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SINUMERIK
SINUMERIK
840D sl/840Di sl/840D/840Di/810D
Special functions
Function Manual
Valid for
Control
SINUMERIK 840D sl/840DE sl
SINUMERIK 840Di sl/840DiE sl
SINUMERIK 840D powerline/840DE powerline
SINUMERIK 840Di powerline/840DiE powerline
SINUMERIK 810D powerline/810DE powerline
Software
NCU system software for 840D sl/DiE sl
NCU system software for 840D/840DE
NCU system software for 840Di/840DiE
NCU system software for 810D/810DE
11/2006
6FC5397-2BP10-2BA0
Preface
3-Axis to 5-Axis
Transformation (F2)
(K6)
(M3)
Loadable Compile Cycles
(TE01)
Simulation of Compile
Cycles (TE02)
Speed/Torque Coupling,
Master-Slave (TE3)
Package (TE4)
(TE8)
Axis pair for collision
protection (TE9)
Version
1.0
3D Tool Radius
7.4
3.3
Compensation (W5)
7.4
NC/PLC interface signals
(Z3)
Appendix (A)
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   Summary of Contents for Siemens sinumerik 840D sl

  • Page 1

    Master-Slave (TE3) Handling Transformation Package (TE4) MCS Coupling (TE6) Valid for Retrace Support (TE7) Control SINUMERIK 840D sl/840DE sl Cycle-Independent Path- SINUMERIK 840Di sl/840DiE sl Synchronous Signal Output SINUMERIK 840D powerline/840DE powerline (TE8) SINUMERIK 840Di powerline/840DiE powerline Axis pair for collision...

  • Page 2

    Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

  • Page 3

    • Manufacturer/service documentation A monthly updated publications overview with respective available languages can be found in the Internet under: http://www.siemens.com/motioncontrol Select the menu items "Support" → "Technical Documentation" → "Overview of Publications". The Internet version of DOConCD (DOConWEB) is available under: http://www.automation.siemens.com/doconweb...

  • Page 4

    Preface Standard version This documentation only describes the functionality of the standard version. Extensions or changes made by the machine tool manufacturer are documented by the machine tool manufacturer. Other functions not described in this documentation might be executable in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing.

  • Page 5

    Preface Technical information The following notation is used in this documentation: Signal/Data Notation Example NC/PLC interface ... NC/PLC interface signal: When the new gear step is engaged, the following NC/PLC signals interface signals are set by the PLC program: Signal data (signal name) DB31, ...

  • Page 6

    The EC Declaration of Conformity for the EMC Directive can be found/obtained • in the internet: http://www.ad.siemens.de/csinfo under product/order no. 15257461 • with the relevant branch office of the A&D MC group of Siemens AG. Special functions Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 7: Ncu System Software For 840d Sl/840de Sl

    840D sl/840Di sl/840D/840Di/810D Data lists Special functions: 3-Axis to 5-Axis Transformation (F2) Function Manual Valid for Control SINUMERIK 840D sl/840DE sl SINUMERIK 840Di sl/840DiE sl SINUMERIK 840D powerline/840DE powerline SINUMERIK 840Di powerline/840DiE powerline SINUMERIK 810D powerline/810DE powerline Software Version NCU system software for 840D sl/840DE sl 1.3...

  • Page 8

    Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

  • Page 9

    Table of contents Brief description ............................5 5-axis Transformation ........................5 3-axis and 4-axis transformation....................7 Orientation transformation with a swivelling linear axis..............8 Universal milling head........................10 Orientation axes ...........................11 Cartesian manual travel .......................12 Cartesian PTP travel........................12 Generic 5-axis transformation......................12 Online tool length offset .......................13 1.10 Activation via parts/program/softkey....................13 1.11...

  • Page 10

    Table of contents 2.8.2 Orientation movements with axis limits..................63 2.8.3 Orientation compression ......................64 2.8.4 Orientation relative to the path ....................68 2.8.5 Programming of orientation polynominals................... 72 2.8.6 Tool orientation with 3-/4-/5-axis transformations ............... 75 2.8.7 Orientation vectors with 6-axis transformation................75 Orientation axes ..........................

  • Page 11

    Brief description 5-axis Transformation Function The "5-Axis Transformation" machining package is designed for machining sculptured surfaces that have two rotary axes in addition to the three linear axes X, Y, and Z. This package thus allows an axially symmetrical tool (milling cutter, laser beam) to be oriented in any desired relation to the workpiece in the machining space.

  • Page 12

    Brief description 1.1 5-axis Transformation Tool orientation Tool orientation can be specified in two ways: • Machine-related orientation The machine-related orientation is dependent on the machine kinematics. • Workpiece-related orientation The workpiece-related orientation is not dependent on the machine kinematics. It is programmed by means of: –...

  • Page 13

    Brief description 1.2 3-axis and 4-axis transformation 3-axis and 4-axis transformation Function The 3- and 4-Axis transformations are distinguished by the following characteristics: Transformation Features 3-axis Transformation 2 linear axes 1 rotary axis 4-Axis transformation 3 linear axes 1 rotary axis Both types of transformation belong to the orientation transformations.

  • Page 14

    Brief description 1.3 Orientation transformation with a swivelling linear axis. Figure 1-2 Schematic diagram of a 4-axis transformation with moveable workpiece Orientation transformation with a swivelling linear axis. Function The orientation transformation with swivelling linear axis is similar to the 5-axis transformation of Machine Type 3, though the 3rd linear axis is not always perpendicular to the plane defined by the other two linear axes.

  • Page 15

    Brief description 1.3 Orientation transformation with a swivelling linear axis. Figure 1-3 Schematic diagram of a machine with swivelling linear axis Special functions: 3-Axis to 5-Axis Transformation (F2) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 16

    Brief description 1.4 Universal milling head Universal milling head Function A machine tool with a universal milling head has got at least 5 axes: • 3 linear axes – for linear movement [X, Y, Z] – move the machining point to any random position in the working area •...

  • Page 17

    Brief description 1.5 Orientation axes Orientation axes Model for describing change in orientation There is no such simple correlation between axis motion and change in orientation in case of robots, hexapodes or nutator kinamatics, as in the case of conventional 5-axes machines. For this reason, the change in orientation is defined by a model that is created independently of the actual machine.

  • Page 18

    Brief description 1.6 Cartesian manual travel Cartesian manual travel Function The "Cartesian Manual Operation" function can be used to set one of the following coordinate systems as reference system for JOG motion to be selected separately for translation and orientation as: •...

  • Page 19

    Brief description 1.9 Online tool length offset Online tool length offset Function The system variable $AA_TOFF[ ] can be used to overlay the effective tool lengths in 3-D in runtime. For an active orientation transformation (TRAORI) or for an active tool carrier that can be oriented, these offsets are effective in the particular tool axes.

  • Page 20

    Brief description 1.11 Orientation compression Special functions: 3-Axis to 5-Axis Transformation (F2) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 21

    Detailed description Note The transformations described below require that individual names are assigned to machine axes, channels and geometry axes when the transformation is active. Compare macchine data: MD10000 $MN_AXCONF_MACHAX_NAME_TAB (machine axis name) MD20080 $MC_AXCONF_CHANAX_NAME_TAB (name of the channel axis in the channel) MD20060 $MC_AXCONF_GEOAX_NAME_TAB (name of the geometry axis in the channel) Besides this no unambiguous assignments are present.

  • Page 22

    Detailed description 2.1 5-axis transformation The kinematic transformation requires information about the design (kinematics) of the machine, which are stored in machine data. The kinematic transformation does not act on positioning axes. 2.1.2 Machine types for 5-axis transformation Kinematics of machines for 5-axis transformation 5-axis machines are generally equipped with three linear and two rotary axes: the latter may be implemented as a two-axis swivel head, a two-axis rotary table or as a combination of single-axis rotary table and swivel head.

  • Page 23

    Detailed description 2.1 5-axis transformation Figure 2-1 Machine types for 5-axis transformation Note Transformations that do not fulfill all the conditions mentioned here (3 and 4-axis transformations, orientation transformation with swivelling linear axes, universal milling head) are described in separate sub chapters. 2.1.3 Configuration of a machine for 5-axis transformation To ensure that the 5-axis transformation can convert the programmed values to axis...

  • Page 24

    Detailed description 2.1 5-axis transformation Machine type The machine types have been designated above as types 1 to 3 and are stored in the following machine data as a two-digit number: MD24100 $MC_TRAFO_TYPE_1 (definition of channel transformation 1) MD24480 $MC_TRAFO_TYPE_10 (definition of channel transformation 10) The following table contains a list of machine types, which are suitable for 5-axis transformation.

  • Page 25

    Detailed description 2.1 5-axis transformation Geometry information Information concerning machine geometry is required so that the 5-axis transformation can calculate axis values: This information is stored in the machine data (in this case, for the first transformation in the channel): MD24500 $MC_TRAFO5_PART_OFFSET_1 (workpiece-oriented offset) •...

  • Page 26

    Detailed description 2.1 5-axis transformation Figure 2-3 Schematic diagram of CA kinematics, moved tool Position vector in MCS $MC_TRAFO5_PART_OFFSET_n[0 ..2] Vector of programmed position in BCS Tool correction vector $MC_TRAFO5_BASE_TOOL_n[0 .. 2] $MC_TRAFO5_JOINT_OFFSET_n[0 .. 2] Special functions: 3-Axis to 5-Axis Transformation (F2) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 27

    Detailed description 2.1 5-axis transformation Figure 2-4 Schematic diagram of CB kinematics, moved workpiece Figure 2-5 Schematic diagram of AC kinematics, moved tool, moved workpiece Special functions: 3-Axis to 5-Axis Transformation (F2) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 28

    Detailed description 2.1 5-axis transformation Assignment of direction of rotation The sign interpretation setting for a rotary axis is stored in the sign machine data for 5-axis transformation. MD24520 $MC_TRAFO5_ROT_SIGN_IS_PLUS_1[n] (sign of rotary axis 1/2/3 for 5-axis transformation 1) MD24620 $MC_TRAFO5_ROT_SIGN_IS_PLUS_2[n] (sign of rotary axis 1/2/3 for 5-axis transformation 2) Transformation types Ten transformation types per channel can be configured in the following machine data:...

  • Page 29

    Detailed description 2.1 5-axis transformation Programming The orientation of the tool can be programmed in a block directly by specifying the rotary axes or indirectly by specifying the Euler angle, RPY angle and direction vector. The following options are available: •...

  • Page 30

    Detailed description 2.1 5-axis transformation Figure 2-7 Change in cutter orientation while machining inclined edges Special functions: 3-Axis to 5-Axis Transformation (F2) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 31

    Detailed description 2.1 5-axis transformation Figure 2-8 Change in orientation while machining inclined edges ORIMCS cosntitutes the basic setting The basic setting can be changed via the following machine data: MD20150 MC_GCODE_RESET_VALUES (RESET position of G groups) MD20150 $MC_GCODE_RESET_VALUES [24] = 1 ⇒ ORIWCS is basic setting MD20150 $MC_GCODE_RESET_VALUES [24] = 2 ⇒...

  • Page 32

    Detailed description 2.1 5-axis transformation Alarm 17630 or 17620 is output for G74 and G75 if a transformation is active and the axes are involved in the transformation. This applies irrespective of orientation programming. If the start and end vectors are inverse parallel when ORIWKS is active, then no unique plane is defined for the orientation programming, resulting in the output of alarm 14120.

  • Page 33

    Detailed description 2.1 5-axis transformation 2.1.5 Singular positions and handling Extreme velocity increase If the path runs in close vicinity to a pole (singularity), one or several axes may traverse at a very high velocity. Alarm 10910 "Irregular velocity run in a path axis" is then triggered. The programmed velocity is then reduced to a value, which does not exceed the maximum axis velocity.

  • Page 34

    Detailed description 2.1 5-axis transformation $MC_TRAFO5_POLE_LIMIT This machine data identifies a limit angle for the 5th axis of the first MD24540 $MC_TRAFO5_NON_POLE_LIMIT_1 or the second MD24640 $MC_TRAFO5_NON_POLE_LIMIT_2 5-axis transformation with the following properties: With interpolation through the pole point, only the fifth axis moves; the fourth axis remains in its start position.

  • Page 35

    Detailed description 2.2 3-axis and 4-axis transformations MD21108 $MC_POLE_ORI_MODE The following machine data can be used to set the response for large circle interpolation in pole position as follows: MD21108 $MC_POLE_ORI_MODE (behavior during large circle interpolation at pole position) Does not define the treatment of changes in orientation during large circle interpolation unless the starting orientation is equal to the pole orientation or approximates to it and the end orientation of the block is outside the tolerance circle defined in the following machine data.

  • Page 36

    Detailed description 2.2 3-axis and 4-axis transformations Variants of 3-axis and 4-axis transformations workpiece Y - Z 32, 33 X - Z 34, 35 any * Note: on types 24 and 40 * In the case of transformation types 24 and 40, the axis of rotation and tool orientation can be set so that the change in orientation takes place at the outside of a taper and not in a plane.

  • Page 37

    Detailed description 2.3 Transformation with swivelled linear axis Transformation with swivelled linear axis Applications Transformation with a swiveling linear axis can be used if the application is characterized by the kinematics described in Chapter "Orientation Transformation with Linear Swivel Axis" and only a small swivel range (<<±...

  • Page 38

    Detailed description 2.3 Transformation with swivelled linear axis Definition of required values As an aid for defining the values for the above-mentioned machine data, the following two sketches show the basic interrelations between the vectors. Figure 2-10 Projections of the vectors to be set in machine data Meanings of vector designations: •...

  • Page 39

    Detailed description 2.3 Transformation with swivelled linear axis Note For the previous diagram, it has been assumed that the machine has been traversed so that the tool holding flange is in line with table zero (marked by *). If this cannot be implemented for geometric reasons, the values for to must be corrected by the deviations.

  • Page 40

    Detailed description 2.3 Transformation with swivelled linear axis Figure 2-11 Machine with swivelling linear axis in position zero The following conversion of geometry into machine data to be specified, is based on the example in Figure . Special functions: 3-Axis to 5-Axis Transformation (F2) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 41

    Detailed description 2.3 Transformation with swivelled linear axis Figure 2-12 Example of vector designation for MD-settings in Figure "Machine with Swivelling Linear Axis in Zero Position" Special functions: 3-Axis to 5-Axis Transformation (F2) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 42

    Detailed description 2.3 Transformation with swivelled linear axis Procedure for setting machine data Perform the following operation: • Calculate the x- and y-components for vector jo, listed in the figure below, "Example of Vector Designation for MD-settings" in Figure "Machine with Swivelling Linear Axis in Zero Position".

  • Page 43

    Detailed description 2.4 Universal milling head Universal milling head 2.4.1 Fundamentals of universal milling head Note The following description of the universal milling head transformation has been formulated on the assumption that the reader has already read and understood the general 5-axis transformation described in Chapter "5-axis Transformation".

  • Page 44

    Detailed description 2.4 Universal milling head Configuring the nutator angle φ The angle of the inclined axis can be configured in a machine data: $MC_TRAFO5_NUTATOR_AX_ANGLE_1: for the first orientation transformation $MC_TRAFO5_NUTATOR_AX_ANGLE_2: for the second orientation transformation The angle must lie within the range of 0 degrees to +89 degrees. Tool orientation Tool orientation at zero position can be specified as follows: •...

  • Page 45

    Detailed description 2.4 Universal milling head Angle definition Figure 2-14 Position of axis A' Axis A' is positioned in the plane spanned by the rectangular axes of the designated axis sequence. If, for example, the axis sequence is CA', then axis A' is positioned in plane Z-X. The angle φ...

  • Page 46

    Detailed description 2.4 Universal milling head Decimal Description Axis sequence 000: AB' 001: AC' 010: BA' 011: BC' 100: CA' 101: CB' Among the full range of options specified in the general concept above, the settings highlighted in gray in the following table are implemented in SW 3.1, the others in SW 3.2 and higher.

  • Page 47

    Detailed description 2.5 Activation and application of 3-axis to 5-axis transformation Active machining plane Since tool orientation in position zero can be set in directions other than just the Z direction, the user must ensure the active machining level is set so that tool length compensation takes effect in the tool orientation direction.

  • Page 48

    Detailed description 2.5 Activation and application of 3-axis to 5-axis transformation Switch-over A switch-over can be made from one active transformation to another transformation configured in the same channel. To do this the TRAORI(n) command must be entered again with a new value for n. RESET/end of program The behavior of the control system with regard to 3-axis/5-axis transformations after run-up, end of program or RESET, is determined by machine data:...

  • Page 49

    Detailed description 2.6 Generic 5-axis transformation and variants Generic 5-axis transformation and variants 2.6.1 Functionality Scope of functions The scope of functions of generic 5-axis transformation covers implemented 5-axis transformations (see Chapter "5-axis Transformation") for perpendicular rotary axes as well as transformations for the universal milling head (one rotary axis parallel to a linear axis, the second rotary axis at any angle to it, see Chapter "Universal Milling Head").

  • Page 50

    Detailed description 2.6 Generic 5-axis transformation and variants 2.6.2 Description of machine kinematics Machine types Like the existing 5-axis transformations, there are three different variants of generic 5-axis transformation: 1. Machine type: Rotatable tool Both rotary axes change the orientation of the tool. The orientation of the workpiece is fixed.

  • Page 51

    Detailed description 2.6 Generic 5-axis transformation and variants Example: 1. A-axis is the rotary axis (parallel to the x direction): MD24570 $MC_TRAFO5_AXIS1_1[0] = 1.0 (direction first rotary axis) MD24570 $MC_TRAFO5_AXIS1_1[1] = 0.0 MD24570 $MC_TRAFO5_AXIS1_1[2] = 0.0 2. B-axis is the rotary axis (parallel to the y direction): MD24572 $MC_TRAFO5_AXIS2_1[0] = 0.0 (direction 2nd rotary axis) MD24572 $MC_TRAFO5_AXIS2_1[1] = 1.0 MD24572 $MC_TRAFO5_AXIS2_1[2] = 0,0...

  • Page 52

    Detailed description 2.6 Generic 5-axis transformation and variants Transformation types Both variants of generic 3- or 4-axis transformation are described by the following transformation types: • 3- or 4-axis transformation with rotatable tool $MC_TRAFO_TYPE_n = 24 • 3- or 4-axis transformation with rotatable workpiece $MC_TRAFO_TYPE_n = 40 In conventional 3-axis or 4-axis transformations, the transformation type also defined the basic tool orientation in addition to the position of the rotary axis, which could then no longer...

  • Page 53

    Detailed description 2.6 Generic 5-axis transformation and variants Comparison Besides the 3- and 4-axis transformations mentioned in Chapter "3- and 4-axis Transformations", the follwing differences should be noted: • Position of the rotary axis: – can be arbitrary – need not be parallel to a linear axis •...

  • Page 54

    Detailed description 2.6 Generic 5-axis transformation and variants Table 2-3 Machine types for generic 5-axis transformation Machine type swivel-/ Tool Workpiece Tool/workpiece Type 3 or rotatable: orientable tool holder Kinematic type: T, P, M Transformation 72 from content of type: $TC_CARR23 Note The transformation only takes place if the orientable toolholder concerned is available and...

  • Page 55

    Detailed description 2.6 Generic 5-axis transformation and variants Assignment for all types of transformation The assignments between the toolholder data for writing the linear offsets and the corresponding machine data for kinematic transformations are determined by the transformation type. The following assignment of all other parameters is identical for all three possible types of transformation: Assignment for all types of transformation together identical MD24100 $MC_TRAFO_TYPE_1 (definition of...

  • Page 56

    Detailed description 2.6 Generic 5-axis transformation and variants Assignments for transformation type 24 Toolholder data assignments dependent on transformation type 24 Transformation type "T" (in accordance with MD24100 $MC_TRAFO_TYPE_1 = 24) MD24500 $MC_TRAFO5_PART_OFFSET_1[0] $TC_CARR1 (+$TC_TCARR41) (translation vector of 5-axis transformation 1) MD24500 $MC_TRAFO5_PART_OFFSET_1[1] $TC_CARR2 (+$TC_TCARR42) MD24500 $MC_TRAFO5_PART_OFFSET_1[2]...

  • Page 57

    Detailed description 2.6 Generic 5-axis transformation and variants Assignments for transformation type 56 Toolholder data assignments dependent on transformation type 56 Transformation type "M" (in accordance with MD24100 $MC_TRAFO_TYPE_1 = 56) MD24560 $MC_TRAFO5_JOINT_OFFSET_1[0] (vector $TC_CARR1 (+$TC_TCARR41) of the kinematic offset of 5-axis transformation 1) MD24560 $MC_TRAFO5_JOINT_OFFSET_1[1] $TC_CARR2 (+$TC_TCARR42) MD24560: TRAFO5_JOINT_OFFSET_1[2]...

  • Page 58

    Detailed description 2.6 Generic 5-axis transformation and variants 2.6.5 Extension of the generic transformation to 6 axes Application With the maximum 3 linear axes and 2 rotary axes, the motion and direction of the tool in space can be completely described with the generic 5-axis transformation. Rotations of the tool around itself, as is important for a tool that is not rotation-symmetric or robots, require an additional rotary axis.

  • Page 59

    Detailed description 2.6 Generic 5-axis transformation and variants Note The four specified transformation types only cover those kinematics in which the three linear axes form a rectangular Cartesian coordinate system, i.e. no kinematics are covered in which at least one rotary axis lies between two linear axes in the kinematic chain. Dedicated machine data exist for each general transformation or for each orientation transformation that are differentiated by the suffixes _1, _2 etc.

  • Page 60

    Detailed description 2.6 Generic 5-axis transformation and variants Note Existing machine data blocks are compatible for transfer, without any changes having to be made in the machine data. The new machine data therefore do not have to be specified for a 3-/4-/5-axis transformation.

  • Page 61

    Detailed description 2.6 Generic 5-axis transformation and variants The position of the orientation coordinate system of a standard tool depends on the active plane G17, G18, G19 according to the following table: Table 2-5 Position of the orientation coordinate system Direction of the orientation vector Direction of the orientation normal vector Note...

  • Page 62

    Detailed description 2.6 Generic 5-axis transformation and variants 2.6.6 Cartesian manual travel with generic transformation Functionality The "Cartesian manual travel" function, as a reference system for JOG mode, allows axes to be set independently of each other in Cartesian coordinate systems: •...

  • Page 63

    Detailed description 2.6 Generic 5-axis transformation and variants Tool orientation The tool can be aligned to the workpiece surface via an orientation movement. The motion of the orientation axes is triggered by the PLC via the VDI interface signals of the orientation axes.

  • Page 64

    Detailed description 2.7 Restrictions for kinematics and interpolation For further explanations of orientation movements, see Chapter "Orientation" and Chapter "Orientation Axes". Note For further information about programming of rotations, see: References: /PGA/ Programming Manual, Work Preparation, Transformation (Programming of Tool Orientation) Restrictions for kinematics and interpolation Fewer than 6 axes Not all degrees of freedom are available for orientation.

  • Page 65

    Detailed description 2.7 Restrictions for kinematics and interpolation Tool orientation using orientation vectors A much better method is to use orientation vectors to program tool orientation in space. Consider the features of polynomial interpolation of orientation vectors described in Chapter "Polynomial Interpolation of Orientation Vectors".

  • Page 66

    Detailed description 2.7 Restrictions for kinematics and interpolation Figure 2-15 Generic 5-axis transformation; end point of orientation inside tolerance circle. End point within the circle If the end point is within the circle, the first axis comes to a standstill and the second axis moves until the difference between target and actual orientation is minimal.

  • Page 67

    Detailed description 2.8 Orientation Orientation 2.8.1 Basic orientation Differences to the previous 5-axis transformations In the 5-axis transformations implemented to date, basic orientation of the tool was defined by the type of transformation. Generic 5-axis transformation can be used to enable any basic tool orientation, i.e. space orientation of the tool is arbitrary, with axes in their initial positions.

  • Page 68

    Detailed description 2.8 Orientation Please note that if all three vector components are zero (because they have been set explicitly so or not specified at all), the basic orientation is not defined by data in the TRAORI(...) call, but by one of the methods described below. If a basic orientation is defined by the above method, it cannot be altered while a transformation is active.

  • Page 69

    Detailed description 2.8 Orientation Examples: 1. Extreme example: A machine with rotatable tool has a C axis as its first rotary axis and an A axis as its second. If the basic orientation is defined in parallel to the A axis, the orientation can only be changed in the X-Y plane (when the C axis is rotating), i.e.

  • Page 70

    Detailed description 2.8 Orientation The following machine data specifies the conditions under which the rotary axis positions may be modified: MD21180 $MC_ROT_AX_SWL_CHECK_MODE Value 0: No modification permitted (default, equivalent to previous behavior). Value 1: Modification is only permitted if axis interpolation is active (ORIAXES or ORIMKS). Value 2: Modification is always permitted, even if vector interpolation (large circle interpolation, conical interpolation, etc.) was active originally.

  • Page 71

    Detailed description 2.8 Orientation Previous function The compressor is only active for linear blocks (G1). It is interrupted by any other type of NC instruction, e.g., an auxiliary function output, but not by parameter calculations. The blocks to be compressed can only contain the following elements: •...

  • Page 72

    Detailed description 2.8 Orientation Rotation of the tool For six-axis machines you can program the tool rotation in addition to the tool orientation. The angle of rotation is programmed with the THETA identifier (THETA=<...>). NC blocks in which additional rotation is programmed, can only be compressed if the angle of rotation changes linearly, meaning that a polynomial with PO[THT]=(...) for the angle of rotation should not be programed.

  • Page 73

    Detailed description 2.8 Orientation Contour accuracy The maximum deviations are not defined separately for each axis, instead the maximum geometric deviation of the contour (geometry axes) and of the tool orientation are checked. This is performed using the following setting data: 1.

  • Page 74

    Detailed description 2.8 Orientation Activation The orientation compressor is activated by one of the G codes COMPON, COMPCURV and COMPCAD. Programming example For the compression of a circle, approximated by a polygon, please see Chapter "Example for Orientation Axes". 2.8.4 Orientation relative to the path Functionality Irrespective of certain technological applications, the previous programming of tool...

  • Page 75

    Detailed description 2.8 Orientation Activate orientation relative to the path The extended function "Orientation relative to the path" is activated with the following machine data: MD21094 $MC_ORIPATH_MODE > 0 (setting for path relative orientation ORIPATH) The tool orientation relative to the path is activated in the part program by programming ORIPATH.

  • Page 76

    Detailed description 2.8 Orientation Set orientation relative to the path The following machine data is used to set in which way the orientation relative to the path is to be interpolated. MD21094 $MC_ORIPATH_MODE (setting for path relative orientation ORIPATH) With ORIPATH the behavior of tool orientation interpolation relative to the path can be activated for various functions: Meaning of units activate proper orientation relative to the...

  • Page 77

    Detailed description 2.8 Orientation Smoothing of the orientation jump ORIPATHS Smoothing of the oreintation jump is done within the setting data SD42670 $SC_ORIPATH_SMOOTH_DIST (path distance to smoothing orientation) of the specified path. The programmed reference of the orientation to the path tangent and normal vector is then no longer maintained within this distance.

  • Page 78

    Detailed description 2.8 Orientation Path relative interpolation of the rotation ORIROTC With 6-axis transformations, in addition to the complete interpolation of the tool orientation relative to the path and the rotation of the tool, there is also the option that only the rotation of the tool relative to the path tangent is interpolated.

  • Page 79

    Detailed description 2.8 Orientation Type 2 polynomials Orientation polynomials of type 2 are polynomials for coordinates PO[XH]: x coordinate of the reference point on the tool PO[YH]: y coordinate of the reference point on the tool PO[ZH]: z coordinate of the reference point on the tool Polynomials for angle of rotation and rotation vectors For 6-axis transformations, the rotation of the tool around itself can be programmed for tool orientation.

  • Page 80

    Detailed description 2.8 Orientation Rotations of rotation vectors with ORIROTC The rotation vector is interpolated relative to the path tangent with an offset that can be programmed using the THETA angle. A polynomial up to the 5th degree can also be programmed with PO[THT]=(c2, c3, c4, c5) for the offset angle.

  • Page 81

    Detailed description 2.8 Orientation Interrupts If an illegal polynomial is programmed, the following alarms are generated: Alarm 14136: Oreintation polynomial is generally not allowed. Alarm 14137: Polynomials PO[PHI] and PO[PSI] are not permitted. Alarm 14138: Polynomials PO[XH], PO[YH], PO[ZH] are not permitted. Alarm 14139: Polynomial for angle of rotation PO[THT] is not permitted.

  • Page 82

    Detailed description 2.9 Orientation axes $VC_TOOLR_DIF Angle between actual value and setpoint of the direction of rotation vector in degrees $VC_TOOLR_STAT Calculation status of the actual value of the direction of rotation vector References: /PGA/ LHB System variables For further information about the programming of polynomials for axis movements with orientation vectors, see Chapter "Orientation vectors".

  • Page 83

    Detailed description 2.9 Orientation axes Assignment to channel axes Machine data TRAFO5_ORIAX_ASSIGN_TAB_1[0..2] (ORI/channel assignment Transformation 1) are used to assign up to a total of 3 virtual orientation axes to the channel, which are set as input variables in machine data $MC_TRAFO_AXES_IN_n[4..6] (axis assignment for Transformation n).

  • Page 84

    Detailed description 2.9 Orientation axes Axis traversal using traverse keys When using the traverse keys to move an axis continuously (momentary-trigger mode) or incrementally, it must be noted that only one orientation axis can be moved at a time. If more than one orientation axis is moved, alarm 20062 "Channel 1 axis 2 already active" is generated.

  • Page 85

    Detailed description 2.9 Orientation axes 2.9.2 Programming for orientation transformation The values can only be programmed in conjunction with an orientation transformation. Programming of orientation Orientation axes are programmed by means of axis identifiers A2, B2 and C2. Euler and RPY values are distinguished on the basis of G-group 50: •...

  • Page 86

    Detailed description 2.9 Orientation axes Note The four variants of orientation programming are mutually exclusive. If mixed values are programmed, alarm 14130 or alarm 14131 is generated. Exception: For 6-axis kinematics with a 3rd degree of freedom for orientation, C2 may also be programmed for variants 3 and 4.

  • Page 87

    Detailed description 2.9 Orientation axes 2.9.3 Programmable offset for orientation axes How the programmable offset works The additional programmable offset for orientation axes acts in addition to the existing offset and is specified when transformation is activated. Once transformation has been activated, it is no longer possible to change this additive offset and no zero offset will be applied to the orientation axes in the event of an orientation transformation.

  • Page 88

    Detailed description 2.9 Orientation axes Orientable tool holder with additive offset On an orientable tool holder, the offset for both rotary axes can be programmed with the system variables $TC_CARR24 and $TC_CARR25. This rotary axis offset can be transferred automatically from the zero offset effective at the time the orientable tool holder was activated.

  • Page 89

    Detailed description 2.10 Orientation vectors 2.10 Orientation vectors 2.10.1 Polynomial interpolation of orientation vectors Polynomial programming for axis motion In the case of a change in orientation using rotary axis interpolation, linear interpolation normally takes place in the rotary axes. However, it is also possible to program the polynomials as usual for the rotary axes.

  • Page 90

    Detailed description 2.10 Orientation vectors ("AXES"): For all path axes and supplementary axes ("VECT"): For orientation axes ("AXES", "VECT"): For path axes, supplementary axes and orientation axes (without argument): deactivates polynomial interpolation for all axis groups Polynomial interpolation is activated for all axis groups by default. Programming of orientation vectors An orientation vector can be programmed in each block.

  • Page 91

    Detailed description 2.10 Orientation vectors PO[PSI]=(b The angle PHI is interpolated according to PSI(u) = b *u + b Length of the parameter interval where polynomials are defined. The interval always starts at 0. Theoretical value range for PL: 0,0001 ... 99999,9999. The PL value applies to the block that contains it.

  • Page 92

    Detailed description 2.10 Orientation vectors Figure 2-17 Movement of the orientation vector in plan view The angle PSI can be used to generate movements of the orientation vector perpendicular to large circle interpolation plane (see previous figure) Maximum polynomials of the 5th degree permitted 5th Degree polynomials are the maximum possible for programming the angles PHI and PSI.

  • Page 93

    Detailed description 2.10 Orientation vectors Boundary conditions Polynomial interpolation of orientation vectors is only possible for control variants in which the following is included in the functional scope: • both an orientation transformation • and a polynomial interpolation. 2.10.2 Rotations of orientation vector Functionality Changes in tool orientation are programmed by specifying an orientation vector in each block, which is to be reached at the end of the block.

  • Page 94

    Detailed description 2.10 Orientation vectors Programming of orientation direction and rotation While the direction of rotation is already defined when you program the orientation with RPY angles, additional parameters are needed to specify the direction of rotation for the other orientations: 1.

  • Page 95

    Detailed description 2.10 Orientation vectors Interpolation of the angle of rotation Higher degree coefficients can be omitted from the coefficient list (..., ..) if these are all equal to zero. In such cases, the end value of the angleand the constant and linear coefficient of the polynomial cannot be programmed directly.

  • Page 96

    Detailed description 2.10 Orientation vectors This is different to ORIROTR, only if the change in orientation does not take place in one plane. This is the case if at least one polynomial was programmed for the "tilt angle" PSI for the orientation. An additional angle of rotation THETA can then be used to interpolate the rotation vector such that it always produces a specific angle referred to the change in orientation.

  • Page 97

    Detailed description 2.10 Orientation vectors The other programming options must be excluded in this case, since the definition of an absolute direction of rotation conflicts with the interpretation of the angle of rotation in these cases. Possible programming combinations are monitored and an alarm is output if applicable.

  • Page 98

    Detailed description 2.10 Orientation vectors • The opening angle of the cone is programmed degrees with the identifier (nutation angle). The value range of this angle is limited to the interval between 0 degrees and 180 degrees. The values 0 degrees and 180 degrees must not be programmed. If an angle is programmed outside the valid interval, an alarm is generated.

  • Page 99

    Detailed description 2.10 Orientation vectors The identifiers have the following meanings: NUT = +... Traverse angle smaller than or equal to 180 degrees NUT = -... Traverse angle greater than or equal to 180 degrees A positive sign can be omitted when programming. Settings for intermediate orientation orientation interpolation on a cone with intermediate ORICONIO...

  • Page 100

    Detailed description 2.10 Orientation vectors orientation interpolation on a cone with tangential ORICONTO orientation: Interpolation on a peripheral surface of the cone with tangential transition A further option for orientation interpolation is to describe the change in orientation through the path of a 2nd contact point on the tool. orientation interpolation with a second curve: Interpolation of ORICURVE orientation with specification of motion of two contact points...

  • Page 101

    Detailed description 2.10 Orientation vectors Interpolation on the peripheral surface of a cone in the ORICONCCW counterclockwise direction. Specification of the end orientation andt cone direction or opening angle of the taper. Interpolation on a peripheral surface of a cone with ORICONIO specification of end orientation and an intermediate orientation.

  • Page 102

    Detailed description 2.11 Online tool length offset 2.11 Online tool length offset Functionality Effective tool length can be changed in real time so that the length changes are also considered for changes in orientation of the tool. System variable $AA_TOFF[ ] applies tool length compensations in 3-D according to the three tool directions.

  • Page 103

    Detailed description 2.11 Online tool length offset Note Changing the effective tool length using online tool length offset produces changes in the compensatory movements of the axes involved in the transformation in the event of changes in orientation. The resulting velocities can be higher or lower depending on machine kinematics and the current axis position.

  • Page 104

    Detailed description 2.11 Online tool length offset Note For further information about programming plus programming examples, please see: References: /PGA/Chapter "Transformations" As long as online tool length offset is active, the VDI signal on the NCK → PLC interface in the following interface signal is set to 1: DB21, ...

  • Page 105

    Detailed description 2.11 Online tool length offset Mode change Tool length compensation remains active even if the mode is changed and can be executed in any mode. If a tool length compensation is interpolated on account of $AA_TOFF[ ] during mode change, the mode change cannot take place until the interpolation of the tool length compensation has been completed.

  • Page 106

    Detailed description 2.11 Online tool length offset Special functions: 3-Axis to 5-Axis Transformation (F2) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 107

    Boundary conditions No boundary conditions apply. Special functions: 3-Axis to 5-Axis Transformation (F2) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 108

    Boundary conditions Special functions: 3-Axis to 5-Axis Transformation (F2) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 109

    Examples Example of a 5-axis transformation CHANDATA(1) $MA_IS_ROT_AX[AX5] = TRUE $MA_SPIND_ASSIGN_TO_MACHAX[AX5] = 0 $MA_ROT_IS_MODULO[AX5]=0 ;----------------------------------------------------------------------------------------------------- ; general 5-axis transformation ; kinematics: 1. rotary axis is parallel to Z 2. rotary axis is parallel to X Movable tool ;----------------------------------------------------------------------------------------------------- $MC_TRAFO_TYPE_1 = 20 $MC_ORIENTATION_IS_EULER = TRUE $MC_TRAFO_AXES_IN_1[0] = 1 $MC_TRAFO_AXES_IN_1[1] = 2...

  • Page 110

    Examples 4.1 Example of a 5-axis transformation $MC_TRAFO5_PART_OFFSET_1[1] = 0 $MC_TRAFO5_PART_OFFSET_1[2] = 0 $MC_TRAFO5_ROT_AX_OFFSET_1[0] = 0 $MC_TRAFO5_ROT_AX_OFFSET_1[1] = 0 $MC_TRAFO5_ROT_SIGN_IS_PLUS_1[0] = TRUE $MC_TRAFO5_ROT_SIGN_IS_PLUS_1[1] = TRUE $MC_TRAFO5_NON_POLE_LIMIT_1 = 2.0 $MC_TRAFO5_POLE_LIMIT_1 = 2.0 $MC_TRAFO5_BASE_TOOL_1[0] = 0.0 $MC_TRAFO5_BASE_TOOL_1[1] = 0.0 $MC_TRAFO5_BASE_TOOL_1[2] = 5,0 $MC_TRAFO5_JOINT_OFFSET_1[0] = 0.0 $MC_TRAFO5_JOINT_OFFSET_1[1] = 0.0 $MC_TRAFO5_JOINT_OFFSET_1[2] = 0.0...

  • Page 111

    Examples 4.1 Example of a 5-axis transformation Orientation vector programming: N110 TRAORI(1) N120 ORIWKS N130 G1 G90 N140 a3 = 0 b3 = 0 c3 = 1 x0 N150 a3 = 0 b3 =-1 c3 = 0 N160 a3 = 1 b3 = 0 c3 = 0 N170 a3 = 1 b3 = 0 c3 = 1 N180 a3 = 0 b3 = 1 c3 = 0 N190 a3 = 0 b3 = 0 c3 = 1...

  • Page 112

    Examples 4.2 Example of a 3-axis and 4-axis transformation Example of a 3-axis and 4-axis transformation 4.2.1 Example of a 3-axis transformation Example: For the machine schematically presented in Figure "Schematic Presentation of a 3-axis Transformation" (see Chapter "3- and 4-axis Transformation", Short Description), the 3-axis transformation can be projected in the following way: $MC_TRAFO_TYPE_n = 18 ;...

  • Page 113

    Examples 4.3 Example of a universal milling head Example of a universal milling head General information The following two subsections show the main steps which need to be taken in order to activate a transformation for the universal milling head. Machine data ;...

  • Page 114

    Examples 4.4 Example for orientation axes Example for orientation axes Example 1: 3 orientation axes for the 1st orientation transformation for kinematics with 6 transformed axes. Rotation must be done in the following sequence: • firstly about the Z axis. •...

  • Page 115

    Examples 4.4 Example for orientation axes Example 2: 3 orientation axes for the 2nd orientation transformation for kinematics with 5 transformed axes. Rotation must be done in the following sequence: • firstly about the X axis. • then about the Y axis and •...

  • Page 116

    Examples 4.5 Examples for orientation vectors Examples for orientation vectors 4.5.1 Example for polynomial interpretation of orientation vectors Orientation vector in Z-X plane The orientation vector is programmed directly in the examples below. The resulting movements of the rotary axes depend on the particular kinematics of the machine. N10 TRAORI ;...

  • Page 117

    Examples 4.5 Examples for orientation vectors 4.5.2 Example of rotations of orientation vector Rotations with angle of rotation THETA In the following example, the angle of rotation is interpolated in linear fashion from starting value 0 degrees to end value 90 degrees. The angle of rotation changes according to a parabola or a rotation can be executed without a change in orientation.

  • Page 118

    Examples 4.6 Example of generic 5-axis transformation Example of generic 5-axis transformation The following example is based on a machine with rotatable tool on which the first rotary axis is a C axis and the second a B axis (CB kinematics, see Figure). The basic orientation defined in the machine data is the bisecting line between the X and Z axes.

  • Page 119

    Examples 4.6 Example of generic 5-axis transformation G17 TCARR=1 TCOABS ; Basic orientation now is angle- N170 ; bisecting Y-Z A3=1 ; Orientation parallel to X N180 ; set → B-90 C-135 B3=1 C3=1 ; Orientation parallel to N190 ; basic orientation → B0 C0 TRAORI(,2.0, 3.0, 6.0) ;...

  • Page 120

    Examples 4.6 Example of generic 5-axis transformation $TC_DPV5[2,2]= 0.5 ; Z component tool cutting edge orientation N150 $TC_DPVN3[2,2]= 0 : X component orientation normal vector N160 $TC_DPVN4[2,2]= 1 ; Y component orientation normal vector N170 $TC_DPVN5[2,2]= 0 ; Z component orientation normal vector N180 TRAORI() ;...

  • Page 121

    Examples 4.7 Example: Compressor for Orientation Example: Compressor for Orientation Exercise In the example program below, a circle approached by a polygon definition is compressed. The tool orientation moves on the outside of the taper at the same time. Although the programmed orientation changes are executed one after the other, but in an unsteady way, the compressor generates a smooth motion of the orientation.

  • Page 122

    Examples 4.7 Example: Compressor for Orientation Special functions: 3-Axis to 5-Axis Transformation (F2) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 123

    Data lists Machine data 5.1.1 General machine data Number Identifier: $MN_ Description 10620 EULER_ANGLE_NAME_TAB Name of Euler angles or names of orientation axes 10630 NORMAL_VECTOR_NAME_TAB Name of normal vectors 10640 DIR_VECTOR_NAME_TAB Name of direction vectors 10642 ROT_VECTOR_NAME_TAB Name of rotation vectors 10644 INTER_VECTOR_NAME_TAB Name of intermediate vector components...

  • Page 124

    Data lists 5.1 Machine data Number Identifier: $MC_ Description 21106 CART_JOG_SYSTEM Coordinate system for Cartesian JOG 21108 POLE_ORI_MODE Behavior during large circle interpolation at pole position 21120 ORIAX_TURN_TAB_1[n] Assignment of rotation of orientation axes about the reference axes, definition 1 [n = 0..2] 21130 ORIAX_TURN_TAB_2[n] Assignment of rotation of orientation axes about the...

  • Page 125

    Data lists 5.1 Machine data Number Identifier: $MC_ Description 24452 TRAFO_AXES_IN_7[n] Axis assignment for transformation 7 [axis index] 24454 TRAFO_GEOAX_ASSIGN_TAB_7[n] Assignment geometry axis to channel axis for transformation 7 [geometry no.] 24460 TRAFO_TYPE_8 Definition of transformation 8 in channel 24462 TRAFO_AXES_IN_8[n] Axis assignment for transformation 8 [axis index] 24464...

  • Page 126

    Data lists 5.1 Machine data Number Identifier: $MC_ Description 24585 TRAFO5_ORIAX_ASSIGN_TAB_1[n] Assignment of orientation axes to channel axes for orientation transformation 1 [n = 0.. 2] 24590 TRAF5_ROT_OFFSET_FROM_FR_1 Offset of transf. rotary axes from WO 24600 TRAFO5_PART_OFFSET_2[n] Offset vector for 5-axis transformation 2 [n = 0.. 2] 24610 TRAFO5_ROT_AX_OFFSET_2[n] Position offset of rotary axis 1/2 for 5-axis...

  • Page 127

    Data lists 5.2 Setting data Setting data 5.2.1 General setting data Number Identifier: $SN_ Description 41110 JOG_SET_VELO Geometry axes 41130 JOG_ROT_AX_SET_VELO Orientation axes 5.2.2 Channelspecific setting data Number Identifier: $SC_ Description 42475 COMPRESS_CONTOUR_TOL Max. contour deviation for compressor 42476 COMPRESS_ORI_TOL Max.

  • Page 128

    Data lists 5.3 Signals Signals 5.3.1 Signals from channel DB number Byte.Bit Description 21, ... 29.4 Activate PTP traversal 21, ... 33.6 Transformation active 21, ... Number of active G function of G function group 25 21, ... 317.6 PTP traversal active 21, ...

  • Page 129

    Index 2-axis swivel head, 59 Calculate rotary axis position, 63 Cartesian manual travel, 12 Change in orientation, 93 3-axis and 4-axis transformation, 7 3-axis and 4-axis transformations, 29 3-axis kinematics, 58 DB21, ... 3-axis to 5-axis transformation DBX318.2, 98 Call and application, 41 DBX318.3, 98 3-axis transformations, 45 DB21, …...

  • Page 130

    Index MD24462, 77 MD24480, 18, 22 Kinematic transformation, 15 MD24482, 18 Kinematics MD24500, 19, 50, 51, 53 swivelling linear axis, 8 MD24510, 19, 49 Kinematics of machines, 16 MD24520, 22, 49 MD24530, 27 MD24540, 27, 59 MD24550, 50, 51, 53 Limit angle for the fifth axis, 28 MD24558, 51, 53 MD24560, 19, 50, 51, 53...

  • Page 131

    Index Orientation transformation, 15 SD42970, 97 Programming, 79 SD42974, 48 Orientation transformation and orientable tool Selection of type of interpolation, 84 holders, 82 Singular positions, 27 Orientation vectors, 84 Singularities, 59 ORIMCS, 23 Start orientation, 91 ORIPLANE, 92, 94 Switch-over to axis interpolation, 64 ORIWCS, 23 swivelled linear axis Application, 31...

  • Page 132

    Index Special functions: 3-Axis to 5-Axis Transformation (F2) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 133

    SINUMERIK 840D sl/840Di sl/840D/840Di/810D Data lists Special functions: Gantry Axes (G1) Function Manual Valid for Control SINUMERIK 840D sl/840DE sl SINUMERIK 840Di sl/840DiE sl SINUMERIK 840D powerline/840DE powerline SINUMERIK 840Di powerline/840DiE powerline SINUMERIK 810D powerline/810DE powerline Software Version NCU system software for 840D sl/840DE sl 1.3...

  • Page 134

    Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

  • Page 135

    Table of contents Brief description ............................5 Detailed description ........................... 7 "Gantry axes" function ........................7 Referencing and synchronization of gantry axes.................12 2.2.1 Introduction ..........................12 2.2.2 Automatic synchronization ......................18 2.2.3 Points to note ..........................19 Start-up of gantry axes.........................21 PLC interface signals for gantry axes ..................27 Miscellaneous points regarding gantry axes................29 Restrictions..............................

  • Page 136

    Table of contents Special functions: Gantry Axes (G1) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 137

    Brief description Gantry axes Gantry axes are mechanically grouped machine axes. Because of this mechanical coupling, gantry axes are always traversed in unison. The control occurs through the "gantry axes" function. The machine axis that is directly traversed is called the leading axis. The machine axis that is traversed in conjunction with the leading axis is called the synchronized axis.

  • Page 138

    Brief description Special functions: Gantry Axes (G1) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 139

    Detailed description "Gantry axes" function Application On large gantry-type milling machines, various axis units (e.g. gantry or crossbeam) are moved by a number of drives, which are mutually independent. Each drive has its own measuring system and thus constitutes a complete axis system. When these mechanically rigidly-coupled axes are traversed, both drives must be operated in absolute synchronism in order to prevent canting of mechanical components (resulting in power/torque transmission).

  • Page 140

    Detailed description 2.1 "Gantry axes" function Terms The following terms are frequently used in this functional description: Gantry axes Gantry axes comprise at least one pair of axes, the leading axis and the synchronized axis. As these axes are mechanically coupled, they must always be traversed simultaneously by the NC.

  • Page 141

    Detailed description 2.1 "Gantry axes" function Note Each axis in the gantry grouping must be set so that it can take over the function of the leading axis at any time, i.e. matching velocity, acceleration and dynamic response settings. The control performs a plausibility check on the axis definition. Components The "gantry axes"...

  • Page 142

    Detailed description 2.1 "Gantry axes" function When below the warning limit, the message and interface signal will automatically be cancelled. When MD37110 = 0 the message will be disabled. Gantry trip limit Alarm 10653 "error limit exceeded" will be signaled when the machine's maximum permissible actual position values are exceeded: MD37120 $MA_GANTRY_POS_TOL_ERROR (gantry trip limit) In order to prevent any damage to the machines, the gantry axes will be immediately shut...

  • Page 143

    Detailed description 2.1 "Gantry axes" function Referencing and synchronization of gantry axes As the example "Gantry-type milling machine" shows, the forced coupling between gantry axes must remain intact in all operating modes as well as immediately after power ON. In cases where an incremental measuring system is being used for the leading or the synchronized axis, the reference point must be approached while maintaining the axis coupling immediately after machine power ON.

  • Page 144

    Detailed description 2.2 Referencing and synchronization of gantry axes Referencing and synchronization of gantry axes 2.2.1 Introduction Misalignment after starting Immediately after the machine is switched on, the leading and synchronized axes may not be ideally positioned in relation to one another (e.g. misalignment of a gantry). Generally speaking, this misalignment is relatively small so that the gantry axes can still be referenced.

  • Page 145

    Detailed description 2.2 Referencing and synchronization of gantry axes The appropriate synchronized axes traverse in synchronism with the leading axis. Interface signal "Referenced/synchronized" of the leading axis is output to indicate that the reference point has been reached. Section 2: Referencing of the synchronized axes As soon as the leading axis has approached its reference point, the synchronized axis is automatically referenced (as for reference point approach).

  • Page 146

    Detailed description 2.2 Referencing and synchronization of gantry axes • Difference is higher than the gantry warning limit for at least one synchronized axis: IS "Gantry synchronization read to start" is set to "1" and the message "Wait for synchronization start of gantry grouping x" is output. The gantry synchronization process is not started automatically in this case, but must be started explicitly by the operator or from the PLC user program.

  • Page 147

    Detailed description 2.2 Referencing and synchronization of gantry axes Figure 2-2 Flowchart for referencing and synchronization of gantry axes Special functions: Gantry Axes (G1) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 148

    Detailed description 2.2 Referencing and synchronization of gantry axes Synchronization process A synchronization process is always required in the following cases: • after the reference point approach of all axes included in a grouping, • if the axes become de-synchronized (s below). Operational sequence failure If the referencing process described above is interrupted as a result of disturbances or a RESET, proceed as follows:...

  • Page 149

    Detailed description 2.2 Referencing and synchronization of gantry axes Loss of synchronization The synchronization of the gantry grouping is lost (IS "Gantry grouping is synchronized" → 0) • The gantry axes were in "Follow-up" mode • The reference position of a gantry axis is lost, e.g. during "Parking" (no measuring system active) •...

  • Page 150

    Detailed description 2.2 Referencing and synchronization of gantry axes Referencing direction selection The zero mark leveling function of the slave axis can be defined via the machine data: MD37150 $MA_GANTRY_FUNCTION_MASK Bit 1 Value Meaning The zero mark leveling function of the slave axis analogous to the machine data: MD34010 $MA_REFP_CAM_DIR_IS_MINUS The zero mark leveling function of the master axis is the same as the slave axis During referencing, the reference point value of the leading axis is specified as the target...

  • Page 151

    Detailed description 2.2 Referencing and synchronization of gantry axes Parameter rate dependence loads with machine data: MD36012 $MA_STOP_LIMIT_FACTOR (exact stop coarse/fine and standstill factor) Note The following interface signal blocks automatic synchronization in all modes except referencing mode: DB31, ... DBX29.5 (no automatic synchronization) Should the automatic synchronization be activated at this point, then the following interface signal must be reset: DB31, ...

  • Page 152

    Detailed description 2.2 Referencing and synchronization of gantry axes Referencing from part program with G74 The referencing and synchronization process for gantry axes can also be initiated from the part program by means of command G74. In this case, only the axis name of the leading axis may be programmed.

  • Page 153

    Detailed description 2.3 Start-up of gantry axes Monitoring functions effective Analogous to normal NC axes, the following monitoring functions do not take effect for gantry axes until the reference point is reached (IS "Referenced/Synchronized"): • Working area limits • Software limit switch •...

  • Page 154

    Detailed description 2.3 Start-up of gantry axes Axis traversing direction As part of the start-up procedure, a check must be made to ensure that the direction of rotation of the motor corresponds to the desired traversing direction of the axis. Correct by means of axial machine data: MD32100 $MA_AX_MOTION_DIR (travel direction).

  • Page 155

    Detailed description 2.3 Start-up of gantry axes Entering gantry trip limits For the monitoring of the actual position values of the synchronized axis in relation to the actual position of the leading axis, the limit values for termination, as well as for the leading and synchronized axes, should be entered corresponding to the specifications of the machine manufacturer: MD37120 $MA_GANTRY_POS_TOL_ERROR (gantry trip limit)

  • Page 156

    Detailed description 2.3 Start-up of gantry axes • MD32420 $MA_JOG_AND_POS_JERK_ENABLE (basic position of axial jerk limitation) • MD32430 $MA_JOG_AND_POS_MAX_JERK (axial jerk) References: /FB1/ Function Manual, Basic Functions, Velocities, Setpoint-Actual Value Systems, Closed- Loop Control (G2) Dynamics matching The leading axis and the coupled axis must be capable of the same dynamic response to setpoint changes.

  • Page 157

    Detailed description 2.3 Start-up of gantry axes This will prevent a warning message being output during traversing motion. In cases where an excessively high additional torque is acting on the drives due to misalignment between the leading and synchronized axes, the gantry grouping must be aligned before the axes are traversed.

  • Page 158

    Detailed description 2.3 Start-up of gantry axes Function generator/measuring function The activation of the function generator and measuring function will be aborted on the synchronized axis with an error message. When an activation of the synchronized axis is absolutely necessary (e.g. to calibrate the machine), the leading and synchronized axes must be temporarily interchanged.

  • Page 159

    Detailed description 2.4 PLC interface signals for gantry axes Start-up support for gantry groupings The start-up functions of the function generator and measuring are parameterized via the PI service. All parameterized axes commence traversing when the NC Start key on the MCP panel is pressed in JOG mode.

  • Page 160

    Detailed description 2.4 PLC interface signals for gantry axes Table 2-3 Effect of interface signals from PLC to axis on leading and synchronized axes PLC interface signal DB31, ... DBX ... Effect on Leading axis Synchronized axis Axis/spindle disable On all axes in gantry No effect grouping Position measuring system 1/2...

  • Page 161

    Detailed description 2.5 Miscellaneous points regarding gantry axes Miscellaneous points regarding gantry axes Manual travel It is not possible to traverse a synchronized axis directly by hand in JOG mode. Traverse commands entered via the traversing keys of the synchronized axis are ignored internally in the control.

  • Page 162

    Detailed description 2.5 Miscellaneous points regarding gantry axes Axes of a gantry grouping must not be known in all channels. The check is not performed when powering up, but only when an attempt is made to replaced the master axis in the channel.

  • Page 163

    Detailed description 2.5 Miscellaneous points regarding gantry axes • To allow "gantry axes" to traverse without a mechanical offset, the dynamic control response settings of the synchronized axes and the leading axis must be identical. In contrast, the "coupled motion" function permits axes with different dynamic control response characteristics to be coupled.

  • Page 164

    Detailed description 2.5 Miscellaneous points regarding gantry axes Special functions: Gantry Axes (G1) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 165

    Restrictions No supplementary conditions apply. Special functions: Gantry Axes (G1) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 166

    Restrictions Special functions: Gantry Axes (G1) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 167

    Example Creating a gantry grouping Introduction The gantry grouping, the referencing of its axes, the orientation of possible offsets and, finally, the synchronization of the axes involved are complicated procedures. The individual steps involved in the process are explained below by an example constellation. Constellation Machine axis 1 = gantry leading axis, incremental measuring system Machine axis 3 = gantry synchronized axis, incremental measuring system...

  • Page 168

    Example 4.2 Setting of NCK PLC interface Reference point machine data (for first encoder each) Axis 1 MD34000 $MA_REFP_CAM_IS_ACTIVE = TRUE MD34010 $MA_REFP_CAM_DIR_IS_MINUS = e.g. FALSE MD34020 $MA_REFP_VELO_SEARCH_CAM = MD34030 $MA_REFP_MAX_CAM_DIST = corresponds to max. distance traversed MD34040 $MA_REFP_VELO_SEARCH_MARKER = MD34050 $MA_REFP_SEARCH_MARKER_REVERSE = e.g.

  • Page 169

    Example 4.2 Setting of NCK PLC interface The NCK sets the following as a confirmation in the axis block of axis 1: DB31, ... DBB101: The PLC user program sets the following for the axis data block of axis 3: DB31, ...

  • Page 170

    Example 4.3 Commencing start-up Commencing start-up Referencing The following steps must be taken: • Select "REF" operating mode • Start referencing for axis 1 (master axis) • Wait until message "10654 Channel 1 Waiting for synchronization start" appears. At this point in time, the NCK has prepared axis 1 for synchronization and registers this to the interface signal: DB31, ...

  • Page 171

    Example 4.3 Commencing start-up • Start referencing again for axis 1 (master axis) with the modified machine data • Wait until message "10654 Channel 1 Waiting for synchronization start" appears • At this point in time, the NCK has prepared axis 1 for synchronization and registers this to the interface signal: DB31, ...

  • Page 172

    Example 4.4 Setting warning and trip limits Setting warning and trip limits As soon as the gantry grouping is set and synchronized, the following machine data must still be set to correspond: MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit) MD37120 $MA_GANTRY_POS_TOL_ERROR (gantry trip limit) Proceed as follows •...

  • Page 173

    Example 4.4 Setting warning and trip limits MD37130 $MA_GANTRY_POS_TOL_REF (gantry trip limit for referencing) These should have the following scales of magnitude at the end of the customizing process: Note The same procedure must be followed when starting up a gantry grouping in which the coupled axes are driven by linear motors and associated measuring systems.

  • Page 174

    Example 4.4 Setting warning and trip limits Special functions: Gantry Axes (G1) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 175

    Data lists Machine data 5.1.1 Axis/spindlespecific machine data Number Identifier: $MA_ Description 30300 IS_ROT_AX Rotary axis 32200 POSCTRL_GAIN factor 32400 AX_JERK_ENABLE Axial jerk limitation 32410 AX_JERK_TIME Time constant for axis jerk filter 32420 JOG_AND_POS_JERK_ENABLE Initial setting for axial jerk limitation 32430 JOG_AND_POS_MAX_JERK Axial jerk...

  • Page 176

    Data lists 5.2 Signals Number Identifier: $MA_ Description 37130 GANTRY_POS_TOL_REF Gantry trip limit for referencing 37140 GANTRY_BREAK_UP Invalidate gantry axis grouping Signals 5.2.1 Signals from mode group DB number Byte.bit Description 11, ... Active machine function REF 5.2.2 Signals from channel DB number Byte.bit Description...

  • Page 177

    Index DB 31, ... MD30300, 22 DBB101, 37, 38, 39 MD32100, 22 DBX1.4, 19, 28 MD32200, 23 DBX1.5, 19, 28 MD32400, 23 DBX1.6, 28 MD32410, 23 DBX101.2, 10, 27 MD32420, 24 DBX101.3, 9, 27 MD32430, 24 DBX101.4, 16, 27 MD32610, 23 DBX101.5, 11, 16, 18, 27 MD32620, 23 DBX101.6, 27...

  • Page 178: Cycle Times (g3)

    SINUMERIK 840D sl/840Di sl/840D/840Di/810D Data lists Special functions: Cycle Times (G3) Function Manual Valid for Control SINUMERIK 840D sl/840DE sl SINUMERIK 840Di sl/840DiE sl SINUMERIK 840D powerline/840DE powerline SINUMERIK 840Di powerline/840DiE powerline SINUMERIK 810D powerline/810DE powerline Software Version NCU system software for 840D sl/840DE sl 1.3...

  • Page 179

    Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

  • Page 180

    Table of contents Brief description ............................5 Detailed description ........................... 7 General Information About Cycle Times..................7 SINUMERIK 810D and 840D......................8 SINUMERIK 840Di with PROFIBUS DP..................9 2.3.1 Description of a DP cycle......................10 2.3.2 Clock cycles and position-control cycle offset ................12 Restrictions.............................. 17 Example..............................

  • Page 181

    Table of contents Special functions: Cycle Times (G3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 182

    Brief description This description explains the relationships and machine data of the various system cycles of the NC: • Basic system clock cycle • Interpolator cycle • Position controller cycle 810D and 840D For SINUMERIK 840D and SINUMERIK 810D, the position control cycle and the interpolator cycle (IPO cycle) are derived from the system basic cycle, which is set in the machine data of the NC.

  • Page 183

    Brief description Special functions: Cycle Times (G3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 184

    Detailed description General Information About Cycle Times Requirements The system clock cycle, position-control cycle and interpolator cycle are defined in the following machine data. MD10050 $MN_SYSCLOCK_CYCLE_TIME (system clock cycle) MD10060 $MN_POSCTRL_SYSCLOCK_TIME_RATIO (factor for position-control cycle) MD10070 $MN_IPO_SYSCLOCK_TIME_RATIO (factor for the interpolation cycle) With MD10050, $MN_SYSCLOCK_CYCLE_TIME sets the system clock cycle for the system software in seconds.

  • Page 185

    Detailed description 2.2 SINUMERIK 810D and 840D Default values for cycle times The default settings ensure that a maximum configuration of the system can power up reliably. The cycle times, e.g., for the NCU 573, can generally be set to lower values. The default cycle times are as follows: cycle 810D...

  • Page 186

    Detailed description 2.3 SINUMERIK 840Di with PROFIBUS DP Block cycle time The block cycle time is the sum of the block change time and block preparation time. It is at least as long as the cycle time for sending the position setpoints to the servos - in normal operation therefore as long as the interpolator cycle.

  • Page 187

    Detailed description 2.3 SINUMERIK 840Di with PROFIBUS DP 2.3.1 Description of a DP cycle Actual values At time T , the actual position values are read from all the equidistant drives (DP slaves). In the next DP cycle, the actual values are transferred to the DP master in the time T Position controller In time T where T...

  • Page 188

    Detailed description 2.3 SINUMERIK 840Di with PROFIBUS DP Key to Fig. above: • T MAPC: Master application cycle: NC position control cycle for SINUMERIK 840Di always applies for: T MAPC • T DP cycle time: DP cycle time • T Data exchange time: Total transfer time for all DP slaves •...

  • Page 189

    Detailed description 2.3 SINUMERIK 840Di with PROFIBUS DP 2.3.2 Clock cycles and position-control cycle offset Cycle times The NC derives the cycle times, system clock cycle, position-control cycle and interpolator cycle from the equidistant PROFIBUS-DP cycle set in the SIMATIC S7 project during configuration of the PROFIBUS.

  • Page 190

    Detailed description 2.3 SINUMERIK 840Di with PROFIBUS DP Figure 2-3 Position control cycle offset compared to PROFIBUS DP cycle Key to Fig. above: • TLag: Computing time requirements for the position controller • TDP: DP cycle time: DP cycle time •...

  • Page 191

    Detailed description 2.3 SINUMERIK 840Di with PROFIBUS DP Conditions and recommendations for MD10062 MD10062 $MN_POSCTRL_CYCLE_DELAY (position control cycle offset) The position controller cycle offset (T ) must be set such that the following conditions are fulfilled within a PROFIBUS-DP/system cycle: •...

  • Page 192

    Detailed description 2.3 SINUMERIK 840Di with PROFIBUS DP MD10059 MD10059 $MN_PROFIBUS_ALARM_MARKER (PROFIBUS alarm marker) Alarm requests in the event of a conflict during startup • In this machine data, alarm requests on the PROFIBUS level are stored even after reboot. If a conflict occurs during startup between the machine data –...

  • Page 193

    Detailed description 2.3 SINUMERIK 840Di with PROFIBUS DP Special functions: Cycle Times (G3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 194

    Restrictions No supplementary conditions apply. Special functions: Cycle Times (G3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 195

    Restrictions Special functions: Cycle Times (G3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 196

    Example No examples are available. Special functions: Cycle Times (G3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 197

    Example Special functions: Cycle Times (G3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 198

    Data lists Machine data 5.1.1 General machine data Number Identifier: $MN_ Description 10050 SYSCLOCK_CYCLE_TIME Basic system clock cycle 10059 PPOFIBUS_ALARM_MARKER PROFIBUS alarm marker (internal only) 10060 POSCTRL_SYSCLOCK_TIME_RATIO Factor for position control clock cycle 10061 POSCTRL_CYCLE_TIME Position control cycle 10062 POSCTRL_CYCLE_DELAY Position control cycle offset 10070 IPO_SYSCLOCK_TIME_RATIO...

  • Page 199

    Data lists 5.1 Machine data Special functions: Cycle Times (G3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 200

    Index IPO cycle, 9 Acceleration time constant, 8 Master application cycle, 11 Master Time, 11 MD10050, 7, 12, 15 MD10059, 15 Basic system clock cycle, 7 MD10060, 7, 9, 15 840Di, 12 MD10061, 12 Block cycle time, 9 MD10062, 12, 14 MD10070, 7, 12, 15 MD33000, 8 Cycle times|Default values, 8...

  • Page 201

    Index Special functions: Cycle Times (G3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 202

    Index Special functions: Gantry Axes (G1) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 203: Contour Tunnel Monitoring

    840D sl/840Di sl/840D/840Di/810D Data lists Special functions: Contour Tunnel Monitoring (K6) Function Manual Valid for Control SINUMERIK 840D sl/840DE sl SINUMERIK 840Di sl/840DiE sl SINUMERIK 840D powerline/840DE powerline SINUMERIK 840Di powerline/840DiE powerline SINUMERIK 810D powerline/810DE powerline Software Version NCU system software for 840D sl/840DE sl 1.3...

  • Page 204

    Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

  • Page 205

    Table of contents Brief description ............................5 Contour tunnel monitoring......................5 Programmable contour accuracy ....................6 Detailed description ........................... 7 Contour tunnel monitoring......................7 Programmable contour accuracy ....................8 Restrictions.............................. 11 Examples..............................13 Programmable contour accuracy ....................13 Data lists..............................15 Machine data..........................15 5.1.1 Channelspecific machine data .....................15 5.1.2 Axis/spindlespecific machine data ....................15 Setting data ..........................15...

  • Page 206

    Table of contents Special functions: Contour Tunnel Monitoring (K6) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 207

    Brief description Contour tunnel monitoring Function The absolute movement of the tool tip in space is monitored. The function operates channel specific. Model A round tunnel with a definable diameter is defined around the programmed path of a machining operation. Axis movements are stopped as an option if the path deviation of the tool tip is greater than the defined tunnel as the result of axis errors.

  • Page 208

    Brief description 1.2 Programmable contour accuracy Figure 1-1 Position of the contour tunnel around the programmed path As long as the calculated actual position of the tool tip remains inside the sketched tunnel, motion continues in the normal way. If the calculated actual position violates the tunnel, an alarm is triggered (in the default setting) and the axes are stopped by "Ramp Stop".

  • Page 209

    Detailed description Contour tunnel monitoring Aim of the monitoring function The aim of the monitoring function is to stop the movement of the axes if axis deviation causes the distance between the tool tip (actual value) and the programmed path (setpoint) to exceed a defined value (tunnel radius).

  • Page 210

    Detailed description 2.2 Programmable contour accuracy Activating The monitoring will only become active if the following conditions are met: • The contour tunnel monitoring function is set. • MD21050 is higher than 0.0. • At least two geometry axes have been defined. Stopping Monitoring can be stopped by enabling the MD setting: MD21050 = 0.0.

  • Page 211

    Detailed description 2.2 Programmable contour accuracy Function The "Programmable contour accuracy" function permits the user to specify a maximum error for the contour in the NC program, which may not be exceeded. The control calculates the factor (servo gain factor) for the axes concerned and limits the maximum path velocity so that the contour error resulting from the lag does not exceed the value specified.

  • Page 212

    Detailed description 2.2 Programmable contour accuracy RESET/end of program On RESET/program end the response set in the following machine data for the G code group 39 will become effective: MD20110 $MC_RESET_MODE_MASK (Definition of control default settings after reset/TP end) MD20112 $MC_START_MODE_MASK (Definition of the control default settings in case of NC start) e.g.

  • Page 213

    Restrictions Coupled motion If coupled motion between two geometry axes is programmed with contour tunnel monitoring, this always results in activation of the contour tunnel monitoring. In this case, the contour tunnel monitoring must be switched off before programming the coupled motion: MD21050 $MC_CONTOUR_TUNNEL_TOL = 0.0 Special functions: Contour Tunnel Monitoring (K6)

  • Page 214

    Restrictions Special functions: Contour Tunnel Monitoring (K6) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 215

    Examples Programmable contour accuracy Extract from part program N10 X0 Y0 G0 ; Enabling of contour accuracy defined by MD N20 CPRECON ; Machine contour at 10 m/min in continuous-path mode N30 F10000 G1 G64 X100 ; Automatic limitation of feed in circle block N40 G3 Y20 J10 ;...

  • Page 216

    Examples 4.1 Programmable contour accuracy Special functions: Contour Tunnel Monitoring (K6) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 217

    Data lists Machine data 5.1.1 Channelspecific machine data Number Identifier: $MC_ Description 20470 CPREC_WITH_FFW Programmed Contour accuracy 21050 CONTOUR_TUNNEL_TOL Response threshold for contour tunnel monitoring 21060 CONTOUR_TUNNEL_REACTION Reaction to response of contour tunnel monitoring 21070 CONTOUR_ASSIGN_FASTOUT Assignment of an analog output for output of the contour error 5.1.2 Axis/spindlespecific machine data...

  • Page 218

    Data lists 5.2 Setting data Special functions: Contour Tunnel Monitoring (K6) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 219

    Index Activating, 8 Parameterization Active feedforward control, 9 Deceleration methods, 7 Aim of the monitoring function, 7 Tunnel size, 7 Analysis, 6 Programmable contour accuracy Analysis output, 8 Active feedforward control, 9 Application, 9 Minimum feed, 9 Programmable contour accuracy Activating, 9 Coupled motion, 11 Quality control, 6...

  • Page 220

    Index Special functions: Contour Tunnel Monitoring (K6) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 221: Axis Couplings And Esr

    840D sl/840Di sl/840D/840Di/810D Data lists Special functions: Axis Couplings and ESR (M3) Function Manual Valid for Control SINUMERIK 840D sl/840DE sl SINUMERIK 840Di sl/840DiE sl SINUMERIK 840D powerline/840DE powerline SINUMERIK 840Di powerline/840DiE powerline SINUMERIK 810D powerline/810DE powerline Software Version NCU system software for 840D sl/840DE sl 1.3...

  • Page 222

    Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

  • Page 223

    Table of contents Brief description ............................7 Coupled motion ..........................7 1.1.1 Function ............................7 1.1.2 Preconditions ..........................8 Curve tables ...........................8 1.2.1 Function ............................8 1.2.2 Preconditions ..........................9 Master value coupling ........................9 1.3.1 Function ............................9 1.3.2 Preconditions ..........................9 Electronic gearbox (EG).......................10 1.4.1 Function ............................10 1.4.2 Preconditions ..........................11 Generic coupling ..........................12...

  • Page 224

    Table of contents Master value coupling ......................... 49 2.3.1 General functionality ........................49 2.3.2 Programming a master value coupling ..................54 2.3.3 Behavior in AUTOMATIC, MDA and JOG modes............... 57 2.3.4 Effectiveness of PLC interface signals..................59 2.3.5 Special characteristics of the axis master value coupling function ..........59 Electronic gearbox (EG)......................

  • Page 225

    Table of contents 2.6.2 Programmed dynamic limits.......................124 2.6.2.1 Programming (VELOLIMA, ACCLIMA)..................124 2.6.2.2 Examples ...........................127 2.6.2.3 System variables........................128 Extended stop and retract (ESR) ....................128 2.7.1 Extended stop and retract (ESR) ....................128 2.7.2 Reactions external to the control ....................130 2.7.3 Drive-independent reactions ......................131 2.7.4 NC-controlled extended stop .....................133 2.7.5...

  • Page 226

    Table of contents Signals............................190 5.4.1 Signals to axis/spindle....................... 190 5.4.2 Signals from axis/spindle ......................191 Index............................Index-193 Special functions: Axis Couplings and ESR (M3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 227

    Brief description Coupled motion 1.1.1 Function The "coupled motion" function enables the definition of simple axis links between a master axis and a slave axis, taking into consideration a coupling factor. Coupled motion has the following features: • Any axis of the NC can be defined as a master axis. •...

  • Page 228

    Brief description 1.2 Curve tables 1.1.2 Preconditions Coupled motion function The coupled motion function forms part of the NCK software. Generic coupling The coupled motion functionality is also available in the generic coupling. However, for basic operation of generic coupling, the following limitations apply: •...

  • Page 229

    Brief description 1.3 Master value coupling 1.2.2 Preconditions Memory configuration Static NC memory Memory space for curve tables in static NC memory is defined by machine data: 18400 $MN_MM_NUM_CURVE_TABS (number of curve tables) 18402 $MN_MM_NUM_CURVE_SEGMENTS (number of curve segments) 18403 $MN_MM_NUM_CURVE_SEG_LIN (number of linear curve segments) 18404 $MN_MM_NUM_CURVE_TABS (number of curve table polynomials) Dynamic NC memory Memory space for curve tables in dynamic NC memory is defined by machine data:...

  • Page 230

    Brief description 1.4 Electronic gearbox (EG) Electronic gearbox (EG) 1.4.1 Function General The "electronic gear" function makes it possible to control the movement of a following axis, depending on up to five master axes. The relationship between each leading axis and the following axis is defined by the coupling factor.

  • Page 231

    Brief description 1.4 Electronic gearbox (EG) Application Examples: • Machine tools for gear cutting • Gear trains for production machines 1.4.2 Preconditions The "Electronic Gearbox" option or the relevant option of generic coupling (refer to "Preconditions" for generic coupling) is a prerequisite for utilization of the function. Special functions: Axis Couplings and ESR (M3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 232

    Brief description 1.5 Generic coupling Generic coupling 1.5.1 Function Function "Generic Coupling" is a general coupling function, combining all coupling characteristics of existing coupling types (coupled motion, master value coupling, electronic gearbox and synchronous spindle). The function allows flexible programming: •...

  • Page 233

    Brief description 1.5 Generic coupling 1.5.2 Preconditions CP Versions Generic coupling is available in a basic version as part of the NCK software and as three optional versions CP-BASIC, CP-COMFORT and CP-EXPERT. This structure is based on the following considerations: •...

  • Page 234

    Brief description 1.5 Generic coupling Table 1-2 Scaling of availability of coupling properties Type A Type B Type C Type D Maximum number of CPSETTYPE-related functionalities (per type) TRAIL - Coupled motion Maximum number of coupled motion groups with the following properties: →...

  • Page 235

    Brief description 1.5 Generic coupling Type A Type B Type C Type D Maximum number of free generic couplings with the following properties: Default (in accordance with CPSETTYPE="CP") Maximum number of master values From part program and synchronous actions Cascading permitted BCS / MCS BCS / MCS Co-ordinate reference (default): CPFRS="BCS")

  • Page 236

    Brief description 1.6 Extended stop and retract (ESR) Extended stop and retract (ESR) 1.6.1 Function The "Extended stop and retract" function (ESR) provides a means to react flexibly to specific error sources while preventing damage to the workpiece: • Extended stop/retract If possible, all axes involved in the electronic coupling are brought to a normal standstill.

  • Page 237

    Detailed description Coupled motion 2.1.1 General functionality The "Coupled motion" function allows the definition of simple axis couplings. Coupling is performed from one leading axis to one or more following axes, the so-called coupled motion axes. A separate coupling factor can be specified for each coupled motion axis. Coupled axis grouping The leading axis and all the coupled motion axes assigned to it together form a coupled axis grouping.

  • Page 238

    Detailed description 2.1 Coupled motion Figure 2-1 Application Example: Two-sided machining Multiple couplings Up to two leading axes can be assigned to one coupled motion axis. The traversing movement of the coupled motion axis then results from the sum of the traversing movements of the leading axes.

  • Page 239

    Detailed description 2.1 Coupled motion Switch ON/OFF Coupled motion can be activated/deactivated via the part programs and synchronous actions. In this context please ensure that the switch on and switch off is undertaken with the same programming: • Switch on: Part program → Switch off: Part program •...

  • Page 240

    Detailed description 2.1 Coupled motion Distance-to-go: Coupled motion axis The distance-to-go of a coupled motion axis refers to the total residual distance to be traversed from dependent and independent traversing. Delete distance-to-go: Coupled motion axis Delete distance-to-go for a coupled motion axis only results in aborting of the independent traversing movement of the leading axis.

  • Page 241

    Detailed description 2.1 Coupled motion 2.1.2 Programming 2.1.2.1 Definition and switch on of a coupled axis grouping (TRAILON) Definition and switch on of a coupled axis grouping take place simultaneously with the TRAILON part program command. Programming Syntax: TRAILON(<coupled motion axis>, <leading axis>, [<coupling factor>]) Effective: modal Parameters:...

  • Page 242

    Detailed description 2.1 Coupled motion 2.1.2.2 Switch off (TRAILON) Switch off of the coupling of a coupled-motion axis with a leading axis takes place through the TRAILOF part program command. Programming Syntax: TRAILON(<coupled motion axis>, <leading axis>) or (in abbreviated form): TRAILOF(<coupled-motion axis>) Effective: modal...

  • Page 243

    Detailed description 2.1 Coupled motion 2.1.3 Effectiveness of PLC interface signals Independent coupled motion axis All the associated channel and axis specific interface signals of the coupled-motion axis are effective for the independent motion of a coupled-motion axis, e.g.: • DB21, ... DBX0.3 (Activate DRF) •...

  • Page 244

    Detailed description 2.1 Coupled motion Tracking (DB31, ... DBX1.4) Activation of tracking for an axis is done via the PLC program by setting the following NC/PLC interface signals: DB31, ... DBX2.1 = 0 (control system enable) DB31, ... DBX1.4 == 1 (tracking mode) When activating tracking mode for a coupled axis grouping, the specified NC/PLC interface signals must be set simultaneously for all axes (master and slave axes) of the coupled axis group.

  • Page 245

    Detailed description 2.1 Coupled motion 2.1.5 Dynamics limit The dynamics limit is dependent on the activation of the coupled axis grouping: • Part program If activation is performed in the part program, the dynamics of all coupled motion axes is taken into account so that no coupled motion axis is overloaded during traversing of the leading axis.

  • Page 246

    Detailed description 2.2 Curve tables Curve tables 2.2.1 General functionality Curve tables A functional relation between a command variable "master value" and an abstract following value is described in the curve table. A following variable can be assigned uniquely to each master value within a defined master value range.

  • Page 247

    Detailed description 2.2 Curve tables Selection of memory type While defining a curve table, it can be defined whether the curve table is created in the static or dynamic NC memory. Note Table definitions in the static NC memory are available even after control system run-up. Curve tables of the dynamic NC memory must be redefined after every control system run- 2.2.2 Memory organization...

  • Page 248

    Detailed description 2.2 Curve tables Insufficient memory If a curve table cannot be created, because sufficient memory is not available, then the newly created table is deleted immediately after the alarm. If insufficient is available, then one or more table(s) that is/are no longer required can be deleted with CTABDEL or, alternatively, memory can be reconfigured via machine data.

  • Page 249

    Detailed description 2.2 Curve tables 2.2.3 Commissioning 2.2.3.1 Memory configuration A defined storage space is available for the curve tables in the static and dynamic NC memory, which is defined through the following machine data: Static NC memory MD18400 $MN_MM_NUM_CURVE_TABS Defines the number of curve tables that can be stored in the static NC memory.

  • Page 250

    Detailed description 2.2 Curve tables 2.2.3.2 Tool radius compensation MD20900 Tool radius compensation can produce segments for which the following axis or leading axis have no movement. A missing movement of the following axis does not normally represent any problem. As against this, a missing movement of the leading axis requests a specification as to how such discontinuities are to be handled, i.e., whether or not a curve table should be generated in these cases.

  • Page 251

    Detailed description 2.2 Curve tables 2.2.4 Programming Definition The following modal language commands work with curve tables: (The parameters are explained at the end of the list of functions.) • Beginning of definition of a curve table: CTABDEF(following axis, leading axis, n, applim, memType) •...

  • Page 252

    Detailed description 2.2 Curve tables Access to curve table segments • Read start value (following axis value) of a table segment CTABSSV(leading value, n, degrees, [following axis, leading axis]) • Read end value (following axis value) of a table segment CTABSEV(master value, n, degrees, [following axis, master axis]) Note If curve table functions such as CTAB(), CTABINV(), CTABSSV() etc., in synchronous...

  • Page 253

    Detailed description 2.2 Curve tables Curve tables in the number range n to m. CTABUNLOCK(n, m) All curve tables, irrespective of memory type CTABUNLOCK() All curve tables in the specified memory type CTABUNLOCK(, , memType) Other commands for calculating and differentiating between curve tables for applications for diagnosing and optimizing the use of resources: •...

  • Page 254

    Detailed description 2.2 Curve tables • Returns the memory in which curve table number n is stored. CTABMEMTYP(n) • Returns the table periodicity. CTABPERIOD(n) • Number of curve segments already used in memory memType. CTABSEG(memType, segType) • Number of curve segments used in curve table number n CTABSEGID(n, segType) •...

  • Page 255

    Detailed description 2.2 Curve tables Parameter • Following axis: Identifier of axis via which the following axis is programmed in the definition. • Leading axis: Identifier of axis via which the leading axis is programmed. • n, m Numbers for curve tables. Curve table numbers can be freely assigned.

  • Page 256

    Detailed description 2.2 Curve tables • segType Optional parameter for entry of segment type Possible values: segType "L" linear segments segType "P" Polynomial segments References: /PGA/ Programming Manual Work Preparation; Path Behavior Chapter Curve Tables (CTAB) Restrictions The following restrictions apply when programming: •...

  • Page 257

    Detailed description 2.2 Curve tables Starting value The first motion command in the definition of a curve table defines the starting value for the leading and following value. All instructions that cause a preprocessing stop must be removed. Example 1 Without tool radius compensation, without memory type ;...

  • Page 258

    Detailed description 2.2 Curve tables Note The value pairs between CTABDEF and CTABEND must be specified for precisely the axis identifiers that have been programmed in CTABDEF as the leading axis and following axis identifiers. In the case of programming errors, alarms or incorrect contours may be generated.

  • Page 259

    Detailed description 2.2 Curve tables CTABINV When using the inversion function for the curve tables CTABINV, it must be noted that the following value mapped to the leading value may not be unique. Within a curve table, the following value can assume the same value for any number of master value positions.

  • Page 260

    Detailed description 2.2 Curve tables Identifying the segment associated with master value X Example of reading the segment starting and end values for determining the curve segment associated with master value X = 30 using CTABSSV and CTABSEV: ; Beginning of the definition of start and N10 DEF REAL STARTPOS ;...

  • Page 261

    Detailed description 2.2 Curve tables Reading values at start and end The values of the following axes and of the master axis at the start and end of a curve table can be read with the following calls: R10 =CTABTSV(n, degrees, F axis), following value at the beginning of the curve table R10 =CTABTEV(n, degrees, F axis), following value at the beginning of the curve table R10 =CTABTSP(n, degrees, F axis), following value at the beginning of the curve table R10 =CTABTEP(n, degrees, F axis), following value at the beginning of the curve table...

  • Page 262

    Detailed description 2.2 Curve tables Figure 2-3 Determining the minimum and maximum values of the table 2.2.6 Activation/deactivation Activation The coupling of real axes to a curve table is activated through this command: LEADON (<Following axis>, <Leading axis>, <n>) with <n> =Number of the curve table Activation is possible: •...

  • Page 263

    Detailed description 2.2 Curve tables Deactivation The switch off of the coupling to a curve table takes place through the following command: LEADON (<Following axis>, <Leading axis>) Deactivation is possible: • In the part program • in synchronized actions Note While programming LEADOF, the abbreviated form is also possible without specification of the leading axis.

  • Page 264

    Detailed description 2.2 Curve tables 2.2.8 Behavior in AUTOMATIC, MDA and JOG modes Activation An activated curve table is functional in the AUTOMATIC, MDA and JOG modes. Basic setting after run-up No curve tables are active after run-up. 2.2.9 Effectiveness of PLC interface signals Dependent following axis With respect to the motion of a following axis that is dependent on the leading axis, only the following axis interface signals that effect termination of the motion (e.g.

  • Page 265

    Detailed description 2.2 Curve tables 2.2.10 Diagnosing and optimizing utilization of resources The following functions allow parts programs to get information on the current utilization of curve tables, table segments and polynomials. One result of the diagnostic functions is that resources still available can be used dynamically with the functions, without necessarily having to increase memory usage.

  • Page 266

    Detailed description 2.2 Curve tables If the sequence of curve tables in memory changes between consecutive calls of CTABID()CTABID(), e.g. due to the deletion of curve tables with CTABDEL(), the CTABID(p, ...) function can supply a different curve table with the same number. To prevent this from happening, the curve tables concerned can be locked, using the CTABLOCK(...) language command.

  • Page 267

    Detailed description 2.2 Curve tables b) Curve table segments • Determine number of used curve segments of the type memType in the memory range. • CTABSEG(memType, segType) • If memType is not specified, the memory type specified in the following machine data: MD20905 $MC_CTAB_DEFAULT_MEMORY_TYPE Result: >= 0: Number of curve segments...

  • Page 268

    Detailed description 2.2 Curve tables c) Polynomials • Determine the number of used polynomials of the memory type CTABPOL(memType) If memType is not specified, the memory type specified in the following machine data: MD20905 $MC_CTAB_DEFAULT_MEMORY_TYPE Result: >= 0: Number of polynomials already used in the memory type -2: Invalid memory type •...

  • Page 269

    Detailed description 2.3 Master value coupling Master value coupling 2.3.1 General functionality Introduction Master value couplings are divided into axis and path master value couplings. In both cases, the axis and path positions are defined by the control system on the basis of master values (e.g.

  • Page 270

    Detailed description 2.3 Master value coupling Virtual leading axis/simulated master value When switching over to master value coupling, the simulation can be programmed with the last actual value read, whereas the path of the actual value is generally outside the control of the NCU.

  • Page 271

    Detailed description 2.3 Master value coupling If (x) is a periodic curve table and this is interpreted as oscillation, the offset and scaling can also be interpreted as follows: • SD43102 $SA_LEAD_OFFSET_IN_POS[Y] the oscillation phase is shifted • SD43104 $SA_LEAD_SCALE_IN_POS[Y] •...

  • Page 272

    Detailed description 2.3 Master value coupling Figure 2-5 Master value coupling offset and scaling (with increment offset) Reaction to Stop All master value coupled following axes react to channel stop and MODE GROUP stop. Master value coupled following axes react to a stop due to end of program (M30, M02) if they have not been activated by static synchronous actions (IDS=...).

  • Page 273

    Detailed description 2.3 Master value coupling Axial functions Actual value coupling causes a position offset between the leading and following axis. This is due to the deadtime in the position controller between the actual value of the leading axis and the following axis necessitated by the IPO cycle. By default, the position offset and following error are compensated by means of linear extrapolation of the master value by this deadtime.

  • Page 274

    Detailed description 2.3 Master value coupling 2.3.2 Programming a master value coupling Definition and activation A master value coupling is defined and activated simultaneously with the modal language command for: • Axis master value coupling LEADON(FA, LA, CTABn) – FA=following axis, as GEO axis name, channel or machine axis name (X,Y,Z,...). –...

  • Page 275

    Detailed description 2.3 Master value coupling Figure 2-6 Activating master value coupling Deactivation A master value coupling is deactivated with the model language command for: • Axis master value coupling LEADOF(FA, LA) – FA=following axis, as GEO axis name, channel or machine axis name (X,Y,Z,...). –...

  • Page 276

    Detailed description 2.3 Master value coupling Coupling type Coupling type is defined by the following setting data: SD43100 $SA_LEAD_TYPE[LA] (type of master value) Switch-over between actual and setpoint value coupling is possible at any time, preferably in the idle phase. LA: Leading axis as GEO axis name, channel axis name or machine axis name (X,Y,Z,...) 0: Actual value coupling (this type of coupling must be used for external leading axes) 1: Setpoint coupling (default setting)

  • Page 277

    Detailed description 2.3 Master value coupling Note If the following axis is not enabled for travel, it is stopped and is no longer synchronous. 2.3.3 Behavior in AUTOMATIC, MDA and JOG modes Efficiency A master value coupling is active depending on the settings in the part program and in the following machine data: MD20110 $MC_RESET_MODE_MASK (definition of initial control system settings after RESET/TP-End)

  • Page 278

    Detailed description 2.3 Master value coupling MD20112 $MC_START_MODE_MASK=0H → Master value coupling remains valid after RESET and START • MD20110 $MC_RESET_MODE_MASK=2001H && MD20112 $MC_START_MODE_MASK=2000H → Master value coupling remains valid after RESET and is canceled with START. However, master value coupling activated via IDS=... remains valid. •...

  • Page 279

    Detailed description 2.3 Master value coupling 2.3.4 Effectiveness of PLC interface signals Leading axis When a coupled axis group is active, the interface signals (IS) of the leading axis are applied to the appropriate following axis via axis coupling. i.e.: •...

  • Page 280

    Detailed description 2.4 Electronic gearbox (EG) These functions have no effect on cyclic machines because they are performed without operator actions. Nor does it make sense to perform automatic (re-)positioning via the NC with external master values. Electronic gearbox (EG) Function With the aid of the "Electronic gearbox"...

  • Page 281

    Detailed description 2.4 Electronic gearbox (EG) Caution Knowledge of the control technology and measurements with servo trace are an absolute prerequisite for using this function. References: /IAD/. Commissioning Guide, /FB1/ Function Manual, Basic Functions; Speeds, Setpoint/Actual Value Systems, Closed-Loop Control System (G2) Coupling type The following axis motion can be derived from either of the following: •...

  • Page 282

    Detailed description 2.4 Electronic gearbox (EG) Number of EG axis groups Several EG axis groups can be defined at the same time. The maximum possible number of EG axis groupings is set in the following machine data: MD11660 $MN_NUM_EG The maximum permissible number of EG axis groups is 31. Note The option must be enabled.

  • Page 283

    Detailed description 2.4 Electronic gearbox (EG) Synchronous positions To start up the EG axis group, an approach to defined positions for the following axis can first be requested. Synchronous positions are specified with: EGONSYN (see below for details) EGONSYNE (extended EGONSYN call). Synchronization If a gear is started with EGON(), EGONSYN() or EGONSYNE() see below, the actual position of the following axis is only identical to the setpoint position defined by the rule of...

  • Page 284

    Detailed description 2.4 Electronic gearbox (EG) Synchronization for EGONSYN 1. With EGONSYN(), the positions of the leading axes and the synchronization position for the following axis are specified by the command. • The control then traverses the following axis with just the right acceleration and velocity to the specified synchronization position so that the following axis is in position with the leading axes at its synchronization position.

  • Page 285

    Detailed description 2.4 Electronic gearbox (EG) Synchronous monitoring The synchronism of the gearbox is monitored in each interpolator cycle on the basis of the actual values of the following and leading axes. For this purpose, the actual values of the axes are computed according to the rule of motion of the coupling.

  • Page 286

    Detailed description 2.4 Electronic gearbox (EG) Difference in synchronism for EG cascades Deviation in synchronism for EG cascades is the deviation of the actual position of the following axis from setpoint position that results fro the rule of motion for the real axes involved.

  • Page 287

    Detailed description 2.4 Electronic gearbox (EG) Further monitoring signals Machine data MD37550 $MA_EG_VEL_WARNING allows a percentage of the speeds and accelerations to be specified in the following machine data MD32000 $MA_MAX_AX_VELO and MD32300 $MA_MAX_AX_ACCEL, with reference to the following axis, which results in the generation of the following interface signals: IS "Speed warning threshold"...

  • Page 288

    Detailed description 2.4 Electronic gearbox (EG) 2.4.1 Performance Overview of EG (Summary) An EG has: • a maximum of 5 lead axes • 1 Following axis • a maximum of 5 assigned curve tables or • a maximum of 5 assigned coupling factors (Z/N) or •...

  • Page 289

    Detailed description 2.4 Electronic gearbox (EG) Reference system The calculations are made in the basic co-ordinate system BCS. Synchronous actions Synchronous actions (see Literature: /FBSY/) are not supported. Block search EG commands are ignored in the case of block search. Mode change In the case of a mode change: •...

  • Page 290

    Detailed description 2.4 Electronic gearbox (EG) Power-up conditions of EG The EG may be powered up: • at the current axis positions (EGON) or • at the synchronized positions to be specified (EGONSYN) • at synchronized positions to be specified with details of an approach mode (EGONSYNE) Block change behavior In the EG activation commands (EGON, EGONSYN, EGONSYNE), it can be specified for which condition (with respect to synchronism) the next block of the parts program is to be...

  • Page 291

    Detailed description 2.4 Electronic gearbox (EG) Definition of an EG axis group An EG axis group is defined through the input of the following axis and at least one, but not more than five, leading axis, each with the relevant coupling type: EGDEF(following axis, leading axis1, coupling type1, leading axis2, coupling type 2,...) The coupling type does not need to be the same for all leading axes and must be programmed separately for each individual leading axis.

  • Page 292

    Detailed description 2.4 Electronic gearbox (EG) 2.4.3 Activating an EG axis group Without synchronization The EG axis group is activated without synchronization selectionwith: EGON(FA, block change mode, LA1, Z1, N1, LA2 , Z2, N2,..LA5, Z5, N5.) The coupling is activated immediately. With: FA: Following axis Depending on block change mode, the next block will be activated:...

  • Page 293

    Detailed description 2.4 Electronic gearbox (EG) Zi: Counter for coupling factor of leading axis i Ni: Denominator for coupling factor of leading axis i Note The parameters indexed with i must be programmed for at least one leading axis, but for no more than five.

  • Page 294

    Detailed description 2.4 Electronic gearbox (EG) "ACN": AbsoluteCo-ordinateNegative, Absolute measurement specification, rotary axis traverses in negative rotation direction "ACP": AbsoluteCo-ordinatePositive, Absolute measurement specification, rotary axis traverses in positive rotation direction "DCT": DirectCo-ordinateTime-optimized, Absolute measurement specification, rotary axis traverses time-optimized to programmed synchronized position "DCP": DirectCo-ordinatePath-optimized, Absolute measurement specification, rotary axis traverses path-optimized to programmed synchronized position : Axis identifier of the leading axis i...

  • Page 295

    Detailed description 2.4 Electronic gearbox (EG) Approach response for moving FA The following axis moves at almost maximum velocity in the positive direction when the coupling is activated by EGONSYNE. The programmed synchronized position of the following axis is 110, the current position 150. This produces the two alternative synchronized positions 110 and 182 (see table above).

  • Page 296

    Detailed description 2.4 Electronic gearbox (EG) With synchronization The syntax specified above applies with the following different meanings. If a curve table is used for one of the leading axes then: : the denominator of the coupling factor for linear coupling must be set to 0. (Denominator 0 would be illegal for linear couplings).

  • Page 297

    Detailed description 2.4 Electronic gearbox (EG) Variant 3 EGOFC(following spindle) The electronic gear is deactivated. The following spindle continues to traverse at the speed/velocity that applied at the instant of deactivation. This call triggers a preprocessing stop. Note Call for following spindles available. For EGOFC a spindle identifier must be programmed. 2.4.5 Deleting an EG axis group An EG axis grouping must be switched off, as described in Chapter "Switching off a EG Axis...

  • Page 298

    Detailed description 2.4 Electronic gearbox (EG) 2.4.7 Response to POWER ON, RESET, operating mode change, block search No coupling is active after POWER ON. The status of active couplings is not affected by RESET or operating mode switchover. More detailed information on special states can be found under "Performance Overview of the Electronic Gearbox".

  • Page 299

    Detailed description 2.4 Electronic gearbox (EG) name Type Access Preprocessing Meaning, value Cond. Index stop Parts Sync Parts Sync program act. program act. $AA_EG_ REAL Denominator of coupl. fact. KF Axis identifier DENOM[a,b] KF = numerator/denominator a: Following axis (from SW 5.2) preset: 1 b: Leading axis Denominator must be positive.

  • Page 300

    Detailed description 2.5 Generic coupling Generic coupling 2.5.1 Basics 2.5.1.1 Coupling modules Coupling module With the aid of a coupling module, the motion of one axis, (→ following axis), can be interpolated depending on other (→ leading) axes. Coupling rule The relationships between leading axis/values and a following axis are defined by a coupling rule (coupling factor or curve table).

  • Page 301

    Detailed description 2.5 Generic coupling Setpoint or actual value of the 1st leading axis/value Setpoint or actual value of the 2nd leading axis/value SynPosLA Synchronized position of the 1st leading axis/value SynPosLA Synchronized position of the 2nd leading axis/value Coupling factor of the 1st leading axis/value Coupling factor of the 2nd leading axis/value The following axis position results from the overlay (summation) of the dependent motion components (FA...

  • Page 302

    Detailed description 2.5 Generic coupling Example: The properties set with the existing coupling call TRAILON(X,Y,2)(following axis, leading axis and coupling factor) are defined in the generic coupling with the following keywords: CPON=(X1) CPLA[X1]=(X2) CPLNUM[X1,X2]=2 Switch on coupling to following axis X1. CPON=(X1) Define axis X2 as leading axis.

  • Page 303

    Detailed description 2.5 Generic coupling Keyword Coupling characteristics / meaning Default setting (CPSETTYPE="CP") CPLCTID Number of curve table Not set CPLSETVAL Coupling reference CMDPOS CPFRS Co-ordinate reference system CPBC Block change criterion CPFPOS + CPON Synchronized position of the following axis when Not set switching on CPLPOS + CPON...

  • Page 304

    Detailed description 2.5 Generic coupling 2.5.1.3 System variables System variables The current state of a coupling characteristic set with a keyword, can be read and written to with the relevant system variable. Note When writing in the parts program, PREPROCESSING STOP is generated. Notation The names of system variables are normally derived from the relevant keywords and a corresponding prefix.

  • Page 305

    Detailed description 2.5 Generic coupling System variable list A list of all system variables which can be used in a generic coupling is contained in the data lists to Partial Manual M3. For a detailed description of system variables, refer to: Literature: /PGA1/ List Manual System Variables 2.5.2...

  • Page 306

    Detailed description 2.5 Generic coupling 2.5.2.2 Delete coupling module (CPDEL) A coupling module created with CPDEF can be deleted with CPDEL. Programming Syntax: CPDEL= (<following axis/spindle>) Identifiers: Coupling Delete Functionality: Deletion of a coupling module. All leading axis modules are deleted with the coupling module and reserved memory is released.

  • Page 307

    Detailed description 2.5 Generic coupling 2.5.2.3 Defining leading axes (CPLDEF or CPDEF+CPLA) The leading axes/spindles defined for a coupling can be programmed/created with the keyword CPLDEF or with the keyword CPLA in conjunction with CPDEF. Programming with CPLDEF Syntax: CPLDEF[FAx]= (<leading axis/spindle>) Identifiers: Coupling Lead Axis Definition Functionality:...

  • Page 308

    Detailed description 2.5 Generic coupling Boundary conditions • CPLDEF is only allowed in blocks without CPDEF/CPON/CPOF/CPDEL. (This limitation applies to the case where the keywords refer to the same coupling module.) • The maximum number of leading axis modules per coupling module is limited (see topic "Preconditions"...

  • Page 309

    Detailed description 2.5 Generic coupling Programming with CPLA and CPDEL Syntax: CPLA[FAx]= (<leading axis/spindle>) Identifiers: Coupling Lead Axis Functionality: Deleting a leading axis/spindle: The leading axis/spindle module will be deleted and the corresponding memory will be released. If the coupling module does not have a leading axis/spindle any more, the coupling module will be deleted and the memory will be released.

  • Page 310

    Detailed description 2.5 Generic coupling 2.5.3 Switching coupling on/off 2.5.3.1 Switching on a coupling module (CPON) A defined coupling module is switched on with the switch command CPON. Coupling characteristics like coupling reference can be programmed together with the switch on command (see topic "Programming Coupling Characteristics").

  • Page 311

    Detailed description 2.5 Generic coupling 2.5.3.2 Switch off coupling module (CPOF) An activated coupling can be deactivated with the CPOF switching command. The deactivation, i.e. the switching off of the coupling to the leading axis, is performed in accordance with the set switch-off properties (see CPFMOF) Programming Syntax: CPOF= (<Following axis / spindle>)

  • Page 312

    Detailed description 2.5 Generic coupling 2.5.3.3 Switching on leading axes of a coupling module (CPLON) CPLON activates the coupling of a leading axis to a following axis. If several leading axes are defined for a coupling module, they can be activated and deactivated separately with CPLON. Programming Syntax: CPLON[FAx]= (<leading axis/spindle>)

  • Page 313

    Detailed description 2.5 Generic coupling 2.5.3.4 Switching off leading axes of a coupling module (CPLOF) CPLOF deactivates the coupling of a leading axis to a following axis. If several leading axes are defined for a coupling module, they can be deactivated separately with CPLOF. Programming Syntax: CPLOF[FAx]= (<leading axis/spindle>)

  • Page 314

    Detailed description 2.5 Generic coupling 2.5.3.5 Implicit creation and deletion of coupling modules Switch-on commands may also be used to create coupling modules (without prior definition with CPDEF). Programming example ; Creates a coupling module for following axis X2 with CPON=(X2) CPLA[X2]=(X1) leading axis X1 and activates the coupling module.

  • Page 315

    Detailed description 2.5 Generic coupling 2.5.4 Programming coupling characteristics 2.5.4.1 Coupling rule (CPLNUM, CPLDEN, CPLCTID) The functional relationship between the leading value and the following value is specified by a coupling rule for each leading axis. This functional relationship can be defined linear via a coupling factor or non-linear via a curve table.

  • Page 316

    Detailed description 2.5 Generic coupling Denominator of the coupling factor Syntax: CPLDEN[FAx,LAx]= <value> Identifiers: Coupling Lead Denominator Functionality: Defines the denominator of the coupling factor for the coupling rule of the following axis/spindle FAx to the leading axis/spindle LAx. Value: Type: REAL Range of to +2...

  • Page 317

    Detailed description 2.5 Generic coupling Example: ; The leading axis specific coupling component of the coupling CPLCTID[X2,X1]=5 of the following axis X2 to the leading axis X1 is calculated with curve table No. 5. Boundary conditions • A coupling factor of zero (CPLNUM=0) is a permissible value. In this case, the leading axis/spindle does not provide a path component for the following axis/spindle, however, it remains a part of the coupling.

  • Page 318

    Detailed description 2.5 Generic coupling Programming Syntax: CPLSETVAL[FAx,LAx]= <value> Identifiers: Coupling Lead Set Value Functionality: Defines tapping of the leading axis/spindle LAx and the reaction point on the following axis/spindle FAx. Coupling STRING reference: Range of values: "CMDPOS" Commanded Position Setpoint value coupling "CMDVEL"...

  • Page 319

    Detailed description 2.5 Generic coupling 2.5.4.3 Co-ordinate reference (CPFRS): The co-ordinate reference of the following axis/spindle specifies in which co-ordinate reference system the coupling component resulting from the coupling is applied. in the base co-ordinate system or in the machine co-ordinate system. It is further specified which co-ordinate reference the leading values of the leading axis spindle must have.

  • Page 320

    Detailed description 2.5 Generic coupling 2.5.4.4 Block change behavior (CPBC) The block change criterion can be used to specify under which conditions the block change with activated coupling is to be permitted in the processing of the part program. The status of the coupling influences the block change behavior.

  • Page 321

    Detailed description 2.5 Generic coupling Programming with WATC Syntax: WAITC(FAx1,BC) Identifiers: Wait for Coupling Condition Functionality: Defines block change criterion with active coupling. Parameter: Designates the following axis and therefore the coupling module. Defines the desired block change criterion. FAx: Type: STRING Range of values: Axes of the channel...

  • Page 322

    Detailed description 2.5 Generic coupling 2.5.4.5 Synchronized position of the following axis when switching on (CPFPOS+CPON) When switching on the coupling (CPON) approach of the following axis can be programmed for a specified synchronized position. The synchronized position takes immediate effect at switch on. The total position, resulting from the synchronized position and the coupling rule, is approached according to the specified synchronization mode (CPFMSON), taking into account the dynamic response limits.

  • Page 323

    Detailed description 2.5 Generic coupling Part program section (Example) ; Activation of coupling to following axis X2. 100 is taken CPON=(X2) CPFPOS[X2]=100 as synchronized position of the following axis. ; Following axis X2 is traversed to position 123. G00 X2=123 ;...

  • Page 324

    Detailed description 2.5 Generic coupling Part program section (Example) ; Activation of coupling to following axis CPON=(X2) CPFPOS[X2]=100 CPLPOS[X2,X1]=200 X2. 100 is taken as synchronized position of following axis and 200 for leading axis X1. ; Leading axis X1 is traversed to N20 X1=280 F1000 position 280.

  • Page 325

    Detailed description 2.5 Generic coupling "ACN" Absolute Co-ordinate For rotary axes only! Negative The rotary axis traverses towards the synchronized position in the negative axis direction. Synchronization is effected immediately. "ACP" Absolute Coordinate For rotary axes only! Positive The rotary axis traverses to the synchronized position in the positive axis direction.

  • Page 326

    Detailed description 2.5 Generic coupling 2.5.4.8 Behavior of the following axis at switch-on (CPFMON) The behavior of the following axis/spindle during switch-on of the coupling can be programmed with the keyword CPFMON. Programming Syntax: CPFMON[FAx]= "<block change criterion>" Identifiers: Coupling Following Mode On Functionality: Defines the behavior of the following axis/spindle during switch-on of the coupling.

  • Page 327

    Detailed description 2.5 Generic coupling 2.5.4.9 Behavior of the following axis at switch-off (CPFMOF) The behavior of the following axis/spindle during complete switch-off of an active coupling can be programmed with the keyword CPFMOF. Programming Syntax: CPFMOF[FAx]= "<switch-off behavior>" Identifiers: Coupling Following Mode Off Functionality: Defines the behavior of the following axis/spindle during complete...

  • Page 328

    Detailed description 2.5 Generic coupling 2.5.4.10 Position of the following axis when switching off (CPFPOS+CPOF) When switching off a coupling (CPOF) traversing to a certain position can be requested for the following axis. Programming Syntax: CPOF=(FAx) CPFPOS[FAx]= <value> Functionality: Defines the switch-off position of the following axis FAx. Value: Type: REAL Range of...

  • Page 329

    Detailed description 2.5 Generic coupling 2.5.4.11 Condition at RESET (CPMRESET) With RESET, the coupling can be activated, deactivated or the current status can be retained. The behavior can be set separately for each coupling module. Programming Syntax: CPMRESET[FAx]= "<Reset behavior>" Identifiers: Coupling Mode RESET Functionality:...

  • Page 330

    Detailed description 2.5 Generic coupling Example: ; On RESET the coupling to following axis X2 is deactivated and CPMRESET[X2]="DEL" then deleted. Boundary conditions • The coupling characteristics set with CPMRESET is retained until the coupling module is deleted with (CPDEL). •...

  • Page 331

    Detailed description 2.5 Generic coupling Example: ; At parts program start, coupling to following axis X2 is CPMSTART[X2]="ON" switched on. Boundary conditions • The coupling characteristics set with CPMSTART are retained until the coupling module is deleted with (CPDEL). • If no coupling characteristics are set with CPMSTART or with set coupling type (CPSETTYPE), behavior at parts program start is determined by the following machine data: MD20112 $MN_START_MODE_MASK...

  • Page 332

    Detailed description 2.5 Generic coupling 2.5.5 Coupling cascading Coupling cascades The coupling modules can be connected in series. The following axis/spindle of a coupling module then becomes the leading axis/spindle of another coupling module. This results in a coupling cascade. Multiple coupling cascades in series is also possible.

  • Page 333

    Detailed description 2.5 Generic coupling 2.5.6 Compatibility 2.5.6.1 Adaptive cycles Adaptive cycles The provision of adaptive cycles as fixed component of the NCK software ensures a syntactic and functional compatibility to coupling calls of existing coupling types (coupled motion, master value coupling, electronic gearbox and synchronous spindle). This means that as long as the manufacturer/user does not need new coupling characteristics, it is not necessary to modify present coupling calls and any dependent application components (e.g.

  • Page 334

    Detailed description 2.5 Generic coupling Memory location Adaptive cycles are stored in the directory "CST". User specific adaptive cycles If necessary (functional completion) the user can copy an adaptive cycle to the directory "CMA" or "CUS" and apply changes there. When reading adaptive cycles, the sequence CUS →...

  • Page 335

    Detailed description 2.5 Generic coupling 2.5.6.2 Coupling types (CPSETTYPE) Coupling types If presetting of coupling types (coupled motion, master value coupling, electronic gearbox and synchronized spindle) is required, when creating the coupling module (CPON/CPLON oder CPDEF/CPLDEF), the keyword CPSETTYPE needs to be used also. Programming Syntax: CPSETTYPE[FAx]= <value>...

  • Page 336

    Detailed description 2.5 Generic coupling Default settings Presettings of programmable coupling characteristics for various coupling types can be found in the following table: Keyword Coupled motion Master value Electronic gear Synchronous (TRAIL) coupling ( (EG) spindle LEAD) (COUP) CPDEF CPDEL CPLDEF CPLDEL CPON...

  • Page 337

    Detailed description 2.5 Generic coupling Additional properties Value ranges or availability of additional properties of a set coupling type (CPSETTYPE) can be found in the following table: Default Coupled motion Master value Electronic gear Synchronous (CP) (TRAIL) coupling ( (EG) spindle LEAD) (COUP)

  • Page 338

    Detailed description 2.5 Generic coupling Boundary conditions • CPSETTYPE can be programmed in synchronous actions. • If the coupling type (CPSETTYPE) is set, certain coupling characteristics are preset and cannot be changed. Subsequent change attempts with keywords cause an error and are rejected with an alarm: CPSETTYPE= TRAIL...

  • Page 339

    Detailed description 2.5 Generic coupling CPSETTYPE= TRAIL LEAD COUP Following axis type Alarm 14092 with axis 2.5.6.3 Projected coupling (CPRES) If the coupling type "Synchronous spindle" is set, (see CPSETTYPE), the coupling properties contained in machine data can be activated instead of the programmed coupling properties. References: /FB2/ Function Manual, Extension Functions;...

  • Page 340

    Detailed description 2.5 Generic coupling Boundary conditions • CPRES is only allowed when the coupling type "Synchronous spindle" (CPSETTYPE="COUP") is set. • Application of CPRES to an already active coupling results in a new synchronization. • Applying CPRES to an undefined coupling module does not result in any action. 2.5.7 Cross-channel coupling, axis replacement The following and leading axes must be known to the calling channel.

  • Page 341

    Detailed description 2.5 Generic coupling Modulo reduced rotary axes as leading axes With modulo reduced rotary axes as leading axes, the input variable is not reduced during the reduction of the leading axis. The non-reduced position is still taken as the input variable, i.e.

  • Page 342

    Detailed description 2.5 Generic coupling Figure 2-10 Example: Modulo reduced rotary axis to linear axis (...) Position indication for X, A Special functions: Axis Couplings and ESR (M3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 343

    Detailed description 2.5 Generic coupling 2.5.9 Behavior during POWER ON, ... Power on No coupling is active at power ON. Coupling modules are not available. RESET The behavior on RESET can be set separately for each coupling module (see CPMRESET). The coupling can be activated, deactivated or the current state can be retained.

  • Page 344

    Detailed description 2.6 Dynamic response of following axis Dynamic response of following axis 2.6.1 Parameterized dynamic limits The dynamics of the following axis is limited by the following MD values: MD32000 $MA_MAX_AX_VELO (maximum axis velocity) MD32300 $MA_MAX_AX_ACCEL (Maximum axis acceleration) 2.6.2 Programmed dynamic limits 2.6.2.1...

  • Page 345

    Detailed description 2.6 Dynamic response of following axis Programming in synchronized actions The possibility of programming VELOLIMA[FA] and ACCLIMA[FA]in synchronized actions depends on the coupling type:. Coupling type Part program Synchronized actions Tangential correction Coupled motion Master value coupling Electronic gearbox Synchronous spindle Generic coupling Synchronization between following and leading axes...

  • Page 346

    Detailed description 2.6 Dynamic response of following axis Acceleration mode Only BRISKAis available for the following axis, i.e., abrupt axis acceleration. Acceleration modes SOFTA and DRIVEAare not available for the following axes described. Furthermore, it is also possible to configure the positions controller as a PI controller. Caution This option can only be used in conjunction with servo trace and with the appropriate technical knowledge of the control.

  • Page 347

    Detailed description 2.6 Dynamic response of following axis 2.6.2.2 Examples Electronic gearbox Axis 4 is coupled to X via an electronic gearbox coupling. The acceleration capability of the following axis is limited to 70% of maximum acceleration. The maximum permissible velocity is limited to 50% of maximum velocity.

  • Page 348

    Detailed description 2.7 Extended stop and retract (ESR) 2.6.2.3 System variables For geometry axis, channel axis, machine axis and spindle axis, the following readable system variables are available in the part program and synchronous actions: Identifier Data type Description Unit Preprocessing $PA_ACCLIMA[n] Acceleration offset set with ACCLIMA[Ax]...

  • Page 349

    Detailed description 2.7 Extended stop and retract (ESR) Solution concept sources The hazard conditions in the control system are checked cyclically (malfuntion ) and linked (synchronous actions). Actions are triggered when reasons for initiating a separation of the tool and the workpiece are detected under the supplementary conditions for temporary upholding of the axis coupling in the electronic gear.

  • Page 350

    Detailed description 2.7 Extended stop and retract (ESR) Interplay of NC-controlled reactions with ... NC-controlled reactions are triggered via channel-specific system variable $AC_ESR_TRIGGER. (not to be mistaken for NC-global system variables for drive- independent retraction $AN_ESR_TRIGGER). stop $AC_ESR_TRIGGER enables a smooth interpolatory on the path or contour.

  • Page 351

    Detailed description 2.7 Extended stop and retract (ESR) 2.7.3 Drive-independent reactions Independent drive reactions are defined axially, that is, if activated each drive processes its stop and retract request independently. There is no interpolatory coupling of axes or coupling adhering to the path on stop or retract (only for control management). Axis reference is performed under time control.

  • Page 352

    Detailed description 2.7 Extended stop and retract (ESR) Drive-independent stop ESR_REACTION = 12 Independent drive stop is • configured (MD37500 $MA_ESR_REACTION=12), • Enabled ($AA_ESR_ENABLE) and • started: System variable $AN_ESR_TRIGGER. Note For drive-independent reactions, the behavior can be determined individually for each axis. Example An example of how the drive-independent reaction can be used, can be found in Chapter "Examples, "ESR".

  • Page 353

    Detailed description 2.7 Extended stop and retract (ESR) 2.7.4 NC-controlled extended stop Response The schedule for extended stop is defined by the following two machine data: MD21380 $MC_ESR_DELAY_TIME1 MD21381 $MC_ESR_DELAY_TIME2 This axis continues interpolating as programmed for the time duration set in the following machine data: MD21380 $MC_ESR_DELAY_TIME1 After the time delay specified in the following machine data has lapsed, controlled braking...

  • Page 354

    Detailed description 2.7 Extended stop and retract (ESR) Times T1 and T2 The times T1 and T2 are parameterized via the machine data: MD21380 $MC_ESR_DELAY_TIME1. MD21381 $MC_ESR_DELAY_TIME2 The timing for NC-controlled extended stop can be taken from the figure below. Figure 2-11 Parameterizable/programmable control-driven shutdown Note...

  • Page 355

    Detailed description 2.7 Extended stop and retract (ESR) Note A following axis of the electronic gearbox follows the leading axis during both phases of the extended stop according to the motion rule, i.e. no independent braking is possible on transition from machine data phase MD 21380 $MC_DELAY_TIME1 to machine data phase MD21381 $MC_ESR_DELAY_TIME2.

  • Page 356

    Detailed description 2.7 Extended stop and retract (ESR) The extended retraction (i.e. LIFTFAST/LFPOS initiated through $AC_ESR_TRIGGER ) cannot be interrupted and can only be terminated prematurely via an EMERGENCY STOP. Speed and acceleration limits for the axes involved in the retraction are monitored during the retraction motion.

  • Page 357

    Detailed description 2.7 Extended stop and retract (ESR) Reactions to stop and axis enable signals Stop characteristics for the retracting movement in response to "Axial feed stop" and "Feed disable" signals are defined with the following channel-specific machine data: MD21204 $MC_LIFTFAST_STOP_COND Bit0: Axial VDI signal feed halt DB31 DBB4.3 =0 Stop of retraction motion with axial feed halt =1 no stop of retraction motion with axial feed halt...

  • Page 358

    Detailed description 2.7 Extended stop and retract (ESR) POLFMLIN The language command POLFMLIN([ axis name1], [axis name2], ..) allows selection of the axes that are to travel on activation of fast lift with POLF, to defined positions in linear reference. A variable parameter list can be used to select any number of axes for lift fast; however, all axes must be located in the same co-ordinate system, (i.e.

  • Page 359

    Detailed description 2.7 Extended stop and retract (ESR) POLFMASK / POLFMLIN interactions The last data entered for a specific axis in one of the two instructions applies. For example: ; linear retraction N200 POLFLIN(X, Y, Z) ; for axes X, Y and Z activated ;...

  • Page 360

    Detailed description 2.7 Extended stop and retract (ESR) General sources General sources (NC-external/global or mode group/channel-specific): • Digital inputs (e.g. on NCU module or terminal box) or the control-internal digital output image that can be read back ($A_IN, $A_OUT) • Channel status ($AC_STAT) •...

  • Page 361

    Detailed description 2.7 Extended stop and retract (ESR) 2.7.7 Logic gating functions: Source and reaction linking The flexible logic operation possibilities of the static synchronized actions can be used to trigger specific reactions based on sources. Linking ofall relevant sources with the aid of static synchronous actionsis the responsibility of the user/machine manufacturer.

  • Page 362

    Detailed description 2.7 Extended stop and retract (ESR) $AC_ESR_TRIGGER (NC-controlled) • NC controlled shutdown is activated by corresponding parameterizing of the following machine data by setting the control signal "$AC_ESR_TRIGGER": MD37500 $MA_ESR_REACTION = 22 Prerequisite: Enable. • NC controlled retraction is activated by corresponding parameterizing of the following machine data andPOLF and POLFMASK in the parts program by setting the control signal "$AC_ESR_TRIGGER": MD37500 $MA_ESR_REACTION = 21...

  • Page 363

    Detailed description 2.7 Extended stop and retract (ESR) Figure 2-12 Voltage level of SIMODRIVE 611D DC link The drive and DC link pulses are deleted at specific voltage levels. This automatically causes the drives to coast down. If this behavior is not desired, the user can use a resistor module to divert the surplus energy.

  • Page 364

    Detailed description 2.7 Extended stop and retract (ESR) Figure 2-13 DC link voltage monitoring SIMODRIVE 611D Communication/ control failure When the NC sign-of-life monitoring responds, a communication/control failure is detected on the drive bus and a drive-independent ESR is performed if appropriately configured. Note Measuring of the intermediate circuit voltage is activated by default, by changing the preset value from 600 V to 0 V.

  • Page 365

    Detailed description 2.7 Extended stop and retract (ESR) 2.7.10 Generator operation/DC link backup DC link backup Temporary intermediate circuit voltage dips can be compensated for by projecting drive MD and appropriately programming the system variable $AA_ESR_ENABLE via static synchronous actions. The bridged time depends on the energy stored by the generator that is used for intermediate circuit backup, as well as on the energy requirements for maintaining the current motions (intermediate circuit backup and monitoring for generator speed limit).

  • Page 366

    Detailed description 2.7 Extended stop and retract (ESR) When the value falls below the intermediate circuit voltage lower limit, the axis/spindle concerned switches from position or speed-controlled operation to generator operation. By braking the drive (default speed setpoint = 0), regenerative feedback to the DC link takes place.

  • Page 367

    Detailed description 2.7 Extended stop and retract (ESR) Figure 2-15 Drive-independent stop SIMODRIVE 611D Responses The speed setpoint currently active as the error occurred will continue to be output for time period T1. This is an attempt to maintain the motion that was active before the failure, until the physical contact is annulled or the retraction movement initiated in other drives is completed.

  • Page 368

    Detailed description 2.7 Extended stop and retract (ESR) Measuring system For the drive there is no reference to the NC geometry system. On the NC side, the unit system of the motor measuring system is only known if it is used as a position measuring system.

  • Page 369

    Detailed description 2.7 Extended stop and retract (ESR) 2.7.13 Configuring aids for ESR Voltage failure The following hardware and software components are required: • Hardware components – SINUMERIK 840D with, e.g. NCU 573 and HMI Advanced – SIMODRIVE 611D with servo drive controls 6SN1 118-0DG... or 6SN1 118-0DH... –...

  • Page 370

    Detailed description 2.7 Extended stop and retract (ESR) Example: C= 6000µF (see Table, 1st row) - 20% = 4800 µF =550V (MD1634) = 350V (assumption) results in: E = 1/2 * 4800µF *((550V) - (350V) ) = 432Ws This energy is available under load for a period of = E / P * η...

  • Page 371

    Detailed description 2.7 Extended stop and retract (ESR) Energy balance When configuring emergency retraction, it is always necessary to establish an energy balance to find out whether an additional capacitor module or a generator axis/spindle (with correspondingly dimensioned centrifugal mass) is required. Stopping as energy supply Changes to rotational speed setpoints of the projected shutdown or retraction axes/spindles follow after about the third interpolation act.

  • Page 372

    Detailed description 2.7 Extended stop and retract (ESR) Generator operation Generator operation is possible in the event that the intermediate circuit power is insufficient for safe retraction (for a period of at least 3 interpolator cycles). The mechanical power of a spindle/axis is used and the energy is optimally fed back to the DC link.

  • Page 373

    Detailed description 2.7 Extended stop and retract (ESR) 2.7.14 Control system response POWER OFF/POWER ON If the retraction logic is stored in motion synchronous actions, it is not yet active on POWER ON. Static synchronous actions that are required to be active immediately after POWER ON must be activated within an ASUB started by the PLC.

  • Page 374

    Detailed description 2.7 Extended stop and retract (ESR) Alarm behavior • Errors in an axis outside the EG axis grouping: This axis switches off "normally". Stop and retract continue "undisturbed" or are triggered by this type of error. • Error in a leading axis (LA): selective switchover to actual value linkage already during stop, otherwise as previously.

  • Page 375

    Detailed description 2.7 Extended stop and retract (ESR) 2.7.15 Boundary conditions Operational performance of the components The "drives, motors, transmitters" axis/spindle components participating in "Extended stop and retract" must be operational. If one of these components fails, the full scope of the described reaction no longer applies.

  • Page 376

    Detailed description 2.7 Extended stop and retract (ESR) Special functions: Axis Couplings and ESR (M3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 377

    Boundary conditions Coupled motion Control system dynamics It is recommended to align the position control parameters of the leading axis and the coupled motion axis within a coupled axis group. Note Alignment of the position control parameters of the leading axis and the coupled motion axis can be performed via a parameter set changeover.

  • Page 378

    Boundary conditions 3.2 Curve tables Special functions: Axis Couplings and ESR (M3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 379

    Examples Coupled motion Application Example: Two-sided machining Example 1 Example of an NC part program for the axis constellation shown in Fig.: ; Activation of 1st coupled axis group TRAILON(V,Y,1) ; Activation of 2nd coupled axis group TRAILON(W,Z,-1) ; Infeed Z and W axes in opposite axial directions G0 Z10 ;...

  • Page 380

    Examples 4.1 Coupled motion Example 2 The dependent and independent movement components of a coupled motion axis are added together for the coupled motion. The dependent component can be regarded as a co- ordinate offset with reference to the coupled motion axis. N01 G90 G0 X100 U100 ;...

  • Page 381

    Examples 4.2 Curve tables Curve tables Definition of a curve table with linear sets %_N_TAB_1_NOTPERI_MPF ;$PATH=/_N_WKS_DIR/_N_KURVENTABELLEN_WPD ; Def.TAB1 0-100mm Kue1/1 notperio. ; FA=Y LA=X Curve No..=1 Not N10 CTABDEF(YGEO,XGEO,1,0) period. ; Start values N1000 XGEO=0 YGEO=0 N1010 XGEO=100 YGEO=100 CTABEND Definition of a curve table with polynomial sets %_N_TAB_1_NOTPERI_MPF ;$PATH=/_N_WKS_DIR/_N_KURVENTABELLEN_WPD...

  • Page 382

    Examples 4.2 Curve tables Definition of a periodic curve table Table No: 2 Master value range: 0 - 360 The following axis traverses from N70 to N90, a movement from 0 to 45 and back to 0. N10 DEF REAL DEPPOS N20 DEF REAL GRADIENT N30 CTABDEF(Y,X,2,1) N40 G1 X=0 Y=0...

  • Page 383

    Examples 4.3 Electronic gear for gear hobbing Electronic gear for gear hobbing 4.3.1 Example of linear couplings Use of axes The following diagram shows the configuration of a typical gear hobbing machine. The machine comprises five numerically closed loop controlled axes and an open loop controlled main spindle.

  • Page 384

    Examples 4.3 Electronic gear for gear hobbing In this case, the workpiece table axis (C) is the following axis which is influenced by three master drives. The setpoint of the following axis is calculated cyclically with the following logic equation: * (z ) + v * (u...

  • Page 385

    Examples 4.3 Electronic gear for gear hobbing Workpiece/tool parameter The values z and u are workpiece or tool dependent and are specified by the NC operator or the parts program. Differential constants Differential constants u and u make allowance for the angle of workpiece teeth and for cutter geometry.

  • Page 386

    Examples 4.3 Electronic gear for gear hobbing Figure 4-2 Extended example with non-linear machine fault compensation and non-linear components on the tooth geometry Special functions: Axis Couplings and ESR (M3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 387

    Examples 4.3 Electronic gear for gear hobbing The following section of a part program is intended to illustrate the general concept; supplementary curve tables and gear wheel/machine parameters are still to be added. Components to be added are marked with <...> . Stated parameters may also have to be modified, e.g.

  • Page 388

    Examples 4.3 Electronic gear for gear hobbing Z, <SynPosC99_Z>, ; Switch-on of leading axis Z 10, 1) ; "&" character means: command continued in next line, no LF nor comment permissible in program ; 2nd gear stage EGDEF(C, C99, 1, Z, 1) ;...

  • Page 389

    Examples 4.3 Electronic gear for gear hobbing System variables In accordance with the above definitions, the following values are entered in the associated system variables by the control. Options of access to these system variables are described in SW 7.1 and higher: References: /PGA1/, List Manual, System Variables The system variables listed below are only used for explanatory purposes!

  • Page 390

    Examples 4.3 Electronic gear for gear hobbing $AA_EG_TYPE[C99, Z] = 1 ; Setpoint value coupling $AA_EG_NUMERA[C99, Z] = R1 * π ; numerator for coupling factor $AA_EG_DENOM[C99, Z] = 1 ; denominator for coupling factor $AA_EG_TYPE[C99, B] = 1 ; Setpoint value coupling $AA_EG_NUMERA[C99, B] = 10 ;...

  • Page 391

    Examples 4.3 Electronic gear for gear hobbing Machine data Extract from MD: ; ************** Channel 1 CHANDATA(1) ; ************** Axis 1, "X" $MC_AXCONF_GEOAX_NAME_TAB[0] = "X" $MC_AXCONF_CHANAX_NAME_TAB[0] = "X" $MC_AXCONF_MACHAX_USED[0]=1 $MN_AXCONF_MACHAX_NAME_TAB[0] = "X1" $MA_SPIND_ASSIGN_TO_MACHAX[AX1] = 0 $MA_IS_ROT_AX[AX1] = FALSE ; *************** Axis 2, "Y" $MC_AXCONF_GEOAX_NAME_TAB[1]="Y"...

  • Page 392

    Examples 4.3 Electronic gear for gear hobbing $MN_AXCONF_MACHAX_NAME_TAB[4] = "B1" $MA_SPIND_ASSIGN_TO_MACHAX[AX5] = 1 $MA_IS_ROT_AX[AX5] = TRUE $MA_ROT_IS_MODULO[AX5] = TRUE ; ************** Axis 6, "C" $MC_AXCONF_CHANAX_NAME_TAB[5] = "C" $MC_AXCONF_MACHAX_USED[5]=6 $MN_AXCONF_MACHAX_NAME_TAB[5] = "C1" $MA_SPIND_ASSIGN_TO_MACHAX[AX6] = 0 $MA_IS_ROT_AX[AX6] = TRUE $MA_ROT_IS_MODULO[AX6] = TRUE ;...

  • Page 393

    Examples 4.4 Generic coupling Generic coupling 4.4.1 Programming examples Direct switch on/off with one leading axis A coupling module is created and activated with following axis X2 and leading axis X1. The coupling factor is 2. CPON=(X2) CPLA[X2]=(X1) CPLNUM[X2,X1]=2 ; The coupling is deactivated and the created coupling CPOF=(X2) module is deleted with CPOF.

  • Page 394

    Examples 4.4 Generic coupling Selective switch-on/off with three leading axes A coupling module is created and activated with following axis X2 and leading axes X1, Z and A. N10 CPDEF=(X2) CPLA[X2]=(X1) CPLA[X2]=(Z) CPLA[X2]=(A) ; All leading axes become active, i.e. all N20 CPON=(X2) contribute a position component according to the coupling rule (coupling component) to axis...

  • Page 395

    Examples 4.4 Generic coupling 4.4.2 Adapt adaptive cycle Target Coupled motion in the machine co-ordinate system must be possible with the existing coupling command TRAILON. The adaptive cycle for TRAILON is supplemented with the coupling characteristic "Co-ordinate reference" (CPFRS). Procedure 1.

  • Page 396

    Examples 4.5 ESR 4.5.1 Use of drive-independent reaction Example configuration • Axis A (spindle) is to operate as generator drive, • in the event of an error, axis X must retract by 10 mm at maximum speed, and • axes Y and Z must stop after a 100 ms delay to give the retraction axis time to cancel the mechanical coupling.

  • Page 397

    Examples 4.5 ESR 6. Formulate trigger condition as static synchronous action(s), e.g.: – dependent on intervention of generator axis: IDS=01 WHENEVER $AA_ESR_STAT[A]>0 DO $AN_ESR_TRIGGER=1 – and/or dependent on alarms that trigger follow-up mode (bit13=2000H): IDS=02 WHENEVER ($AC_ALARM_STAT B_AND 'H2000')>0 DO $AN_ESR_TRIGGER=1 –...

  • Page 398

    Examples 4.5 ESR Parameterization Parameterization or programming required for the example: $MC_ASUP_START_MASK = 7 ; MD11602 ; Function assignment $MA_ESR_REACTION[X]=21 ; MD37500 $MA_ESR_REACTION[Y]=22 $MA_ESR_REACTION[Z]=22 $MA_ESR_REACTION[A]=10 ; Drive configuration for drive independent reactions $MD_RETRACT_SPEED[X]=400000H ; MD1639, ; maximum speed $MD_RETRACT_TIME[X]=10 ; MD1638, ms/maximum emergency retraction time. $MD_GEN_STOP_DELAY[Y]=100 ;...

  • Page 399

    Examples 4.5 ESR Synchronized actions Formulate trigger condition as static synchronous action(s), e.g.: ; dependent on intervention of generator axis: IDS=01 WHENEVER $AA_ESR_STAT[A]>0 DO $AC_ESR_TRIGGER=1 ; and/or dependent on alarms that trigger tracking mode ; activate (Bit13=2000H): IDS=02 WHENEVER ($AC_ALARM_STAT B_AND 'H2000')>0 DO $AC_ESR_TRIGGER=1 ;...

  • Page 400

    Examples 4.5 ESR 4.5.4 Lift fast via a fast input with ASUB Activating Activation via a fast input with ASUB SETINT (1) PRIO=1 ABHEB_Y LIFTFAST ; ASUP activation by fast lift ; with fast entry 1 ; select retraction mode LFPOS ;...

  • Page 401

    Examples 4.5 ESR 4.5.5 Lift fast with several axes Parameterization with several axes and incremental programming $AA_ESR_ENABLE[X1]=1 Activation by ESR $AA_ESR_ENABLE[Z]=1 $AA_ESR_ENABLE[A1]=1 ; select lift-off mode for fast lift-off LFPOS ; program lift-off position for machine axis X1 and POLF[X1]=IC(3.0) POLF[A1]=-4.0 ;...

  • Page 402

    Examples 4.5 ESR 4.5.6 Lift fast with linear relation of axes Retraction in linear relation Example for an activation via a fast input with ASUB: $AA_ESR_ENABLE[X] = 1 Activation by ESR $AA_ESR_ENABLE[Y]=1 $AA_ESR_ENABLE[Z]=1 ; select retraction mode LFPOS ; retraction position for X and Y POLF[X]=19.5 POLF[Y]=33.3 ;...

  • Page 403

    Examples 4.5 ESR Retraction in linear relation and independent Example for parameterization with several axes and incremental programming: $AA_ESR_ENABLE[X1]=1 Activation by ESR $AA_ESR_ENABLE[Y]=1 $AA_ESR_ENABLE[A1]=1) ; select retraction mode LFPOS Lift-off position for POLF[X]=IC(3.0) POLF[A1]=-4.0 ; axis X and A1 ; programming retraction position for Z POLF[Y]=100 X0 Y0 A0 G0 POLFMLIN(X, Y)

  • Page 404

    Examples 4.5 ESR Special functions: Axis Couplings and ESR (M3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 405

    Data lists Machine data 5.1.1 NC-specific machine data Number Identifier: $MN_ Description 11410 SUPPRESS_ALARM_MASK Mask for supporting special alarm outputs 11660 NUM_EG Number of possible electronic gears 11750 NCK_LEAD_FUNCTION_MASK Functions for master value coupling 11752 NCK_TRAIL_FUNCTION_MASK couple motion functions 18400 MM_NUM_CURVE_TABS Number of curve tables (SRAM) 18402...

  • Page 406

    Data lists 5.1 Machine data 5.1.2 Channelspecific machine data Number Identifier: $MC_ Description 20110 RESET_MODE_MASK Definition of control basic setting after run-up and RESET/part program end 20112 START_MODE_MASK Definition of control basic setting after run-up and RESET 20900 CTAB_ENABLE_NO_LEADMOTION Curve tables with jump of following axis 20905 CTAB_DEFAULT_MEMORY_TYPE Default memory type for curve tables...

  • Page 407

    Data lists 5.2 Setting data Setting data 5.2.1 Channelspecific setting data Number Identifier: $SC_ Description 43100 LEAD_TYPE Definition of master value type 43102 LEAD_OFFSET_IN_POS Master value offset 43104 LEAD_SCALE_IN_POS Master value scaling 43106 LEAD_OFFSET_OUT_POS Curve table offset 43108 LEAD_SCALE_OUT_POS Curve table scaling System variables Electronic gear (EG) and master value coupling Identifier...

  • Page 408

    Data lists 5.3 System variables Generic coupling Identifier Description $AA_ACCLIMA Main run acceleration correction set with ACCLIMA $AA_COUP_ACT Coupling type of a following axis/spindle $AA_COUP_CORR Compensation value for synchronous spindle coupling $AA_COUP_OFFS Setpoint position offset $AA_CPACTFA Name of active following axis $AA_CPACTLA Name of active leading axis $AA_CPBC...

  • Page 409

    Data lists 5.3 System variables Identifier Description $AA_JERKLIMA Main run jerk correction set with JERKLIMA $AA_LEAD_SP Simulated master value - position with LEAD $AA_LEAD_SV Simulated master value - speed with LEAD $AA_LEAD_P_TURN Current leading value - position component lost as a result of modulo reduction. $AA_LEAD_P Current leading value - position (modulo reduced) $AA_LEAD_V...

  • Page 410

    Data lists 5.4 Signals Extended stop and retract (ESR) Identifier Description $A_DBB Read/write data byte (8 bits) from/to PLC $A_IN Digital input NC $A_OUT Digital output NC $AA_ESR_ENABLE[axis] 1 = (axial) enable of reaction(s) of "Extended stop and retract" $AA_ESR_STAT[axis] (axial) status feedback signals from "Extended stop and retract"...

  • Page 411

    Data lists 5.4 Signals 5.4.2 Signals from axis/spindle DB number Byte.bit name 31, ... 83.1 Limiting of differential speed 31, ... 83.5 Spindle in setpoint range, differential speed 31, ... 83.6 Speed limit exceeded, total speed 31, ... 83.7 Actual direction of rotation clockwise, total speed 31, ...

  • Page 412

    Data lists 5.4 Signals Special functions: Axis Couplings and ESR (M3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 413

    Index Distance-to-go, 20 Dynamics limit, 24 Interface signals, 22 Programming, 21 $AA_COUP_ACT, 23, 24 Switch ON/OFF, 19 Coupled motion axis as leading axis, 18 coupling Switch off, 84 18400, 8 Coupling factor, 87 18402, 9 Counter, 88 18403, 9 Denominator, 88 18404, 9 Coupling module, 75 18406, 9...

  • Page 414

    Index CPSETTYPE, 104 DBX99.0, 23 Curve segment, 25 DBX99.1, 23 Curve tables, 8, 89 DBX99.3, 62 Activation, 39 DBX99.4, 60, 61 Behavior in operating modes, 41 DB31, ... DBX1.4, 23 Deactivation, 40 DC Link Delete, 27 Backup, 136 Insufficient memory, 26 Energy balance, 137 Interface signals, 41 DC link backup, 131...

  • Page 415

    Index MD1635 $MD_GEN_AXIS_MIN_SPEED, 133 MD1637, 158, 159 Hardware requirements, 14 MD1637 $MD_GEN_STOP_DELAY, 133 MD1638, 158, 159 MD1638 $MD_RETRACT_TIME, 134 MD1639, 158, 159 Independent coupled motion axis, 18 MD1639 $MD_RETRACT_SPEED, 134 Interface to axis exchange, 49 MD18400, 27 Interpolation, 55 MD18402, 27 Introduction, 45 MD18403, 28 MD18404, 28...

  • Page 416

    Index Generic coupling, 14 SD43106, 47 Modulo leading axis, 41 SD43108, 47 Spindles in master value coupling, 49 Starting value, 35 Status of coupling, 24, 55 Stop and retract, 116 NC-controlled extended stop, 120 Stopping, 14 NC-controlled retraction, 122 Synchronization, 113 Following axis, 10 Synchronization difference, 60 Synchronization mode, 96...

  • Page 417: Setpoint Exchange (s9)

    840D sl/840Di sl/840D/840Di/810D Data lists Special functions: Setpoint Exchange (S9) Function Manual Valid for Control SINUMERIK 840D sl/840DE sl SINUMERIK 840Di sl/840DiE sl SINUMERIK 840D powerline/840DE powerline SINUMERIK 840Di powerline/840DiE powerline SINUMERIK 810D powerline/810DE powerline Software Version NCU system software for 840D sl/840DE sl 1.3...

  • Page 418

    Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

  • Page 419

    Table of contents Brief description ............................5 Detailed description ........................... 7 Function ............................7 Interface signals...........................10 Interrupts ............................12 Position control loop........................12 Reference points..........................12 Differences in comparison with the technology card ..............13 Restrictions.............................. 15 Examples..............................17 Data lists..............................19 Machine data..........................19 5.1.1 Axis/spindlespecific machine data ....................19 Index...............................Index-21 Special functions: Setpoint Exchange (S9)

  • Page 420

    Table of contents Special functions: Setpoint Exchange (S9) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 421

    Brief description Function The "Setpoint exchange" function is used in applications in which the same motor is used to traverse different machine axes. Operating conditions The function described below replaces the "Setpoint exchange" technology card function (TE5) for systems with NCK SW ≧ 7.1. An option is required for the function.

  • Page 422

    Brief description Special functions: Setpoint Exchange (S9) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 423

    Detailed description Function The "setpoint exchange" function is required in applications in which a single motor needs to drive a number of axes/spindles such as, for example, on milling machines with special millheads. The spindle motor is operated as both a tool drive and a millhead orienting mechanism.

  • Page 424

    Detailed description 2.1 Function Configuration Setpoint exchange enables a number of axes to use the same drive. The same setpoint channel on this drive is assigned a number of times to define the axes participating in setpoint exchange. For this, the following machine data must be pre-assigned with the same logical drive number for every axis: MD30110 $MA_CTRLOUT_MODULE_NR (setpoint assignment: module number) Note...

  • Page 425

    Detailed description 2.1 Function Activating The setpoint is exchanged and the corresponding interface signals are evaluated in the PLC user program. Note An existing PLC user program may need to be modified due to changes in the meaning of interface signals in comparison with the technology card solution. Only one of the machine axes with the appropriate logical drive number may have control via the setpoint channel of the drive at any one time.

  • Page 426

    Detailed description 2.2 Interface signals Interface signals Axisspecific signals Despite assignment of an individual drive to several axes, the use NC/PLC interface signals remains unchanged. This requires explicit access coordination in the PLC user program. As the same drive is being used, the same status signals from DB31, ... DBB92-95 are displayed in all axes involved in the exchange.

  • Page 427

    Detailed description 2.2 Interface signals Figure 2-4 PLC-controlled sequence of a setpoint exchange between AX1 → AX2 Special functions: Setpoint Exchange (S9) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 428

    Detailed description 2.3 Interrupts Interrupts Drive alarms are only displayed for axes with drive control Position control loop During setpoint exchange, the drive train and therefore the position control loop are isolated. In order to avoid instabilities, exchange only takes place at standstill and once all servo enables have been deleted.

  • Page 429

    Detailed description 2.6 Differences in comparison with the technology card Figure 2-5 Setpoint exchange in conjunction with single-encoder safety integrated system Differences in comparison with the technology card The setpoint exchange implemented in NCK SW 7.1 and higher differs from the compile cycles solution described in TE5 as follows.

  • Page 430

    Detailed description 2.6 Differences in comparison with the technology card Special functions: Setpoint Exchange (S9) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 431

    Restrictions Availability Setpoint exchange is available in SW 7.1 and higher. MD30100 Setpoint exchange is only possible in conjunction with 611D and PROFIBUS drives with: MD30100 $MA_CTRLOUT_SEGMENT_NR=1. 5 or 6. All other settings generate alarm 26018. "Parking" operating status The "parking" operating state can only be exited using the axis with the drive checking function.

  • Page 432

    Restrictions Special functions: Setpoint Exchange (S9) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 433

    Examples No examples are available. Special functions: Setpoint Exchange (S9) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 434

    Examples Special functions: Setpoint Exchange (S9) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 435

    Data lists Machine data 5.1.1 Axis/spindlespecific machine data Number Identifier: $MA_ Description 30130 CTRLOUT_TYPE Output type of setpoint 30200 NUM_ENCS Number of encoders 30220 ENC_MODULE_NR Actual-value assignment: Drive number / measurement circuit number 30230 ENC_INPUT_NR Actual-value assignment: Input on drive module/measuring circuit module Special functions: Setpoint Exchange (S9) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 436

    Data lists 5.1 Machine data Special functions: Setpoint Exchange (S9) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 437

    Index MD30110, 8 MD30230, 8 MD30100, 15 Special functions: Setpoint Exchange (S9) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 438: Tangential Control (t3)

    840D sl/840Di sl/840D/840Di/810D Data lists Special functions: Tangential Control (T3) Function Manual Valid for Control SINUMERIK 840D sl/840DE sl SINUMERIK 840Di sl/840DiE sl SINUMERIK 840D powerline/840DE powerline SINUMERIK 840Di powerline/840DiE powerline SINUMERIK 810D powerline/810DE powerline Software Version NCU system software for 840D sl/840DE sl 1.3...

  • Page 439

    Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

  • Page 440

    Table of contents Brief description ............................5 Detailed description ........................... 7 Characteristics of tangential follow-up control ................7 Using tangential follow-up control ....................9 2.2.1 Assignment between leading axes and following axis..............10 2.2.2 Activation of follow-up control ......................11 2.2.3 Switching on corner response......................12 2.2.4 Termination of follow-up control....................12 2.2.5...

  • Page 441

    Table of contents Special functions: Tangential Control (T3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 442

    Brief description Tangential control The tangential control function belongs to the category of NC functions with coupled axes. It is characterized by the following features: • There are two leading axes which are moved independently by means of normal traversing instructions (leading axes). In addition there is a following axis whose position is determined as a function of the status of these leading axes (position, tangent).

  • Page 443

    Brief description Canceling of follow-up grouping The definition of a follow-up grouping can be canceled in order to track new leading axes with the following axis. Applications The tangential control function can be used for example for the following applications: •...

  • Page 444

    Detailed description Characteristics of tangential follow-up control Task specification Follow-up control for the rotary axis must be implemented so that the axis is always positioned at a specified angle on the programmed path of the two leading axes. Figure 2-1 Tangential control, offset angle of zero degrees to path tangent In the diagram, X and Y are the leading axes in which the path is programmed;...

  • Page 445

    Detailed description 2.1 Characteristics of tangential follow-up control Response on follow-up A difference must made between the following cases: • Without intermediate block (TLIFT) The path velocity of the leading axes is reduced to such an extent that the following axis reaches its target position synchronously with the other axes.

  • Page 446

    Detailed description 2.2 Using tangential follow-up control Using tangential follow-up control Activating The following axis can only be aligned if: • The assignment between the leading and following axes is declared to the system (TANG) • Follow-up control is activated explicitly (TANGON) •...

  • Page 447

    Detailed description 2.2 Using tangential follow-up control Cross-channel block search The cross-channel block search in Program Test mode (SERUPRO "Serch-Run by Program test") can be used to stimulate tangential follow-up axes. More information on cross-channel block search SERUPRO: References: /FB1/Function Manual, Basic Functions; Mode Group, Channel, Program Operation, (K1), Section: Program test 2.2.1 Assignment between leading axes and following axis...

  • Page 448

    Detailed description 2.2 Using tangential follow-up control 2.2.2 Activation of follow-up control Programming The programming is carried out using the pre-defined sub-program TANGON. When the tangential control is activated, the name of the following axis which must be made to follow is transferred to the control.

  • Page 449

    Detailed description 2.2 Using tangential follow-up control 2.2.3 Switching on corner response After axis assignment with TANG(), the TLIFT() instruction must be written if the corner response is to be contained in an intermediate block. TLIFT (C) The control reads the following machine data for the tangential following axis C: MD37400 $MA_EPS_TLIFT_TANG_STEP (Tangent angle for corner recognition) If the tangential angle jump exceeds the angle (absolute value) of the angle set in the MD, the control recognizes a "corner"...

  • Page 450

    Detailed description 2.2 Using tangential follow-up control Note The assignment between 2 master axes and a slave axis programmed with TANG( ... ) is not canceled by TANGOF. Refer to section "Canceling the definition of a follow-up axis assignment". 2.2.5 Switching off intermediate block generation In order to stop generating the intermediate block at corners during program execution with active tangential follow-up control, the TANG() block must be repeated without following...

  • Page 451

    Detailed description 2.2 Using tangential follow-up control Example for geometry axis switchover If the definition of the follow-up axis assignment is not canceled, an attempt to execute a geometry axis switchover is suppressed and an alarm is output. N10 GEOAX(2,Y1) N20 TANG(A, X, Y) N30 TANGON(A, 90) N40 G2 F8000 X0 Y0 I0 J50...

  • Page 452

    Detailed description 2.3 Limit angle Limit angle Description of problem When the axis moves backwards and forwards along the path, the tangent turns abruptly through 180 degrees at the path reversal point. This response is not generally desirable for this type of machining operation (e.g. grinding of a contour). It is far better for the reverse motion to be executed at the same offset angle (negative) as the forward motion.

  • Page 453

    Detailed description 2.3 Limit angle Activation If the current offset angle is outside the active working area limit for the following axis, an attempt is made to return to within the permissible working area by means of the negative offset angle. This response corresponds to that shown in the lower diagram of the above Fig. Special functions: Tangential Control (T3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 454

    Restrictions Availability The "Tangential control" function is an option and available for • SINUMERIK 840D mit NCU 572/573 The special response at path corners, controlled by TLIFT () is available. Special functions: Tangential Control (T3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 455

    Restrictions Special functions: Tangential Control (T3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 456

    Examples Positioning of workpiece Figure 4-1 Tangential positioning of a workpiece on a bandsaw Positioning of tool Figure 4-2 Positioning of a dressing tool on a grinding wheel Special functions: Tangential Control (T3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 457

    Examples Example Corner in area TANG(A,X,Y,1.0,"B") TLIFT(A) G1 G641 X0 Y0 Z0 A0 TANGON(A,0) N4 X10 N5 Z10 N6 Y10 Here, a corner is hidden in the area between N4 and N6. N6 causes a tangent jump. That is why there is no rounding between N5 and N6 and an intermediate block is inserted. In the case of a hidden corner in area, an intermediate block is inserted before the block that has caused the tangent jump.

  • Page 458

    Data lists Machine data 5.1.1 Axis/spindlespecific machine data Number Identifier: $MA_ Description 37400 EPS_TLIFT_TANG_STEP Tangential angle for corner recognition 37402 TANG_OFFSET Default angle for tangential follow-up control System variables Identifier Description $AC_TLIFT_BLOCK Current block is an intermediate block generated by TLIFT Special functions: Tangential Control (T3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 459

    Data lists 5.2 System variables Special functions: Tangential Control (T3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 460

    Index Corner, 5 MD37400, 5, 11 Corner in area, 18 MD37402, 10 Intermediate block, 5 Tangential control, 5 Applications, 5 TANGON, 11 Special functions: Tangential Control (T3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 461

    Index Special functions: Tangential Control (T3) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 462: Installation And Activation Of

    840D sl/840Di sl/840D/840Di/810D Data lists Special functions: Installation and Activation of Loadable Compile Function Manual Valid for Control SINUMERIK 840D sl/840DE sl SINUMERIK 840Di sl/840DiE sl SINUMERIK 840D powerline/840DE powerline SINUMERIK 840Di powerline/840DiE powerline SINUMERIK 810D powerline/810DE powerline Software Version NCU system software for 840D sl/840DE sl 1.3...

  • Page 463

    Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

  • Page 464

    Table of contents Brief description ............................5 Brief description (840Di) ........................5 Brief description (840Di) ........................7 Detailed description ........................... 9 Loadable compile cycles 840D/840D sl..................9 2.1.1 Loading a compile cycle with HMI Advanced ................10 2.1.2 Loading a compile cycle with HMI Embedded ................11 2.1.3 Loading a compile cycle from an external computer with WinSCP3 ...........12 2.1.4...

  • Page 465

    Table of contents Special functions: Installation and Activation of Loadable Compile Cycles (TE01) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 466

    This section describes how technology functions are installed and activated in the form of loadable compile cycles. The description applies to all of the following technology functions available from Siemens: • 1D/3D clearance control in position control cycle Order no.: 6FC5 251-0AC05-0AA0 Compile cycle: CCCLC.ELF...

  • Page 467

    Brief description 1.1 Brief description (840Di) as well as to user-specific technology functions. The following technology functions are not available in the form of compile cycles: • Analog axis The compile cycle is now available as a hardware solution. • Speed/torque coupling The compile cycle is a generally-available function from SW 6.4 and higher.

  • Page 468

    Brief description 1.2 Brief description (840Di) Brief description (840Di) The description of how to load and activate compile cycles in conjunction with the SINUMERIK 840Di can be found in: References: /HBI/ SINUMERIK 840Di Manual; NC Startup with HMI Advanced, "Loadable Compile Cycles" section Special functions: Installation and Activation of Loadable Compile Cycles (TE01) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 469

    Brief description 1.2 Brief description (840Di) Special functions: Installation and Activation of Loadable Compile Cycles (TE01) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 470

    Compile cycles are functional expansions of the NCK system software that can be created by the machine manufacturer and/or by Siemens and then imported in the control later. As part of the open NCK system architecture, compile cycles have comprehensive access to data and functions of the NCK system level via defined software interfaces.

  • Page 471

    (extension .ELF for executable and linking format), please contact your regional Siemens sales partner. Note Compile cycles created by Siemens are options that require explicit activation and licensing. References: Ordering information in Catalog NC 60/61 2.1.1 Loading a compile cycle with HMI Advanced...

  • Page 472

    Detailed description 2.1 Loadable compile cycles 840D/840D sl 2.1.2 Loading a compile cycle with HMI Embedded Requirement To transfer the compile cycle to the control, the following requirements must be met: A storage medium (e.g. USB FlashDrive), which stores the compile cycle, is connected to the PCU.

  • Page 473

    Detailed description 2.1 Loadable compile cycles 840D/840D sl 2.1.3 Loading a compile cycle from an external computer with WinSCP3 Requirement To transfer the compile cycle to the control, the following requirements must be met: • The external computer (programming device/PC) which the compile cycle is loaded onto is linked to the PCU via a network (TCP/IP).

  • Page 474

    Detailed description 2.1 Loadable compile cycles 840D/840D sl Interface version Each interface version is displayed under: • Interface version of the NCK system software HMI Advanced: Diagnosis > Service Display > Version > NCU Version Display (excerpt) ------------------------------------------- CC Interface Version: 1st digit 2nd digit @NCKOPI .

  • Page 475

    Detailed description 2.1 Loadable compile cycles 840D/840D sl Dependencies The following dependencies exist between the interface versions of a compile cycle and the NCK system software: • 1st digit of the interface version number The 1st digit of the interface version number of a compile cycle and the NCK system software must be the same .

  • Page 476

    Detailed description 2.1 Loadable compile cycles 840D/840D sl 2.1.6 Activating the technological functions in the NCK Option The corresponding option must be enable before activating a technology function as described below. If the option data has not been set, the following alarm appears every time the NCK boots and the technology function will not be activated: Bit number Alarm 7202 "XXX_ELF_option_bit_missing: <...

  • Page 477

    The following alarms should be added to the alarm texts of the technology functions: 075999 0 0 "Channel %1 Sentence %2 Call parameter is invalid" Proceed as follows 1. Please copy the "oem_alarms_deu.ts" file from the "/siemens/sinumerik/hmi/lng" directory to the "/oem/sinumerik/hmi/lng" directory. 2. Rename the file ("xxx_deu.ts").

  • Page 478

    9. Restart HMI sl. Further information about creating alarm text files with HMI sl can be taken from: Literature: /IAM/ SINUMERIK 840D sl Commissioning Manual; Chapter: Configuring user alarm texts 2.1.8.2 Creating alarm texts with HMI Advanced The following alarms should be added to the alarm texts of the technology functions: 075999 0 0 "Channel %1 Sentence %2 Call parameter is invalid"...

  • Page 479

    4. Restart HMI Embedded. For more information about creating alarm texts with HMI Embedded, please refer to: Literature: /IAM/ SINUMERIK 840D sl/840Di sl/840D/840Di/810D Commissioning CNC Part 2 (HMI); Commissioning HMI Embedded (IM2), Chapter: Creating In-House Texts Concept for 840Di/840Di sl...

  • Page 480

    Boundary conditions Transition to newer NCK versions (840D) In order to be able to use technology functions from an existing archive in conjunction with newer NCK versions (NCK 06.03.23 and later), the archive must first be updated before being loaded in the NC. Requirements The following requirements must be met in order to update an archive: •...

  • Page 481

    Boundary conditions 3.1 Transition to newer NCK versions (840D) 3.1.1 Create backup archive Standard Creating an archive to backup user data as a default action is described in: References: /IAD/ Startup Manual 840D/SIMODRIVE 611D: "Data Backup" section Optimized Data backup with optimization of the static NC memory usage is only necessary if an archive for an NCK Version 6.3.xx is being used and the static NC memory usage needs to be optimized.

  • Page 482

    Boundary conditions 3.1 Transition to newer NCK versions (840D) 3.1.3 Loading compile cycles See sections: "Loading a compile cycle with HMI Advanced" "Loading a compile cycle with HMI Embedded" "Loading a compile cycle from an external computer with WinSCP3" 3.1.4 NCU RESET When the NCK is rebooted after an NCU reset, the compile cycles are loaded onto the NCK system software.

  • Page 483

    Boundary conditions 3.1 Transition to newer NCK versions (840D) 3.1.7 Convert archive The archive created in the standard procedure or together with optimization of the static NC memory usage (see "Create backup archive" section) has to be converted. The arc4elf.exe program is required for this purpose (available from E-Support).

  • Page 484

    Examples No examples are available. Special functions: Installation and Activation of Loadable Compile Cycles (TE01) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 485

    Examples Special functions: Installation and Activation of Loadable Compile Cycles (TE01) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 486

    Data lists Machine data 5.1.1 NC-specific machine data Number Identifier: $MN_ Description 60900 + i CC_ACTIV_IN_CHAN_XXXX[n] n = 0: Activating the technology function in NC channels with: with: i = 0, 1, XXXX = function code n = 1: 2, 3, ... n = 0 or 1 Additional functions within the technology function Special functions: Installation and Activation of Loadable Compile Cycles (TE01)

  • Page 487

    Data lists 5.1 Machine data Special functions: Installation and Activation of Loadable Compile Cycles (TE01) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 488

    Index Alarm texts, 15 Interface versions, 11 Compile cycle SW version, 13 Interface versions, 11 Loading from an external computer, 11 Loading with HMI Advanced, 10 Loading with HMI Embedded, 10 Technology functions, activation, 14 Software version, 13 SW version, 13 Compile cycles, loadable, 9 Special functions: Installation and Activation of Loadable Compile Cycles (TE01) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 489

    Index Special functions: Installation and Activation of Loadable Compile Cycles (TE01) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 490: Simulation Of Compile Cycles (te02)

    840D sl/840Di sl/840D/840Di/810D Data lists Special functions: Simulation of Compile Cycles (TE02) Function Manual Valid for Control SINUMERIK 840D sl/840DE sl SINUMERIK 840Di sl/840DiE sl SINUMERIK 840D powerline/840DE powerline SINUMERIK 840Di powerline/840DiE powerline SINUMERIK 810D powerline/810DE powerline Software Version NCU system software for 840D sl/840DE sl 1.3...

  • Page 491

    Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

  • Page 492

    Table of contents Brief description ............................5 Function ............................5 Requirements..........................5 Detailed description ........................... 7 OEM transformations ........................7 Boundary conditions ..........................9 Examples..............................11 Data lists..............................13 Index...............................Index-15 Special functions: Simulation of Compile Cycles (TE02) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 493

    Table of contents Special functions: Simulation of Compile Cycles (TE02) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 494

    Brief description Function If part programs, which use compile cycles, are simulated on the SINUMERIK user interface (e.g. HMI Advanced) simulation is aborted and corresponding error messages are issued. The reason is that compile cycle support has not yet been implemented on the HMI. The measures described below show how to set up the simulation runtime environment to enable the simulation of part programs, which use compile cycles, without error messages.

  • Page 495

    Brief description 1.2 Requirements Special functions: Simulation of Compile Cycles (TE02) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 496

    Detailed description OEM transformations When using OEM transformations, the simulation runtime environment has to be set. Proceed as follows installation path 1. Create a new directory: "< >/OEM" in addition to the standard directory: installation path "< >/MMC2" in the directory structure of the HMI application on the computer on which the HMI application (e.g.

  • Page 497

    Detailed description 2.1 OEM transformations 3. In the "OEM" directory, create the file "DPSIM.INI" with the following contents: [PRELOAD] CYCLES=1 CYCLEINTERFACE=0 4. Close the HMI application. 5. Launch the HMI application. 6. In the directory for the manufacturer cycles, create the file "TRAORI.SPF" with the following contents: PROC TRAORI(INT II) 7.

  • Page 498

    Boundary conditions No boundary conditions apply. Special functions: Simulation of Compile Cycles (TE02) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 499

    Boundary conditions Special functions: Simulation of Compile Cycles (TE02) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 500

    Examples No examples are available. Special functions: Simulation of Compile Cycles (TE02) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 501

    Examples Special functions: Simulation of Compile Cycles (TE02) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 502

    Data lists No signals or machine data are required for this function. Special functions: Simulation of Compile Cycles (TE02) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 503

    Data lists Special functions: Simulation of Compile Cycles (TE02) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 504

    Index OEM transformations Requirements, 5 Special functions: Simulation of Compile Cycles (TE02) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 505

    Index Special functions: Simulation of Compile Cycles (TE02) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 506: Clearance Control (te1)

    840D sl/840Di sl/840D/840Di/810D Data lists Special functions: Clearance Control (TE1) Function Manual Valid for Control SINUMERIK 840D sl/840DE sl SINUMERIK 840Di sl/840DiE sl SINUMERIK 840D powerline/840DE powerline SINUMERIK 840Di powerline/840DiE powerline SINUMERIK 810D powerline/810DE powerline Software Version NCU system software for 840D sl/840DE sl 1.3...

  • Page 507

    Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

  • Page 508

    Table of contents Brief description ............................5 Detailed description ........................... 7 Function description........................7 Clearance control.........................10 2.2.1 Control dynamics .........................10 2.2.2 Velocity feedforward control......................12 2.2.3 Control loop structure........................14 2.2.4 Compensation vector ........................15 Technological features of clearance control ................18 Sensor collision monitoring ......................19 Startup............................20 2.5.1 Activating the technological function....................20...

  • Page 509

    Table of contents Data lists..............................55 Machine data..........................55 5.1.1 Drive-specific machine data (840D).................... 55 5.1.2 Drive-specific machine data (840Di) ................... 55 5.1.3 NC-specific machine data ......................55 5.1.4 Channelspecific machine data ....................56 5.1.5 Axis/spindlespecific machine data ....................57 Signals............................

  • Page 510

    Brief description Function Description The "clearance control" technological function is used to maintain a one-dimensional (1D) or three-dimensional (3D) clearance required for technological reasons during a defined machining process. The clearance to be maintained may be e.g. the distance of a tool from the workpiece surface to be machined.

  • Page 511

    Brief description Special functions: Clearance Control (TE1) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 512

    Detailed description Function description Laser cutting technology is used as an example for the detailed description of the "clearance control" functionality . Laser cutting During laser cutting, a divergent parallel laser beam is directed across a fiber-optic cable or via a mirror to a light-collecting lens mounted on the laser machining head. The collecting lens focuses the laser beam at its focal point.

  • Page 513

    Detailed description 2.1 Function description Figure 2-1 System components for clearance control with SINUMERIK 840D System overview (840Di) An overview of the system components required for clearance control in conjunction with SINUMERIK 840Di is provided in the following diagram. Figure 2-2 System components for clearance control with SINUMERIK 840Di Special functions: Clearance Control (TE1) Function Manual, 11/2006, 6FC5397-2BP10-2BA0...

  • Page 514

    Detailed description 2.1 Function description 1D/ 3D machining Clearance control can be used for 1D and 3D machining with up to five interpolatory axes. • 1D machining In the case of 1D machining, clearance control is only applied to one axis, e.g. axis Z, as shown in the example machine configuration in the system overview for each SINUMERIK system (see "System components for clearance control with SINUMERIK 840D"...

  • Page 515

    Detailed description 2.2 Clearance control Clearance control 2.2.1 Control dynamics Closed-loop control gain Kv The dynamic response of the closed control loop (sensor - open-loop control - axis) is determined by the maximum closed-loop control gain Kv. The closed-loop control gain Kv is defined as: Clearance control characteristics Clearance control is based on the two characteristics shown in the following diagram: •...

  • Page 516

    Detailed description 2.2 Clearance control • The clearance sensor measures the actual distance from the workpiece surface and returns as its output variable a voltage in [V], which is almost directly proportional to the distance. • The clearance control function uses the parameterized voltage/velocity characteristic from the voltage provided by the clearance sensor to calculate a compensatory velocity for the clearance-controlled axes that is appropriate for the clearance.

  • Page 517

    Detailed description 2.2 Clearance control (840Di) SINUMERIK 840Di with I/O modules and drives connected via PROFIBUS-DP produces a deadtime T dead = 2 * position controller cycle + 2 * speed controller cycle + conversion time + channel dead cycle time + 2 * "PROFIBUS-DP cycle" + To •...

  • Page 518

    Detailed description 2.2 Clearance control Optimizing the control response If the control response of the axis is too rigid due to the velocity feedforward control, the control response can be optimized with the following axis-specific NC machine data: • MD32410 $MA_AX_JERK_TIME (time constant for the axial jerk filter). •...

  • Page 519

    Detailed description 2.2 Clearance control 2.2.3 Control loop structure The figures below provide an overview of how the clearance control function is embedded in the control loop structure of the NC position controller and the internal structure of the function. Figure 2-4 Control structure, position controller with clearance control (principle) Special functions: Clearance Control (TE1)

  • Page 520

    Detailed description 2.2 Clearance control Figure 2-5 Control structure, clearance control (principle) 2.2.4 Compensation vector Standard compensation vector The compensation vector of the clearance control and the tool orientation vector are normally identical. Consequently, the compensation movement of the clearance control is normally always in the direction of the tool orientation.

  • Page 521

    Detailed description 2.2 Clearance control Note In all the figures in this chapter, the traversing movement of the machining head needed in order to machine the workpiece is in the direction of the Y coordinate, i.e. perpendicular to the drawing plane. As long as the tool orientation, and hence the compensation vector, is perpendicular to the workpiece surface, no disadvantage for the machining process results from the compensation movements of the clearance control.

  • Page 522

    Detailed description 2.2 Clearance control Figure 2-8 Programmable compensation vector Changes in orientation Based on the above observations, a different behavior also results when the orientation of the machining head is changed while the clearance control is active. In the following diagram the normal case is shown on the left (compensation vector == tool orientation vector);...

  • Page 523

    Detailed description 2.3 Technological features of clearance control The meaning of the individual positions of the machining head is as follows: 1. Programmed position of the machining head 2. Actual position of the machining head with clearance control active before the orientation change 3.

  • Page 524

    Detailed description 2.4 Sensor collision monitoring • Control options via the PLC interface The following signals are available at the PLC interface: Status signals: – Closed-loop control active – Overlaying movement at standstill – Lower limit reached – Upper limit reached. Control signals: –...

  • Page 525

    Detailed description 2.5 Startup Startup Compile cycle Before starting up the technological function, make sure that the corresponding compile cycle has been loaded and activated. References: FB3/ Function Manual, Special Functions, Installation of Compile Cycles (TE01) /HBI/SINUMERIK 840Di Manual, NC Installation and Start-Up with HMI Advanced, Loadable Compile Cycles chapter 2.5.1 Activating the technological function...

  • Page 526

    Detailed description 2.5 Startup 2.5.3 Parameter settings for input signals (840D) The following input signals must be parameterized in the machine data: • Clearance sensor input voltage – 1 analog input • "Sensor collision" input signal (optional) – 1 digital input Analog input The following machine data must be parameterized for the analog input: •...

  • Page 527

    Detailed description 2.5 Startup 2.5.4 Parameter settings for input signals (840Di) The following input signals must be parameterized in the machine data: • Clearance sensor input voltage – 1 analog input • "Sensor collision" input signal (optional) – 1 digital input Analog input The following machine data must be parameterized for the analog input: •...

  • Page 528

    Detailed description 2.5 Startup 2.5.5 Parameters of the programmable compensation vector Reference coordinate system The programmable compensation vector specifies the direction in which the compensation movement of the clearance control takes place. The compensation vector always refers to the basic coordinate system (machine coordinate system). The start coordinates [Xa, Ya, Za] of the compensation vector coincide with