sinumerik

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SINUMERIK The powerful CNC platform for machine tools

Contents

SINUMERIK — a CNC in a class of its own 04 Powerful motors 22

SINUMERIK 828D family 06 Solutions for the control cabinet 26

SINUMERIK 840D sl family 08 SINUMERIK Ctrl-Energy 27

SINUMERIK MDynamics 10 Everything for safety 28

SINUMERIK Operate — the graphical user interface 12 SINUMERIK Integrate 30

Innovative measuring cycles and more 14 SINUMERIK Manufacturing Excellence 31

Complete machining with SINUMERIK CNC 16 More information about service and support 32

SINAMICS S120 drives 18 Technical information overview 34

Always the ideal CNCWith SINUMERIK®, Siemens offers you an integrated and seamless system platform for machine tool automation used in various metalcutting industries and technologies. The SINUMERIK concept: one CNC system, many options — from the CNC through drives and motors up to the complete control cabinet. SINUMERIK is easy-to-operate and offers you innovative functions and technology cycles for even more cost-effective manufacturing. The programming meth-ods always precisely fit your requirements — no matter if you’re machining small or large series, simple or complex parts.

4

In a class of its own — SINUMERIK CNC

SINUMERIK is a standard system platform used to auto-

mate machine tools and offers you cost-effective solu-

tions for every machining technology and industry.

SINUMERIK CNCs are designed to machine simple as well as complex parts in individual and series production across every technology. As a result, the ideal automation solution is available for each and every application. SINUMERIK is used globally in every metalcutting industry and reliably meets your every need when it comes to ruggedness, optimum usability and flexibility, as well as outstanding performance.

The SINUMERIK system platform

The SINUMERIK system platform has different versions to meet the widest range of needs when it comes to equip-ping machine tools — SINUMERIK 828D BASIC T and BASIC M for standard turning and milling machines, the compact SINUMERIK 828D — as well as the premium SINUMERIK 840D sl CNC.

Modularity for the perfect solution

The modular SINUMERIK system offers a high degree of flexibility and openness for every machine application and manufacturing environment. The combination of state-of-the-art operator panel, PCU, a high performance NCU that meets your particular need, our SINAMICS S120 drive as well as innovative motors, offers you plenty of options. Customers can perfectly harmonize and coordinate the components with each another — precisely tailored to the demands of the machine tool builder and the final loca-tion of the machine.

Compact class CNC — SINUMERIK 828D BASIC T and BASIC M

Compact class CNC — SINUMERIK 828D

Premium class CNC — SINUMERIK 840D sl

Applications ■Standard turning and milling machines

■Turning and milling machines ■ Ideal for the widest range of machining technologies

Design ■Compact panel CNC with a horizontal and vertical operator panel layout

■Compact panel CNC with a hori-zontal and vertical operator panel layout ■Available in two performance versions

■Modular, scalable CNC as universal control ■Available in three performance versions

Output ■Up to 5 axes/spindles ■1 machining channel

■Up to 8 axes/spindles ■1 machining channel

■Up to 93 axes/spindles ■Up to 10 machining channels

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6

SINUMERIK 828D — the CNC family for turning and milling machines

The SINUMERIK 828D BASIC T / BASIC M and the SINUMERIK 828D CNCs have been specifically designed for turn-

ing and milling machine applications. In a panel-based CNC system, CNC, PLC, operator control and axis control

for up to six CNC measuring circuits are combined in a very compact unit, which fits into every operator panel

housing. In spite of its compact dimensions, the SINUMERIK 828D family is an absolute powerhouse, which

fulfills every need — CNC functions such as kinematic transformation or powerful tool management are already

integrated.

TM54F

PC/PG

Modem router

SINUMERIK 828DService interface(Ethernet TCP/IP)

PLC I/O interfaceMCP

PP 72/48D PN PP 72/48D 2/2A PN

Handwheel

Mini handheld unit PN/PN coupler

Factory network(Ethernet TCP/IP)

RS232 C

Main spindle motor Servomotor Main spindle motor

NX10(only version T)

SINAMICS S120

DRIVE-CLiQ

GSM/GPRS modemPC

DMC20Encoder systemconnection

PC/PG

Performance and functionality for a diverse range of applications

In the milling version, vertical and horizontal machining centers with up to 6 axes/spindles can be equipped. Thanks to SINUMERIK MDynamics and Advanced Surface, SINUMERIK 828D is also suitable for machining mold workpieces.

The turning version offers up to 8 axes/spindles. This means that single-channel inclined bed lathes can be equipped with a counter-spindle and a Y-axis. As a result of the intelligent technology functions, milling and drilling operations can be performed without restriction at face and peripheral surfaces.

With SINUMERIK 828D BASIC, the 828D-series can also be used for standard turning and milling machines with up to 5 axes/spindles.

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SINUMERIK 828D BASIC / SINUMERIK 828D

•Minimum space requirements

•Complete package — with 8.4“/10.4“ TFT, full QWERTY keyboard, USB, Ethernet, etc.

•Low-maintenance —no hard disk, battery or fan

•80-bit NANOFP technology

•Advanced Surface — intelligent motion control

•SINUMERIK Operate user interface

•Fully graphical CNC and DIN programming

•User-friendly commissioning and expandability

•Text message (SMS)-based process monitoring

•Animated Elements — graphical user support with moving image sequences and context-sensi-tive online help

Compact and user-friendly

Thanks to its small dimensions, the SINUMERIK 828D fam-ily is even suitable for compact operator panel housings. It offers the highest degree of user-friendliness, features either an 8.4“ or 10.4“ color display and comes standard with a full QWERTY keyboard.

Scalability

The SINUMERIK 828D family is available in both a horizon-tal and vertical operator panel layout. With the SINUMERIK 828D BASIC, as well as two performance versions of the SINUMERIK 828D, a wide range of machine performance levels can be precisely addressed.

Rugged

The operator panel front of the SINUMERIK 828D BASIC and SINUMERIK 828D are manufactured from an extremely rugged die-cast magnesium that can stand up to the harshest application conditions. The CNC key-board’s mechanical keys are located behind an embossed foil and are optimally protected against moisture and humidity.

Communicative

SINUMERIK 828D BASIC and SINUMERIK 828D are equipped with state-of-the-art communication interfaces — Compact Flash (CF) card, USB and the service interface are accessible from the front of the operator panel, directly behind the flap, which can be closed even if a Compact Flash card is inserted.

Low maintenance

The SINUMERIK 828D family is especially low maintenance and service friendly — it has no fans and hard disks — parts that are typically prone to wear. Additionally, a bat-tery is not required, and by using NV-RAM memories, buff-ering can be eliminated.

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SINUMERIK 840D sl — the powerful CNC family for the widest range of applications

SINUMERIK 840D sl is a universal and flexible CNC system for up to 93 axes in the same mechanical design as our

SINAMICS S120 drive. It’s a distributed, scalable and open CNC system that can be networked. With a wide range of

functions it is admirably suited for almost any technology – and sets the standard when it comes to dynamic

performance, precision and network integration.

Open and flexible user interface and CNC

An essential feature of the SINUMERIK 840D sl — the dis-tributed system architecture, fully-integrated into the mechanical design and communication structure of SINAMICS S120. Hardware and software can be scaled independently of one another. In conjunction with hubs, the internal drive communication based upon DRIVE-CLiQ significantly reduces machine wiring costs. Additionally, you benefit from an extremely flexible operating concept based upon thin client units. This modularity allows you to implement innovative machines that are perfectly tai-lored to your particular application. SINUMERIK 840D sl is available in various performance versions.

SINUMERIK 840D sl — BASIC

With SINUMERIK 840D sl BASIC — based upon the SINAMICS S120 Combi drive system — SINUMERIK 840D sl facilitates the entry into the modular and flexible pre-mium class for machines with up to six axes. This is a cost-optimized solution for machines that require the exten-sive functionality and the outstanding performance of the SINUMERIK 840D sl.

HT8 handheld unit

SINAMICS S120 and SINUMERIK 840D sl

SINAMICS S120 single axis(es)

SV

Industrial PC PCU 50.3

Industrial Ethernet

PROFIBUS

DRIVE-CLiQ

Servomotor(s)Servomotors Main spindle motor

Expansion, SINUMERIK

NX15

SINAMICS S120 (for high power ratings)

Operator panel front with TCU

9

SINUMERIK 840D sl BASIC / SINUMERIK 840D sl

•For up to 93 axes/spindles in 10 machining channels

•80-bit NANOprecision

•7.5“/10“/12“/15“/19“ TFT operator panel fronts

•SINUMERIK Operate graphical user interface

•Animated Elements — graphical user sup-port based upon moving image sequences and a context-sensitive online help

•SINUMERIK MDynamics — 3 axes/5 axes technology packages

•Several operator panels can be connected to one CNC

•Tool management functions

•SINUMERIK Safety Integrated safety functions

SINUMERIK 840D sl — type 1A

The modular and scalable SINUMERIK 840D sl system plat-form for sophisticated machines, together with the SINAMICS S120 drive platform, provides you with the usual level of performance and the ability to control up to 31 axes.

SINUMERIK 840D sl — type 1B

A new performance class of the SINUMERIK 840D sl with enhanced performance through multi-core technology and a more powerful PLC offers an even higher precision based upon the innovative SINAMICS S120 drive platform, as well as the highest control dynamics for the best sur-face results when machining. With NCU link, it is possible to expand the system to be able to control a maximum of 93 NC axes. Additional special axes can be implemented using the CU 320-2. The optimized HMI and graphical per-formance increases the operating efficiency and the speed for the machine operator when simulating workpieces.

High degree of of versatility

The system platform offers comprehensive options for every machining technology and innovative functions for machine tools. SINUMERIK 840D sl can be used around the world for milling, turning, drilling, grinding, laser machining, nibbling, punching and even on multi-tasking machines. The SINUMERIK 840D sl is the first-choice in machining applications that include mold-and-die, high-speed cut-ting, wood and glass, composites, power generation, medical part manufacturing, handling, transfer lines, rotary cycle machines, large series production and shop-floor environments. The SINUMERIK 840D sl is comprised of the operator panel, PCU, a high-performance NCU based upon your application needs, the SINAMICS S120 drive system and innovative motors. It offers you a wealth of options, which means that you can tailor your machine to match your requirements.

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SINUMERIK MDynamics — made for perfect milling

With SINUMERIK MDynamics, milling technology packages comprised of CNC hardware, intelligent CNC func-

tions and CAD/CAM solutions are available for SINUMERIK controls in the compact and premium classes.

SINUMERIK MDynamics — SINUMERIK 828D compact class CNC for 3 axis/3+2 axis machining

SINUMERIK 828D integrates a technology package for 3-axis milling machines, and can handle every milling and drilling application — and naturally, in any swiveled work-piece planes and on cylindrical workpieces.

SINUMERIK MDynamics — SINUMERIK 840D sl premium class CNC for 3-axis/3+2 axis and 5-axis machining

With the SINUMERIK 840D sl you can select between the two SINUMERIK MDynamics technology packages — one for three axes and the other for five axes. The pack-ages can be expanded by additional functions to precisely meet your machining needs.

Data handling program handling

SINUMERIK 828D compact class CNC for 3 axis-/3+2 axis machining

SINUMERIK 840D sl premium class CNC for 3 axis/3+2 axis as well as 5-axis machining SINAMICS

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Functions in detail

SINUMERIK 828D SINUMERIK 840D sl3 axis/3+2-axis machining 3 axis/3+2-axis machining 5-axis machining

Func

tions

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uded

in th

e pa

ckag

e ■Advanced Surface ■User memory on a user Compact Flash (CF) card

■Advanced Surface ■User memory on a user Compact Flash (CF) card ■Spline interpolation ■Transmit and peripheral surface trans-formation ■Automatic measuring cycles ■3-D simulation- simultaneous recording ■ShopMill/ShopTurn- machining step programming ■Residual material detection

■Advanced Surface ■User memory on a user Compact Flash (CF) card ■Spline interpolation ■Transmit and peripheral surface trans-formation ■Automatic measuring cycles ■3-D simulation-simultaneous recording ■ShopMill/ShopTurn- machining step programming ■Residual material detection ■5-axis machining package ■3-D tool radius compensation ■Measuring kinematics

Opt

iona

l fun

ctio

ns

■Spline interpolation ■Transmit and peripheral surface transformation ■Automatic measuring cycles ■3-D simulation-simultaneous recording ■ShopMill/ShopTurn- machining step programming ■Residual material detection ■Expanded machining functions

■Measuring kinematics ■Volumetric Compensation System (VCS)

■Volumetric Compensation System (VCS)

CAD/CAM/post- processor connection Setup Programming

Technology cycles, automatic measuring cycles

High-Speed Cutting (HSC) functions Advanced Surface HMI functions

SINUMERIK MDynamics

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The SINUMERIK Operate graphical user interface is

transparent and can be intuitively used. This combines

simple usability, functionality and technology for ef-

ficient operator control and programming. In addition,

SINUMERIK Operate allows machining step program-

ming and high-level language programming to be

linked under one system interface. The result — very

fast, rational and intuitive NC programming using a

standard interface for SINUMERIK CNC.

The SINUMERIK Operate user interface

The look-and-feel is the same — whether you’re milling or turning

Intelligent SINUMERIK Operate functions support the operator in the simplest ways during day-to-day work — for example, screenshots using the CTRL+P key combination. The optimum display employing the modern Windows style is user oriented. The new user interface sets a new stan-dard, also when it comes to graphical support. Animated Elements are a helpful function, as they can graphically simulate machining steps in an animated way before the machining step is actually executed. Practical tooltips make operation even more straightforward.

Technology cycles — aligned for every programming type

Circular pockets, thread recesses and deep hole drilling — SINUMERIK offers you a unique range of technology cycles for standard geometries, including an engraving cycle. The allocation to the machine position is realized simply using a wide range of pre-configured position patterns. You also benefit from these for face or peripheral workpiece surfaces being turned or in the swiveled planes for workpieces being milled.

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ShopMill/ShopTurn machine step programming

programGUIDE DIN/ISO G-Code programming with cycle support

SINUMERIK Operate offers unique programming meth-

ods for every application. These include the ShopMill/

ShopTurn machining step programming, as well as

programGUIDE, the SINUMERIK high-level program-

ming language. Innovative technology cycles are

also available.

Programming the way you like it

Machining step programming with ShopMill and ShopTurn

In addition to programGUIDE, ShopMill and ShopTurn offer you unique machining step programming for the shortest programming times. This makes it the perfect answer for the individual and small batch production.

■Machining steps are clearly shown without requiring any knowledge about G-code ■Technology functions with geometrical elements can be simply cascaded ■The workpiece is dynamically displayed during programming ■Graphical machining step editor and geometry computer to simply enter the workplace contours ■Powerful 3D CNC simulation

SINUMERIK high-level language with programGUIDE — CNC programming for the highest degree of productivity

SINUMERIK programGUIDE high-level language stands for DIN/ISO G-code program-ming with new cycle support — and is perfect for average and large batch produc-tion. This means that programGUIDE offers the maximum degree of flexibility, short machining times and the highest productivity.

■programGUIDE with graphical cycle support screens including tooltip and Animated Elements ■CNC language with high-level programming instructions and ASCII editor ■Dynamic dotted line graphics for cycle masks ■Wide selection of standard drilling, milling and turning cycles ■Contour computer including cycles for contour milling and residual material detection ■Powerful 3D CNC simulation ■Online ISO dialect interpreter available

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Innovative measuring cycles and workpiece simulation

SINUMERIK provides you with graphical support

when measuring workpieces, tools and the kinemat-

ics during the process — with a competitive range of

practical cycles. Five-axis workpiece simulation of our

system platform offers you a higher degree of safety

and reliability and checks options during workpiece

programming.

Innovative measuring cycles for workpiece and tool management in automatic mode

Using automatic measurements at the machine, SINUMERIK measuring cycles guarantee the quality of the machined parts:

■Powerful cycles to automatically measure workpieces and tools ■Automatic measuring cycle in programGUIDE and ShopMill/ShopTurn ■ Input screen forms with graphical support and automatic logging of the measurement results

SINUMERIK measuring cycles are also available in the SINUMERIK Operate style, with Animated Elements in different programming types, such as programGUIDE or ShopMill.

Innovative measuring cycles with kinematic measuring function — CYCLE996 (for SINUMERIK 840D sl)

CYCLE996 — measure kinematics was developed to mea-sure multi-axis kinematics. It is easy-to-use and does not require any additional measuring equipment. Probing with the calibration ball uses a 3D probe and the “Measure kinematics” cycle in three ball positions. The cycle can be directly called from the NC program. When compared to conventional measurements, CYCLE996 offers significant time savings with outstanding measurement accuracy.

CNC simulation — workpiece simulation for multi-side machining

The 3D simulation with a three-level view and volume model of the machined part — including simultaneous recording in automatic mode — also ensures a higher degree of security. The blank can be entered and simulation speed can be regu-lated using softkeys. SINUMERIK 840D sl offers help and security during program-ming and simultaneously during five-axis machining. Pro-gramming can be immediately checked using the wide range of different workpiece views during simulation. You can zoom in and out — cuts can be placed on the swiveled planes even during five-axis simultaneous machining.

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Efficient operation thanks to Animated Elements and state-of-the-art tool and program management

Parameters that are entered into the CNC control on a

daily basis result in machine motion. Using static help

screens, they can only be displayed with some restric-

tions. Animated Elements offers you a completely new

level of convenience when entering data. They com-

pletely redefine the term graphic programming and

operation – thanks to a unique display with moving

image sequences. The clear and transparent tool and

program management also provides support.

Reliable setup and programming

How can a workpieces zero-point be determined using a circular spigot? In which sequence must the probe be positioned and how does the CNC retract the probe? Ani-mated Elements makes this quite easy — a short moving image sequence shows you the probing procedure, and you can also see a motion sequence as an example. For instance, helical plunging into a milled pocket or when making the distinction between chip removal and chip breaking during deep-hole drilling. In this instance, a static help screen would only provide a multitude of arrows that are difficult to interpret.

Tool and program management made easy

SINUMERIK CNC offers state-of-the-art transparent tool and program management functionality. The tool list has a configurable display and can be intuitively operated and displayed using context-sensitive functions and self-explanatory symbols — for efficient management of tool data. Using innovative program management, workpiece sub-directories can be created on local drives and external storage media can be accessed. Users benefit as they can quickly check the program, have convenient data transfer and can easily handle programming.

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Complex workpieces require cost-effective production techniques and innovative CNC solutions. SINUMERIK

CNCs support multi-tasking machines when machining workpieces in one operation. SINUMERIK has all of the

functions to manufacture parts on a machining center — also when changing between different technologies.

The SINUMERIK Operate graphical user interface offers integrated turning functions for milling, milling functions

for turning, and supports all of the usual kinematics and multi-tools for even more cost-effective production.

Cost-effective machining of complex workpieces on multi-tasking machines

Simple operation of multi-tasking machines

As a standard, SINUMERIK has innovative functions to operate multi-task-ing machines, such as mill-turning turn-milling machines, which makes part manufacturing easier and more cost-effective in just one machining operation. The SINUMERIK Operate graphical user interface offers integrated turning functionality for milling, and integrated milling functionality for turning; this is complemented by innovative measuring cycles in the Animated Elements design. The usability and look-and-feel are completely identical, even when switching between different technologies. Tool management facilitates simple handling of every tool, as well as multi-tools in a stan-dard user interface. Programming in programGUIDE has been supple-mented by functions such as the aligning and positioning of turning and milling tools, as well as turning and milling cycles — including contour programming. It’s now possible to simulate multi-tasking programs, lead-ing to an even higher machining efficiency.

User-friendly solution for multi-channel machines

A display for several channels is included in the wide range of functions to achieve simple operability. When milling, via a second channel, handling modules or tool changes can be controlled and displayed, for example. This offers you an even higher degree of flexibility and cost-efficiency dur-ing production.

Using the programSYNC option, multi-channel machining operations can be simply and efficiently synchronized. When using simulation in conjunc-tion with SINUMERIK 840D sl, multi-channel machining can also be visual-ized in an excellent way. As a result, multi-channel machining operations can be programmed even more efficiently —

■Create the structure of the part programs ■Fill the individual machining steps (blocks) ■Simulate part programs ■Run-in part programs (either channel by channel or spindle by spindle) ■New block building function — programSYNC including the option of forming blocks.

17

Efficient tool management

For efficient tool data management, including all of the details, SINUMERIK Operate has extended the tool management function for milling, drilling and turning tools. Tool and magazine data are shown on a screen with all of the associated details. All of the tool parameters are available — also for combined technologies. All tool types including turning tools are displayed using clear and transparent symbols. In addition, complex tools, which make tool changing superfluous and facilitate higher productivity during production, are supported by SINUMERIK CNC for use in multi-tasking machines.

Maximum productivity and flexibility in programming

With programGUIDE and ShopMill/ShopTurn, SINUMERIK Operate has inno-vative functions for complex workpiece programming and offers maximum productivity and flexibility thanks to innovative technology cycles.

Innovative functions for programming complex workpieces using programGUIDE

Kinematic cycle Alignment of the turning and milling tool and swiveling of the coordinate system for turning or milling.

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SINAMICS S120 — the flexible, modular drive system for demanding tasks

With SINAMICS S120, we offer you the perfect solution platform for high-performance applications in industrial

machine and plant construction — a modular system that permits the highest degree of flexibility. An entire

foundation of components and functions that are coordinated with one another to allow tailored solutions to be

implemented, to individually address the particular application area. The modular SINAMICS system is the opti-

mum platform to implement individual solutions.

Design Blocksize Combi Booksize Chassis

Drive type AC/AC device, single-axis

AC/AC device, multi-axis

Modular DC/AC system, multi-axis

Power ranges 0.37 … 90 kW (0.5 … 120 HP)

16 ... 20 kW (22 … 30 HP)

1.6 … 107 kW (2 … 145 HP)

110 … 250 kW (150 … 338 HP)

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High productivity and modularity

SINAMICS S120 for the coordinated motion control of your machine — high performance multi-axis configura-tions with modular multi-axis or independent single-axis modules. The modular system covers the power range extending from 0.12 all the way up to 300 kW. In conjunc-tion with SINUMERIK CNC, the SINAMICS S120 is the per-fect basis for modular plant and machine concepts in the power range up to 250 kW. Engineering costs are signifi-cantly reduced using standard and integrated engineering tools.

The new SINAMICS S120 Combi — a drive class all by itself

SINAMICS S120 Combi offers the usual SINAMICS func-tionality in an integrated drive concept, tailored for com-pact turning and milling machines. Sporting a multitude of technical highlights, SINAMICS S120 Combi sets new standards in this class of drives.

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SINAMICS S120 drives — fast and precise in every application

SINAMICS S120 booksize drives

offer you optimum cooling solu-

tions in three cooling types —

Reliable

Numerous intelligent protection functions of the SINAMICS S120 guarantee optimum system availability. All power modules are short-circuit, ground fault and over-voltage-proof. An intelligent combination of sensors and algorithms monitors the temperature of the power units, therefore avoiding thermal overload.

Compact and transparent

As a result of its compact design, SINAMICS S120 can be installed in the smallest control cabinets. All connections are easy to access, thereby reducing installation costs. Data and power cables are strictly separated. Using DRIVE-CLiQ, CNC, drives and motors communicate with one and the same data protocol. As a result, you can network all of the components with just one cable type.

Automatic configuration

With DRIVE-CLiQ, SINAMICS S120 has an optimum data highway. The components of the SINAMICS S120 drive control integrated in the SINUMERIK CNC are automati-cally identified using the electronic type plates — for fast and reliable commissioning. SINAMICS automatically iden-tifies the drive configuration when drive components are subsequently added — plug-and-play as it should be.

Highest dynamic performance

With DSC (Dynamic Servo Control) SINAMICS S120 offers a unique closed-loop position control technique to facilitate the highest dynamic performance of the spindle and feed motors. An adaptive current controller helps to optimally utilize the performance of the motors. The productivity of your machine is significantly increased thanks to the acceleration values that can be attained. The SINAMICS S120 Active Line Modules keep the DC link voltage abso-lutely constant — even when line voltage fluctuates. The acceleration time of the spindle can therefore be signifi-cantly reduced, further increasing the productivity of your machine.

External air cooling

20–30%

70–80%

Internal air cooling

100%

Cold Plate cooling

70–80%20–30%

Water or convection

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Perfect surface quality

SINAMICS S120 facilitates a perfect workpiece quality. Natural resonance points of the machine can be almost completely suppressed using the intelligent filter func-tions in the closed-loop control. Teamed up with the high accuracy three-phase current actual value sensing, allows you to achieve perfect workpiece surfaces. A high-resolu-tion position actual value sensing in the nanometer range ensures high precision contour machining — thus guaran-teeing absolutely smooth workpiece surfaces.

Flexible connection to the line supply

SINAMICS S120 is designed for connection to line supplies in the range from 380 V up to 480 V, therefore covering as standard 70 percent of the voltage levels used worldwide.

Energy efficiency

Using the multi-axis concept and energy recovery based on Smart Line and Active Line modules, SINAMICS S120 reduces the energy usage. Up to the full regenerative power, no unnecessary heat is generated in the control cabinet. With the intelligent compensation of capacitive

and inductive reactive currents, SINAMICS S120 monitors that neither unnecessary energy losses occur in the line supply nor current harmonics. This not only prevents other loads from being negatively influenced, but further reduces the heat generated in the control cabinets.

Optimum cooling solutions for the power electronics

Booksize format power modules are available in three cooling types —

■ Internal air cooling — the power loss of the power unit is dissipated in the control cabinet. ■External cooling — the power loss of the power unit is cooled using a heat sink that extends through the mounting plate — in a separate cooling chamber or outside the cabinet. ■Cold plate cooling — the power loss of the power unit is dissipated to an external liquid heat sink via a thermal interface at the rear of the module.

Type range according to dimension

1.3 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250

Single-axis drives in the blocksize format

Internal air cooling 1.3 A up to 178 A

A=

3 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250

Motor modules in the booksize format

Internal, external air cooling and Cold Plate cooling 3 A up to 200 A

A=

130 140 150 160 170 180 190 200 210 230 250 270 290 310 330 350 370 390 410 430 450 470 490

Motor modules in the chassis format

Internal air cooling 210 A to 490 A

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Powerful motors for each and every application

Whether high standstill torques or rated powers, high maximum speeds or dynamic performance, air- or water-

cooling — our extensive portfolio of motors offers you the optimum type for every drive application over a wide

power range. These include synchronous and induction servomotors, as well as highly innovative linear and

rotary direct drives.

1FK7 servomotors for standard applications

Our 1FK7 motors can be universally used in a high degree of protection with their extended torque range of up to 150 Nm and cover a wide variety of machining applica-tions. They have stall torques that lie between 0.18 and 48 Nm and rated speeds of between 2000 and 6000 rpm. Three motor versions that offer the best torque to rotor moment of inertia ratio are available.

■1FK7 High Dynamic — with its extremely low rotor mo-ment of inertia — is capable of extremely high accelera-tion rates. ■1FK7 Compact — addresses a wide spectrum of ap-plications as a result of its well-balanced ratio between torque and intrinsic moment of inertia. ■1FK7 High Inertia — has rugged control properties even with high and variable load moments of inertia.

1FT7 servomotors — for high-performance applica-tions with 400 percent overload capability and high encoder resolutions up to 24-bits

With their outstanding smooth running properties, we recommend our new 1FT7 synchronous servomotors for demanding applications involving state-of-the-art machine tool construction. The motors are available with either air- or water-cooling. They cover rated speeds extending from 1500 up to 6000 rpm — and stall torques from 2 up to 125 Nm — are very compact and equipped with a newly developed encoder coupling. This protects the encoder to a high degree from surge loads. 1FT7 motors have a crossover profile that permits simple instal-lation, and now also from the rear. They also sport a con-nector that can be rotated with a quick release mecha-nism that simplifies connection for faster installation and reduced service times.

1FK7 HI 1FT7

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Direct drives for the highest precision and dynamic performance

1FN3/1FN6 linear motors

The essential advantage of linear direct drives — effects involving elasticity, play and friction are almost com-pletely avoided, as well as natural oscillations in the drive train. This allows the highest degree of dynamic perfor-mance and precision to be achieved in motion control applications. Teamed up with the SINAMICS S120 drive system, we can offer you an optimum drive system to address every requirement of the machine tool industry. Our 1FN3 and 1FN6 linear motors set themselves apart as a result of the highest traversing velocity of up to 800 m/min, extreme dynamic performance and outstanding preci-sion. 1FN3 motors have an IP65 degree of protection and permit maximum forces of up to 20,700 N. 1FN6 motors have degrees of protection IP23 up to IP65 and maximum forces up to 8000 N. Neither of the series has mechanical transmission elements such as ballscrews or belts.

1FW6 torque motors

Our torque motors are perfectly suited for rotary axes with extremely high torques, and they can be directly integrated into the machine. They run with the highest precision and dynamic performance, as elasticity and play in the drive train are avoided and the total mass and fric-tional forces can be minimized. Additionally, they set themselves apart due to their high availability as they have no mechanical transmission elements that can wear. Yet another advantage — their compact design and the low number of components mean that they take up a minimum amount of space. 1FW6 torque motors are the first choice for use in rotary cyclic machines, rotary tables, swivel and rotary axes, revolver and drum indexing units, dynamic tool magazines and spindles in milling machines. These torque motors have torques up to 10,900 Nm.

1FN3 1FW6

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Powerful motors for machine tool applications

Whether belt drive, hollow shaft motor, built-in motor

or integrated motor spindle — the main spindles of

turning, milling and grinding machines can be driven

in a wide variety of ways. The main spindle drive

represents an essential component of your machine’s

productivity, machining performance, production pre-

cision and machine availability.

Optional sensor module with DRIVE-CLiQ for WEISS spindles

It’s easy to connect WEISS spindles to the SINAMICS drive and SINUMERIK CNC — the Weiss spindle DRIVE-CLiQ is a new sensor module that enormously reduces cabling costs and simplifies and accelerates machine commissioning. This means that the rotary encoder signals, analog clamp-ing state, digital piston position interrogation as well as the motor temperature can now be simply transferred from the spindle to SINAMICS and SINUMERIK.

SINUMERIK option — integrated spindle monitor to supplement the WEISS spindle DRIVE-CLiQ

Using this option, machine users can quickly an easily call up information about the spindle state on the HMI using various screen forms. The integrated spindle monitor responds to questions regarding operating time, load with reference to power, torque and speed, the number of tool changes and the actual tool clamping state.

The dynamic powerhouse for main drives 1PH8 — motor range

The 1PH8 is a compact series of induction motors with power ratings up to 300 kW and squirrel-cage rotors in IP55/IP65. This series expands the power range of the well-proven 1PH/1PM series, and offers the optimum ver-sion for every application. The motors are available with forced-ventilation or water-cooling, with solid or hollow shaft, as well as a wide range of bearing designs and vari-ous encoder types for closed-loop speed control and high-precision positioning. Additional features of this motor type include outstanding power and vibration quality, concentricityupto10μm,highdynamicperformance(short acceleration times), maximum speeds up to 20,000 rpm. Water-cooled 1PH8 motors especially come into their own where extreme ambient conditions prevail, such as high temperatures, dust, dirt or aggressive atmospheres, which rule out air-cooling. The same is true in processes, in which the environment cannot tolerate any negative thermal effects.

1PH8

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Built-in induction motors 1PH2 motors for direct drives

1PH2 built-in motors are liquid-cooled three-phase induc-tion motors. They are used if, as a result of the compact design, the motor must be integrated into the machine. The workpiece is machined with the highest degree of precision without the effect of transverse drive forces as a result of the smooth and precise spindle operation. These motors have power ratings of between 7.5 and 30.9 kW.

Synchronous built-in motors Main spindle synchronous motors — highly-dynamic performance and extremely compact

1FE1 built-in motors are compact, water-cooled synchro-nous motors that are supplied as components — the sta-tor and the rotor. They have maximum speeds of up to 40,000 rpm and power ratings up to 104 kW (S1 duty). They are available in the two main versions — high-torque and high-speed. Permanent-magnet motor spindles (PE spindles) increase the power density and cost-efficiency of CNC machines. They are used wherever the shortest accel-eration times are demanded, but also the highest require-ments relating to machining quality, precision and smooth running operation.

Motor spindles with a high control dynamic performance

The advantages of motor spindles include stiff, compact design, the highest power density, as well as lower total weight and frictional forces. They can be deployed with-out using additional mechanical transmission elements, such as belts and gearboxes. This permits the shortest machining times and a high con-trol dynamic performance. They facilitate a high produc-tion precision as the spindle position and speed are directly acquired. Our portfolio has the following series —

■Standard motor spindles for milling machines — for use in vertical and horizontal machine designs ■Motor spindles for milling, drilling, turning and grinding ■Motor spindles that we have specifically developed according to individual customer specifications

Hybrid spindle

This newly-developed motor spindle that is suitable for speeds up to 24,000 rpm. It can replace or supplement indirect spindle drive solutions in vertical machining cen-ters. Its innovative design allows the productivity and machining quality of these machines to be increased.

1PH2 1FE1 2SP1 Hybrid spindle

26

Solutions for the control cabinet

Today, state-of-the-art automation is hardly con-

ceivable without flexible, distributed solutions —

solutions that are tailored to your specific demands

and result in significant cost-savings. In addition

to cost-effective CNC and drive systems, Siemens

also offers the complete range of services for cabinet

building. These range from support and development,

through building of the equipment, up to supply and

support during the commissioning phase.

Competent control cabinet building

Our control cabinets are built to a high level of industrial quality in Chemnitz, Germany. Services offered include the checking of collision and free space in 3D design lay-outs, as well as automated checks and testing. When required, our customers can obtain complete modules, including switching devices, cable harnesses, pneumatic and hydraulic components. They are supported by order centers and production teams that are assigned to specific customers. The highest degree of flexibility is secured by employing customer-specific logistic modules, flexible production capacities and production areas, as well as change management in every process phase.

Experienced in engineering

We provide our customers with consulting services regard-ing the designing and dimensioning of equipment in com-pliance with the relevant standards for drive technology, control systems, operational control and safety. We engi-neer, carry-out design-to-cost projects — and where required, changeover customer documentation to UL or other technologies. Additionally, we provide support when selecting and optimizing suitable cabinet climate control systems. In addition to calculations and simulation routines, we also carry-out checks by making measure-ments in our own heat laboratory with load simulation.

Our recommendation — control cabinet certification

As your partner, we recommend that you certify your con-trol cabinets. This is for quality assurance reasons — and to secure the productivity of your machine or system. Additional advantages for you include repair and service contracts, minimized production downtimes, as well as reduced spare part requirements. We can certify individual control cabinets and standard control cabinets — no mat-ter if the control cabinets are built in our factory or at your facility.

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With a wide range of drive and motor components, CNC and drive functions, PC software solutions, as well as SINUMERIK Manufacturing Excellence services, SINUMERIK Ctrl-Energy sets new standards for the energy efficiency of machine tools.

Ctrl-E Energy analysisUsing the Energy Analysis function, the CNC not only acquires the energy usage of the drive system, but of the entire machine. This allows machine users to analyze their energy usage for each workpiece, and if required, to opti-mize the machining strategy. Operators can visualize the energy consumption by simply pressing the Ctrl + E shortcut key.

Ctrl-E profileCtrl-E Efficient standby provides machine tool builders a configuring platform to control the energy-saving modes of the machine. This means that loads can be specifically shutdown when the machine is at a standstill. The opera-tor can very quickly and simply influence the energy-sav-ing modes using the Ctrl + E shortcut key.

SINUMERIK Ctrl-Energy — Energy savings through the simple touch of a button

As a CNC technology leader, we provide powerful and

technically-sophisticated functions to increase the

energy efficiency of your machine. To supplement the

functions that can be called from the graphical user

interface, SINUMERIK Ctrl-Energy offers an extensive

portfolio of energy-efficient systems, solutions and

services. Drive and motor components

CNC and drive functions

PC software solutions

SINUMERIK Manufacturing Excellence

services

SINUMERIK Ctrl-Energy

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It’s safe to say more safety

If it involves the safety of man and machine, then

SINUMERIK makes no compromises. Safety Integrated

is a comprehensive safety package to protect people

and machines. However, your data is also reliably

protected by employing increased NC hardware and

software security.

Well-conceived safety concept

By using Safety Integrated, your machine can be safely and practically operated under all of the required operat-ing conditions — for example during setup and test modes with the protective door open. Safety functions fulfill the requirements according to Safety Integrity Level SIL 2 of IEC 61508 and according to Performance Level PL d in compliance with EN ISO 13849. As a result, all of the main requirements specified in the EC Machinery Directive can be simply and cost-effectively implemented —

■Functions to safely monitor velocity and standstill ■Functions to safely segregate working zones and pro-tected areas and for area identification* ■All of the safety-relevant signals can be directly con-nected via PROFIBUS with the PROFIsafe protocol and logically combined internally*

* for SINUMERIK 840D sl

Reliable data protection

Your data is also permanently protected: The complete security of NC hardware and software guarantees protec-tion and long-term stability in your manufacturing envi-ronment. The “hardened” PC controller hardware (PCU) is based upon a type-tested, standard IT security configura-tion. At an early stage, intelligent components, especially control systems, are subject to simulated attacks, and a weak point analysis is performed to test the system design and identify possible IT security gaps. The result — Windows XP-based PCUs, configured as type-tested high-security workstation. SINUMERIK offers reliable protection by using the latest virus scanners and an activated and optimally configured firewall.

Immune to attacks

The “hardened” NC software of SINUMERIK 840D sl is based on embedded LINUX. The operating system of the NCUs in SINUMERIK has been immunized using the hard-ening process — for complete protection against malware — which can damage Windows systems. Additionally, a firewall in the system kernel with optimized and pre-con-figured package filters, so that the CNC can be used as a firewall to protect all of the communication networks behind it.

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Intelligent fire protection solutions with Sinorix al-deco PLUS

Safe machine operation

With Sinorix al-deco PLUS, fire detection and extinguish-ing are realized completely pneumatically — without any electric power supply and independent of the machine. As a result, Sinorix al-deco PLUS is insensitive to technical disturbances and does not respond incorrectly. This secures continuous machine operation and reduces over-all maintenance costs — no special maintenance work is required in order to keep high operational safety.

Unique personal protection

Sinorix al-deco PLUS fire extiguishing systems for equipment correspond to the highest safety requirements in-line with the latest Machinery Directive 2006/42/EC. This is achieved using lines and pipes that are protected twice in conjunction with redundant and self-monitoring components. This tech-nology means that a machine can only be operated after a positive system check — and only releases the machine door after fire extinguishing has been inhibited and checked.

Reliable environmental protection

The fire extinguishing agent used by Sinorix al-deco PLUS is a pure natural gas, therefore not electrically conductive and chemically inert. This means that no harmful reaction prod-ucts are released when it comes into contact with fire and it is environmentally-friendly.

Sinorix al-deco PLUS — your advantages at a glance

•Highest degree of safety for man, machine and the environment

•Unique personal protection complying with the latest Machinery Directive

•VdS-certified valves and self-monitoring components are used

•Insensitive to technical disturbances

•Online monitoring for fast intervention

•All of the system data are recorded as a safety-relevant verification

•Redundant monitoring of all safety- relevant functions

•Efficiency based on well-proven control standards

European legislation specifies fire protection for machine tools and their associated equipment that represent a

fire risk. Using Sinorix™ al-deco PLUS, we offer an intelligent fire extinguishing system that provides the high-

est degree of safety for man, machine and the environment — over the complete lifecycle of the machine. Here,

safety-related components for personal protection are employed with which Sinorix al-deco PLUS fulfills the high

requirements of EU legislation. You can find additional information online: www.siemens.com/sinorix

SINUMERIK Integrate — integrating the CNC into your company processes

30

From development and procurement up to production and sales — integrating machine and production data

into the workflow is becoming increasingly more important. Integrating the machine tool into your company

processes is an essential pre-requisite to achieve lean and efficient production. SINUMERIK® Integrate has six

modules that provide a comprehensive portfolio for the integration of machine tools into communication, engi-

neering and manufacturing processes within the machining environment.

Production

Integration into SINUMERIK

Machine development Customizing

Know-how protection

Integration into production

Communication Production and logistics

Service and maintenance

SINUMERIK Integrate

Engineering

Create-it!

Analyze-it!

■Generating and adapting inter-faces in SINUMERIK Operate ■Generating your own compile cycles within the framework of Open Architecture

■Functions for condition-based maintenance ■Analytical functions based upon key parameters

Access-it!

Lock-it!

■Know-how protection for SINUMERIK

■Programming interfaces to the machine tool and the server ■Remote access to the machine for diagnostics

Manage-it!

Run-it!

■Runtimes to run individual screen user interfaces with SINUMERIK within the frame-work of Open Architecture ■Running your own compile cycles on the NC kernel and the drives as well as the virtual NC kernel (VNCK)

■Organization and management of NC programs and tools

31

Advantages for the machine tool builder —

•Shorter machine development times

•Cost-optimized machine development

•Improved machine service

•Machines with optimum dynamic performance

•Opens up new potential for offering services

•Lower warranty costs

Advantages for the machine tool end-user —

•Lower workpiece machining costs

•Optimized processes

•Improved productivity and availability

•Optimized quality

SINUMERIK Manufacturing Excellence — our portfolio of services for machines and processes

Machine Development•Simulation and commissioning

of machines•Shortens machine

development times

Manufacturing IT•Functions for planning and carry-

ing out production•Optimizes processes and increases

transparency in the machine environment

Condition Monitoring•Functions for condition-based

maintenance•Reduces machine downtimes

Extended Machine Contracts•Lump-sum contracts for personnel

and materials with agreed upon response times

•Secures the availability of machines and systems

Productivity Improvement•Optimization of machine processes•Reduces cycle times and improves

the quality

Machine Retrofit•Modernization of the automation

and mechanical system•Extends the machine service life

Service & Support•Comprehensive service, e.g.

replacement parts and on-site service

•Secures a high availability of machines and systems

If you want to optimize your production, then you must

evaluate your machines as a whole. Only then can the

optimum package of measures take effect in every phase

of the lifecycle. SINUMERIK® Manufacturing Excellence

provides you with the needed support, with a combina-

tion of products, solutions and services. Corresponding to

the individual requirements of machines and processes,

selected modules from this package of services are used,

which when required, can also be specifically adapted.

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Machine tool service and support

Whether you require a service technician, expert advice or even a spare part — during the complete lifecycle of

your machine or system, we can offer you the support you need. One of the main pillars to guaranteeing high

machine and system availability is through the range of services we provide through our local service organiza-

tion, including spare parts and repair. Our field service technicians can even offer you services for the commis-

sioning and maintenance of your machines. Just ask.

During production, you'll also benefit from —

■Spare parts supply ■Replacement and repair of components ■Component checking/diagnostics ■Component upgrade service ■General overhaul of components

Ask your regional service person about all of the services we can provide.

Service and support — your advantages at a glance:

■Can be reached 24/7 — 365 days a year ■Specialists are there for you locally around the world ■Highly-available spare parts ■Favorably-priced replacement parts

Service and support — your advantages at a glance:

Europe: Germany +49 180 5050 222 America: USA +1 847 640 1595 Asia: China +86 1064 719 990

www.siemens.com/automation/service&support

Even more information about SINUMERIK

We can offer you more than just first-class products within the framework of our SINUMERIK system platform

and systems for the widest range of requirements. We can comprehensively and expertly support you

in every tasks when it comes to machine tools.

33

Global technology competence — Technology and Application Centers

Our Technology and Application Centers (TAC) are impor-tant information platforms and meeting points for machine tool builders and end-users. Here, we have the opportunity to demonstrate our systems, solutions and services through training classes and events. Find more information online: www.siemens.com/cnc4you.

Duplicate headline as the one below!

With SinuTrain, we offer you PC-based training for the SINUMERIK CNC. In addition to the classic courses and seminars, we online learning modules, learning software and technical books. In-line with what is required in the real world and perfectly tailored to the various training levels, we offer everything for your learning success — from basic training, to programming and operation, up to full training classes for machine tool professionals. Find more information online: www.siemens.com/sinutrain.

Documentation just a mouse click away

Using our DOConWEB service, you can research our docu-mentation online — with full text search and index search through the list of contents. Additionally, you can compile your own individual documentation quickly and easily to meet your needs. Find more information online: www.siemens.com/automation/doconweb.

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Technical information overview828D 840D sl

ConfigurationMechanical design Panel DriveAxes / spindles / NCU link, up to 6(M), 8(T) 31 / 93Channels up to 1 10Mode groups up to 1 10CNC user memory up to 5 MB 15 MbyteUser memory on the PCU 50.3 hard disk – 12 GbyteOperating componentsOperator panel fronts, TFT display 10“ 7.5“/10“/12“/15“/19“Operator panel fronts, TFT display, touch – 15“Machine control panels / handheld terminals / handwheels / / / / Axis functionsAcceleration with jerk limitationTravel to end stop / with Force Control / / Spindle functionsVarious thread cutting functionsOriented spindle stopFlying axis synchronizationInterpolation80-bit NANOFP technology (floating point accuracy)Interpolating axes, up to 4 20Universal interpolator NURBS (non-uniform rational B-splines)Three-axis compressor / five-axis compressor / – / Spline interpolationAdvanced SurfaceCouplingsFollowing axesInclined axisSynchronous spindle / multi-edge (CP basic / static) *

Synchronous axis pair (gantry axes) Leading value coupling / curve table interpolation / electronic gear (without code tables / CP Basic / Comfort / Expert) –

Electronic gear (with curve tables / CP Expert) –TransformationsTransmit and peripheral surface transformation (e.g. parallel slot wall)Transformation for machine-specific kinematics –Measuring functions / measuring cyclesMeasuring during setupMeasuring cycles / logging measuring results / / Synchronous motion actionsAsynchronous sub-routinesSynchronous actions and fast help function output including three synchronous functionsPositioning axes and spindles using synchronous actions

Standard (basic scope) CNC option – not available * not available in all versions

35 Standard (basic scope) CNC option – not available * not available in all versions

828D 840D slProgrammingProgramming language (DIN 66025 and high-level language expansion)Online ISO dialect interpreterTechnology cycles for drilling / milling and turningProgramming support for geometry and cycles (programGUIDE)Programming support with “Animated Elements”"Manual Machine / machining step programming ShopMill / ShopTurn – / – / SimulationSimulation for turning and milling in a surface representationSimulation in 3-D view Simultaneous recording (real-time simulation of the current machining) ToolsTool management / tool monitoring / / Tool management functions (TDI) –Communication / data managementData storage Compact Flash card / USB device / / Manage network drives (Ethernet) Data storage on the PCU hard drive –Operator controlExpanded operating functions for complex turning and milling operationsSeveral operator panels connected to a CNC –CompensationTemperature compensationSag compensation Compensation in space (VCS plus) –Oscillation suppression (Vibration Extinction VIBX) –Open ArchitectureSimple configuration of user screens / Easy Screen (Run MyScreens) / /

Integrating screens, software and technological know-how (Create MyHMI) –

PLCIntegrated SIMATIC PLC S7-200 S7-300Maximum PLC memory in Kbyte / operations – / 24,000 1536 / –Processing time, typical in ms / kilo operations 0.02 0.03Distributed peripherals (I/O) via PROFIBUS DP / PROFINET – / – / Safety functionsSafety Integrated (Safe Torque Off, Safe Brake Control, Safe Stop 1)SINUMERIK Safety Integrated –Commission functionsAuto Servo Tuning (AST) / Automatic speed and position controller optimizationDiagnostic functionsAlarms and messagesRemote diagnostics

Siemens AG Industry Sector Motion Control Systems P.O. Box 31 80 91050 ERLANGEN GERMANY

The information in this brochure only provides a general description and performance features. For a specific appli-cation, this information will not always be applicable in the form described here. The required performance features are only binding if they have been expressly agreed upon in the form of a written contract. All product designations could be trademarks or product names of Siemens AG or other companies, which, if used by third parties, could infringe the rights of their owners.

Everything you ever wanted to know about SINUMERIK CNC: www.siemens.com/sinumerik Everything about shopfloor manufacturing: www.siemens.com/cnc4you Everything about the SINUMERIK Manufacturing Excellence portfolio of services: www.siemens.com/sinumerik/manufacturing-excellence Information about CNC training: www.siemens.com/sinumerik/training

Subject to change without prior notice Order No.: E20001-A1490-P610-X-7600 Dispo 06311 WÜ/37269 STAN.52.2.01 WS 11113.0 Printed in Germany © Siemens AG 2011