.

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The profile of a shaped tool can be defined within its data page, either by creating as many
elementary elements as comprise it, or by importing it from an external file.
The simplest format is a PGMX file that describes the geometry of the profile.
Some conventions must be observed to correctly import a PGMX file and convert it into a tool
profile:
 the tool profile must be described by an open curve consisting of two or more segments
(polyline);
 the first and last point of the polyline must be at different Y coordinates and lie on the
same X;
 the profile must describe half of the vertical section of the tool
 profiles with more than one segment at the same Y are not permitted;
 segments that form undercuts in the tool profile are not permitted;
 the curves of the profile cannot go beyond, in X, the vertical line which joins the first and
last points of the polyline and which constitutes the rotation axis of the tool;
 the profile must be drawn on the upper plane;
 its position can be any;
 if the tool profile also contains other parts above it (ring nut, etc.) then the real tool profile
part must start from Y and develop at negative heights, leaving the upper part at positive
Y.
Once the PGMX is imported, it is automatically converted into the basic elements that make up
the profile.
The imported profile is also analysed and compared with the current (possibly not yet set)
overall dimensions and diameter values: if there is a discrepancy between the data set in the

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tool body fields and the dimensions detected by the imported profile, a warning message is
shown to the user asking whether to keep the current data or to overwrite them with those from
the imported profile. If confirmed, the data is overwritten and aligned with the imported profile;
otherwise the pre-existing data are left.
A tool profile can also be imported from its solid model in IGES, STEP or STL file format.
The imported tool model is ''rotated'' and the resulting solid of revolution profile is extracted. This
geometry is then used in the same way as that described in the previous paragraph.
It is assumed that the model of the cutter is positioned with the upper part of the stem at Z = 0
(any ring nut or other will end up at positive Z coordinates).
12.9.1.2.2 Sanders
This type of tool is used to increase the finish of a machining process by using an abrasive
sheet.

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12.9.1.2.3 Edge scraper
The EdgeScraper tool is used during the edging process to scrape the edge.
It consists of a pair of knives that scrape the edge applied to a profile
The EdgeScraper is loaded on a horizontal double output head and is always paired with the
trimmer tool.
The tool General Data area lists the machining data as well as the tool encumbrance data:
The Edge Scraper operation is defined with the Track feeling and Time parameters: the tool
rests on the panel being scraped with the tool Horizontal and Vertical Track Feeling, then it
closes on the panel in a time defined in the Tool Closure field.
At the end of the machining the tool, before exiting the panel, will open by a time defined in the
Tool Opening field.
The Edge fields define the scraper operation interval, that is the minimum and maximum edge
thickness that the tool is able to scrape.

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12.9.1.2.4 Glue scraper
The GlueScraper tool is used during the edging process to scrape the adhesive used to glue the
edge.
It consists of a pair of small blades that scrape the excess glue after an edging.
The GlueScraper is loaded on a horizontal double output head and is always paired with the
trimmer tool.
The Glue Scraper operation is defined with the Track feeling and Time parameters: the tool
rests on the panel being scraped with the tool Horizontal and Vertical Track Feeling, then it
closes on the panel in a time defined in the Tool Closure field.
Tool Opening field.

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12.9.1.2.5 Trimmers
The trimmer tool is used during the edge banding process to finish the edge. It consists of a pair
of cutters that trim the edge applied to a profile after the edge banding and overhangs from the
upper and lower side of the panel. The trimmer is loaded on a horizontal double output head
and is always paired with the scraper tool.
The trimmer operation is defined with the Track feeling and Time parameters: the tool rests on
the panel being trimmed with the tool Horizontal and Vertical Track Feeling, then it closes on the
panel in a time defined in the Tool Closure field.
Tool Opening field.
The Edge fields define the trimmer operation interval, that is the minimum and maximum edge
thickness that the tool is able to trim.

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12.9.1.3 Blades
Blades are all contained in the category "Blades".
In order to insert a blade in the data-base, click on the command "Universals" in the menu
"Blades" and fill all fields to describe the blade shape and use properties (speed, rotation
number and so on)

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12.9.1.4 Mortises
Mortises are used to make sharp-edged eyelets.
The data to be inserted is very particular and different from the other types of tools

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12.9.1.5 Contact tools
This category of tools does not undertake removals and is subdivided into:
- Probles
- Pressure rollers
12.9.1.5.1 Probes
Probes are all included in the field "Tools for contact".
In order to insert a probe in the data-base, click on the command " sphere-shaped" in the menu
"Probes" and fill all fields to describe the probe shape and use properties (speed and so on).

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12.9.1.5.2 Pressure rollers
These components are used to press the edges on the side of the panel.
To insert a new pressure roller, enter the category of Contact tools Pressure rollers, then with a
right click on the mouse, select "New pressure roller"

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12.9.1.6 Special tools
This category includes devices that are not tools but are assembled on spindles.
The types in this category are:
- Manipulators
- Blowers
12.9.1.6.1 Manipulators
A manipulator is a device used to move the suction cups on certain types of machines.
To insert a new Manipulator, click on menu "Manipulator tool" from the "Special tools" menu
then fill in all relevant fields that appear to describe the shape and characteristics of use.

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12.9.1.6.2 Blowers
A Blower is a device used to clean certain areas of the machine or parts of the piece.
To insert a new Blower, click on menu "Blower tool" from the "Special tools" menu then fill in all
relevant fields that appear to describe the shape and characteristics of use.
12.9.1.6.3 Anti-adhesive
The anti-adhesive tool serves to apply an anti-adhesive product before applying the edge to a
panel to prevent excess glue on the edge from sticking to the panel, thereby facilitating panel
removal

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The tool is part of the special tools group and once created it must be loaded
on a generic head for use in Maestro Anti-adhesive processing. As with all
other tools, the tool can be created directly from the machining tree or from
the Anti-adhesive button in the ribbon.
The page above describes the tool lists its specifications.

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12.9.1.6.4 Polishing
The polishing tool serves to apply a polishing product by brushing the glue line and the rounded
surfaces produced by edge scraping.
The tool is part of the special tools group and once created it must be loaded on a generic head
for use in Maestro Brushing processing.
As with all other tools, the tool can be created directly from the machining tree or from the
Polishing button in the ribbon.
The page describing the tool lists its specifications:

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12.9.1.7 Heads
The heads are divided into the following categories:
Inclined angular head Weldon
End cutting unit Qinx head

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Head 2 horiontal outlets Lower lateral copier
Edge cleaning head Generic Head

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End cutting unit-rebater head
In order to insert a head in the data base, click on the command related to the head type in the
menu "Heads" and fill all fields to describe the head shape and use properties (speed, rotation
number and so on).
Each head has at least one Spindle on which a previously described tool can be assembled.

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12.9.1.7.1 Weldon
Of all the cartridges, the Weldon is the only one that can work on the lower face.
It is therefore the one that is most at risk of collision with the clamping devices underneath the
workpiece.
To avoid collisions, it is very important to configure all head parameters correctly:
In particular, the parameters that define the head size with respect to the axis of the operating
unit: Length X Positive, Length X Negative, Width Y Positive
Negative Y Width and Lateral Dimension
The head oriented with "Pivot angle" at 0 is seen as in the image above, so the dimensions
"Positive X Length","Side Dimension" and "X Offset" are those found on the right of the spindle
axis.

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12.9.1.7.2 General Head
This type of head can be configured with more than one spindle
Spindles can be added to the head of generic heads.
Do this by right-clicking the mouse on the Generic head's name and choose "Add spindle" from
the appearing context menu.
Fill-in new added spindle data.
Proceed to complete defining Generic head.

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12.9.1.8 Aggregates tools
Define an aggregate tool when using a "physical tool" in programming with different tools
diameters or useful lengths.
The aggregate tool corresponds to "physical tool" having more virtual tools.
Click on "Aggregate tool" control in "Aggregate tools" menu and fill-in Tool 1 field with previously
described tool name, to insert an Aggregate tool in the database.
Right-click the mouse on the aggregate name and choose "Add tool" from the appearing context
menu to add another tool to the aggregate.
Fill in Tool 2 with the name of another tool.
Proceed to complete aggregate definition.

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12.9.2 Modifying tolls
In order to modify a tool:
- Search the tool in the type folders:
- choose the tool
- modify the values
- confirm the modification by clicking on the button "Apply"
In order to confirm the tool data-base modification, the tool data-base saving must be performed
(see paragraph 12.5 )
12.9.3 Tool removal
In order to remove a tool data-base:
- Search the tool in the type folders:
- choose the tool
- click with the right button on the tool name
- click on the command "Remove" in the contextual menu
In order to confirm the tool data-base modification, the tool data-base saving must be performed
(see paragraph 12.5 )
12.10 Virtual tools
A tool can be associated to an alias, thereby creating a virtual tool with which to create
machinings.
The advantage of using virtual tools in machining is they allow you to create projects without
worrying about the geometric and technological specification of the tools to be used and that
these are updated once the project is loaded into the machine. This means that each machine
must have its own association table between physical tools and their aliases if you want to work
with virtual tools.
You can create this table by opening the editor
using the Virtual tools button in the Machine
Tools tab.

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The same button is also found in ToolManager
The following window will appear:
At the top is the button for saving the tool-alias association table, next to it is a selector for the
tool file (.tlgx) to be used and the tools it contains will be displayed in the tool tree on the left.
The centre of the window displays the list of aliases created and the associated tool. On the
right of each line is a button to delete the association.
To create a new virtual tool, simply double click in the tree above the tool for which you want to
associate an alias or right click on "Create alias". A window will appear for entering the desired
alias and by proceeding with the operation the virtual tool will appear in the list.
At this point, by saving the table of virtual tools, they can be used in creating machinings
through the tool selector. The virtual tools will be identified with a special red dot and with the
name of the alias to distinguish them from physical tools.

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Recommendations for use: to maximise the potential of virtual tools, we recommend using a
single tlgx containing all the tools of the various machines and defining the virtual tools table in
each machine. In this way, projects can be generated in the office, including via MSL (Maestro
Scripting Language), using virtual tools which will then be replaced with physical tools when the
project is loaded into the machine.

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13 Tool equipment
Tool equipment establishes which tools are assembled on the operator groups that do not have
a change tool.
On such operator groups (Borings, Spindles without change tool and the like), tools are to be
assembled manually: therefore, the operator must store in the tool equipment section the tools
assembled on the spindles.
Tool equipment is managed through the application "ToolEquipmentManager.exe" that can be
automatically launched by clicking on the icon "Tool Equipment" of teh "Machines" - "Tools"
menu.
ToolEquipmentManager.exe can also be launched autonomously from the installation directory
by clicking on the “ToolEquipementManager.exe” file.
The Tool equipment interface looks like this:

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13.1 Tool Equipment default
You can change the tooling defaults by clicking on the "Options" menu in the "Tools" folder of
the Master interface.
In order to change the name of the tools default, click on the file "Preferences" and fill in the field
"Default tools in spindles tooling file"

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13.2 Tool Equipment creation
To create the Tool Equipment ,use the “New” command of the "Home"
menu, option "Create"
13.3 Open Tool Equipment
To open an existing Tool Equipment ,use the “Open” command of the
"Home" menu, option "File"
A window will be displayed from which you can select a file with extension .atrx
13.4 Close Tool Equipment
To close the Tool Equipment ,use the “Close” command of the "Home"
menu, option "File"
If the tool equipment database has not been saved yet the following question is displayed:
Clicking “Yes” automatically recalls the “Save Tool Equipment"

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13.5 Save Tool Equipment
To save a Tool Equipment file, click on “Save” command of the "Home"
menu, option "File".
If the Tool Equipment file already had a name, no question will be asked.
If the Tool Equipment had been created, "Save with name” function will be recalled
The Tool Equipment name can be specified in the “File name:” box
then click on “Save”.
N.B.: The folder where all .atrx files are saved is always the subfolder "Atrx" of the Maestro
installation file.

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13.6 Tool Equipment activation
To activate a tool equipment file use the “Machines” “ Tools” - "Equipment" menu.
By clicking on the arrow placed under "Tool Equipment", the list of the available tool equipment
files will appear.
The tool equipment with a check on its left is the one that is active at that moment.
To activate another database simply select it with the left hand button of the mouse.

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13.7 Tool equipment editor
In order to match Tool with Spindle, select :
- A configuration file (.cfgx)
- A tools data-base ( .tlgx)
13.7.1 Configuration selection
Such selection identifies the operator groups available.
Selection is done by clicking on one of the configurations contained in the "Machines -
Configuration" menu
13.7.2 Tools database selection
This selection allows the identification of the tools database you want to use to equip the
machine.
Selection is done by clicking on one of the configurations contained in the "Machines - Tools"
menu

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13.7.3 Machine Selection
If you have selected a configuration containing
more than one machine, you can select the
machine you wish to equip.
To do this, select the machine visible in the pull-
down menu that appears in the "Machines"
menu.
13.7.4 Operator Group Selection
If the machine is equipped with more than one Operator Group,
you can select the group you want to equip.
To do this, select the operator group visible in the menu
"Views".
Alternatively, a series of operator groups of the same type can be displayed simultaneously, e.
g. all "Vertical Heads" or all "Side Heads".
Obviously, this representation will depend on the machine configuration.

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13.7.5 Association Tool-Spindle
In order to match a tool with a spindle, use the following interface :
Where :
- Displays the characteristics of the object type selected.
- On the right there are the tools of the tools database
- In the middle there are the spindles of the selected operator group with the tools that
have already been assigned to the spindles.
In order to match a tool with a spindle :
- Activate "Instrument Mode".
- Select a tool (on the right)
- Clicking on all the spindles on which the selected tool is to be
assembled.(The spindle number will be replaced with the
diametre of the mounted tool.)
13.7.6 Tool removal from the spindle
In order to remove a tool from a spindle :
- Select a spindle and click on "Remove"
"Remove" can be obtained:
- By right-clicking on a spindle

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13.7.7 Viewing Tool Information
Regardless of the selected mode, it is always possible to have
information about the tool mounted on a spindle by simply
moving the Mouse onto the tool.
A Tool-Tip with complete tool information appears.
The colour of the circle representing the tool is provided as
additional information:
The Black Circle represents a rotation right
The Red Circle represents a rotation left
13.7.8 Spindle information display
With "Navigate Mode", you can check the information for each spindle.
By clicking on each spindle in the central area, the
information of the selected spindle will appear in the left
area.
The selected spindle graphics will be displayed:
Yellow for empty spindles
- Green for chucks with a tool.

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13.7.9 Displaying Equipment
The tooling in the central area can be displayed in three modes:
1. Complete
2. Spindles
3. Tools
The "Full View" displays a number on each spindle it represents:
- Spindle name (when the spindle is empty)
- The diameter of the tool (in the case of drill bits)
- The name of the tool (if not a drill bit)
The "Spindle view" displays a number on each spindle representing the spindle name.
In "Tool Viewing" only the numbers they represent will be displayed;
- The diameter of the tool (in the case of drill bits)
- The name of the tool (if not a drill bit)

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13.8 Print fixturing data
To print the tooling, use the "Print" command in the "Home- File"
menu.
The result of printing is a file that:
On the first page shows a series of information related to the file name, the type of
measurement unit used and the date of printing, as well as a series of explanatory legends on
the document:

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The following is a list of the drill bits or cutters required for mounting (with the necessary number
for each tool).
Finally, there is the assembly diagram for the machine listing the spindles of each head with the
tool to be mounted.

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13.9 Comparing tooling
After changing an existing tooling, a comparison could be used to
evaluate the differences with the previous tooling.
To compare the equipment, use the "Print" command in the
"Home-File" menu.
Selecting the command opens a window in which 2 tools must be specified,
the current and final one, i. e., the one you want to load into the machine.
When you select Apply, a comparison file with the same name is generated
of the current tooling with a new extension. atrxCmp.
By clicking on "Yes", the comparison file is displayed.

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Example:
Previous file: atrx. atrx. atrx test
Existing file: atrx test - Updated. atrx test.
Comparison files: atrx. atrxCmp test

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In the diagram, the tools to be removed are represented by a red cross.
The. atrxCmp file can also be printed, the result is similar to that of tooling printing with some
important differences.
- On the start page there is a new legend about the tools to be mounted/disassembled.
- The pattern of the heads shows only the spindles in which a tool has to be removed or
mounted.
- The list of drills or cutters required are only those that must be

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mounted/replaced in the tooling

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13.10 Tools wear
''Wear'' management involves tracking tool use (by space travelled for cutters and blades - by
number of interventions/descents for drills) based on the "name" assigned in the tool database
(TLGX).
Specifically, at each use (first or subsequent) of a tool (execution of a machine PGMX
programme), its use is permanently recorded in the wear database, regardless of the
manipulation of the master data that should be performed in TLGX.
Removing or changing the name of a tool in the TLGX does not delete its history from the wear
database. Therefore, for example, the re-proposition of a tool in any TLGX (insertion of a new
tool or name change for a tool already present), with a name that already has a wear history
tracked in the database means that the wear recorded in the database under that name is
attributed to this tool. The operator may reset the wear data in the case of a tool that is new or
renewed (eg: re-sharpening).
It therefore follows that if multiple TLGXs are used to manage one or more machines, any tools
with the same name present in different TLGXs are considered by the software to be the same
physical tool (in terms of wear).
Tool wear management must be enabled in the visible screen with "Tools-Options-Parameters-
User-wear tools" by placing a flag under "Enable management".
The wear status will be displayed in Yellow and Green Red to immediately see if the tools
should be replaced.
The representation is what you see in the options:
Green Tool with less than 30% wear (new)
Yellow: Tool with wear ranging from 30 to 70% (still usable)
Red: Tools with wear greater than 70% (to be replaced)
Note that the image shows the state of the tool's integrity and not its wear, even if the concept is
the same.
Tool wear is controlled by the following controls:
13.10.1 Tool wear display
The display of the wear status is obtained with the "Display" command on the "Wear"menu.
The graphical representation of the wear status is represented by the colours Green-Yellow-
Red, with a number representing the percentage of use.

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13.10.2 Tool wear update
The display of the wear status may be misaligned compared to effective use as the machine
operated after the wear status display.
The "Update" command will be used to read the wear data rewritten by PanelMac.
13.10.3 Reset wear.
When inserting one or more new tools, the degree of wear must be reduced to zero.
To do this, use the "Reset selection" and "Reset all" commands.
With the "Reset selection" command active, you can reset the wear state of all the tools
selected subsequently.
By clicking on "Reset everything", the following message will be displayed:
Clicking on "yes" will reset the wear conditions of all tools in the active tooling.
13.10.4 Wear report
If the tooling contains wear information, a printout is possible.
Selecting the Report button opens a window in which you can choose the type of report:
- for all tools in the setup
- only for tools with a wear value higher than a certain threshold.

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The tool wear report file has the following key:
Listed below are all the orders placed with their progress.

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14 Edges Database(EdgeManager)
The edges database (EdgeManager) contains all the information necessary to define the
edgesused for the edge banding operations.
The “EdgeManager.exe” application is used to manage the edges database and
it is launched automatically by clicking on “Edges” in the “Machines” menu.
EdgeManager can also be launched autonomously from the Maestro installation directory by
clicking on the “EdgeManager.exe” file.
The EdgeManager main window looks like this:

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14.1 Edges Database Default
The tools database defaults can be changed by clicking on the “Options” menu
of the “Tools” folder.
14.1.1 “Edges Database Name” Default
To change the default name of a new Edges database proceed as follows:
Click on “Options”
Fill in the “Default edges file name” field
14.1.2 “Edges Database Folder” Default
To change the name of the folder that the edges database are opened and saved:
Select the “Folders” node on the left tree
Fill in the “Maestro edges directory path” field

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14.1.3 Automatic Export of the Edges Database in Ext. format
In this options page you can enable/disable the automatic export of the edge database in Ext
format (function necessary to interface with Genio).
To enable/disable the automatic export of the edges database in the Ext format proceed as
follows:
Select the “Parameters” node on the left tree
Select “Enable/disable automatic export of edges file in Ext format when saving”
Fill in the “Ext file export folder path” field

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14.2 Edges Database Creation
To create an edges database use the “New” command in the “Home”
“File” menu.
The database will appear empty but already structured as follows:
14.3 Open Edges Database
To open an existing edges database click on “Open”.
A window will be displayed from which you can select a file with extension .Edgx.
The default folder will be the one defined, as described in section
14.1.2 “Edge Database Folder” Default
Then select an .Edgx file and then open
Or double click on the .Edgx file.
If there was an edges database already open, the “Close Edges Database” function
would be performed automatically.
14.4 Close Edges Database
To close an open edges database click on “Close”.

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If the edges database has not been saved yet the following question is displayed:
Clicking “Yes” automatically recalls the “Save Edges Database"
function.
14.5 Save Edges Database
To save an open edges database click on “Save”.
If the edges database already had a name, no question will be asked.
If the Database was just created the “Save with name” function will be recalled.

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The default folder that will be suggested is the one defined, as described in
section 14.1.2 “Edges Database Folder” default
The edges database name can be specified in the “File name:” box
then click on “Save”.
14.6 Activate Edges Database
To enter an edge banding operation in a project, select an edges database to activate it, as the
edge banding operations are described by combining an edge to a 2D geometry.
To activate an edges database use the “Machines” “ Tools” menu.
Click on the “Edges” key to display the list of edges databases available in the
“default” folder.
The edges database with a check at its left is the one active.
To activate another database simply select it with the left hand button of the mouse.

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14.7 Edges
The edges are the objects used for the edge banding operations.
In order to use them you must know the technological information of each edge.
The information collected must be entered in the Edges Database.
14.7.1 Entering Edges
To enter a new edge in the database use the command in the “Home” menu
After having selected the enter a new edge command, fill in the fields in the "General Data" and
"Edge Data" menu:
This data will be the same for all edges. Then you must enter for each edge the
specific “machining technology” data and the “close” data.

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14.7.1.1 Edge name
The “Name” field must be filled with the code which will be used during machining.
The description field can contain the main edge specifications in order to immediately
see the type of edge.
14.7.1.2 Edge data
In the Edges data section enter the following:
- Edge Thickness
- Edge Height
- Flexibility: numerical value between 1 and 9; 1 indicates maximum flexibility, 9 minimum
flexibility
- Material: this field is used to describe the type of material used for the edge
- Pressure of the glue counter roller: pressure mode of the glue counter roller for this type
of edge. High or Low pressure of the glue counter roller
- Type of cutting slice: cutting slice mode for this type of edge; High or Low cutting
pressure
- Colour: the edge colour can be specified to make it easier to identify it
14.7.1.3 Machining Technological Data
When a new edge is added, it is assigned a default machining technology. The technology
contains the edge data that affect the edge banding operation.
By selecting the drop down menu you can associate one of the machining technologies in the
database to the edge.

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14.8 Technologies Manager
The Technologies Master is used to display, create, change and delete the machining
technologies. The Technologies Manager is opened with the “Open Technologies Manager…”
key, under the technology selection menu or with the “Open Technologies Manager” key on the
Home menu:
Selecting the “Open Technologies Manager” opens the “Technologies Manager” window:
On the left of this window the technologies in the database are displayed, while the technology
parameters are displayed on the right.
When a technology is selected on the left of the window, the fields on the right are updated.

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The fields on the right can be changed for each technology, except for the default technology;
this is the standard technology used to create an edge. In a second stage the new edge can be
associated to a technology already in the database or create a new one with the Technologies
Manager.
To add a technology to the list of technologies use the “Add Technology” command
in the window menu. (“+” icon).
Similarly to remove a technology from the list of technologies use the “Remove
Technology” command in the window menu. (“X” icon).
The default technology cannot be deleted.
The technology data are:
14.8.1 Name
- Technology name
14.8.2 Speed
- Speed: standard edge banding speed
- Speed: minimum edge banding speed
The following parameters are used for the speed optimizer:
- Minimum application radius: minimum radius of the profile on which the optimizer applies
the speed attribute.
- Maximum application radius: maximum radius of the profile on which the optimizer
applies the speed attribute.

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14.8.3 Edge heating lamps
 Status of the edge heating lamps when the edge banding starts: on/off.
 Speed during the lamps switch on
 Maximum radius for the lamps switch on: maximum curvature radius of the trajectory
above which the edge heating lamps cannot be switched on.
- Power of the lamps expressed in percentage.
14.8.4 Edge dispensing
Extra dispensing during the head downstroke from the magazine at the first approach point of
the profile being edge banded.
Open profile:
- Extra dispensing of the edge during the approach section
- Extra dispensing of the edge on the profile being edge banded
Closed profile:
- Extra dispensing of the edge during the approach section
- Extra dispensing of the edge on the profile being edge banded

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14.8.5 Roller stop optimization
- Stop time: Stop time of the edge banding head along the profile.
- Maximum application radius: maximum curvature radius of the trajectory above which the
roller stop cannot be optimised.
14.8.6 Stoptime of the edge bander in infeed and outfeed to the
profile
Open profile:
- Edge bander stop time on the first point of the profile being edge banded.
- Edge bander stop time on the last point of the profile being edge banded.
Closed profile:
- Edge bander stop time on the first point of the closed profile being edge banded.
- Edge bander stop time on the last point of the closed profile being edge banded.

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14.8.7 Edge in closure compensation
Defines the compensation in the closure of an edge banding. The reference is the type of
geometry of the final section of a closed edge banding.
- Linear section: compensation.
- Arc section: based on the concavity of the section (concave arc, convex arc) a table is
defined that associates a compensation to the curvature radius of the section.
The sections that have a curvature arc within an interval in the table will have a
compensation extracted from the interpolation of the compensation data of that interval.
14.8.8 Edge banding early-late
Solo per profili aperti:
- Posticipo ingresso della bordatura:
- Anticipo uscita della bordatura

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15 Post-Processor
Projects performed with Maestro can be exported in xxl or pgm files as input data for the
interface "Xilog"
15.1 Create .xxl and .pgm files
To create .xxl and .pgm files from the Maestro Post-Processor, proceed as follows:
1) Install Xilog
2) Set the output folder
3) Run the Post-Processor
15.1.1 Xilog installation
In order to translate project into files compatible with Xilog (xxl or pgm) it is necessary that Xilog
is installed.
In order to choose the field for Xilog installation, click on the icon "Options" in the field "Tools"
Write the folder name in the field "Xilog folder"

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15.1.2 Set output folder
To set the Maestro Post-Processor output folder use the “Options” command in the “Tools”
folder.
If you select the folder "Post", following screen will appear:
The "Output Folder" is the folder where XXL or PGM projects will be written as selected in
"Output Format"

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15.1.3 Execution Post-Processor
In order to translate the open project in a file compatible witht Xilog (xxl or pgm) use the
command "Post" in the menu "Machines".
If this message appears:
You have to insert the correct path where Xilog has been inserted (see paragraph 15.1.1)
If the translation is well performed, following message will appear:
By clicking on "Yes", the program for Xilog will be displayed.

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15.2 Create .epl files
To generate the EPL file(Worktable Editor) during the Post-Processor select one of the two
items in the “Options-Parameters_Worktable” menu.
By selecting:
“Print positionings on EPL file with motor driven table and suction cups blockage”
When executing the Post-Processor an EPL file will be produced as well as the .xxl and .pgm
files.
Normally only the manual tables produce an EPL file.
For motor driven tables the .epl file produced will contain only the bars and supports positioning
of the first phase in Arrange.
By selecting:
“Print positionings on “Layout” EPL file and with PB with motor driven table”
When executing the Post-Processor the .xxl and .pgm files will also include PB instructions and
the EPL file will also be produced.

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15.3 XXL/PGM editor
The XXL/PGM file editor allows you to edit past projects using the Xilog editor within Maestro
CNC.
To use it, simply open an XXL/PGM file using the "Open" button by selecting the corresponding
format in the file type selector.
Once the file is selected, its contents are displayed in the editor as you can see in the next
image, and it can be edited from here.
At the top we find the "Open" button that allows you to open another XXL/PGM file; the Save
and Save with name buttons to save the current file in XXL or PGM format; the "Close" button to
close the editor; the Cut, Copy and Paste functions, also available from the keyboard (CTRL +
X, CTRL + C, CTRL + V); as well as the Undo and Redo commands (CTRL + Z, CTRL + Y).
The line numbers are displayed to the left of the text, and at the bottom we find the line and
column values corresponding to the position of the cursor in the text.
In the right column we find the command to move to a line of the file, the command to find the
occurrences of a string and the command to replace it with a new string.

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16 Appendix
16.1 Sizes used by Maestro
Maestro uses several files with following sizes:
csv Workpieces for nesting and mixx definition
epl Instructions to set clamps/suction pads
lbdx machine elements library
lbsx supports library
mixx File for mix of workpieces
nstx Nesting projects
nstrptx Nesting report file
pgm Files exported for Xilog
pgmx Projects
settings Save the configuration parameters
tlgx Data-base Tools
xcs Script Files
xml Instructions to set parameters/geometries
xsp Sub-programs
xxl Files exported for Xilog
pgm Files exported for Xilog

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