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Surface grinding

SINUMERIK
SINUMERIK 802D sl
Surface grinding
Programming and Operating Manual
Valid for
Controller
SINUMERIK 802D sl G/N
11/2012
6FC5398-5CP10-3BA0

Software release
1.4 SP7
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Turning on, reference point
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approach
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Part programming
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System
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Cycles
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Programming
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Appendix
1
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3
4
5
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8
9
10
11
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A

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   Summary of Contents for Siemens SINUMERIK 802D sl

  • Page 1 Programming and Operating Manual ___________________ Automatic mode ___________________ Part programming ___________________ System ___________________ Cycles ___________________ Programming ___________________ Network operation ___________________ Data Backup ___________________ PLC diagnostics ___________________ Appendix Valid for Controller Software release SINUMERIK 802D sl G/N 1.4 SP7 11/2012 6FC5398-5CP10-3BA0...
  • Page 2 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
  • Page 3: Preface

    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 FAQs You can find Frequently Asked Questions in the Service&Support pages under Product Support.
  • Page 4 The EC Declaration of Conformity for the EMC Directive can be found on the Internet at: http://support.automation.siemens.com Here, enter the number 15257461 as the search term or contact your local Siemens office. Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 5: Table Of Contents

    Table of contents Preface ..............................3 Description............................... 11 Control and display elements.......................11 Error and status displays ......................12 Key definition of the full CNC keyboard (vertical format).............13 Key definition of the machine control panel .................15 Coordinate systems ........................16 Software user interface..........................21 Screen layout ..........................21 Operating areas ...........................25 The help system...........................26...
  • Page 6: Table Of Contents

    Table of contents Selection and start of a part program..................73 Block search..........................74 Simultaneous recording ......................77 Stop / cancel a part program....................... 80 Reapproach after cancellation ....................80 Repositioning after interruption ....................81 Execute from external ......................... 81 Part programming ............................
  • Page 7: Table Of Contents

    Table of contents 9.3.2.2 Error handling within cycles .......................159 9.3.3 Cycle call and parameter list......................160 Zyklenunterstützung im Programmeditor...................163 Z positioning with grinding wheel - CYCLE406................164 Safety position - CYCLE407 ......................167 3-stage plunge cut oscillation (roughing, finishing and fine-finishing) - CYCLE408 ....168 3-stage surface grinding (roughing, finishing and fine-finishing) - CYCLE409......171 Dressing and profiling - CYCLE416...................175 9.10...
  • Page 8: Table Of Contents

    Table of contents 10.3.9 Feedrate F..........................240 10.3.10 Exact stop / continuous-path control mode: G9, G60, G64 ............241 10.3.11 Acceleration pattern: BRISK, SOFT..................244 10.3.12 Percentage acceleration override: ACC..................245 10.3.13 Fourth axis..........................246 10.3.14 Dwell time: G4........................... 247 10.3.15 Travel to fixed stop........................
  • Page 9: Table Of Contents

    11.6 Establishing an RS232 connection to the control ..............307 11.7 Establishing a peer-to-peer Ethernet connection to the control..........308 11.8 Establish the Ethernet network connection to the control (only with SINUMERIK 802D sl pro).............................310 11.9 Additional network functions ......................312 11.9.1 Sharing directories ........................312 11.9.2...
  • Page 10 Table of contents Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 11: Description

    Description Control and display elements Operator control elements The defined functions are called up via the horizontal and vertical softkeys. For a description, please refer to this manual: Figure 1-1 CNC operator panel Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 12: Error And Status Displays

    Serious error, remedy through power OFF/ON RDY (green) Ready for operation NC (yellow) Signoflife monitoring CF (yellow) Reading from/writing to CF card References You can find information on error description in the SINUMERIK 802D sl Diagnostics Manual Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 13: Key Definition Of The Full Cnc Keyboard (vertical Format)

    Description 1.3 Key definition of the full CNC keyboard (vertical format) Key definition of the full CNC keyboard (vertical format) Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 14 Description 1.3 Key definition of the full CNC keyboard (vertical format) Hot keys In the part program editor and in the input fields of the HMI, the following functions can be carried out with certain shortcut keys on the full CNC keyboard: Shortcut key Function <CTRL>...
  • Page 15: Key Definition Of The Machine Control Panel

    Description 1.4 Key definition of the machine control panel Key definition of the machine control panel Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 16: Coordinate Systems

    Description 1.5 Coordinate systems Note This documentation assumes an 802D standard machine control panel (MCP). Should you use a different MCP, the operation may be other than described herein. Coordinate systems As a rule, a coordinate system is formed from three mutually perpendicular coordinate axes. The positive directions of the coordinate axes are defined using the so-called "3-finger rule"...
  • Page 17 Description 1.5 Coordinate systems Figure 1-3 MCS for grinding (cylindrical grinding machine, surface grinding machine) Figure 1-4 Machine coordinate system The origin of this coordinate system is the machine zero. This point is only a reference point which is defined by the machine manufacturer. It does not have to be approachable.
  • Page 18 Description 1.5 Coordinate systems Workpiece coordinate system (WCS) To describe the geometry of a workpiece in the workpiece program, a right-handed, right- angled coordinate system is also used. The workpiece zero can be freely selected by the programmer in the Y axis. In the Z axis, it lies in the turning center.
  • Page 19 Description 1.5 Coordinate systems Clamping the workpiece For machining, the workpiece is clamped on the machine. The workpiece must be aligned such that the axes of the workpiece coordinate system run in parallel with those of the machine. Any resulting offset of the machine zero with reference to the workpiece zero is determined along the Y axis and entered in a data area intended for the settable work offset.
  • Page 20 Description 1.5 Coordinate systems Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 21: Software User Interface

    Software user interface Screen layout Figure 2-1 Screen layout The screen is divided into the following main areas: ● Status area ● Application area ● Note and softkey area Status area Figure 2-2 Status area Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 22 Software user interface 2.1 Screen layout Table 2- 1 Explanation of the screen controls in the status area Numbering Display Icon Significance ① Active operating area Position (operating area key <POSITION>) System (operating area key <SYSTEM>) Program (operating area key <PROGRAM>) Program Manager (operating area key <PROGRAM MANAGER>) Parameter (operating area key <OFFSET...
  • Page 23 Software user interface 2.1 Screen layout Numbering Display Icon Significance AUTOMATIC ③ Alarm and message line In addition, the following is displayed: 1. Alarm number with alarm text, or 2. Message text ④ Selected part program (main program) ⑤ Program state RESET Program canceled / default state Program is running...
  • Page 24 Software user interface 2.1 Screen layout Table 2- 2 Explanation of the screen controls in the note and softkey area Screen item Display Significance ① RECALL symbol Pressing the <RECALL> key lets you return to the higher menu level. ② Information line Displays notes and information for the operator and fault states ③...
  • Page 25: Operating Areas

    To change to another operating area, press the relevant key on the CNC full keyboard (hard key). Protection levels The SINUMERIK 802D sl provides a concept of protection levels for enabling data areas. The control system is delivered with default passwords for the protection levels 1 to 3. Protection level 1...
  • Page 26: The Help System

    Software user interface 2.3 The help system In the menus listed below the input and modification of data depends on the protection level set: ● Tool offsets ● Work offsets ● Setting data ● RS232 settings ● Program creation / program correction The help system Comprehensive online help is stored in the control system.
  • Page 27 Software user interface 2.3 The help system Softkeys This function opens the selected topic. Figure 2-5 Help system: Description of the topic Use this function to select cross references. A cross reference is marked by the characters ">>..<<". This softkey is only displayed if a cross reference is displayed in the application area.
  • Page 28 Software user interface 2.3 The help system Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 29: Turning On, Reference Point Approach

    Turning on, reference point approach Note When you turn on the SINUMERIK 802D sl and the machine, please also observe the machine documentation, since turning on and reference point approach are machine- dependent functions. Operating sequence First, switch on the power supply for the CNC and the machine.
  • Page 30 Turning on, reference point approach Press the arrow keys. If you select the wrong approach direction, no motion is carried out. One after the other, move each axis to the reference point. You can exit the function by selecting another operating mode (MDA, AUTOMATIC or JOG). To access the functions described below, you need to select "Jog"...
  • Page 31: Setup

    Setup Entering tools and tool offsets Functionality The "OFFSET PARAM" operating area allows you to store the parameters required for machine operation. Operating sequences This function opens the "Tool offset data" window which contains a list of the tools created. Use the cursor keys and the <Page Up>/<Page Down>...
  • Page 32 Setup 4.1 Entering tools and tool offsets Softkeys Clearing the calculated dresser data. Use this softkey to delete the tool. Opens a lower-level menu bar offering all functions required to create and display further tool data. This function is used to enter - guided by the menu - the nominal dimensions and monitoring data of the grinding wheel.
  • Page 33: Create New Tool

    Setup 4.2 Create new tool Create new tool Functionality The tool offsets consist of various data describing the geometry, the wear and the tool type. Each tool contains a defined number of parameters, depending on the tool type. Tools are identified by a number (T number).
  • Page 34 Setup 4.2 Create new tool Operating sequences (new tool) This function opens an input screen in which the tool number, tool type, and grinding wheel shape are to be entered or selected. Figure 4-3 New tool Confirm your input using <OK>. Figure 4-4 New tool inserted A data record loaded with zero will be included in the tool list.
  • Page 35 Setup 4.2 Create new tool Note: Cylindrical grinding begins with S2. Flat grinding begins with S1. The conversion is done internally, for an entered value of 1. For standard wheels (vertical and inclined), the D numbers are assigned a fixed meaning (refer to the "Offset values"...
  • Page 36 Setup 4.2 Create new tool Figure 4-5 Corrective values Cutting edges 7-9 are the three available dressing tools have a fixed allocation to the standard contour cutting edge. Table 4- 1 Allocation of dressers D field Dresser Assignment Dresser 1 Left-hand front cutting edge Dresser 2 Right-hand rear cutting edge...
  • Page 37 Setup 4.2 Create new tool In the next step, the tool data are to be entered. ● Nominal dimensions for monitoring ● Geometry data ● Technological data ● Data for the dressers Nominal dimensions and monitoring This function opens in input screen into which grinding wheel nominal dimensions and monitoring data are entered.
  • Page 38 Setup 4.2 Create new tool The following wheel types are available: ● Vertical wheel without back-slopes (type 1) ● Vertical wheel with back-slopes (type 2) ● Left-hand side inclined wheel (type 3) ● Right-hand side inclined wheel (type 4) ● Free contour (type 0) The input screen is self-explaining.
  • Page 39 Setup 4.2 Create new tool Dresser Use the "1st dresser", "2nd dresser" or "3rd dresser" softkeys to access the dialog box for entering or verifying the dresser data. Figure 4-9 Fixed dresser Use the "Type" toggle field to select the dresser type: Fixed dresser: Tile/Diamond Form roll 1 to 3...
  • Page 40 Setup 4.2 Create new tool Figure 4-11 Diamond roll Parameter tables The function opens a summary of all cutting edge parameters. Note: This function is available only with a password set (Customer). Figure 4-12 The following table contains all cutting edge data. Tool offset data See Chapter "Parameter tables of tool offset data"...
  • Page 41: Register Dresser

    Setup 4.3 Register dresser Register dresser Functionality This function is used to determine the dresser positions in the machine for dressers that are used by means of the geometry axes. The axis values are determinded in machine coordinates by the HMI and transmitted to the cycle. Operation The dresser is sensed in JOG mode.
  • Page 42: Sense Workpiece

    Setup 4.4 Sense workpiece For standard grinding wheels, the D number of the wheel is automatically selected in accordance with the choice of dresser for dressers 1 and 2. For the 3rd dresser, select the D number or approach the edge of the active wheel as it is not automatically recognized.
  • Page 43 Setup 4.4 Sense workpiece Press the <Calculate position> softkey to calculate the setpoint. Note This procedure must be done for each axis separately. Exit the "Register workpiece" function. Special features in connection with manual grinding If you have interrupted manual grinding (Page 45) with the PLC key "Handwheel" during manual grinding, then the last position of the infeed axis can be calculated following "Measure workpiece"...
  • Page 44: Shaping/dressing

    Setup 4.5 Shaping/dressing Shaping/dressing Functionality This function is used to shape a "raw" grinding wheel without generating an NC program. The procedure always refers to the currently active tool. Operation Shaping is done in JOG mode. The input screen is opened. Figure 4-16 Shaping The required shaper values that are machined in dressing strokes are entered using the...
  • Page 45: Manual Grinding

    Setup 4.6 Manual grinding In the cycle, the shaper allowance is machined first and then all dressing strokes are executed. The current state is shown in the fields. The procedure can be aborted at any time. To restart it, press the <Start prof.> softkey. Values can be modified. Exit the "Profiling"...
  • Page 46 Setup 4.6 Manual grinding Manual grinding, no oscillation The figure below shows an input screen with parameters for manual grinding without oscillation: Figure 4-18 Manual grinding without oscillation This function starts manual grinding with the handwheel. A prompt appears. Figure 4-19 Prompt Execution of manual grinding with handwheel (without oscillation).
  • Page 47 Setup 4.6 Manual grinding Manual grinding, oscillation The figure below shows an input screen with parameters for manual grinding with oscillation: Figure 4-20 Manual grinding with oscillation If you have selected oscillation, then you should use this function to enter the oscillation data (see figure below): Figure 4-21 Manual grinding with oscillation data in X and Z...
  • Page 48 Setup 4.6 Manual grinding The following oscillation data is possible: ● Position 1 (start)/2 (end): – Use the numeric keypad to enter position 1/2 in the relevant input field. – Use traversing key <X> or <Z> on the machine control panel to approach position 1/2 and use vertical softkey "Position 1"/"Position 2"...
  • Page 49: Program Setting Data

    Setup 4.7 Program setting data Program setting data Functionality The setting data are used to define the settings for the operating states. These can be changed as necessary. Operating sequence You are now in the <OFFSET PARAM> operating area. Press the "Setting data" softkey. The start screen "Setting data" is opened. Other softkey functions are available here with which you can set various control system options.
  • Page 50 Setup 4.7 Program setting data ● Dry run feed (DRY) The feedrate which can be entered here will be used instead of the programmed feedrate in the AUTOMATIC mode if the "Dry run feed" function is selected. ● Starting angle for thread (SF) For thread cutting, a start position for the spindle is displayed as the start angle.
  • Page 51 Setup 4.7 Program setting data Times Counters Figure 4-25 Times, Counters Meaning: ● Total parts: Total number of workpieces produced (total actual) ● Parts requested: Number of workpieces required (workpiece setpoint) ● Number of parts: This counter registers the number of all workpieces produced since the starting time.
  • Page 52 Setup 4.7 Program setting data Use this function to display all setting data for the control system in the form of a list. The setting data are divided up into general, axis-specific and channel-specific data. They can be selected using the following softkey functions: ●...
  • Page 53: Arithmetic Parameter R

    Setup 4.8 Arithmetic parameter R Arithmetic parameter R Functionality In the "R parameters" start screen, any R parameters that exist within the control system are listed. These global parameters can be set or queried by the programmer of the part program for any purpose in the program and can be changed as required.
  • Page 54: User Data

    Setup 4.9 User data User data Functionality The user data is internally processed in the cycles. This data can be changed as necessary. Operating sequences These can be found in the <OFFSET PARAM> operating area. Press the <User data> softkey. This will open the "User data" start screen for the cycles. Figure 4-28 User data Place the cursor bar on the input field to be modified and enter the values.
  • Page 55: Manual Mode

    Manual mode Manual mode Manual mode is supported by the JOG and MDA operating modes. Figure 5-1 JOG menu tree, "Position" operating area Figure 5-2 MDA menu tree, "Position" operating area Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 56: Jog Mode - "position" Operating Area

    Manual mode 5.2 JOG mode - "Position" operating area JOG mode - "Position" operating area 5.2.1 JOG mode Operating sequences Use the <JOG> key on the machine control panel to select the Jog mode. To traverse the axes, press the appropriate key for the X, Y, or Z axis. The axes will traverse continuously at the velocity stored in the setting data until the key is released.
  • Page 57 Manual mode 5.2 JOG mode - "Position" operating area Figure 5-3 JOG mode start screen Parameter Table 5- 1 Description of the parameters in the JOG start screen Parameter Explanation Displays the axes existing in the machine coordinate system (MCS) or in the workpiece coordinate system (WCS) If you traverse an axis in the positive (+) or negative () direction, a plus or minus sign will appear in the relevant field.
  • Page 58 Manual mode 5.2 JOG mode - "Position" operating area Note If a second spindle is integrated into the system, the workspindle will be displayed using a smaller font. The window will always display the data of only one spindle. The control system displays the spindle data according to the following aspects: The master spindle (large display) is displayed: - Idle, - at spindle start...
  • Page 59: Assigning Handwheels

    Manual mode 5.2 JOG mode - "Position" operating area 5.2.2 Assigning handwheels Operating sequence Select the "JOG" operating mode. Press the <Handwheel> softkey. The "Handwheel" window appears on the screen. After the window has been opened, all axis identifiers are displayed in the "Axis" column, which simultaneously appear in the softkey bar.
  • Page 60: Mda Mode (manual Input) "position" Operating Area

    Manual mode 5.3 MDA mode (manual input) "Position" operating area MDA mode (manual input) "Position" operating area Functionality In the MDA mode, you can create or execute a part program. CAUTION The Manual mode is subject to the same safety interlocks as the fully automatic mode. Furthermore, the same prerequisites are required as in the fully automatic mode.
  • Page 61 Manual mode 5.3 MDA mode (manual input) "Position" operating area Parameter Table 5- 2 Description of the parameters in the MDA working window Parameter Explanation Displays the existing axes in the MCS or WCS If you traverse an axis in the positive (+) or negative () direction, a plus or minus sign will appear in the relevant field.
  • Page 62 Manual mode 5.3 MDA mode (manual input) "Position" operating area Softkeys The horizontal softkeys are explained in the section titled "JOG mode - 'Position' operating area" (Page 56). The G function window displays G functions whereby each G function is assigned to a group and has a fixed position in the window.
  • Page 63: Teach In

    Manual mode 5.3 MDA mode (manual input) "Position" operating area 5.3.1 Teach In Functionality You can use the "Teach In" function to create and change simple traversing blocks. You can transfer axis position values directly into a newly generated or changed part program record. The axis positions are reached by traversing with the axis direction keys and transferred into the part program.
  • Page 64 Manual mode 5.3 MDA mode (manual input) "Position" operating area Select the appropriate softkey for the traversing block. "Technological data" Figure 5-8 Technological data Enter the appropriate technological data (e.g. feedrate: 1000). Click "Insert transfer" to add a new part program block. The new part program block will be added in front of the block selected with the cursor.
  • Page 65 Manual mode 5.3 MDA mode (manual input) "Position" operating area You traverse the axes and teach-in a rapid traverse block with the approached positions. "Linear" Figure 5-10 Linear You traverse the axes and teach in a linear block with the approached positions. "Circular"...
  • Page 66 Manual mode 5.3 MDA mode (manual input) "Position" operating area Operation in the "Rapid traverse", "Linear", and "Circular" dialogs Use the axis keys to traverse the axes to the required position that you want to add/change in the part program. Click "Insert transfer"...
  • Page 67: Automatic Mode

    Automatic mode Automatic mode Menu tree Figure 6-1 Automatic menu tree Preconditions The machine is set up for the AUTOMATIC mode according to the specifications of the machine manufacturer. Operating sequence Select Automatic mode by pressing the <Automatic> key on the machine control panel. The Automatic start screen appears, displaying the position, feedrate, spindle, and tool values, as well as the currently active block.
  • Page 68 Automatic mode 6.1 Automatic mode Figure 6-2 Automatic start screen Parameter Table 6- 1 Description of the parameters in the working window Parameter Explanation Displays the existing axes in the MCS or WCS If you traverse an axis in the positive (+) or negative () direction, a plus or minus sign will appear in the relevant field.
  • Page 69 Automatic mode 6.1 Automatic mode Note If a second spindle is integrated into the system, the workspindle will be displayed using a smaller font. The window will always display the data of only one spindle. The control system displays the spindle data according to the following aspects: The master spindle is displayed: - Idle, - at spindle start...
  • Page 70 Automatic mode 6.1 Automatic mode This window displays the auxiliary and M functions currently active. Selecting the softkey repeatedly will close the window. All the G functions are displayed. Use this softkey to display the "Axis feedrate" window. Pressing the softkey repeatedly will close the window. Use this softkey to switch from the seven-block to the three-block display.
  • Page 71 Automatic mode 6.1 Automatic mode Use this softkey to close the screen. Use the block search function to go to the desired program location. Forward block search with calculation During the block search, the same calculations are carried out as during normal program operation, but the axes do not move.
  • Page 72: Machining Offset

    Automatic mode 6.2 Machining offset Machining offset Functionality Fine offsets can be entered in Y and Z, globally for each seat or individually for a specific seat. From then on, these offsets will always be used for the grinding work (seat). Note If the NC program is in STOP or RESET, then offsets can be entered.
  • Page 73: Selection And Start Of A Part Program

    Automatic mode 6.3 Selection and start of a part program ● Offset of Y by -0.1 mm (Y is the infeed axis) at the allowance point of 0.05 mm. The changeover point for roughing/finishing is at 0.06 mm. It follows from this that the complete allowance is increased by 0.1mm. The resulting actual allowance is 0.15 mm ->...
  • Page 74: Block Search

    Automatic mode 6.4 Block search Place the cursor bar on the desired program. Use the <Execute> softkey to select the program to be executed (see also "External execution"). The name of the selected program will appear in the "Program name" screen line.
  • Page 75 Automatic mode 6.4 Block search Figure 6-7 Block search Block search to block start Block search to block end Block search without calculation The interruption location is loaded. Use this softkey to perform the block search by entering a term you are looking for. Figure 6-8 Entering a search term Surface grinding...
  • Page 76 Automatic mode 6.4 Block search The search term can be entered with the following functions: ● "Text" The systems jumps to the line with the corresponding text. A toggle field is provided to define from which position you will search for the term. ●...
  • Page 77: Simultaneous Recording

    Automatic mode 6.5 Simultaneous recording Choose between the following options in the toggle field: ● Do not correct any axis ● Correct tool ● Machining offsets When you select <OK>, the parameters will be inserted in the program after the selected block.
  • Page 78 Automatic mode 6.5 Simultaneous recording ● "Show ..." – "All G17 blocks" – "All G18 blocks" – "All G19 blocks" ● "Display areas" See the following page for a description. ● "Delete window" ● "Cursor" – "Set cursor" – "Cursor fine", "Cursor coarse", "Cursor very coarse" When the cursor keys are pressed, the cross hair moves in small, average or large steps.
  • Page 79 Automatic mode 6.5 Simultaneous recording Figure 6-12 Display area "Window max" Operating sequence to set and save the display area 1. You have selected an area in the simulation view. 2. Press the "Display areas" function. 3. Press the "Window min/max" so that a maximum display can be see according to the screen "Display areas "Window max".
  • Page 80: Stop / Cancel A Part Program

    Automatic mode 6.6 Stop / cancel a part program Stop / cancel a part program Operating sequence With <NC STOP> the execution of a part program is interrupted. The interrupted machining can be continued with <NC START>. Use <RESET> to abort the program currently running. By pressing <NC START>...
  • Page 81: Repositioning After Interruption

    In <AUTOMATIC> mode > <PROGRAM MANAGER> operating area, the following interfaces are available for external execution of programs: Customer CompactFlash card RCS connection for external execution via network (only for SINUMERIK 802D sl pro) Manufacturer's drive USB FlashDrive Surface grinding...
  • Page 82 Automatic mode 6.9 Execute from external Start in the following start screen of the Program Manager: Figure 6-13 The "Program Manager" start screen Use vertical softkey "Ext. execution" to transmit the selected external program to the control system; to execute this program, press <NC START>. While the contents of the buffer memory are being processed, the blocks are reloaded automatically.
  • Page 83 Automatic mode 6.9 Execute from external At the end of the program or in case of <RESET>, the program is automatically removed from the control system. Note For "Execute externally", no block search is possible. Requirements for external execution via network ●...
  • Page 84 Automatic mode 6.9 Execute from external Operating sequences for external execution via network Select the <AUTOMATIC> mode key. Press the <PROGRAM MANAGER> key on the machine control panel. Press "RCS connect.". You go to the directories of the PC. Place the cursor bar on the desired program. Press "Ext.
  • Page 85: Part Programming Overview

    Part programming Part programming overview Menu tree Figure 7-1 "Program Manager" menu tree Functionality The PROGRAM MANAGER operating area is the management area for workpiece programs in the control system. In this area, programs can be created, opened for modification, selected for execution, copied, and inserted.
  • Page 86 Part programming 7.1 Part programming overview Operating sequence Press the <PROGRAM MANAGER> key to open the program directory. Figure 7-2 The "Program Manager" start screen Use the cursor keys to navigate in the program directory. To find program names quickly, simply type the initial letter of the program name.
  • Page 87 Part programming 7.1 Part programming overview Note Selecting individual files: Position the cursor on the corresponding file and press the <Select> key. The selected line will change its color. If you press the <Select> key once more, the selection is canceled. This function will enter one or several files in a list of files (called 'clipboard') to be copied.
  • Page 88 This softkey is needed in connection with the work in the network. Additional information is provided in Chapter, network operation (only for SINUMERIK 802D sl pro). The functions required for reading out/reading in files are provided via the RS232 interface.
  • Page 89: Enter New Program

    Part programming 7.2 Enter new program Enter new program Operating sequences You have selected the PROGRAM MANAGER operating area. Use the "NC directory" softkeys to select the storage location for the new program. Press "New". You have the choice of the following options: Figure 7-3 New program After presssing the softkey "New directory"...
  • Page 90: Editing Part Programs Or Text Files

    Part programming 7.3 Editing part programs or text files Editing part programs or text files Functionality A part program or sections of a part program in the NC memory can only be edited if they are currently not being executed. Any modifications to the part program are stored immediately.
  • Page 91 Part programming 7.3 Editing part programs or text files Menu tree Figure 7-5 "Program" menu tree Operating sequence In the PROGRAM MANAGER operating area, select the program to be edited. Press the <Open> softkey. The selected program will open. Softkeys Use this softkey to edit a file.
  • Page 92 Part programming 7.3 Editing part programs or text files Use this softkey to delete a selected text (alternatively: <XTRL+X>) Use the <Find> softkey to search for a string in the program file displayed. Type the term you are looking for in the input line and use the <OK> softkey to start the search.
  • Page 93: Free Contour Programming

    Part programming 7.4 Free contour programming Free contour programming 7.4.1 Free contour programming (surface grinding) Functionality Free contour programming is a support tool for the editor. The contour programming function enables you to create simple and complex contours. A contour program editor (FCI) calculates any missing parameters for you as soon as they can be obtained from other parameters.
  • Page 94 Part programming 7.4 Free contour programming Figure 7-6 Define a start point Initially, you define a contour start point (see Chapter "Defining a start point (Page 97)"). The contour is then programmed step-by-step (see chapter "Programming example, surface grinding (Page 105)"). Figure 7-7 Edit contour elements Softkeys for the contour elements...
  • Page 95: Program A Contour

    Part programming 7.4 Free contour programming ● Straight line in the horizontal direction (longitudinal) ● Oblique straight line ● Circular arc A pole is a theoretical contour element. Straight lines and circular arcs can also be defined by polar coordinates in reference to a pole. 7.4.2 Program a contour Operating sequences...
  • Page 96 Part programming 7.4 Free contour programming 4. To create a new part program, select softkey "New", enter a name and confirm with "OK". You are now in the ASCII editor. 5. Press softkey "Contour". The input screen for "Define a start point" is displayed. You will find a guide to defining the start point in the section "Define a start point".
  • Page 97: Define A Start Point

    Part programming 7.4 Free contour programming 7.4.3 Define a start point Operating sequences When entering a contour, begin at a position which you already know and enter it as the starting point. The sequence of operations for defining the start point of a contour is as follows: ●...
  • Page 98: Softkeys And Parameters

    Part programming 7.4 Free contour programming 1. Enter the values for the starting point. The values must be specified as absolute dimensions (reference dimension). 2. Select the approach motion to the start point in input field "Approach start point" with softkey "Alternative"...
  • Page 99 Part programming 7.4 Free contour programming Vertical softkeys The following contour elements are available for programming contours: Straight line in the vertical direction (X direction) Straight line in the horizontal direction (Z direction). Oblique line in the X/Z direction. Enter the end point of the line using coordinates or an angle.
  • Page 100 Part programming 7.4 Free contour programming Figure 7-12 Help mode Parameter Beginning at the start point, enter the first contour element, e.g. a vertical straight line (see screenshot below). Figure 7-13 Straight line in vertical direction Select the "All parameters" softkey to display a selection list of all the parameters for the contour element.
  • Page 101 Part programming 7.4 Free contour programming Transition to next element A transition element ("Trans. to next element") can be used whenever there is a point of intersection between two neighboring elements; this can be calculated from the input values. You can choose to insert either a radius RND, a chamfer CHR or an undercut as the transition element between any two contour elements.
  • Page 102 Part programming 7.4 Free contour programming Contour allowance Under "Contour allowance", you can specify a side-based parallel contour allowance. It is displayed as an allowance in the graphics window. Contour chain on left in main screen Once the input is acknowledged with "Accept element" or "Abort", you can navigate around the contour chain (left of the main screen) using the ↑, ↓...
  • Page 103: Parameterize Contour Element

    Part programming 7.4 Free contour programming 7.4.5 Parameterize contour element Functionality The following softkeys are provided for programming the contour on the basis of preassigned parameters: Tangent to preceding element The "Tangent preced. elem." softkey presets the angle α2 to a value of 0. The contour element has a tangential transition to the preceding element, i.e.
  • Page 104 Part programming 7.4 Free contour programming Save a contour element If you have entered the available data for a contour element or selected the desired contour by means of the "Select dialog" softkey, select the "Accept element" softkey to store the contour element and return to the main screen.
  • Page 105: Programming Example, Surface Grinding

    Part programming 7.4 Free contour programming Delete contour element Use the cursor keys to select the element you wish to delete. The selected contour symbol and associated contour element in the programming graphic are highlighted in red. Then press the "Delete element" softkey and confirm the query. Undo an input By selecting the "Abort"...
  • Page 106 Part programming 7.4 Free contour programming Example The following diagram shows a programming example for the "Free contour programming" function. Figure 7-16 Programming example Note For our example, for a correct display, the display machine data MD290 CTM_POS_COORDINATE_SYSTEM is set to 0. Operating sequences for the contour in the diagram "Programming example"...
  • Page 107 Part programming 7.4 Free contour programming ● The following diagram shows cycle CYCLE429, which you parameterize in the part program editor under "Grinding cycles" > "Grinding" > "Contour grinding". Figure 7-17 CYCLE429 ("contour grinding") ● Before you program the free contour, add the following commands into the part program: ;************* CONTOUR BEGINS ************ N35 TGST: N40 G64...
  • Page 108 Part programming 7.4 Free contour programming The sequence of individual actions required to program the contour are listed in the table below. Table 7- 1 Programming example, surface grinding Operating step Softkey Parameter "Contour" Entering the start point: Plane selection: G17 Start point: X: 100 "Accept element"...
  • Page 109 Part programming 7.4 Free contour programming Part program editor ● You are again in the part program editor. ● Still add the following commands: N75 TSGS_E: ;************* CONTOUR END ************ N80 M17 Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 110 Part programming 7.4 Free contour programming Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 111: System" Operating Area

    System "System" operating area Functionality The SYSTEM operating area includes functions required for parameterizing and analyzing the NCK, the PLC and the drive. Depending on the functions selected, the horizontal and the vertical softkey bars change. The menu tree shown below only includes the horizontal softkeys. Menu tree Figure 8-1 System menu tree...
  • Page 112 ● User password It is possible to change certain data corresponding to the access levels. If you do not know the password, access will be denied. Note Also see SINUMERIK 802D sl "Lists". Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 113 System 8.1 "System" operating area Figure 8-3 Entering the password After selecting the "Accept" softkey, the password is set. Use "Cancel" to return without any action to the " SYSTEM" main screen. "Change Password" Figure 8-4 Change password Depending on the access right, various possibilities are offered in the softkey bar to change the password.
  • Page 114 System 8.1 "System" operating area Resetting the credential User network log-in Use "Change language" to select the user interface language. Figure 8-5 User interface language Use the cursor keys to select the language and confirm it by pressing "OK". Note The HMI is automatically restarted when a new language is selected.
  • Page 115: System - "start-up" Softkeys

    System 8.2 SYSTEM - "Start-up" softkeys The NC and PLC data are backed up. The drive data are not backed up. Note Saved data can be called via the following operator action: • Press the <SELECT> key while the control system is booting. •...
  • Page 116: System - "machine Data" Softkeys

    You will find a description of the machine data in the following manufacturers´ documents: SINUMERIK 802D sl List Manual SINUMERIK 802D sl Function Manual for turning, milling, nibbling Machine data Any changes in the machine data have a substantial influence on the machine.
  • Page 117 System 8.3 SYSTEM - "Machine data" softkeys CAUTION Incorrect parameterization may result in destruction of the machine! The machine data are divided into the groups described in the following. General machine data Open the "General machine data" window. Use the Page Up / Page Down keys to browse forward / backward.
  • Page 118 System 8.3 SYSTEM - "Machine data" softkeys This function provides various display filters for the active machine data group. Further softkeys are provided: ● "Expert": Use this softkey to select all data groups of the expert mode for display. ● "Filter active": Use this softkey to activate all data groups selected. After you have quit the window, you will only see the selected data on the machine data display.
  • Page 119 System 8.3 SYSTEM - "Machine data" softkeys The data of axis 1 are displayed. Use "Axis +" or "Axis " to switch to the machine area of the next or previous axis. The contents of the machine data are updated. Channel-specific machine data Open the "Channel-specific machine data"...
  • Page 120 System 8.3 SYSTEM - "Machine data" softkeys Figure 8-11 Drive machine data To display the parameters, position the cursor on the appropriate unit and press the "Parameter display" softkey. For a description of the parameters, please refer to the documentation of SINAMICS drives. Figure 8-12 Parameter list Switch to the respective drive objects.
  • Page 121 System 8.3 SYSTEM - "Machine data" softkeys Display of machine data Open the "Display machine data" window. Use the PageUp / PageDown keys to browse forward / backward. Figure 8-13 Display of machine data Use the "Softkey color" and "Window color" softkeys to specify user-defined color settings. The displayed color consists of the components red, green and blue.
  • Page 122: System - "service Display

    System 8.4 SYSTEM - "Service display" Use this softkey to change the color of the border of dialog boxes. The "Active window" softkey function will assign your settings to the focus window, and the "Inactive window" function to the non-active window. Figure 8-15 Edit frame color.
  • Page 123 System 8.4 SYSTEM - "Service display" This window displays information on the axis drive. The "Axis +" or "Axis -" softkeys are additionally displayed. These can be used to display the values for the next or previous axis. This window displays information in respect of the digital drive. The window displays information on external bus settings.
  • Page 124: Action Log

    System 8.4 SYSTEM - "Service display" 8.4.2 Action log The function "Action log" is provided for service events. The contents of the action log file can only be accessed through a system password on the HMI. Figure 8-17 Action log Irrespective of the system password, it is possible to output the file using softkey "Save under..."...
  • Page 125 System 8.4 SYSTEM - "Service display" ● Measuring of abscissa and ordinate values as a difference between two marker positions; ● Storing of the result as a file in the part program directory. Thereafter, it is possible to export the file using either RCS802 or the CF card and to process the data in MS Excel. Figure 8-18 Servo trace start screen The header of the diagram contains the current scaling of the abscissa and the difference...
  • Page 126 System 8.4 SYSTEM - "Service display" Figure 8-20 Select signal ● Selecting the axis: To select the axis, use the "Axis" toggle field. ● "Signal type": Following error Controller difference Contour deviation Position actual value Speed actual value Speed setpoint Compensation value Parameter block Position setpoint controller input...
  • Page 127 System 8.4 SYSTEM - "Service display" The parameters for the measuring time and for the trigger type for channel 1 can be set in the lower screen half. The remaining channels will accept this setting. ● Determining the measuring period: The measuring period in ms is entered directly into the "Measuring period"...
  • Page 128 System 8.4 SYSTEM - "Service display" Figure 8-21 Marker steps The markers are moved using the cursor keys at a step size of one increment. larger step sizes can be set using the input fields. The value specifies how many grid units the marker must be moved per "SHIFT"...
  • Page 129: Version/hmi Details

    System 8.4 SYSTEM - "Service display" 8.4.4 Version/HMI details This window displays the version numbers and the date of creation of the individual CNC components. Figure 8-23 Version Note The version releases shown in the version screen shot are for example only. Saves the contents of the "Version"...
  • Page 130 System 8.4 SYSTEM - "Service display" Figure 8-24 The "HMI version" menu area This "Registry details" function displays the assignment of the hard keys (operating area keys POSITION (machine), OFFSET PARAM (parameter), PROGRAM (program), PROGRAM MANAGER (progman), ...) for the programs to be started in the form of a list. For the meanings of the individual columns, please refer to the table below.
  • Page 131 The "Font details" function displays the data of the loaded character sets in the form of a list. Figure 8-26 Font details Entering the license key. Figure 8-27 License key References SINUMERIK 802D sl Operating Instructions for Turning, Milling, Grinding, Nibbling; Licensing in SINUMERIK 802D sl Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 132: Service Msg

    8.4 SYSTEM - "Service display" Setting the licensed options. Figure 8-28 Options References SINUMERIK 802D sl Operating Instructions for Turning, Milling, Grinding, Nibbling; Licensing in SINUMERIK 802D sl Executes a warm restart at the control. 8.4.5 Service MSG The "Service MSG" function allows message texts/messages to be output via the following interfaces: ●...
  • Page 133 System 8.4 SYSTEM - "Service display" The message texts/messages are programmed in the part program using a specified syntax. The particular syntax is described in the following table: Table 8- 2 Syntax of the message texts/messages Output Syntax ("<interface>: Message text") via RS-232-C MSG ("V24: Message text") Note:...
  • Page 134 System 8.4 SYSTEM - "Service display" Settings for output via the RS232 interface Settings of the RS232 output interface. Figure 8-30 Dialog box, RS232 interface settings "Sending messages via this interface can be activated or deactivated using the "Send via RS232"...
  • Page 135 System 8.4 SYSTEM - "Service display" Figure 8-31 Parameters of the RS232 interface Note When using the MSG service via RS232, the RS232 interface must not be active for another application. The means, e.g. the RS232 interface must not be active from the operating area <SYSTEM> "PLC"...
  • Page 136 System 8.4 SYSTEM - "Service display" Sending messages to the selected file is activated or deactivated using the "Send to file" checkbox. When the interface is deactivated, messages are not output and the information line "Processing error MSG command occurred". A path, the file name and the max.
  • Page 137 The error log can be used for analysis when the information line "Processing error MSG command occurred" is output. Example of programming using the "MSG" command For SINUMERIK 802D sl, messages programmed in the NC program are displayed in the alarm display as standard. Table 8- 3 Activating/deleting messages N10 MSG ("Roughing the contour")
  • Page 138 System 8.4 SYSTEM - "Service display" Table 8- 6 Messages to the output interface file N20 MSG ("FILE: Roughing the contour") ; The text "Roughing the contour" is sent to the selected file Note If MSG commands follow one another, then a dwell time must be programmed between the commands.
  • Page 139: Date, Time

    System 8.4 SYSTEM - "Service display" 8.4.6 Date, time Dialog box for setting the date and time of the control. Figure 8-34 Dialog box "Date and time" Input options in the dialog window "Date and time" ● Setting the time Enter the time in the "time"...
  • Page 140: System - "plc" Softkeys

    System 8.5 SYSTEM - "PLC" softkeys SYSTEM - "PLC" softkeys This softkey provides further functions for diagnostics and commissioning of the PLC. This softkey opens the configuration dialog for the interface parameters of the STEP 7 connection using the RS232 interface of the control system. If the RS232 interface is already occupied by the data transfer, you can only connect the control system to the PLC802 programming tool on the programming device/PC once data transfer has been completed.
  • Page 141 System 8.5 SYSTEM - "PLC" softkeys Modem If the data transfer is performed on the RS232 interface via modem, start with the following initialization option: Figure 8-36 Initialize the modem The following initializations are possible via toggle fields: ● Baud rate 9600 / 19200 / 38400 / 57600 / 115200.
  • Page 142 System 8.5 SYSTEM - "PLC" softkeys You can select the following modem types via toggle field: ● Analog modem ● ISDN box ● Mobile phone Note The types of both communication partners must match with each other. When you want to enter several AT command sets, you have to start with AT only once and simply have to add all other commands, e.g.
  • Page 143 System 8.5 SYSTEM - "PLC" softkeys Format Binary Hexadecimal Decimal The binary representation is not possible with double words. Counters and timers are represented decimally. Figure 8-38 PLC status display The operand address displays the value incremented by 1. The operand address displays the value respectively decremented by 1. Use this softkey to delete all operands.
  • Page 144 System 8.5 SYSTEM - "PLC" softkeys Figure 8-39 PLC status list Use this softkey to change the value of the highlighted variable. Press the "Accept" softkey to confirm your changes. Use this softkey to assign the active column a new area. To this end, the interactive screenform offers four areas to choose from.
  • Page 145 On the right-hand side, the Insert and Delete functions are provided to modify the reference list. List of references for interface signals SINUMERIK 802D sl Function Manual; Various Interface Signals (A2) SINUMERIK 802D sl List Manual Writes the selected file name to the clipboard.
  • Page 146 Machine manufacturer Machine manufacturer 201 to 255 Siemens Siemens The notation is carried out for each program by lines. Two columns are intended per line, which must be separated from each other by TAB, space or the "|" character. In the first column, the PLC reference number must be specified, and in the second column, the file name.
  • Page 147: System - "start-up Files" Softkeys

    ● Customer CF card: Customer data on the CF card ● RCS connection: Data of a drive shared on PC using the the RCS tool (only for SINUMERIK 802D sl pro) ● RS232: Serial Interface ● Manufacturer drive: Data that the manufacturer specifically stored ●...
  • Page 148 Reading-in and reading-out data on a CompactFlash Card (CF card). Reading-in and reading-out data to a PC via a network. The RCS tool must be installed on the PC (only for SINUMERIK 802D sl pro). Note The RCS tool provides a detailed online help function. Refer to this help menu for further details e.g.
  • Page 149 System 8.6 SYSTEM - "Start-up files" softkeys Note Using the softkey function "Continue...", you may also inspect the transmission log. The "Error log" function is available for that. Use this function to display and change the RS232 interface parameters. Any changes in the settings come into effect immediately.
  • Page 150 System 8.6 SYSTEM - "Start-up files" softkeys Baud rate ... used to set the interface transmission rate. 300 baud 600 baud 1200 baud 2400 baud 4800 baud 9600 baud 19200 baud 38400 baud 57600 baud 115200 baud Stop bits Number of stop bits with asynchronous transmission Input: 1 stop bit (default setting) 2 stop bits...
  • Page 151 System 8.6 SYSTEM - "Start-up files" softkeys Figure 8-45 Manufacturers` archive, archive file not yet created Vertical softkeys The following vertical softkeys are available upon activating the file functions: ● "Rename": Use this function to rename a file selected beforehand using the cursor. ●...
  • Page 152: System - "commissioning Wizard" Softkeys

    The function " Commissioning wizard" is displayed if the machine manufacturer has configured a commissioning dialog. Procedure: See the SINUMERIK 802D sl operating instructions for turning, milling, grinding, nibbling, Chapter "Create commissioning dialogs" or on the toolbox, the example shown under ..\Special\ Commissioning wizard.
  • Page 153: Alarm Display

    System 8.8 Alarm display Softkeys The following applies to all softkeys: This function is only available if appropriate instructions have been saved by the machine manufacturer. ● "Activating" This function activates the selected function. The activation procedure is symbolized using a "wait" symbol. After successful completion of the activation, an "available" symbol is displayed.
  • Page 154 System 8.8 Alarm display Softkeys Use this softkey to display all alarms sorted by their priorities. The highest priority alarm is at the beginning of the list. Use this softkey to display the alarms sorted by the time of their occurrence. The most recent alarm stands at the beginning of the list.
  • Page 155: Overview Of Cycles

    ● Sharpening is aimed at restoring the wheel's ability to cut. The workpiece grinding cycles enable surface grinding with the Y/Z infeed axes (right- angled). Grinding cycles The SINUMERIK 802D sl controller supports the following cycles for surface grinding: CYCLE406 Z positioning with grinding wheel CYCLE407...
  • Page 156 Cycles 9.1 Overview of cycles The cycles are supplied with the tool box. They are loaded via the RS232 interface into the part program memory during the start-up of the control system. Operation while a machining cycle is underway All cycles are compatible with both automatic infeed and handwheel infeed. You have the option of interrupting the machining process while it is underway and forcing intermediate dressing.
  • Page 157: Cycle Requirements

    Cycles 9.2 Cycle requirements Note The functions associated with the icons (e.g. "interrupt cycle") remain effective all the time that there is an infeed amount available. The "interrupt cycle" function also applies during air grinding. Cycle requirements Prerequisites The following requirements must be met in respect of the individual grinding cycles: 1.
  • Page 158: Programming Cycles

    Cycles 9.3 Programming cycles Programming cycles A cycle is defined as a subroutine with a name and parameter list assigned. 9.3.1 Call and return conditions The G functions effective prior to the cycle call and the programmable offsets remain active beyond the cycle.
  • Page 159: Error Messages And Error Handling

    Reference For more information on errors and required responses, as well as messages output in the controller's dialog line, please refer to the SINUMERIK 802D sl Diagnostics Manual. 9.3.2.2 Error handling within cycles Alarms with numbers between 61000 and 62999 generated in the cycles. This range of numbers, in turn, is divided again with regard to alarm responses and cancel criteria.
  • Page 160: Cycle Call And Parameter List

    Cycles 9.3 Programming cycles 9.3.3 Cycle call and parameter list The cycles use user-defined variables. The defining parameters for the cycles can be transferred via the parameter list when the cycle is called. Note Cycle calls must always be programmed in a separate block. Basic information on assigning parameters to cycles The Programming Guide describes the parameter list of every cycle with the ●...
  • Page 161 Cycles 9.3 Programming cycles Hardware prerequisites The grinding machine must meet additional hardware requirements before any grinding cycles can be used. One or two handwheels are required for motion overlay during setup. There must be connection options for the following external equipment: ●...
  • Page 162 Cycles 9.3 Programming cycles Figure 9-2 Coordinate systems for grinding Plane definition Before using the grinding cycles, G507 must be activated. Typically, the infeed axis is the first geometry axis. A tool length compensation must be selected before the cycle is called. Tool length compensation is always effective in the selected plane and remains active even after the end of the cycle.
  • Page 163: Zyklenunterst├╝tzung Im Programmeditor

    Cycles 9.4 Zyklenunterstützung im Programmeditor Zyklenunterstützung im Programmeditor The program editor provides programming support for adding cycle calls to the program and for entering parameters. Function The cycle support offers the following functions: ● Cycle selection via soft keys ● Input screen forms for parameter assignment with help displays Decompilable program code is generated from the individual screens.
  • Page 164: Z Positioning With Grinding Wheel - Cycle406

    Cycles 9.5 Z positioning with grinding wheel - CYCLE406 To add a cycle call to the program, carry out the following steps one after the other: ● From the horizontal softkey bar, selection bars for the individual cycles can be selected using the <Grinding cycles>...
  • Page 165 Cycles 9.5 Z positioning with grinding wheel - CYCLE406 Parameter Data type Meaning MODE Type of approach: 0 = Sensor+Handwheel 1 = Sensor+ measurement 2 = Handwheel only 3 = Handwheel+measurement Y_POS REAL Y end position Z_POS REAL Z position for setting value ZSTW REAL Feed value for longitudinal positioning, incr.
  • Page 166 Cycles 9.5 Z positioning with grinding wheel - CYCLE406 Sketch of the geometry parameters Figure 9-4 Z positioning with grinding wheel - CYCLE406 Programming example Machining sequence: ● Inching at position -100.0000 mm to Y position -20.0000 mm, old offset is deleted first and axis value is set at the end point.
  • Page 167: Safety Position - Cycle407

    Cycles 9.6 Safety position - CYCLE407 Safety position - CYCLE407 Programming CYCLE407(YS, STORE, KOORD) Parameter Table 9- 2 Parameters of CYCLE407 Parameter Data type Meaning REAL Safety height STORE Stores position globally 0/1 KOORD Position in WCS=1 and in MCS=0 Function This cycle is used for approaching a safety position during the grinding process or during interruptions such as intermediate dressing.
  • Page 168: Stage Plunge Cut Oscillation (roughing, Finishing And Fine-finishing) - Cycle408

    Cycles 9.7 3-stage plunge cut oscillation (roughing, finishing and fine-finishing) - CYCLE408 3-stage plunge cut oscillation (roughing, finishing and fine-finishing) - CYCLE408 Programming CYCLE408 (N_SITZ, XSTART, XEND, YEND ZEND, KS, Y_A_LU, Y_A_SR, Y_A_SL, Y_A_FS, Z_A_LU, Z_A_SR, Z_A_SL, Z_A_FS, LUZ, SRZ, SLZ, FSZ, N_SR, N_SL, N_FS, D_SR, D_SL, D_FS, ESL, EFS, FX_SR, FX_SL, FX_FS, FR) Parameter Table 9- 3...
  • Page 169 Cycles 9.7 3-stage plunge cut oscillation (roughing, finishing and fine-finishing) - CYCLE408 Parameter Data type Meaning FX_FS REAL X feedrate, fine-finishing REAL Feedrate at reversal point Function The 3-stage plunge-cut cycle is called for the purpose of machining a slot or surface that is smaller than the wheel width.
  • Page 170 Cycles 9.7 3-stage plunge cut oscillation (roughing, finishing and fine-finishing) - CYCLE408 Sketch of the geometry parameters Figure 9-6 3-stage plunge cut workshop cycle (roughing, finishing and fine-finishing) - CYCLE408 Programming example - 1 Machining sequence: ● Plunge cut in Y direction at a peripheral speed of 20 m/s. ●...
  • Page 171: Stage Surface Grinding (roughing, Finishing And Fine-finishing) - Cycle409

    Cycles 9.8 3-stage surface grinding (roughing, finishing and fine-finishing) - CYCLE409 ● Infeed of 0.03 mm per stroke with acoustic emission sensor and 0.02 mm infeed for roughing, 0.01 mm infeed for finishing, and 0.002 mm infeed for fine-finishing. ● 1 sparking-out stroke following roughing, 2 strokes following finishing, and 3 strokes following fine-finishing.
  • Page 172 Cycles 9.8 3-stage surface grinding (roughing, finishing and fine-finishing) - CYCLE409 Parameter Data type Meaning with structure-borne noise 0=no 1=yes Y_A_LU REAL Air grinding allowance (incr.) Y_A_SR REAL Roughing allowance (incr.) Y_A_SL REAL Finishing allowance (incr.) Y_A_FS REAL Fine-finishing allowance (incr.) REAL Air grinding feedrate, per stroke REAL...
  • Page 173 Cycles 9.8 3-stage surface grinding (roughing, finishing and fine-finishing) - CYCLE409 The cycle automatically divides cutting into roughing, finishing and fine-finishing. Sparking-out strokes can be programmed for the end of each stage. Off-loading is also possible at the end of the roughing and finishing stages. Dressing strokes can be programmed to take place prior to each technology step.
  • Page 174 Cycles 9.8 3-stage surface grinding (roughing, finishing and fine-finishing) - CYCLE409 Programming example Machining sequence: ● Grind surface at a grinding wheel peripheral speed of 20 m/s. ● In part program block N30: air allowance of 0.05 mm and roughing allowance of 0.05 mm, finishing allowance of 0.025 mm, and fine-finishing allowance of 0.005 mm.
  • Page 175: Dressing And Profiling - Cycle416

    Cycles 9.9 Dressing and profiling - CYCLE416 Dressing and profiling - CYCLE416 Programming CYCLE416 (Y_AB, Z_AB_L, Z_AB_R, F_DL_AB, F_BL_AB, F_DR_AB, F_BR_AB, F_Z_AB, N_ABR, GWPS, N_AWST) Parameter Table 9- 5 Parameters of CYCLE416 Parameter Data type Meaning Y_AB REAL Dressing amount in Y (incr.) Z_AB_L REAL Dressing amount in Z, left/front (incr.)
  • Page 176 Cycles 9.9 Dressing and profiling - CYCLE416 Sketch of the geometry parameters Figure 9-8 Dressing and profiling - CYCLE416 Programming example Machining sequence: ● Single-stroke dressing with dressing amounts of 0.02 mm (left) and 0.01 mm (right) after every 5 workpieces. ●...
  • Page 177: Oscillating Plunge Cutting - Cycle426

    Cycles 9.10 Oscillating plunge cutting - CYCLE426 9.10 Oscillating plunge cutting - CYCLE426 Programming CYCLE426( N_SITZ, XSTART, XEND, YEND, ZEND, ZU_ART, KS, Y_A_LU, Y_A_SR, Z_A_LU, Z_A_SR, LUZ, SRZ, N_FR, A_HEB, FR, FX) Parameter Table 9- 6 Parameters of CYCLE426 Parameter Data type Meaning N_SITZ...
  • Page 178 Cycles 9.10 Oscillating plunge cutting - CYCLE426 Machining will take place in the Z direction if no roughing allowance has been programmed for Y. A higher infeed amount can be used at the start of machining. Once contact has been detected using an acoustic emission sensor, the tool will retract by the acoustic emission sensor infeed amount minus the grinding infeed amount.
  • Page 179 Cycles 9.10 Oscillating plunge cutting - CYCLE426 Programming example - 1 Machining sequence: ● Plunge cut in Y direction at a grinding wheel peripheral speed of 20 m/s with two infeed blocks. ● In part program block N30: allowance of 0.1 mm and infeed of 0.005 mm per stroke, no retraction at the end and, therefore, grinding immediately continues in part program block N40 with an allowance of 0.02 mm and infeed of 0.002 mm per stroke.
  • Page 180: Surface Grinding With Continuous Infeed - Cycle427

    Cycles 9.11 Surface grinding with continuous infeed - CYCLE427 9.11 Surface grinding with continuous infeed - CYCLE427 Programming CYCLE427( N_SITZ, XSTART, XEND, ZSTART, ZEND, YEND, ZU_ART, KS, A_LU, A_SR, LUZ, SRZ, N_FR, A_HEB, FY, FX, FZ) Parameter Table 9- 7 Parameter CYCLE427 Parameter Data type...
  • Page 181 Cycles 9.11 Surface grinding with continuous infeed - CYCLE427 Once contact has been detected using an acoustic emission sensor, the tool will retract by the acoustic emission sensor infeed amount minus the grinding infeed amount. If no acoustic emission sensor input has been configured, the cycle will immediately switch to the handwheel at the start of the operation.
  • Page 182 Cycles 9.11 Surface grinding with continuous infeed - CYCLE427 Programming example Machining sequence ● Oscillation with continuous infeed in Z direction at a grinding wheel peripheral speed of 20 m/s with two infeed blocks. ● In part program block N30: allowance of 0.1 mm and infeed of 0.005 mm per stroke, no retraction at the end and, therefore, grinding immediately continues in part program block N40 with an allowance of 0.02 mm and infeed of 0.002 mm per stroke.
  • Page 183: Surface Grinding With Intermittent Infeed - Cycle428

    Cycles 9.12 Surface grinding with intermittent infeed - CYCLE428 9.12 Surface grinding with intermittent infeed - CYCLE428 Programming CYCLE428( N_SITZ, XSTART, XEND ZSTART, ZEND, YEND, ZU_ART, ZZU_ART, KS, A_LU, A_SR, LUZ, SRZ, N_FR, A_HEB, FY, FX, FZ) Parameter Table 9- 8 Parameter CYCLE428 Parameter Data type Meaning...
  • Page 184 Cycles 9.12 Surface grinding with intermittent infeed - CYCLE428 This infeed is circular so that sudden acceleration can be avoided. With this method, it is also possible to select the infeed side in the Z direction. Y infeed takes place at the X and Z reversal points (left/rear, right/rear, left/front or right/front).
  • Page 185 Cycles 9.12 Surface grinding with intermittent infeed - CYCLE428 Sketch of the geometry parameters Figure 9-11 Surface grinding with intermittent infeed - CYCLE428 Programming example Machining sequence: ● Oscillation with continuous infeed in Z direction at a grinding wheel peripheral speed of 20 m/s with two infeed blocks.
  • Page 186: Profile Grinding - Cycle429

    Cycles 9.13 Profile grinding - CYCLE429 9.13 Profile grinding - CYCLE429 Programming CYCLE429( N_SITZ, XSTART, ZSTART, YEND, KS, A_LU, A_SR, LUZ, SRZ, N_FR, A_HEB, FX, KONTUR) Parameter Table 9- 9 Parameters of CYCLE429 Parameter Data type Meaning N_SITZ Seat number XSTART REAL X axis starting position (abs)
  • Page 187 Cycles 9.13 Profile grinding - CYCLE429 Sequence Enter allowance in work offset. Traverse to retraction amount. Traverse to X starting position and Z starting position. Call contour program. Retract and reset work offset. Approach the start point again until the allowance has been machined. At the end, the tool retracts by the retraction amount.
  • Page 188 Cycles 9.13 Profile grinding - CYCLE429 N10 T1D1 N20 CYCLE446( 20) CYCLE429( 0, 100, 0, 0, 0, 0, 0.02, 0, 0.005, 2, 20, 10000, "K123") N30 Y0 N40 CYCLE429( 1, 100, 0, 0, 0, 0.02, 0, 0.005, 2, 20, 10000, "K123") N50 M30 Example contour program %_N_K123_SPF...
  • Page 189: Dressing With Profile Roller - Cycle430

    Cycles 9.14 Dressing with profile roller - CYCLE430 9.14 Dressing with profile roller - CYCLE430 Programming CYCLE430 (Y_AB, F_TVOR, F_VOR, N_AUS, N_ABR, GWPS, N_AWST) Parameter Table 9- 10 Parameters of CYCLE430 Parameter Data type Meaning Y_AB REAL Dressing amount in Y (incr.) F_TVOR REAL Insertion stroke in mm/rev...
  • Page 190 Cycles 9.14 Dressing with profile roller - CYCLE430 Sketch of the geometry parameters Figure 9-13 Dressing with profile roller - CYCLE430 Programming example Machining sequence: ● 2-stroke dressing with a dressing amount of 0.02 mm and 2 sparking-out revolutions every 5 workpieces. ●...
  • Page 191: Selection Of The Grinding Wheel Peripheral Speed - Cycle446

    Cycles 9.15 Selection of the grinding wheel peripheral speed - CYCLE446 9.15 Selection of the grinding wheel peripheral speed - CYCLE446 Programming CYCLE446(SUG) Parameter Table 9- 11 Parameters of CYCLE446 Parameter Data Type Meaning GWPS REAL Value of the grinding wheel peripheral speed [m/s or feet/s] Function This function is used to switch on the grinding wheel at a desired peripheral wheel speed,...
  • Page 192 Cycles 9.15 Selection of the grinding wheel peripheral speed - CYCLE446 Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 193: Fundamental Principles Of Nc Programming

    Programming 10.1 Fundamental principles of NC programming 10.1.1 Program names Each program has its own program name. The name can be freely chosen during program creation, taking the following conventions into account: ● The first two characters must be letters. ●...
  • Page 194: Word Structure And Address

    Programming 10.1 Fundamental principles of NC programming 10.1.3 Word structure and address Functionality/structure A word is a block element and mainly constitutes a control command. The word consists of: ● Address characters: generally a letter and a ● Numerical value: a sequence of digits which with certain addresses can be added by a sign put in front of the address, and a decimal point.
  • Page 195: Block Format

    Programming 10.1 Fundamental principles of NC programming 10.1.4 Block format Functionality A block should contain all data required to execute a machining step. Generally, a block consists of several words and is always completed with the end-of-block character " L "...
  • Page 196 Programming 10.1 Fundamental principles of NC programming Comment, remark The instructions in the blocks of a program can be explained using comments (remarks). A comment always starts with a semicolon " ; " and ends with end-of-block. Comments are displayed together with the contents of the remaining block in the current block display.
  • Page 197: Fonts

    Programming 10.1 Fundamental principles of NC programming 10.1.5 Fonts The following characters are used for programming; they are interpreted in accordance with the relevant definitions. Letters, digits A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W X, Y, Z 0, 1, 2, 3, 4, 5, 6, 7, 8, 9 No distinction is made between upper and lower case letters.
  • Page 198: List Of Instructions

    Programming 10.1 Fundamental principles of NC programming 10.1.6 List of instructions Functions available with SINUMERIK 802D sl plus and pro Address Meaning Value assignments Information Programming Tool offset number 0 ... 9only integer, Contains offset data for a D... no sign certain tool T...
  • Page 199 Programming 10.1 Fundamental principles of NC programming Address Meaning Value assignments Information Programming 2: Special motions, dwell time Dwell time G4 F...;separate block, F: Time in seconds non-modal G4 S..;separate block, S: in spindle revolutions Reference point approach G74 X1=0 Z1=0 ;separate block, (machine axis identifier!) Fixed point approach...
  • Page 200 Programming 10.1 Fundamental principles of NC programming Address Meaning Value assignments Information Programming Tool radius compensation left of contour Tool radius compensation right of contour G500 Settable work offset OFF 8: Settable zero offset modally effective 1st Settable zero offset 2nd Settable zero offset 3rd Settable zero offset 4th Settable zero offset...
  • Page 201 WALIMOF Working area limitation OFF G290 * SIEMENS mode 47: External NC languages The functions marked with an asterisk (*) act when starting the program (in the default condition of the control system, unless otherwise programmed and if the machine manufacturer has preserved the default settings for the grinding technology).
  • Page 202 Programming 10.1 Fundamental principles of NC programming Address Meaning Value assignments Information Programming Reserved; do not use Reserved; do not use CW rotation of spindle (for master spindle) CCW rotation of spindle (for master spindle) Spindle stop (for master spindle) Mn=3 CW rotation of spindle (for spindle n) n = 1 or = 2...
  • Page 203 Programming 10.1 Fundamental principles of NC programming Address Meaning Value assignments Information Programming Arithmetic ± 0.0000001 ... R1=7.9431 R2=4 parameters 9999 9999 R299 (8 decimal places) or with specification with specification of an of an exponent: exponent: ± (10-300 ... R1=-1.9876EX9;...
  • Page 204 Programming 10.1 Fundamental principles of NC programming Address Meaning Value assignments Information Programming Tool number 1 ... 32 000 The tool change can be T... only integer, no performed either directly using sign the T command or only with M6. This can be set in the machine data.
  • Page 205 Programming 10.1 Fundamental principles of NC programming Address Meaning Value assignments Information Programming Chamfer; 0.001 ... 99 Inserts a chamfer of the N10 X... Z..CHR=... in the contour 999.999 specified leg length between N11 X... Z... definition two contour blocks Radius for circular 0.010 ...
  • Page 206 Programming 10.1 Fundamental principles of NC programming Address Meaning Value assignments Information Programming FRCM Modal feedrate for 0, >0 In case FRCM=0: Feedrate For the unit, see F and G94, chamfer/rounding Fwill act G95; for rounding/modal rounding, see RND, RNDM Axis: Travel to fixed stop =1: select...
  • Page 207 Programming 10.1 Fundamental principles of NC programming Address Meaning Value assignments Information Programming MEAW Measurement without =+1: Measuring input 1, rising N10 MEAW=1 G1 X... Z... deletion of distance- edge F... to-go =-1: Measuring input1, falling edge $A_DBB[n] Data byte Reading and writing PLC N10 $A_DBR[5]=16.3 ;...
  • Page 208 Programming 10.1 Fundamental principles of NC programming Address Meaning Value assignments Information Programming $P_NUM_ Number of Read-only SPINDLES configured spindles $AA_S[n] Actual speed of Spindle number n =1 or =2, spindle n read-only $P_S[n] Last programmed Spindle number n =1 or =2, speed of spindle n read-only $AC_...
  • Page 209: Positional Data

    Programming 10.2 Positional data Address Meaning Value assignments Information Programming Thread starting point 0.001 ... 359.999 Specified in degrees; the thread See G33 when using G33 starting point with G33 will be offset by the specified value SPI(n) converts the spindle n =1 or =2, number n into the axis identifier: e.g.
  • Page 210 Programming 10.2 Positional data Overview of typical dimensions The basis of most NC programs is a drawing with concrete dimensions. When implementing in a NC program, it is helpful to take over exactly the dimensions of a workpiece drawing into the machining program. These can be: ●...
  • Page 211: Plane Selection: G17 To G19

    Programming 10.2 Positional data 10.2.2 Plane selection: G17 to G19 Functionality To assign, for example, tool radius and tool length compensations, a plane with two axes is selected from the three axes X, Y and Z. In this plane, you can activate a tool radius compensation.
  • Page 212: Absolute/incremental Dimensioning: G90, G91, Ac, Ic

    Programming 10.2 Positional data 10.2.3 Absolute/incremental dimensioning: G90, G91, AC, IC Functionality With the instructions G90/G91, the written positional data X, Y, Z, ... are evaluated as a coordinate point (G90) or as an axis position to traverse to (G91). G90/G91 applies to all axes.
  • Page 213: Dimensions In Metric Units And Inches: G71, G70, G710, G700

    Programming 10.2 Positional data G91 applies to all axes and can be deselected in a subsequent block by G90 (absolute dimensioning). Specification with =AC(...), =IC(...) After the end point coordinate, write an equality sign. The value must be specified in round brackets.
  • Page 214: Polar Coordinates, Pole Definition: G110, G111, G112

    Programming 10.2 Positional data Information Depending on the default setting you have chosen, the control system interprets all geometric values as either metric or inch dimensions. Tool offsets and settable work offsets including their display are also to be understood as geometrical values; this also applies to the feedrate F in mm/min or inch/min.
  • Page 215 Programming 10.2 Positional data Polar angle AP=... The angle is always referred to the horizontal axis (abscissa) of the plane (for example, with G17: X axis). Positive or negative angle specifications are possible. The polar angle remains stored and must only be written in blocks in which it changes, after changing the pole or when switching the plane.
  • Page 216: Programmable Work Offset: Trans, Atrans

    Programming 10.2 Positional data Programming example N10 G17 ; X/Y plane N20 G111 X17 Y36 ; Pole coordinates in the current workpiece coordinate system N80 G112 AP=45 RP=27.8 ; New pole, relative to the last pole as a polar coordinate N90 ...
  • Page 217 Programming 10.2 Positional data Programming TRANS X... Y... Z... ; programmable offset, deletes old instructions for offsetting, rotation, scaling factor, mirroring ATRANS X... Y... Z... ; programmable offset, additive to existing instructions TRANS ; without values: clears old instructions for offset, rotation, scaling factor, mirroring The instructions that contain TRANS or ATRANS each require a separate block.
  • Page 218: Programmable Rotation: Rot, Arot

    Programming 10.2 Positional data 10.2.7 Programmable rotation: ROT, AROT Functionality The rotation is performed in the current plane G17 or G18 or G19 using the value of RPL=... specified in degrees. Programming ROT RPL=... ; Programmable rotation, deletes old instructions for offsetting, rotation, scaling factor, mirroring AROT RPL=...
  • Page 219: Programmable Scaling Factor: Scale, Ascale

    Programming 10.2 Positional data Programming example N10 G17 ... ; X/Y plane N20 TRANS X20 Y10 ; Programmable translation N30 L10 ; Subroutine call; contains the geometry to be offset N40 TRANS X30 Y26 ; New offset N50 AROT RPL=45 ;...
  • Page 220: Programmable Mirroring: Mirror, Amirror

    Programming 10.2 Positional data Programming example N10 G17 ; X/Y plane N20 L10 ; Programmed contour original N30 SCALE X2 Y2 ; Contour in X and Z enlarged two times N40 L10 N50 ATRANS X2.5 Y18 ; Values are also scaled! N60 L10 ;...
  • Page 221 Programming 10.2 Positional data Figure 10-9 Example for mirroring with the tool position shown Programming example Mirroring in different coordinate axes with influence on an active tool radius compensation and G2/G3: N10 G17 ; X/Y plane, Z standing vertically on it N20 L10 ;...
  • Page 222: Workpiece Clamping - Settable Work Offset: G54 To G59, G500, G53, G153

    Programming 10.2 Positional data 10.2.10 Workpiece clamping - settable work offset: G54 to G59, G500, G53, G153 Functionality The settable work offset specifies the position of the workpiece zero on the machine (offset of the workpiece zero with respect to the machine zero). This offset is determined upon clamping of the workpiece into the machine and must be entered in the corresponding data field by the operator.
  • Page 223 Programming 10.2 Positional data Figure 10-10 Settable zero offset Figure 10-11 Various workpiece clamping positions when drilling/milling Programming example N10 G54 ... ; Call first settable zero offset N20 L47 ; Machining of workpiece 1, here using L47 N30 G55 ... ;...
  • Page 224: Programmable Working Area Limitation: G25, G26, Walimon, Walimof

    Programming 10.2 Positional data 10.2.11 Programmable working area limitation: G25, G26, WALIMON, WALIMOF Functionality With G25, G26, a working area can be defined for all axes in which it is possible to traverse, with no traversing allowed outside this area. With the tool length compensation active, the tool tip is decisive;...
  • Page 225: Axis Movements

    • The channel axis designation from MD20080 AXCONF_CHANAX_NAME_TAB should be used for G25, G26. With SINUMERIK 802D sl, kinematic transformations (TRANSMIT, TRACYL) are possible. It is possible that different axis designations for MD20080 and the MD20060 AXCONF_GEOAX_NAME_TAB geometry axis designation are specified here.
  • Page 226 Programming 10.3 Axis movements Programming G0 X... Y... Z... ; Cartesian coordinates G0 AP=... RP=... ; Polar coordinates G0 AP=... RP=... Z... ; Cylindrical coordinates (3dimensional) Note Another option for linear programming is available with the angle specification ANG=... (see Section "Blueprint programming").
  • Page 227: Linear Interpolation With Feedrate: G1

    Programming 10.3 Axis movements 10.3.2 Linear interpolation with feedrate: G1 Functionality The tool moves from the starting point to the end point along a straight path. The path velocity is determined by the programmed F word. All axes can be traversed simultaneously. G1 remains active until canceled by another instruction from this G group (G0, G2, G3, ...).
  • Page 228: Circular Interpolation: G2, G3

    Programming 10.3 Axis movements Programming example N05 G0 G90 X40 Y48 Z2 S500 M3 ; The tool traverses in rapid traverse on P1, three axes concurrently, spindle speed = 500 rpm, clockwise N10 G1 Z-12 F100 ; Infeed on Z-12, feed 100 mm/min N15 X20 Y18 Z-10 ;...
  • Page 229 Programming 10.3 Axis movements The description of the desired circle can be given in various ways: Figure 10-16 Possibilities of circle programming with G2/G3 using the example of the axes X/Y and G2/G3 remains active until canceled by another instruction from this G group (G0, G1, ...). The path velocity is determined by the programmed F word.
  • Page 230 Programming 10.3 Axis movements Input tolerances for the circle Circles are only accepted by the control system with a certain dimensional tolerance. The circle radius at the starting and end points are compared here. If the difference is within the tolerance, the center point is exactly set internally.
  • Page 231 Programming 10.3 Axis movements Programming example: Definition of center point and end point Figure 10-18 Example for center point and end point specification N5 G90 X30 Y40 ; Starting point circle for N10 N10 G2 X50 Y40 I10 J-7 ; End point and center point Note Center point values refer to the circle starting point! Programming example: End point and radius specification...
  • Page 232 Programming 10.3 Axis movements N5 G90 X30 Y40 ; Starting point circle for N10 N10 G2 X50 Y40 CR=12.207 ; End point and radius Note With a negative leading sign for the value with CR=-..., a circular segment larger than a semi-circle is selected.
  • Page 233 Programming 10.3 Axis movements Programming example: Definition of center point and aperture angle Figure 10-21 Example for center point and aperture angle specification N5 G90 X30 Y40 ; Starting point circle for N10 N10 G2 I10 J-7 AR=105 ; Center point and aperture angle Note Center point values refer to the circle starting point! Programming example: Polar coordinates...
  • Page 234: Circular Interpolation Via Intermediate Point: Cip

    Programming 10.3 Axis movements N1 G17 ; X/Y plane N5 G90 G0 X30 Y40 ; Starting point circle for N10 N10 G111 X40 Y33 ; Pole = circle center N20 G2 RP=12.207 AP=21 ; Polar specifications 10.3.4 Circular interpolation via intermediate point: CIP Functionality If you know three contour points of the circle, instead of center point or radius or aperture angle, then it is advantageous to use the CIP function.
  • Page 235: Circle With Tangential Transition: Ct

    Programming 10.3 Axis movements Programming example N5 G90 X30 Y40 ;Starting point circle for N10 N10 CIP X50 Y40 I1=40 J1=45 ; End point and intermediate point 10.3.5 Circle with tangential transition: CT Functionality With CT and the programmed end point in the current plane G17 through G19, a circle is generated which is connected tangentially to the previous path segment (circle or straight line) in this plane.
  • Page 236: Fixed Point Approach: G75

    Programming 10.3 Axis movements 10.3.6 Fixed point approach: G75 Functionality By using G75, a fixed point on the machine, e.g. tool change point, can be approached. The position is stored permanently in the machine data for all axes. A maximum of four fixed points can be defined for each axis.
  • Page 237 Programming 10.3 Axis movements Note The programmed position values for X1, Y1, Z1 (any value, here = 0) are ignored, but must still be written. From SW 1.4 SP7 From SW 1.4 SP7 it is possible to take into account four fixed points. Prerequisite is that the axis machine data MD30610 $MA_NUM_FIX_POINT_POS=4 is set.
  • Page 238: Reference Point Approach: G74

    Measuring with touch-trigger probe: MEAS, MEAW Functionality The function is available for SINUMERIK 802D sl plus and pro. If the instruction MEAS=... or MEAW=... is in a block with traversing movements of axes, the positions of the traversed axes for the switching edge of a connected measuring probe are registered and stored.
  • Page 239 Programming 10.3 Axis movements MEAW=1 G1 X... Y... Z... F... ; Measuring with rising edge of the probe, without clearing the distance to go MEAW=-1 G1 X... Y... Z... F... ; Measuring with falling edge of the probe, without clearing the distance to go CAUTION For MEAW: Measuring probe travels to the programmed position even after is has triggered.
  • Page 240: Feedrate F

    Programming 10.3 Axis movements 10.3.9 Feedrate F Functionality The feed F is the path velocity and represents the value of the geometric sum of the velocity components of all axes involved. The individual axis velocities therefore result from the portion of the axis path in the overall distance to be traversed. The feedrate F is effective for the interpolation types G1, G2, G3, CIP, and CT and is retained until a new F word is written.
  • Page 241: Exact Stop / Continuous-path Control Mode: G9, G60, G64

    Programming 10.3 Axis movements 10.3.10 Exact stop / continuous-path control mode: G9, G60, G64 Functionality G functions are provided for optimum adaptation to different requirements to set the traversing behavior at the block boundaries and for block advancing. Example: For example, you would like to quickly position with the axes or you would like to machine path contours over multiple blocks.
  • Page 242 Programming 10.3 Axis movements Figure 10-25 Exact stop window coarse or fine, in effect for G60/G9; enlarged display of the windows Programming example N5 G602 ; Exact stop window coarse N10 G0 G60 Z... ; Exact stop modal N20 Y... Z... ;...
  • Page 243 Programming 10.3 Axis movements For non-tangential transitions (corners), the velocity can be reduced rapidly enough so that the axes are subject to a relatively high velocity change over a short period of time. This may lead to a significant jerk (acceleration change). The size of the jerk can be limited by activating the SOFT function.
  • Page 244: Acceleration Pattern: Brisk, Soft

    Programming 10.3 Axis movements 10.3.11 Acceleration pattern: BRISK, SOFT BRISK The axes of the machine change their velocities using the maximum permissible acceleration value until reaching the final velocity. BRISK allows time-optimized working. The set velocity is reached in a short time. However, jumps are present in the acceleration pattern. SOFT The axes of the machine accelerate along a non-linear, constant characteristic until reaching the final velocity.
  • Page 245: Percentage Acceleration Override: Acc

    Programming 10.3 Axis movements 10.3.12 Percentage acceleration override: ACC Functionality Certain program sections can require the axis and spindle acceleration set via the machine data to be changed using the program. This programmable acceleration is a percentage acceleration override. For each axis (e.g. X) or spindle (S), a percentage value >0% and ≤200% can be programmed.
  • Page 246: Fourth Axis

    Programming 10.3 Axis movements 10.3.13 Fourth axis Functionality Depending on the machine variant, a fourth axis may be necessary, e.g. dividing unit, swiveling dresser, head dresser, etc. This axis can take the form of either a linear or a rotary axis.
  • Page 247: Dwell Time: G4

    Programming 10.3 Axis movements 10.3.14 Dwell time: G4 Functionality Between two NC blocks, you can interrupt the machining for a defined time by inserting a separate block with G4; e.g. for relief cutting. The words with F... or S... are only used in this block for the specified time. Any previously programmed feedrate F or a spindle speed S remain valid.
  • Page 248: Travel To Fixed Stop

    Programming 10.3 Axis movements 10.3.15 Travel to fixed stop Functionality This function is available for 802D sl plus and 802D sl pro. The travel to fixed stop (FXS = Fixed Stop) function can be used to establish defined forces for clamping workpieces, such as those required for sleeves and grippers. The function can also be used for the approach of mechanical reference points.
  • Page 249 Programming 10.3 Axis movements Note When selected, the fixed stop must be located between the start and end positions. The parameters for torque FXST[ ]= and window width FXSW[ ]= are optional. If these are not written, the values from existing setting data (SD) are in effect. Programmed values are imported to the setting data.
  • Page 250 Programming 10.3 Axis movements Fixed stop reached When the fixed stop has been reached: ● The distance-to-go is deleted and the position setpoint is manipulated. ● The drive torque increases to the programmed limit value FXST[ ]=... or the value from SD and then remains constant.
  • Page 251 – 5: Travel to fixed stop is deselected. The deselection is not yet completed. Query of the system variable in the part program initiates a preprocessing stop. For SINUMERIK 802D sl, only the static states can be detected before and after selection/deselection.
  • Page 252: Spindle Movement

    Programming 10.4 Spindle movement 10.4 Spindle movement 10.4.1 Spindle speed S, directions of rotation Functionality The spindle speed is programmed in revolutions per minute under the address S provided that the machine possesses a controlled spindle. The direction of rotation and the start or end of the movement are specified via M commands (also see Section "Miscellaneous function M").
  • Page 253: Spindle Speed Limitation: G25, G26

    Programming 10.4 Spindle movement 10.4.2 Spindle speed limitation: G25, G26 Functionality In the program, you can limit the limit values that would otherwise apply for a controlled spindle by writing G25 or G26 and the spindle address S with the speed limit value. This overwrites the values entered in the setting data at the same time.
  • Page 254: Spindle Positioning: Spos

    Programming 10.4 Spindle movement 10.4.3 Spindle positioning: SPOS Functionality Requirement: The spindle must be technically designed for position control. With the function SPOS= you can position the spindle in a specific angular position. The spindle is held in the position by position control. The speed of the positioning procedure is defined in machine data.
  • Page 255: Gear Stages

    10.4.5 2. Spindle Function With SINUMERIK 802D sl plus and 802D sl pro, a 2nd spindle is provided. For these control systems, the kinematic transformation functions for grinding are possible. These functions require a second spindle for the driven workpiece.
  • Page 256 Programming 10.4 Spindle movement Programming via spindle number Some spindle functions can also be selected via the spindle number: S1=..., S2=... ; Spindle speed for spindle 1 or 2 M1=3, M1=4, M1=5 ; Specifications for direction of rotation, stop for spindle 1 M2=3, M2=4, M2=5 ;...
  • Page 257: Special Functions

    Programming 10.5 Special functions 10.5 Special functions 10.5.1 Constant cutting rate: G96, G97 Requirement A controlled spindle must be present. Functionality With activated G96 function, the spindle speed is adapted to the currently machined workpiece diameter (transverse axis) such that a programmed cutting rate S remains constant on the tool edge: Spindle speed times diameter = constant.
  • Page 258 Programming 10.5 Special functions Upper speed limit LIMS= During machining from large to small diameters, the spindle speed can increase significantly. In this case, it is recommended the upper spindle speed limitation LIMS=..LIMS is only effective with G96 and G97. By programming LIMS=..., the value entered into the setting data (SD 43230: SPIND_MAX_VELO_LIMS) is overwritten.
  • Page 259: Rounding, Chamfer

    Programming 10.5 Special functions 10.5.2 Rounding, chamfer Functionality You can insert the chamfer (CHF or CHR) or rounding (RND) elements into a contour corner. If you wish to round several contour corners sequentially in the same manner, use the "Modal rounding" (RNDM) command. You can program the feedrate for the chamfer/rounding with FRC=...
  • Page 260 Programming 10.5 Special functions Chamfer CHF or CHR A linear contour element is inserted between linear and circle contours in any combination. The edge is broken. Figure 10-29 Inserting a chamfer with CHF using the example "Between two straight lines" Figure 10-30 Inserting a chamfer with CHR using the example "Between two straight lines"...
  • Page 261: Contour Definition Programming

    Programming 10.5 Special functions Rounding RND or RNDM A circle contour element can be inserted with tangential connection between the linear and circle contours in any combination. Figure 10-31 Examples for inserting roundings Programming examples for rounding N5 F... N10 G1 X... RND=4 ;...
  • Page 262 Programming 10.5 Special functions Programming ANG=... ; Angle specification for defining a straight line RND=... ; Insert rounding, value: Radius of chamfer CHR=... ; Insert chamfer, value: Side length of the chamfer Information The blueprint programming function is executed in the current plane G17 to G19. It is not possible to change the plane during blueprint programming.
  • Page 263 Programming 10.5 Special functions Figure 10-33 Multiple block contours using the example of the G17 plane Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 264: Tool And Tool Offset

    ; Tool number: 1 ... 32 000 Note In the control system, you can simultaneously store the following maximum values: ● SINUMERIK 802D sl plus: 7 tools with 9 cutting edges each ● SINUMERIK 802D sl pro: 14 tools with 9 cutting edges each. Surface grinding...
  • Page 265: Tool Offset Number D

    Programming 10.6 Tool and tool offset Programming example N10 T1 D1 ; Tool 1 cutting edge 1 N70 T588 ; Tool 588 10.6.3 Tool offset number D Functionality It is possible to assign 1 to 9 data fields with different tool offset blocks (for multiple cutting edges) to a specific tool.
  • Page 266 Programming 10.6 Tool and tool offset Tool length compensations become effective immediately when the tool is active; when no D number was programmed with the values of D1. The compensation is retracted with the first programmed traversing of the associated length compensation axis.
  • Page 267: Selecting The Tool Radius Compensation: G41, G42

    Programming 10.6 Tool and tool offset 10.6.4 Selecting the tool radius compensation: G41, G42 Functionality A tool with a corresponding D number must be active. The tool radius offset (cutting edge radius offset) is activated by G41/G42. The controller automatically calculates the required equidistant tool paths for the programmed contour for the respective current tool radius.
  • Page 268 Programming 10.6 Tool and tool offset Starting the compensation The tool approaches the contour on a straight line and positions itself vertically to the path tangent in the starting point of the contour. Select the start point so as to ensure collision-free traversing. Figure 10-37 Start of the tool radius compensation with the example G42, tool point direction =3 Information As a rule, the block with G41/G42 is followed by the block with the workpiece contour.
  • Page 269: Corner Behavior: G450, G451

    Programming 10.6 Tool and tool offset 10.6.5 Corner behavior: G450, G451 Functionality Using the functions G450 and G451, you can set the behavior for non-continuous transition from one contour element to another contour element (corner behavior) when G41/G42 is active. Internal and external corners are detected by the control system automatically.
  • Page 270: Tool Radius Compensation Off: G40

    Programming 10.6 Tool and tool offset 10.6.6 Tool radius compensation OFF: G40 Functionality The compensation mode (G41/G42) is deselected with G40. G40 is also the switch-on position at the beginning of the program. The tool ends the block before G40 in the normal end position (compensation vector vertical to the tangent in the end point);...
  • Page 271: Special Cases Of The Tool Radius Compensation

    Programming 10.6 Tool and tool offset 10.6.7 Special cases of the tool radius compensation Change of the compensation direction The G41 ⇄ G42 compensation direction can be changed without writing G40 in between. The last block that uses the old compensation direction will end at the normal end position of the compensation vector in the end point.
  • Page 272: Example Of Tool Radius Compensation

    Programming 10.6 Tool and tool offset Acute contour angles If very sharp outside corners occur in the contour with active G451 intersection, the control system automatically switches to transition circle. This avoids long idle motions. 10.6.8 Example of tool radius compensation The wheel should have the contour shown in the figure.
  • Page 273: Miscellaneous Function M

    Programming 10.7 Miscellaneous function M ① N120 Z118 ; Dressing contour section ① N130 Y30 Z123 ; Dressing contour section ① N140 Z123 ; Dressing contour section N150 G0 Y-90 ;Move clear N160 MIRROR ; End compensation mode 10.7 Miscellaneous function M Functionality The miscellaneous function M initiates switching operations, such as "Coolant ON/OFF"...
  • Page 274: H Function

    (programmable logic controller). In all, a maximum of 10 such function outputs are possible in a block. Information With the SINUMERIK 802D sl plus and 802D sl pro, two spindles are possible. This results in an expanded programming capability for the M commands - only for the spindles: M1=3, M1=4, M1=5, M1=40, ...
  • Page 275: Arithmetic Parameters (r Variables), Lud And Plc Variables

    Programming 10.9 Arithmetic parameters (R variables), LUD and PLC variables Note In addition to M and H functions, T, D, and S functions can also be transferred to the PLC (programmable logic controller). In all, a maximum of 10 function outputs of this type are possible in a part program block.
  • Page 276 Programming 10.9 Arithmetic parameters (R variables), LUD and PLC variables The value of the exponent is written after the EX characters; maximum total number of characters: 10 (including leading signs and decimal point) Range of values for EX: -300 to +300 Example: R0=-0.1EX-5 ;Meaning: R0 = -0.000 001...
  • Page 277: Local User Data (lud)

    Programming 10.9 Arithmetic parameters (R variables), LUD and PLC variables N50 R14=R3+R2*R1 ;Result, the same as block N40 N60 R15=SQRT(R1*R1+R2*R2) ;Meaning: N70 R1= -R1 ;The new R1 is the negative old R1 Programming example: Assign R parameters to the axes N10 G1 G91 X=R1 Z=R2 F300 ;Separate blocks (traversing blocks) N20 Z=R3...
  • Page 278 Programming 10.9 Arithmetic parameters (R variables), LUD and PLC variables Programming / data types DEF BOOL varname1 ;Boolean typ, values: TRUE (=1), FALSE (=0) DEF CHAR varname2 ;Char type, 1 ASCII code character: "a", "b", ... ;Numerical code value: 0 ... 255 DEF INT varname3 ;Integer type, integer values, 32 bit value range: ;-2 147 483 648 through +2 147 483 647 (decimal)
  • Page 279: Reading And Writing Plc Variables

    Programming 10.9 Arithmetic parameters (R variables), LUD and PLC variables Example: N10 PVAR7[2]=24 ;The third field element (with index 2) is assigned the value 24. Value assignment for field with SET instruction: N20 PVAR5[2]=SET(1,2,3) ;After the 3rd field element, different values are assigned.
  • Page 280: Program Jumps

    Programming 10.10 Program jumps Note Writing of PLC tags is generally limited to a maximum of three tags (elements). Where PLC tags are to be written in rapid succession, one element will be required per write operation. If more write operations are to be executed than there are elements available, then block transfer will be required (a preprocessing stop may need to be triggered).
  • Page 281: Unconditional Program Jumps

    Programming 10.10 Program jumps 10.10.2 Unconditional program jumps Functionality NC programs process their blocks in the sequence in which they were arranged when they were written. The processing sequence can be changed by introducing program jumps. The jump destination can be a block with a label or with a block number. This block must be located within the program.
  • Page 282: Conditional Program Jumps

    Programming 10.10 Program jumps 10.10.3 Conditional program jumps Functionality Jump conditions are formulated after the IF instruction. If the jump condition (value not zero) is satisfied, the jump takes place. The jump destination can be a block with a label or with a block number. This block must be located within the program.
  • Page 283 Programming 10.10 Program jumps Programming example for comparison operators R1>1 ;R1 greater than 1 1 < R1 ;1 less than R1 R1<R2+R3 ;R1 less than R2 plus R3 R6>=SIN( R7*R7) ; R6 greater than or equal to SIN (R7) squared Programming example N10 IF R1 GOTOF LABEL1 ;If R1 is not null then go to the block...
  • Page 284: Program Example For Jumps

    Programming 10.10 Program jumps 10.10.4 Program example for jumps Task Approaching points on a circle segment: Existing conditions: Start angle: 30° in R1 Circle radius: 32 mm in R2 Position spacing: 10° in R3 Number of points: 11 in R4 Position of circle center in Z: 50 mm in R5 Position of circle center in X: 20 mm in R6 Figure 10-43 Linear approach of points on a circle segment...
  • Page 285: Subroutine Technique

    Programming 10.11 Subroutine technique 10.11 Subroutine technique 10.11.1 General information Usage Basically, there is no difference between a main program and a subroutine. Frequently recurring machining sequences are stored in subroutines, e.g certain contour shapes. These subroutines are called at the appropriate locations in the main program and then executed.
  • Page 286 Programming 10.11 Subroutine technique Figure 10-44 Example of a sequence when a subroutine is called in a two-channel manner. Subroutine name The subprogram is given a unique name allowing it to be selected from several subroutines. When you create the program, the program name may be freely selected provided the following conventions are observed: The same rules apply as for the names of main programs.
  • Page 287 Please make sure that the values of your arithmetic parameters used in upper program levels are not inadvertently changed in lower program levels. When working with SIEMENS cycles, up to 7 program levels are needed. Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 288: Calling Machining Cycles

    ; Call of cycle 82, separate block 10.11.3 Execute external subroutine (EXTCALL) Function With SINUMERIK 802D sl pro, it is possible to reload and execute programs with the EXTCALL command via the following external data carriers: ● Customer CompactFlash card (drive D) ●...
  • Page 289 Programming 10.11 Subroutine technique Programming with path specification in SD42700 EXT_PROGRAM_PATH ("<program name>") EXTCALL Parameter EXTCALL ; Keyword for subroutine call <program name> ; Constant/variable of STRING type Example: EXTCALL ("RECHTECKTASCHE.MPF") Programming without path specification in SD42700 EXT_PROGRAM_PATH ("<path\program name>") EXTCALL Parameter EXTCALL...
  • Page 290 Programming 10.11 Subroutine technique Examples 1. Processing of external customer CompactFlash Card or USB FlashDrive System: SINUMERIK 802D sl pro The "Main.mpf" main program is stored in NC memory and is selected for execution: N010 PROC MAIN N020 ... N030 EXTCALL ("D:\EXTERNE_UP\BOHRUNG") N040 ...
  • Page 291: Timers And Workpiece Counters

    Programming 10.12 Timers and workpiece counters 10.12 Timers and workpiece counters 10.12.1 Runtime timer Functionality The timers are prepared as system variables ($A...) that can be used for monitoring the technological processes in the program or only in the display. These timers are read-only.
  • Page 292 Programming 10.12 Timers and workpiece counters ● $AC_CUTTING_TIME Tool action time (in seconds) The runtime of the path axes is measured in all NC programs between NC START and end of program / RESET without rapid traverse active and with the tool active (default setting).
  • Page 293: Workpiece Counter

    Programming 10.12 Timers and workpiece counters 10.12.2 Workpiece counter Functionality The "Workpiece counter" function provides counters for counting workpieces. These counters exist as system variables with write and read access from the program or via operator input (observe the protection level for writing!). Machine data can be used to control counter activation, counter reset timing and the counting algorithm.
  • Page 294: Multiple Feedrate Values In One Block

    Programming 10.13 Multiple feedrate values in one block Display The contents of the active system variables are visible on the screen under <OFFSET PARAM> -> "Setting data" ">" "Times/counters": Total parts= $AC_TOTAL_PARTS Required parts= $AC_REQUIRED_PARTS Number of parts =$AC_ACTUAL_PARTS, $AC_SPECIAL_PARTS not available for display "Number of parts"...
  • Page 295 Programming 10.13 Multiple feedrate values in one block Note If feedrates, dwell time or return path are programmed for an axis on account of an external input, this axis must in this block must not be programmed as POSA axis (positioning axis over multiple blocks).
  • Page 296: Oscillation

    Programming 10.14 Oscillation Example of several operations in one block N20 T1 D1 F500 G0 X100 ;Initial setting N25 G1 X105 F=20 F3=5 ; Roughing with F, finishing withF3, F2=0.5 ST=1.5 ; smooth-finishing with F2, dwell time 1.5 s SR= 0.5 ;return path 0.5 mm N30 ...
  • Page 297 Programming 10.14 Oscillation FA[axis]= Feed for oscillating axis OSCTRL [axis]= (Set, reset options) OSNSC [axis]= Number of sparking-out strokes OSE [axis]= End position OS [axis]= 1 = activate oscillation; 0 = deactivate oscillation Stopping times at reversal points: OST1, OST2 Hold time Movement in exact stop area at reversal point Interpolation continues without wait for exact stop...
  • Page 298 Programming 10.14 Oscillation Description The following apply to the oscillating axis: ● Every axis may be used as an oscillation axis. ● Several oscillation axes can be active at the same time (maximum: the number of the positioning axes). ● Linear interpolation is always active for the oscillating axis –...
  • Page 299 Programming 10.14 Oscillation Setting feed, FA The feedrate is the defined feedrate of the positioning axis. If no feedrate is defined, the value stored in the machine data applies. Defining the sequence of motions, OSCTRL The control settings for the movement are set with enable and reset options. OSCTRL[oscillating axis] = (set-option, reset-option) The set options are defined as follows (the reset options deselect the settings): Reset options...
  • Page 300 Programming 10.14 Oscillation Several options are appended with plus characters. Example: The oscillating motion for the Z axis should stop at the reversal point 1 when switched off. Where ● an end position is approached, ● a changed feed acts immediately and should immediately stop the axis after the deletion of distance-to-go.
  • Page 301: Network Operation

    The RCS802 tool must have been installed on the PC. Note The RCS802 tool is part of the toolbox of the SINUMERIK 802D sl and is supplied on a CD. Ethernet connections Thanks to the integrated network adapter, the control system is network-capable. The following connections are possible: ●...
  • Page 302: Interfaces And Functions Of The Rcs802 Tool

    With the RCS802 tool (Remote Control System), you have a tool for your PC that will support you in your daily work with SINUMERIK 802D sl. You establish the connection between the control system and the RCS802 tool on the PC...
  • Page 303: Working On The Basis Of A Network Connection

    Network operation 11.2 Working on the basis of a network connection 11.2 Working on the basis of a network connection The remote access (access to the control system from a PC or from a network) to the control system is disabled by default. After a local user logs on at the PC, the RCS tool provides the following functions: ●...
  • Page 304 Network operation 11.3 User management Figure 11-1 User accounts The user accounts serve for saving personal settings of the users. A user account is required for communication between the control with the RCS802 tool on the PC. For this purpose, the user has to enter this password on the HMI during RCS log-in (seeUser log in - RCS log in (Page 305)) via the network.
  • Page 305 Network operation 11.4 User log in - RCS log in 11.4 User log in - RCS log in For the Ethernet connections, you must first log on to the control system as a user. In the <SYSTEM> operating area, select the "RCS Connect" softkey. The user log-in input screen will appear.
  • Page 306: Setting The Connections On The Rcs802 Tool

    Network operation 11.5 Setting the connections on the RCS802 tool 11.5 Setting the connections on the RCS802 tool RCS802 tool Figure 11-3 Explorer window of the RCS802 tool After starting the RCS802 tool, you will be in OFFLINE mode. In this mode you only manage files on your PC.
  • Page 307: Establishing An Rs232 Connection To The Control

    Network operation 11.6 Establishing an RS232 connection to the control 11.6 Establishing an RS232 connection to the control You are now in the <SYSTEM> operating area. Press the "PLC” softkey. Figure 11-5 Communication settings RS232 Set the parameters for communication in the "STEP 7 Connect" dialog. Activate the RS232 connection with the "Connect.
  • Page 308: Establishing A Peer-to-peer Ethernet Connection To The Control

    Network operation 11.7 Establishing a peer-to-peer Ethernet connection to the control No modifications to the settings are possible in this state. The softkey label changes to "Connect. OFF". In the lower right corner of the screen, the icon shows that the connection to PC via the RS232 interface is active.
  • Page 309 Network operation 11.7 Establishing a peer-to-peer Ethernet connection to the control Figure 11-8 "Network configuration" main screen Press the "Peer-to-peer" softkey. Figure 11-9 "Peer-to-peer" The following message is shown on the HMI: "Connection is set up" ● IP Address: 169.254.11.22 ●...
  • Page 310: Establish The Ethernet Network Connection To The Control (only With Sinumerik 802d Sl Pro)

    Network operation 11.8 Establish the Ethernet network connection to the control (only with SINUMERIK 802D sl pro) 11.8 Establish the Ethernet network connection to the control (only with SINUMERIK 802D sl pro) Prerequisite The control system is connected to the PC or the local network via the X5 interface.
  • Page 311 Network operation 11.8 Establish the Ethernet network connection to the control (only with SINUMERIK 802D sl pro) Table 11- 3 Network configuration required Parameter Explanation DHCP DHCP log: A DHCP server is needed in the network which dynamically distributes the IP addresses.
  • Page 312: Additional Network Functions

    Network operation 11.9 Additional network functions 11.9 Additional network functions 11.9.1 Sharing directories This function defines the rights for access of remote users to the file system of the control system. Use the Program manager to select the directory you want to share. Use the "Next..."...
  • Page 313: Connecting / Disconnecting Network Drives

    Network operation 11.9 Additional network functions ● By pressing the "Add" softkey, you arrive at the user list. Select the user. With "Add" you can make any entries in the "Shared" field. ● Define the user rights (Authorizations). – Full access User has full access –...
  • Page 314 Network operation 11.9 Additional network functions Connecting network drives The "Connect" function is used to assign a local drive to a network drive. Note You have shared a directory for a network connection with a certain user on a PC. The RCS802 tool includes a detailed online help function.
  • Page 315 Network operation 11.9 Additional network functions Disconnecting network drives By selecting the ">>Back" softkey and the "Disconnect" function you can disconnect an existing network connection. 1. Place the cursor on the relevant drive. 2. Press the "Disconnect" softkey. The selected network drive is disconnected from the control. Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 316 Network operation 11.9 Additional network functions Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 317: Data Backup

    Data Backup 12.1 Data transfer via RS232 interface Functionality The RS232 interface of the control system can be used to output data (e.g. part programs) to an external data backup device or to read in data from there. The RS232 interface and your data backup device must be matched with each other.
  • Page 318 Data Backup 12.1 Data transfer via RS232 interface Further softkeys Load files via the RS232 interface. The following function is provided at this level: Transmission protocol This log contains all transmitted files including status information: ● For files to be output : name of file error log ●...
  • Page 319: Creating / Reading In / Reading Out A Start-up Archive

    12.2 Creating / reading in / reading out a start-up archive 12.2 Creating / reading in / reading out a start-up archive References SINUMERIK 802D sl Operating Instructions for Turning, Milling, Grinding, Nibbling; Data Backup and Series Start-Up Operating sequence Press the "Start-up files" softkey in the <SYSTEM> operating area.
  • Page 320 Data Backup 12.2 Creating / reading in / reading out a start-up archive Figure 12-3 Contents of the start-up archive By pressing the <Select> key, the respective files can be individually selected/deselected in the start-up archive. Writing the start-up archive to a customer CompactFlash card/USB FlashDrive Requirement: The CompactFlash Card/USB FlashDrive is inserted, and the start-up archive has been copied to the clipboard.
  • Page 321 Data Backup 12.2 Creating / reading in / reading out a start-up archive Figure 12-4 Insert files Reading in start-up archive from customer CompactFlash card/USB FlashDrive To import a start-up archive, perform the following operator actions: 1. CompactFlash card/USB FlashDrive are inserted 2.
  • Page 322: Reading In / Reading Out Plc Projects

    Data Backup 12.3 Reading in / reading out PLC projects 12.3 Reading in / reading out PLC projects When reading in a project, this will be transferred to the file system of the PLC and then activated. To complete the activation, the control system is restarted (warm start). Reading in project from CompactFlash card/USB FlashDrive To read in a PLC project, perform the following operator actions: 1.
  • Page 323: Plc Diagnostics

    PLC diagnostics 13.1 PLC diagnosis represented as a ladder diagram Functionality A PLC user program consists to a large degree of logical operations to realize safety functions and to support process sequences. These logical operations include the linking of various contacts and relays. As a rule, the failure of a single contact or relay results in a failure of the whole system/installation.
  • Page 324: Screen Layout

    PLC diagnostics 13.2 Screen layout 13.2 Screen layout The screen layout with its division into the main areas corresponds to the layout already described in section "Software Interface". Any deviations and supplements pertaining to the PLC diagnostics are shown in the following screen.
  • Page 325: Operating Options

    PLC diagnostics 13.3 Operating options 13.3 Operating options In addition to the softkeys and the navigation keys, this area provides still further key combinations. Hotkeys The cursor keys move the focus over the PLC user program. When reaching the window borders, it is scrolled automatically.
  • Page 326 PLC diagnostics 13.3 Operating options Keystroke combination Action Down a field to the first field of the first network to the last field of the last network Opens the next program block in the same window Opens the previous program block in the same window Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 327 PLC diagnostics 13.3 Operating options Keystroke combination Action The function of the Select key depends on the position of the input focus. Table line: Displays the complete text line • Network title: Displays the network comment • Command: Displays the complete operands •...
  • Page 328 PLC diagnostics 13.3 Operating options The values of the operands can be monitored and changed during program execution using the "PLC status display" window. Figure 13-3 PLC status display Use the "Status list" softkey to display and modify PLC signals. Figure 13-4 Status list Using the "Window 1 ..."...
  • Page 329 PLC diagnostics 13.3 Operating options The logics in the ladder diagram (LAD) display the following: ● Networks with program parts and current paths ● Electrical current flow through a number of logical operations Figure 13-5 Window 1, OB1 This softkey can be used to select the list of the PLC program blocks. Figure 13-6 Select the PLC program block Surface grinding...
  • Page 330 PLC diagnostics 13.3 Operating options Using this softkey will display the following properties of the selected program block: ● Symbolic name ● Author ● Comments Figure 13-7 Properties of the selected PLC program block Selecting this softkey displays the table of local variables of the selected program block. There are two types of program blocks.
  • Page 331 PLC diagnostics 13.3 Operating options With longer texts, it is possible to display the whole text by pressing the SELECT key. When a program block is protected by a password, this softkey can be used to enable the display of the ladder diagram. A password is required for this.
  • Page 332 PLC diagnostics 13.3 Operating options Figure 13-10 "Program status" ON – absolute representation Use this softkey to switch between the absolute and symbolic representation of the operands. The softkey labelling changes accordingly. Depending on the selected type of representation, the operands are displayed either with absolute or symbolic identifiers.
  • Page 333 PLC diagnostics 13.3 Operating options You can search for the operands and constants as whole words (identifiers). Depending on the display settings, you can search for symbolic or absolute operands. "OK" starts the search. The found search element is highlighted by the focus. If nothing is found, an appropriate error message will appear in the notes line.
  • Page 334 PLC diagnostics 13.3 Operating options Selecting this softkey displays all symbolic identifiers used in the highlighted network. Figure 13-13 Network symbol information table Use this softkey to display the list of cross references. All operands used in the PLC project are displayed.
  • Page 335 PLC diagnostics 13.3 Operating options Figure 13-15 Cross references main menu (symbolic)) You can open the appropriate program segment directly in the 1/2 window using the "Open in Window 1" or "Open in Window 2" function. Use this softkey to switch between the absolute and symbolic representation of the components.
  • Page 336 PLC diagnostics 13.3 Operating options Figure 13-16 Cursor M251.0 in OB1 network 2 Figure 13-17 M251.0 in OB1 network 2 in window 1 Searching operands in the cross-reference list (see following screen). You can search for the operands as whole words (identifiers). When searching, uppercase and lowercase letters are ignored.
  • Page 337 PLC diagnostics 13.3 Operating options Search criteria: ● Down (from the current cursor position) ● Whole program block (from the beginning) Figure 13-18 Searching for operands in cross references The text you are looking for is displayed in the notes line. If the text is not found, a corresponding error message is displayed which must be confirmed with "OK".
  • Page 338 PLC diagnostics 13.3 Operating options Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 339: A.1 User Data

    Appendix User data The user data is internally processed in the grinding cycles. They are stored in the program manager of the control system (in the directory \DEF) as a definition file and remain stored even when the control is switched off and on. Description of the user data The parameters included in the definition files are described as follows: Name...
  • Page 340 Appendix A.1 User data Name Type Default Description Value _GC_MF[0] Grinding spindle direction of rotation (M3) _GC_MF[1] Swing in measurement control (M21) _GC_MF[2] Swing out measurement control (M22) _GC_MF[3] Structure-borne noise ON (M33) _GC_MF[4] Structure-borne noise OFF (M34) _GC_MF[5] Advance dresser (M41) _GC_MF[6] Retract dresser (M42) _GC_MF[7]...
  • Page 341: A.2 Parameter Tables Of The Tool Data

    Appendix A.2 Parameter tables of the tool data Name Type Default Description Value _GC_FWEG REAL Free wheel travel path (measurement control) _GC_SEARCHS Tag for seat regrinding is evaluated by the cycles so that the individual seat can be identified via a block search. _GC_SEARCH Tag for seat regrinding is evaluated by the cycles so that the individual seat can be identified via a block search.
  • Page 342 Appendix A.2 Parameter tables of the tool data TPC6 REAL GWPS ratio TPC7 REAL Bypassing strategy (obstacle diameter) TPC8 REAL Basic cutting edge for dressing contour TPC9 REAL X shift TPC10 REAL Z shift Table A- 2 1. Cutting edge 2. Cutting edge for left/right wheel edge for grinding wheel Tx Dy Tool type=403 Tx Dy...
  • Page 343 Appendix A.2 Parameter tables of the tool data Tx Dy DPC9 REAL Usable wheel width Tx Dy DPC10 REAL No. of contour program Table A- 3 3. Cutting edge for grinding wheel Tx Dy Tool type=403 Tx Dy Cutting edge position (1...9) Tx Dy REAL D - Diameter of the new wheel...
  • Page 344 Appendix A.2 Parameter tables of the tool data Table A- 4 4. to 6th cutting edge for grinding wheels Tx Dy Tool type=403 Tx Dy Cutting edge position (1...9) Tx Dy REAL D - Diameter of the new wheel Tx Dy REAL L - Distance to the wheel reference point Tx Dy...
  • Page 345 Appendix A.2 Parameter tables of the tool data Table A- 5 7. to 9th cutting edge for dressers Tx Dy Tool type=403 Tx Dy Cutting edge position (1...9) Tx Dy REAL Position Tx Dy REAL Position Tx Dy REAL Position Tx Dy REAL R - Tool nose radius...
  • Page 346 Appendix A.2 Parameter tables of the tool data In addition to the default coding of the tool data (tool type, cutting edge position, etc.), the following coded parameters are used. Encoding Wheel type $TC_TPC1[T] free contour Standard contour straight without rear definitions Standard contour straight with rear definitions Standard contour inclined left Standard contour inclined right...
  • Page 347: A.3 Miscellaneous

    Appendix A.3 Miscellaneous Miscellaneous A.3.1 Pocket calculator The calculator function can be activated from any operating area using <SHIFT> and <=> or <CTRL> and <A>. For calculating, the four basic arithmetic operations are available, as well as the functions "sine", "cosine", "squaring" and "square root". A bracket function is provided to calculate nested terms.
  • Page 348: A.3.2 Editing Asian Characters

    Appendix A.3 Miscellaneous Characters that may be entered +, -, *, / Basic arithmetic operations Sine function The X value (in degrees) in front of the input cursor is replaced by the sin(X) value. Cosine function The X value (in degrees) in front of the input cursor is replaced by the cos(X) value.
  • Page 349: A.3.2.1 Simplified Chinese

    Appendix A.3 Miscellaneous A.3.2.1 Simplified Chinese Simplified Chinese With <Alt + S>, you have selected the Editor to enter asian characters. Figure A-2 Simplified Chinese "Pinyin input method" The following functions can be selected using the <Select> key: ● Pinyin input method ●...
  • Page 350 Appendix A.3 Miscellaneous Learning function The editor opens a learning function if a phonetic spelling is entered, for which there is no match in the control system. This function allows syllables or words to be combined, which are then permanently available after saving.
  • Page 351 Appendix A.3 Miscellaneous After being completely compiled, the word is saved with the <Input> key and simultaneously inserted in the program editor. Figure A-6 Simplified Chinese "Learning function" 4 Note The learning function can be opened/closed using the plus/minus key. See also Importing the dictionary (Page 355) Surface grinding...
  • Page 352: A.3.2.2 Traditional Chinese (as Used In Taiwan)

    Appendix A.3 Miscellaneous A.3.2.2 Traditional Chinese (as used in Taiwan) Traditional Chinese (as used in Taiwan) With <Alt + S>, you have selected the Editor to enter asian characters. Figure A-7 Chinese traditional entry in the Editor In the Editor, the following functions can be selected: ●...
  • Page 353 Appendix A.3 Miscellaneous The selection is displayed in the Zhuyin input field and should be confirmed using the <Input> key or by entering an additional digit. Figure A-8 Zhuyin input method If the field for the sound is "green" and if "black triangles" are displayed to the left, then using the cursor keys <down>...
  • Page 354 Appendix A.3 Miscellaneous The required character is selected using the following keys: ● Numeric keys <0> to <9> ● Cursor keys <left> and <right> ● If the cursor keys are used, then the selection should be completed using the <Input> key.
  • Page 355: A.3.2.3 Importing The Dictionary

    Appendix A.3 Miscellaneous A.3.2.3 Importing the dictionary Importing the dictionary Note For the following languages, a dictionary can be imported for the asian Editor: • Simplified Chinese • Chinese (traditional) The system offers the option of importing your own dictionaries into the control. These can be created with any UNI code Editor by adding the corresponding Chinese characters to the Pinyin phonetic spelling.
  • Page 356: A.3.2.4 Korean

    Appendix A.3 Miscellaneous A.3.2.4 Korean Korean To enter Korean characters, you will need a keyboard with the keyboard assignment shown below. In terms of key layout, this keyboard is the equivalent of an English QWERTY keyboard and individual characters must be grouped together to form syllabic blocks. Figure A-13 Korean keyboard assignment The Korean alphabet (Hangeul) consists of 24 letters: 14 consonants and 10 vowels.
  • Page 357 Appendix A.3 Miscellaneous ● Input via matrix If you only have access to a control keyboard, then you can use a matrix input method as an alternative to the keyboard assignment shown above. All you will need for this is the numeric keypad.
  • Page 358: A.4 Overview

    Appendix A.4 Overview Overview Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 359: Glossary

    Glossary Effective wheel width Wheel width of the inclined grinding wheel which is used to machine the diameter. It is dependent upon: ● the physical width ● the evading height ● the angle of the wheel Evasion/evasion angle Tapering of the left or right side of the grinding wheel for face-grinding operations in which a so-called cross-grinding is produced.
  • Page 360 Glossary Shoulder Left or right side of the grinding wheel or of the tool Workpiece peripheral speed in m/min XWP/ZWP when dressing a free contour Workpiece offset for offsetting the programmed contour to the current cutting edge of the grinding wheel; which is necessary so that workpiece coordinates can be programmed in the free contour.
  • Page 361: Index

    Index " Enabling the communication ports, 311 Enter tools, 33 "Display areas", 78 Error displays, 12 "Program" operating area, 96 Ethernet network, 302 Execution from external, 81 EXTCALL, Access right, 25 Address, 194 Arithmetic parameters, 53 FA, 299 Asynchronous oscillation, 296 Feedrate values in one block, 294 Axis assignment, 158 Files...
  • Page 362 Index OST1, 296 OST2, 296 LED displays on the CNC operator panel (PCU), 12 Overview of cycles, 155 Machine data, 116 Parameter list, 160 Axis-specific machine data, 118 Part program, 96 Channel-specific machine data, 119 selection and start, 73 Display of machine data, 121 Stopping / canceling, 80 Drive machine data, 119 Password, 304...
  • Page 363 Index Start, 158 Start point, 102 Status displays, 12 Tangent to preceding element, 103 Transmission messages, 318 Transmission protocol, 318 User accounts, 303 User log-in, 305 User management, 303 Password, 304 Users, 303 Word structure, 194 Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...
  • Page 364 Index Surface grinding Programming and Operating Manual, 11/2012, 6FC5398-5CP10-3BA0...

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