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Siemens SINUMERIK 802D sl Function Manual Download Page 295

 

Punching and Nibbling (N4) 

 

15.6 Protection zones 

Turning, Milling, Nibbling 
Function Manual, 11/2012, 6FC5397-1CP10-5BA0 

295

 

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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 

Summary of Contents for SINUMERIK 802D sl

Page 1: ...Function Manual Valid for Control system Software version SINUMERIK 802D sl G N 1 4 SP7 SINUMERIK 802D sl T M 1 4 SP7 11 2012 6FC5397 1CP10 5BA0 Preface Various Interface Signals A2 1 Axis Monitoring A3 2 Continuous Path Mode Exact Stop and LookAhead B1 3 Acceleration B2 4 Travel to fixed stop F1 5 Gantry axes G1 6 Velocities Setpoint Actual Value Systems Closed Loop Control G2 7 Manual and Handwh...

Page 2: ...Siemens AG Industry Sector Postfach 48 48 90026 NÜRNBERG GERMANY Order number 6FC5397 1CP10 5BA0 Ⓟ 08 2013 Technical data subject to change Copyright Siemens AG 2005 2012 All rights reserved ...

Page 3: ...Manual Continuation Positioning Axes P2 17 Reference Point Approach R1 18 Rotary Axes R2 19 Spindle S1 20 Indexing Axes T1 21 Tangential Control T3 22 Speed torque coupling master slave TE3 23 Feed V1 24 Tool Compensation and Monitoring W1 25 Appendix A ...

Page 4: ...be operated only by personnel qualified for the specific task in accordance with the relevant documentation in particular its warning notices and safety instructions Qualified personnel are those who based on their training and experience are capable of identifying risks and avoiding potential hazards when working with these products systems Proper use of Siemens products Note the following WARNIN...

Page 5: ...end any questions about the technical documentation e g suggestions for improvement corrections to the following address docu motioncontrol siemens com My Documentation Manager MDM Under the following link you will find information to individually compile OEM specific machine documentation based on the Siemens content www siemens com mdm Training For information about the range of training courses...

Page 6: ...e machine manufacturer Other functions not described in this documentation might be executable in the control However no claim can be made regarding the availability of these functions when the equipment is first supplied or in the event of servicing For the sake of simplicity this documentation does not contain all detailed information about all types of the product and cannot cover every conceiv...

Page 7: ...nds for the axis 0 Axis 1 1 Axis 2 n Axis n 1 Machine data MD MD_NR MD_NAME description e g MD30300 IS_ROT_AX rotary axis Setting data SD SD_NR SD_NAME description e g SD41200 JOG_SPIND_SET_VELO JOG velocity for the spindle The chapter titles are supplemented by a code in brackets e g Chapter 1 EMERGENCY STOP N2 This brief description is used in cross references to other chapters The machine and s...

Page 8: ...2 to 7 are described in this document Protection level 1 machine data is only referred to in special cases expert mode Data types The following data types are used in the control DOUBLE Floating point value 64 bit value Input limits from 4 19 10 307 to 1 67 10308 DWORD Integer values 32 bit values Input limits from 2 147 483 648 to 2 147 483 648 decimal as hexadecimal value 0000 through FFFF BYTE ...

Page 9: ...B 32 1 6 1 3 Reading variables from the NCK area 33 1 6 1 4 Writing variables from the NCK area 34 1 6 2 NC variable 36 1 7 Signals from PLC 40 2 Axis Monitoring A3 41 2 1 Overview of monitoring functions 41 2 2 Motion monitoring functions 41 2 2 1 Contour monitoring 41 2 2 2 Position monitoring 42 2 2 3 Standstill monitoring 44 2 2 4 Clamping monitoring 45 2 2 5 Speed setpoint monitoring 46 2 2 6...

Page 10: ...3 6 2 Interface signals 68 4 Acceleration B2 69 4 1 Acceleration profiles 69 4 2 Jerk limitation on interpolator level 69 4 3 Jerk limitation in JOG mode 70 4 4 Percentage acceleration correction ACC 71 4 5 Data lists 72 5 Travel to fixed stop F1 73 5 1 Brief description 73 5 2 Functionality 73 5 3 Response to RESET and function abort 80 5 4 Block search response 80 5 5 Miscellaneous 81 5 6 Data l...

Page 11: ... 7 2 Metric inch measuring system 118 7 2 1 Conversion of basic system by part program 119 7 2 2 Manual switchover of the basic system 120 7 3 Setpoint actual value system 123 7 3 1 General 123 7 3 2 Drives with DRIVE CLiQ 124 7 3 3 Speed setpoint and actual value routing 126 7 3 4 Speed setpoint output 128 7 3 5 Actual value processing 129 7 3 6 Evaluation of internal drive variables 131 7 4 Clos...

Page 12: ...Monitoring functions in the individual modes 171 10 2 4 Interlocks in the individual modes 172 10 3 Processing a part program 173 10 3 1 Program mode and part program selection 173 10 3 2 Start of part program or part program block 173 10 3 3 Part program interruption 174 10 3 4 RESET command 175 10 3 5 Program control 176 10 3 6 Program status 176 10 3 7 Channel status 177 10 3 8 Eventdriven prog...

Page 13: ...ol 227 11 5 Data lists 228 11 5 1 Machine data 228 11 5 2 Setting data 228 11 5 3 Interface signals 228 12 Kinematic Transformation M1 229 12 1 Brief description 229 12 2 TRANSMIT 230 12 2 1 Overview 230 12 2 2 TRANSMIT configuration 231 12 3 TRACYL 236 12 3 1 Overview 236 12 3 2 TRACYL configuration 240 12 3 3 Programming example TRACYL 245 12 4 Special features of TRANSMIT and TRACYL 247 12 5 Da...

Page 14: ...70 15 2 5 PLC signals specific to punching and nibbling 271 15 2 6 Punching and nibbling specific reactions to standard PLC signals 271 15 2 7 Signal monitoring 272 15 3 Activation and deactivation 272 15 3 1 Language commands 272 15 3 2 Functional expansions 276 15 4 Automatic path segmentation 280 15 4 1 General information 280 15 4 2 Operating characteristics with path axes 282 15 4 3 Response ...

Page 15: ...marks with synchronization 324 18 3 5 Phase 2 Travel to fixed stop 325 18 4 Referencing with absolute encoders 328 18 4 1 General 328 18 4 2 Operator assisted calibration 328 18 5 Secondary conditions for absolute encoders 329 18 5 1 Calibrating absolute encoders 329 18 6 Data lists 330 18 6 1 Machine data 330 18 6 2 Interface signals 331 19 Rotary Axes R2 333 19 1 General 333 19 2 Modulo 360 degr...

Page 16: ... axes in AUTOMATIC modes 372 21 2 4 Traversing of indexing axes by PLC 372 21 3 Parameterization of indexing axes 373 21 4 Programming of indexing axes 375 21 5 Starting up indexing axes 376 21 6 Special features of indexing axes 379 21 7 Data lists 380 21 7 1 Machine data 380 21 7 2 Interface signals 380 22 Tangential Control T3 381 22 1 Brief description 381 22 2 Characteristics of Tangential co...

Page 17: ...rogram 406 23 12 4 Release the mechanical brake 406 23 13 Data lists 407 23 13 1 Machine data 407 23 13 2 Interface signals 408 24 Feed V1 409 24 1 Path feedrate F 409 24 1 1 Feedrate with G33 G34 G35 thread cutting 411 24 1 2 Feedrate for G63 tapping with compensation chuck 413 24 1 3 Feedrate for G331 G332 tapping without compensation chuck 414 24 1 4 Feedrate for chamfer rounding FRC FRCM 415 2...

Page 18: ... 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 A Appendix 435 A 1 List of abbreviations 435 A 2 Overview 439 Glossary 441 Index 459 ...

Page 19: ...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 The PLC user program does not have to handle the exchange of data and signals From the users point of view this takes place automatically 6SLQGOH Q LV Q LV 6LJQDOV IURP 1 6LJQDOV WR 1 LV 6LJQDOV IURP 1 6LJQDOV WR 1 HQHUDO 6LJQDOV IURP 1 6LJQDOV WR 1 6LJQDOV IURP...

Page 20: ...nel signals Axis spindle signals 1 2 Signals from PLC to NCK 1 2 1 Access authorization Access authorization 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 provide...

Page 21: ...go 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 The next program block is then started Axis spindle disable V380x 0001 3 IS Axis spindle disable can be used for test purposes Axis disable for axis If IS Axis disable is output for this axis ...

Page 22: ...e interpolator but derived from the actual position value Since recording of the actual position value of the axis continues it is not necessary to re home the axis when follow up mode is cancelled Standstill clamping and positioning monitoring are not effective in follow up mode Effect The IS Follow up mode is only of relevance if the drive controller enable has been removed e g by IS Controller ...

Page 23: ...ts occur Application The traversing axes must be brought to a standstill by a rapid stop due to a fault 3 By the control if the following event occurs IS EMERGENCY STOP V2600 0000 1 is active Removal of controller enable for a moving axis spindle The spindle is braked to standstill with rapid stop taking account of MD36610 AX_EMERGENCY_STOP_TIME duration of the braking ramp in error states Alarm 2...

Page 24: ... 4001 0 to 2 Using bit combination A B C the PLC user program can select up to eight different drive parameter sets Speed controller integrator disabled V380x 4001 6 The PLC user program inhibits the integrator of the speed controller for the drive The speed controller is thus switched from PI to P controller Pulse enable V380x 4001 7 The PLC user program enables the pulses for the axis spindle Ho...

Page 25: ...ol 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 NCK alarm with processing stop present V3300 0004 7 The control sends this signal to the PLC to indicate that at least one NCK alarm which has interrupted or aborted the current program run processing stop is active fo...

Page 26: ...er sets can be selected by the PLC Drive ready V390x 4001 5 Checkback signal indicating that the drive is ready The conditions required for traversing the axis spindle are fulfilled Integrator for n controller disabled V390x 4001 6 The speed controller integrator is disabled The speed controller has thus been switched from PI to P controller Pulse enabled V390x 4001 7 The pulse enable for the driv...

Page 27: ...speed nact is lower than the set threshold speed nx nact nset V390x 4002 6 The PLC receives this signal confirming that the actual speed nact has reached the new setpoint allowing for the tolerance band set in the drive and continues to remain within the tolerance band 1 4 Signals from PLC to HMI OP key disable V1900 5000 2 IS OP key disable can be applied to disable 1 signal or enable 0 signal th...

Page 28: ...ATH _N_CUS_DIR Each line contains two columns These are separated via tabs or blanks or characters The first column contains the program number the second the program name Examples _N_PLCPROG_LST PATH _N_CUS_DIR 1 BOHR2 MPF 2 PUMPT14 MPF 54 BOHR3 MPF Program number VB 1700 1000 corresponds to the following IS Program has been selected V1700 2000 0 Program selection error V1700 2000 1 When a progra...

Page 29: ... automatically deleted by the PLC operating system 1 5 Signals from HMI to PLC Program has been selected V1700 2000 0 Successful selection of the required NC program is signaled back from the HMI to the PLC This signal is available for one PLC cycle It corresponds with VB1700 1000 Program selection error V1700 2000 1 Failed selection of the required NC program is signaled back from the HMI to the ...

Page 30: ...art Only one service can run at a time The service is selected via V1200 0000 1 and V1200 0000 2 Service V1200 0000 2 V1200 0000 1 Start PI service in the NCK area 1 0 Read variables from the NCK area 0 0 Write variables from the NCK area 0 1 Start A job is started by setting the signal V1200 0000 0 1 A new job can only be started if the previous job has been completed i e the acknowledgement sign...

Page 31: ...of the valid range Variable index V1200 1000 outside of the valid range After evaluating the result the Start signal V1200 0000 0 is reset by the user The PLC operating system then resets Job completed or Error in job UURU LQ MRE RE FRPSOHWHG 6WDUW Figure 1 3 Pulse diagram Explanations regarding the pulse diagram 1 Starting of the job by setting Start Job completed and Error in job must be reset 2...

Page 32: ...ority 1 VB1200 0001 2 Assignment of Interrupt 2 to the CMA_DIR PLCASUP2_SPF program The interrupt has Priority 2 The following must be taken into account during the initialization The PI service ASUB requires executing only once after a restart and is then retained An initialization may only be performed when the channel is not active If a Ramp up program event has been configured the initializati...

Page 33: ...relevant field index must be specified as a column and or line index e g R parameter no Values The range 120x 1008 11 is not relevant for reading 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 from VB120x 3004 are entered type specific...

Page 34: ...index See Section NC variable 1 6 1 4 Writing variables from the NCK area 1 to 8 values can be written with a write job variable x 0 7 There is a variable specific part of the interface for this Job V120x 1000 Result V120x 3000 Job variable specific part NC variable The NC variable is selected in the variable index VB120x 1000 see Section NC variable Area number column line index VB120x 1001 VB120...

Page 35: ...ress 10 Object does not exist Values The range 120x 3004 07 is not relevant for writing Relevant interface signals Address Name Valid values V1200 0000 0 Start 0 1 V1200 0000 1 Write variable 1 V1200 0000 2 PI service 0 Job global part VB1200 0001 Number of variables 1 8 VB120x 1000 Variable index VB120x 1001 Area number VB120x 1002 Line index NCK variable VB120x 1004 Column index NCK variable Job...

Page 36: ...arameters please refer to Chapter Tool Offset W1 Variable cuttEdgeParam r w VB120x 1000 1 VB120x 1001 VW120x 1002 EdgeNo 1 numCuttEdgeParams ParameterNo WORD VW120x 1004 T number 1 32000 WORD VD120x 1008 Write Data to NCK variable x data type of the variables REAL VD120x 3004 Read Data from NCK variable x data type of the variables REAL Variable numCuttEdgeParams Number of P elements of an edge Va...

Page 37: ... workpiece and tool gauging 11 WPFRAME current 5th system frame workpiece reference points 12 CYCFRAME current 6th system frame cycles The max frame index is 12 The value of numMachAxes is contained in the variable with variable index 4 Variable linShift r VB120x1000 3 VB120x1001 VW120x1002 Frame index numMachAxes axis number VW120x1004 VD120x1008 VD120x3004 Read Data from NCK variable x data type...

Page 38: ... Variable actLineNumber Line number of the current NC block 0 Prior to program start 1 Not available due to error 2 Not available due to DISPLOF Variable actLineNumber r VB120x1000 6 VB120x1001 VW120x1002 VW120x1004 VD120x1008 VD120x3004 Read Data from NCK variable x data type of the variables DINT Variable r0078 1 CO Current actual value torque generating Arms Index 1 Smoothed with p0045 Variable...

Page 39: ...120x1008 VD120x3004 Read Data from NCK variable x data type of the variables REAL Variable r0081 CO Torque utilization in percent Variable r0081 r VB120x1000 12 VB120x1001 No of drive module VW120x1002 VW120x1004 VD120x1008 VD120x3004 Read Data from NCK variable x data type of the variables REAL Variable r0082 1 CO Active power actual value kW Index 1 Smoothed with p0045 Variable r0082 0 2 r VB120...

Page 40: ...on Manual 11 2012 6FC5397 1CP10 5BA0 1 7 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 0 0 Ramp up with default values 0 1 Ramp up with saved data 1 0 ...

Page 41: ...onitoring Function The principle on which the contour monitoring function works is the constant comparison of the measured actual position value with that calculated from the NC position setpoint For the precalculation of the following error a model is used that simulates the dynamics of the position control including feedforward control So that the monitoring function does not respond incorrectly...

Page 42: ...toring in MD36400 The actual servo gain factor must correspond to the desired servo gain factor set via MD32200 POSCTRL_GAIN servo gain factor With analog spindles MD32260 RATED_VELO rated motor speed and MD32250 RATED_OUTVAL rated output voltage must be checked Check optimization of the speed controller Check smooth running of the axes Check machine data for traversing movements feed override acc...

Page 43: ...s and position controlled spindles Deactivation When the programmed Exact stop limit fine has been reached or a new setpoint has been output e g for positioning according to Exact stop coarse followed by a block change the position monitoring is deactivated Effect If the limit value for Exact stop fine has not yet been reached when the positioning monitoring time has elapsed the following action i...

Page 44: ...e set to a relatively long value Position controller gain high max position monitoring time can be set to a relatively short value Note The size of the positioning window affects the block change time The smaller the tolerances that are selected the longer the positioning action will take which in turn means a longer time before the next command can be executed 2 2 3 Standstill monitoring Function...

Page 45: ...scillation change machine data for control gain MD32200 POSCTRL_GAIN servo gain factor Standstill window too small change machine data MD36030 STANDSTILL_POS_TOL standstill tolerance Axis is mechanically pushed out of position eliminate cause 2 2 4 Clamping monitoring Function If the axis must be clamped once it has been positioned the clamping monitoring function can be activated via IS Clamping ...

Page 46: ...ction Speed setpoint monitoring checks whether the setpoint specification does not exceed the maximum permissible drive speed in MD 36210 MD36210 CTRLOUT_LIMIT maximum speed setpoint If required the speed is limited to this value and the axis spindle stopped and an alarm output The maximum speed for the axes in percent exceeds the speed at which the velocity in MD3200 MAX_AX_VELO is reached 100 Th...

Page 47: ...till The default value of this time is zero Using speed setpoint limiting will turn the control loop into a non linear control loop This generally causes contour deviations if speed setpoint limiting is continued for an axis A control margin must therefore be set see the section titled Speed setpoint output Causes of errors A measuring circuit error or drive error is present Setpoints are too high...

Page 48: ...s then these are also braked by rapid stop with following error reduction default for partial position setpoint 0 Troubleshooting tips Check actual values Check position control direction control sense Check MD36200 AX_VELO_LIMIT threshold value for velocity monitoring Check speed setpoint cable for analog spindles 2 3 Encoder monitoring functions 2 3 1 Encoder limit frequency monitoring Function ...

Page 49: ...standstill with rapid stop with open position control loop along a speed setpoint ramp The braking ramp time is set in MD36610 AX_EMERGENCY_STOP_TIME duration of the braking ramp for error states If the axis is assigned to an interpolatory grouping with other axes then these are also braked by rapid stop with following error reduction default for partial position setpoint 0 Remedy After the axes h...

Page 50: ...re also braked using a rapid stop with following error reduction default for partial position setpoint 0 Causes of errors MD36300 ENC_FREQ_LIMIT encoder limit frequency set too high Encoder cable damaged Encoder or encoder electronics defective Note When an error occurs in the measuring circuit interface signal Referenced synchronized 1 V390x 0000 4 is cancelled i e the axis must be re referenced ...

Page 51: ...E_MODE_CHOICE braking behavior at hardware limit switch If the axis is assigned to an interpolatory grouping with other axes then these are also stopped according to the method selected in MD36600 BRAKE_MODE_CHOICE braking behavior at hardware limit switch The direction keys in the approach direction are disabled Remedy Reset Move in the opposite direction in JOG mode Correct the program 2 4 2 Sof...

Page 52: ...s Depending on the mode different responses to an attempted software limit switch violation are possible AUTO MDA The block that would violate the software limits switches is not started The previous block is terminated properly Program execution is terminated Alarm 10720 Software limit switch or is signaled JOG The axis stops at the software limit switch position Alarm 10621 Axis at software limi...

Page 53: ... to determine whether the monitor is to take account of the tool radius One pair of values minus plus is possible for each axis to describe the protected working area Define working area limits The working area limits can be defined or changed in two ways Via the operator panel in the Parameters operating area using the following setting data SD43430 WORKAREA_LIMIT_MINUS Working area limitation mi...

Page 54: ...ation can be activated with the modal G code WALIMON and deactivated with WALIMOF The working area limitation does not function for endlessly turning rotary axes i e if MD30310 ROT_IS_MODULO 1 Modulo conversion for rotary axis and spindle Effect reaction Depending on the mode the response to an attempted violation of the working area limitation can be different AUTO MDA The block that violates the...

Page 55: ...rbox MD31050 DRIVE_AX_RATIO_DENOM load gearbox denominator MD31060 DRIVE_AX_RATIO_NUMERA load gearbox numerator Gear ratio encoder possibly for spindle MD31070 DRIVE_ENC_RATIO_DENOM measuring gearbox denominator MD31080 DRIVE_ENC_RATIO_NUMERA measuring gearbox numerator MD32810 EQUIV_SPEEDCTRL_TIME Equivalent time constant speed control loop for feedforward control Encoder resolution MD31020 ENC_R...

Page 56: ...TOL Standstill tolerance 36040 STANDSTILL_DELAY_TIME Delay time standstill monitoring 36050 CLAMP_POS_TOL Clamping tolerance with Clamping active interface signal 36060 STANDSTILL_VELO_TOL Maximum velocity speed Axis spindle stationary 36100 POS_LIMIT_MINUS 1 Minus software limit switch 36110 POS_LIMIT_PLUS 1 Plus software limit switch 36120 POS_LIMIT_MINUS2 2 Minus software limit switch 36130 POS...

Page 57: ...ion 43420 WORKAREA_LIMIT_PLUS Working area limitation plus 43430 WORKAREA_LIMIT_MINUS Working area limitation minus 2 6 3 Interface signals Number Bit Name Axis spindle specific V380x 0001 5 Position measuring system 1 V380x 0002 3 Clamping in progress V380x 0003 6 Velocity spindle speed limitation V380x 1000 0 1 Hardware limit switch minus hardware limit switch plus V380x 1000 2 3 2 Software limi...

Page 58: ...Axis Monitoring A3 2 6 Data lists Turning Milling Nibbling 58 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 59: ...ond way is called continuouspath mode and it attempts to avoid deceleration of the path velocity at the block boundary in order to change to the next block with as little change of path velocity as possible LookAhead is a procedure in continuous path mode that achieves velocity control with LookAhead over several NC part program blocks 3 2 General Machine axes that are related interpolatively must...

Page 60: ...cesses cause axes to stop PLC acknowledgment If acknowledgment by the PLC is required for an auxiliary function that is output before or after the end of motion the axes stop at the end of the block Missing following blocks If following blocks are conditioned too slowly e g External processing the axes stop at that last possible block boundary Emptying of the buffer If the NC part program requests...

Page 61: ...al setpoint position deviation of the axis has remained within a specific distance The value of the permissible distance is stored in MD36010 STOP_LIMIT_FINE exact stop fine Exact stop coarse G602 Functions as exact stop fine although the monitoring window is stored in MD36000 STOP_LIMIT_COARSE exact stop coarse To permit a faster block change than with the exact stop fine criterion the exact stop...

Page 62: ...The continuous path mode is suitable if a contour is to be traversed as quickly as possible Continuous path mode is suitable if A contour is to be traversed precisely An absolutely constant velocity is required Implicit exact stop In some cases an exact stop needs to be generated in continuouspath mode to allow the execution of subsequent actions In such situations the path velocity is reduced to ...

Page 63: ...e velocity has not needed to be reduced on account of the PLC acknowledgment time the velocity is maintained until the end of the block and then reduced as described above If the acknowledgment arrives while the axis is decelerating the axis is not accelerated back up to the requested velocity 3 4 2 Velocity reduction according to overload factor Function This function lowers the path velocity in ...

Page 64: ...very NC part program block by means of program code G64 BRISK active not SOFT Continuous path mode G64 can be interrupted non modally when exact stop G9 is selected de selected when exact stop G60 is selected 3 4 3 Jerk limiting along the path through velocity reduction Introduction With the jerk limiting along the path another method of influencing the continuous path mode is introduced While the...

Page 65: ...n already be set for acceleration limits in machine data MD32300 MAX_AX_ACCEL MD32431 MAX_AX_JERK acts on the axes interpolated by the path if SOFT smooth acceleration curve is active within a block A basic distinction is made between the axis acceleration curve within a block and at the transition between two blocks Advantages The deployment of axis specific machine data for the path offers the f...

Page 66: ...ngential path transitions were available With the LookAhead function It is possible to plan the acceleration and deceleration phase with approximately tangential path transitions over several blocks in order to achieve a higher feedrate with shorter distances Deceleration to velocity limits is possible with LookAhead such that violation of the acceleration and velocity limit is prevented 1 RQWLQXR...

Page 67: ...ookAhead function fixed value Velocity profiles In addition to the fixed plannable velocity limitations LookAhead can also take account of the programmed velocity This makes it possible to achieve a lower velocity by applying LookAhead beyond the current block Following block velocity One possible velocity profile contains the determination of the following block velocity Using information from th...

Page 68: ... 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 36000 STOP_LIMIT_COARSE Exact stop coarse 36010 STOP_LIMIT_FINE Exact stop fine 36020 POSITIONING_TIME Delay time exact stop fine 3 6 2 Interface signals Number Bit Name Channel specific V3300 0004 3 All axes stationary Axis spindle spe...

Page 69: ...elocity and acceleration This time loss can be compensated for by setting a higher acceleration for the axes However it has the following advantages Reduced wear to mechanical parts of the machine Reduction of the excitation of highfrequency difficult to control vibrations of the machine 4 2 Jerk limitation on interpolator level Selection and deselection of jerk limited acceleration MD32431 MAX_AX...

Page 70: ...on and jerk whilst traversing in continuous path mode and at block transitions can be found in Chapter Continuous Path Mode Exact Stop and LookAhead B1 Note We recommend setting the following machine data for each axis with the same values MD32431 MAX_AX_JERK and MD32432 PATH_TRANS_JERK_LIM maximum axis specific jerk for path movement at block transition 4 3 Jerk limitation in JOG mode The jerk li...

Page 71: ...e the reference 100 corresponds to the active spindle mode and gear stage n 1 5 MD35200 GEAR_STEP_SPEEDCTRL_ACCEL n in open loop control mode MD35210 GEAR_STEP_POSCTRL_ACCEL n in positioning mode Examples N10 ACC X 80 80 acceleration for the X axis Effectiveness The limitation is effective in all interpolation types of the AUTOMATIC and MDA modes The limitation is not active in JOG mode and during...

Page 72: ...ntifier 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 ...

Page 73: ...necting a probe Travel to fixed stop can be performed simultaneously for several axes and parallel to the movement of other axes The fixed stop can be approached on a path straight line circle Availability The travel to fixed stop function is available when MD37000 FIXED_STOP_MODE travel to fixed stop mode 1 is set The function can then be started from the NC program with command FXS x 1 5 2 Funct...

Page 74: ...alue from SD43520 FIXED_STOP_WINDOW applies If a value is programmed this is applied and adopted by the SD43520 Initially the SD is loaded using the value from MD37020 FIXED_STOP_WINDOW_DEF If no clamping torque is programmed the value from SD43510 FIXED_STOP_TORQUE applies If a value is programmed this is applied and adopted by the SD43510 Initially the SD is loaded using the value from MD37010 F...

Page 75: ...1 Fixed stop successfully approached axis is in fixed stop monitoring window 2 Approach to fixed stop has failed axis is not at fixed stop 3 Travel to fixed stop activated 4 Fixed stop detected 5 Travel to fixed stop will be de selected the de selection is not yet completed Query of the system variables in the part program initiates a preprocessing stop As a result of the status query in the part ...

Page 76: ... contact with the mechanical fixed stop workpiece the closedloop control in the drive raises the torque so that the axis can move on The torque rises up to the programmed limit value and then remains constant The status fixed stop reached can depending on the MD37040 FIXED_STOP_BY_SENSOR fixed stop recognition by sensor be determined in the following ways FIXED_STOP_BY_SENSOR 0 The status fixed st...

Page 77: ...top alarms MD37050 FIXED_STOP_ALARM_MASK can suppress the output of the following alarms 20091 Fixed stop not reached 20094 Fixed stop aborted Fixed stop is not reached If the programmed end position is reached without the Fixed stop reached status being recognized then the torque limit in the drive is cancelled and IS Activate travel to fixed stop is reset Depending on MD37060 FIXED_STOP_ACKN_MAS...

Page 78: ... Activate travel to fixed stop The torque limitation is then cancelled and a block change executed Deselection The NC detects deselection of the function on the basis of command FXS x 0 Then a preprocessing stop STOPRE is initiated internally since it can not be foreseen where the axis will be after deselection The torque limitation and monitoring of the fixed stop monitoring window are cancelled ...

Page 79: ... reached Without ramp The torque limit is changed without taking into account the ramp if FXS with FXS 1 is activated to make sure that the reduction takes effect immediately The drive needs to be de energized as quickly as possible in the event of a fault Response to pulse inhibit for the drive MD37002 FIXED_STOP_CONTROL can be used to control the response in the case of pulse inhibit at a fixed ...

Page 80: ...As soon as the fixed stop is reached the function remains operative even after RESET Function abort In the case of an EMERGENCY STOP the NC and drive cannot respond i e the PLC must respond CAUTION Make sure that after canceling the function travel to fixed stop by EMERGENCY STOP no dangerous machine situation with MD37002 FIXED_STOP_CONTROL e g canceling pulse disable can arise The fixed stop mon...

Page 81: ...t purposes after successful travel to fixed stop Combination with measuring function Measure with deletion of distancetogo MEAS command and Travel to fixed stop cannot be programmed at the same time in one block Contour monitoring Axis specific contour monitoring is not performed while Travel to fixed stop is active Selection for G64 In MD37060 FIXED_STOP_ACKN_MASK bit 0 must be 0 do not wait for ...

Page 82: ...ram 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 67 RU 0 B6723B72548 B ORFN FKDQJH 6 6 UHDFKHG 6 FWLYDWH 6 ORFN ZLWK 6 0 B6723B7 5 2 0RWRU FXUUHQW ROORZLQJ HUURU Figure 5 2 Diagram for FXS with a digital drive ...

Page 83: ...fixed stop detection 37040 FIXED_STOP_BY_SENSOR Fixed stop detection via sensor 37050 FIXED_STOP_ALARM_MASK Enabling the fixed stop alarms 37060 FIXED_STOP_ACKN_MASK Monitoring of PLC acknowledgments for travel to fixed stop 5 6 2 Setting data Number Identifier Name Axis specific 43500 FIXED_STOP_SWITCH Selection of travel to fixed stop 43510 FIXED_STOP_WINDOW Fixed stop monitoring window 43520 FI...

Page 84: ...Travel to fixed stop F1 5 6 Data lists Turning Milling Nibbling 84 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 85: ...ion The machine axis that is directly traversed is called the leading axis The machine axis that is traversed in synchronism with it is called the synchronized axis Together the leading axis and synchronized axis form a gantry axis grouping The difference between the actual positions of the leading axis and synchronized axis is monitored continuously When the actual position value of the synchroni...

Page 86: ...rpose of the gantry axes function is to control and monitor machine axes which are rigidly coupled in this way Terms The following terms are frequently used in this functional description Gantry axes Gantry axes comprise one pair of axes the leading axis and the synchronized axis As these axes are mechanically coupled they must always be traversed simultaneously by the NC The difference between th...

Page 87: ...not be the slave axis in another type of axis coupling A synchronized axis must not be defined as the leading axis in another axis grouping Note Each axis in the gantry grouping must be set so that it can take over the function of the leading axis at any time i e matching velocity acceleration and dynamic response settings The control performs a plausibility check on the axis definition Components...

Page 88: ...NING gantry warning limit In addition the following interface signal will be output to the PLC V390x 5005 3 gantry warning limit exceeded When below the warning limit the message and interface signal will automatically be cancelled When MD37110 0 the message will be disabled Gantry trip limit Alarm 10653 Error limit exceeded will be signaled when the machine s maximum permissible actual position v...

Page 89: ...n as the gantry synchronization process As soon as this has been carried out the following interface signal is sent to the PLC V390x 5005 5 gantry grouping is synchronized The operational sequence for referencing and synchronizing gantry axes is described in detail under the topic Referencing and synchronizing of gantry axes Closed loop control The dynamic control response settings for the coupled...

Page 90: ...xes can still be referenced In special cases e g gantry axes were brought to a standstill because of a disturbance power failure or EMERGENCY OFF before the axes can be traversed the dimensional offset must be checked for permissible tolerance values and a compensatory motion executed if necessary To execute this compensatory motion the gantry grouping must be separated by means of the following m...

Page 91: ... The dependency between the leading axis and synchronized axis is inverted in the control for this phase so that the leading axis now traverses in synchronism with the synchronized axis IS Referenced synchronized of the synchronized axis is output to indicate that the reference point has been reached The gantry axis dependency then reverts to its previous status Section 3 Gantry synchronization On...

Page 92: ...have reached their target position ideal position IS Gantry grouping is synchronized is set to 1 followed by re activation of the gantry axis coupling The position actual value of all axes in the gantry grouping must now be identical The gantry synchronization process is now complete Difference is higher than the gantry warning limit for the synchronized axis IS Gantry synchronization read to star...

Page 93: ... HLWKHU RI WKHVH RSWLRQV LV VHW XVLQJ 0 6 6WDUW JDQWU V QFKURQL DWLRQ 2SHUDWRU VWDUWV JDQWU V QFKURQL DWLRQ SURFHVV 6 DQWU V QFKURQL DWLRQ UHDG WR VWDUW 0HVVDJH DLW IRU V QFKURQL DWLRQ WR VWDUW HYLDWLRQ 0 FWXDO SRVLWLRQV RI OHDGLQJ D LV DQG V QFKURQL HG D LV FRPSDUHG 5HIHUHQFH SRLQW UHDFKHG QG 6 5HIHUHQFHG V QFKURQL HG IRU V QFKURQL HG D LV 6 QFKURQL HG D LV DSSURDFKHV UHIHUHQFH SRLQW OHDGLQJ D LV...

Page 94: ...ynchronization under the following conditions only JOG REF mode must be active The following interface signal must be set V3100 0001 2 active machine function REF V390x 5005 5 0 gantry grouping is synchronized All grouping axes operate within the tolerance windows V390x 5005 4 1 Gantry synchronization ready to start Axis is not referenced in the NC channel V3300 0001 0 0 referencing active If gant...

Page 95: ...gantry grouping is moving and is then rescinded and both axes have drifted apart less than the standstill tolerance of the following axis then the gantry grouping will automatically synchronize It no longer needs to go in the BA REF Reference point selection To ensure that the shortest possible paths are traversed when the gantry axes are referenced the reference point values for the leading and s...

Page 96: ...ynchronized as a result The leading axis sets IS Gantry grouping is synchronous to 0 regardless of the positions of the axes If the gantry grouping is switched from follow up mode to position control mode axis synchronism is automatically restored provided the actual value monitoring function does not detect a difference between the positions of the leading and synchronized axes that is greater th...

Page 97: ...rencing MD34110 REFP_CYCLE_NR axis sequence for channel specific referencing After the reference point of the leading axis has been reached the synchronized axis is referenced first as described above Referencing from part program with G74 The referencing and synchronization process for gantry axes can also be initiated from the part program by means of command G74 In this case only the axis name ...

Page 98: ... axis Compensation values are applied separately for each individual gantry axis These values must therefore be defined and entered for the leading axis and the synchronized axes during start up The compensations do not become operative internally in the control until the axis is referenced or the gantry grouping synchronized The following applies Compensation type Takes effect when PLC interface ...

Page 99: ... desired traversing direction of the axis Correct by means of axial machine data MD32100 AX_MOTION_DIR traversing direction Activation of the axis grouping MD37100 GANTRY_AXIS_TYPE a b gantry axis definition This machine data is determined for the following gantry axis Which gantry grouping 1 the axis is to be assigned to Whether it is to act as a leading or synchronized axis Table 6 1 Possible va...

Page 100: ...s MD32200 POSCTRL_GAIN servo gain factor MD32620 FFW_MODE precontrol parameter MD32610 VELO_FFW_WEIGHT precontrol factor for acceleration speed precontrol MD32810 EQUIV_SPEEDCTRL_TIME equivalent time constant speed control loop for precontrol The following control parameters must be set to the same value for the leading axis and synchronized axis MD32400 AX_JERK_ENABLE axial jerk limitation MD3241...

Page 101: ...for the leading and synchronized axes must first be set to almost identical values To ensure that the synchronization compensatory motion of the gantry axes is not started automatically during first commissioning the gantry warning limit must be set to 0 before referencing MD37100 GANTRY_POS_TOL_WARNING gantry axis definition This will prevent a warning message being output during traversing motio...

Page 102: ...ortant to check the acceleration phases This limit value also determines the position deviation value at which gantry synchronization is automatically started in the control Calculating and activating compensations In cases where the gantry axes require compensation sag or leadscrew error the compensation values for the leading axis and the synchronized axis must be calculated and entered in the a...

Page 103: ...ion generator and measuring function to such low values that the activated axis traverses a shorter distance than the position tolerance allows Always activate the traversing range limits as a check see above Note As a supplement to the more general description given here of features of start up and dynamic control response of drives a complete example of a concrete constellation defined on the ba...

Page 104: ... Gantry warning limit exceeded V390x 5005 3 x Gantry trip limit exceeded V390x 5005 2 x x relevant for Effect of axial interface signals on gantry axes a Axial interface signals from PLC to axis PLC NCK The axial interface signals from the PLC to the axis are always referred to all gantry axes in the grouping In this case all gantry axes leading and synchronized axis have equal priority For exampl...

Page 105: ...synchronized axis and the leading axis is always set on an axis specific basis and output to the PLC Exception When the leading axis is being traversed the interface signals are also set for the synchronized axis V390x 0004 6 7 traverse command minus plus 6 6 Miscellaneous points regarding gantry axes Manual travel It is not possible to traverse a synchronized axis directly by hand in JOG mode Tra...

Page 106: ...he following MD parameterization is ignored for the synchronized axes MD30450 IS_CONCURRENT_POS_AX 1 reset default neutral axis channel axis The state of the leading axis is assumed The user is informed about the inappropriate configuration with display alarm 4300 Position display The position actual value display shows the actual values of both the leading axis and the synchronized axes The same ...

Page 107: ...incremental measuring system Machine axis 3 gantry synchronized axis incremental measuring system The following MD describes the output values Individual settings must be corrected or added later according to the information below Gantry machine data Axis 1 MD37100 GANTRY_AXIS_TYPE 1 MD37110 GANTRY_POS_TOL_WARNING 0 MD37120 GANTRY_POS_TOL_ERROR 1 mm MD37130 GANTRY_POS_TOL_REF 100 mm max misalignme...

Page 108: ...34080 REFP_MOVE_DIST 0 MD34090 REFP_MOVE_DIST_CORR 0 MD34092 REFP_CAM_SHIFT 0 MD34100 REFP_SET_POS 0 MD34200 ENC_REFP_MODE 1 6 7 2 Setting of NCK PLC interface Introduction An automatic synchronization process during axis referencing must first be disabled in order to prevent any damage to grouping axes that are misaligned Disabling of automatic synchronization The PLC user program sets the follow...

Page 109: ...LILFDQFH 6 QFKURQL HG D LV DQWU D LV 9 Figure 6 6 NCK PLC interface VB390x 5005 relative to synchronized axis 6 7 3 Commencing start up Referencing The following steps must be taken Select REF operating mode Start referencing for the leading axis axis 1 Wait until message 10654 Channel 1 Waiting for synchronization start appears At this point the NCK has prepared the leading axis for synchronizati...

Page 110: ...a Wait until message 10654 Channel 1 Waiting for synchronization start appears At this point the NCK has prepared axis 1 for synchronization and sends the same interface signal as shown in the image above Examine actual positions of machine Case A or B might apply 5 5 GLII DVH DVH Figure 6 8 Possible results of referencing the leading axis If Case A applies the synchronization process can be start...

Page 111: ...y trip limit Set a very small value in the machine data MD37110 GANTRY_POS_TOL_WARNING gantry warning limit When you put a heavy dynamic strain on the axes always be careful to re enter the self canceling alarm 10652 channel 1 axis 2 gantry warning limit exceeded Now increase MD37110 Do this until the alarm no longer appears The interface indicates the status specified below That must occur in the...

Page 112: ...JERK_TIME Time constant for axis jerk filter 32420 JOG_AND_POS_JERK_ENABLE Initial setting for axial jerk limitation 32430 JOG_AND_POS_MAX_JERK Axial jerk 32610 VELO_FFW_WEIGHT 0 5 Feedforward control factor for speed feedforward control 32620 FFW_MODE Feedforward control mode 32810 EQUIV_SPEEDCTRL_TIME 0 5 Equivalent time constant speed control loop for precontrol 32900 DYN_MATCH_ENABLE Dynamic r...

Page 113: ...ber Bit Name Leading axis Synchronized axis Mode specific V3100 0001 2 Active machine function REF Channel specific V3300 0001 0 Referencing active Axis specific V380x 5005 4 Start gantry synchronization x V380x 5005 5 Automatic synchronization locking x V390x 0000 4 Referenced synchronized 1 V390x 5005 2 Gantry trip limit exceeded x V390x 5005 3 Gantry warning limit exceeded x V390x 5005 4 Gantry...

Page 114: ...Gantry axes G1 6 8 Data lists Turning Milling Nibbling 114 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 115: ...rmula QWHUSRODWLRQ F FOH V SURJU SDWK OHQJWK LQ SDUW SURJUDP EORFN PP RU GHJUHHV 9PD With a higher feedrate resulting from program and affected by feed override the maximum path velocity is limited to Vmax This automatic feedrate limiting can lead to a drop in velocity over several blocks with programs generated by CAD systems with extremely short blocks Example Interpolation cycle 12 ms N10 G0 X0...

Page 116: ...value ranges change accordingly maximum number of decimal points is constant 7 1 2 Traversing ranges The range of values of the traversing range depends on the computational resolution selected If MD10200 INT_INCR_PER_MM computational resolution for linear positions 1000 incr mm or MD10210 INT_INCR_PER_DEG computational resolution for angular positions 1000 incr degree are assigned their default v...

Page 117: ...PLAY_RESOLUTION_INCH can be used to configure the display resolution for linear position values in inches For the programming of part programs the input resolutions listed in the Programming Guide apply The desired computational resolution is defined via MD10200 INT_INCR_PER_MM computational resolution for linear positions or MD10210 INT_INCR_PER_DEG computational resolution for angular positions ...

Page 118: ... 1 s 1 s Position controller servo gain 1 s 1 s Rev feedrate 1 mm rev 1 inch rev Compensation value linear position 1 mm 1 inch Compensation value angular position 1 degree 1 degree 7 2 Metric inch measuring system The control system can operate with the inch or the metric measurement system The initial state is defined via MD10240 SCALING_SYSTEM_IS_METRIC metric basic system Depending on the sett...

Page 119: ...rams including data sets zero offset tool offset programmed in the measuring system which differs from the basic system are read in from an external source the initial state must first be changed via machine data MD10240 SCALING_SYSTEM_IS_METRIC Data exchange with the PLC of interface signals containing dimension information e g feedrate for path and positioning axes is always carried out in the s...

Page 120: ...P P P Pitch P P P P Programmable offset rotation P P P P Programmable offset G54 G55 etc G G P P Working area limits G25 G26 G G P P Tool offsets G G P P Length related machine data G G P P Length related setting data G G P P Length related system variables G G P P R parameters G G G G Siemens cycles P P P P Jog handwheel increment factor G G G G 7 2 2 Manual switchover of the basic system General...

Page 121: ... This process takes place independently of the protection level currently set Note MD20150 can only be read written in expert mode protection level 1 System data When changing over the measuring system from the view of the user all length related specifications are converted to the new measuring system automatically This includes Positions Feed rates Acceleration rates Jerk Tool offsets Compensati...

Page 122: ... two dimension systems Depending on the current setting in MD10240 SCALING_SYSTEM_IS_METRIC the control automatically selects the appropriate value Note MD31090 JOG_INCR_WEIGHT can only be read written in expert mode access level protection level 1 Default setting for each axis Metric MD31090 JOG_INCR_WEIGHT 0 0 001 mm Inch MD31090 JOG_INCR_WEIGHT 1 0 00254 mm 0 0001 inch Data backup Data sets whi...

Page 123: ...for each axis spindle The setpoint output at the setting device is done digitally or in the case of analog spindles 10 V unidirectionally or bidirectionally Simulation axes The speed control loop of an axis can be simulated for test purposes The axis traverses with a following error similar to a real axis A simulation axis is defined by setting MD30130 CTRLOUT_TYPE n setpoint output type and MD302...

Page 124: ...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 The drive is assigned a drive number via the slot in the DRIVE CLiQ system Please note that the ALM Active Line Module is al...

Page 125: ...30110 3 4 2 1 30120 1 1 1 1 30130 1 1 1 1 30134 0 0 0 0 30200 1 1 1 1 30230 1 1 1 1 30220 3 4 2 1 Note In the case of dual axis power modules both drives A and B are each assigned to an axis The commissioning of the drives is performed via the drive machine data Thus the topology can be identified and the motor data set up MD13060 DRIVE_TELEGRAM_TYPE n is used to set the default message frame type...

Page 126: ...ting Prerequisite for routing All NC machine axes must be uniquely defined in MD10000 AXCONF_MACHAX_NAME_TAB n machine axis name This name must be unique across the whole system Note To connect an analog instead of a digital spindle install the MCPA module When doing so various additional notes must be observed These can be found in Reference BE Operating Instructions Section Connecting an analog ...

Page 127: ...actual value assignment must be performed identically to the speed setpoint assignment the same drive number For the actual value assignment please refer to the diagram below The parameterization is described in the associated machine data 0RWRU 0RGXOH 0RWRU 0RGXOH 5 9 L4 PHDVXULQJ V VWHP 6 1 0 6 0RWRU 0RGXOH 0 6SLQGOH 0RWRU 0RGXOH VO ULYH ULYH ULYH ULYH 5 9 L4 PHDVXULQJ V VWHP 5 9 L4 PHDVXULQJ V ...

Page 128: ...easuring system slot on the module MD32110 ENC_FEEDBACK_POL n 1 correct the direction 7 3 4 Speed setpoint output Q 0RWRU RDG JHDUER 0 5 9 B B5 7 2B 120 Q 0 5 9 B B5 7 2B180 5 Q 1XPEHU RI ORDG UHYROXWLRQV VSLQGOH 1XPEHU RI PRWRU UHYROXWLRQV 0 6 5 B3 7 RU OLQHDU D HV RQO DOO VFUHZ 0 B027 21B 5 0 RQWURO Q 6SLQGOH Figure 7 5 Speed setpoint output Traversing direction MD32100 AX_MOTION_DIR traversing ...

Page 129: ...l system must be informed of the valid actual value resolution Depending on the type of axis linear axis rotary axis spindle analog spindle and the type of actual value resolution direct indirect the following machine data must be parameterized to calculate the actual value acquisition for the main applications Linear axis Rotary axis Spindle Machine data Encoder on motor Encoder on motor Encoder ...

Page 130: ...g path evaluation However they must be entered correctly for the setpoint calculation Otherwise the required servo gain factor will not be set Variants of actual value acquisition The associated machine data for different variants of actual value acquisition is described below Linear axis with rotary encoder on motor 0 1 B 6B 5 7 0 1 B5 62 0 6B527B DOO VFUHZ 6SLQGOH Q RDG JHDUER 0RWRU Q QFRGHU Q 6...

Page 131: ...on of internal drive variables Note This function is under license and is not available with version T M value If the corresponding option is activated without a valid license alarm 8081 1 option s that has 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 r...

Page 132: ...oothed with a PT1 filter The filter time constant is defined using the following MD MD32920 AC_FILTER_TIME smoothing filter time constant for adaptive control Specifying 0 seconds for the smoothing time deactivates the filter Data formats The user must take the following points into account with regard to the data formats of the process data stored in the system variables The PDA is transferred to...

Page 133: ... in MD13060 is different from the one defined in p0922 alarm 26015 Axis 1 machine data 2 3 value not permissible is output in this case 2 corresponds to the identifier for MD13060 Application examples System variables during synchronization with a modal effect ID 1 WHENEVER TRUE DO R0 VA_LOAD X System variables in a part program WHENEVER VA_LOAD X 80 DO AC_OVR 80 G1 G90 X200 F10000 7 4 Closed loop...

Page 134: ...ode a high servo gain factor MD32200 POSCTRL_GAIN n position controller servo gain is required The index n of the machine data has the following code closed loop control parameter set no 0 5 However if the servo gain factor is too high this will result in instability overshoots and possibly impermissibly high loads on the machine The maximum permissible servo gain factor depends on the following D...

Page 135: ...stage is assigned its own parameter set The relevant parameter set is activated in accordance with the Actual gear stage IS V380x 2000 0 to 2 The machine data that is changed over with the spindle gear stage is listed in the section titled Spindles IS Actual gear stage Active parameter set 000 2 index 1 001 2 index 1 010 3 index 2 011 4 index 3 100 5 index 4 101 6 index 5 Axis parameter sets Param...

Page 136: ...ment Drive number module number analog spindle 30120 CTRLOUT_NR 0 Setpoint Output to module 30130 CTRLOUT_TYPE 0 Output type of setpoint 30134 IS_UNIPOLAR_OUTPUT 0 Setpoint output is unipolar analog spindle 30200 NUM_ENCS Number of encoder 1 spindle without encoder value 0 30220 ENC_MODULE_NR 0 Actual value Drive module number measuring circuit number 30230 ENC_INPUT_NR 0 Actual value Input number...

Page 137: ...E 0 5 Equivalent time constant speed control loop for feedforward control 32920 AC_FILTER_TIME Smoothing filter time constant for adaptive control 35100 SPIND_VELO_LIMIT 0 5 Maximum spindle speed 36200 AX_VELO_LIMIT 0 5 Threshold value for velocity monitoring 36210 CTRLOUT_LIMIT 0 Maximum speed setpoint 36730 DRIVE_SIGNAL_TRACKING Detection of additional drive actual values The machine data marked...

Page 138: ...Velocities Setpoint Actual Value Systems Closed Loop Control G2 7 5 Data lists Turning Milling Nibbling 138 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 139: ...veral machine axes are moved simultaneously there is no interpolatory relation Coordinate systems The user has the option of traversing axes in the coordinate systems Machine coordinate system MCS machine axes manually traversable Workpiece coordinate system WCS geometry axes manually traversable Machine functions Variants exist for manual traverse the so called machine functions Continuous traver...

Page 140: ...pleted otherwise alarm 20062 Axis already active is output Two geometry axes can be traversed simultaneously with the handwheels 1 and 2 Note A separate channel specific PLC interface supplies geometry axes Transverse axis in turning technology A geometry axis is defined as a transverse axis If radius programming DIAMOF is selected instead of diameter programming DIAMON the following must be noted...

Page 141: ...Y1 Z Z1 for default setting The separate PLC interface area of the geometry axes must be used for control Velocity override The velocity at which axes traverse in JOG can also be influenced by the axis specific feedrate override switch for machine axes provided that axis specific IS Override active V380x 0001 7 is set If the switch is set at 0 the axis is not traversed even if IS Override active i...

Page 142: ...ed Software limit switches 1 or 2 axis must be referenced Hardware limit switches The control ensures that the traversing movement is aborted as soon as the first valid limitation has been reached Velocity control ensures that deceleration is initiated early enough for the axis to stop exactly at the limit position e g software limit switch Only when the hardware limit switch is triggered does the...

Page 143: ... VB380x 0005 Traversing keys The plus and minus traversing keys are selected to move the relevant axis in the appropriate direction Traverse key signals PLC to NCK IS For geometry axes traverse in WCS V3200 1000 7 6 V3200 1004 7 6 V3200 1008 7 6 For machine axes spindle traverse in MCS V380x 004 7 6 If both traversing keys of an axis are pressed simultaneously there is no traversing movement or if...

Page 144: ...d by the NCK to the PLC For geometry axes V3300 1001 0 V3300 1005 0 V3300 1009 0 to 5 For machine axes spindle V390x 0005 0 to 5 Settable increments The operator can set different increment sizes Fixed increments whose increment sizes are common to all axes INC1 INC10 INC100 INC1000 only via IS INC10000 A variable increment INCvar The increment setting for the variable increment can also be made f...

Page 145: ...face through the PLC user program Only here can several machine axes be assigned to one handwheel simultaneously Using menu assisted operation HMI Pressing the Handwheel softkey in the JOG mode basic menu displays the Handwheel window This enables an axis WCS or MCS to be assigned to each handwheel A separate user interface between the HMI and PLC is provided to allow activation of the handwheel f...

Page 146: ...0 001 mm if the basic system setting is metric Pulse weighting of the handwheel using general MD11320 HANDWH_IMP_PER_LATCH handwheel pulses per locking position Motion command While the axis is moving the Travel command or Travel command interface signal is transmitted to the PLC depending on the direction of motion For geometry axes V3300 1000 7 6 V3300 1004 7 6 V3300 1008 7 6 For machine axes sp...

Page 147: ...ovement takes place only after standstill setpoint side of the axis new function Response at software limit switches working area limitation When axes are traversed in JOG mode they can traverse only up to the first active limitation before the corresponding alarm is output Depending on the machine data MD11310 HANDWH_REVERSE the behavior is as follows as long as the axis on the setpoint side has ...

Page 148: ... NC program Travel towards tool change points loading points and pallet change points Requirements The Approaching fixed point in JOG can be activated only in the JOG mode The function cannot be enabled in the JOG REPOS and JOG REF sub modes and in JOG in the AUTOMATIC mode The axis to be traversed must be referenced A kinematic transformation may not be active The axis to be traversed must not be...

Page 149: ...andstill at the fixed point The corresponding NC PLC interface signal is sent on reaching the fixed point with Exact stop fine JOG Approaching fixed point reached V390x 1001 3 5 This display signal is also reported if the axis reaches the fixed point position in the machine coordinate system using other methods e g NC program synchronized action at the setpoint end and comes to a standstill at the...

Page 150: ...ixed point in JOG function This is done by resetting the activation signal to 0 V380x 1001 0 2 0 The message signals JOG Approaching fixed point active and JOG Approaching fixed point reached are canceled on leaving the fixed point position Special case Axis is already on fixed point The axis cannot be moved if while starting the fixed point traverse the axis is already at the position of the fixe...

Page 151: ...y axes 8 5 3 Parameter setting Movement in the opposite direction The response while traversing in the opposite direction i e against the direction of the approaching fixed point depends on the setting of Bit 2 in the machine data MD10735 JOG_MODE_MASK settings for JOG mode Bit Value Description 0 Travel in the opposite direction is not possible default setting 2 1 Movement in the opposite directi...

Page 152: ...n indexing position Frames active All active frames are ignored Traversing is performed in the machine coordinate system Offset values active Active compensation values external work offset synchronized action offset AA_OFF online tool offset are also applied The fixed point is a position in the machine coordinates system An alarm is signaled if an offset movement external work offset synchronized...

Page 153: ...S 2 AX4 180 3rd Fixed point of AX4 180 degree MD30600 FIX_POINT_POS 3 AX4 270 4th Fixed point of AX4 270 degree Initial situation Machine axis 4 is referred and is in Position 0 degree This corresponds to the 1st fixed point and is output via the following NC PLC interface signal V390x 1001 0 1 bit 0 2 1 Approaching fixed point 2 The control is switched in the JOG mode The Approaching fixed point ...

Page 154: ...ometry axes with transverse axis functions Axis spindle specific 30600 FIX_POINT_POS n Fixed point positions for the axis 30610 NUM_FIX_POINT_POS Number of fixed point positions for an axis 32000 MAX_AX_VELO Maximum axis velocity 32010 JOG_VELO_RAPID Rapid traverse in JOG mode 32020 JOG_VELO JOG axis velocity 32300 MAX_AX_ACCEL Axis acceleration 32420 JOG_AND_POS_JERK_ENABLE Enable for axis spec j...

Page 155: ...eometry axis 3 V3200 1000 V3200 1004 V3200 1008 7 or 6 7 or 6 7 or 6 Traversing keys plus or minus for geometry axis 1 for geometry axis 2 for geometry axis 3 V3200 1000 V3200 1004 V3200 1008 0 to 6 0 to 6 0 to 6 Machine function INC1 to continuous for geometry axis 1 for geometry axis 2 for geometry axis 3 V3300 1000 V3300 1004 V3300 1008 1 0 1 0 1 0 Handwheel active 2 1 for geometry axis 1 for g...

Page 156: ...nt approach in JOG binary coded fixed point 1 to 4 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 V390x 0005 0 to 6 Active machine function INC1 to continuous V390x 1001 0 to 2 Fixed point approach in JOG active binary coded V390x 1001 3 to 5 Fixed point reached binary coded ...

Page 157: ...ing types of auxiliary function are available Miscellaneous function M Spindle function S Auxiliary function H Tool number T Tool offset D Feed F for SINUMERIK 802D there is no output from F to PLC Output of auxiliary functions to PLC The auxiliary function output sends information to the PLC indicating for example when the NC program needs the PLC to perform specific switching operations on the m...

Page 158: ...Number per block Meaning Area Area Type Meaning max M Spindle no 1 2 0 99 INT Function Specific numbers are assigned a fixed function 5 Switchgear protection Spindle no 1 2 0 3 4028 ex 38 REAL Spindle speed 1 H Any 0 99 3 4028 ex 38 REAL Any Functions have no effect in the NCK only to be implemented on the PLC 3 D 0 32000 INT Tool selection 1 D 0 9 INT Tool offset selection D0 deselection default ...

Page 159: ...he PLC user program s point of view 9 3 Transfer of values and signals to the PLC interface Time of transfer In the case of auxiliary functions which are output at the end of a block e g M2 the output is only made after all axis movements and the SPOS movement of the spindle have been completed If several auxiliary functions with different output types prior during at end of motion are programmed ...

Page 160: ...distributed to the AUXFU groups To do so the password for protection level 2 must be set Then the control must be turned off and on again Now the subsequent machine data with an index n greater than zero are available and additional values can be entered An allocated auxiliary function is defined in the following machine data MD22000 AUXFU_ASSIGN_GROUP n auxiliary function group MD22010 AUXFU_ASSI...

Page 161: ...hould be kept Group 3 S functions by default should be kept Group 4 M78 M79 Group 5 M80 M81 Group 6 H1 10 H1 11 H1 12 Group 7 all T functions Password for protection level 2 is set Make entry in MD11100 AUXFU_MAXNUM_GROUP_ASSIGN 8 Then turn off the control and turn it on again or perform the control start up through the softkey and define the remaining machine data with a subsequent restart of the...

Page 162: ...ar auxiliary functions and before the movement Note If the auxiliary functions are to be collected during the block search they must be assigned to an auxiliary function group 9 6 Description of the auxiliary functions 9 6 1 M function Application You can use the M functions to enable the various switching operations on the machine per part program Scope of functions Five M functions per part prog...

Page 163: ...Scope of functions One T function per part program block is possible Peculiarity T0 is reserved for the following function remove the current tool from the tool holder without loading a new tool 9 6 3 D function The D function is used to select the tool offset for the active tool Tool offsets are described in detail under Reference BP_ Operation and Programming 9 6 4 H function Application The H f...

Page 164: ...ROUP n Auxiliary function group 22010 AUXFU_ASSIGN_TYPE n Auxiliary function type 22020 AUXFU_ASSIGN_EXTENSION n Auxiliary function extension 22030 AUXFU_ASSIGN_VALUE n Auxiliary function value 9 7 2 Interface signals Number Bit Name Channel specific V2500 0000 0 to 4 M function 1 change to M function 5 change V2500 0006 0 S function 1 change V2500 0008 0 T function 1 change V2500 0010 0 D functio...

Page 165: ...unction 2 REAL format VB2500 4012 Extended address of S function 2 BYTE VD2500 5000 D function 1 DINT VW2500 6004 Extended address of H function 1 Word VD2500 6000 H function 1 REAL format VW2500 6012 Extended address of H function 2 Word VD2500 6008 H function 2 REAL format VW2500 6020 Extended address of H function 3 Word VD2500 6016 H function 3 REAL format V2500 1000 0 7 Decoded M signals M00 ...

Page 166: ...Auxiliary Function Outputs to PLC H2 9 7 Data lists Turning Milling Nibbling 166 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 167: ...ivating The required operating mode is activated by the interface signals in the VB 3000 0000 If several modes are selected at the same time the priority of the operating modes is as follows JOG high priority The axes can be traversed manually with the handwheel or the traversing keys Channel specific signals and interlocks are not observed MDA Program blocks can be processed AUTOMATIC lower prior...

Page 168: ...V3200 0007 4 IS NC stop at block limit V3200 0007 2 Depending on the interface signal used either only the axes or in addition the spindles of the channels are stopped or the axes at block end RESET The active part program is aborted by the IS Reset V3000 0000 7 The following actions are executed when the IS Reset is triggered Part program preparation is stopped immediately Axes and spindles are s...

Page 169: ...mpossible The same applies for MDA from which one may change neither directly nor indirectly to AUTO provided the Reset state is present The table shows the possible operating mode changes depending on the current operating mode and the channel state Channel in reset or Channel interrupted Table 10 1 Operating mode change depending on channel state AUTOMATIC JOG MDI AUTO previousl y MDI previousl ...

Page 170: ...of operation AUTOMATIC JOG MDI Functions 1 2 3 1 3 4 3 5 3 1 2 3 6 7 Loading a part program from outside through Services sb sb sb sb sb sb sb sb Processing a part program block s s b s s b Block search s s b Reference point approach via part program command G74 sb sb s Function can be started in this status b Function can be processed in this status 1 Channel in reset 2 Channel interrupted 3 Chan...

Page 171: ...x x x HW limit switch x x x x x x x x x x x x x x Exact stop coarse fine x x x x x x x x x x x x x x Clamping tolerance x x x x x x x x x x x x x x DAC limit analog spindle x x x x x x x x x x x x x x Contour monitoring x x x x x x x Spindle specific monitoring functions Speed limit exceeded x x x x x x Spindle is stationary x x x x x x x x x x x x x x Spindle synchronized x x x x x x Speed in set...

Page 172: ...x x x x x x x x x x x x Channel specific interlocks Feed stop x x x x x x x NC Start disable x x x x x x x x x x x x x x Read in disable x x x x x x x x x x x x x x Axis specific interlocks Spindle disable x x x x x x x x x x x x x x Controller disable x x x x x x x x x x x x x x Axis disable x x x x x x x x x x x x x x Spindle specific interlocks Controller disable x x x x x x x x x x x x x x Spi...

Page 173: ... signals Selection A part program can be selected only if the relevant channel is in the Reset state The part program can be selected via operator input Machine operating area Program manager the PLC Selection of a program via the program number in Program list see Manual Operation and Programming Chapter System Reselection of an active program via the PLC HMI interface see Section Signals from HM...

Page 174: ...gram or part program block is automatically processed and IS Channel status active V3300 0003 5 and IS Program status running V3300 0003 0 are set The program is processed until the end of the program has been reached or the channel is interrupted or aborted by a STOP or RESET command Interrupts The START command is not effective if the prerequisite is not fulfilled Then one of the following inter...

Page 175: ...ubsequent stop of the part program processing The block indicator stops at the point of interruption 10 3 4 RESET command Function The RESET command IS Reset V3000 000 7 can be executed in every channel state This command is aborted by another command A RESET command can be used to interrupt an active part program or part program blocks After execution of the Reset command IS Channel status reset ...

Page 176: ...0 4 Program control Function Selection signal Activation signal Checkback signal SKP skip block V1700 0001 0 V3200 0002 0 DRY dry run feedrate V1700 0000 6 V3200 0000 6 ROV rapid traverse override V1700 0001 3 V3200 0006 6 Preselection SBL single block coarse SBL single block fine Single block User specific V3200 0000 4 M1 programmed stop V1700 0000 5 V3200 0000 5 V3300 0000 5 PRT program test V17...

Page 177: ...e 0 X IS Spindle stop X M2 in the block X M0 M1 in the block X IS Single block X Auxiliary functions output to PLC but not yet acknowledged X 10 3 7 Channel status Channel states The current channel status is signaled at the interface for the channel The PLC can then trigger certain responses and interlocks configured by the manufacturer depending on the status at the interface The channel status ...

Page 178: ... M2 in the block X M0 M1 in the block X IS Single block X Auxiliary functions output to PLC but not yet acknowledged X 10 3 8 Eventdriven program calls Application In the case of certain events an implied user program is to start This allows the user to activate the initial settings of functions or carry out initialization routines by part program command Event selection MD20108 PROG_EVENT_MASK ev...

Page 179: ... is ignored during the simulation Request which start event In the user program the system variable P_PROG_EVENT can be used to request the event which enabled the part program Event Part program start Table 10 7 Sequence when starting a part program Seque nce Command Boundary conditions must be satisfied before the command Comments 1 Channel selection Reset status Operating mode selection AUTO or...

Page 180: ...MASK MD20150 GCODE_RESET_VALUES MD20152 GCODE_RESET_MODE Control activated Reset sequence with evaluation The G code reset position continues to be specified with machine data Event Operator panel reset Table 10 9 Processing sequence in operator panel reset Seque nce Command Boundary conditions must be satisfied before the command Comments 1 Selection of channel and mode any Initial state Any mode...

Page 181: ...E_RESET_VALUES MD20152 GCODE_RESET_MODE Control activated Reset sequence with evaluation The G code reset position continues to be specified with machine data Chronological sequences For part program start and part program end Time sequence of VDI signals VB3300 0003 Program status and Channel status when processing a part program with an event driven program call for part program start and part p...

Page 182: ...nals 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 Neither IS V3300 0003 4 Program status aborted nor V3300 0003 7 Channel status reset are received between the program end and the start of the program event This is also the case between an operator panel reset and ...

Page 183: ...xecution is output The display can be suppressed in the current block display using the DISPLOF attribute in the PROC statement A single block stop can be disabled with SBLOF attribute command or via MD10702 IGNORE_SINGLEBLOCK_MASK prevent single block stop with Bit 0 The response to read in disable and single block processing can be controlled separately through the machine data MD20106 PROG_EVEN...

Page 184: ...ted from the RESET channel state is followed by an event driven program call as in earlier versions Bit0 1 An ASUB started from the RESET channel state is not followed by an event driven program call With the Part program start _N_CMA_DIR _N_PROG_EVENT_SPF is executed as a subroutine _N_PROG_EVENT_SPF must be ended with M17 or RET A return by means of REPOS command is not permitted and triggers al...

Page 185: ..._S Ax4 0 Speed for spindle start through virtual interface N20 ENDIF N30 M17 ENDIF M17 Start with RESET key One of the following part programs is automatically started with the RESET key Whose name is in MD11620 PROG_EVENT_NAME program name for Prog Event and that has been stored in one of the _N_CUS_DIR or _N_CMA_DIR directories _N_PROG_EVENT_SPF default Control via MD20107 PROG_EVENT_IGN_INHIBIT...

Page 186: ...ssed in the action blocks The spindle programming that accumulated during the block search can be output at a later point in time e g in an ASUB The program data for this is stored in the following system variables P_SEARCH_S P_SEARCH_SDIR P_SEARCH_SGEAR P_SEARCH_SPOS P_SEARCH_SPOSMODE 10 3 9 Asynchronous subroutines ASUBs Function It is possible to activate two different ASUBs PLCASUP1_SPF and PL...

Page 187: ... are of relevance for PLCASUP2_SPF Table 10 11 Assignment of the signals to the pulse diagram Signal Address PLCASUP1_SPF Address PLCASUP2_SPF Start V3400 0000 0 V3400 0001 0 Being executed V3400 1000 1 V3400 1001 1 Completed V3400 1000 0 V3400 1001 0 Error V3400 1000 3 V3400 1001 3 Interrupt no not allocated V3400 1000 2 V3400 1001 2 6WDUW HLQJ H HFXWHG RPSOHWHG UURU 9 9 9 9 Function activation v...

Page 188: ...ith the set bit Bit 0 is assigned to interrupt channel 1 PLCASUP1 Bit 1 is assigned to interrupt channel 2 PLCASUP2 The machine data is effective only if MD11602 ASUP_START_MASK Bit2 0 MD20117 IGNORE_SINGLEBLOCK_ASUP execute interrupt program completely in spite of single block In spite of selected SBL processing mode an assigned user ASUB is processed completely for the interrupt channel with the...

Page 189: ...5 x x x NC Start 14 mode change 4 or 6 6 x x x Direction key 15 mode change 4 or 5 7 x x x NC Start 14 8 x x x NC Start 15 9 x x x NC Start 13 mode change 10 or 11 10 x x x NC Start 16 mode change 9 or 11 11 x x x Direction key 17 mode change 9 or 10 12 x x x NC Start 13 mode change 10 or 11 13 x x x NC Stop 12 14 x x x NC Stop 7 at block end 5 15 x x x NC Stop 8 at JOG end 6 16 x x x NC Stop 10 a...

Page 190: ...SHG ZLWK 5HDG LQ GLVDEOH W 3URJUDP DERUWHG ZLWK 5 6 7 3URJUDP 1 0 6 0 1 0 LV UXQQLQJ 6SLQGOH UDPS XS 6 5HDG LQ GLVDEOH 9 6 1 6WDUW GLVDEOH 9 1 6723 IURP 3 1 67 57 IURP 3 6 6SLQGOH 6723 9 6 RQWUROOHU HQDEOH VSLQGOH 9 6 HHG 6723 D LV 9 6 RQWUROOHU HQDEOH D LV 9 6 3URJUDP VWDWXV VWRSSHG 9 6 3URJUDP VWDWXV DERUWHG 9 6 3URJUDP VWDWXV UXQQLQJ 9 6 6SLQGOH LQ VHWSRLQW UDQJH 9 6 6SLQGOH VWDWLRQDU 9 6 DFW V...

Page 191: ...rogram processing with dry run feedrate Processing of certain program sections Skipping certain program parts Graphic simulation 10 4 2 Program processing without axis movements PRT Functionality The part program can be started and processed with active Program test function via the IS NC Start V3200 0007 1 i e with auxiliary function outputs dwell times Only the axes spindles are simulated The so...

Page 192: ...he program is advanced to the next part program block via IS NC Start V3200 0007 1 When the function single block is activated the part program stops after every program block during processing In this case the activated single block type must be observed Single block type The following different types of single block are provided Single block coarse With this type of single block the blocks that ...

Page 193: ...are set IS Channel status interrupted V3300 0003 6 IS Program status stopped V3300 0003 2 The following interface signals are reset IS Channel status active V3300 0003 5 IS Program status running V3300 0003 0 10 4 4 Program processing with dry run feedrate DRY Functionality The part program can be started via IS NC Start V3200 0007 1 When the function is active the traversing velocities programmed...

Page 194: ...DRY status line on the user interface 10 4 5 Block search Processing of certain program sections Functionality To set the program run to a certain block target block of a part program the block search function can be used It can be selected whether or not the same calculations are to be performed during the block search up to the target block as would be performed during normal program operation A...

Page 195: ...rogrammed position is approached using the type of interpolation valid in the target block This is not true to contour Only the axes programmed in the target block are moved Block search without calculation Is used for a quick search in the main program No calculations are performed The internal controller values indicate the status valid before the search Whether the program can be executed subse...

Page 196: ...s Action blocks contain the actions accumulated during block search with calculation e g auxiliary function outputs and tool T D spindle S and feed programming commands During block search with calculation contour or block end point actions such as M function outputs are accumulated in so called action blocks These blocks are output on an NC Start after Search target found Note The action blocks a...

Page 197: ...circle end point error on G2 G3 Note For further information about the block search function please see Reference BP_ Operation and Programming 10 4 6 Skip part program blocks SKP Functionality When testing or breaking in new programs it is useful to be able to disable or skip certain part program blocks during program execution 6NLS EORFNV 1 DQG 1 GXULQJ SURFHVVLQJ ORFN EHLQJ SURFHVVHG 1 0 1 1 1 ...

Page 198: ...ough the Program operating area open program and Simulation softkey Here the IS Simulation active V1900 0000 6 is set and reset again on leaving the Program operating area or changing to Edit Display Due to numerous operating possibilities a complete workpiece or else only enlarged details of it can be displayed on the screen References BP_ Operation and Programming PLC user program The PLC user p...

Page 199: ...ng The start is timer specific Each active run time measurement is automatically interrupted in the stopped program state or for feedrate override zero The behavior of the activated timers for active dry run feedrate and program testing can be specified using machine data Total execution time in seconds of NC programs in the automatic mode in seconds AC_OPERATING_TIME In the AUTOMATIC mode the run...

Page 200: ... by the program or by operation note protection level for writing Range of values 0 to 999 999 999 The following channel specific machine data can be used to control counter activation counter reset timing and the counting algorithm MD27880 PART_COUNTER activation of workpiece counters MD27882 PART_COUNTER_MCODE workpiece counting with user defined M command Counter Number of workpieces required w...

Page 201: ... with their own definition Alarm output can be defined for the case of identity with AC_REQUIRED_PARTS workpiece target Users must reset the counter themselves The first output of the M command for counting after resetting the counter applies as start point This M command is set in MD27880 PART_COUNTER or MD27882 PART_COUNTER_MCODE for the relevant counter Display The contents of the counters are ...

Page 202: ...EOaxis no 0 2 20070 AXCONF_MACHAX_USED n Machine axis number valid in channel channel axis no 0 4 20080 AXCONF_CHANAX_NAME_TAB n Channel axis name in channel channel axis no 0 4 20100 DIAMETER_AX_DEF Geometry axis with transverse axis function 20106 PROG_EVENT_IGN_SINGLEBLOCK Prog events ignore the single block 20107 PROG_EVENT_IGN_INHIBIT Prog events ignore the read in disable 20108 PROG_EVENT_MA...

Page 203: ...in channel 0 63 22030 AUXFU_ASSIGN_VALUE n Auxiliary function value aux func no in channel 0 63 22550 TOOL_CHANGE_MODE New tool offset for M function Timers and counters of the channel Number Identifier Name Channel specific 27860 PROCESSTIMER_MODE Activation of the program runtime measurement 27880 PART_COUNTER Activation of the workpiece counters 27882 PART_COUNTER_MCODE n Workpiece counting via...

Page 204: ...802 READY V3100 0001 2 Active machine function REF Channel signals Number Bit Name PLC to NCK V3200 0000 4 Activate single block V3200 0000 5 Activate M01 V3200 0000 6 Activate dry run feed V3200 0001 0 Activate referencing V3200 0001 7 Activate program test V3200 0002 0 Block skip V3200 0006 0 Feed disable V3200 0006 1 Read in disable V3200 0006 2 Delete distance to go V3200 0006 3 Delete UP numb...

Page 205: ...us Aborted V3300 0003 5 Channel status Active V3300 0003 6 Channel status Interrupted V3300 0003 7 Channel status Reset V3300 4001 1 Workpiece target reached HMI to PLC V1700 0000 5 M01 selected V1700 0000 6 Dry run feed rate selected V1700 0001 3 Feed rate override selected for rapid traverse V1700 0001 7 Program test selected V1700 0002 0 Skip block selected V1900 0000 6 Simulation active ASUB s...

Page 206: ...Operating Modes Program Operation K1 10 7 Data lists Turning Milling Nibbling 206 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 207: ...ays ignore the compensation values and show the position values of an ideal machine The compensation values are displayed in the System Service Display Service Axes operating area under Abs compens value meas system 1 11 2 Backlash compensation Effect In the case of axes spindle with indirect measuring systems mechanical backlash results in corruption of the traverse path causing an axis for examp...

Page 208: ...1 1 Positive backlash normal case Negative backlash The encoder lags behind the machine part e g table the table then travels too far The correction value entered is negative High backlash compensation values The user has the option of applying the backlash compensation value gradually in several increments when the relevant axis reverses direction This prevents an excessive setpoint step change f...

Page 209: ... compensated for by the relevant position dependent compensation values The compensation values are derived from measured error curves and entered in the control in the form of compensation tables during installation A separate table must be created for each compensation relation The compensation values and additional table parameters are entered in the compensation tables using special system var...

Page 210: ...H Figure 11 2 Linear interpolation between the interpolation points Compensation value at reference point The compensation table should be structured such that the compensation value at the reference point is zero This prevents position jumps occurring when the LEC is activated after reference point approach 11 3 2 LEC Function The leadscrew error compensation measuring system error compensation L...

Page 211: ...nsation table 350 interpolation points N 0 349 are possible Note The max possible interpolation points are entered in the axis specific machine data MD38000 MM_ENC_ENC_COMP_MAX_POINTS 0 The following measuring system specific parameters must be set for the table see Fig Compensation table parameters system variables for LEC Compensation value for interpolation point N in compensation table AA_ENC_...

Page 212: ...the compensation table is repeated cyclically i e the compensation value at position AA_ENC_COMP_MAX interpolation point AA_ENC_COMP 0 k AXi is immediately followed by the compensation value at position AA_ENC_COMP_MIN interpolation point AA_ENC_COMP 0 0 AXi For rotary axes with modulo 360 it is therefore suitable to program 0 AA_ENC_COMP_MIN as the starting position and 360 AA_ENC_COMP_MAX as the...

Page 213: ...NC_COMP_STEP 0 X1 2 0 distance between interpolation points 2 0 mm AA_ENC_COMP_MIN 0 X1 200 0 compensation starts at 200 0 mm AA_ENC_COMP_MAX 0 X1 40 0 compensation ends at 40 0 mm AA_ENC_COMP_IS_MODULO 0 X1 0 compensation without modulo function M17 Values for more than 350 interpolation points result in alarm 12400 Element does not exist LV SRVLWLRQ QWHUSRODWLRQ SRLQWV RPSHQVDWLRQ YDOXH LQHDU LQ...

Page 214: ...or compensation which is why an axis assignment is required in every compensation table In order to compensate for sag of one axis base axis which results from its own weight the absolute position of another axis compensation axis must be influenced Sag compensation is therefore an inter axis compensation As illustrated in the diagram below the further the machining head moves in the negative Y1 a...

Page 215: ...An axis can be defined as the input variable base axis for several compensation tables settable via system variables 2 An axis can be defined as the recipient of the output variable compensation axis of several compensation tables settable via system variable The total compensation value is derived from the sum of the individual compensation values The following definition applies for the maximum ...

Page 216: ...ensation table It is thus possible for example to alter the compensation relations either from the part program or from the PLC user program e g switching over the tables depending on the machining requirements 10 With setting MD10260 CONVERT_SCALING_SYSTEM 1 basic system switchover active activates the following axial machine data MD32711 CEC_SCALING_SYSTEM_METRIC system of units of sag compensat...

Page 217: ...sation If the resulting total compensation value is greater than the maximum value alarm 20124 Sum of compensation values too high is output Program processing is not interrupted The compensation value output as an additional setpoint is limited to the maximum value Alteration of the total compensation value is also limited axially When the limit value defined by the following machine data is viol...

Page 218: ...WDWLRQ 7DEOH VXPPDWLRQ 7DEOH PXOWLSOLFDWLRQ 2XWSXW DVVLJQPHQW QDEOH WDEOH HYDOXDWLRQ HLJKWLQJ IDFWRU RPSHQVDWLRQ WDEOH W QSXW DVVLJQPHQW 3RVLWLRQ VHWSRLQW LGHDO DVLF D LV LV Q LV LV Q LV B 1 B0 B 680 B0 B 9 2 6 1B B08 7 B B7 W 6 1B B 287387B 6 W B 7 B 1 B 7 B 7 6 1B W 6 1B W 6 VWHP YDULDEOH 6HWWLQJ GDWD 0DFKLQH GDWD 6 1B B 1387B 6 W 6 6 Figure 11 5 Generation of compensation value for sag compensa...

Page 219: ... sag compensation function does not become active until the following conditions are fulfilled The option Sag compensation multidimensional has been enabled The function has been activated for the relevant machine axis compensation axis MD32710 CEC_ENABLE AXi 1 The compensation values have been stored in the non volatile NC user memory and are active after power ON Evaluation of the relevant compe...

Page 220: ... applied Distance between interpolation points AN_CEC_STEP t The distance between interpolation points defines the distance between the input values for the compensation table t 1B B67 3 W 1B B0 W ದ 1B B0 1 W Starting position AN_CEC_MIN t The initial position is the base axis position at which the compensation table t begins interpolation point 0 The compensation value for the initial position is...

Page 221: ...ded as an additional compensation value to the total compensation value of the compensation table Syntax AN_CEC_MULT_BY_TABLE t1 t2 where t1 index of table 1 of compensation axis t2 number of table 2 of compensation axis Please note that the number and index of the same table are different In general Table number table index 1 Compensation with modulo function AN_CEC_IS_MODULO t When compensation ...

Page 222: ...ample The following example shows the compensation table for sag compensation of axis Y1 Depending on the position of the Y1 axis a compensation value is applied to the X1 Z1 axis _N_NC_CEC_INI CHANDATA 1 AN_CEC 0 0 0 1 Compensation value interpolation point 0 for X1 0 µm AN_CEC 0 1 0 01 2 Compensation value interpolation point 1 for X1 10 µm AN_CEC 0 2 0 012 3 Compensation value interpolation poi...

Page 223: ...without modulo function M17 Table multiplication With the table compensation function any table can be multiplied by any other table i e even by itself The multiplication link is established using the system variables described above The following example for the compensation of machine foundation sagging illustrates an application of table multiplication On large machines sagging of the foundatio...

Page 224: ...tory compensation Measurement The Measurement function supplies the compensated actual position values required by the machine operator or programmer TEACH IN The TEACH IN function also uses compensated actual position values to determine the positions to be stored Software limit switches The compensated actual position values are also monitored at the software limit switches Position display The ...

Page 225: ...rence point of the basic axis is lost IS Referenced synchronized 1 V390x 0000 4 0 the LEC and sag compensation functions are deactivated in the affected axes When the reference point is reached these compensations are automatically reactivated Setting servo enables As a result of the compensation relationship a traversing motion by the basic axis may also cause the compensation axis to move making...

Page 226: ...ard control can be activated and de activated by means of the following high level language elements in the part program FFWON Feedforward control ON FFWOF Feedforward control OFF activation setting With MD32630 FFW_ACTIVATION_MODE the activation via FFWON or de activation via FFWOF of a specific axis can be determined FFWON and FFWOF are used to activate and de activate respectively the feedforwa...

Page 227: ... axis spindle and then entered in the machine data see next section 11 4 2 Speed feedforward control In the case of speed feedforward control a velocity setpoint is also applied directly to the input of the speed controller see figure below 0 48 9B63 75 B7 0 ULYH 1 3RVLWLRQ DFWXDO YDOXH 6SHHG FRQWUROOHU 3RVLWLRQ FRQWURO OHU UHIHUHQFH YDOXH 6HWSRLQW HHGIRUZDUG FRQWURO Figure 11 8 Speed feedforward ...

Page 228: ...M_METRIC Scaling system for sag compensation 32720 CEC_MAX_SUM Maximum compensation value for sag compensation 32730 CEC_MAX_VELO Change in velocity with CEC 32810 EQUIV_SPEEDCTRL_TIME 0 5 Equivalent time constant of the speed control loop 36500 ENC_CHANGE_TOL Backlash compensation partial section 38000 MM_ENC_COMP_MAX_POINTS 0 Interpolation points for encoder spindle compensation LEC for display ...

Page 229: ... of grooves A TRACYL variant is provided for lathes A second variant is provided for lathes with an additional Y machine axis or for milling machines with a suitable rotary table Machine prerequisite The lathe must be equipped with a C axis capable main spindle A second spindle must be able to drive the milling tool When used with TRACYL the milling machine must be equipped with a rotary table tha...

Page 230: ...main spindle as rotary axis Figure 12 1 Face end milling of turned parts with TRANSMIT 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 The linear axis XM intersects the rotary axis CM center of rotation Activation de activation of TRANSMIT The TRANSMIT function is activated in the ...

Page 231: ...e movement of the machine axes XM and CM produces the contour on the face end of the turned part with the milling cutter in accordance with the X Y path programmed straight or circular path The programmed Z axis infeed continues to be traversed as the Z axis 12 2 2 TRANSMIT configuration General The TRANSMIT transformation function is configured using machine data settings Note A file containing d...

Page 232: ...4120 TRAFO_GEOAX_ASSIGN_TAB_1 n Geometry axes for transformation 1 MD24200 TRAFO_TYPE_2 256 for second TRANSMIT transformation MD24210 TRAFO_AXES_IN_2 n Channel axes for transformation 2 MD24220 TRAFO_GEOAX_ASSIGN_TAB_2 n Geometry axes for transformation 2 Required assignment of channel axes for TRANSMIT transformation in machine data MD24110 MD24210 TRAFO_AXES_IN_1 2 0 Channel axis number of axis...

Page 233: ... defined as the center of rotation at point X 0 Y 0 of TRANSMIT plane X machine axis intersects the center of rotation In the vicinity of the pole small positional changes in the geometry axes X Y generally result in large changes in the machine rotary axis position exception path only results in a movement of the XM axis Workpiece machining operations close to the pole are therefore not recommend...

Page 234: ...CONF_MACHAX_USED 4 0 Channel axis names in 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 TRANSMIT transformation type Definition of transformation 1 in channel MD24100 TRAFO_TYPE_1 256 ...

Page 235: ...the special treatment of the tool offset only when required Change of tool length component for change of plane SD42940 TOOL_LENGTH_CONST 18 Assignment of the tool length offset independent of tool type SD42950 TOOL_LENGTH_TYPE 2 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_MACHA...

Page 236: ...G D LV SHUSHQGLFXODU WR URWDU D LV 0 LV LV SDUDOOHO WR URWDU D LV 0 5RWDU D LV 60 RUN VSLQGOH 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 The linear axis XM intersects the rotary axis CM center of rotatio...

Page 237: ...ics 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 This type of kinematics is typical for milling machines and makes it possible to machine grooves where the groove wall and groove base are mutually perpendicular provided t...

Page 238: ...with TRAFOOF in a separate block d machining diameter of the cylinder in mm TRAFOOF deactivates any active transformation function Programming principle without YM axis the geometry axes X Y Z are programmed N10 G0 X Z SPOS starting positions spindle in position control N20 G19 G94 T plane feed type select milling tool N30 SETMS 2 switchover master spindle is now the milling spindle N40 TRACYL 24 ...

Page 239: ...ersed as the X axis 7KH F OLQGHU XQUROOHG DW WKH RXWVLGH GLDPHWHU G UHVXOWV LQ SHULSKHUDO VXUIDFH ZLWK WKH SURJUDPPLQJ SODQH 7KLV LV DOVR XVHG WR GHWHUPLQH WKH URWDWLRQDO GLUHFWLRQ RI WKH FLUFOH IRU URRYH G S Figure 12 7 Peripheral surface of cylinder G19 Y Z plane OFFN address Distance of groove side wall from the reference contour also see TRACYL programming example Programming OFFN Distance in ...

Page 240: ...rmation is deactivated Additional assignments are specified for a transformation Note The assigned machine axis names channel axis names and geometry axis names must differ MD10000 AXCONF_MACHAX_NAME_TAB MD20080 AXCONF_CHANAX_NAME_TAB MD20060 AXCONF_GEOAX_NAME_TAB Exception for TRACYL The axis names of MD20060 and MD20080 geometry and channel axes can be the same for the TRACYL transformation e g ...

Page 241: ...is YM axis Machine data specifically for TRACYL MD24900 TRACYL_ROT_AX_OFFSET_1 Rotational position rotary axis setting when Y 0 in degrees 0 360 QJOH D E LQ GHJUHHV D 5RWDWLRQDO SRVLWLRQ RI URWDU D LV ZLWK E 3RVLWLRQ RI E D Figure 12 8 Rotational position of axis in the peripheral cylinder surface MD24910 TRACYL_ROT_SIGN_IS_PLUS_1 If the rotary axis rotates in an anti clockwise direction on the X ...

Page 242: ...D10000 AXCONF_MACHAX_NAME_TAB 0 X1 MD10000 AXCONF_MACHAX_NAME_TAB 1 Z1 MD10000 AXCONF_MACHAX_NAME_TAB 2 SP1 MD10000 AXCONF_MACHAX_NAME_TAB 3 SP2 MD10000 AXCONF_MACHAX_NAME_TAB 4 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 MD200...

Page 243: ...2 0 1 MD24110 TRAFO_AXES_IN_2 1 3 MD24110 TRAFO_AXES_IN_2 2 2 MD24110 TRAFO_AXES_IN_2 3 0 MD24110 TRAFO_AXES_IN_2 4 0 Assignment of geometry axes to channel axes MD24120 TRAFO_GEOAX_ASSIGN_TAB_2 0 1 MD24120 TRAFO_GEOAX_ASSIGN_TAB_2 1 3 MD24120 TRAFO_GEOAX_ASSIGN_TAB_2 2 2 Special TRACYL settings Offset of rotary axis MD24800 TRACYL_ROT_AX_OFFSET_1 0 Sign of rotary axis MD24810 TRACYL_ROT_SIGN_IS_P...

Page 244: ...e 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 See Chapter Tool Compensation and Monitoring W1 ...

Page 245: ...he reference contour Tool radius The tool radius in relation to the groove side wall is automatically taken into account with G41 G42 The full functionality of the plane tool radius compensation is available steady transition at outer and inner corners as well as solution of bottleneck problems 3HULSKHUDO VXUIDFH 0LOOLQJ WRRO 2 1 3L 1 1 1 3URJUDPPHG SDWK 3DWK 1 1 3DWK 1 1 2 1 Figure 12 11 Groove w...

Page 246: ...osition Y is now transformer axis N50 X20 M2 3 S2 300 Feed tool to groove base switch on milling spindle Approach of groove wall N60 G1 G42 Y70 Z100 TRC selection to approach groove wall Machining groove section path I N70 Z50 Groove part parallel to cylinder plane N80 Y10 Groove part parallel to circumference N90 OFFN 11 5 Change groove wall offset Machining groove section path II N100 G1 G42 Y10...

Page 247: ...a limit for axes affected by the transformation WALIMOF Continuous path control and rounding are interrupted An instructed intermediate movement block with chamfer or radius is not inserted Please note on deselection Tool radius compensation must be deselected G40 Continuous path control and rounding are interrupted An instructed intermediate movement block with chamfer or radius is not inserted F...

Page 248: ...f 2nd transformation possibly with axis sequence 24210 TRAFO_AXES_IN_2 Axis assignment at input of 2nd transformation 24220 TRAFO_GOEAX_ASSIGN_TAB_2 Geo axis assignment for 2nd transformation 24800 TRACYL_ROT_AX_OFFSET_1 Deviation of rotary axis from zero position in degrees 1st TRACYL 24810 TRACYL_ROT_SIGN_IS_PLUS_1 Sign of rotary axis for TRACYL 1st TRACYL 24820 TRACYL_BASE_TOOL_1 Distance of to...

Page 249: ...ecific measuring is integrated into this sequence The PLC user program must include the required functionality The measured offset values of the tool are available in the tool offset memory at the end of the measuring sequence The exact operating instructions are contained in Reference BP_ Operation and Programming 13 2 Hardware requirements 13 2 1 Probes that can be used General In order to measu...

Page 250: ...e used for this purpose for milling and machining centers Multidirectional probe 3D This probe type can be used unconditionally for measuring tool and workpiece dimensions Bidirectional probe This probe type is handled in the same way as a mono probe in milling and machining centers Bi directional probes can be used to take workpiece measurements on lathes Mono directional probe This probe type ca...

Page 251: ... immunity when connecting probes shielded lines must be used Reference BA Instruction Manual Section Configuring SINAMICS S120 with 802D sl 13 3 Channel specific measuring 13 3 1 Measuring mode Measuring commands MEAS and MEAW The measuring operation is activated from the part program A trigger event and a measuring mode are programmed Two different measuring modes are available MEAS Measurement w...

Page 252: ... as soon as the probe fulfills the activation criterion rising or falling edge Execution of the measurement job can thus be checked in the part program System variable AA_MM axis Access to measured value in the machine coordinate system MCS Read in part program axis stands for the name of the measurement axis X Y System variable AA_MW axis Access to measured value in the workpiece coordinate syste...

Page 253: ...l test The functional test for the probe is conducted favorably via an NC program _N_PRUEF_MESSTASTER_MPF Testing program probe connection N10 R10 Flag for trigger status N20 R11 MESSWERT_IN_X N30 T1 D1 Preselect tool offset for probe N40 ANF G0 G90 X0 F150 Starting position and meas velocity N50 MEAS 1 G1 X100 Measurement at measuring input 1 in the X axis N60 STOPRE N70 R10 AC_MEA 1 Read switchi...

Page 254: ...50 Prepositioning in the measured axis N25 MEAS 1 G1 X100 Measurement at 1st measuring input with rising switching edge in the X axis N30 STOPRE Stop decoding for subsequent evaluation of the result automatically executed when reading MEA N35 R11 AC_MEA 1 Read switching signal at 1st measuring input N37 IF R11 0 GOTOF FEHL1 Check switching signal N40 R R12 AA_MW X Read measured value in workpiece ...

Page 255: ...s re measured not its wear Softkeys and templates are provided for use by the user in JOG mode This supports the user during tool measuring Reference BP_ Operation and Programming Note The PLC user program must be created with the necessary sequences The functionality is not available beforehand Extreme caution must be taken when approaching the probe The probes only have a limited deflection path...

Page 256: ...ent and GEO lengths 2 and 3 are equal to zero The result for the radius is entered in the geometry component The associated adapter and wear components of both axes of the level are deleted Probe The tool measuring probe is a touch probe at a fixed location or is swiveled into the working area by means of a mechanical device If the probe plate is of rectangular design the edges should be aligned p...

Page 257: ...en the selected axis is traversed NCK outputs the IS Probe 1 active V27000001 0 The PLC then sets IS Feed disable V3200 0006 0 and NCK stops the axis movement Feed disable is maintained as long as a traverse key is depressed in JOG and the IS Measuring in JOG is active V1700 0003 7 is set After this the PLC outputs the IS Reset V3000 000 7 The traverse movement in JOG is thereby cancelled HMI reco...

Page 258: ...ing or probe calibration is complete the function can be deselected via the Back softkey This also resets the IS Measuring in JOG active V1700 0003 0 It is also reset when the operating area is exited The automatic program can be cancelled via IS Reset V3000 0000 7 or measuring in JOG can be closed via the the Back softkey This also cancels any set IS Feed disable V3200 0006 0 and IS Change mode d...

Page 259: ...03 7 Measuring in JOG active V1800 0000 0 AUTOMATIC mode request by HMI V1800 0000 1 MDA mode request by HMI V1800 0000 2 JOG mode request by HMI V1800 0000 4 Change mode disable request by HMI V1800 0000 6 Start measuring in JOG request by HMI V1800 0001 2 REF machine function request by HMI HMI signals from PLC to HMI VD1900 5004 Tool number for tool measuring in JOG input by PLC General from NC...

Page 260: ...Measurement M5 13 6 Data lists Turning Milling Nibbling 260 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 261: ...EN ISO 12100 1 EN ISO 12100 2 EN 418 EN 60204 1 EMERGENCY STOP in the control system The control system supports the machine manufacturer in implementing an EMERGENCY STOP function on the basis of the following features Activation of EMERGENCY STOP sequence in the NC via a PLC input The EMERGENCY STOP procedure in the NC reduces the speed of all axes and spindles as quickly as possible Unlocking o...

Page 262: ...aked along a braking ramp defined in MD36610 AX_EMERGENCY_STOP_TIME 2 The IS 802 READY V3100 0000 3 is reset 3 The IS EMERGENCY STOP active V2700 0000 1 is set 4 Alarm 3000 is set 5 On expiry of a delay that is set for specific axes spindles in MD36620 SERVO_DISABLE_DELAY_TIME shutdown delay controller enable the controller enable is cancelled It must be noted that MD36620 must be specified at lea...

Page 263: ...efined by the manufacturer can therefore be assumed 14 3 EMERGENCY STOP acknowledgment Acknowledge EMERGENCY STOP The EMERGENCY STOP state is reset only if IS Acknowledge EMERGENCY STOP V2600 0000 2 followed by IS Reset V3000 0000 7 are set It must be noted in this respect that IS Acknowledge EMERGENCY STOP and IS Reset must be set together for a long enough period for IS EMERGENCY STOP active V27...

Page 264: ...ancels the EMERGENCY OFF state unless IS EMERGENCY OFF V2600 0000 1 is still set 14 4 Data lists 14 4 1 Machine data Number Identifier Name Axis specific 36610 AX_EMERGENCY_STOP_TIME Length of the braking ramp for error states 36620 SERVO_DISABLE_DELAY_TIME Shutdown delay controller enable 14 4 2 Interface signals Number Bit Name General V2600 0000 0 Braking on the contour with EMERGENCY STOP V260...

Page 265: ...Stroke control 15 2 1 General information Functionality The stroke control is used in the actual machining of the workpiece The punch is activated via an NC output signal when the position is reached The punching unit acknowledges its punching motion with an input signal to the NC No axis may move within this time period Repositioning takes place after the punching operation High speed signals Hig...

Page 266: ...e hand they are applied via a high speed output to ensure that the punch stroke is not initiated until the metal sheet is stationary On the other they are applied via a high speed input to ensure that the sheet remains stationary while the punch is active The high speed digital inputs and outputs on the control are used to drive the punching unit The following signal chart illustrates the signal s...

Page 267: ...s is triggered by signal A0 For safety reasons signal E0 is high active in the case of an open circuit Stroke active is always set and the axes do not move The Stroke active signal is not reset again until the tool has moved away from the metal sheet t4 t3 The NC reacts to the Stroke active signal at instant t3 by canceling the Stroke initiation signal From this point in time onwards the NC is in ...

Page 268: ... plane The following diagram shows the various criteria that can be applied to stroke initiation DFW VWRS ILQH DFW VWRS FRDUVH QG RI LQWHUSRODWLRQ W W W W W W Figure 15 2 Signal chart Criteria for stroke initiation The time interval between t1 and t2 is determined by the reaction of the punching unit to setting of output A0 This cannot be altered but can be utilized as a lead time for minimizing d...

Page 269: ...ached a standstill at the instant of punching provided that the axis data is set appropriately However this variant also results in a maximum dead time see t1 G603 Depending on velocity and machine dynamics approximately 3 5 interpolation cycles are processed at the end of interpolation before the axes reach zero speed MD26018 NIBBLE_PRE_START_TIME In connection with MD26018 it is possible to dela...

Page 270: ...fter punching In this case the time interval between t4 and t 4 acts as a switching time dependent reaction time It is determined by the interpolation sampling time and the programmed punching nibbling mode PON SON When the punching unit is controlled via PON SON the maximum delay time is calculated to be t 4 t4 3 x interpolation cycles PONS SONS If the punch is controlled by PONS SONS the delay t...

Page 271: ...ayed stroke Activates delayed stroke output if permitted by PDELAYON V3200 0003 1 manual stroke initiation Enables the operator to initiate a punching operation controlled via the PLC without executing the part program The manual stroke initiation is acknowledged with IS V3300 0006 1 15 2 6 Punching and nibbling specific reactions to standard PLC signals Feed stop With IS Feed stop V3200 1000 3 V3...

Page 272: ...t acknowledgement by the high speed input A currently activated stroke cannot be suppressed 15 3 Activation and deactivation 15 3 1 Language commands Punching and nibbling functions are activated and deactivated via configurable language commands These replace the special M functions that were used in earlier systems Reference BPN Operation and Programming Nibbling Groups The language commands are...

Page 273: ...efined via machine data SPIF1 first interface is active SPIF2 second interface is active Note Only one function at a time can be active within a G code group similar for example to the various interpolation modes G0 G1 G2 G3 etc which are also mutually exclusive SPOF Punching and nibbling OFF The SPOF function terminates all punching and nibbling functions In this state the NCK responds neither to...

Page 274: ...information of the type mentioned then only one stroke takes place in this block since the start and end points are identical Programming example N70 X50 SPOF position without punch initiation N80 X100 SON activate nibbling initiate a stroke before the motion X 50 and on completion of the programmed movement X 100 SONS Nibbling ON in position control cycle SONS behaves in the same way as SON The f...

Page 275: ...y OFF PDELAYOF deactivates punching with delay function i e the punching process continues normally PDELAYON and PDELAYOF form a G code group Programming example SPIF2 activates the second punch interface i e the stroke is controlled via the second pair of high speed I Os see machine data MD26004 and MD26006 N170 PDELAYON X100 SPOF position without punch initiation activate delayed punch initiatio...

Page 276: ...15 3 2 Functional expansions Alternate interface Machines that alternately use a second punching unit or a comparable medium can be switched over to a second I O pair The second I O pair can be defined via the following machine data MD26004 NIBBLE_PUNCH_OUTMASK MD26006 NIBBLE_PUNCH_INMASK The interface is switched by command SPIF1 or SPIF2 Full punching nibbling functionality is available on both ...

Page 277: ...ME Example With an IPO cycle of 9 ms a stroke shall be released two cycles after reaching the interpolation end MD26018 NIBBLE_PRE_START_TIME 0 018 s A pre initiation time can also be programmed in setting data SD42402 NIBPUNCH_PRE_START_TIME This setting takes effective only if MD26018 0 has been set Monitoring of the input signal If the stroke active signal is fluctuating between strokes due to ...

Page 278: ... with this minimum interval The following programming measures example can be taken to prevent this N N100 STOPRE N110 SC_MINTIME_BETWEEN_STROKES 1 3 The function is not active when SD42404 0 Travel dependent acceleration An acceleration characteristic can be defined with PUNCHACC Smin Amin Smax Amax This command can be used to define different acceleration rates depending on the distance between ...

Page 279: ...lready been programmed via ACC then the acceleration limits defined with PUNCHACC refer to the reduced acceleration rate The function is deselected with Smin Smax 0 The acceleration rate programmed beforehand with ACC remains operative Block search In the case of a search for a block containing a nibbling function it is possible to program whether the punch stroke is executed at the block beginnin...

Page 280: ...SPP and SPN can be configured Note The values programmed with SPP are either mm or inch settings depending on the initial setting analogous to axes The automatic path segmentation function ensures that the path is divided into equidistant sections with linear and circular interpolation When the program is interrupted and automatic path segmentation is active SPP SPN the contour can be reentered on...

Page 281: ... PON is active Exception MD26014 PUNCH_PATH_SPLITTING 1 SPN has a non modal action Any previously programmed SPP value is suppressed for the block containing SPN but is re activated again in the following blocks Supplementary conditions The path segmentation function is operative with linear and circular interpolation The interpolation mode remains unchanged i e circles are traversed when circular...

Page 282: ... SPP and SPN until the programmed end point is reached This also applies to rotatable tool axes if programmed The response can be adjusted for single axes Example of SPP N1 G01 X0 Y0 SPOF Position without punch initiation N2 X75 SPP 25 SON Nibble with feed value 25 mm initiate punch before the first movement and after each path segment N3 Y10 Position with reduced SPP value because traversing dist...

Page 283: ...his is normally executed at the beginning of the first segment with nibbling operations and at its end with punching operations This means that when n segments are programmed n strokes are executed with punching operations but n 1 with nibbling Furthermore where no traversing information is available only a single stroke is executed even if several are programmed Should it be necessary to generate...

Page 284: ...utomatic path segmentation Turning Milling Nibbling 284 Function Manual 11 2012 6FC5397 1CP10 5BA0 segments Since punching is active the first stroke is initiated at the end of the first segment 631 631 Example Figure 15 5 Workpiece ...

Page 285: ...nt 3 mm activate nibbling N140 X525 SPOF Position at starting point of nibbling section on pitch circle path N170 G02 G91 X 62 5 Y62 5 I0 J62 5 SON Incremental circular interpolation with interpolation parameters activate nibbling N180 G00 G90 Y300 SPOF Position 15 4 3 Response in connection with single axes The path of single axes programmed in addition to path axes is distributed evenly among th...

Page 286: ...ave 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 In block N20 the C axis is rotated through 15 in each of the three intermediate blocks The axis response is the same in block N30 in the case of circular interpolation three sub blocks each with 15 axis rotation r 1 r r ...

Page 287: ... 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 It behaves in the same way in the circular interpolation block below r 1 r r r r r r 1 1 ...

Page 288: ...k The following circular interpolation block rotates the C axis through 15 in every sub block r 1 r r r r r r 1 1 The axis response illustrated in the diagram above can be particularly useful when applied to the axis of a rotatable tool in cases where it is used to place the tool in a defined direction e g tangential in relation to the contour but where the tangential control function must not be ...

Page 289: ...e block end If the functionality described above is to be implemented in a variant not specific to nibbling applications but with alignment of the special axis then stroke initiation can be suppressed by the following PLC interface signal V3200 0003 2 stroke suppression Application e g alignment of electron beam during welding A similar response can be programmed with the following machine data se...

Page 290: ...ormation 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 Tangential control for normal alignment of rotary axes for punches in relation to workpiece LH 6WDPS 7RRO URWDU D LV Figure 15 6 Illustration of a rotatable tool axis ...

Page 291: ...xis and C1 the die axis TRAILON C1 C 1 Enabling the coupled motion grouping G01 X100 Y100 C0 PON Initiate stroke with C axis C1 axis position C 0 C1 X150 C45 Initiate stroke with C axis C1 axis position C 45 C1 M30 Basic position No coupled motion groupings are active after power up Once the two tool axes have approached the reference point the coupled motion grouping is not generally separated ag...

Page 292: ...d additional angle is added to the calculated angle The tangential control function can be used in the linear and circular interpolation modes Example Linear interpolation The punching nibbling machine has a rotatable punch and die with separate drives 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 X10 Y5 Start pos...

Page 293: ...n of rotatable tool axes C C1 N60 M2 0RXQWLQJ SRVLWLRQ 3RVLWLRQ 3XQFKLQJ 1 1 1 1 1 1 1 1 1 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: ...ntrol with offset 90 N20 G03 X35 86 Y24 14 CR 20 SPP 16 SON Circular interpolation path segmentation four strokes are executed with 90 offset angle and tangential alignment along circular path N25 G0 X74 14 Y35 86 C0 PON Rotation of tool axes to 0 stroke N27 TANGON C 0 Activate tangential control with offset 0 N30 G03 X40 Y50 I 14 14 J14 14 SPN 5 SON Circular interpolation path segmentation five s...

Page 295: ...igure 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 ...

Page 296: ...art 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 Defined start of nibbling first stroke at 1 last stroke at 2 N30 Y20 Defined start of nibbling first stroke at 3 last stroke at 4 N40 X20 Defined start of nibbling first stroke at 5 last stroke at 6 N50 SPOF N60 M2 ...

Page 297: ...tial axis N8 TANGON Z 0 Select tangential control N10 G0 X20 Y120 Position 1 is approached N20 X120 SPP 20 SON Defined start of nibbling tangential control selected first stroke at 1 last stroke at 2 N30 SPOF TANGOF Deselect nibbling mode and deselect tangential control N38 TANGON Z 90 Select tangential control N40 Y20 SON Defined start of nibbling tangential control selected first stroke at 2 rot...

Page 298: ...ned start of nibbling 5 punches initiated N20 X10 Y30 SPP 0 One punch is initiated at the end of the path N30 X90 SPP 20 4 punches initiated at intervals of 20 mm N40 SPOF N50 M2 Example 4 Programming of SPN Program code Comment N5 G0 X10 Y10 Positioning N10 X90 SPN 4 SON Defined start of nibbling 5 5 punches initiated N20 X10 Y30 PON One punch is initiated at the end of the path N30 X90 SPN 4 4 p...

Page 299: ...10 Y30 Positioning N10 X90 SPP 20 PON No defined start of nibbling 4 punches initiated N15 Y10 One punch is initiated at the end of the path N20 X10 SPP 20 4 punches initiated at intervals of 20 mm N25 SPOF N30 M2 Example 6 Programming of SPN Program code Comment N5 G0 X10 Y30 Positioning N10 X90 SPN 4 PON No defined start of nibbling 4 punches initiated N15 Y10 One punch is initiated at the end o...

Page 300: ...he vertical line of holes punch single hole N110 G91 Y125 SPP 25 PON End point coordinates incremental path segment 25 mm activate punching N120 G90 X150 SPOF Absolute dimensioning position at the start point 2 of the horizontal line of holes N130 X375 SPP 45 PON End point coordinates path segment 45 mm N140 X275 Y160 SPOF Positioning to starting point 3 of the oblique line of holes N150 X150 Y75 ...

Page 301: ...MASK Definition of punching and nibbling axes 26014 PUNCH_PATH_SPLITTING Activation of automatic path segmentation 26016 PUNCH_PARTITION_TYPE Behavior of single axes with active automatic path segmentation 26018 NIBBLE_PRE_START_TIME Automatically activated pre initiation time 26020 NIBBLE_SIGNAL_CHECK Monitoring of the input signal 15 8 2 Setting data Number Identifier Description Channel specifi...

Page 302: ...ng Nibbling 302 Function Manual 11 2012 6FC5397 1CP10 5BA0 Number Bit Name V3200 0003 4 Delayed stroke V3200 0003 5 Manual stroke initiation Signals from channel V3300 0006 0 Stroke initiation active V3300 0006 1 Acknowledgement of manual stroke initiation ...

Page 303: ...e functions INC incremental dimension and handwheel traverse in JOG are interpreted and traversed as diameter values for the associated transverse axis traversal in WCS with this axis Setpoint actual value display If the DIAMON function is activated for a transverse axis then the position distancetogo and REPOS offset are displayed in the diameter when the workpiece coordinate system WCS is select...

Page 304: ...e axis with the MEAS MEASW functions i e the internal radius values are doubled and stored For measurement or reading in the MCS the calculated values are stored as radius values 16 3 Constant cutting rate G96 Functionality Requirement A controlled spindle must be present With activated G96 function the spindle speed is adapted to the currently machined workpiece diameter position of the transvers...

Page 305: ... Axes P1 16 3 Constant cutting rate G96 Turning Milling Nibbling Function Manual 11 2012 6FC5397 1CP10 5BA0 305 GLDPHWHU 6 VSLQGOH VSHHG 6 6 Q 6 Q FRQVWDQW 7UDQVYHUVH D LV 0 Figure 16 1 Constant cutting rate G96 ...

Page 306: ...Transverse Axes P1 16 3 Constant cutting rate G96 Turning Milling Nibbling 306 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 307: ...ting mode even when a part program is already being processed in the channel The part program continues to run uninhibited even if the concurrent positioning axis has not reached the position defined by the PLC Activation from PLC The concurrent positioning axis is activated via the user interface area 380x 3000 390x 3000 from the PLC Feedrate with feedrate setting 0 the feedrate is determined by ...

Page 308: ...UL 1 MD30320 DISPLAY_IS_MODULO 1 During acceleration the axis becomes a neutral axis When a traverse request is transferred via the VDI interface a neutral axis without preceding axis replacement automatically changes to a competing positioning axis PLC axis After completing the traverse if for instance the programmed end position has been reached or if the traverse has been interrupted the axis a...

Page 309: ...x 3000 7 1 Positioning axis active indicates that the function is active and that the output signals are valid WR 3 D LV IURP 3 D LV 3RVLWLRQLQJ D HV DFWLYH 3RVLWLRQ UHDFKHG 6WDUW UURUV Figure 17 1 Pulse diagram normal condition 1 First function activation via positive edge of Start 2 Positioning axis active 1 shows that the function is active and that the output signals are valid 3 Positive ackno...

Page 310: ...ction activation via positive edge of Start 14 Positioning axis active 1 shows that the function is active and that the output signals are valid Cancel The PLC axis control cannot be aborted by means of parameter Start but only by means of the axial interface signals e g delete distancetogo The axial interface also returns status signals of the axis that may need to be evaluated e g exact stop tra...

Page 311: ... of a traverse request from the VDI interface area an illegal change to a PLC axis is ended with the start signal Competing positioning axis active at the VDI interface Note Competing positioning axes get their block end points exclusively from the PLC an can be started at any point in time 17 3 Data lists 17 3 1 Machine data Number Identifier Description Axis spindle specific 30460 BASE_FUNCTION_...

Page 312: ...d to the NC while still in motion 50 32 Permanently assigned PLC axis jogs or references 60 3C Permanently assigned PLC axis channel status does not currently permit a start 100 64 Corresponds to alarm number 16830 105 69 Corresponds to alarm number 16770 106 6a Corresponds to alarm number 22052 107 6b Corresponds to alarm number 22051 108 6c Corresponds to alarm number 22050 109 6d Corresponds to...

Page 313: ...1 83 Software limit switch minus 132 84 Working area limitation plus 133 85 Working area limitation minus 135 8 Corresponds to alarm number 17501 136 88 Corresponds to alarm number 17503 System or other serious alarms 200 c8 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 314 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 315: ...cing mode Output cam An output cam for referencing may be required for linear axes and its signal has the following tasks Selection of the direction of travel when approaching the zero mark synchronized pulse Selection of the zero mark where required BERO A BERO inductive proximity switch can be deployed as the encoder for the synchronized pulse instead of the zero mark of the position encoder pre...

Page 316: ...is specific MD34110 REFP_CYCLE_NR axis sequence for channel spec referencing can be used to define the sequence in which the machine data is referenced If all axes entered in MD34110 REFP_CYCLE_NR have reached their end points the All axes referenced interface signal V3300 0004 2 is enabled Special features Referencing is aborted with Reset interface signal V3000 0000 7 All axes that have not reac...

Page 317: ...an be subdivided into three phases 1 Phase Traversing to the reference cam 2 Phase Synchronization with the zero mark 3 Phase Traversing to the reference point W 3KDVH 3KDVH 3KDVH 0 5 3B9 2B326 5HIHUHQFH SRLQW SRVLWLRQLQJ YHORFLW 0 5 3B9 2B6 5 B0 5 5 5HIHUHQFH SRLQW FUHHS YHORFLW 0 5 3B9 2B6 5 B 0 5HIHUHQFH SRLQW DSSURDFK YHORFLW _9HORFLW _ 3RVLWLRQ PHDVXULQJ V VWHP HUR PDUN 6 5HIHUHQFHG V QFKURQL...

Page 318: ...xis comes to a halt and a corresponding alarm is displayed The machine axis cannot be stopped and restarted with NC stop NC start Monitoring of the zero mark is active with MD34060 REFP_MAX_MARKER_DIST Characteristics of traversing to the reference point phase 3 The feedrate override and feedrate stop is in effect The machine axis can be stopped and re started with NC stop NC start If reference po...

Page 319: ...h of a reference cam Example of case Synchronizing pulse before cam reference coordinate before synchronizing pulse synchronizing pulse search with falling cam edge The reference cam must be long enough so that when the cam is approached with the reference point approach velocity the braking operation ends at the cam the axis comes to a standstill at the cam and the cam is exited in the opposite d...

Page 320: ... marks This can be achieved by Set MD34080 REFP_MOVE_DIST MD34090 REFP_MOVE_DIST_CORR MD 34100 REFP_SET_POS 0 Reference axis In JOG mode traverse the axis to half the path length between the two zero marks This path is independent of the pitch of the leadscrew S and the gear ratio n e g S 10 mm rev n 1 1 produces a path of 5 mm Calibrate the cam switch so that switching is done at exactly this pos...

Page 321: ...th of approx 20 mm is all that is required to reference the machine axis Referencing can be performed from any axis position in the positive or negative direction exception end of travel range 18 3 2 Basic parameter assignment Linear measuring systems The following data must be set to parameterize linear measuring systems The absolute offset between the machine zero point and the position of the f...

Page 322: ...e where the exact position of the machine axis relative to machine zero can be determined easily using a laser interferometer for example 3 Determine the actual position of the machine axis via the operator interface screen 4 Measure the current position of the machine axis with reference to the machine zero point 5 Calculate absolute offset and enter in MD34090 The absolute offset is calculated w...

Page 323: ...antage Plausibility check by NC is possible Increase in reliability of referencing result 18 3 3 Chronological sequence Chronological sequence Referencing with distance coded reference marks can be divided into two phases Phase 1 Travel across the reference marks with synchronization Phase 2 Traveling to a fixed destination point 9 UHI SRLQW DSSURDFK GHOD 9 WUDYHUVH FRPPDQG PLQXV 9 DQG WUDYHUVLQJ ...

Page 324: ... 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 Sequence when starting from the reference cam If the machine axis is at the reference cam at the start of the reference point traversing it accelerates to the parameterized reference point creep velocity against the p...

Page 325: ...erence marker distance The machine axis will then traverse in opposite direction at half the parameterized reference point creep velocity MD34040 and the search for reference mark is restarted If a faulty reference mark distance is detected again the machine axis is stopped and the reference point traversing is aborted alarm 20003 fault in the measuring system Abort criterion If the parameterized ...

Page 326: ...4070 REFP_VELO_POS reference point positioning velocity MD34100 REFP_SET_POS reference point value The machine axis is referenced To identify this the NC sets the relevant interface signal V390x 0000 4 1 referenced synchronized 1 No travel to target position The machine axis is now referenced To identify this the NC sets the relevant interface signal V390x 0000 4 1 referenced synchronized 1 Featur...

Page 327: ...ecial features of rotary measuring systems On rotary distancecoded measuring systems the absolute position can only be determined uniquely within one revolution Depending on the mechanical mounting of the encoder the overtravel of the absolute position in the hardware does not always coincide with the traversing range of the rotary axis Special features of modulo rotary axes With module rotary axe...

Page 328: ... measurement system is not synchronized by approaching a reference cam It is calibrated instead For this purpose the actual value of the absolute encoder is set once during start up and transferred to the control 18 4 2 Operator assisted calibration Basic procedure Move the axis to be calibrated to a defined position to set the resulting actual value Chronological sequence 1 Set MD34200 ENC_REFP_M...

Page 329: ..._POS appears in the actual value display of the axis position 8 Exit JOG REF operating mode The calibration operation for this axis is now complete 18 5 Secondary conditions for absolute encoders 18 5 1 Calibrating absolute encoders Calibration time The calibration process determines the offset between the machine zero and the encoder zero and stores it in a non volatile memory Normally calibratio...

Page 330: ...ed out after loading and activating the data 18 6 Data lists 18 6 1 Machine data Number Identifier Name Channel specific 20700 REFP_NC_START_LOCK NC Start disable without reference point Axis specific 30200 NUM_ENCS Number of encoders 30240 ENC_TYP 0 Actual value encoder type 30330 MODULO_RANGE Magnitude of modulo range 30340 MODULO_RANGE_START Starting position of modulo range 31122 BERO_DELAY_TI...

Page 331: ... sequence for channel specific referencing 34200 ENC_REFP_MODE 0 Referencing mode 34210 ENC_REFP_STATE 0 Status of absolute encoder 34220 ENC_ABS_TURNS_MODULO 0 Absolute encoder range for rotary encoders 34330 REFP_STOP_AT_ABS_MARKER 0 Distancecoded linear measuring system without destination point 36300 ENC_FREQ_LIMIT 0 Encoder frequency limit 36302 ENC_FREQ_LIMIT_LOW 0 Encoder limit frequency re...

Page 332: ...Reference Point Approach R1 18 6 Data lists Turning Milling Nibbling 332 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 333: ...limited e g when the tool or workpiece is rotated Definition of a rotary axis An axis is declared as rotary axis with the aid of MD30300 IS_ROT_AX 1 Note The geometry axes X Y Z cannot be used as rotary axes or spindle MD20050 AXCONF_GEOAX_ASSIGN_TAB assignment of geometry axis channel axis defines these geometry axes Axis addresses axis identifiers direction DUWHVLDQ FRRUGLQDWH V VWHP Figure 19 1...

Page 334: ...one in a block If rotary axes and linear axes traverse along a common path with G94 or G95 the feed should be interpreted in the unit of measurement of the linear axes e g mm min inch min The tangential velocity of the rotary axis in this case refers to the diameter DE unit diameter DE 360 p mm with p circle constant If the diameter is the same as the unit diameter D DE the programmed angular spee...

Page 335: ...d positioning MD30310 ROT_IS_MODULO as well as the position display MD30320 DISPLAY_IS_MODULO individually in modulo 360 for each rotary axis depending on the particular machine requirements Axis is modulo MD30310 ROT_IS_MODULO 1 Activation of this machine data allows the special rotary axis response to be utilized The positioning action of the rotary axis for programming G90 AC ACP ACN or DC A mo...

Page 336: ...ammed is output for values with a negative sign or 360 ACP positive and ACN negative define the traversing direction of the rotary axis unambiguously irrespective of actual position When programming with AC or with G90 the traversing direction depends on the actual position of the rotary axis If the target position is greater than the actual position the axis traverses in the positive direction ot...

Page 337: ...e can be negative and 360 The value s sign unequivocally defines the rotary axis traversing direction Example C IC 720 C axis traverses to 720 incrementally in the positive direction C IC 180 C axis traverses to 180 incrementally in the negative direction Endless traversing range As soon as the modulo function is active no limit is placed on the traversing range software limit switches are not act...

Page 338: ...h the modulo axis In this case however the traversing range is limited by the software limit switches Limited traversing range The traversing range is limited as with linear axes The range limits are defined by the plus and minus software limit switches 19 4 Data lists 19 4 1 Machine data Number Identifier Name General 10000 AXCONF_MACHAX_NAME_TAB Machine axis name 10210 INT_INCR_PER_DEG Computati...

Page 339: ...anual 11 2012 6FC5397 1CP10 5BA0 339 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 ...

Page 340: ...Rotary Axes R2 19 4 Data lists Turning Milling Nibbling 340 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 341: ... G26 LIMS Position encoder assembly on the spindle or on the spindle motor Spindle monitoring for min and max speed Dwell time in spindle revolutions G4 S An enabled spindle can be used instead of a controlled spindle However a spindle speed S is then not entered via the program but for example manually gearbox at the machine This does not permit programming of speed limits The following is possib...

Page 342: ... V390x 0000 0 20 2 Spindle modes Spindle modes The spindle can have the following modes Control mode see Section Spindle control mode Oscillation mode see Section Spindle oscillation mode Positioning mode see Section Spindle positioning mode Axis mode see Section Spindle axis mode Tapping without compensating chuck see also Chapter Feed V1 63 2 63 2 0 0 0 0 0 7DSSLQJ ZLWKRXW FRPSHQVDWLQJ FKXFN 632...

Page 343: ...ositioning mode Positioning mode control mode M3 M4 or M5 are used to change to control mode if the orientation of the spindle is to be terminated The last programmed spindle speed S value is reactivated Positioning mode oscillation mode If the orientation of the spindle is to be terminated M41 to M45 can be used to change to oscillation mode When the gear change is complete the last programmed sp...

Page 344: ...inues at G94 With G95 the axes stop due to the missing feedrates as does the program run if G1 G2 is active 20 2 2 Spindle oscillation mode Note The function for oscillation via the PLC is not available for the G N plus and pro versions Starting oscillation mode This oscillation movement makes it easy to engage a new gear stage In principle the new gear stage can also be engaged without oscillatio...

Page 345: ...rates in the opposite direction same direction as phase 1 etc Oscillation via PLC With the IS Oscillation speed V380x 2002 5 the spindle motor accelerates to the velocity with oscillation acceleration specified in MD35400 SPIND_OSCILL_DES_VELO oscillation speed The direction of rotation is determined by IS Set direction of rotation counterclockwise or IS Set direction of rotation clockwise V380x 2...

Page 346: ...set the oscillation stops However the spindle remains in oscillation mode The IS Gear changed should always be used for terminating gear stage change The IS Reset V3000 0000 7 does not terminate oscillation mode If an indirect measuring system is used synchronization is lost The spindle is re synchronized the next time the zero mark is crossed Reset during gear stage change The spindle cannot be s...

Page 347: ...PLC and the spindle has reached its position IS Exact stop fine for spindle V390x 0000 7 Requirements A spindle position actual value encoder is absolutely essential Positioning from rotation D D 0 1 B 5 4B 0 7B 2 HQFRGHU OLPLW IUHTXHQF UHV QFKURQL DWLRQ YDOXH RI 0 3KDVH WR 0 63 1 B326 75 B9 2 SRVLWLRQ FRQWURO DFWLYDWLRQ VSHHG 6326 0 1 B 5 4B 0 7 HQFRGHU OLPLW IUHTXHQF 7LPH V 6SHHG UHY PLQ Figure ...

Page 348: ...e brakes from the calculated braking point with MD35210 GEAR_STEP_POSCTRL_ACCEL to the target position Phase 5 The position control remains active and stops the spindle in the programmed position The IS Position reached with exact stop fine V390x 0000 7 and coarse V390x 0000 6 are set if the distance between the spindle actual position and the programmed position spindle setpoint position is less ...

Page 349: ...ce between the spindle actual position and the programmed position spindle setpoint position is less than the settings for the exact stop fine and coarse limits MD36010 STOP_LIMIT_FINE and MD36000 STOP_LIMIT_COARSE Positioning from standstill spindle is synchronized The spindle has already been turned by one spindle revolution with M3 and M4 and was then brought to a standstill with M5 D D 3KDVH W...

Page 350: ...oning SPOS is cancelled with Reset or NC stop 20 2 4 Spindle axis mode When axis mode For certain machining tasks on lathes For face machining with TRANSMIT or peripheral surface machining with TRACYL the spindle must be operated as rotary axis Outside of TRANSMIT and TRACYL you can perform normal rotary axis functions In this case it is programmed under the address of the rotary axis e g C Requir...

Page 351: ... this process is referred to as referencing see Chapter Reference Point Approach R1 Installation position of the position measurement system Directly on the motor in combination with a BERO proximity switch on the spindle zero mark encoder Directly on the spindle Above the measuring gearbox plus BERO switch on the spindle Synchronization possibilities When the spindle is switched on the spindle ca...

Page 352: ...e programmed which exceeds the maximum encoder limit frequency MD36300 ENC_FREQ_LIMIT the maximum mechanical speed limit of the encoder must not be exceeded the synchronization is lost The spindle continues to rotate but with reduced functionality If a speed is then reached that is below the encoder limit frequency in MD36302 ENC_FREQ_LIMIT_LOW value of MD36300 the spindle automatically synchroniz...

Page 353: ...HOHFWLRQ Q PD PD VSLQGOH VSHHG RI WKH QG JHDU VWDJH J PLQ PLQ VSLQGOH VSHHG RI WKH QG JHDU VWDJH IRU DXWRP JHDU VWDJH VHOHFWLRQ J PD PD VSLQGOH VSHHG RI WKH QG JHDU VWDJH IRU DXWRP JHDU VWDJH VHOHFWLRQ LWK DXWRPDWLF JHDU VWDJH VHOHFWLRQ WKLV VSHHG UDQJH LV QRW XWLOL HG LQ JHDU VWDJH PD Q PD J PD Q PLQ J PD J PLQ J VSHHG 0D PRWRU 6SLQGOH VSHHG UHY PLQ 0RWRU VSHHG UHY PLQ Figure 20 6 Gear stage chan...

Page 354: ... Change gear V390x 2000 3 and the IS Set gear stage A to C V390x 2000 0 to 2 are enabled The automatic gear stage selection function initially compares the programmed spindle speed with the minimum and maximum speed of the current gear stage If the comparison is positive a new gear stage is not defined If the comparison is negative the comparison is performed on each of the gear stages starting wi...

Page 355: ... via M40 and S value or M41 to M45 is not performed same effect as if the IS Read in disable V3200 0006 1 were enabled When stationary the spindle IS Axis spindle stationary V390x 0001 4 can be activated with the IS Oscillation speed V380x 2002 5 see Section Spindle oscillation mode When the new gear stage is engaged the PLC user sets the IS Actual gear stage V380x 2000 0 to 2 and IS Gear changed ...

Page 356: ...OH LV VWDWLRQDU DQG RVFLOODWLRQ VWDUWV RVFLOODWLRQ YLD 1 7KH 2VFLOODWLRQ VSHHG LQWHUIDFH VLJQDO PXVW EH HQDEOHG E WKH WLPH W W KHQ 6 LV SURJUDPPHG WKH 1 GHWHFWV D QHZ JHDU VWDJH QG JHDU VWDJH HQDEOHV 6 KDQJH JHDU DQG LQKLELWV H HFXWLRQ RI WKH QH W SDUW SURJUDP EORFN W W W W 7 7 6 6SLQGOH VWRS 6SLQGOH VSHHG QWHUQDO IHHG GLVDEOH QG JHDU VWDJH HQJDJHG VW JHDU VWDJH HQJDJHG 6 2VFLOODWLRQ VSHHG 6 FWXDO...

Page 357: ...he machine data included in a parameter set are marked specifically in Section Machine Data The following machine data is added per gear stage for each parameter set index n n 1 1st gear stage of the spindle etc MD35110 GEAR_STEP_MAX_VELO n MD35120 GEAR_STEP_MIN_VELO n MD35130 GEAR_STEP_MAX_VELO_LIMIT n MD35140 GEAR_STEP_MIN_VELO_LIMIT n MD35200 GEAR_STEP_SPEEDCTRL_ACCEL n MD35210 GEAR_STEP_POSCTR...

Page 358: ...ning SPOS ACP Pos The position is always approached with positive direction of motion If necessary the direction of motion is inverted prior to positioning SPOS IC Pos The traversing path is specified The direction of traversing is obtained from the sign in front of the traversing path If the spindle is in motion the direction of traversing is inverted if necessary to allow traversing in the progr...

Page 359: ...W JHDU VWDJH 3URJUDPPDEOH VSLQGOH VSHHG OLPLW 3URJUDPPDEOH VSLQGOH VSHHG OLPLW 06 0D LPXP VSLQGOH VSHHG IRU FXUUHQW JHDU VWDJH 6SHHG UDQJH RI VSLQGOH RU VSLQGOH FKXFN 6 LV VSLQGOH VWDWLRQDU 0LQLPXP VSLQGOH VSHHG IRU FXUUHQW JHDU VWDJH 0D LPXP VSLQGOH VSHHG 0D LPXP HQFRGHU OLPLW IUHTXHQF 6SHHG Figure 20 9 Ranges of spindle monitoring functions speeds 20 6 1 Axis spindle stationary Only when the spi...

Page 360: ...d A maximum speed is defined for maximum spindle speed spindle monitoring which the spindle may not exceed The maximum spindle speed is entered in MD35100 SPIND_VELO_LIMIT The control limits an excessive spindle speed setpoint to this value If the actual spindle speed exceeds the maximum spindle speed despite allowance for the spindle speed tolerance MD35150 SPIND_DES_VELO_TOL there is a drive fau...

Page 361: ...indle position encoder is monitored by the control the limit can be exceeded It is the responsibility of the machine tool manufacturer to ensure that the configuration of the spindle motor gearbox measuring gearbox encoder and machine data prevents the maximum speed of the actual spindle position encoder from being exceeded Maximum encoder limit frequency exceeded If the spindle reaches a speed in...

Page 362: ...em monitors the distance from the spindle with reference to the actual position to the programmed spindle set position target point Two limit values can be defined as incremental path starting at the spindle set position in the following machine data MD36000 STOP_LIMIT_COARSE exact stop limit coarse MD36010 STOP_LIMIT_FINE exact stop limit fine Regardless of the two limit values the positioning of...

Page 363: ...ese functions require a second spindle for the driven milling tool The main spindle is operated as a rotary axis with these functions Master spindle A series of functions is connected to the master spindle which are only possible for this spindle G95 Rev feedrate G96 G97 Constant cutting rate LIMS Upper speed limit for G96 G97 G33 G34 G35 G331 G332 Thread cutting thread interpolation M3 M4 M5 S Si...

Page 364: ...for spindle 2 M1 40 M1 45 Gear stages for spindle 1 if available M2 40 M2 45 Gear stages for spindle 2 if available SPOS n Position spindle n SPI n Converts the spindle number n into the axis identifier e g SP1 or CC n must be a valid spindle number 1 or 2 The spindle identifiers SPI n and Sn are identical in terms of function P_S n Last programmed speed of spindle n AA_S n Actual speed of spindle...

Page 365: ...DISPLAY_IS_MODULO Position display 31050 DRIVE_AX_RATIO_DENOM n Denominator load gearbox 31060 DRIVE_AX_RATIO_NUMERA n Numerator load gearbox 32200 POSCTRL_GAIN n Servo gain factor Kv 32810 EQUIV_SPEEDCTRL_TIME n Equivalent time constant speed control circuit for feedforward control 34040 REFP_VELO_SEARCH_MARKER Reference point creep speed 34060 REFP_MAX_MARKER_DIST Monitoring of zero mark distanc...

Page 366: ...illation 35440 SPIND_OSCILL_TIME_CW Oscillation time for M3 direction 35450 SPIND_OSCILL_TIME_CCW Oscillation time for M4 direction 35500 SPIND_ON_SPEED_AT_IPO_START Feed enable with spindle in setpoint range 35510 SPIND_STOPPED_AT_IPO_START Feed enable with stationary spindle 36060 STANDSTILL_VELO_TOL Threshold velocity Axis spindle stationary 36200 AX_VELO_LIMIT n Threshold value for velocity mo...

Page 367: ...LC VB380x 2003 Spindle override V380x 5006 4 Spindle positioning V390x 0000 7 Position reached with exact stop fine V390x 0000 6 Position reached with exact stop coarse V390x 0000 4 Referenced synchronized 1 V390x 0000 2 Encoder limit frequency exceeded 1 V390x 0000 0 Spindle no axis V390x 0001 7 Current controller active V390x 0001 6 Speed control loop active V390x 0001 5 Position controller acti...

Page 368: ...Spindle S1 20 9 Data lists Turning Milling Nibbling 368 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 369: ...exing axes are known as coded positions or indexing positions Applications Indexing axes are used predominantly in connection with specific types of tool magazines such as tool turrets tool chain magazines or tool cartridge magazines The coded positions refer to the individual locations of the tools in the magazines During a tool change the magazine is positioned at the location containing the too...

Page 370: ...1 1 When the reference point is reached the indexing axis moves only to indexing positions in JOG mode during conventional and incremental traversing Exception No indexing positions are approached when traversing with the handwheel V390x 0000 4 referenced synchronized 1 0 If the axis is not referenced the indexing positions are not taken into account during manual traversal in JOG Continuous trave...

Page 371: ...er indexing position to be approached Handwheel traversal When the indexing axis is traversed by means of the handwheel in JOG mode the indexing positions are ignored As the handwheel is turned the indexing axis moves to any position depending on the basic system in mm inches or degrees If traversing of the indexing axis with the handwheel is to be interlocked this can be handled by the PLC user p...

Page 372: ...ach absolute coded position in positive direction CACN Approach absolute coded position in negative direction CIC Approach incremental coded position CDC Approach coded position along direct shortest path With absolute positioning the indexing position to be approached is programmed and with incremental positioning the number of indexes to be traversed in the or direction is programmed On rotary a...

Page 373: ...ation for indexing axis in MD Name is output during ramp up Indexing position tables The axis positions in mm or degrees assigned to the indexes must be stored for each indexing axis in the form of a table in machine data Any value can be entered for the distance between the individual indexing positions Note Up to two indexing position tables are permitted MD10910 INDEX_AX_POS_TAB_1 n MD10930 IND...

Page 374: ...starting with the negative to the positive traversing range with no gaps between the entries Consecutive position values cannot be identical The axis positions must be entered in the basic coordinate system If the indexing axis is defined as a rotary axis with modulo 360 MD30300 IS_ROT_AX 1 and MD30310 ROT_IS_MODULO 1 the following points must be considered for indexing positions Indexing position...

Page 375: ...IC Absolute POS B CAC 20 Indexing axis B approaches coded position index 20 in absolute mode The direction of traversing depends on the current actual position Absolute in positive direction POS B CACP 10 Indexing axis B approaches coded position index 10 in absolute mode in the positive direction of rotation only possible with rotary axes Absolute in negative direction POS B CACN 10 Indexing axis...

Page 376: ...axes Procedure The procedure for starting up indexing axes is identical to normal NC axes linear and rotary axes Rotary axis If the indexing axis is defined as a rotary axis MD30300 IS_ROT_AX 1 with modulo 360 conversion MD30310 ROT_IS_MODULO 1 indexing positions are also approached with modulo 360o Only positions within the range from 0 to 359 999 can then be entered in the indexing position tabl...

Page 377: ...ary axis Tool turret with eight locations The tool turret is defined as a continuously rotating rotary axis The distances between the eight turret locations are constant The first turret location is located at position 0 LV SRVLWLRQ QGH LQJ SRVLWLRQ r r r r r r r r Figure 21 1 Example Tool turret with eight locations The indexing positions for the tool turret are entered in indexing position table...

Page 378: ...tween the ten locations are different The first location is at position 100 mm LV SRVLWLRQ PP QGH LQJ SRVLWLRQ Figure 21 2 Example Workholder as an indexing axis The indexing positions for the workholder are entered in table 2 MD10930 INDEX_AX_POS_TAB_2 0 100 1 indexing position at 100 MD10930 INDEX_AX_POS_TAB_2 1 0 2 indexing position at 0 MD10930 INDEX_AX_POS_TAB_2 2 100 3 indexing position at 1...

Page 379: ...nced In handwheel traversing with JOG continuous or JOG incremental the indexing axis stops at the indexing position ahead of the software limit switch Axis positions Since the axis positions stored in the indexing position tables only correspond to the machine positions when the axis is referenced an NC start must be disabled for as long as the indexing axis is not referenced Position display Pos...

Page 380: ...sition 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 Axis spindle specific 30300 IS_ROT_AX Rotary axis 30310 ROT_IS_MODULO Modulo conversion for rotary axis 30320 DISPLAY_IS_MODULO Position display is modulo 360 30500 INDEX_AX_ASSIGN_POS_TAB Axis is indexing axis 21 7 2 Interface signals Number Bit Name Ax...

Page 381: ... The coupled axes are axes in the same NC channel The position of the following axis can be the input value for a transformation Tangential control is only active in AUTOMATIC or MDA modes Application examples Positioning and tangential tracking of a rotatable tool during nibbling Tracking of the workpiece alignment for a belt saw Positioning and tangential tracking of a dressing tool on a grindin...

Page 382: ... 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 C is the following axis the position of which is determined by the control depending on the leading axis path and the desired angle between the tangent and alignment in C The tangential control will function only if the leading axes are used as path...

Page 383: ...r recognition In this inserted intermediate block the rotary axis is moved as fast as possible to the position corresponding to the tangent after the corner The limit values set for this axis are not violated At the beginning of the intermediate block the path velocity of the leading axes is zero Information In blocks with G641 rounding no intermediate block is generated for the following axis wit...

Page 384: ...Effect on transformations The position of the rotary axis to which follow up control is applied can act as the input value for a transformation See Kinematic Transformations M1 Section TRANSMIT Note The user is recommended to program TLIFT if tangential control is used together with a transformation TLIFT prevents the follow up axis from overtraveling and protects against excessive compensating mo...

Page 385: ...g factor of 1 can be omitted the same applies for B Example of abbreviated call TANG C X Y Examples of possible calls TANG C X Y 1 TANG C X Y 1 B Example of complete call TANG C X Y 1 B S 22 3 3 Switching on the axis coupling TANGON Programming The axis coupling is switched on using the predefined subroutine TANGON The following axis to be tracked is specified This specification refers to the defi...

Page 386: ...ck 22 3 5 Switching off the axis coupling TANGOF Programming The axis coupling is switched off using the predefined subroutine TANGOF The following axis is hereby specified This specification refers to the definition of leading and following axes made beforehand with TANG With reference to the above example the termination is TANGOF C The follow up control process initiated with TANGON is terminat...

Page 387: ... cancelled 22 3 8 Programming examples Example with insertion of an intermediate block for positioning of rotary axis N10 TANG C X Y 1 Definition of the tangential control N20 TLIFT C Activate Insert intermediate block at corners N30 G1 G641 X0 Y0 F1000 N40 TANGON C Activate tangential control N50 X10 N60 Y10 Before this block is processed rotary axis C is repositioned in an intermediate block N70...

Page 388: ...lue for the position of the following axis C in example in relation to the base coordinate system are transferred to the control with G25 and G26 working area limit These working area limitations are activated with WALIMON and deactivated again with WALIMOF The working area limitation must be active at the instant of path reversal Reference BPN Operation and Programming Nibbling Effect If the curr...

Page 389: ...ng 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 Number Identifier Name Axis specific 37400 EPS_TLIFT_TANG_STEP Tangential angle for corner recognition 37402 TANG_OFFSET Default angle for tangential follow up control ...

Page 390: ...Tangential Control T3 22 5 Data lists Turning Milling Nibbling 390 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 391: ...e 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 Additional applications Compensation of gear backlash and backlash in the gear tooth flank due to mutual tension in the drives Coupling decoupling of rota...

Page 392: ...us the next time the axis stops This allows the coupling status to be changed even during part program processing For brake control the interface signal Master slave coupling status active should be used If a master axis is simultaneously configured as the slave an alarm is issued So cascading is not possible If a coupling is requested and closed the control activation signals are derived directly...

Page 393: ... slave axes An additional torque can be used to achieve a tension between the master and slave axis If different motors are used individual weighting factors can be used to adapt the torque distribution 3RVLWLRQVHW 6 9 0 67 5 HLJKWLQJ ULYH 3RVLWLRQ FRQWUROOHU 6HUYR WUDFH 7RUTXH FRPSHQVDWLRQ FRQWUROOHU 6HUYR WUDFH 7HQVLRQ WRUTXH QVHW 7RUTXH FRQWUROOHU 6SHHG FRQWUROOHU 6SHHG FRQWUROOHU 0 0 QDFW LVHW...

Page 394: ...tant is entered in drive parameter p0045 The same value should be set in the master and slave axes The gain factor MD37256 MS_TORQUE_CTRL_P_GAIN corresponds to the percentage ratio of the maximum axis velocity MD32000 MAX_AX_VELO to the rated driving torque p2003 of the slave axis The I component is disabled in the default setting The integral time MD37258 MS_TORQUE_CTRL_I_TIME is entered in secon...

Page 395: ...you can achieve tension between the master axis and slave axis when the torque compensation controller is active The tension torque is entered as a percentage of the rated torque and is active straight away The tension torque tension torque is applied via a PT1 filter Specifying a filter time constant MD37266 MS_TENSION_TORQ_FILTER_TIME 0 activates the filter The tension torque chosen must be high...

Page 396: ... made The current coupling status can be read out in the slave axis via PLC interface signal Master slave coupling active V390x 5000 7 In the part program and from the synchronized actions the current coupling status can be output via the system variable of the slave axis AA_MASL_STAT Spindle coupling The MASLOFS Slv1 instruction can be used to disconnect the coupling in the same way as MASLOF and...

Page 397: ...ge Master slave switchover active is displayed on the user interface Activation deactivation during motion Activation deactivation of the coupling in motion has been implemented only for spindles in speed control mode For axes and spindles in positioning mode switchover is still carried out when the axis is at a standstill Activation during motion The coupling procedure at different speeds is divi...

Page 398: ..._VELO_TOL_COARSE velocity tolerance coarse MD37272 MS_VELO_TOL_FINE velocity tolerance fine Note The Velocity tolerance coarse signal can be used to implement a PLC monitoring function that checks a coupled grouping for loss of speed synchronism The Velocity tolerance fine signal can be used to derive the time taken to close the coupling mechanically and activate the torque compensation controller...

Page 399: ...ave spindle do not supply updated values until reprogrammed Coupling characteristics For spindles in speed control mode the coupling characteristics of the MASLON MASLOF MASLOFS and MASLDEL instructions as well as the PLC with IS Master slave on V380x 5000 7 are defined explicitly via the following machine data MD37263 MS_SPIND_COUPLING_MODE MD37263 0 Coupling and disconnection take place only at ...

Page 400: ... V390x 0001 6 drive status signals are missing in the master or slave axis the PLC interface signal Master slave active V390x 5000 7 is reset in the slave axis while it is at a standstill When the master and slave axes return to closed loop control mode IS Master slave active is set on the slave axis The PLC activates the torque compensation controller using the following IS V380x 5000 4 The statu...

Page 401: ...ation Position offsets of the slave axis such as spindle pitch errors backlash temperature and sag offsets are computed but not active because there is no position controller Correct calculation of the backlash compensation requires that the backlash of the slave axis is always overtraveled by the motion of the master axis in coupled mode Disconnecting the coupling during an axis reversal error wi...

Page 402: ...n between the master and slave axes is not possible during clamping as the torque compensatory controller is deactivated during clamping operations Status changes to the master slave coupling have no effect during travel to fixed stop Specification of a new status is only accepted when the fixed stop function has been completed Weight counterbalance The additional torque for the electronic counter...

Page 403: ...using the slave axis the master axis is braked automatically This produces an asymmetric response on closure and separation of the coupling In contrast to closing there is no automatic braking on separation If a traversing movement is programmed for a slave axis that has already been coupled the alarm 14092 Channel 1 Block 2 Axis 3 has the wrong type appears The setpoint position of the coupled sl...

Page 404: ...e current limit this may mean that no adjusting reserves are left over in the coupled state for the torque compensation controller to use in order to distribute the torque between the master and the slave as required The maximum master spindle chuck speed is to be configured as less than or equal to that of the slave spindles MD35100 SPIND_VELO_LIMIT The axial velocity monitoring function should b...

Page 405: ...ration Preconditions One configured master axis MD37250 MS_ASSIGN_MASTER_SPEED_CMD 0 Activation of a master slave coupling via MD37262 MS_COUPLING_ALWAYS_ACTIVE 0 The coupling is open Typical sequence of operations Action Effect comment Approach coupling position Each axis moves to the coupling position Close coupling mechanically Both axes are mechanically coupled to one another Request to close ...

Page 406: ... temporarily Both axes are mechanically coupled to one another N30 AX1 100 Move master slave grouping Coupled via the speed setpoint the slave axis follows the master axis N40 MASLOF AX2 Open the coupling The axes are mechanically disconnected from one another N50 AX1 200 AX2 200 The axes are traversed separately N60 M30 23 12 4 Release the mechanical brake This application allows implementation o...

Page 407: ... MS_ASSIGN_MASTER_SPEED_CMD Master axis for speed setpoint coupling 37252 MS_ASSIGN_MASTER_TORQUE_CTR Master axis for torque distribution 37254 MS_TORQUE_CTRL_MODE Connection of torque control output 37255 MS_TORQUE_CTRL_ACTIVATION Activate torque compensatory control 37256 MS_TORQUE_CTRL_P_GAIN Gain factor of torque compensatory controller 37258 MS_TORQUE_CTRL_I_TIME Reset time for torque compens...

Page 408: ...0 23 13 2 Interface signals Number Bit Name Axis specific V380x 5000 4 Activate torque compensatory controller V380x 5000 7 Activate master slave coupling V390x 5000 2 Velocity tolerance fine V390x 5000 3 Velocity tolerance coarse V390x 5000 4 State of torque compensation controller V390x 5000 7 State of master slave coupling ...

Page 409: ...ev of the spindle or inch rev only meaningful when the spindle is running The inch dimension system applies with G700 or system setting inch with MD10240 SCALING_SYSTEM_IS_METRIC 0 Dimension units for F with G96 G97 For lathes the group with G94 G95 has been extended by the G96 G97 functions for the constant cutting rate ON OFF These functions also influence the S word With activated G96 function ...

Page 410: ...erface signals If the revolutional feedrate is active IS Revolutional feedrate V3300 0001 2 is set If the G96 G332 function is active the IS Constant cutting rate active V390x 2002 0 is set for the spindle Alarms If no F word is programmed at G1 G2 G3 alarm 10860 is issued An axis movement is not possible However please note SD42110 DEFAULT_FEED If F0 is programmed alarm 14800 is issued If G95 is ...

Page 411: ...xceeded The feedrate F is not relevant It is however kept in the memory The axis velocity e g for a cylinder thread results from the set spindle speed S and the programmed pitch K Fz mm min speed S rev min pitch K mm rev Note For G34 and G35 the pitch change in mm rev2 is programmed under the F address Reference BP_ Operation and Programming Minimum spindle speed In order to ensure smooth rotation...

Page 412: ... cutting values and short machining times or to simplify the handling of this issue If no values are specified the values from the setting data SD apply The specifications in the program are written in SD42010 THREAD_RAMP_DISP 0 1 If this path is not sufficient for traversing at the configured axis acceleration the axis is overloaded in terms of acceleration Alarm 22280 Programmed run in path too ...

Page 413: ...This achieves a smooth change in the axis movement Pitch change F with G34 G35 If you already know the starting and final lead of a thread you can calculate the pitch change F to be programmed according to the following equation PP UHY H D The identifiers have the following meanings Ke Pitch of axis target point coordinate mm rev Ka Initial pitch progr under I and K mm rev LG Thread length in mm 2...

Page 414: ...ammed pitch However the maximum axis velocity defined in MD32000 MAX_AX_VELO cannot be exceeded The feedrate F is not relevant It is however kept in the memory Interface signal If the G331 G332 function is active the IS Tapping without compensation chuck active V390x 2002 3 is set for the spindle Note The tapping may only be carried out without a compensation chuck if an exact dynamic adjustment o...

Page 415: ... G95 FRCM Modal feedrate for chamfer rounding Value 0 Feedrate in mm min G94 or mm rev G95 Modal feedrate for chamfer rounding ON Value 0 Modal feedrate for chamfer rounding OFF Feedrate F applies to the chamfer rounding Notes F FRC FRCM are not active when a chamfer is traversed with G0 If the feedrate F is active for chamfer rounding it is by default the value from the block which leads away fro...

Page 416: ...esulting velocity is selected to achieve the maximum possible path velocity under consideration of both axes If for example two axes have the same maximum velocity and also travel the same path the path velocity 1 41 max axis velocity The feedrate F is not relevant for G0 It is however kept in the memory Rapid traverse override In the AUTOMATIC operating mode it can be set through the Position ope...

Page 417: ...H FRQWURO SDQHO 6 3 3URJU 6 YDOXH 3 3URJU YDOXH 0D L PXPb YDOXH HHG RYHUULGH IURP PDFKLQH FRQWURO SDQHO 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 Feed disable The channel specific interface si...

Page 418: ...stop interface signal V380x 0004 3 is used to stop the spindle Spindle stop is active with G33 and G63 Note Contour deviations thread error 24 3 3 Feedrate override via a machine control panel General The operator can use the feedrate override switch to increase or decrease the path feedrate relative to the programmed feedrate in percent with immediate effect The feedrates are multiplied by the ov...

Page 419: ...g the operator panel display ROV the IS Feedrate override for rapid traverse selected V1700 0001 3 is set and must be transferred by the PLC user program to the IS Rapid traverse override active V3200 0006 6 The value itself is to be transferred by the PLC user program from a machine control panel to the IS Rapid traverse override VB3200 0005 The channel specific feedrate and rapid traverse overri...

Page 420: ...pt from the 1st position i e the override is 100 Note The 1st switch position of the Gray coded interfaces for the value represents a special case In this case the override factor of the 1st switch position is also used if the IS Rapid traverse override active Feedrate override active Override active are not set Thus 0 is issued as the override value for axes acts the same as Feed disable The foll...

Page 421: ...Rapid traverse override active V3200 0006 7 Feed rate override active V32001000 3 Feed stop geometry axis 1 V32001004 3 Feed stop geometry axis 2 V32001008 3 Feed stop geometry axis 3 V1700 0000 6 Dry run feed rate selected V1700 0001 3 Feed rate override selected for rapid traverse V3300 0001 2 Revolutional feed rate active Axis spindle specific VB380x 0000 Feed override VB380x 2003 Spindle overr...

Page 422: ...Feed V1 24 4 Data lists Turning Milling Nibbling 422 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 423: ...ification with T numbers from 0 to 32000 Definition of a tool with a maximum of nine cutting edges offset blocks through D number Cutting edge is described by tool parameters Tool type Geometry Length radius Wear Length radius Cutting edge position for turning tools Tool change selectable Immediately with T command or through M6 Tool radius compensation Compensation active for all interpolation ty...

Page 424: ... up to nine cutting edges The nine tool cutting edges are assigned to the D functions D1 to D9 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 ...

Page 425: ...compensation with G41 G42 is only permitted in a program block with G0 rapid traverse or G1 linear interpolation Detailed description of the tool compensation offset including tool radius compensation Reference BP_ Operation and Programming Section Tool and tool offset 25 4 Tool monitoring Note This function is not available with T M value 25 4 1 Tool monitoring overview General The tool monitorin...

Page 426: ...t 3 Reserved Bit 4 1 0 Prewarning limit reached not reached TC_TP9 t Type of the monitoring function for the tool with the number t 0 No monitoring 1 Service life monitored tool 2 Quantity monitored tool These system variables can be read written in the NC program and can be accessed through the control HMI As the Tool management function package is not available for SINUMERIK 802D these system pa...

Page 427: ...ow the value of Service life prewarning limit TC_MOP1 t d during machining the IS Tool prewarning limit reached V5300 0000 0 and the IS T number for tool prewarning limit VD5300 1000 are set If the remaining service life 0 an alarm is issued and the IS Tool limit reached V5300 000 1 as well as the IS T number for tool limit VD5300 1004 are set The tool changes to the disabled condition and cannot ...

Page 428: ...uted INT t Internal T number 0 For all tools 0 For this tool t 0 Absolute value generation t INT d Optional D number of the tool with the number t 0 For this D number 0 All cutting edges of the tool t INT mon Optional bit encoded parameters for the monitoring type values like TC_TP9 1 Tool life 2 Quantity 0 All actual values of the monitoring functions active for tool t are set to their setpoints ...

Page 429: ...e the last time SETPIECE was activated are included in the update If a tool is active at the time SETPIECE is called this is counted as well As soon as a block with path axis movements is executed after SETPIECE this tool is also considered for the subsequent SETPIECE call SETPIECE x x 1 32000 The number of workpieces that have been produced since the last execution of the SETPIECE function The co...

Page 430: ...er also be performed through the RESETMON state t d mon function as already described for the tool life monitoring Example DEF INT state At program start define the variable for status feedback N100 RESETMON state 12 1 2 Setpoint updating of the unit counter for T12 D1 25 4 4 Examples of the service life monitoring Activating the tool monitoring when the Tool monitoring option is present MD18080 M...

Page 431: ...NST allocation of the tool length components to the geometry axes SD42950 TOOL_LENGTH_TYPE allocation of the tool length components independent of tool type Note The modified setting data will become effective with the next cutting edge selection Tool length and plane change SD42940 TOOL_LENGTH_CONST Value of the setting data equal to 0 The behavior corresponds to the standard definition The lengt...

Page 432: ...length 1 and 2 are exchanged compared to the assignment with the corresponding positive values The following table shows the assignment of the tool lengths 1 to 3 to the geometry axes for drills milling cutters tool types 100 to 299 Plane value Length 1 Length 2 Length 3 17 Z Y X 18 Y X Z 19 X Z Y 17 Z X Y 18 Y Z X 19 X Y Z Each value not equal to 0 which is not equal to one of the six listed valu...

Page 433: ...gnment always as for milling tools Value 2 Length assignment always as for turning tools Notes The influence of these two setting data only refers to tool lengths The tool radius is not affected If SD42940 TOOL_LENGTH_CONST is set not equal to 0 and the value in SD42950 TOOL_LENGTH_TYPE is 1 or 2 the related table for the assigned tool type milling or turning tool applies in SD42940 Example SD4294...

Page 434: ...Definition of tool parameters 22550 TOOL_CHANGE_MODE New tool offsets with M function This machine data is not available with 802D sl value 25 6 2 Interface signals Number Bit Name Channel specific V1900 5001 0 Update tool list V2500 0008 0 T function 1 change V2500 0010 0 D function 1 change VD2500 2000 T function 1 VD2500 5000 D function 1 V2500 1000 6 M6 V3200 0013 5 Deactivate workpiece counte...

Page 435: ...t character coding ASUB Asynchronous subroutine AUXFU Auxiliary Function B BA Mode of operation BAG Mode group BERO Proximity limit switch C CAD Computer Aided Design CNC Computerized Numerical Control CPU Central Processing Unit D DAC Digital to Analog Converter DB Data Block interface signals DRIVE CLiQ Drive Component Link with IQ DRY DRY run Dry run feedrate DW Data Word DWORD Double Word curr...

Page 436: ...rdware limit switch I IBN Commissioning INC Increment IPO Interpolator J JOG Jogging Setup mode K KV Gain factor of control loop L LR Position controller M MCP Machine Control Panel MD Machine Data MDI Manual Data Automatic Manual input MCS Machine Coordinate System MPF Main Program File NC part program main program MCP Machine Control Panel N NC Numerical Control NCK Numerical Control Kernel IS I...

Page 437: ...proach function REPOS Reposition function ROV Rapid Override Input correction Switchgear protection SBL Single Block SD Setting Data SK Softkey SKP Skip Function for skipping a part program block PLC Programmable logic controller LEC Leadscrew error compensation SW Software SW limit switch Software limit switches D TRANSMIT Transform Milling Into Turning Coordination transformation for milling ope...

Page 438: ...Appendix A 1 List of abbreviations Turning Milling Nibbling 438 Function Manual 11 2012 6FC5397 1CP10 5BA0 TRC Tool Radius Compensation WZ Tool TO Tool Offset ...

Page 439: ...5 VO 3URJUDPPLQJ DQG 2SHUDWLQJ 0DQXDO ದ 7XUQLQJ ದ 0LOOLQJ ದ OLQGULFDO JULQGLQJ ದ 6XUIDFH JULQGLQJ ದ 1LEEOLQJ ದ 0DQXDO PDFKLQH SOXV 6 180 5 VO LDJQRVWLFV 0DQXDO OHFWURQLF GRFXPHQWDWLRQ 6 180 5 6 1 0 6 0RWRUV 2 21 2 21 0DQXIDFWXUHU VHUYLFH GRFXPHQWDWLRQ 6 180 5 VO 2SHUDWLQJ LQVWUXFWLRQV 6 180 5 VO XQFWLRQ 0DQXDO 8VHU GRFXPHQWDWLRQ 6 180 5 VO VO XQFWLRQ 0DQXDO 62 GLDOHFWV 6 180 5 VO 3DUDPHWHU 0DQXDO ...

Page 440: ...Appendix A 2 Overview Turning Milling Nibbling 440 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 441: ...operator panel in plain text with date and time and the corresponding symbol for the cancel criterion Alarms and messages are displayed separately 1 Alarms and messages in the part program Alarms and messages can be displayed in plain text directly from the part program 2 Alarms and messages from the PLC Alarms and messages for the machine can be displayed in plain text from the PLC program No add...

Page 442: ...X Y and Z are identified using A B and C Additional axes situated parallel to the specified axes can be designated using other letters Axis name See Axis identifier Backlash compensation Compensation for a mechanical machine backlash e g backlash on reversal for ball screws Backlash compensation can be entered separately for each axis Base axis Axis whose setpoint or actual value position forms th...

Page 443: ...s Axis around which the tool spindle describes a controlled rotational and positioning movement Channel A channel is characterized by the fact that it can process a part program A channel exclusively controls the axes and spindles assigned to it Circular interpolation The tool moves on a circle between specified points on the contour at a given feedrate and the workpiece is thereby machined CNC Se...

Page 444: ... same path velocity as possible Contour Contour of the workpiece Contour monitoring The following error is monitored within a definable tolerance band as a measure of contour accuracy An unacceptably high following error can cause the drive to become overloaded for example In such cases an alarm is output and the axes are stopped Coordinate system See Machine coordinate system Workpiece coordinate...

Page 445: ...ng accuracy even at high path velocities Feedforward control can be selected and deselected on an axis specific basis via the part program Editor The editor makes it possible to create edit extend join and import programs texts program blocks Exact stop When an exact stop statement is programmed the position specified in a block is approached exactly and if necessary very slowly To reduce the appr...

Page 446: ...following components work offset rotation scaling mirroring Geometry Description of a workpiece in the workpiece coordinate system Geometry axis Geometry axes are used to describe a 2 or 3 dimensional area in the workpiece coordinate system Ground Ground is taken as the total of all linked inactive parts of a device which will not become live with a dangerous contact voltage even in the event of a...

Page 447: ... on number of increments The number of increments can be stored as setting data or be selected by means of a suitably labeled key i e 10 100 1000 10000 Incremental dimension Also incremental dimension A destination for axis traversal is defined by a distance to be covered and a direction referenced to a point already reached See Absolute dimension Intermediate blocks Motions with selected tool off...

Page 448: ...ords with specified notation that have a defined meaning in the programming language for part programs Kv Servo gain factor a control variable in a control loop Ladder logic Ladder logic is a graphical programming language STEP 7 for representing electric circuit diagrams Leadscrew error compensation Compensation for the mechanical inaccuracies of a leadscrew participating in the feed The control ...

Page 449: ...ne tool to which all derived measuring systems can be traced back Macro techniques Grouping of a set of instructions under a single identifier The identifier represents the set of consolidated instructions in the program Main block A block prefixed by containing all the parameters required to start execution of a part program Main memory The main memory is a RAM in the CPU that the processor acces...

Page 450: ... at a time Mode of operation An operating concept on a SINUMERIK control The following modes are defined Jog MDA Automatic NC 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 NCK Numerical Control Kernel Component of the NC that executes the part ...

Page 451: ...rkpiece or material Part program Series of instructions to the NC that act in concert to produce a particular workpiece Likewise this term applies to execution of a particular machining operation on a given raw part Part program block Part of a part program that is demarcated by a line feed There are two types main blocks and subblocks Path axis Path axes include all machining axes of the channel ...

Page 452: ...erforms an auxiliary movement on a machine tool e g tool magazine pallet transport Positioning axes are axes that do not interpolate with path axes Program block Program blocks contain the main program and subroutines of part programs Programmable frames Programmable frames enable dynamic definition of new coordinate system output points while the part program is being executed A distinction is ma...

Page 453: ...y of an alarm A rapid stop is one of the responses which can be set for these alarms As part of this 0 is immediately specified as the speed setpoint for the machine axis affected without a braking ramp This will cause the relevant drives to brake to a standstill as quickly as possible i e at their respective current limits Reference point Machine tool position that the measuring system of the mac...

Page 454: ...assigned defined functions in the software Software limit switch Software limit switches limit the traversing range of an axis and prevent an abrupt stop of the slide at the hardware limit switch Two value pairs can be specified for each axis and activated separately by means of the PLC Spline interpolation With spline interpolation the control can generate a smooth curve characteristic from only ...

Page 455: ...nction allows threads to be tapped without a compensation chuck By using the interpolating method of the spindle as a rotary axis and the drilling axis threads can be cut to a precise final drilling depth e g for blind hole threads requirement spindles in axis operation Text editor The control system provides a function for editing Chinese characters in the program editor and in the PLC alarm text...

Page 456: ...s User memory All programs and data such as part programs subroutines comments tool offsets and zero offsets frames as well as channel and program user data can be stored in the shared CNC user memory User program User programs for the S7 300 automation systems are created using the programming language STEP 7 The user program has a modular layout and consists of individual blocks The basic block ...

Page 457: ...ea Three dimensional zone into which the tool tip can be moved on account of the physical design of the machine tool See Protection zone Working area limitation With the aid of the working area limitation the traversing range of the axes can be further restricted in addition to the limit switches One value pair per axis may be used to describe the protected working area Workpiece Part to be made m...

Page 458: ...Glossary Turning Milling Nibbling 458 Function Manual 11 2012 6FC5397 1CP10 5BA0 ...

Page 459: ...279 C Channel 167 Channel status 177 Clamping protection zone 295 Closed loop control 133 Commands MEAS MEAW 251 Compensation table 211 Computational resolution 117 Concurrent positioning axes 307 Continuous travel 143 Contour violation 52 Coupled motion 291 Cyclic signal exchange 20 D D functions 424 Direction of rotation reversal 388 Display resolution 117 Drive variables 131 Dry run feedrate 19...

Page 460: ... 61 Interpolatory compensation Compensation table 209 Linear interpolation 210 J Jerk limit 64 Jerk limitation 64 JOG Approaching a fixed point 148 L Language command SPN 283 SPP 282 Leading axis 87 Leadscrew error compensation LEC 210 Linear axis Limit switch monitoring 50 Traversing range 116 with rotary encoder on motor 130 LookAhead 66 M Master slave 391 Measuring accuracy 253 Measuring system...

Page 461: ...ic 316 Channel specific 316 with incremental measuring system 317 Referencing with absolute encoders 328 Reset 264 Rotary axes Absolute programming 337 Feedrate 334 Incremental programming 337 Modulo 360 335 Software limit switches 335 Traversing range 116 Units of measurement 334 Rotary axes Axis addresses 333 Rotary axis Definition 333 with rotary encoder on motor 130 S Sag compensation 214 Serv...

Page 462: ...Index Turning Milling Nibbling 462 Function Manual 11 2012 6FC5397 1CP10 5BA0 V Velocities 115 Velocity reduction 64 Velocity reduction according to overload factor 63 W Working area limitation 335 ...

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