-
SINUMERIK
SINUMERIK 840D sl / 828DExtended Functions
Function Manual
Validfor ControlsystemSINUMERIK840Dsl/840DEslSINUMERIK828D
Software VersionCNCsoftware 4.4
09/20116FC5397-1BP40-2BA0
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: Own
channel - only 840D sl10P2: 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 informationWarning 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.
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 PersonnelThe 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 productsNote the following:
TrademarksAll names identified by are registered trademarks of
the SiemensAG. 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 LiabilityWe 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.
DANGERindicates that death or severe personal injury will result
if proper precautions are not taken.
WARNINGindicates that death or severe personal injury may result
if proper precautions are not taken.
CAUTIONwith a safety alert symbol, indicates that minor personal
injury can result if proper precautions are not taken.
CAUTIONwithout a safety alert symbol, indicates that property
damage can result if proper precautions are not taken.
NOTICEindicates that an unintended result or situation can occur
if the corresponding information is not taken into account.
WARNINGSiemens 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.
Siemens AGIndustry SectorPostfach 48 4890026 NRNBERGGERMANY
Order number:6FC5397-1BP40-2BA0 02.2011
Copyright SiemensAG2011.Technical data subject to change
-
Extended FunctionsFunction Manual 09/2011, 6FC5397-1BP40-2BA0
3
Preface
SINUMERIK documentationThe SINUMERIK documentation is organized
in the following categories:
General documentation
User documentation
Manufacturer/service documentation
Additional informationYou can find information on the following
topics at www.siemens.com/motioncontrol/docu:
Ordering documentation/overview of documentation
Additional links to download documents
Using documentation online (find and search in
manuals/information)
Please send any questions about the technical documentation
(e.g. suggestions for improvement, corrections) to the following
address:
[email protected]
My Documentation Manager (MDM)Under the following link you will
find information to individually compile OEM-specific machine
documentation based on the Siemens content:
www.siemens.com/mdm
Training For information about the range of training courses,
refer under:
www.siemens.com/sitrain
SITRAIN - Siemens training for products, systems and solutions
in automation technology
www.siemens.com/sinutrain
SinuTrain - training software for SINUMERIK
FAQsYou can find Frequently Asked Questions in the
Service&Support pages under Product Support.
http://support.automation.siemens.com
http://www.siemens.com/motioncontrol/docu:mailto:[email protected]://www.siemens.com/mdmhttp://www.siemens.com/sitrainhttp://www.siemens.com/sinutrainhttp://support.automation.siemens.com
-
Preface
Extended Functions4 Function Manual, 09/2011,
6FC5397-1BP40-2BA0
SINUMERIKYou can find information on SINUMERIK under the
following link:
www.siemens.com/sinumerik
Target groupThis publication is intended for:
Project engineers
Technologists (from machine manufacturers)
System startup engineers (Systems/Machines)
Programmers
BenefitsThe 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.
Standard versionThis 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.
Technical Support You will find telephone numbers for other
countries for technical support in the Internet under
http://www.siemens.com/automation/service&support
http://www.siemens.com/automation/service&supporthttp://www.siemens.com/sinumerik
-
Preface
Extended FunctionsFunction Manual, 09/2011, 6FC5397-1BP40-2BA0
5
Information on structure and contents
InstallationStructure 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- Overview
Index of terms
Notation of system dataThe following notation is applicable for
system data in this documentation:
NoteFor 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 Basic Functions; NC/PLC
Interface Signals (Z2)Function Manual Special Functions; NC/PLC
Interface Signals (Z3)
alarms:Diagnostics Manual
Signal/Data Notation ExampleNC/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)
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Preface
Extended Functions6 Function Manual, 09/2011,
6FC5397-1BP40-2BA0
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.)
Data typesThe following elementary data types are used in the
control system:
NoteSignal addressThe 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.
Type Meaning Value rangeINT Signed integers -2147483648 ...
+2147483647REAL Figures with decimal point acc. to IEEE (2,2*10-308
1,8*10+308)BOOL Truth values TRUE (1) and FALSE (0) 1, 0CHAR ASCII
characters Corresponding to code 0 to 255STRING Character string,
number of characters in [...] Maximum of 200 characters (no
special
characters)AXIS Axis names only All axis identifiers in the
channelFRAME Geometrical parameters for moving, rotating, scaling,
and
mirroringArrays can only be formed from similar elementary data
types. Up to 3-dimensional arrays are possible.
-
Preface
Extended FunctionsFunction Manual, 09/2011, 6FC5397-1BP40-2BA0
7
SINUMERIK 828D system performance (region)
PPU240.2 / 241.2 PPU 260.2 / 261.2 PPU 280.2 / 281.2BASIC T
BASIC M T M T M
System performanceBasic quantity of axes/spindles 3 4 3 4 3
4Max. number of axes/spindles 5 5 6 6 8 6Max. number of
interpolating axes 4 4 4 4 4 4Max. number: Channels / mode groups
1/1 1/1 1/1 1/1 1/1 1/1Min. block change time 9ms 9ms 6ms 6ms 6ms
3msSpeed/current control cycle 125s 125s 125s 125s 125s 125sCNC
user memory (buffered) 1 MB 1 MB 3MB 3MB 5MB 5MB
CNC functionsTool Management Number of tools/cutting edges
80/160 80/160 128/256 128/256 256/512 256/512Max. number of ASUBs
(permanently set)
2 2 2 2 2 2
TRANSMIT / TRACYL Inclined Y axis - - - - -Synchronous spindle
for counterspindle - - - - -Synchronous spindle for polygon
machining
- - -
Gantry Temperature compensation
Drive functionsSafety Integrated: Safe Torque Off, Safe Brake
Control
Safety Integrated: Safe velocity
HMI, CNC programmingShopMill/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
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Preface
Extended Functions8 Function Manual, 09/2011,
6FC5397-1BP40-2BA0
PLCSIMATIC S7-200 (integrated) Basic I/O modules:PP 72/48D PNPP
72/48D 2/2A PN (being prepared)
PLC cycle time 9ms 9ms 6ms 6ms 6ms 6msMax. number of PLC
operations 24000 24000 24000 24000 24000 24000Servo-synchronous
high-speed PLC task
Reaction time to process interrupts (terminal to terminal)
7.5ms 7.5ms 7.5ms 7.5ms 4.5ms 4.5ms
Max. number of digital inputs/outputs 216/144 216/144 288/192
288/192 360/240 360/240Max. number of analog inputs/outputs 6/6 6/6
8/8 8/8 10/10 10/10
Commissioning functionsService Planner (maintenance
scheduler)
Easy Extend (for managing machine units)
Easy Archive (data archiving)
PPU240.2 / 241.2 PPU 260.2 / 261.2 PPU 280.2 / 281.2BASIC T
BASIC M T M T M
T TurningM Milling Standard (basic scope) Option- Not
available
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9
Table of contents
Preface.........................................................................................................................................................3
1 A4: Digital and analog NCK I/Os
...............................................................................................................27
1.1 Brief Description
........................................................................................................................
27
1.2 NCK I/O via
PLC........................................................................................................................
281.2.1 General functionality
..................................................................................................................
281.2.2 NCK digital inputs/outputs
.........................................................................................................
331.2.2.1 NCK digital inputs
......................................................................................................................
331.2.2.2 NCK digital outputs
....................................................................................................................
351.2.3 Connection and logic operations of fast NCK inputs/outputs
.................................................... 381.2.4 NCK
analog inputs/outputs
........................................................................................................
401.2.4.1 NCK analog inputs
.....................................................................................................................
401.2.4.2 NCK analog outputs
..................................................................................................................
431.2.5 Direct PLC I/Os, addressable from the NC
................................................................................
471.2.6 Analog-value representation of the NCK analog input/output
values ........................................ 501.2.7 Comparator
inputs
.....................................................................................................................
51
1.3 NCK I/O via PROFIBUS - only 840D sl
.....................................................................................
551.3.1 Functionality
..............................................................................................................................
551.3.2 Parameter assignment
..............................................................................................................
561.3.3 Programming
.............................................................................................................................
581.3.3.1 Communication via part programs/synchronous actions
...........................................................
581.3.3.2 Communication via compile cycles
............................................................................................
61
1.4 Constraints
................................................................................................................................
631.4.1 NCK I/O via PLC
........................................................................................................................
631.4.2 NCK I/O via PROFIBUS - only 840D sl
.....................................................................................
64
1.5
Examples...................................................................................................................................
651.5.1 NCK I/O via PLC
........................................................................................................................
651.5.1.1 Writing to PLC-I/Os
....................................................................................................................
651.5.1.2 Reading from PLC-I/Os
.............................................................................................................
661.5.2 NCK I/O via PROFIBUS - only 840D sl
.....................................................................................
671.5.2.1 PROFIBUS-I/O in write direction
...............................................................................................
671.5.2.2 PROFIBUS-I/O in read direction
................................................................................................
691.5.2.3 Query of the RangeIndex in case of "PROFIBUS-I/O in write
direction" ................................... 71
1.6 Data
lists....................................................................................................................................
731.6.1 Machine data
.............................................................................................................................
731.6.1.1 General machine data
...............................................................................................................
731.6.1.2 Channelspecific machine data
.................................................................................................
741.6.2 Setting data
...............................................................................................................................
741.6.2.1 General setting data
..................................................................................................................
741.6.3 Signals
.......................................................................................................................................
741.6.3.1 Signals to NC
.............................................................................................................................
741.6.3.2 Signals from NC
........................................................................................................................
74
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2 B3: Several operator panels connected to several NCUs,
distributed systems - only 840D sl .................75
2.1 Brief Description
........................................................................................................................
752.1.1 Topology of distributed system configurations
...........................................................................
752.1.2 Several operator panels and NCUs with control unit
management (option) .............................. 802.1.2.1
General information
...................................................................................................................
802.1.2.2 System Features
........................................................................................................................
812.1.2.3 Hardware
...................................................................................................................................
822.1.2.4 Functions
...................................................................................................................................
842.1.2.5 Configurability
............................................................................................................................
852.1.3 Several operator panel fronts and NCUs, standard
functionality ...............................................
862.1.3.1 System Features
........................................................................................................................
862.1.3.2 Functions
...................................................................................................................................
872.1.3.3 Configurability
............................................................................................................................
892.1.3.4 MPI/OPI network rules
...............................................................................................................
932.1.4 NCU link
.....................................................................................................................................
942.1.4.1 General information
...................................................................................................................
942.1.4.2 Technological description
..........................................................................................................
972.1.4.3 Link axes
...................................................................................................................................
992.1.4.4 User-specification link communication via link variables
.........................................................
1002.1.4.5 Lead link axes
..........................................................................................................................
100
2.2 Several operator panel fronts and NCUs with control unit
management option ...................... 1022.2.1 Hardware
structure
..................................................................................................................
1022.2.2 Properties
................................................................................................................................
1022.2.3 Configuration file NETNAMES.INI
...........................................................................................
1042.2.4 Structure of the configuration file
.............................................................................................
1042.2.5 Creating and using the configuration file
.................................................................................
1092.2.6 Power up
.................................................................................................................................
1102.2.7 HMI switchover
........................................................................................................................
1132.2.8 Suppression
.............................................................................................................................
1132.2.9 Connection and switchover conditions
....................................................................................
1152.2.10 Implementation of control unit switchover
................................................................................
1162.2.11 Operator interface
....................................................................................................................
1162.2.12 Operating mode switchover
.....................................................................................................
1182.2.13 MCP switchover
.......................................................................................................................
120
2.3 Several operator panel fronts and NCUs, standard
functionality............................................. 1212.3.1
Configurations
..........................................................................................................................
1212.3.2 Switchover of connection to another NCU
...............................................................................
1252.3.3 Creating and using the configuration file
.................................................................................
1262.3.4 Power up
.................................................................................................................................
1262.3.5 NCU replacement
....................................................................................................................
127
2.4 Restrictions for switchover of operator
components................................................................
129
2.5 Link
communication.................................................................................................................
1302.5.1 General information
.................................................................................................................
1302.5.2 Parameter assignment: NC system cycles
..............................................................................
1312.5.3 Parameter assignment: Link communication
...........................................................................
1332.5.4 Configuration
...........................................................................................................................
1332.5.5 Wiring the NCUs
......................................................................................................................
1342.5.6 Activation
.................................................................................................................................
134
2.6 Link axes
.................................................................................................................................
135
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Table of contents
2.6.1 Configuration of link axes and container axes
.........................................................................
1372.6.2 Axis data and signals
...............................................................................................................
1412.6.3 Output of predefined auxiliary functions in the case of an
NCU link ........................................ 1432.6.4
Supplementary conditions for link axes
...................................................................................
1442.6.5 Programming with channel and machine axis identifiers
......................................................... 1462.6.6
Flexible configuration
...............................................................................................................
146
2.7 Axis container
..........................................................................................................................
1472.7.1 System variables for axis containers
.......................................................................................
1532.7.2 Machining with axis container (schematic)
..............................................................................
1542.7.3 Axis container behavior after Power ON
.................................................................................
1552.7.4 Axis container response to mode switchover
..........................................................................
1552.7.5 Axis container behavior in relation to ASUBs
..........................................................................
1552.7.6 Axis container response to RESET
.........................................................................................
1552.7.7 Axis container response to block searches
.............................................................................
1552.7.8 Behavior when withdrawing the release for axis container
rotation ......................................... 1552.7.9
Supplementary conditions for axis container rotations
............................................................
157
2.8 User-specific link variables
......................................................................................................
1602.8.1 Link variables
...........................................................................................................................
1602.8.2 Reading drive data via link variables
.......................................................................................
165
2.9 Lead link
axis...........................................................................................................................
167
2.10 System of units within a link grouping
.....................................................................................
170
2.11 Supplementary conditions
.......................................................................................................
1712.11.1 Several operator panels and NCUs with control unit
management option .............................. 1712.11.2 Several
operator panel fronts and NCUs, standard functionality
............................................. 1712.11.3 Link axes
.................................................................................................................................
1722.11.4 Axis container
..........................................................................................................................
1722.11.5 Lead link axis
...........................................................................................................................
172
2.12
Examples.................................................................................................................................
1732.12.1 Configuration file NETNAMES.INI with control unit
management option ................................ 1732.12.2
User-specific reconfiguring of PLC program control unit switchover
....................................... 1762.12.2.1 Description of
operational sequences (overview)
....................................................................
1762.12.2.2 Description of operational sequences (details)
........................................................................
1772.12.2.3 Defined logical functions/defines
.............................................................................................
1862.12.2.4 Graphical representation of function sequences
.....................................................................
1872.12.3 Configuration file NETNAMES.INI, standard functionality
....................................................... 1942.12.3.1
Two operator panel fronts and one NCU
.................................................................................
1942.12.3.2 One operator panel front and three NCUs
...............................................................................
1952.12.4 Quick M:N commissioning based on examples
.......................................................................
1972.12.4.1 Example 1
................................................................................................................................
1972.12.4.2 Example 2
................................................................................................................................
2002.12.4.3 Example 3
................................................................................................................................
2052.12.4.4 Description of FB9
...................................................................................................................
2092.12.4.5 Example of calling FB9
............................................................................................................
2122.12.4.6 Example of override switchover
...............................................................................................
2132.12.4.7 Switchover between MCP and HT6
.........................................................................................
2142.12.4.8 General Information
.................................................................................................................
2152.12.5 Link axis
...................................................................................................................................
2172.12.6 Axis container coordination
.....................................................................................................
2192.12.6.1 Axis container rotation without a part program wait
.................................................................
219
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2.12.6.2 Axis container rotation with an implicit part program
wait ........................................................
2192.12.6.3 Axis container rotation by one channel only (e.g.
during power up) ........................................ 2192.12.7
Evaluating axis container system variables
.............................................................................
2202.12.7.1 Conditional branch
...................................................................................................................
2202.12.7.2 Static synchronized action with $AN_AXCTSWA
....................................................................
2202.12.7.3 Wait for certain completion of axis container rotation
..............................................................
2202.12.8 Configuration of a multi-spindle turning machine
.....................................................................
2222.12.9 Lead link axis
...........................................................................................................................
2302.12.9.1 Configuration
...........................................................................................................................
2302.12.9.2 Programming
...........................................................................................................................
232
2.13 Data lists
..................................................................................................................................
2332.13.1 Machine data
...........................................................................................................................
2332.13.1.1 General machine data
.............................................................................................................
2332.13.1.2 Channelspecific machine data
................................................................................................
2332.13.1.3 Axis/spindlespecific machine data
..........................................................................................
2332.13.2 Setting data
.............................................................................................................................
2342.13.2.1 General setting data
................................................................................................................
2342.13.2.2 Axis/spindle-specific setting data
.............................................................................................
2342.13.3 Signals
.....................................................................................................................................
2342.13.3.1 Signals from NC
.......................................................................................................................
2342.13.3.2 Signals from HMI/PLC
.............................................................................................................
2342.13.3.3 General online interface
...........................................................................................................
2352.13.3.4 Signals from axis/spindle
.........................................................................................................
2362.13.4 System variables
.....................................................................................................................
237
3 B4: Operation via PG/PC - only 840D sl
.................................................................................................239
3.1 Brief Description
......................................................................................................................
239
3.2 Software
installation.................................................................................................................
2413.2.1 System requirements
...............................................................................................................
2413.2.2 Installation
...............................................................................................................................
2423.2.3 Supplementary software conditions
.........................................................................................
2473.2.4 Start program
...........................................................................................................................
2473.2.5 Close program
.........................................................................................................................
248
3.3 Operation via PG/PC
...............................................................................................................
2493.3.1 General operation
....................................................................................................................
2493.3.2 Additional information
..............................................................................................................
2513.3.3 Operation of operator panel fronts
...........................................................................................
252
3.4 Simulation of part
programs.....................................................................................................
253
3.5 Marginal
conditions..................................................................................................................
253
3.6 Data lists
..................................................................................................................................
253
4 H1: Manual travel and handwheel travel
.................................................................................................255
4.1 product
brief.............................................................................................................................
2554.1.1 Overview
..................................................................................................................................
2554.1.2 General characteristics of manual travel in JOG
.....................................................................
2564.1.3 Control of manual-travel functions via PLC interface
...............................................................
2604.1.4 Control-system response to power ON, mode change, RESET,
block search, REPOS ......... 261
4.2 Continuous
travel.....................................................................................................................
2624.2.1 General functionality
................................................................................................................
262
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Table of contents
4.2.2 Distinction between inching mode continuous mode
...............................................................
2634.2.3 Special features of continuous travel
.......................................................................................
264
4.3 Incremental travel (INC)
..........................................................................................................
2654.3.1 General functionality
................................................................................................................
2654.3.2 Distinction between inching mode and continuous mode
........................................................ 2664.3.3
Special features of incremental travel
.....................................................................................
267
4.4 Handwheel travel in
JOG.........................................................................................................
2684.4.1 General functionality
................................................................................................................
2684.4.2 Travel request
..........................................................................................................................
2764.4.3 Double use of the handwheel
..................................................................................................
280
4.5 Handwheel override in automatic mode
..................................................................................
2824.5.1 General functionality
................................................................................................................
2824.5.2 Programming and activating handwheel override
...................................................................
2874.5.3 Special features of handwheel override in automatic mode
.................................................... 289
4.6 Contour handwheel/path input using handwheel (option)
....................................................... 290
4.7 DRF offset
...............................................................................................................................
293
4.8 Start-up: Handwheels
..............................................................................................................
2964.8.1 General information
.................................................................................................................
2964.8.2 Connection via PPU - only 828D
.............................................................................................
2974.8.3 Connected via PROFIBUS - only 840D sl
...............................................................................
2984.8.4 Connected via Ethernet - only 840D sl
....................................................................................
301
4.9 Special features of manual travel
............................................................................................
3054.9.1 Geometry-axis manual travel
...................................................................................................
3054.9.2 Special features of spindle manual travel
................................................................................
3064.9.3 Monitoring functions
................................................................................................................
3084.9.4 Other
........................................................................................................................................
309
4.10 Approaching a fixed point in
JOG............................................................................................
3104.10.1 Introduction
..............................................................................................................................
3104.10.2 Functionality
............................................................................................................................
3114.10.3 Parameter setting
....................................................................................................................
3134.10.4 Programming
...........................................................................................................................
3154.10.5 Supplementary Conditions
......................................................................................................
3154.10.6 Application example
................................................................................................................
316
4.11 Data
lists..................................................................................................................................
3174.11.1 Machine data
...........................................................................................................................
3174.11.1.1 General machine data
.............................................................................................................
3174.11.1.2 Channelspecific machine data
...............................................................................................
3174.11.1.3 Axis/spindlespecific machine data
..........................................................................................
3184.11.2 Setting data
.............................................................................................................................
3184.11.2.1 General setting data
................................................................................................................
3184.11.3 Signals
.....................................................................................................................................
3194.11.3.1 Signals from NC
......................................................................................................................
3194.11.3.2 Signals to mode group
.............................................................................................................
3194.11.3.3 Signals from mode group
........................................................................................................
3194.11.3.4 Signals to channel
...................................................................................................................
3204.11.3.5 Signals from channel
...............................................................................................................
3214.11.3.6 Signals to axis/spindle
.............................................................................................................
3224.11.3.7 Signals from axis/spindle
.........................................................................................................
322
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5 K3: Compensation
...................................................................................................................................323
5.1
Introduction..............................................................................................................................
323
5.2 Temperature
compensation.....................................................................................................
3245.2.1 Description of functions
...........................................................................................................
3245.2.2 Commissioning
........................................................................................................................
3275.2.2.1 Temperature-dependent parameters
.......................................................................................
3275.2.2.2 Temperature compensation type and activation
......................................................................
3285.2.2.3 Maximum compensation value per IPO clock cycle
................................................................
3285.2.3 Example
...................................................................................................................................
3295.2.3.1 Commissioning the temperature compensation for the Z
axis of a lathe ................................. 329
5.3 Backlash
compensation...........................................................................................................
3325.3.1 Description of functions
...........................................................................................................
3325.3.2 Commissioning
........................................................................................................................
3335.3.2.1 Backlash
..................................................................................................................................
3335.3.2.2 Weighting factor for backlash
..................................................................................................
3335.3.2.3 Applying the backlash compensation step-by-step
..................................................................
333
5.4 Interpolatory compensation
.....................................................................................................
3345.4.1 General information
.................................................................................................................
3345.4.2 Compensation of leadscrew errors and measuring system
errors .......................................... 3375.4.2.1
Measuring system error compensation (MSEC)
......................................................................
3375.4.2.2 Commissioning
........................................................................................................................
3385.4.2.3 Example
...................................................................................................................................
3415.4.3 Compensation of sag and angularity errors
.............................................................................
3425.4.3.1 Description of functions
...........................................................................................................
3425.4.3.2 Commissioning
........................................................................................................................
3475.4.3.3 Examples
.................................................................................................................................
3515.4.4 Direction-dependent leadscrew error compensation
...............................................................
3605.4.4.1 Description of functions
...........................................................................................................
3605.4.4.2 Commissioning
........................................................................................................................
3615.4.4.3 Example
...................................................................................................................................
3655.4.5 Extension of the sag compensation with NCU link - only
840D sl ........................................... 3695.4.6
Special features of interpolatory compensation
.......................................................................
378
5.5 Dynamic feedforward control (following error
compensation)..................................................
3805.5.1 General properties
...................................................................................................................
3805.5.2 Speed feedforward control
.......................................................................................................
3825.5.3 Torque feedforward control
......................................................................................................
3845.5.4 Dynamic response adaptation
.................................................................................................
3865.5.5 Forward feed control for command- and PLC axes
.................................................................
3875.5.6 Secondary conditions
..............................................................................................................
388
5.6 Friction compensation (quadrant error compensation)
............................................................
3905.6.1 General properties
...................................................................................................................
3905.6.2 Conventional friction compensation
.........................................................................................
3915.6.2.1 Description of functions
...........................................................................................................
3915.6.2.2 commissioning
.........................................................................................................................
3935.6.3 Quadrant error compensation using neural networks - only
840D sl ....................................... 4005.6.3.1
Fundamentals
..........................................................................................................................
4005.6.3.2 Parameterization of neural QEC
..............................................................................................
4035.6.3.3 Learning the neural network
....................................................................................................
4105.6.3.4 Commissioning of neural QEC
................................................................................................
414
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Table of contents
5.6.3.5 Further optimization and intervention options
..........................................................................
4175.6.3.6 Quick commissioning
...............................................................................................................
423
5.7 Circularity
test..........................................................................................................................
426
5.8 Measures for hanging (suspended axes)
................................................................................
4315.8.1 Electronic counterweight
.........................................................................................................
4315.8.2 Reboot delay
...........................................................................................................................
433
5.9 Data
lists..................................................................................................................................
4355.9.1 Machine data
...........................................................................................................................
4355.9.1.1 General machine data
.............................................................................................................
4355.9.1.2 Channelspecific machine data
...............................................................................................
4355.9.1.3 Axis/Spindle-specific machine data
.........................................................................................
4365.9.2 Setting data
.............................................................................................................................
4375.9.2.1 General setting data
................................................................................................................
4375.9.2.2 Axis/spindle-specific setting data
.............................................................................................
4375.9.3 Signals
.....................................................................................................................................
4375.9.3.1 Signals from NC
......................................................................................................................
4375.9.3.2 Signals from mode group
........................................................................................................
4375.9.3.3 Signals from channel
...............................................................................................................
4375.9.3.4 Signals from axis/spindle
.........................................................................................................
437
6 K5: Mode groups, channels, axis interchange
........................................................................................439
6.1 Brief
description.......................................................................................................................
439
6.2 Mode groups - only 840D
sl.....................................................................................................
441
6.3 Channels - only 840D sl
..........................................................................................................
4426.3.1 Channel synchronization (program coordination)
....................................................................
4426.3.2 Conditional wait in continuous path mode WAITMC
...............................................................
4456.3.3 Running-in channel-by-channel
...............................................................................................
449
6.4 Axis/spindle
replacement.........................................................................................................
4556.4.1 Introduction
..............................................................................................................................
4556.4.2 Example of an axis replacement
.............................................................................................
4586.4.3 Axis replacement options
........................................................................................................
4596.4.4 Replacement behavior NC program
........................................................................................
4606.4.5 Transition the axis into the neutral state (RELEASE)
..............................................................
4616.4.6 Transferring an axis or spindle into the part program
(GET, GETD) ....................................... 4626.4.7
Automatic axis replacement
....................................................................................................
4636.4.8 Axis replacement via PLC
.......................................................................................................
4656.4.9 Set axis replacement behavior variable.
..................................................................................
4686.4.10 Axis interchange via axis container rotation
............................................................................
4696.4.11 Axis replacement with and without preprocessing stop
...........................................................
4706.4.12 Axis exclusively controlled from the PLC
.................................................................................
4716.4.13 Axis permanently assigned to the PLC
....................................................................................
4726.4.14 Geometry axis in rotated frame and axis replacement
............................................................
4736.4.15 Axis replacement from synchronized actions
..........................................................................
4756.4.16 Axis interchange for leading axes (gantry)
..............................................................................
477
6.5 Marginal
conditions..................................................................................................................
478
6.6 Data
lists..................................................................................................................................
4806.6.1 Machine data
...........................................................................................................................
4806.6.1.1 General machine data
.............................................................................................................
480
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6FC5397-1BP40-2BA0
6.6.1.2 Channel-specific machine data
................................................................................................
4806.6.1.3 Axis/spindlespecific machine data
..........................................................................................
4826.6.2 Setting data
.............................................................................................................................
4836.6.2.1 Channelspecific setting data
...................................................................................................
4836.6.3 Signals
.....................................................................................................................................
4836.6.3.1 Signals to/from BAG
................................................................................................................
4836.6.3.2 Signals to/from Channel
..........................................................................................................
483
7 M1: Kinematic transformation
.................................................................................................................485
7.1 Brief
description.......................................................................................................................
4857.1.1 TRANSMIT (option)
.................................................................................................................
4857.1.2 TRACYL (option)
.....................................................................................................................
4867.1.3 TRAANG (option)
.....................................................................................................................
4877.1.4 Chained transformations
..........................................................................................................
4887.1.5 Activating transformation machine data via parts
program/softkey ......................................... 488
7.2 TRANSMIT (option)
.................................................................................................................
4897.2.1 Preconditions for TRANSMIT
..................................................................................................
4907.2.2 Settings specific to TRANSMIT
...............................................................................................
4937.2.3 Activation of TRANSMIT
..........................................................................................................
4977.2.4 Deactivation of the TRANSMIT function
..................................................................................
4977.2.5 Special system reactions with TRANSMIT
..............................................................................
4987.2.6 Machining options for TRANSMIT
...........................................................................................
5027.2.7 Working area limitations
..........................................................................................................
5097.2.8 Overlaid motions with TRANSMIT
...........................................................................................
5107.2.9 Monitoring of rotary axis rotations over 360
...........................................................................
5107.2.10 Constraints
...............................................................................................................................
511
7.3 TRACYL (option)
.....................................................................................................................
5137.3.1 Preconditions for TRACYL
.......................................................................................................
5167.3.2 Settings specific to TRACYL
....................................................................................................
5207.3.3 Activation of TRACYL
..............................................................................................................
5257.3.4 Deactivation of the TRACYL function
......................................................................................
5257.3.5 Special system reactions with TRACYL
..................................................................................
5267.3.6 Jog
...........................................................................................................................................
529
7.4 TRAANG
(option).....................................................................................................................
5307.4.1 Preconditions for TRAANG (inclined axis)
...............................................................................
5327.4.2 Settings specific to TRAANG
...................................................................................................
5347.4.3 Activation of TRAANG
.............................................................................................................
5377.4.4 Deactivation of TRAANG
.........................................................................................................
5387.4.5 Special system reactions with TRAANG
..................................................................................
5387.4.6 Inclined axis programming (G05, G07)
....................................................................................
540
7.5 Chained
transformations..........................................................................................................
5427.5.1 Activating chained transformations
..........................................................................................
5457.5.2 Switching off a chained transformation
....................................................................................
5457.5.3 Special characteristics of chained transformations
..................................................................
5467.5.4 Persistent transformation
.........................................................................................................
5467.5.5 Axis positions in the transformation chain
...............................................................................
552
7.6 Cartesian PTP
travel................................................................................................................
5557.6.1 Programming of position
..........................................................................................................
5597.6.2 Overlap areas of axis angles
...................................................................................................
5607.6.3 Examples of ambiguities of position
........................................................................................
560
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Table of contents
7.6.4 Example of ambiguity in rotary axis position
...........................................................................
5627.6.5 PTP/CP switchover in JOG mode
...........................................................................................
562
7.7 Cartesian manual travel
(optional)...........................................................................................
563
7.8 Activating transformation machine data via parts
program/softkey ......................................... 5717.8.1
Functionality
............................................................................................................................
5717.8.2 Constraints
..............................................................................................................................
5727.8.3 Control response to power ON, mode change, RESET, block
search, REPOS ..................... 5747.8.4 List of machine data
affected
...................................................................................................
574
7.9 Constraints
..............................................................................................................................
5787.9.1 Chained transformations
.........................................................................................................
578
7.10
Examples.................................................................................................................................
5797.10.1 TRANSMIT
..............................................................................................................................
5797.10.2 TRACYL
..................................................................................................................................
5817.10.3 TRAANG
..................................................................................................................................
5867.10.4 Chained transformations
.........................................................................................................
5887.10.5 Activating transformation MD via a parts program
..................................................................
5927.10.6 Axis positions in the transformation chain
...............................................................................
593
7.11 Data
lists..................................................................................................................................
5977.11.1 Machine data
...........................................................................................................................
5977.11.1.1 TRANSMIT
..............................................................................................................................
5977.11.1.2 TRACYL
..................................................................................................................................
5987.11.1.3 TRAANG
..................................................................................................................................
6007.11.1.4 Chained transformations
.........................................................................................................
6017.11.1.5 Non transformation-specific machine data
..............................................................................
6017.11.2 Signals
.....................................................................................................................................
6017.11.2.1 Signals from channel
...............................................................................................................
601
8 M5: Measuring
........................................................................................................................................603
8.1 Brief
description.......................................................................................................................
603
8.2 Hardware requirements
...........................................................................................................
6048.2.1 Probes that can be used
..........................................................................................................
604
8.3 Channel-specific measuring
....................................................................................................
6068.3.1 Measuring mode
......................................................................................................................
6068.3.2 Measurement results
...............................................................................................................
607
8.4 Setting zeros, workpiece measuring and tool measuring
........................................................ 6088.4.1
Preset actual value memory and scratching
............................................................................
6088.4.2 Workpiece measuring
..............................................................................................................
6098.4.2.1 Input values
.............................................................................................................................
6098.4.2.2 Measurement selection
...........................................................................................................
6178.4.2.3 Output values
..........................................................................................................................
6188.4.2.4 Calculation method
..................................................................................................................
6188.4.2.5 Units of measurement and measurement variables for the
calculation ................................... 6218.4.2.6
Diagnostics
..............................................................................................................................
6238.4.3 Types of workpiece measurement
...........................................................................................
6238.4.3.1 Measurement of an edge (measurement type 1, 2, 3)
............................................................
6238.4.3.2 Measurement of an angle (measurement type 4, 5, 6, 7)
........................................................ 6288.4.3.3
Measurement of a hole (measurement type 8)
........................................................................
6328.4.3.4 Measurement of a shaft (measurement type 9)
.......................................................................
635
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6FC5397-1BP40-2BA0
8.4.3.5 Measurement of a groove (measurement type 12)
..................................................................
6368.4.3.6 Measurement of a web (measurement type 13)
......................................................................
6398.4.3.7 Measurement of geo axes and special axes (measurement
type 14, 15) ............................... 6408.4.3.8 Measurement
of an oblique edge (measurement type 16)
...................................................... 6428.4.3.9
Measurement of an oblique angle in a plane (measurement type 17)
..................................... 6448.4.3.10 Redefine
measurement around a WCS reference frame (measurement type 18)
.................. 6488.4.3.11 Measurement of a 1-, 2- and
3-dimensional setpoint selection
(measurement type 19, 20, 21)
................................................................................................
6518.4.3.12 Measurement of an oblique angle (measurement type 24)
..................................................... 6568.4.3.13
Measurement of a rectangle (measurement type 25)
..............................................................
6608.4.3.14 Measurement for saving data management frames
(measurement type 26) .......................... 6628.4.3.15
Measurement for restoring backed-up data management frames
(measurement type 27) ..... 6638.4.3.16 Measurement for defining an
additive rotation for taper turning (measurement type 28) ........
6648.4.4 Tool measuring
........................................................................................................................
6658.4.5 Types of workpiece measurement
...........................................................................................
6668.4.5.1 Measurement of tool lengths (measurement type 10)
.............................................................
6668.4.5.2 Measurement of tool diameter (measurement type 11)
...........................................................
6688.4.5.3 Measurement of tool lengths with zoom-in function
(measurement type 22) .......................... 6698.4.5.4
Measuring a tool length with stored or current position
(measurement type 23) ..................... 6708.4.5.5 Measurement
of a tool length of two tools with the following orientation:
................................ 671
8.5 Measurement accuracy and functional testing
........................................................................
6828.5.1 Measurement accuracy
...........................................................................................................
6828.5.2 Probe functional testing
...........................................................................................................
683
8.6 Simulated
measuring...............................................................................................................
6848.6.1 General functionality
................................................................................................................
6848.6.2 Position-related switch request
................................................................................................
6848.6.3 External switch request
............................................................................................................
6868.6.4 System variable
.......................................................................................................................
687
8.7 Channels - only 840D
sl...........................................................................................................
6888.7.1 Measuring mode 1
...................................................................................................................
6888.7.2 Measuring mode 2
...................................................................................................................
6898.7.3 Continuous measurement
........................................................................................................
6898.7.3.1 Continous measurement on completion of programmed
traversing motion ............................ 6898.7.3.2
Continuous measurements with deletion of distance-to-go
..................................................... 6908.7.3.3
Continuous measurements modally over several blocks
......................................................... 6908.7.4
Functional test and repeat accuracy
........................................................................................
691
8.8 Data lists
..................................................................................................................................
6938.8.1 Machine data
...........................................................................................................................
6938.8.1.1 General machine data
.............................................................................................................
6938.8.1.2 Channel-specific machine data
................................................................................................
6938.8.2 System variables
.....................................................................................................................
693
9 N3: Software cams, position switching cycles - only 840D sl
..................................................................695
9.1 Brief Description
......................................................................................................................
695
9.2 Cam signals and cam positions
...............................................................................................
6969.2.1 Generation of cam signals for separate output
........................................................................
6969.2.2 Generation of cam signals with gated output
...........................................................................
6999.2.3 Cam positions
..........................................................................................................................
7039.2.4 Lead/delay times (dynamic cam)
.............................................................................................
705
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Table of contents
9.3 Output of cam
signals..............................................................................................................
7069.3.1 Activating
.................................................................................................................................
7069.3.2 Output of cam signals to PLC
..................................................................................................
7069.3.3 Output of cam signals to NCK I/Os in position control
cycle ................................................... 7079.3.4
Timer-controlled cam signal output
.........................................................................................
7089.3.5 Independent, timer-controlled output of cam signals
...............................................................
710
9.4 Position-time cams
..................................................................................................................
711
9.5 Supplementary Conditions
......................................................................................................
713
9.6 Data
lists..................................................................................................................................
7149.6.1 Machine data
...........................................................................................................................
7149.6.1.1 General machine data
.............................................................................................................
7149.6.2 Setting data
.............................................................................................................................
7149.6.2.1 General setting data
................................................................................................................
7149.6.3 Signals
.....................................................................................................................................
7159.6.3.1 Signals to axis/spindle
.............................................................................................................
7159.6.3.2 Signals from axis/spindle
.........................................................................................................
715
10 N4: Own channel - only 840D sl
.............................................................................................................717
10.1 Brief Description
......................................................................................................................
717
10.2 Stroke control
..........................................................................................................................
71810.2.1 General information
.................................................................................................................
71810.2.2 High-speed signals
..................................................................................................................
71910.2.3 Criteria for stroke initiation
.......................................................................................................
72110.2.4 Axis start after punching
..........................................................................................................
72310.2.5 PLC signals specific to punching and nibbling
........................................................................
72410.2.6 Punching and nibbling-specific reactions to standard PLC
signals ......................................... 72410.2.7 Signal
monitoring
.....................................................................................................................
725
10.3 Activation and
deactivation......................................................................................................
72610.3.1 Language commands
..............................................................................................................
72610.3.2 Functional expansions
.............................................................................................................
73110.3.3 Compatibility with earlier systems
...........................................................................................
735
10.4 Automatic path segmentation
..................................................................................................
73710.4.1 General information
.................................................................................................................
73710.4.2 Operating characteristics with path axes
.................................................................................
73910.4.3 Response in connection with single axes
................................................................................
743
10.5 Rotatable tool
..........................................................................................................................
74810.5.1 General information
.................................................................................................................
74810.5.2 Coupled motion of punch and die
............................................................................................
74910.5.3 Tangential control
....................................................................................................................
750
10.6 Protection
zones......................................................................................................................
754
10.7 Supplementary conditions
.......................................................................................................
755
10.8
Examples.................................................................................................................................
75610.8.1 Examples of defined start of nibbling operation
.......................................................................
756
10.9 Data
lists..................................................................................................................................
76110.9.1 Machine data
...........................................................................................................................
76110.9.1.1 General machine data
.............................................................................................................
76110.9.1.2 Channelspecific machine data
...............................................................................................
761
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6FC5397-1BP40-2BA0
10.9.2 Setting data
.............................................................................................................................
76110.9.2.1 Channelspecific setting data
...................................................................................................
76110.9.3 Signals
.....................................................................................................................................
76210.9.3.1 Signals to channel
...................................................................................................................
76210.9.3.2 Signals from channel
...............................................................................................................
76210.9.4 Language commands
..............................................................................................................
762
11 P2: Positioning axes
................................................................................................................................763
11.1 Product brief
............................................................................................................................
763
11.2 Own channel, positioning axis or concurrent positioning
axis ................................................. 76611.2.1
Own channel - only 840D sl
.....................................................................................................
76611.2.2 Positioning axis (posAxis)
........................................................................................................
76711.2.3 Concurrent positioning axis
.....................................................................................................
770
11.3 Motion behavior and interpolation functions
............................................................................
77111.3.1 Path interpolator and axis interpolator
.....................................................................................
77111.3.2 Interpolation response of path axis in G0
................................................................................
77111.3.3 Autonomous singleaxis operations
.........................................................................................
77311.3.4 Autonomous single-axis functions with NC-controlled ESR
.................................................... 779
11.4 Velocity
....................................................................................................................................
781
11.5 Programming
...........................................................................................................................
78211.5.1 General
....................................................................................................................................
78211.5.2 Revolutional feed rate in external programming
......................................................................
785
11.6 Block change
...........................................................................................................................
78611.6.1 Settable block change time
......................................................................................................
78811.6.2 End of motion criterion with block search
................................................................................
793
11.7 Control by the PLC
..................................................................................................................
79411.7.1 Starting concurrent positioning axes from the PLC
.................................................................
79611.7.2 PLC-controlled axes
................................................................................................................
79611.7.3 Control response of PLC-controlled axes
.................................................................