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Siemens SINUMERIK 802D, Programming And Operating Manual

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Cylindrical grinding 
Programming and Operating Manual, 07/2009, 6FC5398-4CP10-2BA0 

395

 

Glossary 

Effective wheel width 

Wheel width of the inclined grinding wheel which is used to machine the diameter. It is 

dependent upon: 
●

 

the physical width 

●

 

the evading height 

●

 

the angle of the wheel 

Evasion/evasion angle 

Tapering of the left or right side of the grinding wheel for face-grinding operations in which a 

so-called cross-grinding is produced. 

GAP/structure-borne noise/air grinding 

Bridging the air gap between the workpiece and grinding wheel with a structure-borne noise 

microphone, which is built into the machine. 

GWPS 

Grinding wheel peripheral speed in m/s 

MCPA 

Input card for rapid I/O to the control system 

MD 

Machine data; machine data are predefined variables (system variables), with which the 

NCK, as per the requirements of the machine manufacturer, is adapted to the machine-tool. 

SD 

Setting data are system variables that indicate the current machine properties to the NCK. 

Unlike machine data, changes to setting data always become effective immediately. 

Seat 

Machining operation 

Summary of Contents for SINUMERIK 802D

Page 1: ...______ ______________ Preface Description 1 Software interface 2 Turning on reference point approach 3 Define 4 Manual mode 5 Automatic mode 6 Part programming 7 System 8 Cycles 9 Programming 10 Network operation 11 Data Backup 12 PLC diagnostics 13 Application Examples 14 Appendix A SINUMERIK SINUMERIK 802D sl Cylindrical grinding Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 Valid ...

Page 2: ...vant documentation for the specific task 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 WARNING Siemens products may only be used for the applications described ...

Page 3: ... direct access to the publications in DOConWEB Compiling individual documentation on the basis of Siemens contents with the My Documentation Manager MDM refer to http www siemens com mdm My Documentation Manager provides you with a range of features for generating your own machine documentation Training and FAQs Information on the range of training courses and FAQs frequently asked questions are a...

Page 4: ...ot contain all detailed information about all types of the product and cannot cover every conceivable case of installation operation or maintenance Technical support If you have any technical questions please contact our hotline Europe Africa Phone 49 180 5050 222 Fax 49 180 5050 223 0 14 min from German landlines mobile phone prices may differ Internet http www siemens com automation support requ...

Page 5: ...131 98 2176 E mail mailto docu motioncontrol siemens com A fax form is available in the appendix of this document SINUMERIK Internet address http www siemens com sinumerik EC Declaration of Conformity The EC Declaration of Conformity for the EMC Directive can be found obtained on the internet http support automation siemens com under the product order No 15263595 at the relevant regional office of...

Page 6: ...Preface Cylindrical grinding 6 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 ...

Page 7: ...elp system 30 3 Turning on reference point approach 33 3 1 Turning On and Reference Point Approach 33 4 Define 35 4 1 Entering tools and tool offsets 35 4 2 Create new tool 37 4 3 Sense dresser 46 4 4 Sense workpiece 48 4 5 Shaping dressing 50 4 6 Sense probe 52 4 7 Manual grinding 54 4 8 Program setting data 58 4 9 Arithmetic parameter R 62 4 10 User data 63 5 Manual mode 65 5 1 Manual mode 65 5 ...

Page 8: ...isplay 120 8 4 1 Action log 122 8 4 2 Servo trace 123 8 4 3 Version HMI details 127 8 4 4 Service MSG 131 8 5 SYSTEM PLC softkeys 137 8 6 SYSTEM Start up files softkeys 145 8 7 Alarm display 150 9 Cycles 153 9 1 Overview of cycles 153 9 2 Programming cycles 155 9 2 1 Call and return conditions 155 9 2 2 Error messages and error handling 156 9 2 2 1 General information 156 9 2 2 2 Error handling wi...

Page 9: ...ius diameter dimensions DIAMOF DIAMON DIAM90 242 10 2 5 Programmable work offset TRANS ATRANS 244 10 2 6 Programmable scaling factor SCALE ASCALE 245 10 2 7 Programmable mirroring MIRROR AMIRROR 247 10 2 8 Programmable mirroring MIRROR AMIRROR _2 248 10 2 9 Settable zero offset G54 to G59 G507 to G512 G500 G53 G153 250 10 2 10 Programmable working area limitation G25 G26 WALIMON WALIMOF 251 10 3 A...

Page 10: ...on 303 10 9 Arithmetic parameters LUD and PLC variables 304 10 9 1 Arithmetic parameter R 304 10 9 2 Local User Data LUD 306 10 9 3 Reading and writing PLC variables 308 10 10 Program jumps 309 10 10 1 Jump destination for program jumps 309 10 10 2 Unconditional program jumps 310 10 10 3 Conditional program jumps 311 10 10 4 Program example for jumps 313 10 11 Subroutine technique 315 10 11 1 Gene...

Page 11: ...g reading in reading out a start up archive 353 12 3 Reading in reading out PLC projects 356 12 4 Copying and pasting files 357 13 PLC diagnostics 359 13 1 Screen layout 360 13 2 Operating options 361 14 Application Examples 373 14 1 Cycle example 1 373 14 2 Cycle example 2 375 A Appendix 377 A 1 User data 377 A 2 Parameter tables of the tool data 380 A 3 Miscellaneous 385 A 3 1 Pocket calculator ...

Page 12: ...Table of contents Cylindrical grinding 12 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 ...

Page 13: ... this manual RUL RQWDO VRIWNH V 9HUWLFDO VRIWNH V Figure 1 1 CNC operator panel LED displays on the CNC operator panel PCU The following LEDs are installed on the CNC operator panel 55 5 1 The individual LEDs and their functions are described in the table below Table 1 1 Status and error displays LED Significance ERR red Serious error remedy through power OFF ON RDY green Ready for operation NC ye...

Page 14: ...1 Control and display elements Cylindrical grinding 14 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 References You can find information on error description in the SINUMERIK 802D sl Diagnostics Manual ...

Page 15: ...6 7 3 5 0 RSHUDWLQJ DUHD NH 3DUDPHWHU RSHUDWLQJ DUHD 6 67 0 50 RSHUDWLQJ DUHD NH 6 VWHP ODUP RSHUDWLQJ DUHD QRW DVVLJQHG XUVRU NH V 6HOHFWLRQ NH WRJJOH NH 1XPHULF NH V RXEOH DVVLJQPHQW DW WKH 6KLIW OHYHO OSKDQXPHULF NH V RXEOH DVVLJQPHQW DW WKH 6KLIW OHYHO HOHWH NH QVHUW NH 326 7 21 RSHUDWLQJ DUHD NH 3RVLWLRQ RSHUDWLQJ DUHD 352 5 0 0 1 5 RSHUDWLQJ DUHD NH 3URJUDP 0DQDJHU RSHUDWLQJ DUHD 86720 RSHUD...

Page 16: ...nput fields of the HMI the following functions can be carried out with certain key combinations on the full CNC keyboard Keystroke combination Function CTRL and C Copy selected text CTRL and B Select text CTRL and X Cut selected text CTRL and V Paste copied text ALT and L Changeover to small letters ALT and H or HELP key Call help system ALT and S Switch in and switch out the Editor for Asian char...

Page 17: ...e control panel 8VHU GHILQHG NH ZLWK 8VHU GHILQHG NH ZLWKRXW 1 5 0 17 QFUHPHQW 2 5 5 1 32 17 5HIHUHQFH SRLQW 8720 7 6 1 2 6LQJOH EORFN 0 18 7 0DQXDO LQSXW 63 1 67 57 RXQWHUFORFNZLVH 63 1 6723 63 1 67 57 ORFNZLVH 5 3 75 9 56 29 5 5DSLG WUDYHUVH RYHUULGH D LV D LV HHGUDWH RYHUULGH HHGUDWH FRQWURO 6SLQGOH 6SHHG 2YHUULGH 6SLQGOH RYHUULGH 0 5 1 6723 5 6 7 6723 1 6723 67 57 1 67 57 ...

Page 18: ...ntrol panel Cylindrical grinding 18 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 Note This documentation assumes an 802D standard machine control panel MCP Should you use a different MCP the operation may be other than described herein ...

Page 19: ...gramming it is always assumed that the tool traverses relative to the coordinate system of the workpiece which is intended to be stationary Figure 1 2 Determination of the axis directions to one another coordinate system for programming Machine coordinate system MCS The orientation of the coordinate system relative to the machine depends on the respective machine type It can be rotated in differen...

Page 20: ...he workpiece program a right handed right angled coordinate system is also used The workpiece zero can be freely selected by the programmer in the Z axis In the X axis it lies in the turning center ZRUNSLHFH HUR RUNSLHFH RUNSLHFH RUNSLHFH Figure 1 4 Workpiece coordinate system Relative coordinate system In addition to the machine and workpiece coordinate systems the control system provides a relat...

Page 21: ...iece zero is determined along the Z axis and entered in a data area intended for the settable work offset In the NC program this offset is activated during program execution e g using a programmed G54 RUNSLHFH RUNSLHFH 0b 0b 0DFKLQH 0DFKLQH RUNSLHFH H J Figure 1 5 Workpiece on the machine Current workpiece coordinate system The programmed work offset TRANS can be used to generate an offset with re...

Page 22: ...Description 1 4 Coordinate systems Cylindrical grinding 22 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 ...

Page 23: ...398 4CP10 2BA0 23 Software interface 2 2 1 Screen layout 6WDWXV DUHD SSOLFDWLRQ DUHD 7LS DQG VRIWNH DUHD Figure 2 1 Screen layout The screen is divided into the following main areas Status area Application area Note and softkey area Status area Figure 2 2 Status area ...

Page 24: ... Icon Significance Position operating area key POSITION System operating area key SYSTEM Program operating area key PROGRAM Program Manager operating area key PROGRAM MANAGER Parameter operating area key OFFSET PARAM Active operating area Alarm operating area key ALARM Approaching a reference point JOG JOG INC 1 INC 10 INC 100 INC 1000 INC VAR INC incremental evaluation in the JOG mode Active mode...

Page 25: ...nificance AUTOMATIC Alarm and message line In addition the following is displayed 1 Alarm number with alarm text or 2 Message text Selected part program main program RESET Program canceled default state RUN Program is running Program state STOP Program stopped Program control in automatic mode Note and softkey area Figure 2 3 Note and softkey area ...

Page 26: ... operator and fault states HMI status information ETC is possible pressing this key displays the horizontal softkey bar providing further functions ಯ ಯ Mixed notation active uppercase lowercase letters RS232 connection active Connection to commissioning and diagnostic tools e g Programming Tool 802 active RCS network connection active Softkey bar vertical and horizontal Display of the softkeys in ...

Page 27: ...oftkey to close the screen Use this softkey to cancel the input the window is closed Selecting this softkey will complete your input and start the calculation Selecting this softkey will complete your input and accept the values you have entered This function is used to switch the screenform from diameter programming to radius programming DFN ERUW FFHSW 2 5 ...

Page 28: ...ng operating areas POSITION Machine operation 2 6 7 3 5 0 OFFSET PARAM Entering the compensation values and setting data PROGRAM Creation of part programs PROGRAM MANAGER Part program directory 50 6 67 0 SYSTEM Diagnostics commissioning 50 6 67 0 ALARM Alarm and message lists CUSTOM Users can call their own application To change to another operating area press the relevant key on the CNC full keyb...

Page 29: ...s The control system is delivered with default passwords for the protection levels 1 to 3 Protection level 1 Experts password Protection level 2 Manufacturer password Protection level 3 User password These control the various access rigths In the menus listed below the input and modification of data depends on the protection level set Tool offsets Work offsets Setting data RS232 settings Program c...

Page 30: ...e control system Some help topics are Product brief of all important operating functions Overview and product brief of the NC commands Explanation of the drive parameters Explanation of the drive alarms Operating sequence You can call the help system from any operating area either by pressing the Info key or by using the key combination ALT H Figure 2 4 Help system Table of contents ...

Page 31: ...n the application area If you select a cross reference the Back to topic softkey will also be displayed Select this function to go back to the previous screen Use this function to search for a term in the table of contents Type the term you are looking for and start the search process Help in the Program editor area The help system offers an explanation for each NC operation To display the infotex...

Page 32: ...Software interface 2 4 The help system Cylindrical grinding 32 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 ...

Page 33: ...ion since turning on and reference point approach are machine dependent functions Operating sequence First turn on the power supply of CNC and machine After the control system has booted you are in the Position operating area in the Reference point approach mode The Reference point window is active Figure 3 1 Reference point approach start screen The Reference point window displays whether the axe...

Page 34: ...anual 07 2009 6FC5398 4CP10 2BA0 Press the arrow keys If you select the wrong approach direction no motion is carried out Approach the reference points for each axis one after the other You can exit the function by selecting another operating mode JOG MDA or Automatic For the functions described below select the Jog operating mode ...

Page 35: ...to store the parameters required for machine operation Operating sequences This function opens the Tool offset data window which contains a list of the tools created Use the cursor keys and the Page Up Page Down keys to navigate in this list Figure 4 1 Tool list To input the offsets position the cursor bar on the tool to be changed and press the Tool data softkey 2 6 7 3 5 0 7RRO OLVW ...

Page 36: ...ected This function is used to enter verify the dresser data of the first dresser For dressers 2 and 3 it is selected through the respective softkeys This function is used to enter verify all tool data D1 through D9 Use this function to copy an already existing tool Use this function to search for a tool by its number Use this softkey to create tool compensation data for a new tool This function i...

Page 37: ...er of parameters depending on the tool type Tools are identified by a number T number Operating sequences general Press the OFFSET PARAM key This function opens the Tool list window which contains a list of the tools created Use the cursor keys and the Page Up Page Down keys to navigate in this list Figure 4 2 Tool list The corrections are entered by placing the cursor bar on the tool to be modifi...

Page 38: ... Confirm your input using OK Figure 4 4 New tool inserted A data record loaded with zero will be included in the tool list This data block consists of 9 cutting edges D fields The first 6 cutting edges have a cutting edge type and are used as cutting edge geometry points The tool is assigned to a grinding spindle by an entry in the S No field For values 0 an externally controlled grinding spindle ...

Page 39: ...g edges D1 D3 D5 are on the left hand side and the even cutting edges D2 D4 D6 on the right hand side taking into account the entire wheel width The default setting for inclined wheels is arranged so that always all reference points are identical There is no distinction between left hand and right hand sides The user has the option of redefining the cutting edges in a dressing subprogram For this ...

Page 40: ...HHO LGWK QJOH H Q J W K LGWK 5DGLXV HQJWK HQJWK H Q J W K HQJWK Figure 4 5 Compensation values Cutting edges 7 9 are the three available dressing tools have a fixed allocation to the standard contour cutting edge Table 4 1 Allocation of dressers D field Dresser Assignment D7 Dresser 1 Left hand front cutting edge D8 Dresser 2 Right hand rear cutting edge D9 Dresser 3 Optional for wheel diameter ...

Page 41: ...be entered Nominal dimensions for monitoring Geometry data Technological data Data for the dressers Nominal dimensions and monitoring This function opens in input screen into which grinding wheel nominal dimensions and monitoring data are entered Figure 4 6 Grinding wheel nominal dimensions and monitoring data 7RRO GDWD 1RPLQDO GLPHQVLRQ PRQLWRULQJ ...

Page 42: ...eometry example data for a vertical wheel with back slope The following wheel types are available Vertical wheel without back slopes type 1 Vertical wheel with back slopes type 2 Left hand side inclined wheel type 3 Right hand side inclined wheel type 4 Free contour type 0 The input screen is self explaining Note A red dot shown in the diagrammatic sketch indicates the geometry value just being en...

Page 43: ...s of the technological data the wheel type dependent dressing technology is defined Figure 4 8 Technology example data for a vertical wheel with back slope Dresser Use the 1st dresser 2nd dresser or 3rd dresser softkeys to access the dialog box for entering or verifying the dresser data Figure 4 9 Fixed dresser 7HFKQR ORJ GDWD VW GUHVVHU ...

Page 44: ...Operating Manual 07 2009 6FC5398 4CP10 2BA0 The dresser type is selected in the Type toggle field Fixed dresser Tile Diamond Forming rolls 1 to 3 Diamond rolls 1 to 3 Enter the parameters depending on the selection made Figure 4 10 Forming roll Figure 4 11 Diamond roll ...

Page 45: ...0 45 Parameter tables The function opens a summary of all cutting edge parameters Note This function is available only with a password set Customer Figure 4 12 The following table contains all cutting edge data Tool offset data See the chapter Parameter tables of the tool offset data in the appendix WHQGHG ...

Page 46: ...minded in machine coordinates by the HMI and transmitted to the cycle Operation The dresser is sensed in JOG mode The input screen is opened Figure 4 13 Sense dresser You can use the Dresser no toggle field to select the dresser whose position you wish to sense e g 1 The procedure always starts with X axis The steps required are shown in a text line The axis line to be processed is indicated by an...

Page 47: ...n softkey is used to read and internally save the axis actual value The green check mark at the end of the line indicates this action Thereafter the second axis is processed Once all axes have been sensed press the Calculate position softkey to calculate the dresser position Exit the Sense dresser function 6DYH SRVLWLRQ DOFXODWH SRVLWLRQ DFN ...

Page 48: ...d setpoint to the cycle Operation The workpiece is sensed in JOG mode by scratching the respective axes The input screen is opened Figure 4 14 Sense workpiece The desired axis is selected via the the Axis name toggle field and the workpiece setpoint measured is entered into the Setpoint input field Press the Calculate position softkey to apply the setpoint Note This procedure must be done for each...

Page 49: ... subsequent Sense workpiece Calculate position command The following text appears above the HMI Copy setting value from manual grinding continue with NC start Figure 4 15 Sensing a workpiece after manual grinding The calculation is only possible for the infeed axis from manual grinding and also only once directly after manual grinding If the Sense workpiece command is aborted or a different axis t...

Page 50: ... to the currently active tool Operation Shaping is done in JOG mode The input screen is opened Figure 4 16 Shaping The required shaper values that are machined in dressing strokes are entered using the input fields For a new wheel no wear the shaper allowance is suggested by the control system The number of dressing strokes can be freely selected When you press the Start shaping softkey the follow...

Page 51: ...shaping is executed In the cycle the shaper allowance is machined first and then all dressing strokes are executed The current state is shown in the fields The procedure can be stopped at any time Press the Start shaping softkey to restart the procedure Values can be modified Exit the Shaping function 6WDUW SURI DFN ...

Page 52: ...on is set up for each particular workpiece For calibrating no active tool is required However the workpiece must have been set up using a valid tool since the longitudinal alignment position refers to the workpiece and the associated zero shift Operation The probe is adjusted in JOG mode The probe is positioned in front of the shoulder to be sensed in X axis The input screen is opened Figure 4 18 ...

Page 53: ...until the workpiece is touched This position is set as a value and the probe retracts After a confirmation the X axis traverses to its retract position and the probe swings out The positions determined are taken into account in CYCLE420 if longitudinal alignment has been enabled For this the X measuring position is approached and the Z position can be selected within the cycle Note Both calibratio...

Page 54: ...peration Manual grinding is done in Jog mode The input screen is opened Entry of parameters into the input screen for manual grinding see figure below T or D number Select reciprocating motion via toggle field The following reciprocating motions are possible No function X axis infeed no reciprocation Z axis infeed no reciprocation Z axis infeed reciprocation in X axis X axis infeed reciprocation i...

Page 55: ...reciprocation The figure below shows an input screen with parameters for manual grinding without reciprocation Figure 4 19 Manual grinding without reciprocation This function starts manual grinding with the handwheel A prompt appears Figure 4 20 Prompt Execution of manual grinding with handwheel without reciprocation 6WDUW JULQG 2 ...

Page 56: ...n to enter the reciprocation data see figure below Figure 4 22 Manual grinding with reciprocation data in X The following reciprocating data is possible Position 1 start 2 end Use the numeric keypad to enter position 1 2 in the relevant input field Use traversing key X on the machine control panel to approach position 1 2 and use vertical softkey Position 1 Position 2 to transfer the position to t...

Page 57: ...Sense workpiece To be able to intervene in the grinding procedure when performing manual grinding the PLC buttons for interrupt and dressing are active during manual grinding The PLC button Handwheel terminates manual grinding at the start position of the infeed axis When manual grinding is aborted with the PLC button Handwheel the last position of the infeed axis is saved This saved position of t...

Page 58: ... Setting data is opened Other softkey functions are available here with which you can set various control system options Figure 4 23 Setting data start screen JOG feedrate Feedrate value in JOG mode If the feedrate value is zero the control system will use the value stored in the machine data Spindle Spindle speed Minimum maximum A limitation of the spindle speed in the Max G26 Min G25 fields can ...

Page 59: ...ed as the start angle A multiple thread can be cut by changing the angle when the thread cutting operation is repeated Place the cursor bar on the input field to be modified and enter the value Either press the Input key or move the cursor to confirm Softkeys The working area limitation is active with geometry and additional axes If you want to use a working area limitation its values can be enter...

Page 60: ... with user defined M command Total runtime Total runtime of NC programs in AUTOMATIC mode In the AUTOMATIC mode the runtimes of all programs between NC START and end of program RESET are summed up The timer is zeroed with each power up of the control system Program runtime Active tool operating times The runtime between NC Start and End of program Reset is measured in the selected NC program The t...

Page 61: ...BA0 61 Use this function to display all setting data for the control system in the form of a list The setting data are divided up into general axis specific and channel specific data They can be selected using the following softkey functions General Axis spec Channel spec Figure 4 26 General setting data 0LVF ...

Page 62: ...set or queried by the programmer of the part program for any purpose in the program and can be changed as required Operating sequence These can be found in the OFFSET PARAM operating area Press the R variable softkey The R variables start screen appears Figure 4 27 R parameters start screen Place the cursor bar on the input field to be modified and enter the values Either press the Input key or mo...

Page 63: ...ting sequences These can be found in the OFFSET PARAM operating area Press the User data softkey This will open the User data start screen for the cycles Figure 4 28 User data Place the cursor bar on the input field to be modified and enter the values Either press the Input key or move the cursor to confirm the entry Use this function to search for the user data See also User data Page 377 2 6 7 3...

Page 64: ...Define 4 10 User data Cylindrical grinding 64 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 ...

Page 65: ...HQVH GUHVVHU 6HQVH ZRUNSLHFH DOFXODWH SRVLWLRQ 6HQVH PHDVXULQJ SUREH 3UH VKDS ZDVKHU 6HW SRVLWLRQ 6WDUW VKDS 6DYH SRVLWLRQ DFN DFN DFN 6KDS LQJ 0DQXDO JULQG DFN 6WDUW JULQG 6ZLWFK PP LQFK DFN Figure 5 1 JOG menu tree Position operating area 6HWW LQJV 7HDFK Q 2II 7HDFK Q 7HFKQROR GDWD 5DSLG WUDYHUVH QG EORFN LQHDU LUFXODU 6ZLWFK PP LQFK DFN Figure 5 2 MDA menu tree Position operating area ...

Page 66: ...released If the value of the setting data is zero the value stored in the machine data is used If necessary set the velocity using the override switch If you press the Rapid traverse override key at the same time the selected axis will be traversed at rapid traverse speed while both keys are being held down In the Increment mode you can traverse by adjustable increments using the same operating se...

Page 67: ... the distance traversed by each axis is displayed referred to the interruption point G function Displays important G functions Spindle S r p m Displays the actual value and the setpoint of the spindle speed Feed F mm min Displays the path feedrate actual value and setpoint Tool Displays the currently active tool with the current edge number Note If a second spindle is integrated into the system th...

Page 68: ...e machine for dressers that are used by means of the geometry axes This function is used to detect the workpiece position in the machine with respect to the particular axis This function is used to shape a raw grinding wheel without generating an NC program This function is used to set the measuring position of the probe The measuring position is set up for each particular workpiece Note The param...

Page 69: ...has been opened all axis identifiers are displayed in the Axis column which simultaneously appear in the softkey bar Select the desired handwheel using the cursor Then assign or deselect as appropriate by pressing the relevant axis softkey for the desired axis The symbol appears in the window Figure 5 4 Handwheel menu screen Use the MCS softkey to select the axes from the machine or workpiece coor...

Page 70: ...s subject to the same safety interlocks as the fully automatic mode Furthermore the same prerequisites are required as in the fully automatic mode Operating sequences Select MDA mode via the machine control panel Figure 5 5 MDA start screen Enter one or several blocks using the keyboard Press NC START to start machining During machining editing of the blocks is no longer possible After machining t...

Page 71: ...the MCS or WCS G function Displays important G functions Spindle S r p m Displays the actual value and the setpoint of the spindle speed Feedrate F Displays the path feedrate actual value and setpoint in mm min or mm rev Tool Displays the currently active tool with the current edge number T D Editing window In the Stop or Reset program state an editing window serves to input a part program block N...

Page 72: ...d M functions currently active Selecting the softkey repeatedly will close the window All the G functions are displayed Use this softkey to display the Axis feedrate window Pressing the softkey repeatedly will close the window Use this function to delete blocks from the program window Enter a name in the input field for saving the MDA program in the program directory Alternatively you may select a...

Page 73: ...raversing blocks You can transfer axis position values directly into a newly generated or changed part program record The axis positions are reached by traversing with the axis direction keys and transferred into the part program Operating sequence In the POSITION operating area use the machine control panel to select MDA mode Press the Teach In softkey In the Teach In submode assume the following...

Page 74: ... block inserted in front of it 2 Select the appropriate softkey Technological data Figure 5 8 Technological data Enter the appropriate technological data e g feedrate 1000 Click Insert transfer to add a new part program block The new part program block will be added in front of the block selected with the cursor Click Change transfer to change the selected part program block Use Back to return to ...

Page 75: ... Operating Manual 07 2009 6FC5398 4CP10 2BA0 75 Rapid feed Figure 5 9 Rapid traverse You traverse the axes and teach in a rapid traverse block with the approached positions Linear Figure 5 10 Linear You traverse the axes and teach in a linear block with the approached positions 5DSLG WUDYHUVH LQHDU ...

Page 76: ...ialogs 1 Use the axis keys to traverse the axes to the required position that you want to add change in the part program 2 Click Insert transfer to add a new part program block The new part program block will be added in front of the block selected with the cursor 3 Click Change transfer to change the selected part program block Use Back to return to the Teach In start screen Use Exit Teach In see...

Page 77: ...QG SRLQW 6HW 6HDUFK 3URJUDP RPSHQVDWLRQ RQGLWLRQDO 6WRS 6NLS SLQJ 1RQH DOF 6HDUFKLQJ QWHU UXSW 6LQJOH EORFN ILQH 529 HIIHFWLYH DFN DFN DFN 0DFKLQLQJ RIIVHW 5H JULQGLQJ DFN 6LPXOW UHFRUGLQJ LVSOD DUHDV 6KRZ RRP XWR RRP HOHWLQJ D VFUHHQ RRP XUVRU Figure 6 1 Automatic menu tree Preconditions The machine is set up for the AUTOMATIC mode according to the specifications of the machine manufacturer ...

Page 78: ...ing window Parameter Explanation MCS X Z Displays the existing axes in the MCS or WCS X Z If you traverse an axis in the positive or negative direction a plus or minus sign will appear in the relevant field If the axis is already in the required position no sign is displayed Position mm These fields display the current position of the axes in the MCS or WCS Distance to go These fields display the ...

Page 79: ... to switch to the Program progress window To switch back to the seven block display use the Program sequence softkey Note If a second spindle is integrated into the system the workspindle will be displayed using a smaller font The window will always display the data of only one spindle The control system displays the spindle data according to the following aspects The master spindle is displayed I...

Page 80: ...ting the softkey repeatedly will close the window All the G functions are displayed Use this softkey to display the Axis feedrate window Pressing the softkey repeatedly will close the window Use this softkey to switch from the seven block to the three block display Switches the axis value display between the machine workpiece and relative coordinate systems Displays the Machining offset window Fin...

Page 81: ...llows Each block is decoded separately and a stop is performed at each block an exception are only the thread blocks without dry run feedrate In such blocks a stop is only performed at the end of the current thread block Single block fine can only be selected in the RESET status ROV effective The feedrate override switch will also act on the rapid traverse override Use this softkey to close the sc...

Page 82: ...n values for regrinding When you select OK the parameters will be inserted in the program after the selected block It is possible to simultaneously record when the part program is executed see Chapter Simultaneously recording Page 89 Use this softkey to correct a fault program passage Any changes will be stored immediately 5H JULQG 6LPXOWDQHRXV UHFRUGLQJ RUUHFW SURJUDP ...

Page 83: ...g offset Functionality Fine offsets can be entered in X and Z globally for each seat or individually for a specific seat From then on these offsets will always be used for the grinding work seat Operating sequence The Automatic start screen will display a window for the machining offsets Figure 6 4 Machining offsets 0DFKLQLQJ RIIVHW ...

Page 84: ...s of the machine manufacturer Operating sequence Select Automatic mode by pressing the Automatic key on the machine control panel The Program Manager is opened Use the NC directory default selection or Customer CF card softkeys to enter the appropriate directories Figure 6 5 The Program Manager start screen Place the cursor bar on the desired program Use the Execute softkey to select the program t...

Page 85: ...gram Cylindrical grinding Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 85 If desired here you can specify how you want the program to be executed Figure 6 6 Program control Press NC START to start executing the part program 3URJUDP FRQWURO ...

Page 86: ...he RESET state The block search function provides advance of the program to the required block in the part program The search target is set by positioning the cursor bar directly on the required part program block in the part program Figure 6 7 Block search Block search to block start Block search to block end Block search without calculation The interruption point is loaded ORFN VHDUFK 7R FRQWRXU...

Page 87: ...key to perform the block search by entering a term you are looking for Figure 6 8 Entering the searched term You can use the toggle field to define the starting position for the search Search result The required part program block is displayed in the Current block window Note For Execute externally no block search is possible LQG ...

Page 88: ...ned either with or without an offset but always with the same technological values Displays the Regrinding window Figure 6 9 Regrinding Enter the compensation values for regrinding Choose between the following options in the toggle field Do not correct any axis Correct tool Machining offsets When you select OK the parameters will be inserted in the program after the selected block The block search...

Page 89: ...d NC START Execution of the part program is simultaneously recorded on the HMI using the Simultaneous recording function Figure 6 10 Simultaneous recording start screen You can influence how the simultaneous recording function is displayed on the HMI using the following vertical softkeys Zoom Auto Zoom Zoom Show All G17 blocks All G18 blocks All G19 blocks Display areas See the following page for ...

Page 90: ...hen the cursor keys are pressed the cross hair moves in small average or large steps Exit the Simultaneous recording function Display areas Using the Display areas function you have the possibility of saving a previously selected area from the simulation display The menu for the display area can be selected using the Window min max function Figure 6 11 Display area Window min DFN LVSOD DUHD LQGRZ ...

Page 91: ...y areas function 3 Press the Window min max so that a maximum display can be see according to the screen Display areas Window max 4 In the Comment field you can assign a name to the area 5 Complete the entry with Input 6 Press Save area Activating or deleting an area You have selected a display area Using the cursor keys select the area that you wish to either activate or delete Press Activate are...

Page 92: ...CP10 2BA0 6 6 Stop cancel a part program Operating sequence With NC STOP the execution of a part program is interrupted The interrupted machining can be continued with NC START Use RESET to abort the program currently running By pressing NC START once again the aborted program is restarted and executed from the beginning ...

Page 93: ...an retract the tool from the contour in manual mode JOG Operating sequence Select mode AUTOMATIC mode Opening the Block search window for loading the interruption point The interruption point is loaded The block search to the interruption point will start An adjustment to the start position of the interrupted block will be carried out Press NC START to continue machining ORFN VHDUFK QWHUU SRLQW 7R...

Page 94: ...program NC STOP you can retract the tool from the contour in manual mode JOG The control saves the coordinates of the point of interruption The distances traversed are displayed Operating sequence Select AUTOMATIC mode Press NC START to continue machining CAUTION When reapproaching the interruption point all axes will traverse at the same time Make sure that the traversing area is not obstructed ...

Page 95: ...rd RCS connection for external execution via network only for SINUMERIK 802D sl pro Manufacturer s drive USB FlashDrive Start in the following start screen of the Program Manager Figure 6 13 The Program Manager start screen Use vertical softkey Ext execution to transmit the selected external program to the control system to execute this program press NC START While the contents of the buffer memor...

Page 96: ... starts The program is reloaded continuously At the end of the program or in case of RESET the program is automatically removed from the control system Note For Execute externally no block search is possible Requirements for external execution via network The control system and the external programming device PC are connected via Ethernet The RCS tool is installed on the programming device PC The ...

Page 97: ...nd activated directory of the programming device PC for example 123 456 789 0 External Program Operating sequences for external execution via network Select the AUTOMATIC mode key Press the PROGRAM MANAGER key on the machine control panel Press RCS connect You go to the directories of the PG PC Place the cursor bar on the desired program Press Ext execution The program is transferred into the buff...

Page 98: ...Automatic mode 6 9 Execute from external Cylindrical grinding 98 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 ...

Page 99: ... RS 3DVWH HOHWH 1H W 6HOHFW DOO 6HQG 5HFHLYH UURU ORJ 1H W 0DQX GULYH 86 GULYH 2QO 6 180 5 VO SUR HFXWLRQ IURP H WHUQDO RS 3DVWH HOHWH 1H W HFXWLRQ IURP H WHUQDO RS 3DVWH HOHWH 1H W 6HOHFW DOO 2SHQ 6HOHFW DOO 1HZ GLUHFWRU 1HZ GLUHFWRU 1HZ GLUHFWRU 2SHQ 2SHQ 2SHQ Figure 7 1 Program Manager menu tree Functionality The PROGRAM MANAGER operating area is the management area for workpiece programs in th...

Page 100: ...tem will automatically position the cursor on a program with matching characters Softkeys Use this softkey to display the directories of the NC Use this softkey to select the program on which the cursor is placed for execution The control system will switch to the position display Use NC START to start this program Use the New softkey to create a new program Use the Open softkey to open the file h...

Page 101: ...her press OK to confirm or Abort to cancel This function opens a window displaying the first seven lines of a file if the cursor has been positioned on the program name for a certain time A window opens up where you can enter a file name you are looking for After you have entered the name either press OK to confirm or Abort to cancel A selected directory can be released for network operation The f...

Page 102: ...via the RS232 interface Use this function to transmit files from the clipboard to a PC connected to the RS232 Load files via the RS232 interface For the settings of the interface please refer to the System operating area The part programs must be transmitted using the text format Error log Selecting this softkey provides the functions required to read out read in files via the manufacturer drive a...

Page 103: ...log window will open up for setting up a new file Enter a name and confirm with OK After presssing the softkey New file a dialog window will open up for setting up a new program file in which you can enter the names of the new main programs and subprograms The MPF extension for main programs is entered automatically The SPF extension for subprograms must be entered along with the program name Conc...

Page 104: ...ng executed Any modifications to the part program are stored immediately Figure 7 4 Program editor start screen Menu tree 5XQ LQG 0DFKLQLQJ ULQGLQJ F FOHV 5HFRPS LOH 6HOHFW EORFN RS EORFN GG EORFN HOHWH EORFN 6HH KDSWHU FOHV b 68 WRRO 5HDU GLDP SRVLWLRQ ZLWK ZKHHO UHVVLQJ 3OXQJH FXWWLQJ 5DGLXV JULQGLQJ 1XP EHULQJ X F FOHV RQJLWXGLQDO JULQGLQJ RQWRXU 6HH KDSWHU UHH FRQWRXU SURJUDPPLQJ Figure 7 5 Pr...

Page 105: ...e Find softkey to search for a string in the program file displayed Type the term you are looking for in the input line and use the OK softkey to start the search Use Cancel to close the dialog box without starting the search process Use this softkey to replace the block numbers from the current cursor position up to the program end See Section entitled Cycles Page 161 For recompilation position t...

Page 106: ...Part programming 7 3 Editing the part program Cylindrical grinding 106 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 ...

Page 107: ...rizontal and the vertical softkey bars change The menu tree shown below only includes the horizontal softkeys Menu tree XVWRPHUV FDUG DWD 6WDUW XS LOHV GLW 3 DODUP W W 3URJUDP LVW 3 3URJUDP 6WDWH LVW 3 6WDWH 67 3 FRQQHFW 6HUYLFH RQWURO 6HUYLFH ULYHV 6HUYLFH HV 6HUYLFH LVSOD LVSOD 0 ULYHV 0 KDQQHO 0 LV 0 HQHUDO 0 0DFKLQH GDWD 6WDUW XS 0DQXIDFWXU HU V GULYH 86 ULYH 6HUYLFH RYHUYLHZ 5 6 FRQQHFW 0DQX ...

Page 108: ...e 8 2 System operating area start screen Softkeys The start screen vertical softkeys are described below Set password Three password levels are distinguished in the control system which provide different access rights System password Manufacturer password User password It is possible to change certain data corresponding to the access levels If you do not know the password access will be denied Not...

Page 109: ...creen Change Password Figure 8 4 Change password Depending on the access right various possibilities are offered in the softkey bar to change the password Select the password level using the appropriate softkeys Enter the new password and press Accept to complete your input You will be prompted to enter the new password once more for confirmation Press Accept to complete the password change Use Ab...

Page 110: ...ace language Use the cursor keys to select the language and confirm it by pressing OK Note The HMI is automatically restarted when a new language is selected Use Service language to always select English as the user interface language Press the Service language softkey again to restore the previously active language e g Simpl Chinese Note An asterisk marks the languages you have used HOHWH SDVVZRU...

Page 111: ...cuted Do not carry out any operator actions while the data backup is running The NC and PLC data are backed up The drive data are not backed up Note Saved data can be called via the following operator action Press the SELECT key while the control system is booting In the setup menu select Reload saved user data Press the Input key Note Data that have been backed up can be called again from the ope...

Page 112: ...d up data The system restarts with the data that were last backed up see Backup data The PLC can be started in the following modes Restart Memory reset Furthermore it is possible to link the start with a subsequent debugging mode Selects the power up mode of the HMI Select the desired mode using the cursor Normal power up The system is restarted Power up with default data The system restarts with ...

Page 113: ...RIK 802D sl Function Manual for turning milling nibbling Machine data Any changes in the machine data have a substantial influence on the machine Figure 8 6 Structure of a machine data line Table 8 1 Legend No Significance 1 MD number 2 Name 3 Value 4 Unit so immediately effective cf with confirmation re Reset 5 Effective po Power on CAUTION Incorrect parameterization may result in destruction of ...

Page 114: ...indow Use the Page Up Page Down keys to browse forward backward Figure 8 7 General machine data Executes a warm restart at the control Find Type the number or the name or a part of the name of the machine data you are looking for and press OK The cursor will jump to the data searched Use this softkey to continue searching for the next match HQHUDO 0 1 UHVHW SR LQG RQWLQXH ILQG ...

Page 115: ... softkey to activate all data groups selected After you have quit the window you will only see the selected data on the machine data display Select all Use this softkey to select all data groups of the Expert mode for display Deselect all Selecting this softkey deselects all data groups Figure 8 8 Display filter Axis specific machine data Open the Axis specific machine data window The softkey bar ...

Page 116: ...10 2BA0 Use Axis or Axis to switch to the machine area of the next or previous axis The contents of the machine data are updated Channel specific machine data Open the Channel specific machine data window Use the PageUp PageDown keys to browse forward backward Figure 8 10 Channel specific machine data LV 8SGDWH FKDQ 0 ...

Page 117: ...urrent configuration as well as the states of the control power supply and drive units Figure 8 11 Drive machine data To display the parameters position the cursor on the appropriate unit and press the Parameter display softkey For a description of the parameters please refer to the documentation of SINAMICS drives Figure 8 12 Parameter list Switch to the respective drive objects ULYH 0 LVSOD SDUD...

Page 118: ...oftkey color and Window color softkeys to specify user defined color settings The displayed color consists of the components red green and blue The Change color window displays the values currently set in the input fields The desired color can be produced by changing these values In addition the brightness can be changed The next mixing ratio is displayed temporarily upon completion of an input Us...

Page 119: ...ion to change the colors of the tip and softkey area Figure 8 14 Edit softkey color Use this softkey to change the color of the border of dialog boxes The Active window softkey function will assign your settings to the focus window and the Inactive window function to the non active window Figure 8 15 Edit frame color RORU 6RIWNH RORU LQGRZ ...

Page 120: ...ct of the digital drive The window displays information on external bus settings Use this softkey function to activate the window for the following functions Service network see chapter Network operation Action log see chapter Action log Service Firewall see chapter Network operation Direct connect see chapter Network operation Service MSG see chapter Service MSG This window contains information a...

Page 121: ...5398 4CP10 2BA0 121 This window displays the version numbers and the date of creation of the individual CNC components The following functions can be selected from this window also see chapter Versions HMI details License key Options Save as The displayed versions can be saved in a text file 9HUVLRQ ...

Page 122: ...e contents of the action log file can only be accessed through a system password on the HMI Figure 8 17 Action log Irrespective of the system password it is possible to output the file using softkey Save under on a CF card or on the USB FlashDrive In case of difficulties please contact the hotline see the Technical Support Section in the preface for contacting the hotline FWLRQ ORJ 6DYH XQGHU ...

Page 123: ...ing must be made using the Select signal function To analyze the result the following functions are provided Changing and scaling of abscissa and ordinate Measuring of a value using the horizontal or vertical marker Measuring of abscissa and ordinate values as a difference between two marker positions Storing of the result as a file in the part program directory Thereafter it is possible to export...

Page 124: ...re 8 20 Select signal Selecting the axis To select the axis use the Axis toggle field Signal type Following error Controller difference Contour deviation Position actual value Speed actual value Speed setpoint Compensation value Parameter block Position setpoint controller input Speed setpoint controller input Acceleration setpoint controller input Speed feedforward control value Exact stop fine s...

Page 125: ...to hide show the vertical gridlines Using the Select signal function you can determine the signal to be displayed in the vertical axis The T mark ON T mark OFF softkeys are used to hide show the horizontal gridlines of the time axis Use the markers to determine the differences in the horizontal or vertical directions To do this place the marker on the start point and press Fix V mark or Fix T mark...

Page 126: ...nits the marker must be moved per SHIFT cursor movement When a marker reaches the margin of the diagram the grid automatically appears in the horizontal or vertical direction Use this softkey to save or load trace data Figure 8 22 Trace data Type the desired file name without extension in the File name field Use the Save softkey to save the data with the specified name in the part program director...

Page 127: ... HMI details This window displays the version numbers and the date of creation of the individual CNC components Figure 8 23 Version Note The version releases shown in the version screen shot are for example only Saves the contents of the Version window in a text file The target e g customer CF card can be selected 9HUVLRQ 6DYH XQGHU ...

Page 128: ...version numbers By reloading software components the version numbers can be differ from each other Figure 8 24 The HMI version menu area This Registry details function displays the assignment of the hard keys operating area keys POSITION machine OFFSET PARAM parameter PROGRAM program PROGRAM MANAGER progman for the programs to be started in the form of a list For the meanings of the individual col...

Page 129: ...operating area If a start behavior is required the Change ready to start function allows defining another starting program The starting operating area is then displayed above the table in the Registry Details window The Font details function displays the data of the loaded character sets in the form of a list Figure 8 26 Font details Entering the license key Figure 8 27 License key RQW HWDLOV OLFH...

Page 130: ...UMERIK 802D sl Operating Instructions for Turning Milling Grinding Nibbling Licensing in SINUMERIK 802D sl Setting the licensed options Figure 8 28 Options References SINUMERIK 802D sl Operating Instructions for Turning Milling Grinding Nibbling Licensing in SINUMERIK 802D sl Executes a warm restart at the control 2SWLRQV 1 UHVHW SR ...

Page 131: ...ax is described in the following table Table 8 2 Syntax of the message texts messages Output Syntax interface Message text via RS232 interface V24 MSG V24 Message text in a file MSG File Message text Alarm line at the HMI MSG Alarm text The MSG text output is defined using the MSG command as well as by appropriately parameterizing the output interface For the alarm output only the output interface...

Page 132: ...ox Incoming messages are ignored when the interface is deactivated Note When transferring a file via a serial interface RS232 please note the end of transmission character for RS232 communication analog to the communication setting RS232 on HMI Further when sending via RS232 it can be defined as to which messages are sent for which events Programmed messages from the part program An alarm has occu...

Page 133: ...terface the communication settings from the operating area SYSTEM Start up files RS232 Settings are used Figure 8 31 Parameters of the RS232 interface Note When using the MSG service via RS232 the RS232 interface must not be active for another application The means e g the RS232 interface must not be active from the operating area SYSTEM PLC Step7 connect ...

Page 134: ...e file can be selected Drive D customer CF card F USB drive and the drive connected per RCS connection can be selected in the Path input field 10kByte 100kByte and 1MByte can be selected as max file size When the max size is reached the file is written as ring buffer i e at the beginning as many lines are deleted line by line as is required by the new message at the end of the file Here when sendi...

Page 135: ...using the reset softkey The dialog box is closed by pressing Back Note The error log can be used for analysis when the information line Processing error MSG command occurred is output Example of programming using the MSG command For SINUMERIK 802D sl messages programmed in the NC program are displayed in the alarm display as standard Table 8 3 Activating deleting messages N10 MSG Roughing the cont...

Page 136: ...ge text that defines the output interface of this message Table 8 5 Messages to the RS232 output interface N20 MSG V24 Roughing the contour The text Roughing the contour is sent in the ASCII format via the RS232 interface Table 8 6 Messages to the output interface file N20 MSG FILE Roughing the contour The text Roughing the contour is sent to the selected file Note If in the part program the text ...

Page 137: ...2 interface is already occupied by the data transfer you can connect the control system to the PLC802 programming tool on the programming device PC only if the transmission is completed The RS232 interface is initialized with activation of the connection Figure 8 34 Communication settings The baud rate is set using the toggle field The following values are possible 9600 19200 38400 57600 115200 No...

Page 138: ... via modem start with the following initialization option Figure 8 35 Initialize the modem The following initializations are possible via toggle fields Baud rate 9600 19200 38400 57600 115200 Parity without for 10 bit odd for 11 bit Using the Modem settings softkey you can make the following additional settings for a connection that does not yet exist Figure 8 36 Modem settings ...

Page 139: ...fications to the settings are possible in this state The softkey label changes to Connection inactive By pressing Connection inactive the transfer from the control system can be terminated at any point Now it is possible again to make changes in the settings The active or inactive state is kept even after Power On except power up with the default data An active connection is displayed by a symbol ...

Page 140: ... Figure 8 37 PLC status display The operand address displays the value incremented by 1 The operand address displays the value respectively decremented by 1 Use this softkey to delete all operands Cyclic updating of the values is interrupted Then you can change the values of the operands 2SHUDQG 2SHUDQG HOHWH KDQJH ...

Page 141: ...to display and modify PLC signals There are 3 lists to choose from Inputs default setting left hand list Flags default setting center list Outputs default setting right hand list Variable Figure 8 38 PLC status list Use this softkey to change the value of the highlighted variable Press the Accept softkey to confirm your changes 6WDWXV OLVW KDQJH ...

Page 142: ...form the control system will save your settings Figure 8 39 The Data type selection screen Use the cursor keys and the Page Up Page Down keys to navigate in and between the columns PLC diagnosis using a ladder diagram see chapter PLC diagnosis using a ladder diagram Using the PLC you may select part programs and run them via the PLC To this end the PLC user program writes a program number to the P...

Page 143: ...ences for interface signals SINUMERIK 802D sl Function Manual Various Interface Signals A2 SINUMERIK 802D sl List Manual Writes the selected file name to the clipboard Pastes the file name at the current cursor position Deletes the selected file name from the assignment list Structure of the reference list file PLCPROG LST It is divided into 3 areas Number range Protection level 1 to 100 User area...

Page 144: ...r alarm texts Select the desired alarm number using the cursor At the same time the text currently valid is displayed in the input line Figure 8 41 Editing the PLC alarm text Enter the new text in the input line Press the Input key to complete your input and select Save to save it For the notation of the texts please refer to the operating instructions GLW 3 DODUP W W ...

Page 145: ...m of a list The vertical softkeys provide the control functions possible for the drive in question There are the following permanently set drive assignments 802D data Commissioning data Customer CF card Customer data on the CF card RCS connection Data of a drive released on PC PG via the the RCS tool only for SINUMERIK 802D sl pro RS232 Serial Interface Manufacturer drive Data that the manufacture...

Page 146: ...w error compensation Sag compensation Global user data Commissioning archive drive NC PLC HMI These data constitute a commissioning file for HMI data and are transferred in the binary format using the HMI archive format Drive machine data NC data NC directories Display machine data Leadscrew error compensation Sag compensation PLC project HMI data and applications PLC project PTE A direct exchange...

Page 147: ...ction project management etc Reading in and reading out data via the RS232 interface Note Using the softkey function Continue you may also inspect the transmission log The Error log function is available for that Use this function to display and change the RS232 interface parameters Any changes in the settings come into effect immediately Selecting the Save softkey will save the selected settings ...

Page 148: ...aud 115200 baud Stop bits Number of stop bits with asynchronous transmission Input 1 stop bit default setting 2 stop bits Parity Parity bits are used for error detection These are added to the coded character to convert the number of digits set to 1 into an odd or even number Input No parity default setting Even parity Odd parity Data bits Number of data bits with asynchronous transmission Input 7...

Page 149: ...ction to rename a file selected beforehand using the cursor New directory Creates a new directory Copy Use this softkey to copy one or more files to the clipboard Paste Use this softkey to paste files or directories from the clipboard to the current directory Delete Deletes the selected file name from the assignment list Select all Use this softkey to select all files for subsequent operations Pro...

Page 150: ...s softkey to display all alarms sorted by their priorities The highest priority alarm is at the beginning of the list Use this softkey to display the alarms sorted by the time of their occurrence The most recent alarm stands at the beginning of the list Use this softkey to display the alarms sorted by the time of their occurrence The oldest alarm stands at the beginning of the list Updating of pen...

Page 151: ...gramming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 151 All alarms are logged Figure 8 46 Alarm log The log is deleted using softkey Delete log The file is output using softkey Save under on a CF card or on the USB FlashDrive ODUP ORJ 6DYH XQGHU ...

Page 152: ...System 8 7 Alarm display Cylindrical grinding 152 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 ...

Page 153: ...nological sequence external cylindrical grinding and dressing During external cylindrical grinding cylindrical workpieces are machined on their overall diameter using machining cycles The infeed axis X traverses at right angles to the longitudinal axis Z The cycles support the grinding behind the turning center Grinding tools need to be dressed after a certain time in service to compensate for wor...

Page 154: ...ultiple plunge cutting CYCLE412 Shoulder plunge cutting CYCLE413 Oblique plunge cutting CYCLE414 Radius grinding CYCLE415 Reciprocation CYCLE416 Dressing CYCLE420 General workpiece data CYCLE430 Dressing with profile roller CYCLE446 Selection of grinding wheel peripheral speed CYCLE450 Technological data CYCLE451 Oblique plunge cutting with Z allowance CYCLE452 Longitudinal surface grinding The cy...

Page 155: ... prior to the cycle call and the programmable offsets remain active beyond the cycle The machining level G17 G18 G19 must be defined before calling the cycle A cycle operates in the current plane with the following axes 1st axis of the plane abscissa 2nd axis of the plane ordinate Tool axis infeed axis 3rd axis standing vertically to the plane applicate SSOLFDWH EVFLVVD 2UGLQDWH Level and axis all...

Page 156: ...on on errors and required responses as well as messages output in the controller s dialog line please refer to the SINUMERIK 802D sl Diagnostics Manual 9 2 2 2 Error handling within cycles Alarms with numbers between 61000 and 62999 generated in the cycles This range of numbers in turn is divided again with regard to alarm responses and cancel criteria The error text that is displayed together wit...

Page 157: ... R parameters Constants If R parameters are used in the parameter list they must first be assigned values in the calling program Proceed as follows to call the cycles With an incomplete parameter list or By leaving out parameters If you want to exclude the last transfer parameters that have to be written in a call you can prematurely terminate the parameter list with If any parameters are to be om...

Page 158: ...l equipment Acoustic emission sensor Measurement control Touch trigger probe 7 rapid inputs via MCPA for Measurement control 5 inputs Acoustic emission sensor 2 inputs Call and return conditions The grinding cycles are programmed independently of the actual axis names The collions free approach to the grinding position is to be done in the higher level program before the cycle is called The requir...

Page 159: ... creating the automatic program refer to this zero point The dresser zero is defined during setup by scratching the wheel with the dressing diamonds It serves as a reference point for the dressing program B B 180 B B 180 B B 180 Figure 9 1 Coordinate systems for grinding Plane definition Before using the grinding cycles G507 must be activated Typically the infeed axis is the first geometry axis A ...

Page 160: ... machining on the workpiece diameter It implements the switching over of the feedrate or the defining of the end position at the measuring coordinates in X for roughing finishing and fine finishing The acoustic emission sensor implements the feedrate stop when the workpiece diameter sparkles Time optimized approach conditions are created Longitudinal grinding cycles Longitudinal grinding cycles ar...

Page 161: ... program and for entering parameters Function The cycle support offers the following functions Cycle selection via soft keys Input screen forms for parameter assignment with help displays Decompilable program code is generated from the individual screens Summary of required files The following files constitute the basis for cycle support sc com cov com Note These files are loaded during the start ...

Page 162: ...O DFN 3DWK GUHVVLQJ 5ROOHU GUHVVLQJ 3OXQJH FXWWLQJ DOORZDQFH DFN 7DSHU JULQGLQJ RQJLW VXUIDFH JULQGLQJ QG OHYHO Figure 9 2 Menu tree for cycle support To add a cycle call to the program carry out the following steps one after the other You can use the Grinding cycles softkey in the horizontal softkey bar to access selection bars for the individual cycles The cycle selection is carried out using th...

Page 163: ...3 Recompiling Recompiling of program codes serves to make modifications to an existing program using the cycle support Position the cursor on the line to be modified and select the Recompile softkey This will reopen the corresponding input screen from which the program piece has been created and you can modify and accept the values ...

Page 164: ...calculations UBL REAL Overlapping when performing multiple plunge cutting RAD REAL Crown height B_ART INT Type of machining for plunge cutting or longitudinal grinding 0 longitudinal grind everything 1 plunge cutting roughing 2 roughing finishing plunge cutting 3 plunge cut everything ZU_ART INT Feed type for longitudinal grinding 1 start page 0 both sides 1 end BVU1 REAL Sparking out revolutions ...

Page 165: ...lation method or multiple plunge cutting Infeed when longitudinal grinding takes place at the reversal points Intermediate dressing interruption and use of the handwheel are all supported handwheel only for cylindrical parts The buttons react immediately Following the technological steps of roughing and finishing dressing or off loading can be programmed Sequence Approach allowance position approa...

Page 166: ...nding CYCLE405 Programming example Machining sequence Taper grinding at a grinding wheel peripheral speed of 20 m s Roughing is machined with multiple plunge cuts A dressing stroke takes place prior to fine finishing N10 T1D1 N20 CYCLE446 20 N30 CYCLE405 0 0 200 100 120 0 10 0 1 0 2 2 0 1 0 1 0 03 0 01 0 01 0 005 0 002 1 0 2 0 0 1 0 02 0 01 2 1 0 5 20 30 40 0 1 2 20 N40 M30 ...

Page 167: ...proach CAL INT Sets axis to Z position at end Z_LPOS INT Retraction direction MODE INT Approach type 0 sensor handwheel 1 sensor allowance 2 just handwheel 3 handwheel allowance D_POS REAL Diameter position Z_POS REAL Z position for setting value ZSTW REAL Z offset A_Z REAL Z allowance after contact F_LU REAL Feedrate for sparking F_SR REAL Feedrate for grinding N_FR REAL Sparking out strokes with...

Page 168: ... the Z position If no acoustic emission input has been configured the cycle will immediately switch to the handwheel at the start of the operation provided that an air grinding feedrate exists Sketch of the geometry parameters Figure 9 4 Z positioning with grinding wheel CYCLE406 Programming example Machining sequence Inching at position 50 0000 mm to diameter position 100 0000 mm old offset is de...

Page 169: ... globally 0 1 KOORD INT Position in WCS 1 and in MCS 0 Function This cycle is used for approaching a safety position during the grinding process or during interruptions such as intermediate dressing Sequence The cycle checks the current position and approaches it if the infeed axis is smaller than the value entered The position is approached in accordance with the KOORD parameter in the workpiece ...

Page 170: ...IME REAL Sparking out time MZ INT Measurement control Yes 1 No 0 KS INT Acoustic emission sensor yes 1 no 0 F_KS REAL Feedrate for air grinding mm min OSW REAL Reciprocation travel incr F_OSCILL REAL Reciprocation speed UWERK REAL Workpiece peripheral speed m min Function The plunge cut cycle is called for the machining of a cylindrical seat if the wheel width is greater than or equal to the width...

Page 171: ...on and acoustic emission sensor Additional specified values A_SR 0 2 mm Roughing allowance A_SL 0 1 mm Finishing allowance A_FSL 0 03 mm Fine finishing allowance TIME 5 s Sparking out time B65 B6 B 6 N10 T1 D1 M7 Determine technology values coolant ON N20 S1 2000 M1 3 Turn on workpiece speed N30 S2 1100 M2 4 Turn on wheel speed N40 CYCLE410 1 100 30 3 5 0 2 0 1 0 3 50 45 30 5 0 1 600 10 400 20 Cyc...

Page 172: ...action to the starting position are stopped at the end position for machining after expiry of a sparking out time When using a measurement control there is a compensation capability with the aid of the variable _GC_KORR This parameter specifies whether additional compensation should be computed for the measurement control _GC_KORR 0 Nominal actual deviation is taken into account for the wheel _GC_...

Page 173: ...ing A_LU air allowance The term air allowance is used to denote the distance between the starting position in X and the stock allowance for roughing A_SR A_SL A_FSL allowance For the various machining steps different values can be defined for the allowance These refer to the nominal diameter A_SR Roughing allowance A_SL Finishing allowance A_FSL Fine finishing allowance B62 B 6 B6 B65 F_SR F_SL F_...

Page 174: ...tic emission sensor The KS parameter is used to specify whether an acoustic emission sensor is used 0 without acoustic emission sensor 1 with acoustic emission sensor F_KS feedrate for air grinding With an air grinding feedrate the path between the starting point and the point where the wheel comes into contact with the workpiece with the aid of the acoustic emission sensor is traversed OSW recipr...

Page 175: ...ne finishing 3 roughing finishing fine finishing A_LU REAL Air allowance incr A_SR REAL Roughing allowance incr A_SL REAL Finishing allowance incr A_FSL REAL Fine finishing allowance incr SLZ REAL Infeed amount for finishing incr FSZ REAL Infeed amount for fine finishing incr ZU_ART INT Infeed 1 only on the left 0 on both sides 1 only on the right BVU1 INT Dwell time at reversal point1 BVU2 INT Dw...

Page 176: ...the reciprocating grinding technology To check the workpieces for their finished dimension and to switch the individual feedrates in the various technological sections a measuring device caliper which is already in use during the machining can be used Straight or inclined wheel types can be used Example for multiple plunge cutting A cylinder diameter 200 is to be machined completely using a wheel ...

Page 177: ...ng to finishing allowance retraction to the X starting position and offsetting of the wheel in the Z direction with overlapping Once the roughing plunge cutting is completed over the whole workpiece width the starting position for reciprocation in Z is approached at the position of the finishing allowance in X Finishing and fine finishing are carried out by the infeed amount at the selectable infe...

Page 178: ...s to the finished dimension in the X direction Z_ST starting position in Z Z_END target position in Z Z_ST and Z_END are used to define the starting and target positions of the grinding motion in the Z direction UBL overlap This parameter is used to specify the overlap of the wheel for multiple plunge cutting B_ART machining type The B_ART parameter is used to define the machining type used to mac...

Page 179: ...ters SLZ and FSZ ZU_ART infeed When grinding by reciprocating the wheel is fed in at the reversal points The ZU_ART parameter is used to define whether an infeed by the infeed amount is to be performed only at the left at both or at the right reversal point 8B 57 8B 57 8B 57 98 98 BVU1 and BU2 dwell time at the reversal point The dwell time at reversal point 1 or 2 can be defined using the followi...

Page 180: ...rameter MZ measurement control The MZ parameter is used to specify whether a measurement control is used 0 No measurement control 1 With measurement control KS acoustic emission sensor The KS parameter is used to specify whether an acoustic emission sensoris used 0 without acoustic emission sensor 1 with acoustic emission sensor F_KS feedrate for air grinding With an air grinding feedrate the path...

Page 181: ...ughing F_SL REAL Feedrate for finishing TIME REAL Sparking out time s KS INT Acoustic emission sensor Yes 1 No 0 F_KS REAL Feedrate for air grinding mm min OSW REAL Reciprocation travel incr F_OSCILL REAL Reciprocation speed mm min UWERK REAL Workpiece peripheral speed m min Function The shoulder plunge cutting cycle can be used to machine a workpiece shoulder by plunge cutting in the Z direction ...

Page 182: ...eel speed N40 CYCLE412 1 50 192 3 5 0 2 0 1 45 30 5 1 600 5 500 20 Cycle call N50 M30 End of program Sequence of operations The machining start position is first approached in X then in Z corresponding to the initial position of the grinding wheel in Z if the current X value is less than the X allowance The Z starting position is calculated as the shoulder dimension in Z roughing allowance air all...

Page 183: ...ed to define the starting position of the grinding motion in the X direction B_ART machining type The B_ART parameter is used to define the machining type used to machine a technological section Possible values for B_ART lie in the range between 1 and 3 with the following meaning 1 roughing 2 finishing 3 roughing finishing A_LU air allowance The term air allowance is used to denote the distance be...

Page 184: ...coustic emission sensor The KS parameter is used to specify whether an acoustic emission sensor is used 0 without acoustic emission sensor 1 with acoustic emission sensor F_KS feedrate for air grinding With an air grinding feedrate the path between the starting point and the point where the wheel comes into contact with the workpiece with the aid of the acoustic emission sensor is traversed OSW re...

Page 185: ... Feedrate for fine finishing TIME REAL Sparking out time s MZ INT Measurement control Yes 1 No 0 KS INT Acoustic emission sensor Yes 1 No 0 F_KS REAL Feedrate for air grinding mm min UWERK REAL Workpiece peripheral speed m min Function The oblique plunge cutting cycle is used for machining a cylindrical seat or for machining a shoulder and a diameter simultaneously The wheel width must be greater ...

Page 186: ... X to the finishing diameter 200mm using CYCLE413 the sparking out time is 5 s Table 9 8 Additional specified values A_SR 0 2 mm Roughing allowance A_SL 0 1 mm Finishing allowance A_FSL 0 03mm Fine finishing allowance N10 T1 D1 M7 Determine technology values coolant ON N20 S1 2000 M1 3 Turn on workpiece speed N30 S2 1100 M2 4 Turn on wheel speed N40 CYCLE413 1 200 50 3 5 0 2 0 1 0 03 60 40 30 5 0 ...

Page 187: ... angle inclined axis Machining by grinding is performed simultaneously in the X and Z axes up to finished dimension Once the sparking out time has expired both axes are retracted to the starting position When using a measurement control there is a compensation capability with the aid of the variable _GC_KORR This parameter specifies whether additional compensation should be computed for the measur...

Page 188: ...sed to denote the distance between the starting position in Z and the stock allowance for roughing A_SR A_SL A_FSL allowance For the various machining steps different values can be defined for the allowance These refer to the nominal diameter A_SR Roughing allowance A_SL Finishing allowance A_FSL Fine finishing allowance F_SR F_SL F_FSL feedrate Different feedrates can be specified for the individ...

Page 189: ... 2BA0 189 F_KS feedrate for air grinding With an air grinding feedrate the path between the starting point and the point where the wheel comes into contact with the workpiece with the aid of the acoustic emission sensor is traversed UWERK Use the UWERK parameter to specify the peripheral speed of the workpiece in m min ...

Page 190: ...rner 31 external corner A_LU REAL Air allowance incr A_SR REAL Roughing allowance incr F_SR REAL Feedrate for roughing KS INT Acoustic emission sensor Y 1 N 0 F_KS REAL Feedrate for air grinding mm min UWERK REAL Workpiece peripheral speed m min Function The radius grinding cycle is called whenever an internal or external radius is to be ground with continuous path control In this case the workpie...

Page 191: ...00 M2 4 Turn on wheel speed N40 CYCLE414 1 55 200 10 23 5 0 2 50 1 700 20 Cycle call N50 M30 End of program Sequence of operations The machining start position is first approached in X then in Z corresponding to the initial position of the grinding wheel in X if the current X value is less than the X allowance The starting positions in X and Z are determined as follows Internal radius X X starting...

Page 192: ...e the starting position of the grinding motion in the X direction RAD workpiece radius The RAD parameter is used to program the radius of the corner to be ground LAGE The corner to be machined can either an internal or an external corner The LAGE parameter specifies the type of the corner 23 internal corner the machining is performed CW 31 external corner the machining is performed CCW A_LU air al...

Page 193: ...ic emission sensor is used 0 without acoustic emission sensor 1 with acoustic emission sensor F_KS feedrate for air grinding With an air grinding feedrate the path between the starting point and the point where the wheel comes into contact with the workpiece with the aid of the acoustic emission sensor is traversed UWERK Use the UWERK parameter to specify the peripheral speed of the workpiece in m...

Page 194: ...R REAL Roughing allowance incr A_SL REAL Finishing allowance incr A_FSL REAL Fine finishing allowance incr SRZ REAL Infeed amount for roughing incr SLZ REAL Infeed amount for finishing incr FSLZ REAL Infeed amount for fine finishing incr ZU_ART INT Infeed 1 only on the left 0 on both sides 1 only on the right BVU1 INT Dwell time at reversal point1 BVU2 INT Dwell time at reversal point2 F_PE REAL R...

Page 195: ...the individual feedrates in the various technological sections a measurement control caliper which is already in use during the machining can be used For grinding both wheel types can be used straight or inclined Example for reciprocating This cycle will be used to machine the cylinder diameter 200 completely with grinding by reciprocating using a wheel 70 mm in width When grinding by reciprocatin...

Page 196: ...echnological sequence programmed in the selected mode is executed when grinding by reciprocating The infeed is performed both at the reversal points of the reciprocating motion either on the right on the left or at both points The motion behavior at these reversal points can be programmed In the reversal points a programmed stopping time becomes effective in revolutions of the calculated workpiece...

Page 197: ...o define the starting and target positions of the grinding motion in the Z direction B_ART machining type The B_ART parameter is used to define the machining type used to machine a technological section Possible values for B_ART lie in the range between 1 and 3 with the following meaning 1 roughing 2 finishing and fine finishing 3 roughing finishing and fine finishing A_LU air allowance The term a...

Page 198: ... the left at both or at the right reversal point 8B 57 8B 57 8B 57 98 98 BVU1 and BVU2 holding time at the reversal point The dwell time at reversal point 1 or 2 can be defined using the following value 0 Wait for exact stop fine and then wait for stopping time to elapse The unit for the dwell time is given in workpiece speed after infeed F_SR F_SL F_FSL feedrate Different feedrates can be specifi...

Page 199: ...stic emission sensor The KS parameter is used to specify whether an acoustic emission sensor is used 0 without acoustic emission sensor 1 with acoustic emission sensor F_KS feedrate for air grinding With an air grinding feedrate the path between the starting point and the point where the wheel comes into contact with the workpiece with the aid of the acoustic emission sensor is traversed UWERK Use...

Page 200: ...AL Dressing feedrate in the path left F_DR_AB REAL Dressing feedrate in X right F_BR_AB REAL Dressing feedrate in the path right F_Z_AB REAL Dressing feedrate in Z N_ABR INT Number of dressing strokes USCH REAL Wheel peripheral speed N_AWST INT Number of workpieces between two dressers Function The Dressing and profiling cycle calculates the starting positons and internally calls CYCLE432 This cyc...

Page 201: ... in the tool specific offset data Additional specified values TPG5 58 Wheel width TPG8 45 Angle of the inclined wheel DPC5 12 Shoulder height DPC9 70 024 Usable wheel width TPC1 3 Wheel type The dressing amount in Z is calculated in the cycle Z_AB tan wheel angle X_AB Thus the effective wheel width of 70 0244 mm is kept constant B r 5 N10 T1 D1 M7 Determine technology values coolant ON N20 S1 2000...

Page 202: ...els with a corner radius a chamfer or a relief cut these are machined at the path feedrate The starting position see illustration is also repeatedly approached at rapid traverse after retraction in case of several dressing strokes Dressing at the diameter can be selected to be either by drawing or pushing depending on the technology With each dressing stroke the infeed is performed by the programm...

Page 203: ...eedrate right F_Z_AB REAL Dressing feedrate in Z FFW REAL Retraction travel incr USCH REAL Wheel peripheral speed m s UWERK REAL Workpiece peripheral speed m min Z_LPOS INT Longitudinal position 0 no longitudinal positioning 1 shoulder left Z_SCH REAL Z dimension for shoulder ZSTW REAL Infeed travel for probe incr F_Z_MESS REAL Measuring feedrate N_ABR INT Number of dressing strokes N_AWST INT Num...

Page 204: ... 20 1 0 10 100 1 1 Determine general workpiece data N50 Machining by grinding N60 N70 N80 N90 M30 End of program Sequence of operations In this cycle the general prerequisites for the machining are set Counting of the workpiece cycles and optional call of the dressing program CYCLE416 It can be selected whether or not longitudinal positioning using the probe is required to detect the clamping tole...

Page 205: ...culated using the wheel angle and the X dressing amount FFW retraction travel The FFW parameter specifies the retraction travel in both axes X and Z Z_LPOS longitudinal position Selection of longitudinal positioning 0 no longitudinal positioning 1 shoulder left Z_SCH shoulder dimension in Z The Z_SCH parameter is used to specify the width of the shoulder ZSTW probe infeed travel The ZSTW parameter...

Page 206: ... Cylindrical grinding 206 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 N_AWST number of workpieces before dressing This parameter can be used to define how many workpieces are to be machined completely before the wheel is dressed ...

Page 207: ... used for dressing wheels with a profile roller Following dressing after each stroke the dressed amount is taken into account in the wear parameters of the current tool offset Dressing is performed in accordance with workpiece counter _GC_WKS Sequence of operations If a profiling allowance is specified then this is processed first This value can also be used to search for a dresser if no sensor sy...

Page 208: ...etry parameters Figure 9 7 Dressing with profile roller CYCLE430 Programming example Machining sequence 2 stroke dressing with 0 02 mm dressing amount and 2 sparking out revolutions every 5 workpieces The number of idle strokes and the peripheral speed ratios of the spindles are stored in the tool data N10 T1D1 N20 CYCLE430 0 02 20 0 2 2 2 35 5 N30 M30 ...

Page 209: ...the spindle wheels of a set A setup menu is also required in order to obtain an overview of the wheels used Checking and calculation is performed on the currently largest diameter of the wheels This is a purely calculated monitoring function Internally no limitations are set that implement reliable monitoring This must be ensured by the user For machines without NC spindles it is possible to use a...

Page 210: ... specific machine cutting volume FZ INT Z feedrate in mm rev Function The cycle is used to set the type of infeed feedrate programming and for selecting the Z feedrate when performing longitudinal grinding or reciprocation The selection is saved to the parameters _GC_PARI 0 and _GC_PARI 1 Sketch of the geometry parameters Figure 9 8 Technological data CYCLE450 Programming example Programming the i...

Page 211: ... finishing allowance incr F_SR REAL Feedrate for roughing F_SL REAL Feedrate for finishing F_FSL REAL Feedrate for fine finishing TIME REAL Sparking out time s MZ INT Measurement control Yes 1 No 0 KS INT Acoustic emission Yes 1 No 0 F_KS REAL Feedrate for air grinding mm min UWERK REAL Workpiece peripheral speed m min Function The oblique plunge cutting cycle is used for machining a cylindrical s...

Page 212: ... X axis first then the Z axis or vice versa depending on the park position of the grinding wheel in X The starting positions in X and Z are determined as follows X axis Setpoint diameter roughing allowance air allowance Z axis Shoulder dimension in Z roughing allowance air allowance An acoustic emission sensor can be used for optional sparking in which case the axes are traversed simultaneously at...

Page 213: ...der dimension in the Z direction A_Z shoulder allowance Use A_Z to specify the shoulder allowance B_ART machining type The B_ART parameter is used to define the machining type used to machine a technological section Possible values for B_ART lie in the range between 1 and 3 with the following meaning 1 roughing 2 finishing and fine finishing 3 roughing finishing and fine finishing A_LU air allowan...

Page 214: ...ool dwells at the end position for a defined time This time is called sparking out time It is programmed in s MZ measurement control The MZ parameter is used to specify whether a measurement control is used 0 No measurement control 1 With measurement control KS acoustic emission sensor The KS parameter is used to specify whether an acoustic emission sensor is used 0 without acoustic emission senso...

Page 215: ...sed for internal calculations UBL REAL Overlapping when performing multiple plunge cutting RAD REAL Crown height B_ART INT Type of machining for plunge cutting or longitudinal grinding 0 longitudinal grind everything 1 plunge cutting roughing 2 roughing finishing plunge cutting 3 plunge cut everything ZU_ART INT Feed type for longitudinal grinding 1 start page 0 both sides 1 end BVU1 REAL Sparking...

Page 216: ...el are to be machined Here the shoulder is ground using the oscillation method or multiple plunge cutting Infeed when longitudinal grinding takes place at the reversal points Intermediate dressing interruption and use of the handwheel are all supported handwheel only for cylindrical parts The buttons react immediately Following the technological steps of roughing and finishing dressing or off load...

Page 217: ...inal surface grinding CYCLE452 Programming example Machining sequence Taper grinding at a grinding wheel peripheral speed of 20 m s Roughing is machined with multiple plunge cuts A dressing stroke takes place prior to fine finishing N10 T1D1 N20 CYCLE446 20 N30 CYCLE405 0 0 200 100 120 0 10 0 1 0 2 2 0 1 0 1 0 03 0 01 0 01 0 005 0 002 1 0 2 0 0 1 0 02 0 01 2 1 0 5 20 30 40 0 1 2 20 N40 M30 ...

Page 218: ...Cycles 9 20 Longitudinal surface grinding CYCLE452 Cylindrical grinding 218 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 ...

Page 219: ... has its own program name The name can be freely chosen during program creation taking the following conventions into account The first two characters must be letters Use only letters digits or underscore Do not use delimiters see Section Character set The decimal point must only be used for separation of the file extension Do not use more than 27 characters Example WORKPIECE527 ...

Page 220: ... program consists of a sequence of blocks see Table below Each block represents a machining step Instructions are written in the blocks in the form of words The last block in the execution sequence contains a special word for the end of program e g M2 Table 10 1 NC program structure Set Word Word Word Comment Set N10 G0 X20 1 Set Set N20 G2 Z37 2 Set Set N30 G91 Set N40 Set N50 M2 End of program ...

Page 221: ... WKH D LV PP HHGUDWH PP PLQ Figure 10 1 Word structure example Several address characters A word can also contain several address letters In this case however the numerical value must be assigned via the intermediate character Example CR 5 23 Additionally it is also possible to call G functions using a symbolic name see also section Overview of instructions Example SCALE Enable scaling factor Exte...

Page 222: ...RP WKH UHPDLQLQJ SDUW RI WKH EORFN E 7RWDO QXPEHU RI FKDUDFWHUV LQ D EORFN FKDUDFWHUV Figure 10 2 Block structure diagram Word order If there are several instructions in a block the following order is recommended N G X Z F S T D M H Note regarding block numbers First select the block numbers in steps of 5 or 10 Thus you can later insert blocks and nevertheless observe the ascending order of block ...

Page 223: ...parate block A message is displayed in a special field and remains active until a block with a new message is executed or until the end of the program is reached Max 65 characters can be displayed in message texts A message without message text cancels a previous message MSG THIS IS THE MESSAGE TEXT See also chapter Service MSG Programming example N10 G S company order no 12A71 N20 Pump part 17 dr...

Page 224: ...ters Printable special characters Open parenthesis Inverted commas Close parenthesis _ Underscore belongs to letters Open square bracket Decimal point Close square bracket Comma separator less than Comment start greater than Reserved do not use Main block end of label Reserved do not use Assignment part of equation Reserved do not use Division block suppression System variable identifiers Multipli...

Page 225: ...functions are divided into G groups Only one G function of a group can be programmed in a block A G function can be either modal until it is canceled by another function of the same group or only effective for the block in which it is programmed non modal G or symbolic name e g CIP G group G0 Linear interpolation at rapid traverse rate 1 Motion commands G0 X Z G1 Linear interpolation at feedrate t...

Page 226: ...19 separate block MIRROR Programmable mirroring MIRROR X0 coordinate axis whose direction is changed separate block ATRANS additive translation programming ATRANS X Z separate block ASCALE Additive programmable scaling factor ASCALE X Z scaling factor in the direction of the specified axis separate block AROT additive programmable rotation AROT RPL rotation in the current plane G17 to G19 separate...

Page 227: ...n input G71 Metric dimension data input 13 Inch metr dimension input modally effective G700 Inch dimension data input also for feedrate F G710 Metric dimension data input also for feedrate F G90 Absolute dimension data input G91 Incremental dimension data input 14 Absolute incremental dimension modally effective G94 Feed F in mm min G95 Feedrate F in mm spindle revolutions G96 Constant cutting rat...

Page 228: ...eters 0 001 99 999 999 Thread 0 001 2000 000 Belongs to the Z axis otherwise as with I See G2 G3 and G33 G34 G35 I1 Intermediate point for circular interpolation 0 001 99 999 999 Belongs to the X axis specification for circular interpolation with CIP See CIP K1 Intermediate point for circular interpolation 0 001 99 999 999 Belongs to the Z axis specification for circular interpolation with CIP See...

Page 229: ...1 to M45 Gear stage 1 to gear stage 5 for master spindle Mn 41 to Mn 45 Gear stage 1 to gear stage 5 for spindle n n 1 or 2 M2 41 1st gear stage for spindle 2 M70 M19 Reserved do not use M Remaining M functions Functionality is not defined by the control system and can therefore be used freely by the machine manufacturer N Block number subblock 0 9999 9999 0 9 only integer no sign Can be used to i...

Page 230: ...alue R8 ABS R9 TRUNC Truncate to integer R10 TRUNC R2 LN Natural logarithm R12 LN R9 EXP Exponential function R13 EXP R1 RET Subroutine end Used instead of M2 to maintain the continuous path control mode RET separate block S Spindle speed master spindle 0 001 99 999 999 Unit of measurement of the spindle r p m S S1 Spindle speed for spindle 1 0 001 99 999 999 Unit of measurement of the spindle r p...

Page 231: ...ies to spindle positioning N10 A ACN 45 3 Approach absolute position of the A axis in the negative direction N20 SPOS ACN 33 1 Position spindle ANG Angle for the specification of a straight line for the contour definition 0 00001 359 99999 Specified in degrees one possibility of specifying a straight line when using G0 or G1 if only one end point coordinate of the plane is known or if the complete...

Page 232: ...d profiling N10 CYCLE416 separate block CYCLE420 General workpiece data N10 CYCLE420 separate block CYCLE430 Dressing with profile roller N10 CYCLE430 separate block DC Absolute coordinate approach position directly for rotary axis spindle It is also possible to specify the dimensions for the end point of a rotary axis with DC irrespective of G90 G91 also applies to spindle positioning N10 A DC 45...

Page 233: ...G90 N10 G90 X10 Z IC 20 Z incremental dimension X absolute dimension IF Jump condition If the jump condition is fulfilled the GoTo operation to the block with the following label is performed otherwise the next instruction block will follow In one block several IF instructions are possible Relational operators equal not equal greater than less than greater than or equal to less than or equal to N1...

Page 234: ...s in the machine coordinate system Axis Identifier of an axis X Z traversing when measuring N10 R1 AA_MM X AA_MW axis Measurement result for an axis in the workpiece coordinate system Axis Identifier of an axis X Z traversing when measuring N10 R2 AA_MW X AC_MEA 1 Measuring job status Default condition 0 Default condition probe did not switch 1 Probe switched N10 IF AC_MEAS 1 1 GOTOF Continue prog...

Page 235: ...nt actual count Count of workpieces specified by the user N10 IF AC_ACTUAL_PARTS 15 AC_PARA M Floating decimal parameter for synchronous action Used for buffering and evaluating in synchronous actions 50 parameters index 0 49 are available AC_ MSNUM Number of the active master spindle read only P_ MSNUM Number of programmed master spindle Read only P_NUM_ SPINDLES Number of configured spindles Rea...

Page 236: ... n 2 n Number of the spindle if only SETMS is set the default master spindle comes into effect N10 SETMS 2 separate block 2nd spindle master SF Thread starting point when using G33 0 001 359 999 Specified in degrees the thread starting point with G33 will be offset by the specified value See G33 SPI n converts the spindle number n into the axis identifier n 1 or 2 axis identifier e g SP1 or C SPOS...

Page 237: ...gramming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 237 Address Meaning Value assignments Information Programming G05 Activates oblique plunge cutting Can only be set with inclined axis TRAANG G05 X G07 Approach starting position Can only be set with inclined axis TRAANG G07 X Z ...

Page 238: ...n X AC value only this value applies only for the stated axis and is not influenced by G90 G91 This is possible for all axes and also for SPOS SPOSA spindle positionings and interpolation parameters I J K Absolute dimension X CC value directly approaching the position by the shortest route only this value applies only for the stated rotary axis and is not influenced by G90 G91 Is also possible for...

Page 239: ... instructions G90 G91 the written positional data X Z are evaluated as a coordinate point G90 or as an axis position to traverse to G91 G90 91 applies for all axes Irrespective of G90 G91 certain positional data can be specified for certain blocks in absolute incremental dimensions using AC IC These instructions do not determine the path by which the end points are reached this is provided by a G ...

Page 240: ...l dimensioning G91 With incremental dimensioning the numerical value of the path information corresponds to the axis path to be traversed The leading sign indicates the traversing direction G91 applies to all axes and can be deselected in a subsequent block by G90 absolute dimensioning Specification with AC IC After the end point coordinate write an equality sign The value must be put in round bra...

Page 241: ...ing from this point on Information Depending on the default setting you have chosen the control system interprets all geometric values as either metric or inch dimensions Tool offsets and settable zero offsets including their displays are also to be understood as geometrical values this also applies to the feed F in mm min or inch min The default setting can be set in machine data All examples pro...

Page 242: ...IAMON assesses the end point specification for the X axis as radius or diameter dimensioning The actual value appears in the display accordingly for the workpiece coordinate system For DIAM90 irrespective of the traversing method G90 G91 the actual value of the transverse axis is always displayed as a diameter This also applies to reading of actual values in the workpiece coordinate system with ME...

Page 243: ...o radius position X30 N40 DIAMON Diameter dimensions active N50 G1 X70 Z 20 Traverse to diameter position X70 and Z 20 N60 Z 30 N70 DIAM90 diameter programming for absolute dimension and radius programming for incremental dimension N80 G91 X10 Z 20 Incremental dimension N90 G90 X10 Absolute dimensions N100 M30 End of program Note A programmable offset with TRANS X or ATRANS X is always evaluated a...

Page 244: ...ssible in all axes Note In the X axis the workpiece zero should be in the turning center due to the functions of diameter programming DIAMON and constant cutting speed G96 For this reason use no offset or only a small offset e g as allowance in the X axis RUNSLHFH RIIVHW 2IIVHW RUNSLHFH FWXDO FWXDO RUNSLHFH RULJLQDO Figure 10 5 Effect of the programmable offset Programming TRANS Z programmable off...

Page 245: ...nality A scale factor can be programmed for all axes with SCALE ASCALE The path is enlarged or reduced by this factor in the axis specified The currently set coordinate system is used as the reference for the scale change Programming SCALE X Z programmable scaling factor clears old instructions for offset rotation scaling factor mirroring ASCALE X Z programmable scaling factor additive to existing...

Page 246: ...ample of a programmable scaling factor Programming example N20 L10 Programmed contour original N30 SCALE X2 Z2 contour in X and Z enlarged 2 times N40 L10 Subroutine call see Section Subroutine technique Information In addition to the programmable offset and the scale factor the following functions exist Programmable rotation ROT AROT and programmable mirroring MIRROR AMIRROR These functions are p...

Page 247: ...NC block Parameter MIRROR Absolute mirror image with reference to the currently valid coordinate system set with G54 to G599 AMIRROR Additive mirror image with reference to the currently valid set or programmed coordinate system X Y Z Geometry axis whose direction is to be changed The value specified here can be chosen freely e g X0 Y0 Z0 Example of contour dressing Program the contour shown here ...

Page 248: ...7 2009 6FC5398 4CP10 2BA0 10 2 8 Programmable mirroring MIRROR AMIRROR _2 Additive instruction AMIRROR X Y Z A mirror image which is to be added to an existing transformation is programmed with AMIRROR The currently set or last programmed coordinate system is used as the reference 75 16 0 5525 ...

Page 249: ...y axes are converted automatically by the control into rotations and where appropriate mirrors on the mirror axis specified in the machine data This also applies to settable zero offsets Machine manufacturer You can set the axis around which mirroring is performed via machine data MD MD 10610 0 Mirroring is performed in relation to the programmed axis negation of values MD 10610 1 or 2 or 3 Depend...

Page 250: ...am by selecting from twelve possible groupings G54 to G59 and G507 to G512 For information on operation see Section Setting changing the work offset Programming G54 1 Settable zero offset G55 2 Settable zero offset G56 3 Settable zero offset G57 4 Settable zero offset G58 5 Settable zero offset G59 6 Settable zero offset G507 7 Settable zero offset G508 8 Settable zero offset G509 9 Settable zero ...

Page 251: ...a limitation it must be activated for the respective axis This is done via the input screen under Offset Param Setting data working area limit There are two options for defining the working area Inputting the values via control system input screens under Offset Param Setting data working area limit This also activates the working area limitation in JOG mode Programming with G25 G26 The values for ...

Page 252: ...nt axis identifiers are configured for MD 20080 and for the geometry axis identifiers MD 20060 AXCONF_GEOAX_NAME_TAB G25 G26 is also used in connection with the address S for the spindle speed limitation A working area limitation can only be activated if the reference point for the relevant axes has been approached Programming example N10 G25 X0 Z40 Values of the lower working area limitation N20 ...

Page 253: ...ne data If only one axis traverses it uses its rapid traverse If two axes are traversed simultaneously the path velocity resulting velocity is selected to achieve the maximum possible path velocity in consideration of both axes A programmed feedrate F word has no meaning for G0 G0 remains active until canceled by another instruction from this G group G1 G2 G3 Programming G0 X Z Cartesian coordinat...

Page 254: ...ar coordinates Information Another group of G functions exists for moving into the position see Section Exact stop continuous path control mode G60 G64 For G60 exact stop a window with various precision values can be selected with another G group For exact stop an alternative instruction with non modal effectiveness exists G9 You should consider these options for adaptation to your positioning tas...

Page 255: ... remains active until canceled by another instruction from this G group G0 G2 G3 Programming G1 X Z F Cartesian coordinates G1 AP RP F Polar coordinates Note Another option for linear programming is available with the angle specification ANG 0 Figure 10 11 Linear interpolation with G1 Programming example N05 G54 G0 G90 X40 Z200 S500 M3 The tool traverses in rapid traverse spindle speed 500 r p m c...

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Page 257: ...ons Input tolerances for the circle Circles are only accepted by the control system with a certain dimensional tolerance The circle radius at the starting and end points are compared here If the difference is within the tolerance the center point is exactly set internally Otherwise an alarm message is issued The tolerance value can be set via machine data see Operating Instructions 802D sl Program...

Page 258: ...on N5 G90 Z30 X40 Starting point circle for N10 N10 G2 Z50 X40 CR 12 207 End point and radius Note With a negative leading sign for the value with CR a circular segment larger than a semicircle is selected Programming example Definition of end point and aperture angle r 6WDUW SRLQW HQWHU SRLQW QG SRLQW Figure 10 16 Example for end point and aperture angle specification N5 G90 Z30 X40 Starting poin...

Page 259: ...amming example Definition of center point and aperture angle r 6WDUW SRLQW QG SRLQW HQWHU SRLQW Figure 10 17 Example for center point and aperture angle specification N5 G90 Z30 X40 Starting point circle for N10 N10 G2 K10 I 7 AR 105 Opening angle and center point Note Center point values refer to the circle starting point ...

Page 260: ...pecification of intermediate point I1 for the X axis K1 for the Z axis CIP remains active until canceled by another instruction from this G group G0 G1 The configured dimensional data G90 or G91 applies to the end point and the intermediate point 6WDUW SRLQW QG SRLQW QWHUPHGLDWH SRLQW Figure 10 18 Circle with end point and intermediate point specification using the example of G90 Programming examp...

Page 261: ...FWLRQ Figure 10 19 Circle with tangential transition to the previous path section 10 3 6 Fixed point approach G75 Functionality By using G75 a fixed point on the machine e g tool change point can be approached The position is stored permanently in the machine data for all axes A maximum of four fixed points can be defined for each axis No offset is effective The velocity of each axis is its rapid ...

Page 262: ... is specified fixed point 1 is approached automatically X1 0 Z1 0 Machine axes to be traversed to the fixed point Specify the axes with value 0 with which the fixed point is to be approached simultaneously Each axis is traversed with the maximum axial velocity Programming example N05 G75 FP 1 X1 0 Approach fixed point 1 in X N10 G75 FP 2 Z1 0 Approach fixed point 2 in Z e g for tool change N30 M30...

Page 263: ... trigger probe MEAS MEAW Functionality The function is available for SINUMERIK 802D sl plus and pro If the instruction MEAS or MEAW is in a block with traversing movements of axes the positions of the traversed axes for the switching flank of a connected measuring probe are registered and stored The measurement result can be read in the program for each axis For MEAS the movement of the axes is ha...

Page 264: ...o 0 Measuring result When the probe is successfully activated the result of the measurement is available after the measuring block with the following variables for the axes traversed in the measuring block in the machine coordinate system AA_MM axis in the workpiece coordinate system AA_MW axis axis stands for X or Z Programming example N10 MEAS 1 G1 X300 Z 40 F4000 Measurement with deletion of di...

Page 265: ...e decimal point is not required e g F300 Unit of measure for F with G94 G95 The dimension unit for the F word is determined by G functions G94 F as the feedrate inmm min G95 F as feedrate in mm rev of the spindle only meaningful if the spindle is turning Remark This unit of measure applies to metric dimensions According to Section Metric and inch dimensioning settings with inch dimensioning are al...

Page 266: ...fine G602 Exact stop window coarse Exact stop G60 G9 If the exact stop function G60 or G9 is active the velocity for reaching the exact end position at the end of a block is decelerated to zero Another modal G group can be used here to set when the traversing movement of this block is considered ended and the next block is started G601 Exact stop window fine Block advance takes place when all axes...

Page 267: ...Remark The G9 command only generates exact stop for the block in which it is programmed G60 however is effective until it is canceled by G64 Continuous path control mode G64 The objective of the continuous path control mode is to avoid deceleration at the block boundaries and to switch to the next block with a path velocity as constant as possible in the case of tangential transitions The function...

Page 268: ...ystem automatically determines the velocity control for several NC blocks in advance This enables acceleration and deceleration across multiple blocks with approximately tangential transitions For paths that consist of short travels in the NC blocks higher velocities can be achieved than without look ahead HHG 3URJUDPPHG IHHGUDWH RQWLQXRXV SDWK FRQWURO PRGH ZLWK RRN KHDG RQWLQXRXV SDWK FRQWURO PRG...

Page 269: ...on pattern SOFT The axes of the machine accelerate with nonlinear constant curves until reaching the final velocity With this jerk free acceleration SOFT allows for reduced machine load The same behavior can also be applied to braking procedures 5 6 WLPH RSWLPL HG 62 7 VSDUHV WKH PHFKDQLFDO SDUWV 9HORFLW SDWK 6HWSRLQW W W 7LPH Figure 10 22 Principle course of the path velocity when using BRISK SOF...

Page 270: ...pendent upon the gear stage the selected mode positioning mode or speed mode Programming ACC axis name percentage for axis ACC S percentage for spindle Programming example N10 ACC X 80 80 acceleration for the x axis N20 ACC S 50 50 acceleration for the spindle N100 ACC X 100 Deactivate the override for the X axis Activation The limitation is active in all types of interpolation of the AUTOMATIC an...

Page 271: ... Functionality Through feedforward control the following error in the traversing path is almost zero Traversing with feedforward control permits greater path accuracy and thus better production results Programming FFWON Feedforward control ON FFWOF Feedforward control OFF Programming example N10 FFWON Feedforward control ON N20 G1 X Z F9 N80 FFWOF Feedforward control OFF ...

Page 272: ...th axes However the speed cannot exceed the defined limit value If a block is programmed with this 3rd axis only the axis will traverse using the active feedrate F when the G1 function is executed If the axis is a rotary axis the unit of measurement for F is degrees min with G94 or degrees rev of the spindle with G95 For these axes offsets can be set G54 G59 and programmed TRANS ATRANS Programming...

Page 273: ...is block Any previously programmed feedrate F or a spindle speed S remain valid Programming G4 F Dwell time in seconds G4 S Dwell time in spindle revolutions Programming example N5 G1 F3 8 Z 50 S300 M3 Feed F spindle speed S N10 G4 F2 5 Dwell time 2 5 seconds N20 Z70 N30 G4 S30 dwelling 30 revolutions of the spindle corresponds at S 300 rpm and 100 speed override to t 0 1 min N40 X Feed and spindl...

Page 274: ...thout connecting a probe Programming FXS axis 1 Select travel to fixed stop FXS axis 0 Deselect travel to fixed stop FXST axis Clamping torque specified in of the max torque of the drive FXSW axis Width of the window for fixed stop monitoring in mm degrees Remark The machine axis identifier should be used as the axis identifier e g X1 The channel axis identifier e g X is only permitted if e g no c...

Page 275: ...ure 10 23 Example for travel to fixed stop a quill is pressed onto the workpiece Other programming examples N10 G1 G94 N20 X250 Z100 F100 FXS X1 1 selected for machine axis X1 FXS clamping torque and window width from SDs N20 X250 Z100 F100 FXS X1 1 FXST X1 12 3 selected for machine axis X1 FXS clamping torque 12 3 and window width from SD N20 X250 Z100 F100 FXS X1 1 FXST X1 12 3 FXSW X1 2 selecte...

Page 276: ...far the axis will not be able to follow the specified setpoint the position controller then goes to the limit and the contour deviation increases In this operating state an increase in the torque limit may result in sudden jerky movements Ensure that the axis can still follow For this reason it must be verified that the contour deviation is not larger than that with unlimited torque A rate of rise...

Page 277: ...ng Manual 07 2009 6FC5398 4CP10 2BA0 277 Alarm suppression The issuing of the following alarms can be suppressed with machine data 20091 Fixed stop not reached 20094 Fixed stop aborted Reference SINUMERIK 802D sl Function Manual for Turning Milling Nibbling Travel to Fixed Stop ...

Page 278: ...e g S270 Information If you write M3 or M4 in a block with axis movements the M commands become active before the axis movements Standard setting Axis movements will only start once the spindle has accelerated to speed M3 M4 M5 is also issued before the axis movement However it does not wait for the spindle to stop Axis motion already starts before the spindle comes to a standstill The spindle is ...

Page 279: ...written G25 or G26 only need one separate block each A previously programmed speed S is maintained Programming G25 S Lower spindle speed limitation G26 S Upper spindle speed limitation Information The outmost limits of the spindle speed are set in machine data By entering via the operator panel setting data for further limitations can be activated For the function G96 constant cutting speed an add...

Page 280: ...ndle i e if the measuring system is not yet synchronized In this case the direction is specified in machine data Other movement specifications for the spindle are possible with SPOS ACP SPOS ACN as for rotary axes The movement takes place in parallel with any axis movements in the same block This block is ended when both movements are finished Programming SPOS Absolute position 0 360 degrees SPOS ...

Page 281: ...rated as a rotary axis in these functions Master spindle A series of functions is associated with the master spindle that can only be used with this spindle G95 Rev feedrate G96 G97 Constant cutting rate LIMS upper speed limit for G96 G97 M3 M4 M5 S simple specifications for direction of rotation stop and speed The master spindle is defined via configuration machine data Generally it is the main s...

Page 282: ... 45 gear stages for spindle 2 if available SPOS n Position spindle n SPI n Converts spindle number n to axis identifier e g SP1 or CC n must be a valid spindle number 1 or 2 The functions of spindle identifiers SPI n and Sn are identical P_S n Last programmed speed of spindle n AA_S n Actual speed of spindle n P_SDIR n Last programmed direction of rotation of spindle n AC_SDIR n Current direction ...

Page 283: ... limit speed of the spindle with G96 G97 effective F feedrate in mm revolution as for G95 Remark If G94 instead of G95 was active before a new appropriate F value must be written Rapid traverse With rapid traverse G0 there is no change in speed Exception If the contour is approached at rapid traverse and the next block contains an interpolation type G1 or G2 G3 CIP CT contour block then the speed ...

Page 284: ...because block N31 with G0 N31 X50 Z no change in speed because block N32 with G0 N32 X40 Approach on contour new speed is automatically set as is required for the beginning of block N40 N40 G1 F0 2 X32 Z Feedrate 0 2 mm revolution N180 G97 X Z Deactivating constant cutting rate N190 S new spindle speed r p m Information The G96 function can also be deactivated with G94 or G95 same G group In this ...

Page 285: ...F FRC Non modal feedrate for chamfer rounding Value 0 feedrate in mm min G94 or mm rev 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 The feedrate F applies for the chamfer rounding Information The appropriate instruction CHF or CHR or RND or RNDM is written in the bloc...

Page 286: ...R A linear contour element is inserted between linear and circle contours in any combination The edge is broken KDPIHU 1 1 QJOH ELVHFWRU Figure 10 24 Inserting a chamfer with CHF using the example Between two straight lines KDPIHU 1 1 5 QJOH ELVHFWRU 5 Figure 10 25 Inserting a chamfer with CHR using the example Between two straight lines ...

Page 287: ... or RNDM A circle contour element can be inserted with tangential connection between the linear and circle contours in any combination 6WUDLJKW OLQH VWUDLJKW OLQH 1 51 51 1 5RXQGLQJ 5RXQGLQJ 6WUDLJKW OLQH FLUFOH 1 51 51 5RXQGLQJ 5RXQGLQJ 1 Figure 10 26 Examples for inserting roundings Programming examples for rounding N5 F N10 G1 X RND 4 Insert 1 rounding with radius 4 mm feedrate F N20 X Z N50 G1...

Page 288: ...eometry of the wheel is always entered at under 0 degrees This also applies to fixed inclined wheels The maximum diameter and the wheel width are input into the wheel data image here 10 6 2 Tool T Functionality The tool selection takes place when the T word is programmed Whether this is a tool change or only a preselection is defined in the machine data For grinding the tool change tool call takes...

Page 289: ... amount which means that the odd numbers are left negative wear value and the even numbers are right positive wear value The wear in direction X diameter is the same for all points negative for grinding direction in negative direction Cutting edges 7 to 9 are the three possible dressers of a wheel They are permanently assigned to the sections of the wheel Dresser 1 D7 Left wheel edge Dresser 2 D8 ...

Page 290: ...sation memory Geometrical dimensions Length radius These consist of several components geometry wear The control systems computes the components to a certain dimension e g overall length 1 total radius The respective overall dimension becomes active when the offset memory is activated The way in which these values are computed in the axes is determined by the tool type and the current plane G17 G1...

Page 291: ...UDGLXV 0LQ ZKHHO ZLGWK FWXDO ZKHHO ZLGWK 0D LPXP VSHHG QJOH RI WKH LQFOLQHG ZKHHO 3DUDPHWHU 1R IRU UDGLXV FDOFXODWLRQ HDU YDOXHV FRUUHVSRQG WR WKH UHTXLUHPHQW 2WKHU YDOXHV VKRXOG EH VHW WR IIHFW HQJWK LQ HQJWK LQ 5DGLXV LQ HQJWK LQ HQJWK LQ 5DGLXV LQ HQJWK LQ HQJWK LQ 5DGLXV LQ 7RRO FDUULHU UHIHUHQFH SRLQW 5DGLXV HRPHWU HQJWK DVLV OHQJWK DVLV HQJWK HRPHWU HQJWK 3RVLWLRQ 7RRO QRVH SRVLWLRQ 0D SHULS...

Page 292: ...controller automatically calculates the required equidistant tool paths for the programmed contour for the respective current tool radius G18 must be active Figure 10 28 Tool radius compensation cutter radius compensation Programming G41 X Z Tool radius compensation left of contour G42 X Z Tool radius compensation right of contour Remark The selection can only be made for linear interpolation G0 G...

Page 293: ...nsure collision free traversing 6WDUWLQJ FRQWRXU 6WUDLJKW RPSHQVDWHG 7RRO SDWK 5 FXWWLQJ HGJH UDGLXV 5 3 3 VWDUWLQJ SRLQW RI WKH FRQWRXU 6WDUWLQJ FRQWRXU LUFOH 3 VWDUWLQJ SRLQW RPSHQVDWHG 7RRO SDWK 03 LUFOH UDGLXV 7DQJHQW 5 3 3 VWDUWLQJ SRLQW Figure 10 30 Start of the tool radius compensation with the example G42 tool point direction 3 Information As a rule the block with G41 G42 is followed by th...

Page 294: ...set Cylindrical grinding 294 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 Programming example N10 T F N15 X Z P0 starting point N20 G1 G42 X Z Selection right of contour P1 N30 X Z Starting contour circle or straight line ...

Page 295: ... corners the intersection of the equidistant paths is always approached Programming G450 Transition circle G451 Point of intersection WHUQDO FRUQHU WHUQDO FRUQHU I I 7UDQVLWLRQ FLUFOH UDGLXV WRRO UDGLXV 3RLQW RI LQWHUVHFWLRQ Figure 10 31 Corner behavior at an external corner S S QWHUQDO FRUQHU 3RLQW RI LQWHUVHFWLRQ Figure 10 32 Corner behavior at an internal corner Transition circle G450 The tool ...

Page 296: ...ive the reference point is the tool tip The tool tip then travels to the programmed point upon deselection Always select the end point of the G40 block such that collision free traversing is guaranteed Programming G40 X Z Tool radius compensation OFF Remark The compensation mode can only be deselected with linear interpolation G0 G1 Program both axes If you only specify one axis the second axis is...

Page 297: ...the compensation mode A modified tool radius is active with effect from the block in which the new D number is programmed Its complete modification is only achieved at the end of the block In other words The modification is traversed continuously over the entire block also for circular interpolation Cancellation of compensation by M2 If the offset mode is canceled with M2 program end without writi...

Page 298: ...es S S S S r 5 5 5 5 5 Figure 10 34 Example for contour dressing N1 Contour cut N10 DIAMON F S M Radius dimension technological values N15 G500 Work offset OFF N20 MIRROR X0 Z0 Begin compensation mode N30 G90 G0 X 90 N40 Z 10 N50 X110 Approach R55 N60 G41 G64 G1 Z20 F500 Dressing contour section N70 X100 N80 Z60 RND 20 Dressing contour section N90 X60 N100 Z68 Dressing contour section N110 X40 Z98...

Page 299: ...ffective with the next cutting edge selection Examples With SD 42950 TOOL_LENGTH_TYPE 2 a milling tool used is taken into account in length compensation as a turning tool G17 Length 1 in Y axis length 2 in X axis G18 Length 1 in X axis length 2 in Z axis G19 Length 1 in Z axis length 2 in Y axis With SD 42940 TOOL_LENGTH_CONST 18 the length assignment is performed in all planes G17 to G19 as for G...

Page 300: ...indrical grinding 300 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 Information Detailed information on tool offset special actions can be found in Reference FDescription of Functions Section Special handling of tool compensation ...

Page 301: ...M0 M1 M2 are contained in a block with traversing movements of the axes these M functions become effective after the traversing movements The functions M3 M4 M5 are output to the internal interface PLC before the traversing movements The axis movements only begin once the controlled spindle has ramped up for M3 M4 For M5 however the spindle standstill is not waited for The axis movements already b...

Page 302: ...e transferred to the PLC programmable logic controller In all a maximum of 10 such function outputs are possible in a block Information With the SINUMERIK 802D sl plus and 802D sl pro two spindles are possible This results in an expanded programming capability for the M commands only for the spindles M1 3 M1 4 M1 5 M1 40 M3 M4 M5 M40 for spindle 1 M2 3 M2 4 M2 5 M2 40 M3 M4 M5 M40 for spindle 2 ...

Page 303: ... The meaning of the values for a given H function is defined by the machine manufacturer Programming H0 to H9999 Max 3 H functions per block Programming example N10 H1 1 987 H2 978 123 H3 4 3 H functions in block N20 G0 X71 3 H99 8978 234 With axis movements in block N30 H5 Corresponds to H0 5 0 Note In addition to M and H functions T D and S functions can also be transferred to the PLC programmab...

Page 304: ...he program Programming R0 to R299 Assign values to the arithmetic parameters R R0 Indirect programming Assign a value to the arithmetic parameter R whose number can be found e g in R0 X R0 Assign arithmetic parameters to the NC addresses e g for the X axis Value assignments You can assign values in the following range to the R parameters 0 000 0001 9999 9999 8 decimal places arithmetic sign and de...

Page 305: ...xis addresses traversing instructions Example N10 G0 X R2 Assignment to X axis Arithmetic operations arithmetic functions When operators arithmetic functions are used it is imperative to use conventional mathematical notation Machining priorities are set using round brackets Otherwise multiplication and division take precedence over addition and subtraction Degrees are used for the trigonometrical...

Page 306: ...inition takes place immediately at the start of the program and can also be associated with a value assignment at the same time Otherwise the starting value is zero The name of a variable can be defined by the programmer The naming is subject to the following rules A maximum of 32 characters can be used It is imperative to use letters for the first two characters the remaining characters can be ei...

Page 307: ...gn string Hello Fields In addition to the individual variables one or two dimensional fields of variables of these data types can also be defined DEF INT PVAR5 n One dimensional field type INT n integer DEF INT PVAR6 n m Two dimensional field type INT n m integer Example DEF INT PVAR7 3 Field with 3 elements of the type INT Within the program the individual field elements can be reached via the fi...

Page 308: ...A_DBW n Data word 16 bit value A_DBD n Data double word 32 bit value A_DBR n REAL data 32 bit value n stands here for the position offset start of data area to start of variable in bytes Programming example R1 A_DBR 5 Reading a REAL value offset 5 starts at byte 5 of range Note The reading of variables generates a preprocessing stop internal STOPRE NOTICE Writing of PLC tags is generally limited t...

Page 309: ... must contain a minimum of 2 and a maximum of 8 letters or numbers of which the first two characters must be letters or underscore characters Labels that are in the block that serves as the jump destination are ended by a colon They are always at the start of a block If a block number is also present the label is located after the block number Labels must be unique within a program Programming exa...

Page 310: ...nation can be a block with a label or with a block number This block must be located within the program The unconditional jump instruction requires a separate block Programming GOTOF label Jump forward in the direction of the last block of the program GOTOB label Jump backwards in the direction of the first block of the program Label Selected string for the label jump label or block number 3URJUDP...

Page 311: ... the program if necessary Programming IF condition GOTOF label Jump forward IF condition GOTOB label Jump backwards GOTOF Jump direction forward in the direction of the last block of the program GOTOB Jump direction backwards in the direction of the first block of the program Label Selected string for the label jump label or block number IF Introduction of the jump condition Condition Arithmetic p...

Page 312: ...SIN R7 squared Programming example N10 IF R1 GOTOF LABEL1 If R1 is not null then go to the block having LABEL1 N90 LABEL1 N100 IF R1 1 GOTOF LABEL2 If R1 is greater than 1 then go to the block having LABEL2 N150 LABEL2 N800 LABEL3 N1000 IF R45 R7 1 GOTOB LABEL3 If R45 is equal to R7 plus 1 then go to the block having LABEL3 Several conditional jumps in the block N10 MA1 N20 IF R1 1 GOTOB MA1 IF R1...

Page 313: ...roaching points on a circle segment Existing conditions Start angle 30 in R1 Circle radius 32 mm in R2 Position spacing 10 in R3 Number of points 11 in R4 Position of circle center in Z 50 mm in R5 Position of circle center in X 20 mm in R6 5 3RLQW 5 3RLQW 5 3RLQW 3RLQW 5 3RLQW 5 QXPEHU RI SRLQWV 5 5 Figure 10 36 Linear approach of points on a circle segment ...

Page 314: ...IN R1 R6 Calculation and assignment to axis addresses N30 R1 R1 R3 R4 R4 1 N40 IF R4 0 GOTOB MA1 N50 M2 Explanation In block N10 the starting conditions are assigned to the corresponding arithmetic parameters The calculation of the coordinates in X and Z and the processing takes place in N20 In block N30 R1 is incremented by the clearance angle R3 and R4 is decremented by 1 If R4 0 N20 is executed...

Page 315: ...versally valid machining scenarios By assigning values via included transfer parameters you can adapt the subroutine to your specific application Layout The structure of a subroutine is identical to that of a main program see Section Program structure Like main programs subroutines contain M2 end of program in the last block of the program sequence This means a return to the program level where th...

Page 316: ...me may be freely selected provided the following conventions are observed The same rules apply as for the names of main programs Example BUCHSE7 It is also possible to use the address word L in subroutines The value can have 7 decimal places integers only Please observe With address L leading zeros are meaningful for differentiation Example L128 ist nicht L0128 oder L00128 Dies sind 3 verschiedene...

Page 317: ...m a subroutine not only from a main program In total up to 8 program levels are available for this type of nested call including the main program level 6XESURJUDP 6XESURJUDP 0DLQ SURJUDP WK OHYHO UG OHYHO QG OHYHO VW OHYHO 6XESURJUDP Figure 10 38 Execution with 8 program levels Information Modal G functions can be changed in the subroutine e g G90 G91 When returning to the calling program ensure t...

Page 318: ...nes that implement a certain machining process in a universally valid way Adaptation to the particular problem is performaed directly via supply parameters values when calling the respective cycle Programming example N10 CYCLE83 110 90 Call of cycle 83 transfer values directly separate block N40 RTP 100 RFP 95 5 Set transfer parameters for cycle 82 N50 CYCLE82 RTP RFP Call of cycle 82 separate blo...

Page 319: ...active AN_SETUP_TIME Time since the last control powerup with default values in minutes It is automatically reset in the case of a Control power up with default values AN_POWERON_TIME Time since the last control powerup in minutes It is reset to zero automatically with each power up of the control system Timers that can be deactivated The following timers are activated via machine data default set...

Page 320: ...path axes is measured in all NC programs between NC START and end of program RESET without rapid traverse active and with the tool active default setting The measurement is interrupted when a dwell time is active The timer is automatically set to zero with each power up of the control system Programming example N10 IF AC_CUTTING_TIME R10 GOTOF WZZEIT Tool operation time limit value N80 WZZEIT N90 ...

Page 321: ...ce setpoint reached can be activated via machine data AC_TOTAL_PARTS Total number of workpieces produced total actual The counter specifies the total number of all workpieces produced since the start time The counter is automatically set to zero upon every booting of the control system AC_ACTUAL_PARTS Number of actual workpieces actual This counter registers the number of all workpieces produced s...

Page 322: ...nts of the active system variables are visible on the screen under OFFSET PARAM Setting data Times counters Total parts AC_TOTAL_PARTS Required parts AC_REQUIRED_PARTS Number of parts AC_ACTUAL_PARTS AC_SPECIAL_PARTS not available for display Number of parts is also visible in the AUTOMATIC mode in the Position operating area in the information line ...

Page 323: ...n Activate transformation with the parameterization of the previous selection TRAANG α Activates the first specified inclined axis transformation TRAANG α n Activates the nth agreed inclined axis transformation The maximum value of n is 2 TRAANG α 1 corresponds to TRAANG α α Angle of inclined axis Permissible values for α are 90 degrees α 90 degrees TRAFOOF Transformation off n Number of agreed tr...

Page 324: ...08 ULQGLQJ GLVF RUNSLHFH N10 G0 G90 Z0 MU 10 G54 F5000 G18 G64 T1 D1 Tool selection clamping compensation Plane selection N20 TRAANG 45 Enable inclined axis transformation N30 G0 Z10 X5 Approach start position N40 POS X 4 5 FA X 50 N50 TRAFOOF Deactivate transformation N60 G0 Z10 MU 10 Move clear N70 M30 program in a single block ...

Page 325: ...ific contour 4 Oblique plunge cut grinding Machine manufacturer The following settings are defined in machine data The angle between a machine axis and the oblique axis The position of the zero point of the tool relative to the origin of the coordinate system specified by the inclined axis function The speed reserve held ready on the parallel axis for the compensating movement The axis acceleratio...

Page 326: ...inding wheel can either be cartesian or in the direction of the inclined axis the display stays cartesian All that moves is the real U axis the Z axis display is updated In jog mode REPOS offsets must be traversed using Cartesian coordinates In jog mode with active PTP travel the Cartesian operating range limit is monitored for overtravel and the relevant axis is braked beforehand If PTP travel is...

Page 327: ...cal grinding Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 327 Example 1 1 6 9 ULQGLQJ GLVF RUNSLHFH N Program angle for inclined axis N50 G07 X70 Z40 F4000 Approach starting position N60 G05 X70 F100 Oblique plunge cutting N70 ...

Page 328: ...he unit for the retraction path refers to the current valid unit of measurement mm or inch FMA 2 x FMA 3 x In addition to the path feed you can program up to 2 further feedrates per axis in the block non modal STA Axial dwell time for grinding technology sparking out time non modal SRA Axial return path non modal FMA and F value The axial feedrate FMA value or path feedrate F value corresponds to ...

Page 329: ...rogram up to 2 further feeds per axis in the block The first expression in the square brackets indicates the bit number of the input the second the axis for which the feedrate is to apply FMA 3 x 1000 Axial feedrate with the value 1000 for X axis 3 corresponds to input bit 3 Example of axial dwell time and return path Dwell time and return path are programmed under the following additional address...

Page 330: ...superimposing of oscillation paths are not possible Programming The following addresses allow asynchronized oscillation to be activated and controlled from the part program The programmed values are entered in the corresponding setting data with block synchronization during the main run and remain active until changed again Activate deactivate oscillation OS OS axis 1 resistor OS axis 0 switch off...

Page 331: ...250 for the oscillating axis Three sparking out strokes must be executed at the end of the machining operation followed by approach by oscillation axis to end position 200 The feedrate for the infeed axis is 1 end of the infeed in X direction is at 15 N20 WAITP X Y Z Initial setting N30 G0 X100 Y100 Z100 Switch over in positioning axis operation N40 WAITP X Z N50 OSP1 Z 10 OSP2 Z 100 OSE Z 200 OST...

Page 332: ...limitation SOFT or with acceleration curve with a knee as positioning axes Oscillation reversal points The current offsets must be taken into account when oscillation positions are defined Absolute specification OSP1 Z value 1 Position of reversal point sum of offsets programmed value Relative specification OSP1 Z IC value Position of reversal point reversal point 1 programmed value Example N10 OS...

Page 333: ...d stop at reversal point 2 3 When the oscillation is deactivated do not approach reversal point if no spark out strokes are programmed 4 Approach end position after spark out 8 If the oscillation movement is canceled by deletion of the distance to go then execute spark out strokes and approach end position if appropriate 16 If the oscillation movement is canceled by deletion of the distance to go ...

Page 334: ...Programming 10 15 Oscillation Cylindrical grinding 334 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 ...

Page 335: ...ystem and a PG PC Prerequisites The RCS802 tool is required on the PG PC for communication For connecting the control system via the network various options are available These options are described in the chapters RCS tool and Network operation The connections are enabled via the following control system interfaces RS232 interface Ethernet peer to peer interface Interface Ethernet network availab...

Page 336: ... on PG PC RS232 Is available for value plus and pro Are available Peer to peer Ethernet Is available for value plus and pro Are available Ethernet network Only available for SINUMERIK 802D sl pro Function that requires a license Functions of the RCS802 tool with license key NOTICE You will only obtain the full functionality of the RCS802 tool after importing the license key RCS802 Table 11 2 Funct...

Page 337: ...Control 802 is also available This directory makes data exchange with the control system possible In addition a remote control function is provided for process monitoring The ONLINE connections from the PG PC to the control are parameterized activated via the Setting Connection menu items in the Connection Settings dialog box Figure 11 2 Connection Settings Note The RCS802 tool includes a detailed...

Page 338: ...ow in the SYSTEM operating area Press the PLC softkey Figure 11 3 Communication settings RS232 Set the parameters for communication in the STEP 7 Connect dialog Activate the RS232 connection with the Connect ON softkey Figure 11 4 RS232 connection active No modifications to the settings are possible in this state The softkey label changes to Connect OFF 50 6 67 0 3 RQQHFW WR 67 3 RQQHFW RQ ...

Page 339: ...ou are now in the SYSTEM operating area Press the softkeys Service display Service control Figure 11 5 Service control Press the Direct connect softkey The following message is shown on the HMI Connection is set up IP Address 169 254 11 22 Subnet mask 255 255 0 0 The IP address and subnet mask shown are fixed values These values cannot be changed You can cancel the Ethernet peer to peer connection...

Page 340: ...twork connection to the control You are now in the SYSTEM operating area Press the softkeys Service display Service control Figure 11 6 Service control Press the softkey Service network only available for SINUMERIK 802D sl pro Reference SINUMERIK 802D sl Programming and Operating Manual Network Operation 50 6 67 0 6HUYLFH GLVSOD 6HUYLFH FRQWURO 6HUYLFH QHWZRUN ...

Page 341: ...em is network capable The following connections are possible Ethernet peer to peer Direct connection between control system and PC using a cross over cable Ethernet network Integrating the control system into an existing Ethernet network using a patch cable Screened network operation with encrypted data transfer is possible using an 802D specific transmission protocol This protocol is used e g for...

Page 342: ...ontrol system is connected to the PC or the local network via the X5 interface Entering network parameters Switch to the the SYSTEM operating area Press the Service display Service control system softkeys Select the Service network softkey to display the network configuration window Figure 11 7 Network configuration start screen 50 6 67 0 6HUYLFH GLVSOD 6HUYLFH FRQWURO 6HUYLFH QHWZRUN ...

Page 343: ... the computer name IP address and Subnet mask 1 Press the vertical softkey Save 2 Switch the control system off and on again Computer name Name of the control system in the network IP address Network address of the control system e g 192 168 1 1 Subnet mask Network identification e g 255 255 252 0 Enabling the communication ports Use the Service Firewall softkey to enable or disable communication ...

Page 344: ...e users To create a new account type the user name and the log in password in the input fields A user account is required for communication between HMI and the RCS tool on the programming device PC For this purpose the user has to enter this password on the HMI during RCS log in via network This password is required also if the user want to communicate with the control system from the RCS tool Use...

Page 345: ...pe user name and password into the appropriate input fields and select the Log in softkey to confirm your input After successful log in the user name is displayed in the Current user line Select the Back softkey to close the dialog box Note This log in simultaneously serves for user identification for remote connections Logoff Press the Log off softkey This will log out the current user all user s...

Page 346: ...fault After log in of a local user the following functions are offered to the RCS tool Commissioning functions Data transfer transfer of part programs Remote control for the control system To grant access to a part of the file system first share the relevant directories with other users Note If you share directories with other users the authorized network nodes are granted access to the shared fil...

Page 347: ...e selected directory Do not share this directory Directory will not be shared Share this directory The directory will be shared and a share name must be entered Type an identifier into the Share name field through which authorized users can access the files in the directory By pressing the Add softkey you arrive at the user list Select the user With Add you can make any entries in the Shared field...

Page 348: ...A0 11 3 6 Connecting disconnecting network drives Press the Service display Service control system Service network softkeys in the SYSTEM operating area Use Connect Disconnect to enter the network drive configuration area Figure 11 12 Network connections 50 6 67 0 6HUYLFH GLVSOD 6HUYLFH FRQWURO 6HUYLFH QHWZRUN RQQHFW LVFRQQ ...

Page 349: ... help function The procedure for using this help function is described in Chapter RCS802 share drive Figure 11 13 Connecting network drives Sequences of operation for connecting network drives 1 Place the cursor on a free drive 2 Change to the Path input field using the TAB key Specify the IP address of the server and the sharing name Example 157 163 240 241 Press Connect The server connection is ...

Page 350: ...2009 6FC5398 4CP10 2BA0 Disconnecting network drives By selecting the Back softkey and the Disconnect function you can disconnect an existing network connection 1 Place the cursor on the relevant drive 2 Press the Disconnect softkey The selected network drive is disconnected from the control LV FRQQHFW ...

Page 351: ...terface and your data backup device must be matched with each other Operating sequence You have selected the PROGRAM MANAGER operating area and you are in the overview of the NC programs already created Select the data to be transmitted using either the cursor or the Select all softkey and copy the data to the clipboard Press the RS232 softkey and select the desired transfer mode Figure 12 1 Readi...

Page 352: ...of file and path error log Table 12 1 Transmission messages OK Transmission completed successfully ERR EOF End of text character received but archive file incomplete Time Out The time monitoring is reporting an interruption of the data transfer User Abort Data transfer aborted by the Stop softkey Error Com Error at the COM 1 port NC PLC Error Error message from the NC Error Data Data error 1 Files...

Page 353: ...s softkey in the SYSTEM operating area Creating a start up archive A start up archive can be created either with all components or with some selected components To create an archive with selected components the following operator actions are required Press 802D data Please select the line Start up archive drive NC PLC HMI using the direction keys Press the Input key to open the directory and selec...

Page 354: ... the respective files can be individually selected deselected in the start up archive Writing the start up archive to a customer CompactFlash card USB FlashDrive Requirement The CompactFlash Card USB FlashDrive is inserted and the start up archive has been copied to the clipboard Operating sequence or Press the Customer CF card or USB drive softkey In the directory select the saving location direc...

Page 355: ...sert files Reading in start up archive from customer CompactFlash card USB FlashDrive To import a start up archive perform the following operator actions 1 CompactFlash card USB FlashDrive are inserted 2 Press the Customer CF card USB drive softkey and select the line with the desired archive file 3 Press Copy to copy the file to the clipboard 4 Press the 802D data softkey and position the cursor ...

Page 356: ... the Customer CF card USB drive softkey and select the line with the desired project file in PTE format 3 Press Copy to copy the file to the clipboard 4 Press the 802D data softkey and position the cursor on the PLC Project PT802D PTE line 5 Press the Paste softkey reading in and activation starts Writing project to CompactFlash card USB FlashDrive Perform the following operator actions 1 CompactF...

Page 357: ...d Paste When doing so the Copy function enters the references to the files or directories in a list which is subsequently executed by the Paste function This function will perform the actual copying process The list is kept until a new copying process overwrites this list Special situation If the RS232 interface has been selected as the data target Paste will be replaced by the Send softkey functi...

Page 358: ...Data Backup 12 4 Copying and pasting files Cylindrical grinding 358 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 ...

Page 359: ...al operations include the linking of various contacts and relays As a rule the failure of a single contact or relay results in a failure of the whole system installation To locate causes of faults failures or of a program error various diagnostic functions are offered in the System operating area Operating sequence Press the PLC softkey in the SYSTEM operating area Press PLC program The project st...

Page 360: ... the PLC diagnostics are shown in the following screen Figure 13 1 Screen layout Table 13 1 Key to screen layout Screen item Display Meaning Application area Supported PLC program language Name of the active program block Representation Symbolic name absolute name Program status RUN Program is running STOP Program stopped Status of the application area Sym Symbolic representation abs Absolute repr...

Page 361: ...ion keys this area provides still further key combinations Hotkeys The cursor keys move the focus over the PLC user program When reaching the window borders it is scrolled automatically Table 13 2 Hotkeys Keystroke combination Action or To the first line of the row or To the last line of the row Up a screen Down a screen One field to the left One field to the right Up a field Down a field ...

Page 362: ...of the first network Opens the next program block in the same window and Opens the previous program block in the same window The function of the Select key depends on the position of the input focus Table line Displays the complete text line Network title Displays the network comment Command Displays the complete operands If the input focus is positioned on a command all operands including the com...

Page 363: ...with this softkey Mode Name of the PLC project PLC system version Cycle time Machining time of the PLC user program Figure 13 2 PLC info By pressing the Reset machining time softkey machining time data is reset The values of the operands can be monitored and changed during program execution using the PLC status display window Figure 13 3 PLC status display 3 LQIR 3 VWDWXV ...

Page 364: ... graphical information of a program block The program block is one of the components of the PLC user program The program block can be selected in the Program list using the Open softkey The name of the program block will be displayed on the softkey for e g Window 1 SBR16 The logics in the ladder diagram LAD display the following Networks with program parts and current paths Electrical current flow...

Page 365: ...f the PLC program blocks Figure 13 6 Select the PLC program block Using this softkey will display the following properties of the selected program block Symbolic name Author Comments Figure 13 7 Properties of the selected PLC program block Selecting this softkey displays the table of local variables of the selected program block 3URJUDP EORFN 3URSHU WLHV RFDO YDULDEOHV ...

Page 366: ...on is additionally displayed in a text field above the table With longer texts it is possible to display the whole text by pressing the SELECT key When a program block is protected by a password this softkey can be used to enable the display of the ladder diagram A password is required for this The password can be allocated during creation of a program block in Programming Tool PLC802 The selected...

Page 367: ... LAD acquires the values for the status display in several PLC cycles and then refreshes the status display Figure 13 9 Program status ON symbolic representation Figure 13 10 Program status ON absolute representation Use this softkey to switch between the absolute and symbolic representation of the operands The softkey labelling changes accordingly Depending on the selected type of representation ...

Page 368: ...wing screen When searching uppercase and lowercase letters are ignored Selection in the upper toggle field Search for absolute and symbolic operands Go to network number Find SBR command Further search criteria Search direction down from the current cursor position Whole program block from the beginning In one program block Over all program blocks You can search for the operands and constants as w...

Page 369: ...09 6FC5398 4CP10 2BA0 369 Figure 13 12 Search for absolute operands If the search object is found use the Continue search softkey to continue the search Selecting this softkey displays all symbolic identifiers used in the highlighted network Figure 13 13 Network symbol information table 6 PERO LQIR ...

Page 370: ...nces All operands used in the PLC project are displayed This list indicates in which networks an input output flag etc is used Figure 13 14 Cross references main menu absolute Figure 13 15 Cross references main menu symbolic You can open the appropriate program segment directly in the 1 2 window using the Open in Window 1 or Open in Window 2 function URVV UHIV 2SHQ LQ ZLQGRZ ...

Page 371: ...tifier the description is automatically absolute The type of representation is displayed in the status line at the top right of the window e g Abs The absolute representation is set by default Example You want to view the logic interrelation of the absolute operand M251 0 in network 2 in program block OB1 After the operand has been selected from the cross reference list and the Open in Window 1 so...

Page 372: ...ifiers When searching uppercase and lowercase letters are ignored Search options Search for absolute and symbolic operands Go to line Search criteria Down from the current cursor position Whole program block from the beginning Figure 13 18 Searching for operands in cross references The text you are looking for is displayed in the notes line If the text is not found a corresponding error message is...

Page 373: ... 07 2009 6FC5398 4CP10 2BA0 373 Application Examples 14 14 1 Cycle example 1 Example 1 The following workpiece is to be grinded Z machining direction is to be selected The machining steps are given in the example drawing Figure 14 1 Z machining direction ...

Page 374: ...99 3 0 15 0 03 0 01 0 02 0 01 0 005 1 2 2 3000 4000 5000 1 1 1 2 0 0 5 Longitudinal grinding from right to left N80 CYCLE410 0 180 99 3 0 1 0 03 0 01 0 8 0 10 0 02 1 0 0 5 5 1000 Oscillating plunge cutting N90 T1 D5 N100 CYCLE412 0 130 176 3 0 1 0 01 0 4 0 1 1 0 5 10 1000 Oscillating face plunge cutting N110 T1 D3 N120 CYCLE410 0 170 136 3 0 1 0 030 0 010 0 8 0 1 0 02 1 0 0 5 Plunge cutting N130 T...

Page 375: ...al grinding Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 375 14 2 Cycle example 2 Example 1 The following workpiece is to be grinded Machining is done in Z The machining steps are given in the drawing Figure 14 2 Machining in Z direction ...

Page 376: ...0 3 0 04 0 03 0 01 0 02 0 01 0 005 1 1 1 3000 4000 5000 1 1 1 2 0 0 5 Longitudinal grinding from right to left N90 T1 D3 N100 CYCLE410 0 180 161 3 0 1 0 03 0 01 0 8 0 1 0 2 1 0 0 5 5 1000 Oscillating plunge cutting N110 T1 D5 N120 CYCLE412 0 130 176 3 0 10 0 03 0 1 0 1 1 0 5 10 1000 Oscillating face plunge cutting N130 T1 D3 N140 CYCLE410 0 170 124 3 0 1 0 03 0 01 0 80 0 1 0 08 1 0 0 5 Plunge cutt...

Page 377: ...T 0 1 Selection of the type of plunging feedrate in mm min specific cutting volumes _GC_PAR 1 INT 0 1 Selection of the longitudinal grinding feedrate in mm min or mm rev _GC_PARI 20 INT INTEGER type parameters for inter cycle as well as cycle HMI communication _GC_SYNC INT 0 HMI synchronisation parameters _GC_SYNC INIRE INT 0 Delete synchronisation parameters on reset _GC_WPC INT 0 Workpiece count...

Page 378: ...NT 10 Time measurement control _GC_IN_MZ2 INT 11 Switch over fine finishing measurement control _GC_IN_MZ3 INT 12 Switch over finishing measurement control _GC_IN_MZ4 INT 13 Reserved for inputs outputs _GC_IN_ABR INT 14 Intermediate dressing upon key _GC_IN_HAND INT 15 Handwheel key _GC_IN_BREAK INT 13 Program interrupt key _GC_IN_HUB INT 12 Stroke reversal key _GC_IN_FEEDSTOP INT 11 Infeed stop k...

Page 379: ...nding is evaluated by the cycles so that the individual seat can be identified via a block search _GC_SEARCHSET Tag for seat regrinding is evaluated by the cycles so that the axes can be recalibrated _GC_SEACRHVALUE 0 2 Regrinding calibration values _GC_SUGFEED Independent of basic system 0 GWPS in m s 1 GWPS in feed min _GC_MF 18 Enable program level abort of CYCLE448 _GC_MF 19 Blocking and reset...

Page 380: ...on Tx TPC5 REAL GWPS Tx TPC6 REAL GWPS ratio Tx TPC7 REAL Bypassing strategy obstacle diameter Tx TPC8 REAL Basic cutting edge for dressing contour Tx TPC9 REAL X shift Tx TPC10 REAL Z shift Table A 2 1 Cutting edge 2 Cutting edge for left right wheel edge for grinding wheel Tx Dy DP1 INT Tool type 403 Tx Dy DP2 INT Cutting edge position 1 9 Tx Dy DP3 REAL D Diameter of the new wheel Tx Dy DP4 REA...

Page 381: ...Tx Dy DPC5 REAL Left right shoulder height Tx Dy DPC6 REAL Left right back slope angle Tx Dy DPC7 REAL Left right back slope height Tx Dy DPC8 REAL X overrun Tx Dy DPC9 REAL Usable wheel width Tx Dy DPC10 REAL No of contour program Table A 3 3 Cutting edge for grinding wheel Tx Dy DP1 INT Tool type 403 Tx Dy DP2 INT Cutting edge position 1 9 Tx Dy DP3 REAL D Diameter of the new wheel Tx Dy DP4 REA...

Page 382: ...ved Tx Dy DPC9 REAL Reserved Tx Dy DPC10 REAL Reserved Table A 4 4 to 6th cutting edge for grinding wheels Tx Dy DP1 INT Tool type 403 Tx Dy DP2 INT Cutting edge position 1 9 Tx Dy DP3 REAL D Diameter of the new wheel Tx Dy DP4 REAL L Distance to the wheel reference point Tx Dy DP5 REAL reserved length 3 Tx Dy DP6 REAL R Tool nose radius Tx Dy DP7 REAL Reserved Tx Dy DP8 REAL Reserved Tx Dy DP9 RE...

Page 383: ...Dy DP4 REAL Position Tx Dy DP5 REAL Position Tx Dy DP6 REAL R Tool nose radius Tx Dy DP7 REAL Diameter Tx Dy DP8 REAL Width Tx Dy DP9 REAL Maximum peripheral speed Tx Dy DP10 REAL Maximum speed Tx Dy DP11 REAL Probing data block Tx Dy DP12 REAL dD Change in diameter dressing amount X Tx Dy DP13 REAL dL Change in distance dressing amount Z Tx Dy DP14 REAL Length 3 Tx Dy DP15 REAL dR Change in tool ...

Page 384: ...oding Wheel type TC_TPC1 T 0 free contour 1 Standard contour straight without rear definitions 2 Standard contour straight with rear definitions 3 Standard contour inclined left 4 Standard contour inclined right 5 Standard contour straight profile roller with geo axes Encoding Dressing mode at the diameter TC_DP19 T 1 0 neither drawing nor plunging 3rd dresser 1 drawing last active dresser 2 plung...

Page 385: ...ion is provided to calculate nested terms The bracket depth is unlimited If the input field is already occupied by a value the function will accept this value into the input line of the pocket calculator Input starts the calculation The result is displayed in the pocket calculator Selecting the Accept softkey enters the result in the input field at the current cursor position of the part program e...

Page 386: ...d by the X2 value R Square root function The X value in front of the input cursor is replaced by the X value Bracket function X Y Z Calculation examples Task Input Result 100 67 3 100 67 3 301 sin 45_ 45 S 0 707107 cos 45_ 45 O 0 707107 42 4 Q 16 4 4 R 2 34 3 2 10 34 3 2 10 400 To calculate auxiliary points on a contour the pocket calculator offers the following functions Calculating the tangentia...

Page 387: ...racters can be selected according to the pinyin input method which involves combining letters of the Roman alphabet in order to reproduce the sound of the character The editor will then show a list of characters that correspond to that particular sound You can then select the character you need Figure A 2 Example of editing Simplified Chinese 2WKHU FKDUDFWHUV FDQ EH VHOHFWHG 6RXQG KDUDFWHU QSXW IL...

Page 388: ...y When this function is activated another line showing the combined characters and sounds will appear The editor will then offer various characters for this sound from which you can choose the desired one by entering either of the digits 1 to 9 You can toggle the input cursor between the compound phonetic notations field and the phonetic input field by pressing the TAB key When the cursor is posit...

Page 389: ...equivalent of an English QWERTY keyboard and individual characters must be grouped together to form syllabic blocks Figure A 5 Korean keyboard assignment The Korean alphabet Hangeul consists of 24 letters 14 consonants and 10 vowels The syllable blocks are created by combining consonants and vowels Figure A 6 Korean editor with standard keyboard assignment 6HOHF WLRQ NH ERDUG PDWUL QSXW VHOHFWLRQ ...

Page 390: ... as an alternative to the keyboard assignment shown above All you will need for this is the numeric keypad Figure A 8 Korean editor with selection matrix To select characters proceed as follows Select a row the row will be color highlighted Select a column the character will briefly be color highlighted and then transferred to the Character field Press the input key to transfer the character into ...

Page 391: ...edback on the documentation This document will be continuously improved with regard to its quality and ease of use Please help us with this task by sending your comments and suggestions for improvement via e mail or fax to E mail mailto docu motioncontrol siemens com Fax 49 9131 98 2176 Please use the fax form on the back of this page ...

Page 392: ...tion Cylindrical grinding 392 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 7R 6 0 16 7 0 06 3 2 R UODQJHQ HUPDQ D RFXPHQWDWLRQ URP 1DPH GGUHVV RI RXU FRPSDQ GHSDUWPHQW 6WUHHW LS FRGH LW 3KRQH D 6XJJHVWLRQV DQG RU FRUUHFWLRQV ...

Page 393: ...6 180 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 0...

Page 394: ...Appendix A 5 Overview Cylindrical grinding 394 Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 ...

Page 395: ...AP structure borne noise air grinding Bridging the air gap between the workpiece and grinding wheel with a structure borne noise microphone which is built into the machine GWPS Grinding wheel peripheral speed in m s MCPA Input card for rapid I O to the control system MD Machine data machine data are predefined variables system variables with which the NCK as per the requirements of the machine man...

Page 396: ...ght side of the grinding wheel or of the tool TPS Workpiece peripheral speed in m min XWP ZWP when dressing a free contour Workpiece offset for offsetting the programmed contour to the current cutting edge of the grinding wheel which is necessary so that workpiece coordinates can be programmed in the free contour ...

Page 397: ...Relative coordinate system 20 Workpiece coordinate system WCS 20 Cycle call 157 Cycle support in the program editor 161 D Data transfer 351 Disconnecting network drives 348 Display of machine data 118 Drive machine data 117 E Enabling the communication ports 343 Enter tools 37 Error displays 13 Execution from external 95 F FA 332 Feedrate values in one block 328 Files Copy 357 Paste 357 G G05 326 ...

Page 398: ...nce of motions 333 Oscillation reversal points 332 OSCTRL 330 333 OSE 330 333 OSNSC 330 OSP 332 OSP1 330 OSP2 330 OST 330 OST1 330 OST2 330 Overview Dimensions 238 Overview of cycles 153 P Parameter list 157 Part program Stopping canceling 92 Parts program selection and start 84 Plane definition 155 Printable special characters 224 Program list 143 Program Manager 99 Programmable mirroring 247 Pro...

Page 399: ...Index Cylindrical grinding Programming and Operating Manual 07 2009 6FC5398 4CP10 2BA0 399 W Word structure 221 ...

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