Macros Should be More Automated

On a visit to Proteum Machining, I had the chance to dive into their processes and Dylan was brave enough to let me go full machinist geek and critique his shop. We explored every detail in episode 240 of Within Tolerance, but one of the standout discussions for me was about CNC macros and how they can transform efficiency in machining.

The Macro Debate: Manual vs. Automated

While helping with the kinematic calibration routines on a Hermle C250, I saw several manual steps where Dylan had to call macros from the MDI screen. Not every CNC control operates this way, but many do. Popular systems like Fanuc, Heidenhain, and even Syil’s LNC control use MDI for quick macro access.

Check out this shot of the MDI screen on the Toolpath Syil X7. G65 is the call to a sub-program, and believe it or not, I can name programs with actual words on this control. Revolutionary, right?

Dylan's Macro Workflow

1. Calibrate the tool setter 
2. Measure a tool, then skim cut a block with that tool to establish a known reference
3. Calibrate the z-probe length off that known reference
4. Calibrate the probe tip diameter using a gauge ring 
5. Run the kinematic calibration off a tooling ball
6. Mark all 30 tools as needing to be re-measured when called

He kept these commands handy in his MDI list, calling them one by one. Between steps, he managed manual tasks like cleaning tools, inspecting the probe tip, and installing the gauge ball.

The Case for Automation

I suggested combining these steps into one macro to save time and avoid hovering near the machine for 10 minutes. Naturally, this led to a debate: Is it worth the effort to make a macro more automated?

My answer is always yes. Humans make terrible robots because we are just not designed for repetitive tasks. Automation does not just save time; it also reduces mental fatigue and minimizes errors.

Automating routines like kinematics calibration means you are more likely to run them regularly. Plus, encoding processes into macros eliminates the need for documentation. It is a win on multiple fronts.

Why Isn't Everyone Doing This? 

The Skill Gap

Macro programming is not everyone’s forte. CNC controls like Brother, Fanuc, Syil, and Heidenhain each have quirks, making cross-platform programming challenging for many machinists

The Organization Hurdle

A good macro is not just written; it is planned. Here are some tips to streamline your workflow:

1. Standardize artifact locations: Use a zero-point system or mark spots for gauge blocks.

2. Minimize manual actions: Save probe start locations in a high-number WCS (e.g., G54P100).
3. Automate probe calls: Let the macro handle probe activation.
4. Start with precision: Always begin a macro with a protected move to a specific WCS zero point.

The payoff is a three-step routine that becomes a single macro call, saving time and mental energy.

A Real World Example

On the Syil X7, I developed open-source macros to simplify my probe and toolsetter calibration workflows. The Probe calibration macro has two modes:

Full Mode: 

Manually jog to the starting location once, and it saves the position to a WCS.

Quick Mode: 

Calls the saved position automatically, no jogging required.

I currently use a marked spot on the HWR plate for reference, but even that is not ideal. A fixed gauging plate with some studs would ensure perfect repeatability every time.

Stepping Toward Full CNC Automation

Every incremental automation improvement gets you closer to a fully automated shop. Imagine a robot changing pallets, running the warm-up routine, and performing calibration, all without human intervention. That is the dream, and every small step toward it is worth the effort.

Driving the Future of CNC Programming

Macros are not just about efficiency. They unlock the potential for greater automation. Whether it is reducing manual intervention or paving the way for robotic integration, programming smarter is the future of machining.