SINUMERIK SINUMERIK 840D sl / 828DExtended Functions Function
Manual Valid for Control system SINUMERIK 840D sl / 840DE sl
SINUMERIK 828D Software Version NCU system software 2.6 SP1 03/2010
6FC5397-1BP20-1BA0 Preface A4: Digital and analog NCK I/Os 1B3:
Several operator panels connected to several NCUs, distributed
systems - only 840D sl 2B4: Operation via PG/PC - only 840D sl 3H1:
Manual travel and handwheel travel 4K3: Compensation 5K5: Mode
groups, channels, axis interchange 6M1: Kinematic transformation
7M5: Measuring 8N3: Software cams, position switching cycles - only
840D sl 9N4: Punching and nibbling - only 840D sl 10P2: Positioning
axes 11P5: Oscillation - only 840D sl 12R2: Rotary axes 13S3:
Synchronous spindle 14S7: Memory configuration 15T1: Indexing axes
16W3: Tool change 17W4: Grinding-specific tool offset and
monitoring functions - only 840D sl 18Z2: NC/PLC interface signals
19Appendix A Legal information Warning notice system This manual
contains notices you have to observe in order to ensure your
personal safety, as well as to prevent damage to property. The
notices referring to your personal safety are highlighted in the
manual by a safety alert symbol, notices referring only to property
damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger. DANGER indicates that
death or severe personal injury will result if proper precautions
are not taken. WARNING indicates that death or severe personal
injury may result if proper precautions are not taken. CAUTION with
a safety alert symbol, indicates that minor personal injury can
result if proper precautions are not taken. CAUTION without a
safety alert symbol, indicates that property damage can result if
proper precautions are not taken. NOTICE indicates that an
unintended result or situation can occur if the corresponding
information is not taken into account. If more than one degree of
danger is present, the warning notice representing the highest
degree of danger will be used. A notice warning of injury to
persons with a safety alert symbol may also include a warning
relating to property damage. Qualified Personnel The product/system
described in this documentation may be operated only by personnel
qualified for the specific task in accordance with the relevant
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 in the catalog and in the relevant technical
documentation. If products and components from other manufacturers
are used, these must be recommended or approved by Siemens. Proper
transport, storage, installation, assembly, commissioning,
operation and maintenance are required to ensure that the products
operate safely and without any problems. The permissible ambient
conditions must be adhered to. The information in the relevant
documentation must be observed. Trademarks All names identified by
are registered trademarks of the Siemens AG. The remaining
trademarks in this publication may be trademarks whose use by third
parties for their own purposes could violate the rights of the
owner. Disclaimer of Liability We have reviewed the contents of
this publication to ensure consistency with the hardware and
software described. Since variance cannot be precluded entirely, we
cannot guarantee full consistency. However, the information in this
publication is reviewed regularly and any necessary corrections are
included in subsequent editions. Siemens AG Industry Sector
Postfach 48 48 90026 NRNBERG GERMANY Order number:
6FC5397-1BP20-1BA0 04/2010 Copyright Siemens AG 2010. Technical
data subject to change Extended Functions Function Manual, 03/2010,
6FC5397-1BP20-1BA0 3 Preface SINUMERIK Documentation The SINUMERIK
documentation is organized in three parts: General documentation
User documentation Manufacturer/service documentation Information
on the following topics is available at
http://www.siemens.com/motioncontrol/docu: Ordering documentation
Here you can find an up-to-date overview of publications.
Downloading documentation Links to more information for downloading
files from Service & Support. Researching documentation online
Information on DOConCD and 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 our range of
training courses and FAQs (frequently asked questions) is available
via the page navigation. Target group This publication is intended
for: Project engineers Technologists (from machine manufacturers)
System startup engineers (Systems/Machines) Programmers Benefits
The function manual describes the functions so that the target
group knows them and can select them. It provides the target group
with the information required to implement the functions. Preface
Extended Functions 4 Function Manual, 03/2010, 6FC5397-1BP20-1BA0
Standard version This documentation only describes the
functionality of the standard version. Extensions or changes made
by the machine tool manufacturer are documented by the machine tool
manufacturer. Other functions not described in this documentation
might be executable in the control. This does not, however,
represent an obligation to supply such functions with a new control
or when servicing. Further, for the sake of simplicity, this
documentation does not contain all detailed information about all
types of the product and cannot cover every conceivable case of
installation, operation or maintenance. Installation Structure of
this Function Manual: Inner title (page 3) with the title of the
Function Manual, the SINUMERIK controls as well as the software and
the version for which this version of the Function Manual is
applicable and the overview of the individual functional
descriptions. Description of the functions in alphabetical order
(e.g. A2, A3, B1 etc.) Appendix with: List of abbreviations Fax
template for feedback for documentation Overview Index of terms
Note For detailed descriptions of data and alarm see: Machine and
setting data: Detailed description of machine data (only
electronically on DOConCD or DOConWEB) NC/PLC interface signals:
Function Manual Basic Functions; NC/PLC Interface Signals (Z1)
Function Manual Extended Functions; NC/PLC Interface Signals (Z2)
Function Manual Special Functions; NC/PLC Interface Signals (Z3)
Alarms: Diagnostics Manual Preface Extended Functions Function
Manual, 03/2010, 6FC5397-1BP20-1BA0 5 Notation of system data The
following notation is applicable for system data in this
documentation: Signal/Data Notation Example NC/PLC interface
signals ... NC/PLC interface signal: () When the new gear step is
engaged, the following NC/PLC interface signals are set by the PLC
program: DB31, ... DBX16.0-2 (actual gear stage A to C) DB31, ...
DBX16.3 (gear is changed) Machine data ... machine data: () Master
spindle is the spindle stored in the machine data: MD20090
$MC_SPIND_DEF_MASTER_SPIND (Position of deletion of the master
spindle in the channel). Setting Data ... Setting data: () The
logical master spindle is contained in the setting data: SD42800
$SC_SPIND_ASSIGN_TAB[0] (Spindle number converter) Note Signal
address The description of functions include as of an NC/PLC
interface signal, only the address valid for SINUMERIK 840D sl. The
signal address for SINUMERIK 828D should be taken from the data
lists "Signals to/from ..." at the end of the particular
description of functions. Quantity structure Explanations
concerning the NC/PLC interface are based on the absolute maximum
number of sequential components: Mode groups (DB11) Channels (DB21,
etc.) Axes/spindles (DB31, etc.) Preface Extended Functions 6
Function Manual, 03/2010, 6FC5397-1BP20-1BA0 Data types The
following elementary data types are used in the control system:
Type Meaning Value range INT Signed integers -2147483648 ...
+2147483647 REAL Figures with decimal point acc. to IEEE
(2.2*10-308 1.8*10+308) BOOL Truth values TRUE (1) and FALSE (0) 1,
0 CHAR ASCII characters Corresponding to code 0 to 255 STRING
Character string, number of characters in [...] Maximum of 200
characters (no special characters) AXIS Axis names only All axis
identifiers in the channel FRAME Geometrical parameters for moving,
rotating, scaling, and mirroring Arrays can only be formed from
similar elementary data types. Up to 3-dimensional arrays are
possible. Technical Support If you have any questions, please
contact our hotline: Europe/Africa Phone +49 180 5050 - 222 Fax +49
180 5050 - 223 0.14/min. from German landlines, cell phone prices
may differ Internet
http://www.siemens.de/automation/support-request America Phone +1
423 262 2522 Fax +1 423 262 2200 E-mail
mailto:[email protected] Asia/Pacific Phone +86 1064
757575 Fax +86 1064 747474 E-mail
mailto:[email protected] Note You will find
telephone numbers for other countries for technical support on the
Internet: http://www.automation.siemens.com/partner Preface
Extended Functions Function Manual, 03/2010, 6FC5397-1BP20-1BA0 7
Questions about the manual If you have any queries (suggestions,
corrections) in relation to this documentation, please send a fax
or e-mail to the following address: Fax: +49 9131- 98 2176 Email:
mailto:[email protected] A fax form is available in
the appendix of this document. SINUMERIK Internet address
http://www.siemens.com/sinumerik SINUMERIK 828D system performance
(region) PPU 260 / 261 PPU 280 / 281 T M T M System performance
Basic quantity of axes/spindles 3 4 3 4 Max. number of
axes/spindles 6 6 8 6 Max. number of interpolating axes 4 4 4 4
Max. number of channels/mode groups 1/1 1/1 1/1 1/1 Min. block
change time 6 ms 2 ms 6 ms 1 ms Speed/current control cycle 125 s
125 s 125 s 125 s CNC user memory (buffered) 3 MB 3 MB 5 MB 5 MB
CNC functions Tool Management Number of tools/cutting edges 128/256
128/256 256/512 256/512 Safety Integrated: Safe Torque Off, Safe
Brake Control Safety Integrated: Safe velocity Max. number of ASUBs
(permanently set) 2 2 2 2 TRANSMIT / TRACYL Inclined Y axis - - -
Synchronous spindle for counterspindle - - - Synchronous spindle
for polygon machining - - Gantry Temperature compensation Preface
Extended Functions 8 Function Manual, 03/2010, 6FC5397-1BP20-1BA0
PPU 260 / 261 PPU 280 / 281 T M T M HMI, CNC programming
ShopMill/ShopTurn HMI functions DIN/ISO programming with
programGUIDE Online ISO dialect interpreter ShopMill/ShopTurn
machining step programming Measuring cycles Simulation in surface
display Simulation in 3D display PLC SIMATIC S7-200 (integrated)
Basic I/O modules: PP 72/48D PN PP 72/48D 2/2A PN (being prepared)
PLC cycle time 6 ms 6 ms 6 ms 6 ms Max. number of PLC operations
24000 24000 24000 24000 Servo-synchronous high-speed PLC task
Reaction time to process interrupts (terminal to terminal) 7.5 ms
7.5 ms 4.5 ms 4.5 ms Max. number of digital inputs/outputs 288/192
288/192 360/240 360/240 Max. number of analog inputs/outputs 8/8
8/8 10/10 10/10 Commissioning functions Service Planner
(maintenance scheduler) Easy Extend (for managing machine units)
Easy Archive (data archiving) T Turning M Milling Standard (basic
scope) CNC option - Not available Extended Functions Function
Manual, 03/2010, 6FC5397-1BP20-1BA0 9 Contents
Preface......................................................................................................................................................
3 1 A4: Digital and analog NCK
I/Os..............................................................................................................
27 1.1 Brief description
...........................................................................................................................27
1.2 NCK I/O via
PLC..........................................................................................................................28
1.2.1 General functionality
....................................................................................................................28
1.2.2 NCK digital
inputs/outputs............................................................................................................33
1.2.2.1 NCK digital inputs
........................................................................................................................33
1.2.2.2 NCK digital outputs
......................................................................................................................35
1.2.3 Connection and logic operations of fast NCK inputs/outputs
......................................................39 1.2.4 NCK
analog inputs/outputs
..........................................................................................................41
1.2.4.1 NCK analog
inputs.......................................................................................................................41
1.2.4.2 NCK analog
outputs.....................................................................................................................44
1.2.5 Direct PLC I/Os, addressable from the
NC..................................................................................48
1.2.6 Analog-value representation of the NCK analog input/output
values..........................................51 1.2.7 Comparator
inputs
.......................................................................................................................52
1.3 NCK I/O via PROFIBUS - only 840D sl
.......................................................................................56
1.3.1
Functionality.................................................................................................................................56
1.3.2 Parameter
assignment.................................................................................................................57
1.3.3
Programming................................................................................................................................59
1.3.3.1 Communication via part programs/synchronous
actions.............................................................59
1.3.3.2 Communication via compile
cycles..............................................................................................62
1.4
Constraints...................................................................................................................................64
1.4.1 NCK I/O via
PLC..........................................................................................................................64
1.4.2 NCK I/O via PROFIBUS - only 840D sl
.......................................................................................65
1.5 Examples
.....................................................................................................................................66
1.5.1 NCK I/O via
PLC..........................................................................................................................66
1.5.1.1 Writing to PLC-I/Os
......................................................................................................................66
1.5.1.2 Reading from
PLC-I/Os................................................................................................................67
1.5.2 NCK I/O via PROFIBUS - only 840D sl
.......................................................................................68
1.5.2.1 PROFIBUS-I/O in write
direction..................................................................................................68
1.5.2.2 PROFIBUS-I/O in read
direction..................................................................................................70
1.5.2.3 Query of the RangeIndex in case of "PROFIBUS-I/O in write
direction" .....................................72 1.6 Data lists
......................................................................................................................................74
1.6.1 Machine
data................................................................................................................................74
1.6.1.1 General machine
data..................................................................................................................74
1.6.1.2 Channel-specific machine
data....................................................................................................75
1.6.2 Setting
data..................................................................................................................................75
1.6.2.1 General setting
data.....................................................................................................................75
1.6.3 Signals
.........................................................................................................................................75
1.6.3.1 Signals to
NC...............................................................................................................................75
1.6.3.2 Signals from
NC...........................................................................................................................76
Contents Extended Functions 10 Function Manual, 03/2010,
6FC5397-1BP20-1BA0 2 B3: Several operator panels connected to
several NCUs, distributed systems - only 840D sl .................
77 2.1 Brief description
..........................................................................................................................
77 2.1.1 Topology of distributed system
configurations............................................................................
77 2.1.2 Several operator panels and NCUs with control unit
management (option)............................... 82 2.1.2.1
General
information.....................................................................................................................
82 2.1.2.2 System features
..........................................................................................................................
83 2.1.2.3
Hardware.....................................................................................................................................
84 2.1.2.4
Functions.....................................................................................................................................
86 2.1.2.5 Configurability
.............................................................................................................................
88 2.1.3 Several operator panel fronts and NCUs, standard
functionality................................................ 88
2.1.3.1 System features
..........................................................................................................................
88 2.1.3.2
Functions.....................................................................................................................................
89 2.1.3.3 Configurability
.............................................................................................................................
92 2.1.3.4 MPI/OPI network rules
................................................................................................................
96 2.1.4 NCU link
......................................................................................................................................
97 2.1.4.1 General
information.....................................................................................................................
97 2.1.4.2 Technological
description..........................................................................................................
100 2.1.4.3 Link axes
...................................................................................................................................
102 2.1.4.4 Axis
container............................................................................................................................
103 2.1.4.5 User-specification link communication via link
variables
.......................................................... 103
2.1.4.6 Lead-link axes
...........................................................................................................................
104 2.2 Several operator panel fronts and NCUs with control unit
management option....................... 105 2.2.1 Hardware
structure....................................................................................................................
105 2.2.2
Properties..................................................................................................................................
105 2.2.3 Configuration file NETNAMES.INI
............................................................................................
107 2.2.4 Structure of the configuration file
..............................................................................................
107 2.2.5 Creating and using the configuration
file...................................................................................
112 2.2.6 Power
up...................................................................................................................................
113 2.2.7 HMI
switchover..........................................................................................................................
116 2.2.8 Suppression
..............................................................................................................................
116 2.2.9 Connection and switchover
conditions......................................................................................
118 2.2.10 Implementation of control unit
switchover.................................................................................
119 2.2.11 Operator interface
.....................................................................................................................
119 2.2.12 Operating mode switchover
......................................................................................................
121 2.2.13 MCP switchover
........................................................................................................................
123 2.3 Several operator panel fronts and NCUs, standard
functionality.............................................. 124
2.3.1 Configurations
...........................................................................................................................
124 2.3.2 Switchover of connection to another
NCU................................................................................
128 2.3.3 Creating and using the configuration
file...................................................................................
129 2.3.4 Power
up...................................................................................................................................
129 2.3.5 NCU
replacement......................................................................................................................
130 2.4 Restrictions for switchover of operator
components.................................................................
132 2.5 Link communication
..................................................................................................................
133 2.5.1 General
information...................................................................................................................
133 2.5.2 Parameter assignment: NC system cycles
...............................................................................
134 2.5.3 Parameter assignment: Link
communication............................................................................
135 2.5.4
Configuration.............................................................................................................................
136 2.5.5 Wiring the NCUs
.......................................................................................................................
137 2.5.6
Activation...................................................................................................................................
137 2.6 Link axes
...................................................................................................................................
138 2.6.1 Configuration of link axes and container axes
..........................................................................
140 2.6.2 Axis data and signals
................................................................................................................
144 Contents Extended Functions Function Manual, 03/2010,
6FC5397-1BP20-1BA0 11 2.6.3 Output of predefined auxiliary
functions in the case of an NCU
link..........................................146 2.6.4
Supplementary conditions for link axes
.....................................................................................147
2.6.5 Programming with channel and machine axis
identifiers...........................................................149
2.6.6 Flexible
configuration.................................................................................................................149
2.7 Axis
container.............................................................................................................................150
2.7.1 System variables for axis containers
.........................................................................................156
2.7.2 Machining with axis container (schematic)
................................................................................158
2.7.3 Axis container behavior after Power
ON....................................................................................159
2.7.4 Axis container response to mode switchover
............................................................................159
2.7.5 Axis container behavior in relation to ASUBs
............................................................................159
2.7.6 Axis container response to RESET
...........................................................................................159
2.7.7 Axis container response to block searches
...............................................................................159
2.7.8 Supplementary conditions for axis container rotations
..............................................................159
2.8 User-specific link variables
........................................................................................................163
2.8.1 Link variables
.............................................................................................................................163
2.8.2 Reading drive data via link variables
.........................................................................................168
2.9 System of units within a link
grouping........................................................................................173
2.10 Supplementary
conditions..........................................................................................................174
2.10.1 Several operator panels and NCUs with control unit
management option................................174 2.10.2 Several
operator panel fronts and NCUs, standard
functionality...............................................174
2.10.3 Link
axes....................................................................................................................................175
2.10.4 Axis
container.............................................................................................................................175
2.10.5 Lead-link axis
.............................................................................................................................175
2.11 Examples
...................................................................................................................................176
2.11.1 Configuration file NETNAMES.INI with control unit management
option..................................176 2.11.2 User-specific
reconfiguring of PLC program control unit switchover
.........................................179 2.11.2.1 Description
of operational sequences (overview)
......................................................................179
2.11.2.2 Description of operational sequences
(details)..........................................................................180
2.11.2.3 Defined logical functions/defines
...............................................................................................189
2.11.2.4 Graphical representation of function sequences
.......................................................................190
2.11.3 Configuration file NETNAMES.INI, standard functionality
.........................................................197
2.11.3.1 Two operator panel fronts and one
NCU...................................................................................197
2.11.3.2 One operator panel front and three
NCUs.................................................................................198
2.11.4 Quick M:N commissioning based on
examples.........................................................................199
2.11.4.1 Example 1
..................................................................................................................................199
2.11.4.2 Example 2
..................................................................................................................................202
2.11.4.3 Example 3
..................................................................................................................................208
2.11.4.4 Description of FB9
.....................................................................................................................212
2.11.4.5 Example of calling FB9
..............................................................................................................215
2.11.4.6 Example of override switchover
.................................................................................................216
2.11.4.7 Switchover between MCP and
HT6...........................................................................................218
2.11.4.8 General Information
...................................................................................................................219
2.11.5 Link axis
.....................................................................................................................................221
2.11.6 Axis container
coordination........................................................................................................222
2.11.6.1 Axis container rotation without a part program
wait...................................................................222
2.11.6.2 Axis container rotation with an implicit part program
wait..........................................................223
2.11.6.3 Axis container rotation by one channel only (e.g. during
power up)..........................................223 2.11.7
Evaluating axis container system
variables...............................................................................223
2.11.7.1 Conditional
branch.....................................................................................................................223
2.11.7.2 Static synchronized action with
$AN_AXCTSWA......................................................................223
2.11.7.3 Wait for certain completion of axis container
rotation................................................................224
2.11.8 Configuration of a multi-spindle turning
machine.......................................................................225
Contents Extended Functions 12 Function Manual, 03/2010,
6FC5397-1BP20-1BA0 2.11.9 Lead-link axis
............................................................................................................................
234 2.11.9.1
Configuration.............................................................................................................................
234 2.11.9.2
Programming.............................................................................................................................
236 2.12 Data
lists....................................................................................................................................
237 2.12.1 Machine
data.............................................................................................................................
237 2.12.1.1 General machine
data...............................................................................................................
237 2.12.1.2 Channel-specific machine
data.................................................................................................
237 2.12.1.3 Axis/spindle-specific machine
data...........................................................................................
238 2.12.2 Setting
data...............................................................................................................................
238 2.12.2.1 General setting
data..................................................................................................................
238 2.12.2.2 Axis/spindle-specific setting
data..............................................................................................
238 2.12.3
Signals.......................................................................................................................................
238 2.12.3.1 Signals from
NC........................................................................................................................
238 2.12.3.2 Signals from
HMI/PLC...............................................................................................................
239 2.12.3.3 General online
interface............................................................................................................
239 2.12.3.4 Signals from axis/spindle
..........................................................................................................
241 2.12.4 System
variables.......................................................................................................................
241 2.12.4.1 System
variables.......................................................................................................................
241 3 B4: Operation via PG/PC - only 840D sl
................................................................................................
243 3.1 Brief description
........................................................................................................................
243 3.2 Software
installation..................................................................................................................
245 3.2.1 System requirements
................................................................................................................
245 3.2.2
Installation.................................................................................................................................
246 3.2.3 Supplementary software
conditions..........................................................................................
251 3.2.4 Start
program............................................................................................................................
251 3.2.5 Close
program...........................................................................................................................
251 3.3 Operation via
PG/PC.................................................................................................................
253 3.3.1 General operation
.....................................................................................................................
253 3.3.2 Additional
information................................................................................................................
256 3.3.3 Operation of operator panel
fronts............................................................................................
257 3.4 Simulation of part
programs......................................................................................................
257 3.5 Marginal conditions
...................................................................................................................
258 3.6 Data
lists....................................................................................................................................
258 4 H1: Manual travel and handwheel travel
................................................................................................
259 4.1 Brief description
........................................................................................................................
259 4.1.1 Overview
...................................................................................................................................
259 4.1.2 General characteristics of manual travel in
JOG......................................................................
260 4.1.3 Control of manual-travel functions via PLC
interface................................................................
263 4.1.4 Control-system response to power ON, mode change, RESET,
block search, REPOS.......... 265 4.2 Continuous travel
......................................................................................................................
266 4.2.1 General functionality
.................................................................................................................
266 4.2.2 Distinction between inching mode continuous
mode................................................................
267 4.2.3 Special features of continuous travel
........................................................................................
268 4.3 Incremental travel (INC)
............................................................................................................
269 4.3.1 General functionality
.................................................................................................................
269 4.3.2 Distinction between inching mode and continuous
mode......................................................... 270
4.3.3 Special features of incremental travel
.......................................................................................
271 Contents Extended Functions Function Manual, 03/2010,
6FC5397-1BP20-1BA0 13 4.4 Handwheel travel in
JOG...........................................................................................................272
4.4.1 General functionality
..................................................................................................................272
4.4.2 Travel request
............................................................................................................................277
4.4.3 Double use of the handwheel
....................................................................................................281
4.5 Handwheel override in automatic mode
....................................................................................283
4.5.1 General functionality
..................................................................................................................283
4.5.2 Programming and activating handwheel
override......................................................................287
4.5.3 Special features of handwheel override in automatic
mode......................................................289 4.6
Contour handwheel/path input using handwheel (option)
.........................................................291 4.7
DRF offset
..................................................................................................................................293
4.8 Start-up: Handwheels
................................................................................................................297
4.8.1 General information
...................................................................................................................297
4.8.2 Connection via PPU - only 828D
...............................................................................................298
4.8.3 Connected via PROFIBUS - only 840D sl
.................................................................................299
4.8.4 Connected via Ethernet - only 840D sl
......................................................................................302
4.9 Special features of manual travel
..............................................................................................305
4.9.1 Geometry-axis manual travel
.....................................................................................................305
4.9.2 Special features of spindle manual travel
..................................................................................307
4.9.3 Monitoring
functions...................................................................................................................308
4.9.4 Other
..........................................................................................................................................310
4.10 Approaching a fixed point in
JOG..............................................................................................311
4.10.1 Introduction
................................................................................................................................311
4.10.2
Functionality...............................................................................................................................312
4.10.3 Parameter
setting.......................................................................................................................314
4.10.4
Programming..............................................................................................................................315
4.10.5 Supplementary
conditions..........................................................................................................315
4.10.6 Application
example...................................................................................................................316
4.11 Data lists
....................................................................................................................................318
4.11.1 Machine
data..............................................................................................................................318
4.11.1.1 General machine
data................................................................................................................318
4.11.1.2 Channel-specific machine
data..................................................................................................318
4.11.1.3 Axis/spindle-specific machine
data............................................................................................319
4.11.2 Setting
data................................................................................................................................319
4.11.2.1 General setting
data...................................................................................................................319
4.11.3 Signals
.......................................................................................................................................320
4.11.3.1 Signals from
NC.........................................................................................................................320
4.11.3.2 Signals to mode
group...............................................................................................................320
4.11.3.3 Signals from mode
group...........................................................................................................320
4.11.3.4 Signals to
channel......................................................................................................................320
4.11.3.5 Signals from channel
.................................................................................................................321
4.11.3.6 Signals to axis/spindle
...............................................................................................................321
4.11.3.7 Signals from axis/spindle
...........................................................................................................322
5 K3: Compensation
.................................................................................................................................
323 5.1 Introduction
................................................................................................................................323
5.2 Temperature
compensation.......................................................................................................324
5.2.1 Description of
functions..............................................................................................................324
5.2.2
Commissioning...........................................................................................................................327
5.2.2.1 Temperature-dependent
parameters.........................................................................................327
5.2.2.2 Temperature compensation type and
activation........................................................................328
5.2.2.3 Maximum compensation value per IPO clock cycle
..................................................................328
Contents Extended Functions 14 Function Manual, 03/2010,
6FC5397-1BP20-1BA0 5.2.3 Example
....................................................................................................................................
329 5.2.3.1 Commissioning the temperature compensation for the Z
axis of a lathe.................................. 329 5.3 Backlash
compensation
............................................................................................................
332 5.3.1 Description of
functions.............................................................................................................
332 5.3.2
Commissioning..........................................................................................................................
333 5.3.2.1
Backlash....................................................................................................................................
333 5.3.2.2 Weighting factor for
backlash....................................................................................................
333 5.3.2.3 Applying the backlash compensation
step-by-step...................................................................
334 5.4 Interpolatory
compensation.......................................................................................................
334 5.4.1 General properties
....................................................................................................................
334 5.4.2 Compensation of leadscrew errors and measuring system
errors ........................................... 338 5.4.2.1
Measuring system error compensation (MSEC)
.......................................................................
338 5.4.2.2
Commissioning..........................................................................................................................
339 5.4.2.3 Example
....................................................................................................................................
342 5.4.3 Compensation of sag and angularity
errors..............................................................................
343 5.4.3.1 Description of
functions.............................................................................................................
343 5.4.3.2
Commissioning..........................................................................................................................
348 5.4.3.3
Examples...................................................................................................................................
352 5.4.4 Direction-dependent leadscrew error compensation
................................................................
361 5.4.4.1 Description of
functions.............................................................................................................
361 5.4.4.2
Commissioning..........................................................................................................................
362 5.4.4.3 Example
....................................................................................................................................
366 5.4.5 Extension of the sag compensation with NCU link - only
840D sl ............................................ 370 5.4.6
Special features of interpolatory
compensation........................................................................
378 5.5 Dynamic feedforward control (following error
compensation)...................................................
379 5.5.1 General properties
....................................................................................................................
379 5.5.2 Speed feedforward control
........................................................................................................
382 5.5.3 Torque feedforward control - only 840D sl (option)
..................................................................
384 5.5.4 Dynamic response adaptation
..................................................................................................
386 5.5.5 Forward feed control for command and PLC axes
...................................................................
387 5.5.6 Secondary
conditions................................................................................................................
388 5.6 Friction compensation (quadrant error compensation)
............................................................. 389
5.6.1 General properties
....................................................................................................................
389 5.6.2 Conventional friction
compensation..........................................................................................
391 5.6.2.1 Conventional friction
compensation..........................................................................................
391 5.6.2.2 Commissioning of conventional friction
compensation.............................................................
393 5.6.3 Quadrant error compensation using neural networks - only
840D sl........................................ 402 5.6.3.1
Fundamentals
...........................................................................................................................
402 5.6.3.2 Parameterization of neural
QEC...............................................................................................
405 5.6.3.3 Learning the neural
network......................................................................................................
411 5.6.3.4 Commissioning of neural
QEC..................................................................................................
415 5.6.3.5 Further optimization and intervention
options...........................................................................
419 5.6.3.6 Quick commissioning
................................................................................................................
425 5.7 Circularity test
...........................................................................................................................
428 5.8 Measures for hanging (suspended)
axes..................................................................................
433 5.8.1 Electronic counterweight
...........................................................................................................
433 5.8.2 Reboot delay
.............................................................................................................................
435 5.9 Data
lists....................................................................................................................................
437 5.9.1 Machine
data.............................................................................................................................
437 5.9.1.1 General machine
data...............................................................................................................
437 5.9.1.2 Channel-specific machine
data.................................................................................................
437 5.9.1.3 Axis/spindle-specific machine
data...........................................................................................
438 Contents Extended Functions Function Manual, 03/2010,
6FC5397-1BP20-1BA0 15 5.9.2 Setting
data................................................................................................................................439
5.9.2.1 General setting
data...................................................................................................................439
5.9.2.2 Axis/spindle-specific setting
data...............................................................................................439
5.9.3 Signals
.......................................................................................................................................440
5.9.3.1 Signals from
NC.........................................................................................................................440
5.9.3.2 Signals from mode
group...........................................................................................................440
5.9.3.3 Signals from channel
.................................................................................................................440
5.9.3.4 Signals from axis/spindle
...........................................................................................................440
6 K5: Mode groups, channels, axis interchange
.......................................................................................
441 6.1 Brief description
.........................................................................................................................441
6.2 Mode groups - only 840D sl
.......................................................................................................443
6.3 Channels - only 840D sl
.............................................................................................................444
6.3.1 Channel synchronization (program coordination)
......................................................................444
6.3.2 Conditional wait in continuous path mode WAITMC
.................................................................447
6.3.3 Running-in channel-by-channel
.................................................................................................451
6.4 Axis/spindle replacement
...........................................................................................................457
6.4.1 Introduction
................................................................................................................................457
6.4.2 Example of an axis
replacement................................................................................................460
6.4.3 Axis replacement
options...........................................................................................................461
6.4.4 Replacement behavior NC
program..........................................................................................462
6.4.5 Axis transfer to neutral state
(release).......................................................................................463
6.4.6 Transferring axis or spindle in the part
program........................................................................464
6.4.7 Automatic axis
replacement.......................................................................................................466
6.4.8 Axis replacement via
PLC..........................................................................................................468
6.4.9 Set axis replacement behavior
variable.....................................................................................471
6.4.10 Axis replacement via axis container rotation
.............................................................................472
6.4.11 Axis replacement with and without preprocessing
stop.............................................................473
6.4.12 Axis exclusively controlled from the
PLC...................................................................................474
6.4.13 Axis permanently assigned to the
PLC......................................................................................475
6.4.14 Geometry axis in rotated frame and axis replacement
..............................................................476
6.4.15 Axis replacement from synchronized actions
............................................................................478
6.4.16 Axis interchange for leading axes (gantry)
................................................................................480
6.5 Marginal
conditions....................................................................................................................481
6.6 Data lists
....................................................................................................................................483
6.6.1 Machine
data..............................................................................................................................483
6.6.1.1 General machine
data................................................................................................................483
6.6.1.2 Channel-specific machine
data..................................................................................................483
6.6.1.3 Axis/spindle-specific machine
data............................................................................................485
6.6.2 Setting
data................................................................................................................................486
6.6.2.1 Channel-specific setting
data.....................................................................................................486
6.6.3 Signals
.......................................................................................................................................486
6.6.3.1 Signals to/from BAG
..................................................................................................................486
6.6.3.2 Signals to/from channel
.............................................................................................................486
7 M1: Kinematic transformation
................................................................................................................
487 7.1 Brief description
.........................................................................................................................487
7.1.1 TRANSMIT (option)
...................................................................................................................487
7.1.2 TRACYL
(option)........................................................................................................................488
7.1.3 TRAANG
(option).......................................................................................................................489
7.1.4 Chained
transformations............................................................................................................489
7.1.5 Activating transformation machine data via parts
program/softkey...........................................490
Contents Extended Functions 16 Function Manual, 03/2010,
6FC5397-1BP20-1BA0 7.2 TRANSMIT
(option)...................................................................................................................
490 7.2.1 Preconditions for
TRANSMIT....................................................................................................
492 7.2.2 Settings specific to
TRANSMIT.................................................................................................
495 7.2.3 Activation of
TRANSMIT...........................................................................................................
499 7.2.4 Deactivation of the TRANSMIT function
...................................................................................
499 7.2.5 Special system reactions with TRANSMIT
...............................................................................
500 7.2.6 Machining options for TRANSMIT
............................................................................................
504 7.2.7 Working area
limitations............................................................................................................
511 7.2.8 Overlaid motions with TRANSMIT
............................................................................................
512 7.2.9 Monitoring of rotary axis rotations over 360
............................................................................
512 7.2.10 Constraints
................................................................................................................................
513 7.3 TRACYL
(option).......................................................................................................................
514 7.3.1 Preconditions for
TRACYL........................................................................................................
518 7.3.2 Settings specific to
TRACYL.....................................................................................................
522 7.3.3 Activation of TRACYL
...............................................................................................................
527 7.3.4 Deactivation of the TRACYL function
.......................................................................................
528 7.3.5 Special system reactions with
TRACYL....................................................................................
528 7.3.6
Jog.............................................................................................................................................
531 7.4 TRAANG (option)
......................................................................................................................
532 7.4.1 Preconditions for TRAANG (inclined axis)
................................................................................
534 7.4.2 Settings specific to
TRAANG....................................................................................................
536 7.4.3 Activation of
TRAANG...............................................................................................................
539 7.4.4 Deactivation of
TRAANG..........................................................................................................
540 7.4.5 Special system reactions with
TRAANG...................................................................................
540 7.4.6 Inclined axis programming (G05, G07)
.....................................................................................
542 7.5 Chained
transformations...........................................................................................................
543 7.5.1 Activating chained
transformations...........................................................................................
546 7.5.2 Switching off a chained
transformation.....................................................................................
546 7.5.3 Special characteristics of chained
transformations...................................................................
547 7.5.4 Persistent transformation
..........................................................................................................
547 7.5.5 Axis positions in the transformation
chain.................................................................................
553 7.6 Cartesian PTP travel
.................................................................................................................
556 7.6.1 Programming of position
...........................................................................................................
559 7.6.2 Overlap areas of axis
angles.....................................................................................................
560 7.6.3 Examples of ambiguities of
position..........................................................................................
561 7.6.4 Example of ambiguity in rotary axis
position.............................................................................
562 7.6.5 PTP/CP switchover in JOG
mode.............................................................................................
562 7.7 Cartesian manual travel (optional)
............................................................................................
563 7.8 Activating transformation machine data via parts
program/softkey .......................................... 572
7.8.1 Functionality
..............................................................................................................................
572 7.8.2 Constraints
................................................................................................................................
573 7.8.3 Control response to power ON, mode change, RESET, block
search, REPOS ...................... 575 7.8.4 List of machine data
affected....................................................................................................
575 7.9 Constraints
................................................................................................................................
579 7.9.1 Chained
transformations...........................................................................................................
579 7.10
Examples...................................................................................................................................
580 7.10.1
TRANSMIT................................................................................................................................
580 7.10.2
TRACYL....................................................................................................................................
582 7.10.3
TRAANG...................................................................................................................................
587 7.10.4 Chained
transformations...........................................................................................................
589 7.10.5 Activating transformation MD via a parts
program....................................................................
593 Contents Extended Functions Function Manual, 03/2010,
6FC5397-1BP20-1BA0 17 7.10.6 Axis positions in the transformation
chain
.................................................................................594
7.11 Data lists
....................................................................................................................................598
7.11.1 Machine
data..............................................................................................................................598
7.11.1.1
TRANSMIT.................................................................................................................................598
7.11.1.2
TRACYL.....................................................................................................................................599
7.11.1.3
TRAANG....................................................................................................................................601
7.11.1.4 Chained
transformations............................................................................................................602
7.11.1.5 Non transformation-specific machine data
................................................................................602
7.11.2 Signals
.......................................................................................................................................602
7.11.2.1 Signals from channel
.................................................................................................................602
8 M5:
Measuring.......................................................................................................................................
603 8.1 Brief description
.........................................................................................................................603
8.2 Hardware requirements
.............................................................................................................604
8.2.1 Probes that can be
used............................................................................................................604
8.2.2 Measuring probe
connection......................................................................................................606
8.3 Channel-specific
measuring.......................................................................................................611
8.3.1 Measuring mode
........................................................................................................................611
8.3.2 Measurement results
.................................................................................................................612
8.4 Setting zeros, workpiece measuring and tool
measuring..........................................................613
8.4.1 Preset actual value memory and
scratching..............................................................................613
8.4.2 Workpiece measuring
................................................................................................................614
8.4.2.1 Input
values................................................................................................................................614
8.4.2.2 Measurement
selection..............................................................................................................622
8.4.2.3 Output
values.............................................................................................................................623
8.4.2.4 Calculation method
....................................................................................................................623
8.4.2.5 Units of measurement and measurement variables for the
calculation.....................................626 8.4.2.6
Diagnostics.................................................................................................................................628
8.4.3 Types of workpiece measurement
.............................................................................................628
8.4.3.1 Measurement of an edge (measurement type 1, 2, 3)
..............................................................628
8.4.3.2 Measurement of an angle (measurement type 4, 5, 6,
7)..........................................................633
8.4.3.3 Measurement of a hole (measurement type
8)..........................................................................637
8.4.3.4 Measurement of a shaft (measurement type
9).........................................................................640
8.4.3.5 Measurement of a groove (measurement type
12)....................................................................641
8.4.3.6 Measurement of a web (measurement type 13)
........................................................................644
8.4.3.7 Measurement of geo axes and special axes (measurement type
14, 15).................................645 8.4.3.8 Measurement of
an oblique edge (measurement type
16)........................................................647
8.4.3.9 Measurement of an oblique angle in a plane (measurement
type 17) ......................................649 8.4.3.10
Redefine measurement around a WCS reference frame (measurement type
18)....................653 8.4.3.11 Measurement of a 1-, 2- and
3-dimensional setpoint selection (measurement type 19, 20, 21)
..............................................................................................................................................656
8.4.3.12 Measurement of an oblique angle (measurement type 24)
.......................................................661 8.4.3.13
Measurement of a rectangle (measurement type
25)................................................................665
8.4.3.14 Measurement for saving data management frames (measurement
type 26)............................667 8.4.3.15 Measurement for
restoring backed-up data management frames (measurement type 27)
......668 8.4.3.16 Measurement for defining an additive rotation
for taper turning (measurement type 28)..........669 8.4.4 Tool
measuring
..........................................................................................................................670
8.4.5 Types of workpiece measurement
.............................................................................................671
8.4.5.1 Measurement of tool lengths (measurement type 10)
...............................................................671
8.4.5.2 Measurement of tool diameter (measurement type
11).............................................................673
8.4.5.3 Measurement of tool lengths with zoom-in function
(measurement type 22) ............................674 8.4.5.4
Measuring a tool length with stored or current position
(measurement type 23).......................675 8.4.5.5 Measurement
of a tool length of two tools with
orientation........................................................677
Contents Extended Functions 18 Function Manual, 03/2010,
6FC5397-1BP20-1BA0 8.5 Measurement accuracy and functional
testing..........................................................................
688 8.5.1 Measurement
accuracy.............................................................................................................
688 8.5.2 Probe functional
testing.............................................................................................................
689 8.6 Simulated measuring
................................................................................................................
690 8.6.1 General functionality
.................................................................................................................
690 8.6.2 Position-related switch request
.................................................................................................
690 8.6.3 External switch request
.............................................................................................................
692 8.6.4 System
variable.........................................................................................................................
693 8.7 Examples - only 840D sl
...........................................................................................................
693 8.7.1 Measuring mode 1
....................................................................................................................
693 8.7.2 Measuring mode 2
....................................................................................................................
694 8.7.3 Continuous measurement
.........................................................................................................
695 8.7.3.1 Continous measurement on completion of programmed
traversing motion............................. 695 8.7.3.2
Continuous measurements with deletion of
distance-to-go......................................................
695 8.7.3.3 Continuous measurements modally over several
blocks..........................................................
696 8.7.4 Functional test and repeat
accuracy.........................................................................................
697 8.8 Data
lists....................................................................................................................................
699 8.8.1 Machine
data.............................................................................................................................
699 8.8.1.1 General machine
data...............................................................................................................
699 8.8.1.2 Channel-specific machine
data.................................................................................................
699 8.8.2 System
variables.......................................................................................................................
699 9 N3: Software cams, position switching cycles - only 840D sl
.................................................................
701 9.1 Brief description
........................................................................................................................
701 9.2 Cam signals and cam positions
................................................................................................
702 9.2.1 Generation of cam signals for separate output
.........................................................................
702 9.2.2 Generation of cam signals with gated
output............................................................................
706 9.2.3 Cam positions
...........................................................................................................................
711 9.2.4 Lead/delay times (dynamic cam)
..............................................................................................
712 9.3 Output of cam signals
...............................................................................................................
714 9.3.1
Activating...................................................................................................................................
714 9.3.2 Output of cam signals to
PLC...................................................................................................
714 9.3.3 Output of cam signals to NCK I/Os in position control
cycle..................................................... 715
9.3.4 Timer-controlled cam signal output
...........................................................................................
717 9.3.5 Independent, timer-controlled output of cam
signals................................................................
718 9.4 Position-time
cams....................................................................................................................
720 9.5 Supplementary
conditions.........................................................................................................
722 9.6 Data
lists....................................................................................................................................
723 9.6.1 Machine
data.............................................................................................................................
723 9.6.1.1 General machine
data...............................................................................................................
723 9.6.2 Setting
data...............................................................................................................................
724 9.6.2.1 General setting
data..................................................................................................................
724 9.6.3
Signals.......................................................................................................................................
724 9.6.3.1 Signals to
axis/spindle...............................................................................................................
724 9.6.3.2 Signals from axis/spindle
..........................................................................................................
724 Contents Extended Functions Function Manual, 03/2010,
6FC5397-1BP20-1BA0 19 10 N4: Punching and nibbling - only 840D sl
..............................................................................................
725 10.1 Brief description
.........................................................................................................................725
10.2 Stroke control
.............................................................................................................................725
10.2.1 General information
...................................................................................................................725
10.2.2 High-speed signals
....................................................................................................................726
10.2.3 Criteria for stroke initiation
.........................................................................................................728
10.2.4 Axis start after punching
............................................................................................................730
10.2.5 PLC signals specific to punching and
nibbling...........................................................................731
10.2.6 Punching and nibbling-specific reactions to standard PLC
signals ...........................................731 10.2.7
Signal monitoring
.......................................................................................................................732
10.3 Activation and deactivation
........................................................................................................732
10.3.1 Language commands
................................................................................................................732
10.3.2 Functional expansions
...............................................................................................................737
10.3.3 Compatibility with earlier
systems..............................................................................................742
10.4 Automatic path segmentation
....................................................................................................744
10.4.1 General information
...................................................................................................................744
10.4.2 Operating characteristics with path
axes...................................................................................746
10.4.3 Response in connection with single
axes..................................................................................750
10.5 Rotatable tool
.............................................................................................................................754
10.5.1 General information
...................................................................................................................754
10.5.2 Coupled motion of punch and
die..............................................................................................755
10.5.3 Tangential control
......................................................................................................................756
10.6 Protection zones
........................................................................................................................760
10.7 Supplementary
conditions..........................................................................................................760
10.8 Examples
...................................................................................................................................761
10.8.1 Examples of defined start of nibbling
operation.........................................................................761
10.9 Data lists
....................................................................................................................................766
10.9.1 Machine
data..............................................................................................................................766
10.9.1.1 General machine
data................................................................................................................766
10.9.1.2 Channel-specific machine
data..................................................................................................766
10.9.2 Setting
data................................................................................................................................767
10.9.2.1 Channel-specific setting
data.....................................................................................................767
10.9.3 Signals
.......................................................................................................................................767
10.9.3.1 Signals to
channel......................................................................................................................767
10.9.3.2 Signals from channel
.................................................................................................................767
10.9.4 Language commands
................................................................................................................768
11 P2: Positioning axes
..............................................................................................................................
769 11.1 Brief description
.........................................................................................................................769
11.2 Own channel, positioning axis or concurrent positioning axis
...................................................771 11.2.1 Own
channel - only 840D sl
.......................................................................................................772
11.2.2 Positioning axis (posAxis)
..........................................................................................................773
11.2.3 Concurrent positioning
axis........................................................................................................775
11.3 Motion behavior and interpolation functions
..............................................................................777
11.3.1 Path interpolator and axis interpolator
.......................................................................................777
11.3.2 Interpolation response of path axis in G0
..................................................................................777
11.3.3 Autonomous single-axis
operations...........................................................................................779
11.3.4 Autonomous single-axis functions with NC-controlled
ESR......................................................787 11.4
Velocity.......................................................................................................................................789
Contents Extended Functions 20 Function Manual, 03/2010,
6FC5397-1BP20-1BA0 11.5
Programming.............................................................................................................................
790 11.5.1
General......................................................................................................................................
790 11.5.2 Revolutional feed rate in external
programming.......................................................................
793 11.6 Block
change.............................................................................................................................
793 11.6.1 Settable block change
time.......................................................................................................
797 11.6.2 End of motion criterion with block search
.................................................................................
805 11.7 Control by the
PLC....................................................................................................................
806 11.7.1 Starting concurrent positioning axes from the PLC
..................................................................
808 11.7.2 PLC-controlled
axes...........................................................