Page 1 Measurement (M5) 2 3 H Valid for _ __________________ Control system Software version EMERGENCY OFF (N2) SINUMERIK 802D sl G/N 1.4 SP7 2 4 H SINUMERIK 802D sl T/M 1.4 SP7 _ __________________ Punching and Nibbling (N4) 2 5 H...
Page 2 Siemens AG Order number: 6FC5397-1CP10-5BA0 Copyright © Siemens AG 2005 - 2012. Industry Sector Ⓟ 08/2013 Technical data subject to change All rights reserved Postfach 48 48 90026 NÜRNBERG GERMANY...
Page 3 Continuation Positioning Axes (P2) Reference Point Approach (R1) Rotary Axes (R2) SINUMERIK 802D sl Turning, Milling, Nibbling Spindle (S1) Indexing Axes (T1) Function Manual Tangential Control (T3) Speed/torque coupling, master-slave (TE3) Feed (V1) Tool: Compensation and Monitoring (W1) Appendix...
Page 4 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
Page 5: Preface
Training For information about the range of training courses, refer under: ● www.siemens.com/sitrain SITRAIN - Siemens training for products, systems and solutions in automation technology ● www.siemens.com/sinutrain SinuTrain - training software for SINUMERIK FAQs You can find Frequently Asked Questions in the Service&Support pages under Product Support.
Page 6 Preface SINUMERIK You can find information on SINUMERIK under the following link: www.siemens.com/sinumerik Target group This publication is intended for: ● Project engineers ● Technologists (from machine manufacturers) ● System startup engineers (systems/machines) ● Programmers Benefits The function manual describes the functions so that the target group knows them and can select them.
Page 7 EC Declaration of Conformity The EC Declaration of Conformity for the EMC Directive can be found on the Internet at: http://support.automation.siemens.com Here, enter the number 15257461 as the search term or contact your local Siemens office. Technical information Notations The following notation and abbreviations are used in this documentation: ●...
Page 8 Preface Explanations for the technical data Protection level: Protection levels 0 to 7 have been used. The lock for protection levels 1 to 3 (4 to 7) can be cancelled by entering the correct password and 4 to 7 via IS "Protection level" (e.g. keyswitch position).
Page 9: Table Of Contents
Contents Preface ..............................5 Various Interface Signals (A2) ......................... 19 General ............................19 Signals from PLC to NCK ......................20 1.2.1 Access authorization........................20 1.2.2 General signals ..........................21 1.2.3 Signals for digital drives, to axis/spindle ..................24 Signals from NCK to PLC ......................24 1.3.1 General signals ..........................24 1.3.2 Signals for digital drives, from axis/spindle..................26...
Page 10 Contents 2.6.2 Setting data ..........................57 2.6.3 Interface signals .......................... 57 Continuous Path Mode, Exact Stop and LookAhead (B1)................ 59 Brief description .......................... 59 General............................59 Exact stop............................ 60 Continuous-path mode........................ 62 General............................62 3.4.1 3.4.2 Velocity reduction according to overload factor ................63 3.4.3 Jerk limiting along the path through velocity reduction ...............
Page 11 Contents PLC interface signals for gantry axes ..................104 Miscellaneous points regarding gantry axes................105 Example .............................107 6.7.1 Creating a gantry grouping ......................107 6.7.2 Setting of NCK PLC interface ....................108 6.7.3 Commencing start-up.........................109 6.7.4 Setting warning and trip limits ....................111 Data lists ............................112 6.8.1 Machine data..........................112 6.8.2...
Page 12 Contents 8.6.2 Setting data ..........................154 8.6.3 Interface signals ........................155 Auxiliary Function Outputs to PLC (H2) ....................157 Brief description ........................157 Programming of auxiliary functions................... 158 Transfer of values and signals to the PLC interface ..............159 Grouping of auxiliary functions....................160 Block-search response......................
Page 13 Contents 10.6 Workpiece counter ........................200 10.7 Data lists ............................202 10.7.1 Machine data..........................202 10.7.2 Setting data ..........................203 10.7.3 Interface signals.........................204 Compensation (K3)..........................207 11.1 Brief description .........................207 11.2 Backlash compensation ......................207 11.3 Interpolatory compensation......................209 11.3.1 General ............................209 11.3.2 LEC ............................210 11.3.3 Sag compensation and angularity error compensation .............214 11.3.4 Special features of interpolatory compensation.................224...
Page 14 Contents 13.4.2 Probe functional test ......................... 253 13.5 Tool measuring in JOG ......................255 13.6 Data lists............................ 259 13.6.1 Machine data..........................259 13.6.2 Interface signals ........................259 EMERGENCY OFF (N2)........................261 14.1 Brief description ........................261 14.2 EMERGENCY STOP sequence ....................262 14.3 EMERGENCY STOP acknowledgment ..................
Page 15 Contents 16.3 Constant cutting rate: G96 ......................304 Positioning Axes (P2) ..........................307 17.1 Concurrent positioning axis......................307 17.2 Permanently assigned PLC axis ....................308 17.3 Data lists ............................311 17.3.1 Machine data..........................311 17.3.2 Interface signals.........................311 17.3.3 Error messages..........................312 Reference Point Approach (R1)......................315 18.1 Fundamentals ..........................315 18.2...
Page 16 Contents 20.4 Gear stage change........................353 20.5 Programming..........................357 20.6 Spindle monitoring ........................359 20.6.1 Axis/spindle stationary ......................359 20.6.2 Spindle in setpoint range......................360 20.6.3 Maximum spindle speed ......................360 20.6.4 Minimum/maximum speed for gear stage................. 360 20.6.5 Max. encoder limit frequency ....................361 20.6.6 Target point monitoring ......................
Page 17 Contents Speed/torque coupling, master-slave (TE3)................... 391 23.1 Brief description .........................391 23.2 Coupling diagram........................393 23.3 Configuring a coupling .......................394 23.4 Torque compensatory controller ....................394 23.5 Tension torque ...........................395 23.6 Activating a coupling ........................396 23.7 Response on activation/deactivation ..................397 23.8 Axial interface signals ........................400 23.9 Axial monitoring functions ......................400 23.10...
Page 18 Contents 25.4.3 Workpiece count monitoring...................... 429 25.4.4 Examples of the service life monitoring ..................430 25.5 Special handling of tool compensation ..................431 25.6 Data lists............................ 434 25.6.1 Machine data..........................434 25.6.2 Interface signals ........................434 Appendix..............................435 List of abbreviations ........................435 Overview ...........................
Page 19: Various Interface Signals (A2)
Various Interface Signals (A2) General Brief description This chapter describes the functionality of various interface signals which are of general relevance, but are not described in the function-specific chapters. Interfaces The exchange of signals and data between the PLC user program and the NCK (kernel of the numerical control) or HMI (display unit) is performed via various data areas.
Page 20: Signals From Plc To Nck
Access to programs, data and functions is useroriented and controlled via eight hierarchical protection levels. These are subdivided into: ● Four password levels for Siemens, machine manufacturer (2x) and end user ● Four protection levels for end users (interface signals V2600 0000.4 to .7) This provides a multilevel safety concept for controlling access rights.
Page 21: General Signals
Various Interface Signals (A2) 1.2 Signals from PLC to NCK Figure 1-2 Access protection 1.2.2 General signals Delete distance-to-go (V3200 0006.2) IS "Delete distancetogo (channelspecific)" is only active for path axes. With the rising edge of the interface signal, the distancestogo of all axes in the geometry grouping are deleted and thus brought to a standstill with ramp stop.
Page 22 Various Interface Signals (A2) 1.2 Signals from PLC to NCK Spindle disable (for spindle): If IS "Spindle disable" is set, no more speed setpoints are output to the speed controller in openloop control mode and no more position partial setpoints are output to the position controller in positioning mode.
Page 23 Various Interface Signals (A2) 1.2 Signals from PLC to NCK Position measuring system 1 (V380x 0001.5) A position measuring system may be connected to the spindle. In this case the signal for the spindle has to be set. Axes always require this signal. In this case, a position measuring system must be installed. Controller enable (V380x 0002.1) When the controller enable is activated for the drive, the position control loop of the axis/spindle is closed.
Page 24: Signals For Digital Drives, To Axis/Spindle
Various Interface Signals (A2) 1.3 Signals from NCK to PLC Interpolatory axis grouping: All the axes traversing within the interpolatory axis grouping are stopped as soon as the controller enable signal is cancelled for one of the axes. The axes are brought to a standstill as described above. All axes in the geometry grouping are brought to a standstill with rapid stop.
Page 25 External language mode active (V3300 4001.0) The control system sends this signal to the PLC to indicate that the active program language used for the part program is not a SIEMENS language. A language changeover has been made with G291.
Page 26: Signals For Digital Drives, From Axis/Spindle
Various Interface Signals (A2) 1.3 Signals from NCK to PLC Current control active (V390x 0001.7) The current control loop for the axis/spindle is closed; the current control function is active. Lubrication pulse (V390x 1002.0) The IS "Lubrication pulse" is sent by the NCK and changes status once the axis/spindle has traveled a greater distance than that set in MD33050 LUBRICATION_DIST (travel distance for lubrication from PLC) 1.3.2...
Page 27: Signals From Plc To Hmi
PLC. The current NC program selected can be stored via the command interface (see VB 1700 1001) and also selected again. With SINUMERIK 802D sl, a program with the program name (STRING) is administered. To assign a program name to a program number, the file PLCPROG.LST is available in the control.
Page 28 ● 1 to 100: User area (end user protection level) ● 101 to 200: Machine manufacturer (machine manufacturer protection level) ● 201 to 255: SIEMENS (SIEMENS protection level) The file PLCPROG.LST - where the minimum protection level for end user has been set - can be edited using the operation: "System"...
Page 29: Signals From Hmi To Plc
Various Interface Signals (A2) 1.5 Signals from HMI to PLC "Command" (VB1700 1001) corresponds to the following IS: ● "Execute command" (V1700 2001.0) ● "Command execution error" (V1700 2001.1) When a command > 0 is written, the job is started by the PLC. As soon as the HMI detects a command >...
Page 30: Nc Services
Various Interface Signals (A2) 1.6 NC services NC services 1.6.1 User interface 1.6.1.1 General information Communication jobs can be performed via the "NC services" PLC/NCK interface. The following services are available for this: ● Start program invocation services (PI services) in the NCK area (e.g. ASUB) ●...
Page 31 Various Interface Signals (A2) 1.6 NC services Job, global part The results are written by the PLC operating system; therefore, these signals can only be written by the user. If the job was completed without errors, the "Job completed" signal V1200 2000.0 is set to 1. If an error occurs while executing a read/write job, the "error in job"...
Page 32: Pi Service Asub
Various Interface Signals (A2) 1.6 NC services 1.6.1.2 PI service ASUB Initialization With the ASUB PI service, it is possible to assign the interrupt numbers 1 and 2 fixed program names from the PLC. Prerequisite for this is the existence of the PLCASUP1_SPF or PLCASUP2_SPF programs in the CMA directory.
Page 33: Reading Variables From The Nck Area
Various Interface Signals (A2) 1.6 NC services 1.6.1.3 Reading variables from the NCK area 1 to 8 values can be read with a read job (variable x: 0...7). There is a variable-specific part of the interface for this: ● Job: V120x 1000 ●...
Page 34: Writing Variables From The Nck Area
Various Interface Signals (A2) 1.6 NC services Relevant interface signals Address Name Valid values Job, V1200 0000.0 Start global part V1200 0000.1 Write variable V1200 0000.2 PI service VB1200 0001 Number of variables 1 ... 8 Job, VB120x 1000 Variable index See Section variable-specific NC variable...
Page 35 Various Interface Signals (A2) 1.6 NC services Result, variable-specific part A result is reported for each variable in the job. If the read process was successful, "Variable valid" (V120x 3000.0) is set to 1; the access result VB120x 3001 is 0. When reading, the data as of VB120x 3004 is entered type-specifically.
Page 36: Nc Variable
Various Interface Signals (A2) 1.6 NC services 1.6.2 NC variable Variable cuttEdgeParam Compensation value parameters and cutting edge list with D numbers for a tool. The meanings of the individual parameters depend on the type of the tool in question. Currently, 25 parameters are reserved for each tool edge (but only a part of them is loaded with values).
Page 37 Various Interface Signals (A2) 1.6 NC services ● 3: EXTFRAME = current external work offset ● 4: TOTFRAME = current total work offset = total of ACTFRAME and EXTFRAME ● 5: ACTBFRAME = current total base frame ● 6: SETFRAME = current 1st system frame (PRESET, scratching) ●...
Page 38 Various Interface Signals (A2) 1.6 NC services Variable rpa R parameters Variable rpa [r/w] VB120x1000 VB120x1001 VW120x1002 R number + 1 VW120x1004 VD120x1008 Write: Data to NCK variable x (data type of the variables: REAL) VD120x3004 Read: Data from NCK variable x (data type of the variables: REAL) Variable actLineNumber Line number of the current NC block: ●...
Page 39 Various Interface Signals (A2) 1.6 NC services Variable r0079[1] CO: Torque setpoint at the output of the speed controller (before clock cycle interpolation) [Nm] Index: [1] = Smoothed with p0045 Variable r0079[0...1] [r] VB120x1000 VB120x1001 No. of drive module VW120x1002 VW120x1004 VD120x1008 VD120x3004...
Page 40: Signals From Plc
Various Interface Signals (A2) 1.7 Signals from PLC Signals from PLC Commissioning mode The ramp-up modes are signaled via bit 0 and bit 1 (VB1800 1000) in the user interface. Commissioning mode VB1800 1000.1 VB1800 1000.0 Normal rampup Ramp-up with default values Ramp-up with saved data Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 41: Axis Monitoring (A3)
Axis Monitoring (A3) Overview of monitoring functions Overview of monitoring functions ● Motion monitoring functions – Contour monitoring – Position monitoring – Standstill monitoring – Clamping monitoring – Speed setpoint monitoring – Actual velocity monitoring – Encoder monitoring functions ● Monitoring of static limits –...
Page 42: Position Monitoring
Axis Monitoring (A3) 2.2 Motion monitoring functions Effectiveness Contour monitoring is active for axes and position-controlled spindles. Effect If the contour deviation is too large, this has the following effect: ● Alarm 25050 "Contour monitoring" is triggered ● The axis/spindle is brought to a standstill via a speed setpoint ramp with rapid stop (with open position control loop).
Page 43 Axis Monitoring (A3) 2.2 Motion monitoring functions Figure 2-1 Relation between position, standstill, and clamping monitoring Effectiveness Positioning monitoring is always activated after the termination of motion blocks "according to the setpoint" (setpoint has reached destination). Position monitoring is active for axes and position-controlled spindles. Deactivation When the programmed "Exact stop limit fine"...
Page 44: Standstill Monitoring
Axis Monitoring (A3) 2.2 Motion monitoring functions Cause of error/Remedy ● Position controller gain too low --> change machine data for position controller gain MD32200 POSCTRL_GAIN (servo gain factor) ● Positioning window (exact stop fine), position monitoring time, and position controller gain have not been coordinated -->...
Page 45: Clamping Monitoring
Axis Monitoring (A3) 2.2 Motion monitoring functions Effect When the monitoring function responds, it has the following effects: ● Alarm 25040 "Standstill monitoring" is triggered ● The affected axis/spindle is brought to a standstill with rapid stop (with open position control loop) along a speed setpoint ramp.
Page 46: Speed Setpoint Monitoring
Axis Monitoring (A3) 2.2 Motion monitoring functions Effect If the axis is pushed out of position beyond the clamping tolerance during clamping the following occurs: ● Alarm 26000 "Clamping monitoring" is triggered ● The affected axis/spindle is brought to a standstill with rapid stop (with open position control loop) along a speed setpoint ramp.
Page 47: Actual Velocity Monitoring
Axis Monitoring (A3) 2.2 Motion monitoring functions Effect The following occurs if the maximum speed setpoint value is exceeded: ● Alarm 25060 "Speed setpoint limiting" is triggered ● The affected axis/spindle is brought to a standstill using a rapid stop (with open position control loop) along a speed setpoint ramp.
Page 48: Encoder Monitoring Functions
Axis Monitoring (A3) 2.3 Encoder monitoring functions The actual velocity monitoring is active for axes and spindles. Effect If the "Threshold for velocity monitoring" is exceeded the following occurs: ● Alarm 25030 "Actual velocity alarm limit" is triggered ● The affected axis/spindle is brought to a standstill with rapid stop (with open position control loop) along a speed setpoint ramp.
Page 49: Zero Mark Monitoring
Axis Monitoring (A3) 2.3 Encoder monitoring functions Effect When the limit frequency of an encoder is exceeded the following occurs: ● The "Encoder limit frequency exceeded 1" interface signal (V390x 0000.2) is set. ● Spindle continues to run with closed-loop speed control. If the spindle speed is reduced to a value that causes the encoder frequency to drop below the setting in MD 36302 ENC_FREQ_LIMIT_LOW (% value of MD36300), the spindle is automatically re-synchronized with the reference system of the encoder.
Page 50: Monitoring Of Static Limits
Axis Monitoring (A3) 2.4 Monitoring of static limits Effect If the number of zero mark errors entered in MD36310 ENC_ZERO_MONITORING is reached for a measuring system, alarm 25020 "Zero mark monitoring" is triggered. The affected axis/spindle is brought to a standstill using a rapid stop (with open position control loop) along a speed setpoint ramp.
Page 51: Software Limit Switches
Axis Monitoring (A3) 2.4 Monitoring of static limits If the hardware limit switch is crossed, the PLC signals this to the NC via IS "Hardware limit switch plus/minus" (V380x 1000.1 or .0) and the movement of all axes is stopped. The braking method can be specified via MD36600 BRAKE_MODE_CHOICE (braking behavior at hardware limit switch).
Page 52 Axis Monitoring (A3) 2.4 Monitoring of static limits Effectiveness ● Software limit switch monitoring is activated after reference point approach in all modes. ● The position of the software limit switch can be approached. ● The 2nd software limit switch can be activated via the "2nd software limit switch plus/minus"...
Page 53: Working Area Limitation
Axis Monitoring (A3) 2.4 Monitoring of static limits 2.4.3 Working area limitation Function Working area limits describe the area in which machining is possible. They enable the user to limit the traversing range of the axes in addition to the limit switches. Reference: /BP_/ Operation and Programming A check is made to see whether the tool tip P is within the protected working area.
Page 54 Axis Monitoring (A3) 2.4 Monitoring of static limits Figure 2-4 Working area limitation using the example of the turning machine Effectiveness ● The working area limitation can be activated via SD43410 WORKAREA_MINUS_ENABLE, SD43400 WORKAREA_PLUS_ENABLE (working area limitation in the negative or positive direction active) and takes effect after reference point approach.
Page 55: Supplementary Conditions
Axis Monitoring (A3) 2.5 Supplementary conditions Remedy ● Reset ● Check the working area limit in the part program (G25/G26) or in the setting data. ● Move in the opposite direction (in JOG mode) Supplementary conditions To ensure that the monitoring functions respond correctly, it is important that the correct values are entered in the following machine data: General: ●...
Page 56: Data Lists
Axis Monitoring (A3) 2.6 Data lists Data lists 2.6.1 Machine data Number Identifier Name Channel-specific 21020 WORKAREA_WITH_TOOL_RADIU Allowance for tool radius with working area limitation Axis/spindle-specific 30310 ROT_IS_MODULO Modulo conversion for rotary axis and spindle 32000 MAX_AX_VELO Maximum axis velocity 32200 POSCTRL_GAIN [n] Servo gain factor Kv...
Page 57: Setting Data
Axis Monitoring (A3) 2.6 Data lists 2.6.2 Setting data Number Identifier Name Axis/spindle-specific 43400 WORKAREA_PLUS_ENABLE Working area limitation active in positive direction 43410 WORKAREA_MINUS_ENABLE Working area limitation active in negative direction 43420 WORKAREA_LIMIT_PLUS Working area limitation plus 43430 WORKAREA_LIMIT_MINUS Working area limitation minus 2.6.3 Interface signals Number...
Page 58 Axis Monitoring (A3) 2.6 Data lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 59: Continuous Path Mode, Exact Stop And Lookahead (B1)
Continuous Path Mode, Exact Stop and LookAhead (B1) Brief description For continuous path control, the CNC processes a part program block by block. Only when the functions of the current block have been completed is the next block processed. Various requirements with respect to machining or positioning require different block change criteria.
Page 60: Exact Stop
Continuous Path Mode, Exact Stop and LookAhead (B1) 3.3 Exact stop Velocity for zero cycle blocks The term zero cycle is applied to blocks whose path length is shorter than the distance that can be traveled on the basis of the programmed set feedrate and the interpolator cycle (time).
Page 61 Continuous Path Mode, Exact Stop and LookAhead (B1) 3.3 Exact stop The use of the exact stop function is suitable for precise traversing of contours. Exact stop is not suitable if ● Exact traversing of the contour on the basis of the criterion (e.g. exact stop fine) can deviate from the programmed contour in order to achieve faster machining.
Page 62: Continuous-Path Mode
Continuous Path Mode, Exact Stop and LookAhead (B1) 3.4 Continuous-path mode Continuous-path mode 3.4.1 General In continuous path mode, the path velocity is not decelerated for the block change in order to permit the fulfillment of an exact stop criterion. The objective of this mode is to avoid rapid deceleration of the path axes at the block-change point so that the axis velocity remains as constant as possible when the program moves to the next block.
Page 63: Velocity Reduction According To Overload Factor
Continuous Path Mode, Exact Stop and LookAhead (B1) 3.4 Continuous-path mode Velocity = 0 in continuouspath mode Regardless of the implicit exact stop response, the path motion is braked down to zero velocity at the end of the block in cases where: ●...
Page 64: Jerk Limiting Along The Path Through Velocity Reduction
Continuous Path Mode, Exact Stop and LookAhead (B1) 3.4 Continuous-path mode Overload factor The overload factor restricts step changes in the machine axis velocity at the block transition. To ensure that the velocity jump does not exceed the maximum load on the axis, the jump is derived from the acceleration of the axis.
Page 65: Machine Axis-Specific Jerk Limiting
Continuous Path Mode, Exact Stop and LookAhead (B1) 3.4 Continuous-path mode Activating Jerk limiting at block transitions becomes active if continuous path mode is programmed with G64 and SOFT acceleration characteristics. MD32432 PATH_TRANS_JERK_LIM must contain a positive value. 3.4.4 Machine axis-specific jerk limiting Function The axis-specific machine data MD32431 MAX_AX_JERK[..] can be used to set individual changes in acceleration for each machine axis, like those that can already be set for...
Page 66: Lookahead
Continuous Path Mode, Exact Stop and LookAhead (B1) 3.5 LookAhead LookAhead Function LookAhead is a procedure in continuous path mode (G64) that achieves velocity control with LookAhead over several NC part program blocks beyond the current block. Without LookAhead: If the program blocks only contain very small paths, a velocity per block is achieved that permits deceleration of the axes at the block end point without violating acceleration limits.
Page 67 Continuous Path Mode, Exact Stop and LookAhead (B1) 3.5 LookAhead Operating principle LookAhead functionality is available only for path axes, but not for the spindle. For safety reasons, the velocity at the end of the last prepared block must initially be assumed to be zero because the next block might be very small or be an exact-stop block and the axes must have been stopped by the end of the block.
Page 68: Data Lists
Continuous Path Mode, Exact Stop and LookAhead (B1) 3.6 Data lists Data lists 3.6.1 Machine data Number Identifier Name Channel-specific 29000 LOOKAH_NUM_CHECKED_BLOCKS Number of blocks considered by the LookAhead function Axis/spindle-specific 32431 MAX_AX_JERK Maximum axis-specific jerk for path movement 32432 PATH_TRANS_JERK_LIM Maximum axis-specific jerk for path movement at block transition...
Page 69: Acceleration (B2)
Acceleration (B2) Acceleration profiles Abrupt acceleration changes With the v/t-linear control of the axis velocity that is normally applied, the motion is controlled such that the acceleration rate changes abruptly over time. With the discontinuous, stepped acceleration, jerkfree starting and braking of the axes is not possible, but a timeoptimized velocity/time profile can be implemented.
Page 70: Jerk Limitation In Jog Mode
Acceleration (B2) 4.3 Jerk limitation in JOG mode The program code BRISK in the part program. BRISK is modal. If path axes are programmed in a block with BRISK, the previous block is ended with exact stop. BRISK activates the profile with abrupt acceleration changes associated with v/tlinear velocity control.
Page 71: Percentage Acceleration Correction, Acc
Acceleration (B2) 4.4 Percentage acceleration correction, ACC Percentage acceleration correction, ACC Function Certain program sections can require the axis and spindle acceleration set via the machine data to be changed using the program. This programmable acceleration is a percentage acceleration correction. ACC[channel axis name] = percentage The ACC command in the program allows you to set a percentage for each axis (e.g.
Page 72: Data Lists
Acceleration (B2) 4.5 Data lists Data lists Machine data Number Identifier Name Axis-specific 32300 MAX_AX_ACCEL Axis acceleration 32420 JOG_AND_POS_JERK_ENABLE Enabling axis-specific jerk limitation 32430 JOG_AND_POS_MAX_JERK Axis-specific jerk 32431 MAX_AX_JERK Maximum axis-specific jerk during path movement 32432 PATH_TRANS_JERK_LIM Maximum axis-specific jerk during path movement at the block transition Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 73: Travel To Fixed Stop (F1)
Travel to fixed stop (F1) Note This function is not available with version T/M value. Brief description Application range The travel to fixed stop (FXS = Fixed Stop) function can be used to establish defined forces for clamping workpieces, such as those required for sleeves and grippers. The function can also be used for the approach of mechanical reference points.
Page 74 Travel to fixed stop (F1) 5.2 Functionality The width of the fixed stop monitoring window is set with the command FXSW[Machine axis identifier] = <window width>. Unit: mm, inches or degrees - depending on the basic measurement system, linear or rotary axis. The commands are modal.
Page 75 Travel to fixed stop (F1) 5.2 Functionality Note It is not permissible to program a new position for an axis if the "Travel to fixed stop" function has already been activated for an axis/spindle (not an analog spindle). The spindle must be switched to position-controlled mode before the function is selected.
Page 76 Travel to fixed stop (F1) 5.2 Functionality Selection The NC detects when preparing the block that the function "Travel to fixed stop" is selected via the command FXS[x]=1 and signals the PLC via the IS "Activate travel to fixed stop" that the function has been selected.
Page 77 Travel to fixed stop (F1) 5.2 Functionality The NC then executes a block change or considers the positioning motion to be completed, but still leaves a setpoint applied to the drive actuator to allow the clamping torque to take effect. The fixed stop monitoring function is activated as soon as the stop position is reached.
Page 78 Travel to fixed stop (F1) 5.2 Functionality Interrupts ● If the fixed stop position is not reached when the function is active, alarm 20091 "Fixed stop not reached" is output and a block change executed. ● If a traversing request (e.g. from the part program or from the operator panel) is provided for an axis after the fixed stop has been reached, the alarm 20092 "Travel to fixed stop still active"...
Page 79 Travel to fixed stop (F1) 5.2 Functionality Changing clamping torque and monitoring window The commands FXST[x] and FXSW[x] can be used to change the clamping torque and the fixed stop monitoring window in the part program. The changes take effect before traversing movements in the same block.
Page 80: Response To Reset And Function Abort
Travel to fixed stop (F1) 5.3 Response to RESET and function abort Response to RESET and function abort Response to Reset During selection (fixed stop not yet reached) the function FXS can be aborted with RESET. The termination is carried out such that an "almost achieved" fixed stop (setpoint already beyond the fixed stop, but still within the threshold for the fixed stop detection) will not result in damage.
Page 81: Miscellaneous
Travel to fixed stop (F1) 5.5 Miscellaneous Miscellaneous Inapplicable interface signals The following IS signals (PLC → NCK) have no effect for axes at endstop until deselected (incl. traversing motion): ● IS "Axis/spindle disable" ● IS "Controller enable" Actual position at fixed stop System variable $AA_IM[x] can determine the actual position of the machine axis, e.g.
Page 82 Travel to fixed stop (F1) 5.5 Miscellaneous Diagram The following diagram shows the sequence of the motor current, following error and interface signals for "Activate travel to fixed stop" with a digital drive. Figure 5-2 Diagram for FXS with a digital drive Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 83: Data Lists
Travel to fixed stop (F1) 5.6 Data lists Data lists 5.6.1 Machine data Number Identifier Name Axis-specific 37000 FIXED_STOP_MODE Travel to fixed stop mode 37002 FIXED_STOP_CONTROL Special function when traveling to fixed stop 37010 FIXED_STOP_TORQUE_DEF Default for clamping torque 37012 FIXED_STOP_TORQUE_RAMP_TIME Virtual time until reaching the new clamping torque when traveling to fixed stop 37020...
Page 84 Travel to fixed stop (F1) 5.6 Data lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 85: Gantry Axes (G1)
(have) not been licensed using a license key was (were) set" is output. It will not be possible to operate the machine as normal. For information on operations relating to "Setting (an) option(s)", please refer to the section titled "Licensing in SINUMERIK 802D sl" in the "Turning, Milling, Grinding, Nibbling" Operating Instructions. Gantry axes Gantry axes are mechanically grouped machine axes.
Page 86: Gantry Axes" Function
Gantry axes (G1) 6.2 "Gantry axes" function "Gantry axes" function Application On large gantry-type milling machines, various axis units (e.g. gantry or crossbeam) are moved by a number of drives, which are mutually independent. Each drive has its own measuring system and thus constitutes a complete axis system. When these mechanically rigidly-coupled axes are traversed, both drives must be operated in absolute synchronism in order to prevent canting of mechanical components (resulting in power/torque transmission).
Page 87 Gantry axes (G1) 6.2 "Gantry axes" function Leading axis The leading axis is the gantry axis that exists from the point of view of the operator and programmer and, thus, can be influenced like a standard NC axis. The axis name of the leading axis identifies all axes in the gantry axis grouping.
Page 88 Gantry axes (G1) 6.2 "Gantry axes" function When the "gantry axes" function is active, the synchronized axis setpoint is generated directly from the setpoint of the leading axis in all operating modes. Note The dynamic control response settings for the leading and synchronized axes must be identical.
Page 89 Gantry axes (G1) 6.2 "Gantry axes" function The "Gantry trip limit exceeded" IS is also output if the gantry grouping is jammed (no servo enable, gantry grouping in "Hold" state). The monitoring functions are deactivated while the grouping is operating in "Follow-up" mode.
Page 90: Referencing And Synchronizing Gantry Axes
Gantry axes (G1) 6.3 Referencing and synchronizing gantry axes The forced coupling between the gantry axes can be separated by making the following MD setting and then performing a RESET: MD37140 GANTRY_BREAK_UP = 1 (break up gantry grouping) The gantry axes can then be traversed separately by hand; the monitoring of the warning and trip limits is not operative in this state.
Page 91 Gantry axes (G1) 6.3 Referencing and synchronizing gantry axes Referencing process The flowchart for referencing gantry axes using an incremental measuring system is as follows: Section 1: Referencing of the leading axis Axis-specific referencing of the gantry axes is started by the active machine function REF when the leading axis interface signal is sent from the PLC user program: V380x 0004.7/.6 (traversing key plus/minus) The leading axis approaches the reference point (operational sequence as for reference...
Page 92 Gantry axes (G1) 6.3 Referencing and synchronizing gantry axes The position value is defined by the leading axis: MD34100 REFP_SET_POS (reference point for incremental system) The absolute encoders and distanced-coded encoders of the leading axis will be set to the current actual position of the leading axis or to the reference point by the following machine data: MD34330 REFP_STOP_AT_ABS_MARKER (distancecoded linear measuring system without destination point)
Page 93 Gantry axes (G1) 6.3 Referencing and synchronizing gantry axes Figure 6-2 Flowchart for referencing and synchronization of gantry axes Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 94 Gantry axes (G1) 6.3 Referencing and synchronizing gantry axes Synchronization process A synchronization process is always required in the following cases: ● after the reference point approach of all axes included in a grouping, ● if the axes become desynchronized (see below). Operational sequence failure If the referencing process described above is interrupted as a result of disturbances or a RESET, proceed as follows:...
Page 95 Gantry axes (G1) 6.3 Referencing and synchronizing gantry axes Loss of synchronization The gantry grouping becomes desynchronized (V390x 5005 = 0) if: ● The gantry axes were in "Follow-up" mode ● The reference position of a gantry axis is lost, e.g. during "Parking" (no measuring system active) ●...
Page 96: Automatic Synchronization
Gantry axes (G1) 6.3 Referencing and synchronizing gantry axes During referencing, the reference point value of the leading axis is specified as the target position for all axes in the grouping for the synchronization compensatory motion. This position is then approached without axis coupling. The absolute encoders and distance- coded encoders of the leading axis will be set to the current actual position of the leading axis or to the reference point value;...
Page 97: Points To Note
Gantry axes (G1) 6.3 Referencing and synchronizing gantry axes Note The following interface signal blocks automatic synchronization in all modes except referencing mode: V380x 5005.5 (automatic synchronization locking) If automatic synchronization is to be activated, V380x 5005.5 must be set to "0". Following this, one of the axes in the gantry grouping must be switched from follow-up mode to position-controlled mode.
Page 98 Gantry axes (G1) 6.3 Referencing and synchronizing gantry axes Absolute encoder During the synchronization compensatory motion, all the axes in the gantry axis grouping (in the decoupled state) also traverse to the reference point value of the leading axis, which is defined in the following machine data: MD34100 REFP_SET_POS (reference point value/destination point for distance-coded system)
Page 99: Start-Up Of Gantry Axes
Gantry axes (G1) 6.4 Start-up of gantry axes Start-up of gantry axes General information Owing to the forced coupling which is normally present between leading and synchronized gantry axes, the gantry axis grouping must be commissioned as if it were an axis unit. For this reason, the axial machine data for the leading and synchronized axes must always be defined and entered jointly.
Page 100 Gantry axes (G1) 6.4 Start-up of gantry axes MD37130 GANTRY_POS_TOL_REF (gantry trip limit for referencing) Note The control must then be switched off and then on again because the gantry axis definition and the trip limit values only take effect after power ON. Response to setpoint changes and disturbances The gantry axes can only operate in exact synchronism if the parameters for the control circuits of the leading and synchronized axes are set to the same dynamic response value.
Page 101 Gantry axes (G1) 6.4 Start-up of gantry axes Example When the speed feedforward control is active, the dynamic response is primarily determined by the equivalent time constant of the "slowest" speed control loop. Leading axis: MD32810 EQUIV_SPEEDCTRL_TIME [n] = 5 ms Synchronized axis: MD32810 EQUIV_SPEEDCTRL_TIME [n] = 3 ms Time constant of dynamic response adaptation for synchronized axis:...
Page 102 Gantry axes (G1) 6.4 Start-up of gantry axes Synchronizing gantry axes The gantry synchronization process must be activated with IS "Start gantry synchronization" (see Section "Referencing and synchronizing of gantry axes"). Once the axes have been synchronized (IS "Gantry grouping is synchronized" = 1), the dimensional offset between the leading and synchronized axes must be checked to ensure that it equals 0.
Page 103 Gantry axes (G1) 6.4 Start-up of gantry axes If the gantry grouping is canceled, the following points must be noted: ● Always activate the traversing range limits and set them to the lowest possible values (position tolerance) ● Synchronize the gantry grouping first if possible and then execute a POWER-ON-RESET without referencing the axes again.
Page 104: Plc Interface Signals For Gantry Axes
Gantry axes (G1) 6.5 PLC interface signals for gantry axes PLC interface signals for gantry axes Special IS for gantry axes The special PLC interface signals of the coupled gantry axes are taken via the axial PLC interface of the leading or synchronized axes. Table below shows all special gantry-PLC interface signals along with their codes and indicates whether the IS is evaluated on the leading axis or the synchronized axis.
Page 105: Miscellaneous Points Regarding Gantry Axes
Gantry axes (G1) 6.6 Miscellaneous points regarding gantry axes PLC interface signal Address Effect on Leading axis Synchronized axis Feed stop V380x 0004.4 On all axes in gantry grouping Hardware limit switch minus/plus V380x 1000.0/.1 Axial alarm: Brake request on all axes in gantry grouping 2.
Page 106 Gantry axes (G1) 6.6 Miscellaneous points regarding gantry axes PRESET The PRESET function can only be applied to the leading axis. All axes in the gantry grouping are reevaluated internally in the control when PRESET is activated. The gantry axis then lose their reference and synchronization: V390x 5005.5 = 0 (gantry grouping is synchronized) Default for RESET...
Page 107: Example
Gantry axes (G1) 6.7 Example Example 6.7.1 Creating a gantry grouping Introduction The individual steps involved in the process are explained below using an example constellation: ● Setting up a gantry grouping ● Referencing its axes ● Aligning any offsets ●...
Page 108: Setting Of Nck Plc Interface
Gantry axes (G1) 6.7 Example Reference point machine data The MD values specified apply for the first encoder in both axis 1 and axis 3. MD34000 REFP_CAM_IS_ACTIVE = TRUE MD34010 REFP_CAM_DIR_IS_MINUS = e.g. FALSE MD34020 REFP_VELO_SEARCH_CAM = MD34030 REFP_MAX_CAM_DIST = corresponds to max. distance traversed MD34040 REFP_VELO_SEARCH_MARKER = MD34050 REFP_SEARCH_MARKER_REVERSE = e.g.
Page 109: Commencing Start-Up
Gantry axes (G1) 6.7 Example The NCK sets the following IS as a confirmation: ● For the leading axis (axis 1): Figure 6-5 NCK-PLC interface VB390x 5005 relative to leading axis ● For the synchronized axis (axis 3): Figure 6-6 NCK-PLC interface VB390x 5005 relative to synchronized axis 6.7.3 Commencing start-up...
Page 110 Gantry axes (G1) 6.7 Example In addition, the following steps must be taken: ● RESET ● Read off values in machine coordinate system: e.g. X = 0.941 Y = 0.000 XF = 0.000 ● Enter the X value of the leading axis (axis 1) with inverted sign in the machine data of the synchronized axis (axis 3): MD34090 REFP_MOVE_DIST_CORR = - 0.941 Note...
Page 111: Setting Warning And Trip Limits
Gantry axes (G1) 6.7 Example Continue with Step 1 (see above). ● Start gantry synchronization. PLC sets: V380x 5005.4 = 1 (start gantry synchronization) 6.7.4 Setting warning and trip limits As soon as the gantry grouping is set and synchronized, the following machine data must still be set to correspond: MD37110 GANTRY_POS_TOL_WARNING (gantry warning limit) MD37120 GANTRY_POS_TOL_ERROR (gantry trip limit)
Page 112: Data Lists
Gantry axes (G1) 6.8 Data lists These should have the following scales of magnitude at the end of the customizing process: MD37110 < MD37120 < MD37130 Note The same procedure must be followed when commissioning a gantry grouping in which the axes are operated by linear motors and associated measuring systems.
Page 113: Interface Signals
Gantry axes (G1) 6.8 Data lists Number Identifier Name 37110 GANTRY_POS_TOL_WARNING Gantry warning limit 37120 GANTRY_POS_TOL_ERROR Gantry trip limit 37130 GANTRY_POS_TOL_REF Gantry trip limit for referencing 37140 GANTRY_BREAK_UP Invalidate gantry axis grouping 6.8.2 Interface signals Number Name Leading axis Synchronized axis Mode-specific V3100 0001 Active machine function REF...
Page 114 Gantry axes (G1) 6.8 Data lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 115: Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2)
Velocities, Setpoint/Actual Value Systems, Closed- Loop Control (G2) Velocities, traversing ranges, accuracies 7.1.1 Velocities The maximum path/axis velocities and spindle speed are influenced by the machine design, the dynamic response of the drive and the limit frequency of the actual-value acquisition system (encoder limit frequency).
Page 116: Traversing Ranges
Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.1 Velocities, traversing ranges, accuracies Example: MD10200 INT_INCR_PER_MM = 1,000 [incr./mm] Interpolation cycle = 12 ms ⇒ V = 10 /(1,000 x 12 ms) = 0.005 incr The value range of the feedrates depends on the computational resolution selected. If MD10200 INT_INCR_PER_MM (computational resolution for linear positions) (1,000 incr./mm) or MD10210 INT_INCR_PER_DEG (computational resolution for angular positions) (1,000 incr./degree) are assigned their default values, the following range of...
Page 117: Input/Display Resolution, Computational Resolution
Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.1 Velocities, traversing ranges, accuracies 7.1.3 Input/display resolution, computational resolution The following types of resolution, e.g. resolution of linear and angular positions, velocities, accelerations, and jerk, must be differentiated as follows: ● Input resolution - data is input via the control panel or part programs. ●...
Page 118: Standardizing Physical Quantities Of Machine And Setting Data
Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.2 Metric/inch measuring system 7.1.4 Standardizing physical quantities of machine and setting data Machine and setting data that possess a physical quantity are interpreted in the input/output units below depending on whether the metric or inch system is selected: Physical quantity: Input/output units for standard basic system: Metric...
Page 119: Conversion Of Basic System By Part Program
Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.2 Metric/inch measuring system 7.2.1 Conversion of basic system by part program When programming, it is possible to change over between dimension systems for some workpiece-related specifications with G70/G71 and with G700/G710. Data influenced by G70/G71/G700/G710 is described in the Programming Guide.
Page 120: Manual Switchover Of The Basic System
Tool offsets Length-related machine data Length-related setting data Length-related system variables R parameters Siemens cycles Jog/handwheel increment factor 7.2.2 Manual switchover of the basic system General The dimension system for the whole machine is changed using an HMI softkey "Switch to mm >...
Page 121 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.2 Metric/inch measuring system If the switchover cannot be performed, this is indicated by a message in the user interface. These measures ensure that a consistent set of data is always used for a running program with reference to the system of measurement.
Page 122 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.2 Metric/inch measuring system Input resolution and computational resolution The input/computational resolution is set in the control via MD10200 INT_INCR_PER_MM. The default setting for a metric system is 1000 (0.001 mm). inches is required for an inch system.
Page 123: Setpoint/Actual-Value System
Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.3 Setpoint/actual-value system Setpoint/actual-value system 7.3.1 General Block diagram A control loop with the following structure can be configured for every closed-loop controlled axis/spindle: Figure 7-1 Block diagram of a control loop Setpoint output A setpoint can be output for each axis/spindle.
Page 124: Drives With Drive-Cliq
The control system provides preconfigured system data blocks for various drive configurations. These configurations are set via MD11240 PROFIBUS_SBD_NUMBER[2]. Note Do not change MD11240 [1], [3]. They are reserved for Siemens. See the comprehensive machine data description in the Chapter "Data description" for the full range of selection options.
Page 125 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.3 Setpoint/actual-value system Figure 7-2 Examples: Milling machine with three axes and spindle The configuration is performed via machine data. Table 7- 3 Configuration 30100 30110 30120 30130 30134 30200 30230 30220 Note In the case of dual-axis power modules, both drives (A and B) are each assigned to an axis.
Page 126: Speed Setpoint And Actual-Value Routing
Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.3 Setpoint/actual-value system The SINAMICS drive is thus ready for traversing. Further fine optimization can be performed later via the V24 connection using the Starter tool. The V24 connection must be activated for the connection using the "SYSTEM"...
Page 127 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.3 Setpoint/actual-value system The following machine data of each machine axis must be parameterized: ● MD30110 CTRLOUT_MODULE_NR[n] Assignment of the drive number – [n] = 1 (drive number 1) → SP spindle = machine axis 4 –...
Page 128: Speed Setpoint Output
Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.3 Setpoint/actual-value system Special features MD30110 CTRLOUT_MODULE_NR[n] and MD30220 ENC_MODULE_NR[n] of one machine axis must have the same drive number. For operation of a digital spindle with a second direct position encoder, the following MD must be set for the actual-value assignment.
Page 129: Actual-Value Processing
Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.3 Setpoint/actual-value system If settings beyond the limit are made, the value in MD36210 is used as the limiter, an alarm is output and the axes brought to a halt. See Chapter "Axis monitoring functions" for more details.
Page 130 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.3 Setpoint/actual-value system Machine data Linear axis Rotary axis Spindle Encoder on Encoder on Encoder on Encoder on Without motor motor motor machine measuring system MD31050 Leadscrew load revs load revs DRIVE_AX_RATIO_DENOM[n] revs note *) (load gearbox denominator) "-"...
Page 131: Evaluation Of Internal Drive Variables
(have) not been licensed using a license key was (were) set" is output. It will not be possible to operate the machine as normal. For information on operations relating to "Setting (an) option(s)", please refer to the section titled "Licensing in SINUMERIK 802D sl" in the "Turning, Milling, Grinding, Nibbling" Operating Instructions. Function...
Page 132 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.3 Setpoint/actual-value system Figure 7-10 Standard telegram 116 with process data Activation To transfer drive variables to individual system variables you must set the following machine data: MD36730 DRIVE_SIGNAL_TRACKING = 1 Table 7- 4 Specific drive variables Drive variable System variable...
Page 133: Closed-Loop Control
Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.4 Closed-loop control Consistency check While the SINUMERIK 802D sl is powering up, a consistency check is performed on the parameters for cyclic PROFIBUS communication that are relevant for process data configuration: ● NC: MD13060 DRIVE_TELEGRAM_TYPE[n] (drive telegram type) ●...
Page 134 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.4 Closed-loop control Figure 7-11 Principle of position control for an axis/spindle For a description of jerk limiting, see the section titled "Acceleration" For a description of precontrol, backlash compensation, and leadscrew error compensation, refer to the section titled "Compensation (K3)".
Page 135 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.4 Closed-loop control The following machine data can be changed as related units of data by switching over the parameter set during operation: ● MD31050 DRIVE_AX_RATIO_DENOM[n] (load gearbox denominator) ● MD31060DRIVE_AX_RATIO_NUMERA[n] (load gearbox numerator) ●...
Page 136: Data Lists
Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.5 Data lists Data lists 7.5.1 Machine data Number Identifier Name Specific to control panel DISPLAY_RESOLUTION Display resolution DISPLAY_RESOLUTION_INCH Display resolution for INCH system of measurement DISPLAY_RESOLUTION_SPINDLE Display resolution for spindle General information 10000 AXCONF_MACHAX_NAME_TAB[0]...[5] Machine axis name...
Page 137: Interface Signals
Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.5 Data lists Number Identifier Name 32100 AX_MOTION_DIR Travel direction 32110 ENC_FEEDBACK_POL[0] Sign actual value (feedback polarity) 32200 * POSCTRL_GAIN[0]...[5] Servo gain factor Kv 32450 BACKLASH[0] Backlash 32700 ENC_COMP_ENABLE[0] Interpolatory compensation 32810 * EQUIV_SPEEDCTRL_TIME[0]...[5] Equivalent time constant speed control loop for feedforward control...
Page 138 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2) 7.5 Data lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 139: Manual And Handwheel Travel (H1)
Manual and Handwheel Travel (H1) General characteristics of traversing in JOG JOG mode Axes/Spindles can be traversed manually in JOG mode. The active mode is transmitted to the PLC via the IS "Active mode: JOG" (V3100 0000.2) and is visible in the display, see also Chapter "Operating Modes, Program Operation (K1)".
Page 140 Manual and Handwheel Travel (H1) 8.1 General characteristics of traversing in JOG Handwheel jogging The axes can also be traversed via the handwheel in MCS or WCS. Incremental traversing (INC...) must be set to evaluate the handwheel pulses (see Section "Handwheel traversal in JOG").
Page 141 Manual and Handwheel Travel (H1) 8.1 General characteristics of traversing in JOG Velocity The velocity of the axes/spindle during manual traverse in JOG is defined by the following default values: ● For linear axes with the general SD41110 JOG_SET_VELO (JOG velocity with G94) or for rotary axes with SD41130 JOG_ROT_AX_SET_VELO (JOG velocity for rotary axes) or SD41200 JOG_SPIND_SET_VELO (JOG velocity for the spindle).
Page 142 Manual and Handwheel Travel (H1) 8.1 General characteristics of traversing in JOG In the case of interface signals that are only spindle-specific, while the spindle is traversing in JOG, the following should be noted: ● The following PLC interface signals to the spindle have no effect: –...
Page 143: Continuous Travel
Manual and Handwheel Travel (H1) 8.2 Continuous travel Continuous travel Selection When JOG mode is selected, the active machine function "continuous" interface signal is set automatically: ● For geometry axes: V3300 1001.6, V3300 1005.6, V3300 1009.6 ● For machine axes/spindle: V390x 0005.6 Continuous mode in JOG mode can also be selected via the PLC interface (IS "Machine function: continuous").
Page 144: Incremental Travel (Inc)
Manual and Handwheel Travel (H1) 8.3 Incremental travel (INC) Incremental travel (INC) Programming increments The path to be traversed by the axis is defined by so-called increments (also called "incremental dimensions"). The required increment must be set by the machine user before the axis is traversed.
Page 145: Handwheel Traversal In Jog
Manual and Handwheel Travel (H1) 8.4 Handwheel traversal in JOG Abort traversing movement If you do not want to traverse the whole increment, the traverse movement can be aborted with RESET or "Delete distance-to-go" interface signal (V380x 0002.2). Handwheel traversal in JOG Selection JOG mode must be active.
Page 146 Manual and Handwheel Travel (H1) 8.4 Handwheel traversal in JOG ● MD value = 0 (default): The settings from the handwheel are velocity specifications. When the handwheel is stationary, braking is realized along the shortest path. ● MD value = 1: The settings from the handwheel are path specifications.
Page 147 Manual and Handwheel Travel (H1) 8.4 Handwheel traversal in JOG Movement in the opposite direction Depending on MD11310 HANDWH_REVERSE, the behavior when the traversing direction is reversed is as follows: ● MD value = 0: If the handwheel is moved in the opposite direction, the resulting distance is computed and the calculated end point is approached as fast as possible: If this end point is located before the point where the moving axis can decelerate in the current direction of travel, the unit is decelerated and the end point is approached by moving in the opposite...
Page 148: Fixed-Point Approach In Jog
Manual and Handwheel Travel (H1) 8.5 Fixed-point approach in JOG Fixed-point approach in JOG 8.5.1 Introduction Function The machine user can use the "Approach fixed point in JOG" function to approach axis positions defined using machine data by actuating the traversing keys of the Machine Control Panel or by using the handwheel.
Page 149: Functionality
Manual and Handwheel Travel (H1) 8.5 Fixed-point approach in JOG 8.5.2 Functionality Procedure Procedure in "Approaching fixed point in JOG" ● Selection of JOG mode ● Enabling the "Approach fixed point in JOG" function ● Traversing of the machine axis with traverse keys or handwheel Activation The PLC sets the interface signal after the "Approach fixed point in JOG"...
Page 150 Manual and Handwheel Travel (H1) 8.5 Fixed-point approach in JOG Approaching other fixed point If a different fixed point is set during the fixed-point approach, the axis motion is stopped and the following alarm is signaled: Alarm 17812 "Channel %1 axis %2 fixed-point approach in JOG: Fixed point changed" The message signal "JOG - Approaching fixed point active"...
Page 151: Parameter Setting
Manual and Handwheel Travel (H1) 8.5 Fixed-point approach in JOG Features of spindles A spindle changes to the positioning mode on actuating the "Approaching fixed point in JOG" function. The closed loop position control is active and the axis can traverse to the fixed point.
Page 152: Programming
Manual and Handwheel Travel (H1) 8.5 Fixed-point approach in JOG 8.5.4 Programming System variables The following system variables that can be read in the part program and in the synchronous actions for the "Approach fixed point" function. System variable Description $AA_FIX_POINT_SELECTED [<Axis>] Number of fixed point to be approached $AA_FIX_POINT_ACT [<Axis>]...
Page 153: Application Example
Manual and Handwheel Travel (H1) 8.5 Fixed-point approach in JOG 8.5.6 Application example Target A rotary axis (machine axis 4 [AX4]) is to be moved to Fixed Point 2 (90 degrees) with the "Approaching fixed point in JOG" function. Parameter setting The machine data for the "Approaching fixed point"...
Page 154: Data Lists
Manual and Handwheel Travel (H1) 8.6 Data lists Data lists 8.6.1 Machine data Number Identifier Name General information 10000 AXCONF_MACHAX_NAME_TAB[n] Machine axis name [n = axis index] 10735 JOG_MODE_MASK Settings for JOG mode 11310 HANDWH_REVERSE Defines movement in the opposite direction 11320 HANDWH_IMP_PER_LATCH[0]...[2] Handwheel pulses per locking position...
Page 155: Interface Signals
Manual and Handwheel Travel (H1) 8.6 Data lists 8.6.3 Interface signals Number Name Signals from HMI to PLC V1900 1003 .0 to .2 Axis number for handwheel 1 V1900 1004 .0 to .2 Axis number for handwheel 2 NCK-specific V2600 0001 INC inputs in operating mode range active Specific to operating mode V3000 0000...
Page 156 Manual and Handwheel Travel (H1) 8.6 Data lists Number Name V380x 1002 .0 to .2 Activated fixed-point approach in JOG (binary coded: fixed point 1 to V390x 0000 .7/.6 Position reached with coarse/fine exact stop V390x 0004 .1, .0 Handwheel active (2, 1) V390x 0004 .7 or .6 Traverse command plus or minus...
Page 157: Auxiliary Function Outputs To Plc (H2)
Auxiliary Function Outputs to PLC (H2) Brief description Auxiliary functions For the purpose of workpiece machining operations, it is possible to program process-related functions (feedrate, spindle speed, gear stages) and functions for controlling additional devices on the machine tool (sleeve forward, gripper open, clamp chuck) in the part program in addition to axis positions and interpolation methods.
Page 158: Programming Of Auxiliary Functions
Auxiliary Function Outputs to PLC (H2) 9.2 Programming of auxiliary functions Programming of auxiliary functions General structure of an auxiliary function Letter[address extension]=Value The letters which can be used for auxiliary functions are: M, S, H, T, D, F. An address extension only exists for the H function. The address extension must be an integer.
Page 159: Transfer Of Values And Signals To The Plc Interface
PLC before the path end is reached, see Chapter "Continuous Path Mode (B1)". Interface signals Transfer of the signals from NCK to the PLC: Reference: /LIS/ SINUMERIK 802D sl lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 160: Grouping Of Auxiliary Functions
Auxiliary Function Outputs to PLC (H2) 9.4 Grouping of auxiliary functions Grouping of auxiliary functions Functionality The auxiliary functions of the types M, H, D, T, and S that are to be issued can be grouped to auxiliary function groups by means of machine data. An auxiliary function can only be assigned to one group.
Page 161 Auxiliary Function Outputs to PLC (H2) 9.4 Grouping of auxiliary functions Ungrouped auxiliary functions The output of auxiliary functions that are not assigned to groups is made with the movement. Configuring example: Distribute 8 auxiliary functions to 7 groups: Group 1: M0, M1, M2 (M17, M30) - by default, should be kept Group 2: M3, M4, M5 (M70) - by default, should be kept Group 3: S functions - by default, should be kept Group 4: M78, M79...
Page 162: Block-Search Response
Auxiliary Function Outputs to PLC (H2) 9.5 Block-search response Block-search response Block search with calculation For the block search with calculation all auxiliary functions that are assigned to a group are collected and are issued at the end of the block search before the actual re-entry block (except for group 1: M0, M1,...).
Page 163: T Function
Auxiliary Function Outputs to PLC (H2) 9.6 Description of the auxiliary functions 9.6.2 T function Application The T function can be used to make the tool required for a machining operation available through the PLC. Whether a tool change is to be performed directly with the T command or with a subsequent M6 command can be set in MD22550 TOOL_CHANGE_MODE.
Page 164: S Function
Auxiliary Function Outputs to PLC (H2) 9.7 Data lists 9.6.5 S function The S function is used to determine the speed for the spindle with M3 or M4. For turning machines with G96 (constant cutting speed) the cutting value is specified. Reference: /BPD/ Operation and Programming Data lists...
Page 165 Auxiliary Function Outputs to PLC (H2) 9.7 Data lists Number Name VD2500 3024 M function 4 (DINT) VB2500 3028 Extended address of M function 4 (BYTE) VD2500 3032 M function 5 (DINT) VB2500 3036 Extended address of M function 5 (BYTE) VD2500 4000 S function 1 (REAL format) VB2500 4004...
Page 166 Auxiliary Function Outputs to PLC (H2) 9.7 Data lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 167: Operating Modes, Program Operation (K1)
A channel constitutes a unit in which a part program can be executed. A channel is assigned an interpolator with program processing by the system. A certain mode is valid for it. The SINUMERIK 802D sl control has one channel. 10.2 Operating modes Activating The required operating mode is activated by the interface signals in the VB 3000 0000.
Page 168 Operating Modes, Program Operation (K1) 10.2 Operating modes Possible machine functions in MDA The following machine function can be selected in the MDA operating mode: TEACH IN (insert program blocks) The required machine function is activated with IS "TEACH IN" (V3000 0001.0). The display is visible in the IS "Active machine function TEACH IN"...
Page 169: Mode Change
Operating Modes, Program Operation (K1) 10.2 Operating modes 10.2.1 Mode change General A changeover to another operating mode is requested and activated via the interface. Note The mode is not changed internally until the IS "Channel status active" (V3300 0003.5) is no longer present.
Page 170: Functional Possibilities In The Individual Modes
Operating Modes, Program Operation (K1) 10.2 Operating modes 10.2.2 Functional possibilities in the individual modes Overview of the functions You see from the following table which function can be selected in which operating mode and in which operating state. Table 10- 2 Functional possibilities in the individual modes Mode of operation AUTOMATIC...
Page 171: Monitoring Functions In The Individual Modes
Operating Modes, Program Operation (K1) 10.2 Operating modes 10.2.3 Monitoring functions in the individual modes Overview of monitoring functions Different monitoring functions are active in individual operating modes. Table 10- 3 Monitoring functions and interlocks Mode of operation AUTO Functions Axis-specific monitoring functions or when positioning the spindle SW limit switch + SW limit switch –...
Page 172: Interlocks In The Individual Modes
Operating Modes, Program Operation (K1) 10.2 Operating modes 10.2.4 Interlocks in the individual modes Overview of interlocks Different interlocks can be active in the different operating modes. The following table shows which interlocks can be activated in which operating mode and in which operating state.
Page 173: Processing A Part Program
Operating Modes, Program Operation (K1) 10.3 Processing a part program 10.3 Processing a part program 10.3.1 Program mode and part program selection Definition Program mode applies if a part program is processed in the AUTOMATIC mode or program blocks are processed in the MDA mode. Channel control The Program mode can be controlled even while being executed via interface signals from the PLC.
Page 174: Part Program Interruption
Operating Modes, Program Operation (K1) 10.3 Processing a part program Required signal states The selected part program can now be enabled for processing with the START command. The following enable signals are relevant: IS "802 Ready" (V3100 0000.3) must be set IS "Activate program test"...
Page 175: Reset Command
Operating Modes, Program Operation (K1) 10.3 Processing a part program Execution of command After execution of the STOP command, IS "Program status stopped" (V3300 0003.2) and the IS "Channel status interrupted" (V3300 0003.6) are set. Processing of the interrupted part program can continue from the point of interruption with another START command.
Page 176: Program Control
Operating Modes, Program Operation (K1) 10.3 Processing a part program 10.3.5 Program control Selection/activation The user can control part program processing via the user interface. Under the "Program control" menu (operating mode AUTOMATIC, operating area "Position") certain functions can be selected, whereby some functions act on interface signals of the PLC. These signals are merely selection signals from the user interface.
Page 177: Channel Status
Operating Modes, Program Operation (K1) 10.3 Processing a part program The effect of commands/signals The program status can be controlled by activating different commands or interface signals. The following table shows the resulting program state when these signals are set (status before the signal is set ->...
Page 178: Eventdriven Program Calls
Operating Modes, Program Operation (K1) 10.3 Processing a part program The "Channel status active" signal is obtained when a part program or part program block is being executed or when the axes are traversed in JOG mode. Table 10- 6 Effect on channel status Resulting channel status Commands...
Page 179 Operating Modes, Program Operation (K1) 10.3 Processing a part program Other program name A name is specified in MD11620 PROG_EVENT_NAME (program name of PROG_EVENT). The following directories are searched for the user program in the specified sequence: ● /_N_CUS_DIR/ for user cycles ●...
Page 180 Operating Modes, Program Operation (K1) 10.3 Processing a part program Table 10- 8 Sequence at part program end Seque Command Boundary conditions Comments (must be satisfied before the command) Channel selection: Reset status None Select channel and mode Operating mode selection: AUTO or AUTO and overstoring or MDA or TEACH IN NC Start...
Page 181 Operating Modes, Program Operation (K1) 10.3 Processing a part program Table 10- 10 Sequence with Powerup Seque Command Boundary conditions Comments (must be satisfied before the command) Reset after power up MD20110 RESET_MODE_MASK, Control activated MD20150 GCODE_RESET_VALUES, after ramp up: MD20152 GCODE_RESET_MODE Reset sequence with evaluation /_N_CMA_DIR/_N_PROG_EVENT_SPF or...
Page 182 Operating Modes, Program Operation (K1) 10.3 Processing a part program With operator panel reset: Time sequence of VDI signals VB3300 0003 ("Program status" and "Channel status") when processing with an event-driven program call: Figure 10-2 Time sequence of the interface signals for program status and channel status (2) Note IS V3300 0003.4 ("Program status aborted") and V3300 0003.7 ("Channel status reset") are only received if _N_PROG_EVENT_SPF has been completed.
Page 183 Operating Modes, Program Operation (K1) 10.3 Processing a part program ● The triggering event can be defined at the interface via the PLC program: VB3300 4004 offers the following information: 0 No active event Bit 0 = 1 Part program start from channel status RESET Bit 1 = 1 Part program end Bit 2 = 1 Operator panel reset Bit 3 = 1 Ramp-up...
Page 184 Operating Modes, Program Operation (K1) 10.3 Processing a part program Bit 4 = 1 is set, after First start after search run event The following constraint applies for Bit 0 == 1 (program event after part program start): If the program event ends with the part program command "RET", then RET always leads to an executable block (analogous to M17).
Page 185 Operating Modes, Program Operation (K1) 10.3 Processing a part program Sequence for part program start IF ($P_PROG_EVENT == 1) N 10 R100 = 0 Transfer parameters for machining cycles N 20 M17 ENDIF Sequence for part program end and operator panel reset IF ($P_PROG_EVENT == 2) OR ($P_PROG_EVENT == 3) N10 R20 = 5 N20 ENDIF...
Page 186: Asynchronous Subroutines (Asubs)
Operating Modes, Program Operation (K1) 10.3 Processing a part program Note Recommendation for MD11450 with block search: MD11450 SEARCH_RUN_MODE = ’H7’ (search parameterization) Bit 0 = 1: With the loading of the last action block after block search, the processing is stopped and the VDI signal "Last action block active"...
Page 187 Operating Modes, Program Operation (K1) 10.3 Processing a part program The start signal must be set to logical 0 by the user once the ASUB has been completed or if an error has occurred. Note The call of the ASUB PI service must have been completed before an ASUB may be started. Initialization The initialization is performed via the ASUB PI service, see also Section "Starting PI services in the NCK area (A2)".
Page 188: Responses To Operator Or Program Actions
Operating Modes, Program Operation (K1) 10.3 Processing a part program Configuration The behavior of the ASUB can be influenced via the following standard machine data. ● MD11602 ASUP_START_MASK (ignore stop reasons for ASUB) The machine data specifies which stop reasons are to be ignored for an ASUB start. Recommended: MD11602 = 'H7' ●...
Page 189 Operating Modes, Program Operation (K1) 10.3 Processing a part program Table 10- 12 Responses to operator or program actions Situat Channel Program status Active mode Operator or program action status (Situation after the action) RESET (4) RESET (5) RESET (6) NC Start (13);...
Page 190: Example Of A Timing Diagram For A Program Run
Operating Modes, Program Operation (K1) 10.3 Processing a part program 10.3.11 Example of a timing diagram for a program run Figure 10-4 Examples of signals during a program run Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 191: Program Test
Operating Modes, Program Operation (K1) 10.4 Program test 10.4 Program test 10.4.1 General information on the program test Purpose Several control functions are available for testing a new part program. These functions are provided to reduce danger at the machine and time required for the test phase. It is possible to activate several program test functions simultaneously.
Page 192: Program Processing In Single Block Mode (Sbl)
Operating Modes, Program Operation (K1) 10.4 Program test Selection/activation This function is selected via the user interface in the menu "Program control". IS "Program test selected" (V1700 0001.7) is set on selection of the function. The PLC user program must activate the function via the IS "Activate program test" (V3200 0001.7).
Page 193: Program Processing With Dry Run Feedrate (Dry)
Operating Modes, Program Operation (K1) 10.4 Program test Selection/activation The selection signal normally comes from a user machine control panel. This function must be activated by the PLC user program via the IS "Activate single block" (V3200 0000.4). The preselection whether "Single block coarse" or "Single block fine" type is made in the user interface in the "Program control"...
Page 194: Block Search: Processing Of Certain Program Sections
Operating Modes, Program Operation (K1) 10.4 Program test Selection/activation Operation with dry run feedrate is selected in the "Position" operating area -> "Program control" softkey (AUTOMATIC mode). IS "Dry run feedrate" (V1700 0000.7) is set on selection of the function. In addition, the required dry run feedrate must be entered in the menu "Setting data".
Page 195 Operating Modes, Program Operation (K1) 10.4 Program test Selection/activation The block search is selected in AUTOMATIC mode on the user interface. The search run can be activated with corresponding softkey for the following functions: ● Block search with calculation to contour Is used in any circumstances in order to approach the contour.
Page 196 Operating Modes, Program Operation (K1) 10.4 Program test ● "Last action block active" (V3300 0000.6) Figure 10-5 Chronological order of interface signals After "Block search with calculation at block end point", automatic repositioning is not performed between "Last action block active" and continuation of part program processing by NC Start.
Page 197: Skip Part Program Blocks (Skp)
Operating Modes, Program Operation (K1) 10.4 Program test The alarm 10208 is also output per default at this time. It should indicate to the operator that an NC start is still necessary to continue program processing. Supplementary condition The approach movement "Search with calculation to block end point" is performed using the type of interpolation valid in the target block.
Page 198: Graphic Simulation
● Abort the running program if "Simulation" is exited by setting IS "Reset" (V3000 000.7), etc. Display machine data A number of display machine data (MD283 to MD292) is available for the user-specific configuration of the graphic simulation. References: /LIS/ SINUMERIK 802D sl lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 199: Timers For Program Execution Time
Operating Modes, Program Operation (K1) 10.5 Timers for program execution time 10.5 Timers for program execution time Function Timers are provided under the "Program execution time" function and these can be used for monitoring technological processes in the program or only in the display. These timers are read-only.
Page 200: Workpiece Counter
Operating Modes, Program Operation (K1) 10.6 Workpiece counter Display The contents of the timers are visible on the screen in the "OFFSET/PARAM" operating area -> "Setting data" softkey ->" "Times/counters" softkey: ● Run time = $AC_OPERATING_TIME ● Cycle time = $AC_CYCLE_TIME ●...
Page 201 Operating Modes, Program Operation (K1) 10.6 Workpiece counter ● Number of actual workpieces (current actual): $AC_ACTUAL_PARTS This counter registers the number of all workpieces produced since the starting time. The counter is automatically reset to zero (on condition that $AC_REQUIRED_PARTS is not equal to 0) when the required number of workpieces ($AC_REQUIRED_PARTS) has been reached.
Page 202: Data Lists
Operating Modes, Program Operation (K1) 10.7 Data lists 10.7 Data lists 10.7.1 Machine data NC-specific machine data Number Identifier Name General 10702 IGNORE_SINGLEBLOCK_MASK Prevent single-block stop 11450 SEARCH_RUN_MODE Block search parameter settings 11602 ASUP_START_MASK Ignore stop conditions for ASUB 11604 ASUP_START_PRIO_LEVEL Priorities for ASUP_START_MASK 11620...
Page 203: Setting Data
Operating Modes, Program Operation (K1) 10.7 Data lists Number Identifier Name 20150 GCODE_RESET_VALUES Reset G groups 20152 GCODE_RESET_MODE G code basic setting at RESET Auxiliary function settings of the channel Number Identifier Name Channel-specific 22000 AUXFU_ASSIGN_GROUP[n] Auxiliary function group [aux. func. no. in channel]: 0...63 22010 AUXFU_ASSIGN_TYPE[n]...
Page 204: Interface Signals
Operating Modes, Program Operation (K1) 10.7 Data lists 10.7.3 Interface signals Operating mode signals Number Name PLC to NCK V3000 0000 AUTOMATIC mode V3000 0000 MDA mode V3000 0000 JOG mode V3000 0000 Mode change disable V3000 0000 RESET V3000 0001 Machine function REF NCK to PLC V3100 0000...
Page 205 Operating Modes, Program Operation (K1) 10.7 Data lists Number Name V3200 0007 Reset NCK to PLC V3300 0000 Action block active V3300 0000 Approach block active V3300 0000 M00/M01 active V3300 0000 Last action block active V3300 0001 Referencing active V3300 0001 Block search active V3300 0001...
Page 206 Operating Modes, Program Operation (K1) 10.7 Data lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 207: Compensation (K3)
Compensation (K3) 11.1 Brief description Compensations For SINUMERIK 802D sl, the following axis-specific compensation functions can be activated: ● Backlash compensation ● Interpolatory compensation – LEC (leadscrew error and measuring system error compensation) – Sag compensation and angularity error compensation ●...
Page 208 Compensation (K3) 11.2 Backlash compensation Effectiveness Backlash compensation is always active in all operating modes after reference point approach. Positive backlash The encoder leads the machine part (e.g. table). Since the actual position acquired by the encoder also leads the real actual position of the table, the table travels too short a distance (see diagram below).
Page 209: Interpolatory Compensation
Compensation (K3) 11.3 Interpolatory compensation 11.3 Interpolatory compensation 11.3.1 General Terminology Compensation value: The difference between the axis position measured by the position actual-value encoder and the required programmed axis position (= axis position of the ideal machine). The compensation value is often also referred to as the correction value. Interpolation point: A position of the axis and the corresponding offset value.
Page 210: Lec
Compensation (K3) 11.3 Interpolatory compensation Linear interpolation between interpolation points The traversing path to be compensated - defined using the start and end positions - is divided up into several (number depends on error curve shape) path segments of equal size (see figure).
Page 211 Compensation (K3) 11.3 Interpolatory compensation Effectiveness ● The compensation values are stored in the NC user memory and active (after POWER ON). ● The function has been activated for the relevant machine axis (MD32700 ENC_COMP_ENABLE [0] = 1). ● The axis has been referenced (IS "Referenced/synchronized 1" V390x 0000.4 set). As soon as these conditions have been fulfilled, the axis-specific actual value is altered by the compensation value in all modes and traversed by the machine axis immediately.
Page 212 Compensation (K3) 11.3 Interpolatory compensation ● Starting position: $AA_ENC_COMP_MIN[0,AXi]= ... The starting position is the axis position at which the compensation table for the relevant axis begins (interpolation point 0). The compensation value for the starting position is $AA_ENC_COMP[0,0,AXi]. The compensation value of interpolation point 0 is used for all positions smaller than the starting position (exception: table with modulo function).
Page 213 Compensation (K3) 11.3 Interpolatory compensation Example The following example shows compensation value inputs for machine axis X1 as a program. %_N_AX_EEC_INI CHANDATA(1) $AA_ENC_COMP[0,0,X1]=0.0 ; 1. compensation value (interpolation point 0) +0 mm $AA_ENC_COMP[0,1,X1]=0.01 ; 2. compensation value (interpolation point 1) +10 mm $AA_ENC_COMP[0,2,X1]=0.012 ;...
Page 214: Sag Compensation And Angularity Error Compensation
(have) not been licensed using a license key was (were) set" is output. It will not be possible to operate the machine as normal. For information on operations relating to "Setting (an) option(s)", please refer to the section titled "Licensing in SINUMERIK 802D sl" in the "Turning, Milling, Grinding, Nibbling" Operating Instructions. Prerequisites The sag compensation and angularity error compensation functions cannot be applied for PLC axes.
Page 215 Compensation (K3) 11.3 Interpolatory compensation Figure 11-4 Example of sag caused by own weight Depending on the requirement, several compensation relations can be defined for one axis. The total compensation value results from the sum of all the compensation values of this axis.
Page 216 Note Template "_N_CEC.MPF" is provided for commissioning purposes and can be found in the following path when the Toolbox is installed: C:\Program Files\Siemens\Toolbox 802D_sl\V01040500\Techno\...\Compensation_Templates Once you have adapted the template to meet the requirements of the machine manufacturer, you must transfer it to the control so that it can be executed as a part program.
Page 217 Compensation (K3) 11.3 Interpolatory compensation Monitoring To avoid excessive velocities and acceleration rates on the machine axis as a result of applying sag compensation, the total compensation value is monitored and limited to a maximum value. The maximum compensation value is set for each axis with the following axial machine data: MD32720 CEC_MAX_SUM (maximum compensation value for sag compensation).
Page 218 Compensation (K3) 11.3 Interpolatory compensation Figure 11-5 Generation of compensation value for sag compensation Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 219 Compensation (K3) 11.3 Interpolatory compensation Complex compensation Since it is possible to use the position of an axis as the input quantity (base axis) for several tables, to derive the total compensation value of an axis from several compensation relationships (tables) and to multiply tables, it is also possible to implement sophisticated and complex beam sag and angularity error compensation systems.
Page 220 Compensation (K3) 11.3 Interpolatory compensation Table parameters The position-related corrections for the relevant compensation relationship are stored as system variables in the compensation table. The following parameters must be set for the table: ● Compensation value for interpolation point N of compensation table [t] $AN_CEC [t, N];...
Page 221 Compensation (K3) 11.3 Interpolatory compensation ● Direction-dependent compensation $AN_CEC_DIRECTION[t] This system variable can be used to define whether the compensation table [t] should apply to both travel directions of the base axis or only either the positive or negative direction. 0: Table applies to both directions of travel of the base axis 1: Table applies only to position direction of travel of the base axis -1: Table applies only to negative direction of travel of the base axis...
Page 222 Compensation (K3) 11.3 Interpolatory compensation $AN_CEC_MAX[0] = 360.0 $AN_CEC_IS_MODULO[0] = 1 Note Table parameters containing position data are automatically converted when the scaling system is changed (when the setting in the following machine data is altered): MD10240 SCALING_SYSTEM_IS_METRIC (basic system metric) The position information is always interpreted in the current measuring system.
Page 223 Compensation (K3) 11.3 Interpolatory compensation point 0) ; for Z1: ± 0 µm $AN_CEC [1.1] =0.01 ; 2. Compensation value (interpolation point 1) ; for Z1: + 10 µm $AN_CEC [1.2] =0.012 ; 3. Compensation value (interpolation point 2) ; for Z1: + 12 µm $AN_CEC [1.349] ;...
Page 224: Special Features Of Interpolatory Compensation
Compensation (K3) 11.3 Interpolatory compensation Compensation table 1 (table index = 0) describes the reaction of axis X1 on axis X1 (sine of the position-dependent tilting angle β(X1)). Compensation table 2 (table index = 1) describes the reaction of axis Z1 on axis X1 (linear). In table 1, the multiplication of table 1 (index = 0) with table 2 is to be selected: $AN_CEC_MULT_BY_TABLE[0] = 2 Figure 11-7...
Page 225 Compensation (K3) 11.3 Interpolatory compensation Compensation value display The "Service Axes" screen also shows the following compensated actual position values: Service display axes Meaning Absolute compensation value for Value displayed is the total compensation value calculated from measuring system 1 "Leadscrew error compensation"...
Page 226: Following Error Compensation (Feedforward Control)
This feedforward control is therefore also called "following error compensation". Particularly during acceleration in contour curvatures, e.g. circles and corners, this following error leads to undesirable, velocity-dependent contour violations. The SINUMERIK 802D sl control is equipped with the "Speed feedforward control" feedforward control type.
Page 227: Speed Feedforward Control
Compensation (K3) 11.4 Following error compensation (feedforward control) Optimization of control loop The feedforward control is set on an axis/spindle-specific basis. First of all, the current control loop, speed control loop and position control loop must be set to an optimum for the axis/spindle.
Page 228: Data Lists
Compensation (K3) 11.5 Data lists 11.5 Data lists 11.5.1 Machine data Number Identifier Name Axis-specific 32450 BACKLASH[0] Backlash 32630 FFW_ACTIVATION_MODE Feedforward control can be activated from the program 32700 ENC_COMP_ENABLE[0] Interpolatory compensation active 32710 CEC_ENABLE Sag compensation enable 32711 CEC_SCALING_SYSTEM_METRIC Scaling system for sag compensation 32720 CEC_MAX_SUM...
Page 229: Kinematic Transformation (M1)
The TRANSMIT and TRACYL functions are configured using separate machine data sets and switched on or off by means of special instructions in the program. With SINUMERIK 802D sl, a maximum of two kinematic transformations (TRANSMIT, TRACYL) may be configured and one of them may be activated using the program.
Page 230: Transmit
Kinematic Transformation (M1) 12.2 TRANSMIT 12.2 TRANSMIT 12.2.1 Overview X, Y, Z Cartesian coordinate system for programming of the face-end machining Second spindle (work spindle for milling tool, drill) Z machine axis (linear) X machine axis (linear) C axis (main spindle as rotary axis) Figure 12-1 Face-end milling of turned parts with TRANSMIT Required machine kinematics...
Page 231: Transmit Configuration
The TRANSMIT transformation function is configured using machine data settings. Note A file containing default machine data is available in the SINUMERIK 802D sl "Toolbox". A fast installation of TRANSMIT is possible by defining specific values and loading this file in the control.
Page 232 Kinematic Transformation (M1) 12.2 TRANSMIT The geometry axis assignments specified in MD20050 AXCONF_GEOAX_ASSIGN_TAB only apply when the transformation is de-activated. Additional assignments are specified for a transformation. Note The assigned machine axis names, channel axis names and geometry axis names must differ: •...
Page 233 Kinematic Transformation (M1) 12.2 TRANSMIT ● MD24920 TRANSMIT_BASE_TOOL_1 The control is informed of the position of the tool zero point in relation to the origin of the coordinate system declared for TRANSMIT. The MD has three components for the three axes of the Cartesian coordinate system.
Page 234 Kinematic Transformation (M1) 12.2 TRANSMIT ● Assignment of geometry axis to channel axis MD20050 AXCONF_GEOAX_ASSIGN_TAB[0]=1 MD20050 AXCONF_GEOAX_ASSIGN_TAB[1]=0 MD20050 AXCONF_GEOAX_ASSIGN_TAB[2]=2 ● Geometry axis names in channel MD20060 AXCONF_GEOAX_NAME_TAB[0]="X" MD20060 AXCONF_GEOAX_NAME_TAB[1]="Y" MD20060 AXCONF_GEOAX_NAME_TAB[2]="Z" ● Valid machine axis numbers in channel MD20070 AXCONF_MACHAX_USED[0]=1 MD20070 AXCONF_MACHAX_USED[1]=2 MD20070 AXCONF_MACHAX_USED[2]=3 MD20070 AXCONF_MACHAX_USED[3]=4...
Page 235 Kinematic Transformation (M1) 12.2 TRANSMIT Special TRANSMIT settings: ● Offset of rotary axis MD24900 TRANSMIT _ROT_AX_OFFSET_1=0 ● Sign of rotary axis MD24910 TRANSMIT _ROT_SIGN_IS_PLUS_1=1 ● Vector of base tool MD24920 TRANSMIT_BASE_TOOL_1[0]=0 MD24920 TRANSMIT_BASE_TOOL_1[1]=0 MD24920 TRANSMIT_BASE_TOOL_1[2]=0 Setting data for the special treatment of the tool offset (only when required): ●...
Page 236: Tracyl
Kinematic Transformation (M1) 12.3 TRACYL 12.3 TRACYL 12.3.1 Overview Standard lathe (without Y machine axis) Figure 12-4 Machining grooves on a cylinder surface with X-C-Z kinematics Required machine kinematics The two linear axes (XM, ZM) must be mutually perpendicular. The rotary axis (CM) must travel parallel to the linear axis ZM (rotating around ZM).
Page 237 Kinematic Transformation (M1) 12.3 TRACYL Machine with Y axis Figure 12-5 Machining grooves on a cylinder surface with X-Y-Z-C kinematics Extended machine kinematics The YM linear axis is also available to enable the machine kinematics requirements to be met (see above). This is arranged perpendicular to XM and ZM respectively and, with these, forms a right-handed Cartesian coordinate system.
Page 238 Kinematic Transformation (M1) 12.3 TRACYL Grooves in transverse section Figure 12-6 Grooves with and without groove wall offset Activation/deactivation of TRACYL The TRACYL function is activated in the program with ● TRACYL(d) in a separate block and deactivated with ● TRAFOOF in a separate block d - machining diameter of the cylinder in mm TRAFOOF deactivates any active transformation function.
Page 239 Kinematic Transformation (M1) 12.3 TRACYL Explanation: The movement of the machine axes ZM and CM produces this contour on the peripheral surface of the cylindrical workpiece with the milling cutter in accordance with the Y-Z path programmed (straight or circular). The programmed X axis (infeed) continues to be traversed as the X axis.
Page 240: Tracyl Configuration
Kinematic Transformation (M1) 12.3 TRACYL 12.3.2 TRACYL configuration General The TRACYL transformation function is configured using machine data settings. Note A file containing default machine data is available in the SINUMERIK 802D "Toolbox". A fast installation of TRACYL is possible by defining specific values and loading this file in the control.
Page 241 Kinematic Transformation (M1) 12.3 TRACYL Required assignment of channel axes for TRACYL transformation in machine data MD24110: Configuration without YM axis: TRAFO_AXES_IN_1[0]= Channel axis number of axis radial to rotary axis TRAFO_AXES_IN_1[1]= Channel axis number of rotary axis TRAFO_AXES_IN_1[2]= Channel axis number of axis parallel to rotary axis Configuration without existing YM axis: TRAFO_AXES_IN_1[3] Channel axis number of axis parallel to peripheral cylinder surface...
Page 242 Kinematic Transformation (M1) 12.3 TRACYL Assignment of axis components in MD24920: – TRACYL_BASE_TOOL_1[0]=Tx – TRACYL_BASE_TOOL_1[1]=Ty – TRACYL_BASE_TOOL_1[2]=Tz (see following figure) Figure 12-10 Position of tool zero in relation to machine zero Example: Machine data settings for TRACYL with a standard lathe General settings: Axis names: XM->X1, ZM->Z1, CM->SP1 ●...
Page 243 Kinematic Transformation (M1) 12.3 TRACYL ● Name of channel axis in the channel MD20080 AXCONF_CHANAX_NAME_TAB[0]="X" MD20080 AXCONF_CHANAX_NAME_TAB[1]="Z" MD20080 AXCONF_CHANAX_NAME_TAB[2]="C" MD20080 AXCONF_CHANAX_NAME_TAB[3]="SP2" MD20080 AXCONF_CHANAX_NAME_TAB[4]="" ● Initial setting of master spindle in channel MD20090 SPIND_DEF_MASTER_SPIND=1 TRACYL transformation type for second transformation: ● Without groove wall offset (no YM axis) MD24100 TRAFO_TYPE_2=512 ●...
Page 244 Kinematic Transformation (M1) 12.3 TRACYL Settings for second spindle (milling spindle of the lathe): ● MD30300 IS_ROT_AX[AX4]=1 ● MD30310 ROT_IS_MODULO[AX4]=1 ● MD30320 DISPLAY_IS_MODULO[AX4]=1 ● MD35000 SPIND_ASSIGN_TO_MACHAX[AX4]=2 ● SD43300 ASSIGN_FEED_PER_REV_SOURCE[AX4]=0 Note A special handling of milling tools on lathes with respect to length compensation is possible.
Page 245: Programming Example, Tracyl
Kinematic Transformation (M1) 12.3 TRACYL 12.3.3 Programming example, TRACYL Machining grooves with groove wall compensation MD24100_TRAFO_TYPE_1 = 513 Contour It is possible to machine a groove which is wider than the tool by using address OFFN=... to program the compensation direction (G41, G42) in relation to the programmed reference contour and the distance of the groove side wall from the reference contour.
Page 246 Kinematic Transformation (M1) 12.3 TRACYL CC is the channel axis name of the rotary axis, milling radius of T1, D1: 8.345 mm N1 SPOS=0 ; Transfer of spindle to position control ; (only for lathes) N5 T1 D1 ;Tool selection N10 G500 G0 G64 X50 Y0 Z115 CC=200 ;...
Page 247: Special Features Of Transmit And Tracyl
Kinematic Transformation (M1) 12.4 Special features of TRANSMIT and TRACYL 12.4 Special features of TRANSMIT and TRACYL POWER ON/RESET The system response after POWER ON or RESET (program end) is determined by the settings stored in the following machine data: ●...
Page 248: Data Lists
Kinematic Transformation (M1) 12.5 Data lists 12.5 Data lists 12.5.1 Machine data Number Identifier Name Channel-specific 20110 RESET_MODE_MASK Definition of control basic setting after run-up and RESET/part program end (access only possible at protection level 1/1) 20140 TRAFO_RESET_VALUE Initial setting: Transformation active after Reset 22534 TRAFO_CHANGE_M_CODE M code for transformation changeover...
Page 249: Measurement (M5)
Measurement (M5) 13.1 Brief description Channel-specific measuring A measurement mode is programmed in a part program block (with or without DDTG). A trigger event (edge of the probe) is defined additionally, which will trigger the measurement process. The instructions apply to all axes programmed in this particular block. The program with the measurement process in AUTOMATIC mode is executed and can be employed for workpiece or tool measuring.
Page 250 Measurement (M5) 13.2 Hardware requirements Figure 13-1 Probe types Table 13- 1 Probe assignment Probe type Lathes Milling and machining centers Tool measurements Workpiece Workpiece measurements measurements Multi-directional Bi-directional Mono-directional Bi-directional probes must be used on lathes for workpiece measurements, whereas a mono-probe can also be used for this purpose for milling and machining centers.
Page 251: Probe Connection
13.2.2 Probe connection The probe for SINUMERIK 802D sl is connected to the terminals of X20. The particular assignment is determined by the macro you are using. Thus, all measuring inputs of the axis drive modules are operated whose axes are involved in measuring. For the probe, use an external voltage (24 V) whose reference potential must be connected to X20, pin 12.
Page 252: Measurement Results
Measurement (M5) 13.3 Channel-specific measuring Reference: /BP_/ Operation and Programming Note If a GEO axis (axis in the WCS) is programmed in a measuring block, the measured values are stored for all current GEO axes. 13.3.2 Measurement results Reading measurement results in the program The results of the measuring command can be read in the part program via system variables.
Page 253: Measurement Accuracy And Functional Testing
Measurement (M5) 13.4 Measurement accuracy and functional testing 13.4 Measurement accuracy and functional testing 13.4.1 Measuring accuracy Accuracy The propagation time of the measuring signal is determined by the hardware used. The delay times are in the µs range plus the probe response time. The measurement uncertainty is calculated as follows: Measurement uncertainty = measuring signal propagation time x traversing velocity Correct results can only be guaranteed for traversing velocity where not more than one...
Page 254 Measurement (M5) 13.4 Measurement accuracy and functional testing It is possible to determine the so-called "random dimensional deviations" which are not subject to any trend. %_N_CHECK_ACCURATE_MPF N05 R11 ; Switching signal N06 R12=1 ; Counter N10 R1 to R10 ; MEAS_VAL_IN _X N15 T1 D1 ;...
Page 255: Tool Measuring In Jog
Measurement (M5) 13.5 Tool measuring in JOG 13.5 Tool measuring in JOG Measuring principle The employed tool is traversed to the probe by the user in JOG mode using the traverse keys or handwheel. When the probe switches, the movement is stopped automatically and switched internally to AUTOMATIC mode, and a measuring program is launched.
Page 256 Measurement (M5) 13.5 Tool measuring in JOG Tool offsets The screens initially include the active tool T and the active offset number D for the target of the measurement result entry. A different tool can be specified by the PLC via the interface, or the user can enter a different tool T and/or offset number D.
Page 257 Measurement (M5) 13.5 Tool measuring in JOG ● The adjustment sequence of the probe (calibration) is controlled via the "tool measuring" and "tool calibration" softkeys and the opening window. The tool used in this case is the calibration tool with precisely known and entered dimensions. The calibration tool for the milling technology is of "cutter"...
Page 258 The toolbox for SINUMERIK 802D sl supplied by SIEMENS includes a user example in the PLC library. You can use this. In this case it should be noted that PLC_INI (SBR32) and MCP_NCK (SBR38) must always be opened in OB1 as these transfer the signals of the MEAS_JOG (SBR43) subroutine to the NCK/HMI.
Page 259: Data Lists
Measurement (M5) 13.6 Data lists 13.6 Data lists 13.6.1 Machine data Number Identifier Name General 13200 MEAS_PROBE_LOW_ACTIVE Switching characteristics of probe 13.6.2 Interface signals Number Name HMI signals (from HMI to PLC) V1700 0003 .7 *** Measuring in JOG active V1800 0000 AUTOMATIC mode (request by HMI) V1800 0000...
Page 260 Measurement (M5) 13.6 Data lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 261: Emergency Off (N2)
It is the duty of the machine manufacturer to observe national and international standards (see the notes on standards in the following paragraph). The SINUMERIK 802D sl supports the machine manufacturer in the implementation of the EMERGENCY STOP function in accordance with the specifications in this Description of Functions.
Page 262: Emergency Stop Sequence
EMERGENCY OFF (N2) 14.2 EMERGENCY STOP sequence 14.2 EMERGENCY STOP sequence Requirements Actuation of the EMERGENCY STOP pushbutton or a signal derived directly from the button must be taken to the control system (PLC) as a PLC input. In the PLC user program, this PLC input must be transferred to IS "EMERGENCY STOP"...
Page 263: Emergency Stop Acknowledgment
EMERGENCY OFF (N2) 14.3 EMERGENCY STOP acknowledgment Note The interruption of the power feed to the equipment is the responsibility of the machine manufacturer. If the internal functions in the NC should not be executed in the predetermined sequence in the event of an EMERGENCY STOP, then IS EMERGENCY STOP (V2600 0000.1) may not be set at any time up to the point that an EMERGENCY STOP defined by the machine manufacture in the PLC user program is reached.
Page 264: Data Lists
EMERGENCY OFF (N2) 14.4 Data lists PLC I/Os The PLC user program must switch the PLC I/Os to the correct state for operation of the machine. Reset The EMERGENCY STOP state cannot be reset solely by IS "Reset" (V3000 0000.7) (see diagram above).
Page 265: Punching And Nibbling (N4)
Punching and Nibbling (N4) Note This function is only available for the G/N plus and pro versions. 15.1 Brief Description Subfunctions The functions specific to punching and nibbling operations comprise the following: ● Stroke control ● Automatic path segmentation ● Rotatable punch and die ●...
Page 266: High-Speed Signals
Punching and Nibbling (N4) 15.2 Stroke control PLC signals PLC interface signals are used for non-time-critical functions such as enabling and monitoring. 15.2.2 High-speed signals Functionality High-speed signals are used to synchronize the NC and punching unit. On the one hand, they are applied via a high-speed output to ensure that the punch stroke is not initiated until the metal sheet is stationary.
Page 267 Punching and Nibbling (N4) 15.2 Stroke control Note The "Stroke active" signal is high-active for reasons relating to open-circuit monitoring. The chronological sequence of events for punching and nibbling is controlled by the two signals A and E Set by the NCK and identical to stroke initiation. Defines the status of the punching unit and identical to the "Stroke active"...
Page 268: Criteria For Stroke Initiation
Punching and Nibbling (N4) 15.2 Stroke control 15.2.3 Criteria for stroke initiation Initiate a stroke The stroke initiation must be set, at the earliest, for the point in time at which it can be guaranteed that the axes have reached a standstill. This ensures that at the instant of punching, there is absolutely no relative movement between the punch and the metal sheet in the machining plane.
Page 269 Punching and Nibbling (N4) 15.2 Stroke control Programming Activation Description G603 Stop interpolation The interpolation reaches the block end. In this case, the axes continue to move until the overtravel has been traversed, i.e. the signal is output at an appreciable interval before the axes have reached zero speed (see t"...
Page 270: Axis Start After Punching
Punching and Nibbling (N4) 15.2 Stroke control 15.2.4 Axis start after punching Input signal "Stroke ON" The start of an axis motion after stroke initiation is controlled via input signal "Stroke ON". Figure 15-3 Signal chart: Axis start after punching In this case, the time interval between t and t' acts as a switching-time-dependent reaction...
Page 271: Plc Signals Specific To Punching And Nibbling
Punching and Nibbling (N4) 15.2 Stroke control 15.2.5 PLC signals specific to punching and nibbling Function In addition to the signals used for direct stroke control, channel-specific PLC interface signals are also available. These are used both to control the punching process and to display operational states.
Page 272: Signal Monitoring
Punching and Nibbling (N4) 15.3 Activation and deactivation 15.2.7 Signal monitoring Oscillating signal Owing to aging of the punch hydraulics, overshooting of the punch may cause the "Stroke active" signal to oscillate at the end of a stroke. In this case, an alarm (22054 "Undefined punching signal") can be generated depending on MD26020 NIBBLE_SIGNAL_CHECK.
Page 273 Punching and Nibbling (N4) 15.3 Activation and deactivation Group 36 This group includes the commands which have only a preparatory character and which determine the real nature of the punching function: PDELAYON = punching with delay ON PDELAYOF = punching with delay OFF Since the PLC normally needs to perform some preliminary tasks with respect to these preparatory functions, they are programmed before the activating commands.
Page 274 Punching and Nibbling (N4) 15.3 Activation and deactivation Nibbling ON activates the nibbling function and deselects the other functions in G group35 (e.g. In contrast to punching, the first stroke is made at the start point of the block with the activating command, i.e.
Page 275 Punching and Nibbling (N4) 15.3 Activation and deactivation PONS Punching ON (in position control cycle) behaves in the same way as . For explanation, please refer to PONS SONS PDELAYON Punching with delay ON is a preparatory function. This means that is generally programmed before PDELAYON PDELAYON...
Page 276: Functional Expansions
Punching and Nibbling (N4) 15.3 Activation and deactivation SPIF2 Activation of second punch interface activates the second punch interface, i.e. the stroke is controlled via the second pair of SPIF2 high-speed I/Os (see machine data MD26004 and MD26006). Programming example: N170 SPIF1 X100 PON At the end of the block, a stroke is initiated at the first high-speed output.
Page 277 Punching and Nibbling (N4) 15.3 Activation and deactivation First interface input bit MD26006 NIBBLE_PUNCH_INMASK[0] → Bit 1 SPIF1 Second interface input bit MD26006 NIBBLE_PUNCH_INMASK[1] → Bit 2 SPIF2 Automatically activated pre-initiation time Dead times due to the reaction time of the punching unit can be minimized if the stroke can be initiated before the interpolation window of the axes is reached.
Page 278 Punching and Nibbling (N4) 15.3 Activation and deactivation If a punching dwell time ( ) is also programmed, then the two times are applied PDELAYON additively. If a pre-initiation time at is programmed, it will be effective only if the end of interpolation G603 is reached before the time set in SD 42404: The programmed time becomes operative immediately.
Page 279 Punching and Nibbling (N4) 15.3 Activation and deactivation Example 2 The characteristic defines the following acceleration rates: Distance Acceleration between holes < 3 mm The axis accelerates at a rate corresponding to 75% of maximum acceleration. 3 - 8 mm Acceleration is reduced to 25%, proportional to the spacing.
Page 280: Automatic Path Segmentation
Punching and Nibbling (N4) 15.4 Automatic path segmentation 15.4 Automatic path segmentation 15.4.1 General information Function One of the following two methods can be applied to automatically segment a programmed traversing path: ● Path segmentation with maximum path segment programmed via language command ●...
Page 281 Punching and Nibbling (N4) 15.4 Automatic path segmentation ● The path segments are rounded off by the control system if required so that a total programmed distance can be divided into an integral number of path sections. ● The path segment unit is either mm/stroke or inch/stroke (depending on axis settings). ●...
Page 282: Operating Characteristics With Path Axes
Punching and Nibbling (N4) 15.4 Automatic path segmentation 15.4.2 Operating characteristics with path axes MD26010 All axes defined and programmed via machine data MD26010 PUNCHNIB_AXIS_MASK are traversed along path sections of identical size with until the programmed end point is reached. This also applies to rotatable tool axes if programmed. The response can be adjusted for single axes.
Page 283 Punching and Nibbling (N4) 15.4 Automatic path segmentation If the programmed path segmentation is not an integral multiple of the total path, then the feed path is reduced. X2/Y2: Programmed traversing distance SPP: Programmed SPP value SPP': Automatically rounded-off offset distance Figure 15-4 Path segmentation Example of SPN...
Page 284 Punching and Nibbling (N4) 15.4 Automatic path segmentation segments. Since punching is active, the first stroke is initiated at the end of the first segment. Example Figure 15-5 Workpiece Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 285: Response In Connection With Single Axes
Punching and Nibbling (N4) 15.4 Automatic path segmentation Extract from program ① N100 G90 X130 Y75 F60 SPOF Position at starting point vertical nibbling path sections N110 G91 Y125 SPP=4 SON End point coordinates (incremental); path segment: 4 mm, activate nibbling N120 G90 Y250 SPOF Absolute dimensioning, position at ②...
Page 286 Punching and Nibbling (N4) 15.4 Automatic path segmentation MD26016 PUNCH_PARTITION_TYPE = 0 (default setting) With this setting, the axes behave as standard, i.e. the programmed special axis motions are distributed among the generated intermediate blocks of the active path segmentation function in all interpolation modes.
Page 287 Punching and Nibbling (N4) 15.4 Automatic path segmentation MD26016 PUNCH_PARTITION_TYPE = 1 In contrast to the behavior described above, here the synchronous axis traverses the entire programmed rotation path in the first sub-block of the selected path segmentation function. Applied to the example, the C axis already reaches the programmed end position C = 45 when it reaches X position X = 15.
Page 288 Punching and Nibbling (N4) 15.4 Automatic path segmentation MD26016 PUNCH_PARTITION_TYPE = 2 MD26016 = 2 is set in cases where the axis must behave as described above in linear interpolation mode, but according to the default setting in circular interpolation mode (see 1st case).
Page 289 Punching and Nibbling (N4) 15.4 Automatic path segmentation Supplementary conditions ● If the C axis is not defined as a "Punch-nibble axis", then the C axis motion path is not segmented in block in the above example nor is a stroke initiated at the block end. ●...
Page 290: Rotatable Tool
Punching and Nibbling (N4) 15.5 Rotatable tool 15.5 Rotatable tool 15.5.1 General information Function overview The following two functions are provided for nibbling/punching machines with rotatable punch and lower die: ● Coupled motion for synchronous rotation of punch and die ●...
Page 291: Coupled Motion Of Punch And Die
Punching and Nibbling (N4) 15.5 Rotatable tool 15.5.2 Coupled motion of punch and die Function Using the standard function "Coupled motion", it is possible to assign the axis of the die as a coupled motion axis to the rotary axis of the punch. Activation The "Coupled motion"...
Page 292 Punching and Nibbling (N4) 15.5 Rotatable tool Mode of operation The tangential axis is coupled to the interpolation of the master axes. It is therefore not possible to position the axis at the appropriate punching position tangentially to the path independently of velocity.
Page 293 Punching and Nibbling (N4) 15.5 Rotatable tool N55 TRAILOF (C1, C) ; Deactivate coupled motion of rotatable tool axes C/C1 N60 M2 Figure 15-7 Illustration of programming example in XY plane Example: Circular interpolation In circular interpolation mode, particularly when path segmentation is active, the tool axes rotate along a path tangentially aligned to the programmed path axes in each sub-block.
Page 294 Punching and Nibbling (N4) 15.5 Rotatable tool Programming example: N2 TANG (C, X, Y, 1, "B") ; Define master and slave axes, C is slave axis for X and Y in the base coordinate system N5 G0 F60 X10 Y10 ;...
Page 295: Protection Zones
Punching and Nibbling (N4) 15.6 Protection zones Figure 15-8 Illustration of programming example in XY plane 15.6 Protection zones Clamping protection zone The "Clamping protection zone" function monitors whether clamps and tool could represent a mutual risk. Note No by-pass strategies are implemented for cases where the clamp protection is violated. Reference: /BPN/ Operation and Programming, Nibbling, Section Clamping protection Turning, Milling, Nibbling...
Page 296: Examples Of Defined Start Of Nibbling Operation
Punching and Nibbling (N4) 15.7 Examples of defined start of nibbling operation 15.7 Examples of defined start of nibbling operation Example 1 Example of defined start of nibbling operation Program code Comment N10 G0 X20 Y120 SPP= 20 ; Position 1 is approached N20 X120 SON ;...
Page 297 Punching and Nibbling (N4) 15.7 Examples of defined start of nibbling operation Example 2 This example utilizes the "Tangential control" function. Z has been selected as the name of the tangential axis. Program code Comment N5 TANG (Z, X, Y, 1, "B") ;...
Page 298 Punching and Nibbling (N4) 15.7 Examples of defined start of nibbling operation Examples 3 and 4 for defined start of nibbling Example 3: Programming of SPP Program code Comment N5 G0 X10 Y10 ; Positioning N10 X90 SPP=20 SON ; Defined start of nibbling, ;...
Page 299 Punching and Nibbling (N4) 15.7 Examples of defined start of nibbling operation Examples 5 and 6 without defined start of nibbling Example 5 Programming of SPP Program code Comment N5 G0 X10 Y30 ; Positioning N10 X90 SPP=20 PON ; No defined start of nibbling, ;...
Page 300 Punching and Nibbling (N4) 15.7 Examples of defined start of nibbling operation Example 7 Application example of SPP programming Figure 15-10 Workpiece Extract from program: Program code Comment N100 G90 X75 Y75 F60 PON ; Positioning to starting point (1) of the ;...
Page 301: Data Lists
Punching and Nibbling (N4) 15.8 Data lists 15.8 Data lists 15.8.1 Machine data Number Identifier Name General 11450 SEARCH_RUN_MODE Block search parameter settings Channel-specific 26000 PUNCHNIB_ASSIGN_FASTIN Hardware assignment for input-byte with stroke control 26002 PUNCHNIB_ASSIGN_FASTOUT Hardware assignment for output-byte with stroke control 26004 NIBBLE_PUNCH_OUTMASK[n])
Page 302 Punching and Nibbling (N4) 15.8 Data lists Number Name V3200 0003 Delayed stroke V3200 0003 Manual stroke initiation Signals from channel V3300 0006 Stroke initiation active V3300 0006 Acknowledgement of manual stroke initiation Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 303: Transverse Axes (P1)
Transverse Axes (P1) 16.1 Transverse axis definition Geometry axis as transverse axis The geometry axis X is defined as a transverse axis. The transverse axis is important for lathe functions. 16.2 Diameter programming Activation and deactivation The diameter or radius can be programmed for transverse axes. Program commands "DIAMON"...
Page 304: Constant Cutting Rate: G96
Transverse Axes (P1) 16.3 Constant cutting rate: G96 Conversion of diameter values to internal radius values With diameter programming active, the internal radius values are converted for the transverse axis (i.e. the programmed values are halved): ● Programmed end positions ●...
Page 305 Transverse Axes (P1) 16.3 Constant cutting rate: G96 Figure 16-1 Constant cutting rate G96 Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 306 Transverse Axes (P1) 16.3 Constant cutting rate: G96 Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 307: Positioning Axes (P2)
Positioning Axes (P2) 17.1 Concurrent positioning axis If axes are available on a machine tool for auxiliary movements, they can only be triggered from the PLC during machining operation. Note A positioning axis controlled by the PLC can also be an indexing axis. However, it is not possible to control spindles in versions G/N plus and pro.
Page 308: Permanently Assigned Plc Axis
Positioning Axes (P2) 17.2 Permanently assigned PLC axis Applications Typical applications for concurrent positioning axes include: ● Tool magazines with manual loading and unloading during machining ● Tool magazines with tool preparation during machining 17.2 Permanently assigned PLC axis Function The option of controlling an axis from the PLC is controlled via the machine data MD30460 BASE_FUNCTION_MASK.
Page 309 Positioning Axes (P2) 17.2 Permanently assigned PLC axis Initialization The function is activated by the positive edge of the V380x 3000.7 signal (start positioning axis). The interface signal must remain at logical "1" until the function has been acknowledged positively or negatively by the following interface signals: ●...
Page 310 Positioning Axes (P2) 17.2 Permanently assigned PLC axis Figure 17-2 Pulse diagram error condition Start 8. First function activation via positive edge of Positioning axis active = 1 shows that the function is active and that the output signals are valid Error Positioning axis active...
Page 311: Data Lists
Positioning Axes (P2) 17.3 Data lists Axis control If an axis is in the neutral state, it can be controlled by the signals AXRESET, AXSTOP and AXRESUME, effective in the channel. If during acceleration it is detected that an axis which was defined as a geometry axis simultaneously has been defined as permanently assigned PLC axis, the axis function will be denied with alarm 4320 axis 1% function MA_BASE_FUNCTION_MASK Bit5 and MC_AXCONF_GEOAX_ASSIGN_TAB.
Page 312: Error Messages
Positioning Axes (P2) 17.3 Data lists Number Name V380x 5004 AxStop, stop V380x 5004 PLC controls axis Signals from axis/spindle V390x 0011 PLC axis permanently assigned V390x 3000 Axis cannot be started V390x 3000 Error during traversing V390x 3000 Position reached V390x 3000 Positioning axes active 17.3.3...
Page 313 Positioning Axes (P2) 17.3 Data lists Dec. Hex. Meaning Software limit switch minus Working area limitation plus Working area limitation minus Corresponds to alarm number 17501 Corresponds to alarm number 17503 System or other serious alarms Corresponds to system alarm number 450007 References The alarms are described in: /DIA/ Diagnostics Guide...
Page 314 Positioning Axes (P2) 17.3 Data lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 315: Reference Point Approach (R1)
Reference Point Approach (R1) 18.1 Fundamentals Why reference? The control must be synchronized with the position measurement system of each machine axis so that the control can detect the exact machine zero when it is switched on. This process is known as referencing. The spindle process (synchronizing) is largely described in the Chapter "Spindles".
Page 316 Reference Point Approach (R1) 18.1 Fundamentals Axisspecific referencing Axis-specific referencing is started separately for each machine axis with the "plus/minus traversing keys" interface signal (V380x 0004.7 /.6). All axes can be referenced at the same time. If the machine axes are to be referenced in a particular sequence, the following options are available: ●...
Page 317: Referencing With Incremental Measuring Systems
Reference Point Approach (R1) 18.2 Referencing with incremental measuring systems Note MD20700 REFP_NC_START_LOCK = 1 prevents a part program from being started (alarm output) if not all required axes are referenced. 18.2 Referencing with incremental measuring systems Time sequence The referencing sequence for incremental measuring systems can be subdivided into three phases: 1.
Page 318 Reference Point Approach (R1) 18.2 Referencing with incremental measuring systems Characteristics of traversing to the reference point cam (phase 1) ● The feedrate override and feedrate stop is in effect. ● The machine axis can be stopped/started. ● The cam must be reached within the traversing distance in MD34030 REFP_MAX_CAM_DIST, otherwise a corresponding alarm is triggered.
Page 319 Reference Point Approach (R1) 18.2 Referencing with incremental measuring systems Referencing type Synchronizing pulse Motion sequence (zero mark, BERO) Synchronizing pulse on cam, reference coordinate after synchronizing pulse on cam = with reversal: (MD34050 REFP_SEARCH_MARKER_REVERSE = 1) Without reference cam (MD34000 Reference coordinate after synchronizing REFP_CAM_IS_ACTIVE = 0) pulse...
Page 320 Reference Point Approach (R1) 18.2 Referencing with incremental measuring systems Reference cam adjustment The reference cam must be calibrated exactly. The following factors influence the response time of the control when detecting the reference cam ("Reference point approach delay" interface signal): ●...
Page 321: Referencing With Distancecoded Reference Markers
Reference Point Approach (R1) 18.3 Referencing with distancecoded reference markers 18.3 Referencing with distancecoded reference markers 18.3.1 General information Distance-coded reference markers Measuring systems with distance-coded reference marks consist of two parallel scale tracks: ● Incremental grating ● Reference mark track The distance between any two consecutive reference markers is defined.
Page 322 Reference Point Approach (R1) 18.3 Referencing with distancecoded reference markers Rotary measuring system For rotary measuring systems, the same applies as for linear measuring systems (see above). Determining the absolute offset The following procedure is recommended for the determination of the absolute offset between the machine zero point and the position of the first reference mark of a machine axis: 1.
Page 323: Chronological Sequence
Reference Point Approach (R1) 18.3 Referencing with distancecoded reference markers Referencing methods Referencing with distance-coded reference marks can be performed in one of two ways: ● Evaluation of two consecutive reference marks: MD34200 ENC_REFP_MODE (referencing mode) = 3 Advantage: – Short travel path ●...
Page 324: Phase 1: Travel Across The Reference Marks With Synchronization
Reference Point Approach (R1) 18.3 Referencing with distancecoded reference markers 18.3.4 Phase 1: Travel across the reference marks with synchronization Phase 1: Start For information on starting reference point approach, refer to "Axis-specific referencing" and "Channel-specific referencing." reference cam In measuring systems with distance-coded reference marks, reference cams are not required for the actual referencing action.
Page 325: Phase 2: Travel To Fixed Stop
Reference Point Approach (R1) 18.3 Referencing with distancecoded reference markers Before the machine axis travels over the parameterized number of reference marks, it touches the reference cam. It is then reversed and reference mark search is restarted in the opposite direction. Once the number of reference markers set by means of parameter assignment has been crossed, the machine axis is stopped again and the actual value system of the machine axis is synchronized to the absolute position calculated by the NC.
Page 326 Reference Point Approach (R1) 18.3 Referencing with distancecoded reference markers Phase 2: Sequence In Phase 2, the machine axis completes reference point approach by traversing to a defined target position (reference point). This action can be suppressed in order to shorten the reference point approach: MD34330 STOP_AT_ABS_MARKER Value...
Page 327 Reference Point Approach (R1) 18.3 Referencing with distancecoded reference markers Properties: ● Feedrate override is not active. Machine axis moves internally when feedrate override = 100%. If a feedrate override of 0% is specified, an abort occurs. ● The feed stop (channel-specific and axis-specific) is active. ●...
Page 328: Referencing With Absolute Encoders
Reference Point Approach (R1) 18.4 Referencing with absolute encoders 18.4 Referencing with absolute encoders 18.4.1 General Requirements An axis with absolute encoder is referenced automatically when the control is switched on if the system detects that the relevant axis is already calibrated. This transfer of the absolute value takes place without any axis motion, e.g.
Page 329: Secondary Conditions For Absolute Encoders
Reference Point Approach (R1) 18.5 Secondary conditions for absolute encoders 3. Enter the actual value corresponding to the approached position in MD34100 REFP_SET_POS. This value may be a specified design value (e.g. fixed stop) or can now be determined with a measuring instrument. 4.
Page 330: Data Lists
Reference Point Approach (R1) 18.6 Data lists Note The control may not always recognize the need for recalibration. If it detects such a need, it sets MD34210 to 0 or 1. The following is detected: changeover to another gear speed with a different gear ratio between the encoder and load.
Page 331: Interface Signals
Reference Point Approach (R1) 18.6 Data lists Number Identifier Name 34060 REFP_MAX_MARKER_DIST[0] Maximum distance to reference marker; maximum distance to 2 reference markers with distance-coded scales 34070 REFP_VELO_POS Reference point positioning velocity 34080 REFP_MOVE_DIST[0] Reference point distance/destination point for distancecoded system 34090 REFP_MOVE_DIST_CORR[0]...
Page 332 Reference Point Approach (R1) 18.6 Data lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 333: Rotary Axes (R2)
Rotary Axes (R2) 19.1 General Properties of a rotary axis Rotary axes are always programmed in degrees. They are generally characterized by the fact that they assume the same position after exactly one rotation (modulo 360 degrees). Depending on the application in question, the traversing range of the rotary axis can be limited to less than 360 degrees (e.g.
Page 334 Rotary Axes (R2) 19.1 General Units of measurement The following units of measurement apply as standard to inputs and outputs for rotary axes: Table 19- 1 Units of measurement for rotary axes Physical quantity Units Angular position Degrees. Programmed angular speed Degrees/min MD for angular velocity rev/min...
Page 335: Modulo 360 Degrees
Rotary Axes (R2) 19.2 Modulo 360 degrees Software limit switches The software limit switches and working area limitations are active and are required for swivel axes with a limited operating range. However, in the case of continuously-turning rotary axes with MD30310 ROT_IS_MODULO=1, the software limit switches and working area limitations can be deactivated for individual axes.
Page 336: Programming Rotary Axes
Rotary Axes (R2) 19.3 Programming rotary axes MD30320 DISPLAY_IS_MODULO = 0: Absolute-position display would, in the case of a positive direction of rotation, for example, result in +360° being displayed after one revolution, +720° after two revolutions, etc., in contrast to the modulo 360° display. In this case, the display range is limited by the control in accordance with the linear axes.
Page 337: Rotary Axis Without Modulo Conversion
Rotary Axes (R2) 19.3 Programming rotary axes ● The control calculates the direction of rotation and the traverse path according to the current actual position. If the path to be traversed is the same in both directions (180°), the positive direction of rotation receives preference. ●...
Page 338: Data Lists
Rotary Axes (R2) 19.4 Data lists ● If ACP or ACN are programmed, alarm 16810 "ACP traversing instruction cannot be used" or alarm 16820 "ACN traversing instruction cannot be used" is output. Absolute dimension programming along the shortest path (DC) Example of DC: C=DC(60.3), general: axis name =DC(value) Even if the rotary axis is not defined as a modulo axis, the axis can still be positioned with DC (direct control).
Page 339: Setting Data
Rotary Axes (R2) 19.4 Data lists 19.4.2 Setting data Number Identifier Name General 41130 JOG_ROT_AX_SET_VELO JOG velocity for rotary axes Axis-specific 43430 WORKAREA_LIMIT_MINUS Working area limitation minus 43420 WORKAREA_LIMIT_PLUS Working area limitation plus Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 340 Rotary Axes (R2) 19.4 Data lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 341: Spindle (S1)
Spindle (S1) 20.1 Brief description Spindle functions Depending on the machine type the following functions are possible for a spindle controlled by the NC: ● Input of a direction of rotation for the spindle (M3, M4) ● Input of a spindle speed (S) ●...
Page 342: Spindle Modes
Spindle (S1) 20.2 Spindle modes Definition of the spindle A machine axis is declared a spindle by setting the following machine data: ● MD30300 IS_ROT_AX ● MD30310 ROT_IS_MODULO ● MD30320 DISPLAY_IS_MODULO ● MD35000 SPIND_ASSIGN_TO_MACHAX. The IS "Spindle/no axis" reports the spindle mode (V390x 0000.0). 20.2 Spindle modes Spindle modes...
Page 343: Spindle Control Mode
Spindle (S1) 20.2 Spindle modes Switching between spindle modes ● Control mode ---> oscillation mode The spindle changes to oscillation mode if a new gear stage has been specified using automatic gear stage selection (M40) in conjunction with a new S value or by M41 to M45.
Page 344: Spindle Oscillation Mode
Spindle (S1) 20.2 Spindle modes Independent spindle reset MD35040 SPIND_ACTIVE_AFTER_RESET defines the response of the spindle after reset or program end (M2, M30): ● If MD value=0, the spindle is immediately braked to rest at the valid acceleration. The last programmed spindle speed and direction of rotation are deleted.
Page 345 Spindle (S1) 20.2 Spindle modes Oscillation time The oscillation time for oscillation mode can be defined in a machine date for each direction of rotation: ● Oscillation time in M3 direction (referred to as t1 in the following): MD35440 SPIND_OSCILL_TIME_CW ●...
Page 346 Spindle (S1) 20.2 Spindle modes Block change If the spindle has been changed over to oscillation mode, IS "Change gear" (V390x 2000.3) is set, part program processing is stopped. A new block is not executed. If oscillation mode is terminated using the IS "Gear switched" (V380x 2000.3), the execution of the part program is continued.
Page 347: Spindle Positioning Mode
Spindle (S1) 20.2 Spindle modes 20.2.3 Spindle positioning mode When is positioning mode used? The spindle positioning mode stops the spindle at the defined position and activates the position control, which remains active until it is deactivated. With the SPOS =..program function, the spindle is in positioning mode (see also Section "Programming").
Page 348 Spindle (S1) 20.2 Spindle modes Phase 1b (not shown): Spindle rotates at a speed higher than the encoder limit frequency. The spindle is not synchronized initially, but is then synchronized when the rotation speed falls below the speed defined by the encoder frequency in MD36302 ENC_FREQ_LIMIT_LOW (% value of MD36300).
Page 349 Spindle (S1) 20.2 Spindle modes The direction of rotation is defined by MD35350 SPIND_POSITIONING_ DIR (direction of rotation during positioning from standstill), if no input results from SPOS programming (ACN, ACP, IC). The spindle is synchronized with the next zero mark of the position actual value encoder.
Page 350: Spindle Axis Mode
Spindle (S1) 20.2 Spindle modes Phase 2: Acceleration has been performed up to the speed set in MD35300 SPIND_POSCTRL_VELO (position control activation speed). The brake application point calculation identifies when the programmed spindle position (SPOS=...) can be approached with the acceleration defined in MD35210 GEAR_STEP_POSCTRL_ACCEL. Phase 3 and Phase 4: The sequence for "Deceleration"...
Page 351: Synchronization
Spindle (S1) 20.3 Synchronization Special features ● The feed override switch is active. ● RESET does not terminate the axis mode per default. ● IS "Spindle / no axis" (V390x 0000.0) is set to zero. ● Axis mode can be activated in all gear stages. ●...
Page 352 Spindle (S1) 20.3 Synchronization ● In JOG mode the spindle is started in speed control mode with the direction keys and synchronizes with the next zero mark of the position measurement system or the BERO signal. Value acceptance When synchronizing the spindle, the associated reference point from MD34100 REFP_SET_POS[0] (default value = 0) is transferred and a possible shift of the reference point.
Page 353: Gear Stage Change
Spindle (S1) 20.4 Gear stage change 20.4 Gear stage change Number of gear stages Five gear stages can be configured for the spindle. If the spindle motor is mounted on the spindle directly (1:1) or with a non-adjustable gear ratio, MD35010 GEAR_STEP_CHANGE_ENABLE (gear stage change is possible) must be set to zero.
Page 354 Spindle (S1) 20.4 Gear stage change M41 to M45 The gear stage can be permanently defined in the part program with M41 to M45. If a gear stage is defined by M41 to M45, which is different than the current (actual) gear stage, the IS "Change gear"...
Page 355 Spindle (S1) 20.4 Gear stage change Gear stage change A new gear stage can only be selected when the spindle is stationary. The spindle is stopped internally in the control if a gear stage change is requested. If the new gear stage is preselected by M40 and spindle speed or M41 to M45, the IS "Set gear stage A"...
Page 356 Spindle (S1) 20.4 Gear stage change Figure 20-8 Gear stage change with stationary spindle Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 357: Programming
Spindle (S1) 20.5 Programming Parameter set One parameter set each is provided for each of the five gear stages. The appropriate parameter set is activated using the IS "Actual gear stage A" to "...C" (V380x 2000.0 to .2). It is assigned as follows: Index n PLC interface, Data of the data set...
Page 358 Spindle (S1) 20.5 Programming S... Spindle speed in rpm, e.g. S300 SPOS=... Spindle positioning, e.g. SPOS=270 -> at position 270 degrees. The block change is only performed when the spindle is in position. SPOS=DC(Pos) The direction of motion is retained for positioning while in motion and the position approached.
Page 359: Spindle Monitoring
Spindle (S1) 20.6 Spindle monitoring 20.6 Spindle monitoring Speed ranges The spindle monitoring functions and the currently active functions (G94, G95, G96, G33, G331, G332, etc.) define the admissible speed ranges of the spindle. Figure 20-9 Ranges of spindle monitoring functions / speeds 20.6.1 Axis/spindle stationary Only when the spindle is stationary, i.e.
Page 360: Spindle In Setpoint Range
Spindle (S1) 20.6 Spindle monitoring 20.6.2 Spindle in setpoint range The "Spindle in setpoint range" monitor checks whether the programmed spindle speed has been reached, whether the spindle is stationary (IS "Axis/spindle stationary") or whether it is still in the acceleration phase. In the spindle "control mode", the speed setpoint (programmed speed with spindle override including the active limits) is compared with the actual speed.
Page 361: Max. Encoder Limit Frequency
Spindle (S1) 20.6 Spindle monitoring Minimum speed MD35140 GEAR_STEP_MIN_VELO_LIMIT defines the minimum speed for the gear stage. It is not possible that the speed falls below this (set) speed if an S value is programmed, which is too small. Then, the IS "Setpoint speed increased" (V390x 2001.2) is enabled. The minimum gear stage speed is operative only in spindle open loop control mode;...
Page 362: Target Point Monitoring
Spindle (S1) 20.6 Spindle monitoring If the encoder limit frequency is exceeded, the IS "Referenced/synchronized" V390x 0000.4) is reset for the measurement system and IS "Encoder limit frequency 1 exceeded" (V390x 0000.2) is enabled. If the maximum encoder limit frequency has been exceeded and the speed subsequently falls below the encoder frequency in MD36302 ENC_FREQ_LIMIT_LOW (% value of MD36300 ENC_FREQ_LIMIT), the spindle is automatically synchronized with the next zero mark or the next BERO signal.
Page 363: 2Nd Spindle / Master Spindle
Spindle (S1) 20.7 2nd spindle / master spindle Block change with SPOS If the spindle is being positioned with SPOS, the block change will be dependent on the end point monitoring with the IS "Position reached with exact stop fine". All other functions programmed in the block must have achieved their end criterion (e.g.
Page 364 Spindle (S1) 20.7 2nd spindle / master spindle The definition of the master spindle changed in the program is only valid until End of program/program abort. Thereafter, the configured master spindle is again active. Programming via spindle number Some spindle functions can also be selected via the spindle number: S1=..., S2=...
Page 365: Analog Spindle
Spindle (S1) 20.8 Analog spindle 20.8 Analog spindle Function With the "Analog spindle" function, the MCPA option module is used as the setpoint output, and a free DRIVE-CLiQ encoder interface is used as the actual-value input. For more detailed information see the "adi4.ini" file, which is part of the toolbox and can be found in the "...\Toolbox 802D_sl\V01040000\Special\ADI4"...
Page 366: Setting Data
Spindle (S1) 20.9 Data lists Number Identifier Name 35130 * GEAR_STEP_MAX_VELO_LIMIT[n] Maximum speed of gear stage 35140 * GEAR_STEP_MIN_VELO_LIMIT[n] Minimum speed of gear stage 35150 SPIND_DES_VELO_TOL Spindle speed tolerance 35160 SPIND_EXTERN_VELO_LIMIT Spindle speed limitation via PLC 35200 * GEAR_STEP_SPEEDCTRL_ACCEL[n] Acceleration in speed control mode 35210 * GEAR_STEP_POSCTRL_ACCEL[n] Acceleration in position control mode...
Page 367 Spindle (S1) 20.9 Data lists Number Name VD30x 0004 S function for the spindle (REAL), axis-specific VB380x 0000 Feed override V380x 0001 Override active V380x 0001 Position measuring system 1 V380x 0001 Axis/spindle disable V380x 0002 Spindle reset/delete distancetogo V380x 0002 Controller enable V380x 0003 Velocity/spindle speed limitation...
Page 368 Spindle (S1) 20.9 Data lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 369: Indexing Axes (T1)
Indexing Axes (T1) 21.1 Brief Description Note This function is not available with version T/M value. Indexing axes in machine tools In certain applications, the axis is only required to approach specific grid points (e.g. location numbers). It is necessary to approach the defined grid points, the indexing positions, both in AUTOMATIC and set-up mode.
Page 370: Indexing Axes
Indexing Axes (T1) 21.2 Indexing axes 21.2 Indexing axes 21.2.1 General information General rules Indexing axes can be traversed manually in the setup mode types JOG and INC, from a part program with special instructions for "Coded positions" and by the PLC. Upon reaching the indexing position the following interface signal is given out to the PLC: V390x 1002.6 (indexing axis in position) Hirth indexing axes cannot be traversed in JOG mode before reference point approach.
Page 371 Indexing Axes (T1) 21.2 Indexing axes Incremental traversal in JOG mode (INC) Irrespective of the current increment setting (INC1, ... ,INCvar), the indexing axis always traverses through one indexing position in the selected direction when a traversing key "+" or "-"...
Page 372: Traversing Indexing Axes In Automatic Modes
Indexing Axes (T1) 21.2 Indexing axes 21.2.3 Traversing indexing axes in AUTOMATIC modes Traversal to selected positions An axis defined as an indexing axis can be made to approach any selected position from the NC part program in AUTOMATIC mode. This includes positions between the defined indexing positions.
Page 373: Parameterization Of Indexing Axes
Indexing Axes (T1) 21.3 Parameterization of indexing axes 21.3 Parameterization of indexing axes Definition of the indexing axis An axis (linear or rotary axis) can be defined as an indexing axis with the aid of the axial machine data MD30500 INDEX_AX_ASSIGN_POS_TAB. The number of the indexing position table (1 or 2) must be entered in the machine data.
Page 374 Indexing Axes (T1) 21.3 Parameterization of indexing axes Inch/metric switchover The indexing positions refer to the configured system of units: ● MD10270 POS_TAB_SCALING_SYSTEM = 0: metric ● MD10270 POS_TAB_SCALING_SYSTEM = 1: inch Note MD10270 defines the scaling system of the position data for the following machine data: MD10910 INDEX_AX_POS_TAB_1 MD10930 INDEX_AX_POS_TAB_2 MD10270 affects the following setting data:...
Page 375: Programming Of Indexing Axes
Indexing Axes (T1) 21.4 Programming of indexing axes 21.4 Programming of indexing axes Coded position To allow indexing axes to be positioned from the NC part program, special instructions (so- called Coded positions) are provided with which the indexing numbers (e.g. location numbers) are programmed instead of axis positions in mm or degrees.
Page 376: Starting Up Indexing Axes
Indexing Axes (T1) 21.5 Starting up indexing axes The sign determines the approach direction. Note On modulo rotary axes, the indexing positions are divided in factors of 360° and approached directly. Between indexing positions If an indexing axis is situated between two indexing positions, the program commands have the following effect in AUTOMATIC mode: Program command Effect...
Page 377 Indexing Axes (T1) 21.5 Starting up indexing axes General machine data MD10910 INDEX_AX_POS_TAB_1 [n] Indexing position table 1 MD10930 INDEX_AX_POS_TAB_2 [n] Indexing position table 2 Axial machine data MD30500 INDEX_AX_ASSIGN_POS_TAB Axis is indexing axis (assignment of indexing position table 1 or 2, or 3 for equidistant indexing) Machine data examples The assignment of the above machine data is described in the following paragraphs using two examples.
Page 378 Indexing Axes (T1) 21.5 Starting up indexing axes MD10910 INDEX_AX_POS_TAB_1[6] = 270 7. indexing position at 270° MD10910 INDEX_AX_POS_TAB_1[7] = 315 8. indexing position at 315° Other machine data: MD10900 INDEX_AX_LENGTH_POS_TAB_1= 8 Eight indexing positions in table 1 MD30500 INDEX_AX_ASSIGN_POS_TAB [AX5] = 1 Axis 5 is defined as indexing axis, indexing positions in table 1 MD30300 IS_ROT_AX [AX5] = 1...
Page 379: Special Features Of Indexing Axes
Indexing Axes (T1) 21.6 Special features of indexing axes Other machine data MD10920 INDEX_AX_LENGTH_POS_TAB_2 = 10 Ten indexing positions in table 2 MD30500 INDEX_AX_ASSIGN_POS_TAB [AX6] = 2 Axis 6 is defined as indexing axis, indexing positions in table 2 21.6 Special features of indexing axes Software limit switch The software limit switches are also effective during traversing movements once the indexing...
Page 380: Data Lists
Indexing Axes (T1) 21.7 Data lists 21.7 Data lists 21.7.1 Machine data Number Identifier Name General 10900 INDEX_AX_LENGTH_POS_TAB_1 Number of positions for indexing axis table 1 10910 INDEX_AX_POS_TAB_1[n] Indexing position table 1 10920 INDEX_AX_LENGTH_POS_TAB_2 Number of positions for indexing axis table 2 10930 INDEX_AX_POS_TAB_2[n] Indexing position table 2...
Page 381: Tangential Control (T3)
Tangential Control (T3) Note This function is only available for the T/M pro and G/N pro versions. 22.1 Brief description Function The "tangential control" function belongs to the category of NC functions with coupled axes. The function has the following characteristics: ●...
Page 382: Characteristics Of "Tangential Control" Function
Tangential Control (T3) 22.2 Characteristics of "Tangential control" function 22.2 Characteristics of "Tangential control" function Problem definition Follow-up control for the rotary axis must be implemented so that the axis is always positioned at a specified angle to the tangent on a programmed path of two leading axes. Figure 22-1 Example of a tangential control with an angle of zero degrees to the path tangent In the figure, X and Y are the leading axes inside which the path is programmed.
Page 383 Tangential Control (T3) 22.2 Characteristics of "Tangential control" function Corner in the path contour If the path specified by the leading axes has a corner, jumps in the direction of the path tangent occur at this point. In this situation, the following responses can be selected for the following axis: ●...
Page 384: Use Of "Tangential Control" Function
Tangential Control (T3) 22.3 Use of "Tangential control" function 22.3 Use of "Tangential control" function 22.3.1 Overview Definition, activation The "Tangential control" function requires the following sequence in the program: ● Assignment of leading axes and definition of following axis with TANG( ). ●...
Page 385: Definition Of Axis Coupling: Tang
Tangential Control (T3) 22.3 Use of "Tangential control" function 22.3.2 Definition of axis coupling: TANG Programming The programming is carried out using the predefined subroutine TANG( ). The following parameters are transferred: Parameter Value Following axis (rotary axis) Example: C Leading axis 1 (geometrical axis) Example: X Leading axis 2 (geometrical axis)
Page 386: Response At Corners, Activation "With Intermediate Block": Tlift
Tangential Control (T3) 22.3 Use of "Tangential control" function 22.3.4 Response at corners, activation "with intermediate block": TLIFT Programming Following the definition with TANG( ), the TLIFT instruction with the following axis must be written if the corner response "with intermediate block" is required. TLIFT (C) The control considers the associated machine data MD37400 EPS_TLIFT_TANG_STEP for the tangential following rotary axis C.
Page 387: Deleting The Definition Of Axis Coupling: Tangdel
Tangential Control (T3) 22.3 Use of "Tangential control" function 22.3.7 Deleting the definition of axis coupling: TANGDEL Programming An axis coupling definition specified by TANG(...) remains active after TANGOF. This inhibits a plane change or geometry axis switchover. The predefined subroutine TANGDEL( ) may be used to delete the definition of the axis coupling.
Page 388: Limit Angle For Reversal Of Path Direction
Tangential Control (T3) 22.4 Limit angle for reversal of path direction 22.4 Limit angle for reversal of path direction Problem When the axis moves backwards and forwards along the path, the tangent direction turns abruptly through 180 degrees at the path reversal point. This response is not generally desirable for machining operations (e.g.
Page 389: Data Lists
Tangential Control (T3) 22.5 Data lists N70 WALIMON ; Switch on working area limitation N80 X100 N90 X10 ; Before this block is processed, rotary axis C is repositioned in ; an intermediate block, C' = -60 degrees. N200 M2 22.5 Data lists Machine data...
Page 390 Tangential Control (T3) 22.5 Data lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 391: Speed/Torque Coupling, Master-Slave (Te3)
(have) not been licensed using a license key was (were) set" is output. It will not be possible to operate the machine as normal. For information on operations relating to "Setting (an) option(s)", please refer to the section titled "Licensing in SINUMERIK 802D sl" in the "Turning, Milling, Grinding, Nibbling" Operating Instructions. Function The speed/torque coupling function (master-slave) is used for mechanically-coupled axes that are driven by two separate motors.
Page 392 Speed/torque coupling, master-slave (TE3) 23.1 Brief description Figure 23-2 Carriages (linear motor) for temporary coupling Note Each slave axis has exactly one master axis and vice versa. Characteristics ● If traversing is programmed for a slave axis that has already been linked, an alarm is issued.
Page 393: Coupling Diagram
Speed/torque coupling, master-slave (TE3) 23.2 Coupling diagram 23.2 Coupling diagram If the coupling is closed, the slave axis is traversed only with the load-side setpoint speed of the master axis. It is therefore only speed-controlled, not position-controlled. No positional deviation control is implemented between master and slave axes. A torque compensatory controller divides the torque evenly over the master and slave axes.
Page 394: Configuring A Coupling
Speed/torque coupling, master-slave (TE3) 23.3 Configuring a coupling 23.3 Configuring a coupling Static A master-slave coupling is configured in the slave axis only. Each slave axis is assigned one master axis for speed setpoint coupling and one for torque compensation control (default setting). The assignments done in the following machine data are automatically active in each control start-up.
Page 395: Tension Torque
Speed/torque coupling, master-slave (TE3) 23.5 Tension torque Activation/deactivation via the PLC The torque compensation controller can be activated and deactivated directly via PLC interface signal V380x 5000.4. For this purpose, the following machine data must be set: MD37255 MS_TORQUE_CTRL_ACTIVATION = 1 The activated status can be read back via V390x 5000.4.
Page 396: Activating A Coupling
Speed/torque coupling, master-slave (TE3) 23.6 Activating a coupling 23.6 Activating a coupling The type of activation for a master-slave coupling is defined in the following machine data: MD37262 MS_COUPLING_ALWAYS_ACTIVE Depending on the machine configuration, a distinction is made between a permanent and a temporary master-slave coupling.
Page 397: Response On Activation/Deactivation
Speed/torque coupling, master-slave (TE3) 23.7 Response on activation/deactivation 23.7 Response on activation/deactivation Activating/deactivating during axis standstill Activation/deactivation is not active until the axis next comes to a standstill. If the specification is changed, the sequence is the same as for axis replacement. The coupling is closed when the axis comes to a standstill.
Page 398 Speed/torque coupling, master-slave (TE3) 23.7 Response on activation/deactivation Phase 2 In the second phase, the differential speed between the master and slave spindle is used to generate the following synchronism signals. IS "Velocity tolerance coarse" (V390x 5000.3) IS "Velocity tolerance fine" (V390x 5000.2) The associated limits are defined via the following machine data: MD37270 MS_VELO_TOL_COARSE (velocity tolerance coarse) MD37272 MS_VELO_TOL_FINE (velocity tolerance fine).
Page 399 Speed/torque coupling, master-slave (TE3) 23.7 Response on activation/deactivation Deactivation during motion An active coupling is disconnected using the MASLOF instruction. This instruction is executed directly for a spindle in speed control mode. The slave spindle that is rotating at this point in time retains its most recently used speed until the speed is reprogrammed.
Page 400: Axial Interface Signals
Speed/torque coupling, master-slave (TE3) 23.8 Axial interface signals 23.8 Axial interface signals When a master/slave coupling is requested, the PLC axis enables "Servo enable" (V380x 0002.1) and "Pulse enable" (V380x 4001.7) of the slave axis are derived directly from the specifications of the master axis. The separate PLC axis enable signals have no effect.
Page 401: Response In Conjunction With Other Functions
Speed/torque coupling, master-slave (TE3) 23.10 Response in conjunction with other functions 23.10 Response in conjunction with other functions Function Generator To calibrate the speed control circuit for a closed master-slave coupling, a low value should be set in slave axis MD37268 MS_TORQUE_WEIGHT_SLAVE. Traversing of a coupled- motion slave axis is not prevented by the torque compensatory controller in this case.
Page 402 Speed/torque coupling, master-slave (TE3) 23.10 Response in conjunction with other functions Gantry If one master-slave relationship is defined on each side of the gantry grouping to increase the gain, only the leading axis or following axis may be operated as a master axis. Moving to fixed end stop The travel to fixed stop function can be programmed only in the master axis when a coupling is active and has a different effect on the master and slave axes.
Page 403: Supplementary Conditions
Speed/torque coupling, master-slave (TE3) 23.11 Supplementary conditions Hardware and software limit switches Crossing of hardware and software limit switches is detected in coupled axes; the software limit switch is generally overtraveled on slave axes. The alarm is output on the slave axis, while braking is initiated via the master axis.
Page 404: Examples
Speed/torque coupling, master-slave (TE3) 23.12 Examples Modulo rotary axes ● For the slave axis, the actual value in the "System" menu, "Service Display" softkey, exceeds 360 degrees even if modulo operation has been set for the axis using the following machine data: MD30310 ROT_IS_MODULO ●...
Page 405: Close Coupling Via The Plc
Speed/torque coupling, master-slave (TE3) 23.12 Examples 6. Torque distribution between the master and slave axes is 50% to 50% MD37268 MS_TORQUE_WEIGHT_SLAVE[AX2] = 50 7. Parameters of the torque compensatory controller MD37256 MS_TORQUE_CTRL_P_GAIN[AX2] = 0.5 MD37258 MS_TORQUE_CTRL_I_TIME[AX2] = 5.0 23.12.2 Close coupling via the PLC This application allows you to close or separate a master-slave coupling between the machine axes AX1=Master axis and AX2=Slave axis during operation.
Page 406: Close/Separate Coupling Via Part Program
Speed/torque coupling, master-slave (TE3) 23.12 Examples 23.12.3 Close/separate coupling via part program This application allows you to close or separate a master-slave coupling between the machine axes AX1=Master axis and AX2=Slave via the part program. Preconditions ● One configured master axis (MD37250) ●...
Page 407: Data Lists
Speed/torque coupling, master-slave (TE3) 23.13 Data lists Action Effect/comment Interpreting the feedback Link the following PLC IS for the master axis using AND: V390x 0001.7 (current controller active) V390x 0001.6 (speed controller active) V390x 0001.5 (position controller active) Link the following PLC IS for the slave axis using AND: V390x 0001.7 (current controller active) V390x 0001.6 (speed controller active) V390x 5000.7 (master/slave active)
Page 408: Interface Signals
Speed/torque coupling, master-slave (TE3) 23.13 Data lists 23.13.2 Interface signals Number .Bit Name Axis-specific V380x 5000 Activate torque compensatory controller V380x 5000 Activate master-slave coupling V390x 5000 Velocity tolerance "fine" V390x 5000 Velocity tolerance "coarse" V390x 5000 State of torque compensation controller V390x 5000 State of master-slave coupling Turning, Milling, Nibbling...
Page 409: Feed (V1)
Feed (V1) 24.1 Path feedrate F Functionality The feedrate F is the path velocity of the tool along the programmed workpiece contour. The individual axis velocities therefore result from the portion of the axis path in the overall distance to be traversed. The feedrate F is effective for the interpolation types G1, G2, G3, CIP, and CT and is retained in a program until a new F word is written.
Page 410 Feed (V1) 24.1 Path feedrate F Maximum tool path velocity The maximum path velocity is obtained from the maximum velocities of the relevant axes (MD32000 MAX_AX_VELO) and their proportion of the path. The maximum velocity of an axis stored in the machine data cannot be exceeded. CFC feedrate override for circles When machining circular contours using milling tools and the active tool radius compensation (G41/G42), the feedrate at the milling cutter center must be adjusted if the...
Page 411: Feedrate With G33, G34, G35 (Thread Cutting)
Feed (V1) 24.1 Path feedrate F 24.1.1 Feedrate with G33, G34, G35 (thread cutting) Note The thread cutting function with G33, G34, and G35 is not available for versions G/N plus and pro. Types of thread cutting G33 - thread with constant pitch G34 - thread with (linearly) increasing pitch G35 - thread with (linearly) decreasing pitch Axis velocity...
Page 412 Feed (V1) 24.1 Path feedrate F Information ● The spindle speed override switch should remain unchanged during thread machining (tapping). ● The feedrate override switch is irrelevant in a block with G33, G34, G35. Programmable runin and runout path: DITS, DITE The run-in and run-out path is to be traversed in addition to the required thread.
Page 413: Feedrate For G63 (Tapping With Compensation Chuck)
Feed (V1) 24.1 Path feedrate F ● SD42010 = < 0 to -1: Starting/braking of the feedrate axis at configured acceleration rate. Jerk according to current BRISK/SOFT programming. ● SD42010 = 0: Abrupt starting/braking of the feedrate axis on thread cutting. ●...
Page 414: Feedrate For G331, G332 (Tapping Without Compensation Chuck)
Feed (V1) 24.1 Path feedrate F The compensation chuck absorbs possible path differences of the drill axis to a limited extent. References /BP_/ Operation and Programming 24.1.3 Feedrate for G331, G332 (tapping without compensation chuck) Note The tapping function without compensation chuck is not available for versions G/N plus and pro.
Page 415: Feedrate For Chamfer/Rounding: Frc, Frcm
Feed (V1) 24.1 Path feedrate F 24.1.4 Feedrate for chamfer/rounding: FRC, FRCM Chamfer/rounding You can insert the chamfer (CHF or CHR) or rounding (RND) elements into a contour corner. If you wish to round several contour corners sequentially by the same method, use "Modal rounding"...
Page 416: Rapid Traverse G0
Feed (V1) 24.2 Rapid traverse G0 24.2 Rapid traverse G0 Application The rapid traverse movement G0 is used for rapid positioning of the tool, but not for direct workpiece machining. All axes can be traversed simultaneously. This results in a straight path.
Page 417: Feedrate Control
Feed (V1) 24.3 Feedrate control 24.3 Feedrate control 24.3.1 Overview Figure 24-1 Possibilities for programming and controlling the feedrate 24.3.2 Feedrate disable and feedrate/spindle stop General The "Feed disable" or "Feed/spindle stop" brings the axes to a standstill. The path contour is maintained (exception: G33 block).
Page 418: Feedrate Override Via A Machine Control Panel
Feed (V1) 24.3 Feedrate control Feed stop for axes in the WCS The "Feed stop" interface signals (V3200 1000.3, V32001 004.3, and V3200 1008.3) are used to stop the geometry axes (axes in the WCS) during traversing in the workpiece coordinate system (WCS) in the JOG mode.
Page 419 Feed (V1) 24.3 Feedrate control Channel-specific feedrate and rapid traverse override One enable signal and one byte are provided on the PLC interface for the override factor in percent for feedrate and rapid traverse: ● IS "Feedrate override" (VB3200 0004) ●...
Page 420: Data Lists
Feed (V1) 24.4 Data lists The spindle override is active with G33, but it should not be actuated for reasons of accuracy; also active with G331, G332. In the case of G63, the spindle override is set to a fixed value of 100%. Override active The set override values are effective in all operating modes and machine functions.
Page 421: Interface Signals
Feed (V1) 24.4 Data lists Number Identifier Name 42010 THREAD_RAMP_DISP Acceleration behavior of the feedrate axis when thread cutting 42110 DEFAULT_FEED Default value for path feed 24.4.2 Interface signals Number Name Channel-specific V3200 0000 Activate dry run feed V3200 0004 Feed override V3200 0005 Rapid traverse override...
Page 422 Feed (V1) 24.4 Data lists Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 423: Tool: Compensation And Monitoring (W1)
Tool: Compensation and Monitoring (W1) 25.1 Tool and tool compensation overview Characteristics The SINUMERIK 802D sl control is capable of calculating the tool compensation data for different tool types (drill, milling cutter, turning tool, ...). ● Length compensation ● Radius compensation ●...
Page 424: Tool
The following maximum values for tool compensation blocks can be stored simultaneously in the control system: ● SINUMERIK 802D sl value: 32 data fields (D numbers) ● SINUMERIK 802D sl plus: 64 data fields (D numbers) ● SINUMERIK 802D sl pro: 128 data fields (D numbers) The tool cutting edge is programmed with D1 (edge 1) to D9 (edge 9).
Page 425: Tool Monitoring
Tool: Compensation and Monitoring (W1) 25.4 Tool monitoring Activating the tool offset D1 to D9 activates the tool compensation (offset) for a cutting edge on the active tool. Tool length compensation and tool radius compensation can be activated at different times: ●...
Page 426 Tool: Compensation and Monitoring (W1) 25.4 Tool monitoring Monitoring counter Monitoring counters exist for each monitoring type. The monitoring counters count from a set value >0 down to zero. When a counter has decremented to a value of ≤0, the limit value is reached.
Page 427: Tool Life Monitoring
Tool: Compensation and Monitoring (W1) 25.4 Tool monitoring System variables for active tool The following can be read in the NC program via system variables: ● $P_TOOLNO: Number of the active tool T ● $P_TOOL: Active D number of the active tool Interface signals Some monitoring conditions are made available to the PLC: ●...
Page 428 Tool: Compensation and Monitoring (W1) 25.4 Tool monitoring Setpoint update with RESETMON( ) The RESETMON(state, t, d, mon) function sets the actual value to the setpoint: ● For all cutting edges or only for a specific cutting edge of a specific tool ●...
Page 429: Workpiece Count Monitoring
Tool: Compensation and Monitoring (W1) 25.4 Tool monitoring 25.4.3 Workpiece count monitoring The workpiece count of the active cutting edge of the active tool is monitored. The workpiece count monitoring records all tool cutting edges used to produce a workpiece. If the workpiece count is changed by an operator input, the monitoring data of all the cutting edges that have become active since the last workpiece count are adjusted.
Page 430: Examples Of The Service Life Monitoring
Tool: Compensation and Monitoring (W1) 25.4 Tool monitoring Note The SETPIECE( ) function is not active during the block search. Note Direct writing of $TC_MOP4[t,d] is recommended only in simple cases. A subsequent block with the STOPRE command is required. Setpoint refreshing The setpoint update, i.e.
Page 431: Special Handling Of Tool Compensation
; Set service life in minutes 25.5 Special handling of tool compensation For SINUMERIK 802D sl plus and pro, tool compensation (offset) can be handled as follows. Influence of setting data Using specific setting data the operator / programmer can influence the calculation of the length compensation of the used tool: ●...
Page 432 Tool: Compensation and Monitoring (W1) 25.5 Special handling of tool compensation The assignment of the tool lengths 1 to 3 to the geometry axes for turning tools (tool types 500 to 599) results from the value of the setting data SD42940 in accordance with the following table: Plane/value Length 1...
Page 433 Tool: Compensation and Monitoring (W1) 25.5 Special handling of tool compensation Length compensation for tool type (SD42950 TOOL_LENGTH_TYPE) Value of the setting data equal to 0: The behavior corresponds to the standard definition: The lengths 1 to 3 in geometry and wear are assigned to the actual tool type (milling cutter / drill or turning tool).
Page 434: Data Lists
Tool: Compensation and Monitoring (W1) 25.6 Data lists 25.6 Data lists 25.6.1 Machine data Number Identifier Name General 18080 ** MM_TOOL_MANAGEMENT_MASK Memory reservation for the tool monitoring Channel-specific 20310 ** TOOL_MANAGEMENT_MASK Activation of the tool monitoring 22360 TOOL_PARAMETER_DEF_MASK Definition of tool parameters 22550 TOOL_CHANGE_MODE New tool offsets with M function...
Page 435: Appendix
Appendix List of abbreviations Active Line Module - infeed module for drives ASCII American Standard Code for Information Interchange: American coding standard for the exchange of information by means of 7-bit character coding ASUB Asynchronous subroutine AUXFU Auxiliary Function Mode of operation Mode group BERO Proximity limit switch...
Page 436 Appendix A.1 List of abbreviations Main Spindle Drive Hardware HW Config SIMATIC S7 tool for configuration and parameterization of hardware components within an S7 project HW limit switch Hardware limit switch Commissioning Increment Interpolator Jogging: Setup mode Gain factor of control loop Position controller Machine Control Panel Machine Data...
Page 437 Appendix A.1 List of abbreviations Personal Computer Panel Control Unit - CNC integrated into the operator panel for user interface, system software and soft PLC Program Invocation (PI service, PI index → ASUB) Programmable Logic Control PROFIBUS Process Field Bus: Serial data bus Program Test Point-To-Point Reference point approach function...
Page 438 Appendix A.1 List of abbreviations Tool Radius Compensation Tool Tool Offset Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 439: Overview
Appendix A.2 Overview Overview Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 440 Appendix A.2 Overview Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 441: Glossary
Glossary Absolute dimensions A destination for an axis movement is defined by a dimension that refers to the origin of the currently active coordinate system. See → Incremental dimension. Acceleration with jerk limitation In order to optimize the acceleration response of the machine whilst simultaneously protecting the mechanical components, it is possible to switch over in the machining program between abrupt acceleration and continuous (jerk-free) acceleration.
Page 442 Glossary Auxiliary functions Auxiliary functions enable part programs to transfer → parameters to the → PLC, which then trigger reactions defined by the machine manufacturer. Axes In accordance with their functional scope, the CNC axes are subdivided into: ● Axes: interpolating path axes ●...
Page 443 Glossary Blank Workpiece as it is before it is machined. Block "Block" is the term given to any files required for creating and processing programs. Block search For debugging purposes or following a program abort, the "Block search" function can be used to select any location in the part program at which the program is to be started or resumed.
Page 444 Glossary Compensation table Table containing interpolation points. It provides the compensation values of the compensation axis for selected positions on the basic axis. Compensation value Difference between the axis position measured by the encoder and the desired, programmed axis position. Continuous-path mode The objective of continuous-path mode is to avoid substantial deceleration of the →...
Page 445 Glossary Diagnostics The control has both a self-diagnostics program as well as test functions for servicing purposes: status, alarm, and service displays Dimensions specification, metric and inches Position and pitch values can be programmed in inches in the machining program. Irrespective of the programmable dimensions ( ), the controller is set to a basic system.
Page 446 Glossary Fixed machine point Point that is uniquely defined by the machine tool, e.g. machine reference point. Fixed-point approach Machine tools can approach fixed points such as a tool change point, loading point, pallet change point, etc. in a defined way. The coordinates of these points are stored in the control. The control traverses the relevant axes in →...
Page 447 Glossary High-speed digital inputs/outputs The digital inputs can be used for example to start fast CNC program routines (interrupt routines). High-speed, program-driven switching functions can be initiated via the digital CNC outputs Identifier In accordance with DIN 66025, words are supplemented using identifiers (names) for variables (arithmetic variables, system variables, user variables), subroutines, key words, and words with multiple address letters.
Page 448 Glossary Interrupt routine Interrupt routines are special → subroutines that can be started by events (external signals) in the machining process. A part program block which is currently being worked through is interrupted and the position of the axes at the point of interruption is automatically saved. Control operating mode (setup mode): In JOG mode, the machine can be set up.
Page 449 Glossary Look Ahead The Look Ahead function is used to achieve an optimal machining speed by looking ahead over an assignable number of traversing blocks. Machine axes Physically existent axes on the machine tool. Machine control panel An operator panel on a machine tool with operating elements such as keys, rotary switches, etc., and simple indicators such as LEDs.
Page 450 Numerical Control: Numerical control (NC) includes all components of machine tool control: → NCK, → PLC, HMI, → COM. Note A more correct term for the SINUMERIK 802D sl control would be: Computerized Numerical Control Numerical Control Kernel: Component of the NC that executes the → part programs and basically coordinates the motion operations for the machine tool.
Page 451 Glossary The scope for implementing individual solutions (OEM applications) for the SINUMERIK 802D sl has been provided for machine manufacturers, who wish to create their own user interface or integrate process-oriented functions in the control. Overall reset In the event of an overall reset, the following memories of the → CPU are deleted: ●...
Page 452 Glossary Peripheral module I/O modules represent the link between the CPU and the process. I/O modules are: ● → Digital input/output modules ● → Analog input/output modules Programmable Logic Control Component of → NC: Programmable control for processing the control logic of the machine tool. PLC Programming The PLC is programmed with STEP 7.
Page 453 Glossary Programmable working area limitation Limitation of the motion space of the tool to a space defined by programmed limitations. Protection zone Three-dimensional zone within the → working area into which the tool tip must not pass. R parameters Arithmetic parameter that can be set or queried by the programmer of the → part program for any purpose in the program.
Page 454 Glossary Scaling Component of a → frame that implements axis-specific scale modifications. Serial RS-232-C interface A serial RS-232-C interface is available on the PCU for the data input/output. Machining programs and manufacturer and user data can be loaded and saved via this interface. Setting data Data which communicates the properties of the machine tool to the NC, as defined by the system software.
Page 455 Glossary Subblock Block preceded by "N" containing information for a sequence, e.g. positional data. Subroutine Sequence of statements of a → part program that can be called repeatedly with different defining parameters. The subroutine is called from a main program. Every subroutine can be protected against unauthorized read-out and display.
Page 456 Glossary Tool radius compensation To directly program a desired → workpiece contour, the control must traverse an equistant path to the programmed contour taking into account the radius of the tool that is being used Transformation Additive or absolute work offset of an axis. Traversing range The maximum permissible traversing range for linear axes is ±...
Page 457 Glossary Velocity control In order to achieve an acceptable traverse rate in the case of very slight motions per block, an anticipatory evaluation over several blocks (→ Look Ahead) can be specified. Work offset Specifies a new reference point for a coordinate system through reference to an existing zero point and a →...
Page 458 Glossary Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...
Page 459: Index
Index Commands MEAS, MEAW, 251 Compensation table, 211 Computational resolution, 117 Concurrent positioning axes, 307 Continuous travel, 143 Acceleration, 141 Contour violation, 52 Acceleration characteristic, 278 Coupled motion, 291 Acceleration profiles, 69 Cyclic signal exchange, 20 Abrupt acceleration changes, 69 Acceleration with jerk limitation, 69 Actual-value processing, 129 Actual-value resolution, 129...
Page 460 Index Tapping with compensation chuck G63, 413 Thread cutting G33, 411 Approaching a fixed point, 148 Fixed point positions, 151 Fixed stop, 73 Following block velocity, 67 Following error compensation, 226 Language command SPN, 283 SPP, 282 Leading axis, 87 Gantry Leadscrew error compensation (LEC), 210 Referencing and synchronizing, 90...
Page 461 Index PI services, 30 Units of measurement, 334 Plausibility check, 325 Rotary axes, PLC axis, 307 Axis addresses, 333 PLC service display, 252 Rotary axis PLC/NCK interface, 19 Definition, 333 Position control, 134 with rotary encoder on motor, 130 Position control loop, 133 Position controller gain, 44 Position display, 207 Positioning window, 44...
Page 462 Index Velocities, 115 Velocity reduction, 64 Velocity reduction according to overload factor, 63 Working area limitation, 335 Turning, Milling, Nibbling Function Manual, 11/2012, 6FC5397-1CP10-5BA0...

Siemens SINUMERIK 802D sl Function Manual

1 Various Interface Signals (A2)

2 Axis Monitoring (A3)

3 Continuous Path Mode, Exact Stop and Lookahead (B1)

4 Acceleration (B2)

5 Travel to Fixed Stop (F1)

6 Gantry Axes (G1)

7 Velocities, Setpoint/Actual Value Systems, Closed-Loop Control (G2)

8 Manual and Handwheel Travel (H1)

9 Auxiliary Function Outputs to PLC (H2)

10 Operating Modes, Program Operation (K1)

11 Compensation (K3)

12 Kinematic Transformation (M1)

13 Measurement (M5)

14 Emergency off (N2)

15 Punching and Nibbling (N4)

16 Transverse Axes (P1)

17 Positioning Axes (P2)

18 Reference Point Approach (R1)

19 Rotary Axes (R2)

20 Spindle (S1)

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