Ultimate CNC Flexibility. Infinite Customization.
Total Control.
Unlock next-level productivity with our advanced CNC system—engineered to elevate the performance of any machine tool. With faster processing speeds, precision control, and seamless integration, this CNC solution optimizes machining accuracy, reduces cycle times, and maximizes uptime. Whether you're upgrading existing equipment, building new or want a custom CNC control, our CNC platform delivers the power and flexibility to meet evolving manufacturing demands.
We offer two distinct control upgrades. One is exclusively for Fadal mills.
The other is a Universal CNC upgrade for many CNC mills, routers, ....
These two CNC upgrades offer similar capabilities and performance, and our goal is to make them easy to install and operate on almost any machine.
527F Fadal CNC UPGRADE
The 527F control has been designed in the same form factor as the original control, including all of the connectors. A high-speed CAT5 connection for ultra-fast axis card communication eliminates slow S100 bus restrictions. The 527F uses the card cage to communicate with non-time-critical components such as the mill interface card to make this as close as possible to a plug-and-play control.
544M UNIVERSAL CNC
The 544M control is a highly configurable universal CNC for custom applications. Virtually every aspect of the control can be tailored to the specific application needs of an OEM. The operator input, screen display and functionality can be specified by an OEM and a Calmotion engineer will build upon our core control architecture to create a unique CNC solution
We also offer a pre-engineered 544M CNC that connects to popular servo drives such as Yaskawa Sigma 7 using step and direction pulses. Other drive interfaces are available for OEM applications including CANOPEN, ETHERCAT (COE) and MODBUS (TCP/IP).
AN EMBEDDED CONTROL DESIGNED FROM
THE GROUND UP.
Embedded control requires more expertise, take longer to develop and put into service than PC based systems. Why choose embedded and do it the hard way?
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We know first hand the difficulties of maintaining PC based control systems as new versions of Windows are released. An embedded platform means we do not have to worry about chasing Microsoft Windows updates, versions and its inevitable obsolescence. If connected to a network, you need not worry about security threats as with PC based systems. The 527F is not vulnerable to hackers and virus threats.
PC's and a general purpose operating system are not ideally suited for CNC servo control. This is why so many PC based CNCs use servo motion controllers connected to a PC bus. Our embedded approach eliminates issues associated with operating system changes or updates which can affect the usability and performance of these types of integrated motion controllers.
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Our code and embedded platform is extremely portable and allows us to move to newer, faster technology with ease. We have complete control of our technology.
UNLEASH THE PRODUCTIVITY OF YOUR MACHINE
YOUR MACHINE IS CAPABLE OF SO MUCH MORE.
Eliminate these common bottlenecks:
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DNC data starvation
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Feed rate limitations due to limited block processing.
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Machine banging resulting from poor ramp control.
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Poor cutting performance at high speeds.
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Long load times of large programs into memory using RS-232.
MULTIPROCESSOR ARCHITECTURE
Our introductory product to the CNC market was a replacement for the legacy control made by Fadal Machining Centers. That control made the most of what was available in the 70's and 80's by using a multi-processor approach. Splitting up control requirements across several processors, each with its own responsibility, made it the best CNC in its time.
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We took that same approach, but updated slow 16 bit Intel processors with high-speed 64 bit processors and DSPs which feature single clock instruction math capabilities. Additionally, we have added more processors to further improve the speed and throughput of the control. Our 544M uses a very similar approach, but is enhanced with an even faster and more powerful main CPU.
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The synchronization of motion across each axis is handled by a central host CPU. The host also manages screen information and keeps track of position synchronization relieving the the main CPU to spend more time on G code interpretation, look ahead and ramp control.
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With the 527F and the 544M step and direction CNC, each axis is controlled independently with a high speed DSP (Digital Signal Processor), and communicates with the master host controller via a high speed industrial bus.
The CAN BUS version of the 544M sends position data directly to the servo drive instead of an independent axis card. Multiple CAN BUS ports are used to achieve high speed communication across all axis. (Ethercat COE & MODBUS TCP/IP available for OEM customers)
ADD A PC TO YOUR PENDANT
The 527F comes standard with a NUC computer that autoboots to Calmotion HMI software to display CNC information. The 544M allows for similar configurations.
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The 527F CNC continuously sends screen data to a PC connected USB dongle. The PC has no control capability and functions only as an HMI device.
Having a computer at the machine brings a host of productivity enhancement possibilities.
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Generate CAD/CAM programs at the machine, mirror the 527F operation remotely via TeamViewer/Google remote desktop, check email, pull files from anywhere on the network then place them into the 527F memory, This is also a nice way to perform program simulation using the software of your choice.
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BOOST YOUR PRODUCTIVITY
Precision Innovation in California was looking for ways to improve productivity. Their 6030 machine was making 11 complex parts a day and could not run faster due to machine banging and finish issues at high feed rates. Purchasing a new machine would have been cost prohibitive. Adding a 527F allowed the machine to run significantly faster, producing 18 parts a day with equal or better surface finish.
This opened up nearly 2 days of production each week to generate additional revenue or schedule a reduced work week.
* Performance gains such at this are typical of parts that require heavy CNC computation such as surfacing, advanced ramp control and look ahead.
Email us a typical part program for evaluation. We can estimate likely feed rate improvements.
UNRIVALED PERFORMANCE
Fadal-5 CPU at 250 IPM
Calmotion 527F CPU at 250 IPM
The comparison images depicted here are closeups looking at one area of a Mercedes test cut performed on a 1997 Fadal 6030 VMC with a –5 CPU. Both parts were cut with the exact same machine, program, AC servo amplifiers and motors. Only the control cards from the legacy Fadal CNC 88HS were changed out with the Calmotion 527F cards.
PROGRAM & POSITIONING RESOLUTION
10X THE LEGACY
LEGACY
CALMOTION 527F
ADVANCED RAMP CONTROL
30X THE LEGACY
LEGACY
CALMOTION 527F
STANDARD SPEED
10.2X THE LEGACY
LEGACY
CALMOTION 527F
Each axis controller calculates position at 10X the resolution of the legacy control (microns). Additionally, an improved survey table accepts micron resolution to provide optimal ball screw compensation.