Page 1 2 G1: Gantry axes 3 G3: Cycle times SINUMERIK 4 K6: Contour tunnel monitoring 5 SINUMERIK 840D sl M3: Coupled axes Special Functions 6 R3: Extended stop and retract 7 S9: Setpoint switchover 8 Function Manual T3: Tangential control TE01: Installation and activation 9 ...
Page 2 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
Page 3: Preface
Training For information about the range of training courses, refer under: • www.siemens.com/sitrain SITRAIN - Siemens training for products, systems and solutions in automation technology • www.siemens.com/sinutrain SinuTrain - training software for SINUMERIK FAQs You can find Frequently Asked Questions in the Service&Support pages under Product Support.
Page 4 Preface SINUMERIK You can find information on SINUMERIK under the following link: www.siemens.com/sinumerik Target group This publication is intended for: • Project engineers • Technologists (from machine manufacturers) • System startup engineers (Systems/Machines) • Programmers Benefits The function manual describes the functions so that the target group knows them and can select them.
Page 5 Preface • Appendix with: List of abbreviations Overview • Index of terms Note For detailed descriptions of data and alarm see: • machine and setting data: Detailed description of machine data (only electronically on DOConCD or DOConWEB) • NC/PLC interface signals: Function Manual Basic Functions;...
Page 6 Preface Data types The following elementary data types are used in the control system: Type Meaning Range of values Signed integers -2147483648 ... +2147483647 REAL Figures with decimal point acc. to IEEE -308 +308 ±(2,2*10 … 1,8*10 BOOL Truth values TRUE (1) and FALSE (0) 1, 0 CHAR ASCII characters...
Page 7: Table Of Contents
Table of contents Preface.................................3 F2: Multi-axis transformations ........................23 Brief description......................... 23 1.1.1 5-axis Transformation ........................ 23 1.1.2 3-axis and 4-axis transformation ....................25 1.1.3 Orientation transformation with a swivelling linear axis............. 26 1.1.4 Universal milling head ....................... 28 1.1.5 Orientation axes ........................
Page 8 Table of contents 1.9.5 Orientation relative to the path ....................92 1.9.6 Programming of orientation polynominals ................. 96 1.9.7 Tool orientation with 3-/4-/5-axis transformations ..............99 1.9.8 orientation vectors with 6-axis transformation ................99 1.10 Orientation axes........................101 1.10.1 JOG mode ..........................102 1.10.2 Programming for orientation transformation ................
Page 9 Table of contents PLC interface signals for gantry axes..................167 Miscellaneous points regarding gantry axes ................169 Examples..........................172 2.7.1 Creating a gantry grouping ...................... 172 2.7.2 Setting of NCK PLC interface ....................173 2.7.3 Commencing start-up ......................174 2.7.4 Setting warning and trip limits ....................
Page 10 Table of contents 5.1.1 Product brief ..........................203 5.1.1.1 Function ........................... 203 5.1.1.2 Preconditions ........................... 203 5.1.2 General functionality ........................ 204 5.1.3 Programming ........................... 208 5.1.3.1 Definition and switch on of a coupled axis grouping (TRAILON) ..........208 5.1.3.2 Switch off (TRAILOF) ....................... 209 5.1.4 Effectiveness of PLC interface signals ..................
Page 11 Table of contents 5.5.1.1 Function ........................... 268 5.5.1.2 Preconditions ........................... 268 5.5.2 Basics ............................272 5.5.2.1 Coupling module ........................272 5.5.2.2 Keywords and coupling characteristics ................... 273 5.5.2.3 System variables ........................276 5.5.3 Creating/deleting coupling modules ..................276 5.5.3.1 Creating a coupling module (CPDEF) ..................276 5.5.3.2 Delete coupling module (CPDEL) ....................
Page 12 Table of contents 5.5.12.7 Limitations and constraints ...................... 333 Dynamic response of following axis..................335 5.6.1 Parameterized dynamic limits ....................335 5.6.2 Programmed dynamic limits ....................335 5.6.2.1 Programming (VELOLIMA, ACCLIMA) ..................335 5.6.2.2 Examples ..........................337 5.6.2.3 System variables ........................338 Boundary conditions ........................
Page 13 Table of contents 6.2.10.6 Block search, REPOS ......................382 ESR executed autonomously in the drive................383 6.3.1 Fundamentals .......................... 383 6.3.2 Configuring stopping in the drive ..................... 384 6.3.3 Configuring retraction in the drive .................... 385 6.3.4 Configuring generator operation in the drive ................387 6.3.5 ESR is enabled via system variable ..................
Page 14 Table of contents Using tangential follow-up control.................... 421 8.3.1 Assignment between leading axes and following axis ............. 422 8.3.2 Activation of follow-up control ....................422 8.3.3 Switching on corner response ....................423 8.3.4 Termination of follow-up control ....................424 8.3.5 Switching off intermediate block generation ................
Page 15 Table of contents 11.2.1 Control dynamics ........................458 11.2.2 Velocity feedforward control ....................460 11.2.3 Control loop structure ......................462 11.2.4 Compensation vector ....................... 463 11.3 Technological features of clearance control ................467 11.4 Sensor collision monitoring...................... 469 11.5 Startup ............................. 470 11.5.1 Activating the technological function ..................
Page 16 Table of contents 12.4 Torque compensatory controller ....................512 12.5 Tension torque......................... 515 12.6 Activating a coupling........................ 519 12.7 Response on activation/deactivation ..................521 12.8 Constraints..........................524 12.8.1 Speed/torque coupling (SW 6 and higher) ................524 12.8.2 Axial NC/PLC interface signals ....................525 12.8.3 Interaction with other functions ....................
Page 17 Table of contents 13.11 Cartesian PTP travel with handling transformation package........... 588 13.12 Function-specific alarm texts ....................589 13.13 Boundary conditions ........................ 590 13.13.1 Function-specific boundary conditions ..................590 13.13.2 Interaction with other functions ....................591 13.14 Examples..........................592 13.14.1 General information about start-up ..................592 13.14.2 Starting up a kinematic transformation ..................
Page 18 Table of contents 15.3.5 RESU main program memory area ..................622 15.3.6 Storage of the RESU subroutines .................... 623 15.3.7 ASUB enable ........................... 624 15.3.8 PLC user program ........................624 15.4 Programming ........................... 626 15.4.1 RESU Start/Stop/Reset (CC_PREPRE) .................. 626 15.5 RESU-specific part programs ....................
Page 19 Table of contents 16.2.2.2 Path length-related switching signal output ................651 16.2.3 Calculating the switching instants .................... 652 16.2.4 Switching frequency and switching position distance .............. 652 16.2.5 Approaching switching position ....................653 16.2.6 Programmed switching position offset ..................654 16.2.7 Response to part program interruption ..................
Page 20 Table of contents 17.5 Examples ..........................677 17.5.1 Collision protection ........................677 17.5.2 Collision protection and distance limiter .................. 678 17.6 Data lists ..........................680 17.6.1 Option data ..........................680 17.6.2 Machine data ........................... 680 17.6.2.1 NC-specific machine data ......................680 17.6.2.2 Axis/Spindle-specific machine data ..................
Page 21 Table of contents 19.7.1 General machine data ......................723 19.7.2 Channelspecific machine data ....................723 W6: Path length evaluation ........................725 20.1 Brief description........................725 20.2 Data ............................726 20.3 Parameterization ........................727 20.3.1 General activation ........................727 20.3.2 Data groups ..........................727 20.4 Examples..........................
Page 22 21.11.2 Signals from channel ....................... 750 Appendix ..............................753 List of abbreviations......................... 753 Overview..........................761 Glossary ..............................763 Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 23: F2: Multi-Axis Transformations
F2: Multi-axis transformations Brief 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 24 F2: Multi-axis transformations 1.1 Brief description 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: Euler angles RPY angles...
Page 25: 3-Axis And 4-Axis Transformation
F2: Multi-axis transformations 1.1 Brief description 1.1.2 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 26: Orientation Transformation With A Swivelling Linear Axis
F2: Multi-axis transformations 1.1 Brief description Figure 1-2 Schematic diagram of a 4-axis transformation with moveable workpiece 1.1.3 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 27 F2: Multi-axis transformations 1.1 Brief description Figure 1-3 Schematic diagram of a machine with swivelling linear axis Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 28: Universal Milling Head
F2: Multi-axis transformations 1.1 Brief description 1.1.4 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 29: Orientation Axes
F2: Multi-axis transformations 1.1 Brief description 1.1.5 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 30: Cartesian Manual Travel
F2: Multi-axis transformations 1.1 Brief description 1.1.6 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 31: Online Tool Length Offset
F2: Multi-axis transformations 1.1 Brief description 1.1.9 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 32: 5-Axis Transformation
F2: Multi-axis transformations 1.2 5-axis transformation 5-axis transformation 1.2.1 Kinematic transformation Task of orientation transformation The task of orientation transformation is to compensate movements of the tool nose, which result from changes in orientation, by means of appropriate compensating movements of the geometry axes.
Page 33 F2: Multi-axis transformations 1.2 5-axis transformation 4. Rotary axes turn Tool with two-axis swivel head (machine type 1) Workpiece with two-axis rotary table (machine type 2) Tool and workpiece with single-axis rotary table and swivel head (machine type 3) 5. The following applies to machine types 1 and 2: Rotary axis 1 is treated as the 4th machine axis of the transformation.
Page 34: Configuration Of A Machine For 5-Axis Transformation
F2: Multi-axis transformations 1.2 5-axis transformation 1.2.3 Configuration of a machine for 5-axis transformation To ensure that the 5-axis transformation can convert the programmed values to axis motions, certain information about the mechanical design of the machine is required; this information is stored in machine data: •...
Page 35 F2: Multi-axis transformations 1.2 5-axis transformation Axis assignment The axis assignment at the start of the 5-axis transformation defines the axis that will be mapped by the transformation internally onto a channel axis. Thus, the following is defined in the machine data below: MD24110 $MC_TRAFO_AXES_IN_1 (Axis assignment for transformation 1) MD24482 $MC_TRAFO_AXES_IN_10 (Axis assignment for transformation 10) Geometry information...
Page 36 F2: Multi-axis transformations 1.2 5-axis transformation 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] Figure 1-7 Schematic diagram of CA kinematics, moved tool Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 37 F2: Multi-axis transformations 1.2 5-axis transformation Figure 1-8 Schematic diagram of CB kinematics, moved workpiece Figure 1-9 Schematic diagram of AC kinematics, moved tool, moved workpiece Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 38: Tool Orientation
F2: Multi-axis transformations 1.2 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...
Page 39 F2: Multi-axis transformations 1.2 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 40 F2: Multi-axis transformations 1.2 5-axis transformation The orientation is selected via NC language commands ORIWCS and ORIMCS. Figure 1-11 Change in cutter orientation while machining inclined edges Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 41 F2: Multi-axis transformations 1.2 5-axis transformation Figure 1-12 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 42 F2: Multi-axis transformations 1.2 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 43: Singular Positions And Handling
F2: Multi-axis transformations 1.2 5-axis transformation 1.2.5 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 44 F2: Multi-axis transformations 1.2 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 45 F2: Multi-axis transformations 1.2 5-axis transformation 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 46: 3-Axis And 4-Axis Transformations
F2: Multi-axis transformations 1.3 3-axis and 4-axis transformations 3-axis and 4-axis transformations Introduction 3-axis and 4-axis transformations are special types of the 5-axis transformation initially described. Orientation of the tool is possible only in the plane perpendicular to the rotary axis. The transformation supports machine types with movable tool and movable workpiece.
Page 47 F2: Multi-axis transformations 1.3 3-axis and 4-axis transformations Axis assignments The three translatory axes included in the transformation are assigned to any channel axes via machine data $MC_TRAFO_GEOAX_ASSIGN_TAB_n[0..2] and $MC_TRAFO_AXES_IN_n[0..2]. The following must apply for the assignment of channel axes to geometry axes for the transformation: $MC_TRAFO_GEOAX_ASSIGN_TAB_n[0] = $MC_TRAFO_AXES_IN_n[0] $MC_TRAFO_GEOAX_ASSIGN_TAB_n[1] = $MC_TRAFO_AXES_IN_n[1]...
Page 48: Transformation With Swivelled Linear Axis
F2: Multi-axis transformations 1.4 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 (<<± 90 degrees) is crossed by the first rotary axis.
Page 49 F2: Multi-axis transformations 1.4 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 1-14 Projections of the vectors to be set in machine data Meanings of vector designations: •...
Page 50 F2: Multi-axis transformations 1.4 Transformation with swivelled linear axis The Figure "Example of Vector Designation for MD-settings" shows vector components for the machine shown in Figure "Machine with linear swivel axis in Zero Position" (Chapter "Orientation Transformation with Linear Swivel Axis") and they are named accordingly. Note A physically identical point on the 1st rotary axis (e.g.
Page 51 F2: Multi-axis transformations 1.4 Transformation with swivelled linear axis Figure 1-15 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 Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 52 F2: Multi-axis transformations 1.4 Transformation with swivelled linear axis Figure 1-16 Example of vector designation for MD-settings in Figure "Machine with Swivelling Linear Axis in Zero Position" 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"...
Page 53 F2: Multi-axis transformations 1.4 Transformation with swivelled linear axis This procedure can be used for all kinematics specified under "Kinematics Variants". Observe the tips given in Figure "Projections of Vectors to be set in Machine Data". Zero components With certain geometries or machine zero positions, individual components or complete vectors can become zero.
Page 54: Universal Milling Head
F2: Multi-axis transformations 1.5 Universal milling head Universal milling head 1.5.1 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 55 F2: Multi-axis transformations 1.5 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 56: Parameterization
F2: Multi-axis transformations 1.5 Universal milling head Angle definition Figure 1-18 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 57 F2: Multi-axis transformations 1.5 Universal milling head Table 1-1 MD $MC_TRAFO_TYPE_n Decimal Description Direction of orientation of tool in position zero 00: X direction 01: Y direction 10: Z direction 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...
Page 58: Traverse Of Universal Milling Head In Jog Mode
F2: Multi-axis transformations 1.5 Universal milling head Example of transformation type $MC_TRAFO_TYPE = 148 for example, means: The first rotary axis is parallel to the Z axis, the second rotary axis is an inclined X axis and tool orientation in zero position points in the Z direction.
Page 59: Activation And Application Of 3-Axis To 5-Axis Transformation
F2: Multi-axis transformations 1.6 Activation and application of 3-axis to 5-axis transformation Activation and application of 3-axis to 5-axis transformation Switch on 3-axis to 5-axis transformations (including the transformations for swiveled linear axis and universal milling head) are activated with the TRAORI(n) command, where n represents the number of the transformation (n = 1 or 2).
Page 60 F2: Multi-axis transformations 1.6 Activation and application of 3-axis to 5-axis transformation Option The "5-axis transformation" function and its special types described in this Function Manual are only available as an option. f this option is not implemented in the control system and a transformation is called with the TRAORI command, error message 14780 "Block uses a function that has not been enabled"...
Page 61: Generic 5-Axis Transformation And Variants
F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Generic 5-axis transformation and variants 1.7.1 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 62: Description Of Machine Kinematics
F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants 1.7.2 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 63: Generic Orientation Transformation Variants
F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants 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 1.7.3 Generic orientation transformation variants Expansion Generic orientation transformation for 5-axis transformation has been extended with the following variants for 3-and 4-axis transformation:...
Page 64 F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Effects on orientations Generic 3-axis or 4-axis transformation has the following effect on the various orientations: The resulting tool orientation is defined according to the hierarchy specified for generic 5-axis transformation. Priority: •...
Page 65: Parameterization Of Orientable Tool Holder Data
F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants 1.7.4 Parameterization of orientable tool holder data Application Machine types for which the table or tool can be rotated, can either be operated as true 5-axis machines or as conventional machines with orientable tool holders. In both cases, machine kinematics is determined by the same data, which, due to different parameters, previously had to be entered twice - for tool holder via system varaibles and for transformations via machine data.
Page 66 F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Note The transformation only takes place if the orientable toolholder concerned is available and the value of $TC_CARR23 contains a valid entry for type M, P or T kinematics in lower or upper case.
Page 67 F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Assignment for all types of transformation together identical MD24520 $MC_TRAFO5_ROT_SIGN_IS_PLUS_1[0] (sign of TRUE* rotary axis 1/2/3 for 5-axis transformation 1) MD24520 $MC_TRAFO5_ROT_SIGN_IS_PLUS_1[1] TRUE* *) Machine data MD24520/MD24620 $MC_TRAFO5_ROT_SIGN_IS_PLUS_1/2 are redundant. They are used to invert the direction of rotation of the assigned rotary axis. However, this can also be achieved by inverting the direction of axis vector $MC_TRAFO5_AXIS1/2_1/2.
Page 68 F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Transformation type "P" (in accordance with MD24100 $MC_TRAFO_TYPE_1 = 40) MD24500 $MC_TRAFO5_PART_OFFSET_1[0] $TC_CARR18 (+$TC_TCARR58) MD24500 $MC_TRAFO5_PART_OFFSET_1[1] $TC_CARR19 (+$TC_TCARR59) MD24500 $MC_TRAFO5_PART_OFFSET_1[2] $TC_CARR20 (+$TC_TCARR60) Assignments for transformation type 56 Toolholder data assignments dependent on transformation type 56 Transformation type "M"...
Page 69: Extension Of The Generic Transformation To 6 Axes
F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants 1.7.5 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 70 F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Configuration For configuration of a 6-axis transformation the extensions of the following machine data are required: • The channel axis index of the 3rd rotary axis must be entered in the following machine data: MD24110 $MC_TRAFO_AXES_IN_1[5] (axis assignment for transformation) •...
Page 71 F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Programming of orientation With the extension of the generic orientation transformation to 6 axes, all three degrees of freedom of the orientation can be freely selected. They can be uniquely defined through the position of a rectangular Cartesian coordinate system.
Page 72: Extension Of The Generic Transformation To 7 Axes
F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Note The orientation vector of a tool can also be defined via system the variables $TC_DPV or $TC_DPV3 - $TC_DPV5 in tool data - see /FB1/ Function Manual Basic Machine, Tool Corrections (W1), "Sum and Set-up Corrections".
Page 73 F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Function Another 7th axis is required in connection with the generic 6-axis transformation which rotates the workpiece. This 7th axis is considered only along with Transformer Type 24 (generic 6- axis transformation having 3 rotary axes that move the tool ). The position of the 7th axis is specified according to a strategy of the CAD system and settled with the Cartesian position (X, Y, Z) by the generic transformation in such a way that the axes always approach the TCP position programmed with reference to the workpiece,...
Page 74 F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Description of the kinematics The 7-axis transformation builds on the generic 5-/6-axis transformation. Note The 7-axis transformation also covers kinematics in which the 6th axis is not available. In the following pages, we speak exclusively about a 7th axis or about a 7-axis transformation, even when it is actually the 6th axis in connection with a 5-axis kinematics.
Page 75 F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Position vector in MCS $MC_TRAFO5_PART_OFFSET_n[0..2] Vector of programmed position in the WCS Tool correction vector $MC_TRAFO5_BASE_TOOL_n[0..2] $MC_TRAFO5_JOINT_OFFSET_n[0..2] jo23: $MC_TRAFO6_JOINT_OFFSET_2_3_n[0..2] Figure 1-19 Schematic diagram of 7-axis kinematics Programming 1. Programming the Cartesian position The position of the 7th axis must be programmed in the workpiece coordination system in addition to the Cartesian position.
Page 76 F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Orientation 1. Orientation with axis interpolation If the 7th axis should have no influence on the programmed orientation, the G codes of Groups 25 and 51 must be set accordingly: G code group 25: ORIMKS G code group 51: ORIAXES (if MD 21104 $MC_ORI_IPO_WITH_G_CODE = 1 is set).
Page 77: Cartesian Manual Travel With Generic Transformation
F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Frames The basic coordinate system sits on the 7th axis. It is also rotated when the 7th axis rotates. This way the workpiece coordinate system (WCS) does not remain stationary when the workpiece is rotated over the 7th axis.
Page 78 F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Activation The following machine data not only activates the function, but also sets the permitted coordinate systems. MD21106 $MC_CART_JOG_SYSTEM (coordinate systems for Cartesian JOG) The following setting data sets the virtual kinematics used for traversing motion of the orientation: SD42660 $SC_ORI_JOG_MODE (definition of virtual kinematics for JOG) As opposed to the generic 5-/6-axis transformation, only kinematics can be set in which the...
Page 79 F2: Multi-axis transformations 1.7 Generic 5-axis transformation and variants Rotations with JOG With JOG, the rotations around the specified directions of the respective reference system can be performed with Euler angle or RPY angle. SD42660 $SC_ORI_JOG_MODE = 1: When jogging, Euler angles are traversed, i.e.: the first axis rotates around the z direction, the second axis rotates around the x direction, the third axis (if present) rotates around the new z direction.
Page 80: Restrictions For Kinematics And Interpolation
F2: Multi-axis transformations 1.8 Restrictions for kinematics and interpolation Restrictions for kinematics and interpolation For systems where there are less than six axes available for transformation, the following restrictions must be taken into account. 5-axis kinematics For 5-axis kinematics there are two degrees of freedom for orientation. The assignment of orientation axes and tool vector direction must be selected so that there is no rotation around the tool vector.
Page 81 F2: Multi-axis transformations 1.8 Restrictions for kinematics and interpolation Such a situation would be treated as follows: There is only one relevant machine data, which circles the pole as usual: MD24540 $MC_TRAFO5_POLE_LIMIT_1 (closing angle tolerance for interpolation by pole for 5-xis transformation) MD24640 $MC_TRAFO5_POLE_LIMIT_2 (closing angle tolerance for interpolation by pole for 5-xis transformation) For further information about the handling of singular positions, see:...
Page 82 F2: Multi-axis transformations 1.8 Restrictions for kinematics and interpolation 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. However, since the first rotary axis does not move, the orientation will generally deviate from the programmed value (see previous Figure).
Page 83: Orientation
F2: Multi-axis transformations 1.9 Orientation Orientation 1.9.1 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 84 F2: Multi-axis transformations 1.9 Orientation If a basic orientation is defined by the above method, it cannot be altered while a transformation is active. The orientation can be changed only by selecting the transformation again. Via the orientation of the active tool For 2.: The basic orientation is determined by the tool •...
Page 85: Orientation Movements With Axis Limits
F2: Multi-axis transformations 1.9 Orientation Note The range of settable orientations depends on the directions of the rotary axes involved and the basic orientation. The rotary axes must be mutually perpendicular if all possible orientations are to be used. If this condition is not met, "dead" ranges will occur. Examples: 1.
Page 86: Orientation Compression
F2: Multi-axis transformations 1.9 Orientation The following conditions must be met in order to monitor the axis limits of a rotary axis and modify the calculated end positions: • A generic 5-axis transformation of type 24, 40 or 56 must be active. •...
Page 87 F2: Multi-axis transformations 1.9 Orientation Conditions The orientation movement is compressed in the following cases: • Active orientation transformation (TRAORI) • Active large radius circular interpolation (i.e. tool orientation is changed in the plane which is determined by start and end orientation). Large circle interpolation is performed under the following conditions: MD21104 $MC_ORI_IPO_WITH_G_CODE = 0, ORIWKS is active and...
Page 88 F2: Multi-axis transformations 1.9 Orientation Compression mode The manner in which the tolerances are to be considered is set via the unit position in the machine data: MD20482 $MC_COMPRESSOR_MODE (mode of compression) Value Meaning The tolerances specified with MD33100 $MA_COMPRESS_POS_TOL are observed for all the axes (geo and orientation axes).
Page 89 F2: Multi-axis transformations 1.9 Orientation The hundreds position of MD20482 is used to select which blocks outside the linear blocks (G1) should be compressed. Value Meaning Circular blocks and G0 blocks are not compressed. This is compatible with earlier SW versions.
Page 90: Smoothing Of Orientation Characteristic
F2: Multi-axis transformations 1.9 Orientation General structure of an NC block that be compressed The general structure of an NC block that can be compressed can therefore look like this: N... X=<...> Y=<...> Z=<...> A3=<...> B3=<...> C3=<...> THETA=<...> F=<...> N... X=<...> Y=<...> Z=<...> A2=<...> B2=<...> C2=<...> THETA=<...> F=<...> Programming tool orientation using rotary axis positions Tool orientation can be also specified using rotary axis positions, e.g.
Page 91 F2: Multi-axis transformations 1.9 Orientation Function The "Smoothing the orientation characteristic (ORISON)" function can be used to smooth oscillations affecting orientation over several blocks. The aim is to achieve a smooth characteristic for both the orientation and the contour. Prerequisites The "Smoothing the orientation characteristic (ORISON)"...
Page 92: Orientation Relative To The Path
F2: Multi-axis transformations 1.9 Orientation Example Program code Comments TRAORI() ; Activation of orientation transformation. ORISON ; Activation of orientation smoothing. $SC_ORISON_TOL=1.0 ; Orientation tolerance smoothing = 1.0 degrees. X10 A3=1 B3=0 C3=1 X10 A3=–1 B3=0 C3=1 X10 A3=1 B3=0 C3=1 X10 A3=–1 B3=0 C3=1 X10 A3=1 B3=0 C3=1 X10 A3=–1 B3=0 C3=1...
Page 93 F2: Multi-axis transformations 1.9 Orientation orientation jump should be smoothed in a dedicated, inserted intermediate block. In this case, path motion is stopped in the contour corner. • There are two options of 6-axis transformations: Like tool rotation, tool orientation is interpolated relative to the path using ORIPATH, ORIPATHS.
Page 94 F2: Multi-axis transformations 1.9 Orientation 1. The end orientation of the previous block refers to the tangent and the normal vector at the end of the previous block. Both can differ from this at the start of the current block. Therefore, the start orientation in the current block does not have the same alignment with respect to the tangent and the normal vector as at the end of the previous block.
Page 95 F2: Multi-axis transformations 1.9 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 96: Programming Of Orientation Polynominals
F2: Multi-axis transformations 1.9 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 97 F2: Multi-axis transformations 1.9 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 98 F2: Multi-axis transformations 1.9 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 99: Tool Orientation With 3-/4-/5-Axis Transformations
F2: Multi-axis transformations 1.9 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 100 F2: Multi-axis transformations 1.9 Orientation The reading of the direction of rotation vector with the following system variables is only meaningful for a 6-axis transformation. $P_TOOLROT[n] Rotation direction vector active in the interpreter not applicable in synchronous actions $AC_TOOLR_ACT[n] Active rotation direction vector in the interpolator $AC_TOOLR_END[n] End orientation of the active block $AC_TOOLR_DIFF...
Page 101: Orientation Axes
F2: Multi-axis transformations 1.10 Orientation axes 1.10 Orientation axes Direction The directions around which axes are rotated are defined by the axes of the reference system. In turn, the reference system is defined by ORIMKS and ORIWKS commands: • ORIMKS: Reference system = Basic coordinate system •...
Page 102: Jog Mode
F2: Multi-axis transformations 1.10 Orientation axes Orientation transformation 1: MD24585 $MC_TRAFO5_ORIAX_ASSIGN_TAB_1[n] n = channel axis [0..2] Orientation transformation 2: MD24685 $MC_TRAFO5_ORIAX_ASSIGN_TAB_2[n] n = channel axis [0..2] transformation [1..4] MD24110 $MC_TRAFO5_AXES_IN_1[n] (axis n = channel axis [0..7] assignment for transformation) MD24410 $MC_TRAFO5_AXES_IN_4[n] (axis assignment for transformation 4) transformation [5..8] MD24432 $MC_TRAFO5_AXES_IN_5[n] (axis...
Page 103: Programming For Orientation Transformation
F2: Multi-axis transformations 1.10 Orientation axes Feedrate in JOG When orientation axes are traversed manually, the channel-specific feedrate override switch or the rapid traverse override switch in rapid traverse override is applied. Until now, velocities for traversal in JOG mode have always been derived from the machine axis velocities.
Page 104 F2: Multi-axis transformations 1.10 Orientation axes • ORIVIRT2: Orientation programming on the basis of virtual orientation axes (definition 2) The type of interpolation is distinguished on the basis of G-group 51: • ORIAXES: Orientation programming of linear interpolation of orientation axes or machine axes •...
Page 105 F2: Multi-axis transformations 1.10 Orientation axes Interpolation type The following machine data is used to specify which interpolation type is used: MD21104 $MC_ORI_IPO_WITH_G_CODE (G-code for orientation interpolation): • ORIMKS or ORIWKS (for description, see Chapter "Workpioece Orientation") • G-code group 51 with the commands ORIAXES or ORIVECT ORIAXES: Linear interpolation of machine axes or orientation axes.
Page 106: Programmable Offset For Orientation Axes
F2: Multi-axis transformations 1.10 Orientation axes 1.10.3 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 107: Orientation Transformation And Orientable Tool Holders
F2: Multi-axis transformations 1.10 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 108 F2: Multi-axis transformations 1.10 Orientation axes • MD21134 $MC_ORI_MODULO_RANGE[0...2] (Size of the modulo range for the display of the orientation axes) • MD21136 $MC_ORI_MODULO_RANGE_START[0...2] (Starting position of the modulo range for the display of the orientation axes) Please note the following: •...
Page 109: Orientation Vectors
F2: Multi-axis transformations 1.11 Orientation vectors 1.11 Orientation vectors 1.11.1 Polynomial interpolation of orientation vectors Programming of polynomials for axis motions The rotary axes are normally subjected to linear interpolation in case of orientation changes with the help of rotary axis interpolation. However, it is also possible to program the polynomials as usual for the rotary axes.
Page 110 F2: Multi-axis transformations 1.11 Orientation vectors POLYPATH: In addition to the modal G function POLY, the predefined subprogram POLYPATH(argument) can be used to activate polynomial interpolation selectively for different axis groups. The following arguments are allowed for the activation of polynomial interpolation ("AXES"): For all path axes and supplementary axes ("VECT"):...
Page 111 F2: Multi-axis transformations 1.11 Orientation vectors The two PHI and PSI angles are specified in degrees. POLY Activation of polynomial interpolation for all axis groups. POLYPATH ( ) Activation of polynomial interpolation for all axis groups. "AXES" and "VECT" are possible groups. The coefficients a and b are specified in degrees.
Page 112 F2: Multi-axis transformations 1.11 Orientation vectors PHI and PSI angle Programming of polynomials for the two angles PO[PHI] and PO[PSI] is always possible. Whether the programmed polynomials are actually interpolated for PHI and PSI depends on: • POLYPATH("VECT") and ORIVECT are active, then the polynomials will be interpolated. •...
Page 113: Rotations Of Orientation Vector
F2: Multi-axis transformations 1.11 Orientation vectors Constraints Polynomial interpolation of orientation vectors is only possible for control variants in which the following functions are included in the functional scope: • Orientation transformation • Polynomial interpolation 1.11.2 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 114 F2: Multi-axis transformations 1.11 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 115 F2: Multi-axis transformations 1.11 Orientation vectors The start angle is derived from the start value of the rotation vector, resulting from the end value of the previous block. The constant coefficient of the polynomial is defined by the starting angle of the polynomial. The rotation vector is always perpendicular to the current tool orientation and forms the angle THETAin conjunction with the basic rotation vector.
Page 116 F2: Multi-axis transformations 1.11 Orientation vectors Activation of rotation A rotation of the orientation vector is programmed with the identifier THETA. The following options are available for programming: Programming of an angle of rotation at the end of the block. THETA=<value>...
Page 117: Extended Interpolation Of Orientation Axes
F2: Multi-axis transformations 1.11 Orientation vectors A programmable rotation of the orientation vector is only possible when an orientation transformation (TRAORI) is active. A programmed orientation rotation is only interpolated if the machine kinematics allow rotation of the tool orientation (e.g. 6-axis machines). 1.11.3 Extended interpolation of orientation axes Functionality...
Page 118 F2: Multi-axis transformations 1.11 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 119 F2: Multi-axis transformations 1.11 Orientation vectors Settings for intermediate orientation orientation interpolation on a cone with intermediate ORICONIO orientation: Interpolation on a conical peripheral surface with intermediate orientation setting If this G-code is active, it is necessary to specify an intermediate orientation with A7, B7, C7 which is specified as a (normalized) vector.
Page 120 F2: Multi-axis transformations 1.11 Orientation vectors Besides the two end values, additional polynomials can be programmed in the following form: PO[XH] = (xe, x2, x3, x4, x5): (xe, ye, ze) the end point of the curve, and PO[YH] = (ye, y2, y3, y4, y5): xi, yi, zi the coefficients of the polynomials PO[ZH] = (ze, z2, z3, z4, z5): of the 5th degree maximum.
Page 121 F2: Multi-axis transformations 1.11 Orientation vectors Examples Various changes in orientation are programmed in the following program example: N10 G1 X0 Y0 F5000 N20 TRAORI ; orientation transformation active. N30 ORIVECT ; interpolate WZ orientation as a vector N40 ORIPLANE ;...
Page 122: Online Tool Length Offset
F2: Multi-axis transformations 1.12 Online tool length offset 1.12 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 123 F2: Multi-axis transformations 1.12 Online tool length offset MD21190 $MC_TOFF_MODE (operation of tool offset) The following machine data can be used to set whether the content of the synchronization variable $AA_TOFF[ ] is to be approached as an absolute value or whether an integrating behavior is to take place.
Page 124 F2: Multi-axis transformations 1.12 Online tool length offset Reset Compensation values can be reset with the TOFFOF( ) command. This instruction triggers a preprocessing stop. Accumulated tool length compensations are cleared and incorporated in the basic coordinate system. The run-in is synchronized with the current position in main run. Since no axes can be traversed here, the values of $AA_IM[ ] do not change.
Page 125 F2: Multi-axis transformations 1.12 Online tool length offset System variables In the case of online tool length offset, the following system variables are available to the user: System variables Meaning for online tool length offset $AA_TOFF[ ] Position offset in the tool coordinate system $AA_TOFF_VAL[ ] Integrated position offset in the WCS $AA_TOFF_LIMIT[ ]...
Page 126: Examples
F2: Multi-axis transformations 1.13 Examples 1.13 Examples 1.13.1 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...
Page 127 F2: Multi-axis transformations 1.13 Examples $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 CHANDATA(1) Program example for general 5-axis transformation: ; Definition of tool T1 $TC_DP1[1,1] = 10 ;...
Page 128: Example Of A 3-Axis And 4-Axis Transformation
F2: Multi-axis transformations 1.13 Examples 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 Euler angles program: N200 ORIMKS N210 G1 G90...
Page 129: Example Of A 4-Axis Transformation
F2: Multi-axis transformations 1.13 Examples 1.13.2.2 Example of a 4-axis transformation Example: For the machine schematically presented in Figure "Schematic 4-axis Transformation with movable Workpiece" (see Chapter "3- and 4-axis Transformation", Short Description), the 4-axis transformation can be projected in the following way: $MC_TRAFO_TYPE_n = 18 $MC_TRAFO_GEOAX_ASSIGN_TAB_n[0] = 1 $MC_TRAFO_GEOAX_ASSIGN_TAB_n[1] = 2...
Page 130: Example For Orientation Axes
F2: Multi-axis transformations 1.13 Examples Program ; Definition of tool T1 $TC_DP1[1,1] = 120; Type $TC_DP2[1,1] = 0; $TC_DP3[1,1] = 20; Z length offset vector G17 $TC_DP4[1,1] = 8.; $TC_DP5[1,1] = 5.; TRAORI(1); Activation of transformation ORIMKS; Orientation reference to MCS G0 X1 Y0 Z0 A0 B0 F20000 G90 G64 T1 D1 G17 ;...
Page 131 F2: Multi-axis transformations 1.13 Examples $MC_TRAFO5_ORIAX_ASSIGN_TAB_1[1]=5 ; Channel index of second orientation axis $MC_TRAFO5_ORIAX_ASSIGN_TAB_1[2]=6 ; Channel index of third orientation axis $MC_ORIAX_TURN_TAB_1[0]=3 ; Z direction $MC_ORIAX_TURN_TAB_1[1]=2 ; Y direction $MC_ORIAX_TURN_TAB_1[2]=3 ; Z direction CHANDATA(1) Figure 1-24 3 orientation axes for the 1st orientation transformation for kinematics with 6 transformed axes Example 2: 3 orientation axes for the 2nd orientation transformation for kinematics with 5 transformed...
Page 132: Examples For Orientation Vectors
F2: Multi-axis transformations 1.13 Examples $MC_ORIAX_TURN_TAB_1[0]=1 ; X direction $MC_ORIAX_TURN_TAB_1[1]=2 ; Y direction $MC_ORIAX_TURN_TAB_1[2]=3 ; Z direction CHANDATA(1) Figure 1-25 3 orientation axes for the 2nd orientation transformation for kinematics with 5 transformed axes The rotation through angle C2 about the Z" axis is omitted in this case, because the tool vector orientation can be determined solely from angles A2 and B2 and no further degree of freedom is available on the machine.
Page 133: Example Of Rotations Of Orientation Vector
F2: Multi-axis transformations 1.13 Examples In N40, the orientation vector is rotated in the Z-X plane which is spanned by the start and end vector. Here, the PHI angle is interpolated in a line in this plane between the values 0 and 90 degrees (large circle interpolation).
Page 134: Examples For Generic Axis Transformations
F2: Multi-axis transformations 1.13 Examples N40 Linear interpolation of angle of rotation from starting value 0 degrees to end value 90 degrees. N50 The angle of rotation changes from 90 degrees to 180 degrees in accordance with the parabola. θ(u) = 90 + u N60 A rotation can also be programmed without a change in orientation taking place.
Page 135: Example Of A Generic 6-Axis Transformation
F2: Multi-axis transformations 1.13 Examples $TC_CARR14[1] = 0 ; Angle of rotation of 2nd axis N100 X0 Y0 Z0 B0 C0 F10000 ORIWKS G17 N110 TRAORI() ; Selection of basic transformationorientation ; from machine data N120 C3=1 ; Orientation parallel to Z ;...
Page 136: Example Of A Generic 7-Axis Transformation
F2: Multi-axis transformations 1.13 Examples An orthogonalization is therfore not necessary, and therefore the programmed orientation normal vector is not modified. N100 $TC_DP1[2,2] = 120 ; End mill N110 $TC_DP3[2,2]= ; Length offset vector N120 $TC_DPV [2,2] = 0 ; Tool cutting edge orientation N130 $TC_DPV3[2,2] = 1 ;...
Page 137: Example For The Modification Of Rotary Axis Motion
F2: Multi-axis transformations 1.13 Examples Note While traversing the quadrant in the example, only the 7th axis turns by 360 degrees. The machine remains in the fixed position. 1.13.6.3 Example for the modification of rotary axis motion The machine is a 5-axis machine of machine type 1 (two-axis swivel head with CA kinematics) on which both rotary axes rotate the tool (transformation type 24).
Page 138 F2: Multi-axis transformations 1.13 Examples Programming Comment TRAORI COMPCURV ; The movement describes a circle generated from polygons. The orientation moves on a taper around the Z axis with an opening angle of 45 degrees. N100 X0 Y0 A3=0 B3=-1 C3=1 N110 FOR COUNTER=0 TO NUMBER N120 ANGLE=360*COUNTER/NUMBER N130 X=RADIUS*cos(angle) Y=RADIUS*sin(angle)
Page 139: Data Lists
F2: Multi-axis transformations 1.14 Data lists 1.14 Data lists 1.14.1 Machine data 1.14.1.1 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...
Page 140 F2: Multi-axis transformations 1.14 Data lists Number Identifier: $MC_ Description 21136 ORI_DISP_MODULO_RANGE_START Starting position of the module range for the display of the orientation axes 21150 JOG_VELO_RAPID_ORI[n] Rapid traverse in jog mode for orientation axes in the channel [n = 0..2] 21155 JOG_VELO_ORI[n] Orientation axis velocity in jog mode [n = 0..2]...
Page 141 F2: Multi-axis transformations 1.14 Data lists Number Identifier: $MC_ Description 24464 TRAFO_GEOAX_ASSIGN_TAB_8[n] Assignment geometry axis to channel axis for transformation 8 [geometry no.] 24470 TRAFO_TYPE_9 Definition of transformation 9 in channel 24472 TRAFO_AXES_IN_9[n] Axis assignment for transformation 9 [axis index] 24474 TRAFO_GEOAX_ASSIGN_TAB_9[n] Assignment geometry axis to channel axis for...
Page 142 F2: Multi-axis transformations 1.14 Data lists Number Identifier: $MC_ Description 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 transformation 2 [axis no.] 24620 TRAFO5_ROT_SIGN_IS_PLUS_2[n] Sign of rotary axis 1/2 for 5-axis transformation 2 [axis no.] 24630 TRAFO5_NON_POLE_LIMIT_2...
Page 143: Setting Data
F2: Multi-axis transformations 1.14 Data lists 1.14.2 Setting data 1.14.2.1 General setting data Number Identifier: $SN_ Description 41110 JOG_SET_VELO Geometry axes 41130 JOG_ROT_AX_SET_VELO Orientation axes 1.14.2.2 Channelspecific setting data Number Identifier: $SC_ Description 42475 COMPRESS_CONTOUR_TOL Max. contour deviation for compressor 42476 COMPRESS_ORI_TOL Max.
Page 144 F2: Multi-axis transformations 1.14 Data lists Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 145: G1: Gantry Axes
G1: Gantry axes Brief description Gantry axes are machine axes that are mechanically and rigidly connected with one another, e.g. axes to move the gantry of gantry milling machines. Because of this mechanical coupling, gantry axes must always be traversed together as gantry grouping. The axis via which this gantry grouping is explicitly traversed or programmed is called the leading axis.
Page 146: Gantry Axes" Function
G1: Gantry axes 2.2 "Gantry axes" function "Gantry axes" function Application For gantry milling machines, often various elements - e.g. the gantry or the transverse beams - are moved by several axes operating in parallel that are independent of one another. Each axis comprises a machine axis parameterized in the NC, drive, motor and measuring system.
Page 147 G1: Gantry axes 2.2 "Gantry axes" function Synchronous axis The axes of the gantry grouping, which are traversed by the NC in synchronism with the leading axis, are known as synchronous axes. From the point of view of the programmer and/ or operator, the synchronous axes "do not exist".
Page 148 G1: Gantry axes 2.2 "Gantry axes" function Monitoring the synchronism difference 2 limit values can be specified for the synchronism difference. Gantry warning limit The gantry warning limit is set using the following machine data: MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit) The "Alarm limit exceeded"...
Page 149 G1: Gantry axes 2.2 "Gantry axes" function Extended monitoring of the synchronism difference An extended monitoring of the synchronism difference can be activated using the following machine data: MD37150 $MA_GANTRY_FUNCTION_MASK, Bit 0 = 1 For the extended monitoring, a synchronism difference between the leading and synchronous axis, obtained when tracking or when the gantry grouping is opened, is taken into account.
Page 150 G1: Gantry axes 2.2 "Gantry axes" function Disturbance characteristic If faults occur, which cause an axis of the gantry to be stopped, then the complete gantry grouping is always stopped. Opening the gantry grouping The axis coupling within a gantry grouping can be opened (dissolved) using the following machine data: MD37140 $MA_GANTRY_BREAK_UP = 1 (invalidate gantry grouping) When the setting becomes active, the axes of the gantry grouping can be individually...
Page 151: Referencing And Synchronization Of Gantry Axes
G1: Gantry axes 2.3 Referencing and synchronization of gantry axes Referencing and synchronization of gantry axes 2.3.1 Introduction Misalignment after starting Immediately after the machine is switched on, the leading and synchronous 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 152 G1: Gantry axes 2.3 Referencing and synchronization of gantry axes The appropriate synchronous 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 synchronous axes As soon as the leading axis has approached its reference point, the synchronous axis is automatically referenced (as for reference point approach).
Page 153 G1: Gantry axes 2.3 Referencing and synchronization of gantry axes The next step in the operating sequence depends on the difference calculated between the actual values of the leading and synchronous axes: • difference is smaller than the gantry warning limit: MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit) The gantry synchronization process is started automatically.
Page 154 G1: Gantry axes 2.3 Referencing and synchronization of gantry axes The following flowchart illustrates the referencing and synchronization processes. Figure 2-2 Flowchart for referencing and synchronization of gantry axes Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 155 G1: Gantry axes 2.3 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 156 G1: Gantry axes 2.3 Referencing and synchronization of gantry axes Instead, the actual position of the leading axis is specified as the target position and is approached in the uncoupled state. Note For the leading axis, automatic synchronization can be locked using the following NC/PLC interface signal: DB31, ...
Page 157: Automatic Synchronization
G1: Gantry axes 2.3 Referencing and synchronization of gantry axes Selecting the reference point To ensure that the shortest possible paths are traversed when the gantry axes are referenced, the reference point values from leading and synchronous axes should be the same in the machine data: MD34100 $MA_REFP_SET_POS (reference point value/destination point for distancecoded system)
Page 158: Points To Note
G1: Gantry axes 2.3 Referencing and synchronization of gantry axes If the gantry grouping is switched from follow-up mode to position control mode, axis synchronism is automatically restored provided the actual-value monitor does not detect a difference between the positions of the leading and synchronized axes greater than the setting in the machine data: MD36030 $MA_STANDSTILL_POS_TOL (standstill tolerance) In this case, a new setpoint is specified for the synchronized axis (axes) without interpolation.
Page 159 G1: Gantry axes 2.3 Referencing and synchronization of gantry axes The maximum tolerance for position actual value switchover should be set to a lower value than the gantry warning limit: MD36500 $MA_ENC_CHANGE_TOL (Max. tolerance for position actual value switchover) The two position measuring systems must, however, have been referenced beforehand. The relevant measuring system must be selected before referencing is initiated.
Page 160 G1: Gantry axes 2.3 Referencing and synchronization of gantry axes Activation of axis compensations Compensation functions can be activated for both the leading axis and the synchronized axes. Compensation values are applied separately for each individual gantry axis. These values must therefore be defined and entered for the leading axis and the synchronized axes during start-up.
Page 161: Start-Up Of Gantry Axes
G1: Gantry axes 2.4 Start-up of gantry axes Start-up of gantry axes General information Owing to the forced coupling which is normally present between leading and synchronized gantry axes, the gantry axis grouping must be started up as if it were an axis unit. For this reason, the axial machine data for the leading and synchronized axes must always be defined and entered jointly.
Page 162 G1: Gantry axes 2.4 Start-up of gantry axes Table 2-1 Examples for defining the gantry axis grouping MD37100 $MA_GANTRY_AXIS_TYPE Gantry axis Gantry grouping Leading axis Synchronous axis Leading axis Synchronous axis 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:...
Page 163 G1: Gantry axes 2.4 Start-up of gantry axes References: Function Manual Extended Functions; Compensations (K3) The following control parameters must be set to the same value for the leading axis and synchronized axis: • MD33000 $MA_FIPO_TYPE (fine interpolator type) • MD32400 $MA_AX_JERK_ENABLE (axial jerk limitation) •...
Page 164 G1: Gantry axes 2.4 Start-up of gantry axes Check of dynamic response adaptation: The following errors of the leading and synchronized axes must be equal in magnitude when the axes are operating at the same speed! For the purpose of fine tuning, it may be necessary to adjustservo gain factors or feedforward control parameters slightly to achieve an optimum result.
Page 165 G1: Gantry axes 2.4 Start-up of gantry axes Input of gantry warning limit Once the reference point values for the leading and synchronized axes have been optimized so that the gantry axes are perfectly aligned with one another after synchronization, the warning limit values for all axes must be entered in the following machine data: MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit) To do this, the value must be increased incrementally until the value is just below the alarm...
Page 166 G1: Gantry axes 2.4 Start-up of gantry axes • Always use an offset of 0 for the function generator and measuring function in contrast to the recommendations for normal axes. • Set the amplitudes for function generator and measuring function to such low values that the activated axis traverses a shorter distance than the position tolerance allows.
Page 167: Plc Interface Signals For Gantry Axes
G1: Gantry axes 2.5 PLC interface signals for gantry axes PLC interface signals for gantry axes Special IS for gantry axes The special NC/PLC interface signals of the coupled gantry axes are taken via the axial NC/ PLC interface of the leading or synchronized axes. The table below shows all special gantry NC/PLC interface signals along with their codes and indicates whether the IS is evaluated on the leading axis or the synchronized axis.
Page 168 G1: Gantry axes 2.5 PLC interface signals for gantry axes Effect on NC/PLC interface signal DB31, ... DBX ... Leading axis Synchronous axis Ramp-function generator fast stop (RFGFS) 20.1 On all axes in gantry grouping Select drive parameter set 21.0 - 21.2 Axial Axial Enable Pulses...
Page 169: Miscellaneous Points Regarding Gantry Axes
G1: Gantry axes 2.6 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 170 G1: Gantry axes 2.6 Miscellaneous points regarding gantry axes Axis replacement All axes in the gantry grouping are released automatically in response to a RELEASE command (leading axis). A replacement of the leading axis of a closed gantry grouping is only possible, if all axes of the grouping are known in the channel in which they are to be transferred, otherwise alarm 10658 is signaled.
Page 171 G1: Gantry axes 2.6 Miscellaneous points regarding gantry axes • In the "Gantry Axes" function, the difference of the actual position values from the leading and synchronized axis is monitored continuously and the traversing motion is shut down if there are impermissible deviations. There is no monitoring for the "Coupled motion" function.
Page 172: Examples
G1: Gantry axes 2.7 Examples Examples 2.7.1 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 173: Setting Of Nck Plc Interface
G1: Gantry axes 2.7 Examples 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. FALSE MD34060 $MA_REFP_MAX_MARKER_DIST = Difference betw. cam edge and 0 mark MD34070 $MA_REFP_VELO_POS = MD34080 $MA_REFP_MOVE_DIST = 0 MD34090 $MA_REFP_MOVE_DIST_CORR = 0 MD34092 $MA_REFP_CAM_SHIFT = 0 MD34100 $MA_REFP_SET_POS = 0 MD34200 $MA_ENC_REFP_MODE = 1...
Page 174: Commencing Start-Up
G1: Gantry axes 2.7 Examples The PLC user program sets the following for the axis data block of axis 3: DB31, ... DBX29.4 = 0 The NCK sets the following as a confirmation in the axis block of axis 3: DB31, ...
Page 175 G1: Gantry axes 2.7 Examples At this point in time, the NCK has prepared axis 1 for synchronization and registers this to the interface signal: DB31, ... DBB101 with: In addition, the following steps must be taken: • RESET • Read off values in machine coordinate system: e.g.
Page 176: Setting Warning And Trip Limits
G1: Gantry axes 2.7 Examples • Examine actual positions of machine. Case A or B might apply: Figure 2-3 Possible results after referencing of axis 1 (master axis) If Case A applies, the synchronization process can be started immediately. See step "Start synchronization".
Page 177 G1: Gantry axes 2.7 Examples Proceed as follows • Set the machine data for all axes with a large value to begin with: MD37120 $MA_GANTRY_POS_TOL_ERROR (gantry trip limit) • Set a very small value in the machine data: MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit) When you put a heavy, dynamic strain on the axes, always be careful to re-enter the self- canceling alarm "10652 channel %1 axis %2 gantry warning limit exceeded".
Page 178 G1: Gantry axes 2.7 Examples 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. The error limits entered into machine data MD37110 and MD37120 are considered as additional tolerance values of the actual-value difference of the master and following axis if the IS "Gantry is synchronous"...
Page 179: Data Lists
G1: Gantry axes 2.8 Data lists Data lists 2.8.1 Machine data 2.8.1.1 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...
Page 180: Signals
G1: Gantry axes 2.8 Data lists 2.8.2 Signals 2.8.2.1 Signals from mode group DB number Byte.bit Description 11, ... Active machine function REF 2.8.2.2 Signals from channel DB number Byte.bit Description 21, ... 33.0 Referencing active 2.8.2.3 Signals to axis/spindle DB number Byte.bit Description...
Page 181: G3: Cycle Times
G3: Cycle times 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 SINUMERIK 840D For SINUMERIK 840D the position control cycle and the interpolator cycle (IPO cycle) are derived from the system clock cycle, which is set in the machine data of the NC.
Page 182: Startup
G3: Cycle times 3.2 Startup Startup Parameter assignment system clock cycle, position control cycle and interpolator cycle are defined with 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) MD10050, $MN_SYSCLOCK_CYCLE_TIME sets the system clock cycle of the system software in seconds.
Page 183: Sinumerik 840D
G3: Cycle times 3.3 SINUMERIK 840D SINUMERIK 840D Interpolator cycle The interpolator cycle defines the cycle time in which the setpoint interface to the position controllers is updated. The interpolator cycle is important for two reasons in normal processing: • The product of velocities and interpolator cycles defines the geometry resolution of the interpolated contour.
Page 184 G3: Cycle times 3.3 SINUMERIK 840D If this is not the case, there is an automatic offset and the following alarm is displayed: Alarm 4102 "IPO cycle increased to [ ] ms" Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 185: Sinumerik 840Di With Profibus Dp
G3: Cycle times 3.4 SINUMERIK 840Di with PROFIBUS DP SINUMERIK 840Di with PROFIBUS DP Note Further information on SINUMERIK 840Di can be found in: References: /HBI/ SINUMERIK 840Di Manual, PROFIBUS-DP Communication 3.4.1 Description of a DP cycle Actual values At time T , the actual position values are read from all the equidistant drives (DP slaves).
Page 186 G3: Cycle times 3.4 SINUMERIK 840Di with PROFIBUS DP Master application cycle MAPC: NC position control cycle for SINUMERIK 840Di always applies for: T MAPC DP cycle time: DP cycle time Data exchange time: Total transfer time for all DP slaves Master time: Offset of the start time for NC position control Input time: Time of actual value sensing Output time: time of setpoint activation...
Page 187: Clock Cycles And Position-Control Cycle Offset
G3: Cycle times 3.4 SINUMERIK 840Di with PROFIBUS DP 3.4.2 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 188 G3: Cycle times 3.4 SINUMERIK 840Di with PROFIBUS DP Figure 3-2 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 TDX: Data exchange time: Total transfer time for all DP slaves Master time: Offset of the start time for NC position control Global Control: Broadcast message for cyclic convergence of the equidistance between DP master and DP slaves...
Page 189 G3: Cycle times 3.4 SINUMERIK 840Di with PROFIBUS DP • Cyclic communication with the DP slaves (drives) must be completed before the position controller is started. Condition: T > T • The position controller must have finished before the PROFIBUS-DP/system cycle comes to an end.
Page 190 G3: Cycle times 3.4 SINUMERIK 840Di with PROFIBUS DP Alarm requests in the event of a conflict during startup MD10059 $MN_PROFIBUS_ALARM_MARKER (PROFIBUS alarm marker) In this machine data, alarm requests on the PROFIBUS level are stored even after reboot. If a conflict is found between the following machine data and the data in the PROFIBUS-SDB during the booting, the machine data is adjusted to this SDB and an alarm is set during the next booting: MD10050 $MN_SYSCLOCK_CYCLE_TIME (system clock cycle)
Page 191: Data Lists
G3: Cycle times 3.5 Data lists Data lists 3.5.1 Machine data 3.5.1.1 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...
Page 192 G3: Cycle times 3.5 Data lists Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 193: K6: Contour Tunnel Monitoring
K6: Contour tunnel monitoring Brief description 4.1.1 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.
Page 194: Programmable Contour Accuracy
K6: Contour tunnel monitoring 4.1 Brief description Example The following figure is a diagram of the monitoring area shown by way of a simple example. Figure 4-1 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.
Page 195: Contour Tunnel Monitoring
K6: Contour tunnel monitoring 4.2 Contour tunnel monitoring 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 196 K6: Contour tunnel monitoring 4.2 Contour tunnel monitoring Shutting down Monitoring can be stopped by enabling the MD setting: MD21050 = 0.0. Analysis output The values of deviation of the actual value of the tool tip from the programmed path can – for analysis purposes –...
Page 197: Programmable Contour Accuracy
K6: Contour tunnel monitoring 4.3 Programmable contour accuracy Programmable contour accuracy Initial situation There is always a velocity-dependent difference between setpoint and actual position when an axis is traversed without feedforward control. This lag results in inaccurate curved contours. Function The "Programmable contour accuracy"...
Page 198 K6: Contour tunnel monitoring 4.3 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 initial control settings after RESET/TP- End) MD20112 $MC_START_MODE_MASK (definition of the control default settings in case of NC START)
Page 199: Constraints
K6: Contour tunnel monitoring 4.4 Constraints Constraints Availability of the "Contour tunnel monitoring" function The function is an option ("Contour monitoring with tunnel function"), which must be assigned to the hardware via the license management. 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.
Page 200: Examples
K6: Contour tunnel monitoring 4.5 Examples Examples 4.5.1 Programmable contour accuracy Program code Comment N10 X0 Y0 G0 N20 CPRECON ; Enabling the contour accuracy defined by MD. N30 F10000 G1 G64 X100 ; Machining with10 m/min in the continuous-path mode. N40 G3 Y20 J10 ;...
Page 201: Data Lists
K6: Contour tunnel monitoring 4.6 Data lists Data lists 4.6.1 Machine data 4.6.1.1 Channelspecific machine data Number Identifier: $MC_ Description 20470 CPREC_WITH_FFW Programmable 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...
Page 202 K6: Contour tunnel monitoring 4.6 Data lists Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 203: M3: Coupled Axes
M3: Coupled axes Coupled motion 5.1.1 Product brief 5.1.1.1 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: •...
Page 204: General Functionality
M3: Coupled axes 5.1 Coupled motion • The maximum number of coupled motion groupings is limited to 4. • Only 1 leading axes may be assigned to each coupled motion axis. • Cascading is not possible. Note These restrictions do not apply when NCK software is supplied with the relevant options of generic coupling (refer to "...
Page 205 M3: Coupled axes 5.1 Coupled motion Figure 5-1 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 206 M3: Coupled axes 5.1 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 207 M3: Coupled axes 5.1 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 208: Programming
M3: Coupled axes 5.1 Coupled motion 5.1.3 Programming 5.1.3.1 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 209: Switch Off (Trailof)
M3: Coupled axes 5.1 Coupled motion 5.1.3.2 Switch off (TRAILOF) 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 210 M3: Coupled axes 5.1 Coupled motion This allows the speed to be changed for the independent motion of a coupled motion axis using a feed override or a DRF offset to be defined using the handwheel in AUTOMATIC and MDA modes. Dependent coupled motion axis With respect to the motion of a coupled motion axis, which is dependent on the leading axis, only the coupled-motion axis interface signals that effect termination of the motion (e.g.
Page 211: Status Of Coupling
M3: Coupled axes 5.1 Coupled motion 5.1.5 Status of coupling The coupling status of an axis can be determined using the following system variables: $AA_COUP_ACT[axis identifier] Value Description No coupling active 1, 2, 3 Tangential tracking Synchronous spindle coupling Coupled motion active Master value coupling Following axis of electronic gearbox Note...
Page 212: Curve Tables
M3: Coupled axes 5.2 Curve tables Curve tables 5.2.1 Product brief 5.2.1.1 Function The "curve tables" function can be used to define the complex sequence of motions of an axis in a curve table. Any axis can be defined as a leading axis and a following axis can be traversed by taking a curve table into account.
Page 213: General Functionality
M3: Coupled axes 5.2 Curve tables 5.2.2 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 214: Memory Organization
M3: Coupled axes 5.2 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- 5.2.3 Memory organization...
Page 215 M3: Coupled axes 5.2 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 216: Commissioning
M3: Coupled axes 5.2 Curve tables 5.2.4 Commissioning 5.2.4.1 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 217: Specification Of Memory Type
M3: Coupled axes 5.2 Curve tables Value Description No curve tables that contain a discontinuity in the following axis are produced. Alarm 10949 is output and program processing is aborted. Curve tables with a discontinuity in the following axis can be generated. If a segment contains a discontinuity in the following axis, Alarm 10955 is output but program processing is continued.
Page 218 M3: Coupled axes 5.2 Curve tables • Deleting curve table(s): CTABDEL(n) ; curve table n CTABDEL(n, m) ; [n < m], more than one in the range of numbers ; it is deleted in static "SRAM" and in dynamic "DRAM" of NC memory. •...
Page 219 M3: Coupled axes 5.2 Curve tables Enable/cancel blocking The following functions can be used to enable or cancel deletion and overwrite blocks for parts. programs. • Enable deletion and overwrite block. General form: CTABLOCK(n, m, memType) • Cancel deletion and overwrite block. CTABUNLOCK releases the tables locked with CTABLOCK.
Page 220 M3: Coupled axes 5.2 Curve tables • Table number of nth curve table. General form: CTABID(n, memType) Generates the table number of the nth curve table with memory type memType. CTABID(1, memType) is used to read out the highest curve number (105) of the memory type specified.
Page 221 M3: Coupled axes 5.2 Curve tables • Number of curve polynomials used by curve table number n. CTABPOLID(n) • Number of still possible polynomials in memory memType. CTABFPOL(n) • Maximum number of possible polynomials in memory memType. CTABMPOL(n) Boundary values of curve tables Behavior of the leading axis/following axes on the edges of the curve table: •...
Page 222 M3: Coupled axes 5.2 Curve tables • applim: Behavior at the curve table edges. - 0 non-periodic (table is processed only once, even for rotary axes). 1 periodic, modulo (the modulo value corresponds to the LA table values). 2 periodic, modulo (LA and FA are periodic). •...
Page 223 M3: Coupled axes 5.2 Curve tables Restrictions The following restrictions apply when programming: • The NC block must not generate a preprocessing stop. • No discontinuities may occur in leading axis motion. • Any block that contains a traverse instruction for the following axis must also include a traverse for the leading axis.
Page 224: Access To Table Positions And Table Segments
M3: Coupled axes 5.2 Curve tables N130 AX1=150 AX2=6 ; 3. Curve segment: Master value: 100...150, following value 6 N130 AX1=180 AX2=0 ; 4. Curve segment: Master value: 150...180, following value: 6...0 N200 CTABEND ; End of definition, curve table ;...
Page 225 M3: Coupled axes 5.2 Curve tables Reading segment positions Segment positions of a curve table for the value for the following axis can be read using the CTABSSV and CTABSEV calls. The language commands CTABSSV and CTABSEV generally provide the start and end values of the internal segments of the curve tables for the following axis.
Page 226 M3: Coupled axes 5.2 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: N10 DEF REAL STARTPOS ;Beginning of the definition for the start position of the curve table N20 DEF REAL ENDPOS...
Page 227 M3: Coupled axes 5.2 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 228: Activation/Deactivation
M3: Coupled axes 5.2 Curve tables Figure 5-3 Determining the minimum and maximum values of the table 5.2.7 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>...
Page 229: Modulo-Leading Axis Special Case
M3: Coupled axes 5.2 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 230: Behavior In Automatic, Mda And Jog Modes
M3: Coupled axes 5.2 Curve tables 5.2.9 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. 5.2.10 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...
Page 231: Diagnosing And Optimizing Utilization Of Resources
M3: Coupled axes 5.2 Curve tables 5.2.11 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 232 M3: Coupled axes 5.2 Curve tables When using the CTABID(p, memType) function, no assumptions should be made regarding the sequence of the curve tables in the memory. The CTABID(p, ...) function supplies the ID (table number) of the curve table entered in memory as the pth curve table. If the sequence of curve tables in memory changes between consecutive calls of CTABID()CTABID(), e.g.
Page 233 M3: Coupled axes 5.2 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 234 M3: Coupled axes 5.2 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 235: Master Value Coupling
M3: Coupled axes 5.3 Master value coupling Master value coupling 5.3.1 Product brief 5.3.1.1 Function The "master value coupling" function can be used to process short programs cyclically with close coupling of the axes to one another and a master value that is either generated internally or input from an external source.
Page 236 M3: Coupled axes 5.3 Master value coupling Virtual leading axis/simulated master value If the leading axis is not interpolated by the same NCU, the interpolator that is implemented in the NCU for this particular leading axis can be used for master value simulation. The following MD settings must be defined for this: MD30132 $MA_IS_VIRTUAL_AX[n] = 1 (axis is virtual axis) MD30130 $MA_CTRLOUT_TYPE[n] = 0 (simulation as output type of setpoint)
Page 237 M3: Coupled axes 5.3 Master value coupling Figure 5-4 Master value coupling offset and scaling (multiplied) Figure 5-5 Master value coupling offset and scaling (with increment offset) Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 238 M3: Coupled axes 5.3 Master value coupling 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 239: Programming
M3: Coupled axes 5.3 Master value coupling Spindles in master value coupling A spindle can only be used as the master value coupled following axis if it has been switched to axis mode beforehand. The machine data parameter block of the axis drive then applies. Example: Activation from synchronized action Program code Comment...
Page 240 M3: Coupled axes 5.3 Master value coupling Boundary conditions: • No reference point is required to activate the coupling. • A defined following axis cannot be traversed in the JOG mode (not even if the "Synchronized run fine" or. "synchronized run coarse" interface signal is not there). •...
Page 241 M3: Coupled axes 5.3 Master value coupling Meaning: Following axis as geometry-, channel- or machine axis name (X, Y, Z,...) <FA> Leading axis as geometry-, channel- or machine axis name (X, Y, Z,...) <LA> Software axis is also possible: MD30130 $MA_CTRLOUT_TYPE=0 (setpoint output type) Example: Program code Comment...
Page 242 M3: Coupled axes 5.3 Master value coupling System variables of the master value The following master value system variables can only be read from part program and from synchronous actions: System variable Meaning $AA_LEAD_V[ax] Velocity of the leading axis $AA_LEAD_P[ax] Position of the leading axis $AA_LEAD_P_TURN Master value position...
Page 243: Behavior In Automatic, Mda And Jog Modes
M3: Coupled axes 5.3 Master value coupling Note If the following axis is not enabled for travel, it is stopped and is no longer synchronous. 5.3.4 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 244 M3: Coupled axes 5.3 Master value coupling • MD20110 $MC_RESET_MODE_MASK=2001H && 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=...
Page 245: Effectiveness Of Plc Interface Signals
M3: Coupled axes 5.3 Master value coupling 5.3.5 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 246 M3: Coupled axes 5.3 Master value coupling Logging The curve tables generated by the definition of motion sequences are stored in the battery- backed memory. The curve tables are not lost when the control system is switched off. These functions have no effect on cyclic machines because they are performed without operator actions.
Page 247: Electronic Gearbox (Eg)
M3: Coupled axes 5.4 Electronic gearbox (EG) Electronic gearbox (EG) 5.4.1 Product brief 5.4.1.1 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 248: Preconditions
M3: Coupled axes 5.4 Electronic gearbox (EG) • Traverse time-optimized with respect to programmed synchronized position • Traverse path-optimized with respect to programmed synchronized position Application Examples: • Machine tools for gear cutting • Gear trains for production machines 5.4.1.2 Preconditions The "Electronic Gearbox"...
Page 249 M3: Coupled axes 5.4 Electronic gearbox (EG) It is thus possible for each curve (except for the special case of a straight line) for the leading axis to influence the following axis in a non-linear manner. The function can only be used with EGONSYN.
Page 250 M3: Coupled axes 5.4 Electronic gearbox (EG) The maximum permissible number of EG axis groups is 31. Note The option must be enabled. EG cascading The following axis of an EG can be the leading axis of another EG. For a sample configuration file, see Chapter "Examples".
Page 251 M3: Coupled axes 5.4 Electronic gearbox (EG) Activation response An electronic gearbox can be activated in two different ways: 1. On the basis of the axis positions that have been reached up to now in the course of processing the command to activate the EG axis group is issued without specifying the synchronizing positions for each individual axis.
Page 252 M3: Coupled axes 5.4 Electronic gearbox (EG) Synchronization abort with EGONSYN and EGONSYNE 1. The EGONSYN/EGONSYNE command is aborted under the following conditions and changed to an EGON command: • RESET • Axis switches to tracking The defined synchronization positions are ignored. Synchronous traverse monitoring still takes synchronized positions into account.
Page 253 M3: Coupled axes 5.4 Electronic gearbox (EG) Difference < .. TOL_COARSE As long as the synchronous traverse difference is smaller than the following machine data, IS "Coarse synchronism" DB 31, ... DBX 98.1 is at the interface and IS "Fine synchronism" DB 31, ...
Page 254 M3: Coupled axes 5.4 Electronic gearbox (EG) Other signals If an EGON(), EGONSYN() or EGONSYNE() block is encountered in the main run, the signal "Coupling active" is set for the following axis. If the following axis is only overlaid, the signals "Coupling active"...
Page 255: Performance Overview Of Eg (Summary)
M3: Coupled axes 5.4 Electronic gearbox (EG) Block change mode 1. When an EG axis group is activated, it is possible to specify the conditions under which a part program block change is to be executed: 2. The specification is made with a string parameter with the following meaning: 3.
Page 256 M3: Coupled axes 5.4 Electronic gearbox (EG) Leading axis A leading axis can: • be used once in the same EG • be used as leading axis in several coupling modules • be PLC axis • be command axis Leading and following axis The following is allowed for leading and following axes: real simulated...
Page 257 M3: Coupled axes 5.4 Electronic gearbox (EG) RESET For RESET: • the EG status remains unchanged • the EG configuration is retained End of parts program On end of a part program: • the EG status remains unchanged • the EG configuration is retained Warm start and cold start In the case of a warm start per HMI operation and cold start (POWER OFF/ POWER ON): •...
Page 258: Definition Of An Eg Axis Group
M3: Coupled axes 5.4 Electronic gearbox (EG) 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 processed. Options: •...
Page 259: Activating An Eg Axis Group
M3: Coupled axes 5.4 Electronic gearbox (EG) Preconditions for defining an EG axis group: No existing axis coupling may already be defined for the following axis. (If necessary, an existing axis must be deleted with EGDEL.) EGDEF triggers preprocessing stop with alarm. For an example of how to use the EG gearbox for gear hobbing, please see Chapter "Examples", "Electronic Gearbox for Gear Hobbing".
Page 260 M3: Coupled axes 5.4 Electronic gearbox (EG) With synchronization The EG axis group is activated with synchronization selective: 1. EGONSYN EGONSYN(FA, block change mode, SynPosFA, LA , SynPosLA , Z_LA , N_LA With: FA: Following axis Block change mode: "NOC": Block change takes place immediately "FINE": Block change is performed in "Fine synchronism"...
Page 261 M3: Coupled axes 5.4 Electronic gearbox (EG) 2. EGONSYNE EGONSYNE(FA, block change mode, SynPosFA, Approach mode, LA ,SynPosLA , Z_LA N_LA with: "FA": Following axis Block change mode: "NOC": Block change takes place immediately "FINE": Block change is performed in "Fine synchronization" "COARSE": Block change is performed in "Coarse synchronization"...
Page 262 M3: Coupled axes 5.4 Electronic gearbox (EG) Approach response with FA at standstill In this case, the time-optimized and path-optimized traversing modes are identical. The table below shows the target positions and traversed paths with direction marker (in brackets) for the particular approach modes: Position of the Programmed Traversing...
Page 263 M3: Coupled axes 5.4 Electronic gearbox (EG) Sample notations EGONSYNE(A, "FINE", 110, "NTGT", B, 0, 2, 10) couple A to B, synchronized position A = 110, B = 0, coupling factor 2/10, approach mode = NTGT EGONSYNE(A, "FINE", 110, "DCT", B, 0, 2, 10) couple A to B, synchronized position A = 110, B = 0, coupling factor 2/10, approach mode = EGONSYNE(A, "FINE", 110, "NTGT", B, 0, 2, 10, Y, 15, 1, 3) couple A to B, synchronized position A = 110, B = 0, Y = 15,...
Page 264: Deactivating An Eg Axis Group
M3: Coupled axes 5.4 Electronic gearbox (EG) 5.4.5 Deactivating an EG axis group Variant 1 There are different ways to deactivate an active EG axis grouping. EGOFS(following axis) The electronic gearbox is deactivated. The following axis is braked to a standstill. This call triggers a preprocessing stop.
Page 265: Interaction Between Rotation Feedrate (G95) And Electronic Gearbox
M3: Coupled axes 5.4 Electronic gearbox (EG) 5.4.7 Interaction between rotation feedrate (G95) and electronic gearbox The FPR( ) part program command can be used to specify the following axis of an electronic gear as the axis, which determines the rotational feedrate. The following behavior is applicable in this case: •...
Page 266: System Variables For Electronic Gearbox
M3: Coupled axes 5.4 Electronic gearbox (EG) 5.4.9 System variables for electronic gearbox Application The following system variables can be used in the parts program to scan the current states of an EG axis group and to initiate appropriate reactions if necessary: Table 5-1 System variables, R means: Read access possible Preprocessing...
Page 267 M3: Coupled axes 5.4 Electronic gearbox (EG) Table 5-1 System variables, R means: Read access possible Preprocessing name Type Access Meaning, value Cond. Index stop Parts Parts Sync Sync progra progra act. act. $P_EG_BC[a] STRING Block change criterion for Axis identifier EG activation calls: EGON, a: Following axis EGONSYN:...
Page 268: Generic Coupling
M3: Coupled axes 5.5 Generic coupling Generic coupling 5.5.1 Product brief 5.5.1.1 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 269 M3: Coupled axes 5.5 Generic coupling • Functional scope and required application knowledge increase from the basic version to the optional CP_EXPERT version. • The number of required couplings (following axes, following spindles) and their properties are decisive in the selection of versions. Example of simultaneous operation: If sequential operation of 1 x synchronous spindle pair for part transfer from the main to the supplementary spindle and the 1 x multi-edge turning is required, then the CP-...
Page 270 M3: Coupled axes 5.5 Generic coupling Table 5-3 Scaling of availability of coupling properties Type A Type B Type C Type D Type E Cascading permitted BCS / BCS / BCS / Co-ordinate reference (default): CPFRS="BCS") Synchronized spindle with 1:1 coupling Maximum number of synchronous spindles / multi-edge turning with the following properties: →...
Page 271 M3: Coupled axes 5.5 Generic coupling Table 5-3 Scaling of availability of coupling properties Type A Type B Type C Type D Type E + (max. Non-linear coupling law (CPLCTID) permitted CP - Free generic coupling Maximum number of free generic couplings with the following properties: Default (corresponds to CPSETTYPE="CP"...
Page 272: Basics
M3: Coupled axes 5.5 Generic coupling 5.5.2 Basics 5.5.2.1 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 273: Keywords And Coupling Characteristics
M3: Coupled axes 5.5 Generic coupling The following axis position results from the overlay (summation) of the dependent motion components (FA and FA ), which result from the individual coupling relationships to DEP1 DEP2 the leading axes, and of the independent motion component (FA ) of the following axis: = FA + FA...
Page 274 M3: Coupled axes 5.5 Generic coupling Notation In order to be uniquely assigned, keywords are furnished with the prefix "CP", for Coupling). Depending on meaning and application position, a third letter is used: Keyword prefix Meaning Example Describes the characteristics of the entire coupling. CPON CPF* Describes the characteristics of the following axis...
Page 275 M3: Coupled axes 5.5 Generic coupling Default setting Keyword Coupling characteristics / meaning (CPSETTYPE="CP") Synchronization mode CFAST CPFMSON Behavior of the following axis at switching on STOP CPFMON Behavior of the following axis at complete switch-off STOP CPFMOF Switch-off position of the following axis when Not set CPFPOS + CPOF switching off...
Page 276: System Variables
M3: Coupled axes 5.5 Generic coupling 5.5.2.3 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 part program, PREPROCESSING STOP is generated. Notation The names of system variables are normally derived from the relevant keywords and a corresponding prefix.
Page 277: Delete Coupling Module (Cpdel)
M3: Coupled axes 5.5 Generic coupling Programming Syntax: CPDEF= (<following axis/spindle>) Identifiers: Coupling Definition Functionality: Definition of a coupling module The coupling is not activated. Following axis/ Type: AXIS spindle: Range of values: All defined axis and spindle identifiers in the channel Example: Programming Comment...
Page 278: Defining Leading Axes (Cpldef Or Cpdef+Cpla)
M3: Coupled axes 5.5 Generic coupling Range of values: All defined axis and spindle identifiers in the channel Example: Programming Comment CPDEL=(X2) ; Deletion of the coupling module with following axis X2. Constraints • The switch command CPDEL results in a preprocessing stop with active coupling. Exception: No preprocessing stop occurs in CPSETTYPE="COUP".
Page 279: Delete Leading Axes (Cpldel Or Cpdel+Cpla)
M3: Coupled axes 5.5 Generic coupling Programming with CPLA and CPDEF Syntax: CPLA[FAx]= (<leading axis/spindle>) Identifiers: Coupling Lead Axis Functionality: Definition of leading axis/spindle for following axis/spindle FAx. Leading axis/ Type: AXIS spindle: Range of values: All defined axis and spindle identifiers in the channel Example: Programming...
Page 280 M3: Coupled axes 5.5 Generic coupling Programming with CPLDEL Syntax: CPLDEL[FAx]= (<leading axis/spindle>) Identifiers: Coupling Lead Axis Delete Functionality: Deletion of leading axis/spindle of following axis/spindle FAx. 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 281: Switching Coupling On/Off
M3: Coupled axes 5.5 Generic coupling Example: Programming Comment CPDEL=(X2) CPLA[X2]=(X1) ; Deletion of leading axis X1 of the coupling to following axis X2. Constraints • 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.) •If an active leading axis is deleted, the coupling to this leading axis is implicitly deactivated.
Page 282: Switch Off Coupling Module (Cpof)
M3: Coupled axes 5.5 Generic coupling Example: Programming Comment CPON=(X2) ; Activation of coupling of the following axis X2. Constraints Application of CPON to an already active coupling results in a neurosynchronization. If applicable, changed coupling properties become effective as a result. Any lost synchronization (for example, following axis was in tracking mode) is restored.
Page 283: Switching On Leading Axes Of A Coupling Module (Cplon)
M3: Coupled axes 5.5 Generic coupling 5.5.4.3 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 284: Implicit Creation And Deletion Of Coupling Modules
M3: Coupled axes 5.5 Generic coupling Programming Syntax: CPLOF[FAx]= (<leading axis/spindle>) Identifiers: Coupling Lead Axis Off Functionality: Deactivates the coupling of a leading axis/spindle to the following axis/ spindle FAx. Leading axis/ Type: AXIS spindle: Range of values: Axes of the channel Example: Programming Comment...
Page 285: Programming Coupling Characteristics
M3: Coupled axes 5.5 Generic coupling Constraints • Implicitly created coupling modules (via switch-on commands) are deleted once they are completely deactivated (CPOF). Advantage: Deleting them with CPDEL/CPLDEL is not necessary. Disadvantage (possibly): All coupling properties which were set with CPOF are lost. •...
Page 286 M3: Coupled axes 5.5 Generic coupling Example: Programming Comment CPLNUM[X2,X1]=1.3 ; The numerator of the coupling factor of the coupling of the following axis X2 to the leading axis X1 must be 1.3. Denominator of the coupling factor Syntax: CPLDEN[FAx,LAx]= <value> Identifiers: Coupling Lead Denominator Functionality:...
Page 287: Coupling Relationship (Cplsetval)
M3: Coupled axes 5.5 Generic coupling Example: Programming Comment CPLCTID[X2,X1]=5 ; The leading axis specific coupling component of the coupling of the following axis X2 to the leading axis X1 is calculated with curve table No. 5. Constraints • 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 288: Co-Ordinate Reference (Cpfrs)
M3: Coupled axes 5.5 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 reference: Type: STRING Range of values: "CMDPOS" Commanded Position Setpoint value coupling...
Page 289: Block Change Behavior (Cpbc)
M3: Coupled axes 5.5 Generic coupling Programming Syntax: CPFRS[FAx]= (<co-ordinate reference>) Identifiers: Coupling Following Relation System Functionality: Defines the co-ordinate reference system for the coupling module of the following axis/spindle FAx. Co-ordinate Type: STRING reference: Range of values: ”BCS” Basis Co-ordinate System Basic Coordinate System ”MCS”...
Page 290 M3: Coupled axes 5.5 Generic coupling The block change criterion can be defined with the keyword CPBC or with the programming command WAITC. The instruction programmed last is valid. Programming with PCBC Syntax: CPBC[FAx]= "<block change criterion>" Identifiers: Coupling Block Change Criterium Functionality: Defines block change criterion with active coupling.
Page 291: Synchronized Position Of The Following Axis When Switching On (Cpfpos+Cpon)
M3: Coupled axes 5.5 Generic coupling Parameter: Fax: 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 Type: STRING Range of values: "NOC" Block change is performed irrespective of the coupling status.
Page 292 M3: Coupled axes 5.5 Generic coupling Programming Syntax: CPON=FAx CPFPOS[FAx]= <value> Identifiers: Coupling Following Position Functionality: Defines the synchronized position of the following axis when switching on. AC, IC and GP are possible in position specification. Value: Type: REAL Range of values: All position within the traverse range boundaries Example: Programming Comment...
Page 293: Synchronized Position Of The Leading Axis When Switching On (Cplpos)
M3: Coupled axes 5.5 Generic coupling 5.5.5.6 Synchronized position of the leading axis when switching on (CPLPOS) The current leading axis position, taken as leading value, can be offset. The synchronized position of the leading axis therefore defines the zero point of the input variable. Programming Syntax: CPLPOS[FAx,LAx]= <value>...
Page 294: Synchronization Mode (Cpfmson)
M3: Coupled axes 5.5 Generic coupling Programming Comment N20 X1=280 F1000 ; Leading axis X1 is traversed to position 280. CPON=(X2) ; The current position X1=280 is taken as synchronized position of the leading axis. The previously active synchronized position of the leading axis (200) becomes ineffective.
Page 295: Behavior Of The Following Axis At Switch-On (Cpfmon)
M3: Coupled axes 5.5 Generic coupling "NRGP" Next Ratio Gap Path The next segment is Optimized approached in a path- optimized manner, in accordance with the ratio of the number of gears to the number of teeth. "ACN" Absolute Co-ordinate For rotary axes only! Negative The rotary axis traverses...
Page 296 M3: Coupled axes 5.5 Generic coupling 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. Poweron response: Type: STRING Range of values: "STOP" Stop For spindles only! An active motion of the following spindle is stopped before switch- "CONT"...
Page 297: Behavior Of The Following Axis At Switch-Off (Cpfmof)
M3: Coupled axes 5.5 Generic coupling 5.5.5.9 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:...
Page 298: Position Of The Following Axis When Switching Off (Cpfpos+Cpof)
M3: Coupled axes 5.5 Generic coupling 5.5.5.10 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.
Page 299 M3: Coupled axes 5.5 Generic coupling Programming Syntax: CPMRESET[FAx]= "<Reset behavior>" Identifiers: Coupling Mode RESET Functionality: Defines the behavior of a coupling at RESET. Reset response: Type: STRING Range of values: "NONE" The current state of the coupling is retained. "ON"...
Page 300: Condition At Parts Program Start (Cpmstart)
M3: Coupled axes 5.5 Generic coupling Constraints • The coupling characteristics set with CPMRESET is retained until the coupling module is deleted with (CPDEL). • For the coupling type (CPSETTYPE="TRAIL", "LEAD", "EG" or "COUP") the response is defined by the following machine data during RESET: MD20110 $MC_RESET_MODE_MASK (definition of initial control system settings after RESET/TP-End) →...
Page 301: Status During Part Program Start In Search Run Via Program Test (Cpmprt)
M3: Coupled axes 5.5 Generic coupling Example: Programming Comment CPMSTART[X2]="ON" ; At part program start, coupling to following axis X2 is switched on. Constraints • The coupling characteristics set with CPMSTART are retained until the coupling module is deleted with (CPDEL). •...
Page 302 M3: Coupled axes 5.5 Generic coupling Value: Type: STRING Range of values: "NONE" The current state of the coupling is retained. "ON" When the appropriate coupling module is created, the coupling is switched on. All defined leading axis relationships are activated. This is also performed when all or parts of these leading axis relationships are active, i.e.
Page 303: Offset / Scaling (Cplintr, Cplinsc, Cplouttr, Cploutsc)
M3: Coupled axes 5.5 Generic coupling 5.5.5.14 Offset / scaling (CPLINTR, CPLINSC, CPLOUTTR, CPLOUTSC) An existing coupling relationship between a following axis and a leading axis can be scaled and offset. The effect of these functions on the total setpoint value of the following axes can be viewed from the following formula: Total setpoint value of the following axis Total...
Page 304 M3: Coupled axes 5.5 Generic coupling Scaling the input value Syntax: CPLINSC[FAx,LAx]= <value> Identifiers: Coupling Lead In Scale Factor Functionality: Defines the scaling factor for the input value of the LAx leading axis. Value: Type: REAL Default value: Example: Programming Comment CPLINSC[X2,X1]=0.5 ;...
Page 305: Synchronism Monitoring (Cpsyncop, Cpsynfip, Cpsyncov, Cpsynfiv)
M3: Coupled axes 5.5 Generic coupling Scaling of the output value Syntax: CPLOUTSC[FAx,LAx]= <value> Identifiers: Coupling Lead Out Scale Factor Functionality: Defines the scaling factor for the output value of coupling the following axis FAx with leading axis LAx. Value: Type: REAL Default value:...
Page 306 M3: Coupled axes 5.5 Generic coupling of the leading axes according to the coupling rule) reaches one of the programmed threshold values: Command Meaning Threshold value of position synchronous operation "Coarse" CPSYNCOP[FAx] Threshold value of position synchronous operation "Fine" CPSYNFIP[FAx] Threshold value of speed synchronous operation "Coarse"...
Page 307 M3: Coupled axes 5.5 Generic coupling System variable Meaning $AA_SYNC [FAx] State of the coupling Value State Not synchronized "Coarse" synchronous operation reached "Fine" synchronous operation reached Signal reaction Synchronous operation signals themselves do not stop the involved axes, but can release them via synchronized action or NC/PLC interface signals (refer to Chapter "Extended Shutdown/Retraction (ESR)").
Page 308 M3: Coupled axes 5.5 Generic coupling Threshold value of speed synchronous operation "Coarse" Syntax: CPSYNCOV[FAx]= <value> Designation: Coupling Synchronous Difference Coarse Velocity Functionality: Defines the threshold value for the "Coarse'' speed synchronous operation. Value: Type: REAL Threshold value of speed synchronous operation "Fine" Syntax: CPSYNFIV[FAx]= <value>...
Page 309: Reaction To Stop Signals And Commands (Cpmbrake)
M3: Coupled axes 5.5 Generic coupling Supplementary conditions • When considering the synchronous operation difference, an active coupling cascade is not taken into account. This means: if in the considered coupling module, the leading axis is a following axis in another coupling module, the current actual or setpoint position is still used as input variable for the calculation of the synchronous operation difference.
Page 310: Response To Certain Nc/Plc Interface Signals (Cpmvdi)
M3: Coupled axes 5.5 Generic coupling Examples Example 1: Programming Comment CPDEF=(AX5) CPLA[AX5]=(AX4) CPMBRAKE[AX5]=0 ; Defining a coupling (leading axis Ax4 with following axis Ax5). NST "feed stop / spindle stop" should not brake the coupling group. Example 2: Programming Comment CPDEF=(S2) CPLA[S2]=(S1) Definition of a spindle coupling:...
Page 311 M3: Coupled axes 5.5 Generic coupling Meaning Reserved. Reserved. Reserved. The effect of NC/PLC interface signal DB31, ... DBX1.3 (axis/spindle disable) on the following axis/spindle can be set via bit 3: Bit 3 = 0 DB31, ... DBX1.3 has no effect on the following axis/ spindle. The state of the following axis/spindle with reference to the axis/spindle disable is derived solely from the state of the leading axes/spindles.
Page 312 M3: Coupled axes 5.5 Generic coupling The effect of NC/PLC interface signal DB21, ... DBX25.7 (program test selected) or DB21, ... DBX1.7 (activate program test) on the following axis/spindle can be set via bit 5: Bit 5 = 0 DB21, ... DBX25.7 or DB21, ... DBX1.7 has no effect on the following axis/spindle. The state of the following axis/spindle with reference to the axis/ spindle disable is derived solely from the state of the leading axes/spindles.
Page 313 M3: Coupled axes 5.5 Generic coupling Effect of bits 3/5 and 4/6 The effects of the different motion components on the following axis/spindle as a function of the associated axis/spindle disable are illustrated in the table below: Meaning A/S disable A/S disable A/S disable CPMVDI...
Page 314 M3: Coupled axes 5.5 Generic coupling A/S disable: Axis/spindle disable This refers to the resulting internal state of the axis/spindle disable. The spindle disable, which is set via the NC/PLC interface signal DB31, … DBX1.3 (axis/spindle disable), can be overwritten by states such as program test (DB21, … DBX25.7 or DB21, … DBX1.7) and SERUPRO, thus generating an axis/spindle state which differs from the NC/PLC interface signal.
Page 315: Coupling Cascading
M3: Coupled axes 5.5 Generic coupling 5.5.6 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 316 M3: Coupled axes 5.5 Generic coupling Assignment to existing coupling commands The number of adaptive cycles corresponds to the number of existing coupling commands. The assignment is as follows: Coupling commands Adaptive cycle TRAILON cycle700 TRAILOF cycle701 LEADON cycle702 LEADOF cycle703 COUPDEF cycle704...
Page 317: Coupling Types (Cpsettype)
M3: Coupled axes 5.5 Generic coupling 5.5.7.2 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 or CPDEF/CPLDEF), the keyword CPSETTYPE needs to be used also. Programming Syntax: CPSETTYPE[FAx]= <value>...
Page 318 M3: Coupled axes 5.5 Generic coupling Default settings Presettings of programmable coupling characteristics for various coupling types can be found in the following table: Keyword Coupling type Default Coupled motion Master value Electronic gear Synchronous (CP) (TRAIL) coupling (EG) spindle (LEAD) (COUP) CPDEF...
Page 319 M3: Coupled axes 5.5 Generic coupling Keyword Coupling type CPLOUTTR CPLOUTSC CPSYNCOP MD37200 MD37200 MD37200 CPSYNFIP MD37210 MD37210 MD37210 CPSYNCOV MD37220 MD37220 CPSYNFIV MD37230 MD37230 CPMBRAKE CPMVDI Bit 3 Bit 4 Bit 5 Bit 6 Legend: Pre-processing Main run depends additionally on MD22621 - not relevant or not allowed Additional properties Value ranges or availability of additional properties of a set coupling type (CPSETTYPE) can be found in the following table:...
Page 320 M3: Coupled axes 5.5 Generic coupling Master value Synchronous Default Coupled motion Electronic gear coupling ( spindle (CP) (TRAIL) (EG) LEAD) (COUP) Implicit selection/ deselection of state control Legend: also refer to: Function Manual, Extended Functions; Synchronous Spindle (S3) - not relevant or not allowed Availability of specified characteristics depends on the available version (see " Preconditions [Page 268] ").
Page 321: Projected Coupling (Cpres)
M3: Coupled axes 5.5 Generic coupling CPSETTYPE= TRAIL LEAD COUP CPSETVAL Alarm 16686 Alarm 16686 Alarm 16686 with CMDVEL with CMDVEL with CMDVEL CPFRS Alarm 16686 with BCS CPBC Alarm 16686 Alarm 16686 CPFPOS + CPON Alarm 16686 Alarm 16686 CPFPOS + CPOF Alarm 16686 Alarm 16686...
Page 322: Cross-Channel Coupling, Axis Replacement
M3: Coupled axes 5.5 Generic coupling Following spindle: Type: AXIS Range of values: All defined spindle identifiers in the channel Example: Programming Comment CPLON[S2]=(S1) CPSETTYPE[S2]="COUP" ; Creates a coupling module for following spindle S2 with leading spindle S1 and activates the coupling module.
Page 323: Behavior With Rotary Axes
M3: Coupled axes 5.5 Generic coupling Leading axes Axis change of leading axes can be performed independently of the state of the coupling. 5.5.9 Behavior with rotary axes Rotary axes as leading or following axes It is possible to couple rotary axes to a linear axis and vice versa. Note that a direct assignment of degrees to mm must be performed using the coupling rule.
Page 324 M3: Coupled axes 5.5 Generic coupling Programming Comment N50 A=IC(100) ; A traverses from 40 degrees to 140 degrees, X traverses through additional 50mm to 250. N60 A=ACP(80) ; A traverses in the positive direction to 50 degrees, the traversing path is 300 degrees in the positive direction.
Page 325: Behavior During Power On
M3: Coupled axes 5.5 Generic coupling 5.5.10 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 326: Tracking The Deviation From Synchronism
M3: Coupled axes 5.5 Generic coupling The rapid stop is set at: • Stop A and Stop C (Safety Integrated) • Alarms with rapid stop as configured braking behavior • Reaching the hardware limit switch and rapid stop as configured braking behavior: MD36600 $MA_BRAKE_MODE_CHOICE = 1 Switchover to actual-value coupling.
Page 327 M3: Coupled axes 5.5 Generic coupling When workpieces are transferred from front to rear machining, a position offset may result from the closing of the workpiece receptacle. This could be down to square-edged workpieces or due to the generation of an angular momentum when the workpiece receptacle (chuck) is closed quickly during a movement.
Page 328: Measuring The Deviation From Synchronism
M3: Coupled axes 5.5 Generic coupling 5.5.12.2 Measuring the deviation from synchronism The controller measures the difference between the setpoint positions and actual positions when the following spindle is operating in synchronism. This results in a correction value, which is saved in a system variable. Requirements The following requirements must be met to enable the controller to calculate the correction value:...
Page 329 M3: Coupled axes 5.5 Generic coupling Activation Measuring and tracking of the deviation from synchronism are activated by setting the following NC/PLC interface signal to "1": DB31, ... DBX31.6 (track synchronism) The signal only has an effect on the following spindle. Note In the following cases, signal DB31, ...
Page 330: Entering The Deviation From Synchronism Directly
M3: Coupled axes 5.5 Generic coupling The correction value is the difference between the setpoint and actual-value synchronism positions. This value is saved for the corresponding following spindle in the following system variable: $AA_COUP_CORR[S<n>] (following spindle: correction value for synchronous spindle coupling) Note You must ensure that the velocity of the leading and following axes is kept as constant as...
Page 331: Diagnostics For Synchronism Correction
M3: Coupled axes 5.5 Generic coupling The correction value is incorporated into the setpoint value calculation for the following spindle, in the coupling module. Resetting the setpoint by the coupling offset relieves the tension between the leading and following spindles. The synchronism signals are produced by comparing the actual values with the corrected setpoints.
Page 332: Resetting Synchronism Correction
M3: Coupled axes 5.5 Generic coupling 5.5.12.6 Resetting synchronism correction Versions Synchronism correction can be reset in the following ways: • Writing value "0" to variable $AA_COUP_CORR[S<n>]. Synchronism correction is suppressed via a ramp with reduced accelerating power (just as when a correction value is implemented).
Page 333: Limitations And Constraints
M3: Coupled axes 5.5 Generic coupling Figure 5-11 Time diagram for synchronizing and resetting synchronism correction Note If the correction path has not been traversed in full and the NC/PLC interface signal DB31, ... DBX31.7 (reset synchronism correction) has not been reset, writing to variable $AA_COUP_CORR[S<n>] will not have any effect.
Page 334 M3: Coupled axes 5.5 Generic coupling Correction value If the correction value $AA_COUP_CORR is being written via a part program/synchronized action, as well as being determined due to the "track the deviation from synchronism" function being activated (DB31, ... DBX31.6 = 1), the most recent event to occur is always the one that takes effect.
Page 335: Dynamic Response Of Following Axis
M3: Coupled axes 5.6 Dynamic response of following axis Dynamic response of following axis 5.6.1 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) 5.6.2 Programmed dynamic limits 5.6.2.1...
Page 336 M3: Coupled axes 5.6 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 Parts program Synchronized actions Tangential correction Coupled motion Master value coupling Electronic gearbox Synchronous spindle Generic coupling...
Page 337: Examples
M3: Coupled axes 5.6 Dynamic response of following axis POWER ON During POWER ON the values of VELOLIMA and ACCLIMA are initialized to 100%. Mode change The dynamic offsets remain valid only on transition from AUTO → JOG mode. RESET The validities of the (VELOLIMA and ACCLIMA) dynamic offsets after RESET depend on the setting in the channel-specific machine data: MD22410 $MC_F_VALUES_ACTIVE_AFTER_RESET (F Function is active even after...
Page 338: System Variables
M3: Coupled axes 5.6 Dynamic response of following axis Master value coupling Axis 4 is coupled to X via a master value coupling. The acceleration capability of the following axis is limited to 80% of maximum acceleration. N120 ACCLIMA[AX4]=80 ; 80% N130 LEADON(AX4,X,2) ;...
Page 339: Boundary Conditions
M3: Coupled axes 5.7 Boundary conditions Boundary conditions 5.7.1 General boundary conditions NOTICE Drive optimization At a SINAMICS S120 drive unit, a maximum of 3 drives can be optimized or measured at the same time (speed controller optimization/function generator). Therefore, for a coupling with more than 3 coupled drives at the same time, we recommend that these are distributed over several drive units.
Page 340 M3: Coupled axes 5.7 Boundary conditions External master value axes When using the REPOS or REPOSA parts program instructions in conjunction with external master value axes, it should be ensured that these are released by the channel or switched to a "neutral state"...
Page 341: Examples
M3: Coupled axes 5.8 Examples Examples 5.8.1 Coupled motion Application Example: Two-sided machining Example 1 Example of an NC part program for the axis constellation shown in Fig.: TRAILON(V,Y,1) ; Activation of 1st coupled axis group TRAILON(W,Z,-1) ; Activation of 2nd coupled axis group G0 Z10 ;...
Page 342: Curve Tables
M3: Coupled axes 5.8 Examples 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 N02 TRAILON(U,X,1) ;...
Page 343 M3: Coupled axes 5.8 Examples %_N_TAB_1_NOTPERI_MPF N19 PO[X]=(105.941,1.961,-0.938) PO[Y]=(11.708,-6.820,-1.718) N20 PO[X]=(132.644,-0.196,-0.053) PO[Y]=(6.815,-2.743,0.724) N21 PO[X]=(147.754,-0.116,0.103) PO[Y]=(3.359,-0.188,0.277) N22 PO[X]=(174.441,0.578,-0.206) PO[Y]=(0.123,1.925,0.188) N23 PO[X]=(185.598,-0.007,0.005) PO[Y]=(-0.123,0.430,-0.287) N24 PO[X]=(212.285,0.040,-0.206) PO[Y]=(-3.362,-2.491,0.190) N25 PO[X]=(227.395,-0.193,0.103) PO[Y]=(-6.818,-0.641,0.276) N26 PO[X]=(254.098,0.355,-0.053) PO[Y]=(-11.710,0.573,0.723) N26 PO[X]=(254.098,0.355,-0.053) PO[Y]=(-11.710,0.573,0.723) N27 PO[X]=(310.324,0.852,-0.937) PO[Y]=(-7.454,11.975,-1.720) N28 PO[X]=(328.299,-0.209,0.169) PO[Y]=(-3.197,0.726,-0.643) N29 PO[X]=(360.031,0.885,-0.413) PO[Y]=(0.000,-3.588,0.403) CTABEND N30 M30 Definition of a periodic curve table...
Page 344: Electronic Gear For Gear Hobbing
M3: Coupled axes 5.8 Examples N10 DEF REAL DEPPOS N160 X0 N170 LEADOF(Y,X) N180 DEPPOS = CTAB(75.0,2,GRADIENT) ; Reading the table position at master value 75.0 from the curve table with Table No. 2 N190 G0 X75 Y=DEPPOS ; Positions of leading and following axis N200 LEADON(Y,X,2) ;...
Page 345 M3: Coupled axes 5.8 Examples Figure 5-12 Definition of axes on a gear hobbing machine (example) The functional interrelationships on the gear hobbing machine are as follows: In this case, the workpiece table axis (C) is the following axis which is influenced by three master drives.
Page 346 M3: Coupled axes 5.8 Examples = Rotational speed of milling spindle (B) = Number of gears of the hobbing machine = Number of teeth of the workpiece = Feed velocity of axial axis (Z) = Feed velocity of tangential axis (Y) = Axial differential constant = Tangential differential constant Quantities which influence the setpoint of workpiece axis C...
Page 347 M3: Coupled axes 5.8 Examples Extract from parts program: Program code Comment EGDEF(C,B,1,Z,1,Y,1) ; Definition of EG axis grouping with setpoint coupling (1) from B, Z, Y to C (following axis). EGON(C,"FINE",B,z0,z2,Z,udz,z2,Y,udy,z2) ; Activate coupling. … Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 348: Extended Example With Non-Linear Components
M3: Coupled axes 5.8 Examples 5.8.3.2 Extended example with non-linear components Introduction The following example extends the example in Figure "Axis Definition of a Hobbing Machine" in Chapter "Example of Linear Couplings" with the following: • Machine error compensations which are not linearly dependent on the Z axis, and •...
Page 349 M3: Coupled axes 5.8 Examples 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 350 M3: Coupled axes 5.8 Examples N810 EGONSYN(C99, "NOC", ; Switch-on of leading axis B <SynPosC99>, B, <SynPosC99_B>, 18, 2, & Y, <SynPosC99_Y>, ; Switch-on of leading axis Y R1 * π, 1, & Z, <SynPosC99_Z>, ; Switch-on of leading axis Z 10, 1) ;...
Page 351 M3: Coupled axes 5.8 Examples The system variables listed below are only used for explanatory purposes! ; ************** Gear X (G1) $AA_EG_TYPE[X, Z] = 1 ; Setpoint value coupling $AA_EG_NUMERA[X, Z] = 1 ; curve table No. = 1 $AA_EG_DENOM[X, Z] = 0 ;...
Page 352 M3: Coupled axes 5.8 Examples $AA_EG_NUMERA[C99, B] = 10 ; numerator for coupling factor $AA_EG_DENOM[C99, B] = 1 ; denominator for coupling factor $P_EG_BC[C99] = "NOC" ; Block change criterion $AA_EG_NUM_LA[C99] = 3 ; Number of leading axes $AA_EG_AX[0, C99] = Y ;...
Page 353 M3: Coupled axes 5.8 Examples $MA_IS_ROT_AX[AX1] = FALSE ; *************** Axis 2, "Y" $MC_AXCONF_GEOAX_NAME_TAB[1]="Y" $MC_AXCONF_CHANAX_NAME_TAB[1] = "Y" $MC_AXCONF_MACHAX_USED[1] = 2 $MN_AXCONF_MACHAX_NAME_TAB[1] = "Y1" $MA_SPIND_ASSIGN_TO_MACHAX[AX2] = 0 $MA_IS_ROT_AX[AX2] = FALSE ; *************** Axis 3, "Z" $MC_AXCONF_GEOAX_NAME_TAB[2] = "Z" $MC_AXCONF_CHANAX_NAME_TAB[2] = "Z" $MC_AXCONF_MACHAX_USED[2]=3 $MN_AXCONF_MACHAX_NAME_TAB[2] = "Z1"...
Page 354: Generic Coupling
M3: Coupled axes 5.8 Examples $MA_IS_ROT_AX[AX6] = TRUE $MA_ROT_IS_MODULO[AX6] = TRUE ; ************** Axis 10, "C99" $MC_AXCONF_CHANAX_NAME_TAB[9] = "C99" $MC_AXCONF_MACHAX_USED[9]=10 $MA_SPIND_ASSIGN_TO_MACHAX[AX10] = 0 $MA_IS_ROT_AX[AX10] = TRUE $MA_ROT_IS_MODULO[AX10] = TRUE 5.8.4 Generic coupling 5.8.4.1 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.
Page 355 M3: Coupled axes 5.8 Examples CPOF=(X2) CPLA[X1]=(Z) ; The coupling with leading axis Z is deactivated with CPOF, the coupling with leading axis X1 is retained. The created coupling module remains created. 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 N10 CPDEF=(X2) CPLA[X2]=(X1) CPLA[X2]=(Z) CPLA[X2]=(A) N20 CPON=(X2) ;...
Page 356: Adapt Adaptive Cycle
M3: Coupled axes 5.8 Examples 5.8.4.2 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 357: Data Lists
M3: Coupled axes 5.9 Data lists Data lists 5.9.1 Machine data 5.9.1.1 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...
Page 358: Axis/Spindlespecific Machine Data
M3: Coupled axes 5.9 Data lists 5.9.1.3 Axis/spindlespecific machine data Number Identifier: $MA_ Description 30130 CTRLOUT_TYPE Setpoint output type 30132 IS_VIRTUAL_AX Axis is virtual axis 30455 MISC_FUNCTION_MASK Axis functions 35040 SPIND_ACTIVE_AFTER_RESET Own spindle RESET 37160 LEAD_FUNCTION_MASK Functions for master value coupling 37200 COUPLE_POS_TOL_COARSE Threshold value for "Coarse synchronism"...
Page 359 M3: Coupled axes 5.9 Data lists Identifier Meaning $AA_EG_TYPE Type of coupling for leading axis b $AA_IN_SYNC[FA] Synchronization status of the following axis $AA_LEAD_P Current leading position value (modulo reduced). $AA_LEAD_P_TURN current leading value - position component lost as a result of modulo reduction. $AA_LEAD_SP simulated master value - position MCS $AA_LEAD_SV...
Page 360 M3: Coupled axes 5.9 Data lists Identifier Meaning $AA_CPSYNFIV Threshold value of velocity synchronism "Fine" (main run) $AA_CPLINSC Scaling factor of the input value of a leading axis (main run) $AA_CPLINTR Offset value of the input value of a leading axis (main run) $AA_CPLOUTSC Scaling factor of the output value of the coupling (main run) $AA_CPLOUTTR...
Page 361: Signals
M3: Coupled axes 5.9 Data lists Identifier Meaning $PA_CPLINTR Offset value of the input value of a leading axis (pre-processing) $PA_CPLOUTSC Scaling factor of the output value of the coupling (pre-processing) $PA_CPLOUTTR Offset value of the output value of the coupling (pre-processing) $PA_CPSETTYPE Preset coupling type $PA_JERKLIMA...
Page 362: Signals From Axis/Spindle
M3: Coupled axes 5.9 Data lists 5.9.4.2 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 363: R3: Extended Stop And Retract
R3: Extended stop and retract Brief description The extended stop and retract function - subsequently called ESR - offers the possibility of flexibly responding when a fault situation occurs as a function of the process: • Extended stop Assuming that the specific fault situation permits it, all of the axes, enabled for extended stopping, are stopped in an orderly fashion.
Page 364: Control-Managed Esr
R3: Extended stop and retract 6.2 Control-managed ESR Control-managed ESR 6.2.1 Extended stop and retract (ESR) Using the Extended stop/retract (ESR)" function, axes that have been enabled for the function are stopped and retracted in a defined, delayed fashion. This is done to quickly separate the tool and workpiece in certain programmable system states.
Page 365: Drive-Independent Reactions
R3: Extended stop and retract 6.2 Control-managed ESR In order to perform retraction outside the AUTOMATIC mode as well, triggering of this function is linked to the system variable $AC_ESR_TRIGGER. Retraction initiated via $AC_ESR_TRIGGER is locked, in order to prevent multiple retractions. 6.2.2 Drive-independent reactions Generator operation...
Page 366: Power Failure Detection And Bridging
R3: Extended stop and retract 6.2 Control-managed ESR 6.2.3 Power failure detection and bridging DC link voltage limit values The DC link is monitored against the limit values shown in the following diagram: Figure 6-1 DC link voltage limit values The drive and DC link pulses are cancelled at specific voltage levels, which means that the drives coast-down.
Page 367: Nc-Controlled Extended Stop
R3: Extended stop and retract 6.2 Control-managed ESR 6.2.4 NC-controlled extended stop Parameter assignment NC-controlled extended stopping is parameterized with: MD37500 $MA_ESR_REACTION = 22 Definition of the timing behavior The following machine data is used to define the timing for extended stopping: MD21380 $MC_ESR_DELAY_TIME1 (delay time, ESR axes) MD21381 $MC_ESR_DELAY_TIME2 (ESR time for interpolatory braking) Delay time for ESR axes...
Page 368 R3: Extended stop and retract 6.2 Control-managed ESR Precondition The precondition in this case is that at least one of the axes involved is parameterized as NC controlled retraction or stopping axis: MD37500 $MA_ESR_REACTION > 20 For axes, which are not parameterized as NC controlled retraction or stopping axis, fast braking with subsequent tracking is realized immediately that extended stopping starts ($AC_ESR_TRIGGER = 1).
Page 369: Nc-Controlled Retraction
R3: Extended stop and retract 6.2 Control-managed ESR 6.2.5 NC-controlled retraction Parameter assignment NC-controlled retraction is parameterized with: MD37500 $MA_ESR_REACTION = 21 Behavior If the channel-specific system variable $AC_ESR_TRIGGER = 1 is set, and if there is a retraction axis in this channel and $AA_ESR_ENABLE=1 is set for this, then LIFTFAST is activated in this channel.
Page 370 R3: Extended stop and retract 6.2 Control-managed ESR Supplementary conditions Retraction and/or rapid lift is not executed for the following axes: • Axes, which are not permanently assigned a channel • Axes, which are in the open-loop speed-controlled mode (spindles) •...
Page 371 R3: Extended stop and retract 6.2 Control-managed ESR Examples for the behavior of path axes for different enable signals "NC-controlled retraction" is configured for path axes X and Y: • ESR_REACTION[X] =21 • ESR_REACTION[Y] =21 1. "Extended stop and retract" and retraction motion is enabled for both path axes: $AA_ESR_ENABLE(X)=1 $AA_ESR_ENABLE(Y)=1 POLFMASK(X,Y)
Page 372 R3: Extended stop and retract 6.2 Control-managed ESR Value Description Response to the axial NC/PLC interface signal DB31 DBB4.3 (feed stop) or context-sensitive interpolator stop. Retraction motion stop for axial feed stop or context-sensitive interpolator stop No retraction motion stop for axial feed stop or context-sensitive interpolator stop Response to the channel-spec.
Page 373 R3: Extended stop and retract 6.2 Control-managed ESR NOTICE Frames with rotation Frames with rotation do not influence the retraction position of machine axes. For the same axis names of a channel and machine axis, retraction motion is executed in the workpiece coordinate system.
Page 374: Possible Trigger Sources
R3: Extended stop and retract 6.2 Control-managed ESR Change coordinate system If the coordinate system is to be changed, rapid lift must first be deactivated using POLFMASK orPOLFMLIN, and only then can programming commence with POLF in the new coordinate system.
Page 375: Logic Gating Functions: Source And Reaction Linking
R3: Extended stop and retract 6.2 Control-managed ESR General trigger sources • Digital inputs (NCU module or terminal block) or the internal control image of digital outputs that can be read back: $A_IN, $A_OUT • Channel status: $AC_STAT • VDI signals •...
Page 376: Activating
R3: Extended stop and retract 6.2 Control-managed ESR 6.2.8 Activating Option The function "Extended stop and retract" is an option. Axis-specific function enable ($AA_ESR_ENABLE) The axis-specific function enable is realized using the system variable: $AA_ESR_ENABLE[<axis>] = 1 Axis-specific enable for extended stopping An axis is enabled for extended stopping with: MD37500 $MA_ESR_REACTION[axis] = 22 Axis-specific enable for retraction...
Page 377 R3: Extended stop and retract 6.2 Control-managed ESR DC link energy The energy available in the DC link of the drive units when the line supply fails is calculated as follows: E = 1/2 * C * (VDClink - VDClink alarm Energy in Wattseconds [Ws] Total capacity of intermediate circuit in Farad [F]...
Page 378 R3: Extended stop and retract 6.2 Control-managed ESR Table 6-1 SINAMICS ALM (infeed units): Nominal and minimum buffer times Backup time t Buffer time t Max. capacitance Energy content Energy content [kW] [mF] ) [Ws] ) [Ws] with P [ms] with P [ms] 6000...
Page 379: Control System Response
R3: Extended stop and retract 6.2 Control-managed ESR The energy stored in an axis can be calculated as follows: E = 1/2 * Θ * ω Θ Total moment of inertia ω Angular velocity at the instant in time that a switch-over is made to generator operation This energy is fed back into the DC link with an efficiency of approx.
Page 380 R3: Extended stop and retract 6.2 Control-managed ESR Examples for axes with path relationship For the subsequent examples, two path axes X and Y are assumed, which are configured as NC-controlled retraction axes and are programmed for the retraction positions: •...
Page 381: Power Off/Power On
R3: Extended stop and retract 6.2 Control-managed ESR Initial situation Response in the case of ESR • $AA_ESR_ ENABLE[X] = 1 B is not enabled for ESR. As B is not a path axis, B is immediately stopped with a rapid stop. •...
Page 382: Part Program Start, Nc Start
R3: Extended stop and retract 6.2 Control-managed ESR 6.2.10.4 Part program start, NC start In order that a defined initial state is available when a part program starts, the programmed absolute retraction positions and the enable signals of the retraction axes are deleted when the part program starts.
Page 383: Esr Executed Autonomously In The Drive
R3: Extended stop and retract 6.3 ESR executed autonomously in the drive ESR executed autonomously in the drive 6.3.1 Fundamentals Function Drive-integrated extended stop and retract (ESR) enables the fast separation of workpiece and tool independent of the higher-level control (NC). For this purpose, the following axial functions can be configured in the drive: •...
Page 384: Configuring Stopping In The Drive
R3: Extended stop and retract 6.3 ESR executed autonomously in the drive Note SINAMICS S120, function module "ESR" To activate the function module "ESR", the configuration mode must first be enabled in the SINAMICS S120: • p0009 = 2 (defining the drive type/function module) The "ESR"...
Page 385: Configuring Retraction In The Drive
R3: Extended stop and retract 6.3 ESR executed autonomously in the drive Time at which stopping was triggered Instant in time after the time that was configured in p0892 has expired OFF3/OFF1 Braking ramp as a function of p0891 Figure 6-4 Response to drive-integrated stopping Feedback signal The stopping status is signaled back to the control.
Page 386 R3: Extended stop and retract 6.3 ESR executed autonomously in the drive Parameter Description p0892 ESR: Timer The parameter specifies the total time that elapses to reach the speed specified in p0893 followed by constant velocity travel. This is followed by an OFF1 or OFF3 ramp depending on the parameterization in p0891.
Page 387: Configuring Generator Operation In The Drive
R3: Extended stop and retract 6.3 ESR executed autonomously in the drive 6.3.4 Configuring generator operation in the drive The generator mode for the drive-integrated ESR is configured using the following drive parameters: Parameter Description p0888 ESR: Configuration Value Meaning Generator operation (Vdc controller) Parameter Description...
Page 388: Esr Is Enabled Via System Variable
R3: Extended stop and retract 6.3 ESR executed autonomously in the drive Generator minimum speed The lower limit of the motor speed of the generator axis is configured using drive parameter p2161: Parameter Description p2161 Speed threshold value 3 Speed threshold value for the message: |n_act| < speed threshold value 3 Feedback signal The generator operation status is signaled back to the control.
Page 389: Feedback Of The Esr Status
R3: Extended stop and retract 6.3 ESR executed autonomously in the drive Note The trigger signal must be active in the part program/synchronized action for at least 2 IPO cycles to ensure that the PROFIdrive telegram is transferred to the drive. Mapping in the drive unit System variable $AN_ESR_TRIGGER is mapped to drive parameter p0890.0.
Page 390: Acknowledge Esr Reactions
R3: Extended stop and retract 6.3 ESR executed autonomously in the drive Interrelationship between signals MELDW System variable NC/PLC interface signal MELDW.Bit9 $AA_ESR_STAT .Bit2 (ESR initiated / generator operation (ESR is triggered) active (r0887.12)) MELDW.Bit4 $AA_ESR_STAT .Bit3 DB31, … DBX95.0 (VDC_min controller is active (Vdc link (DC link undervoltage) (VDC link <...
Page 391: Configuring Esr In The Part Program
R3: Extended stop and retract 6.3 ESR executed autonomously in the drive System variable and drive parameters The following diagram shows the relationship between system variables and drive parameters when triggering and acknowledging ESR reactions. ① NC: Enabling the ESR reaction via $AA_ESR_ENABLE = 1 (axis-specific) ②...
Page 392 R3: Extended stop and retract 6.3 ESR executed autonomously in the drive Function: ESRS(...):(stopping) Using the ESRS(...) function, drive parameters can be changed regarding the drive- integrated "stop" ESR function. Syntax ESRS(<access_1>,<stopping time_1>[,...,<axis_n>,<stopping time_n>]) A maximum of 5 axes can be programmed in a function call; n = 5 Meaning Special features of the function: •...
Page 393 R3: Extended stop and retract 6.3 ESR executed autonomously in the drive Parameter: <Axis_n> Function: For the specified axis, writes to drive parameter p0888 (configuration): p0888 = 2 Type: AXIS Range of values: Channel axis identifier Parameter: <retraction velocity _n> Function: For the axis specified under <Axis_n>, writes to drive parameter p0893 (retraction speed):...
Page 394 R3: Extended stop and retract 6.3 ESR executed autonomously in the drive the drive-integrated ESR for an axis is enabled ($AA_ESR_ENABLE[<axis>] == 1), then it is not permissible to change the axial transmission ratio. NOTICE Changing the transmission ratio If the drive-integrated ESR is not enabled for an axis ($AA_ESR_ENABLE[<axis>] == 0), then the axial transmission ratio can be changed.
Page 395: Configuring The Esr Via The Plc User Program
R3: Extended stop and retract 6.3 ESR executed autonomously in the drive Reset behavior The parameter values written using the functions ESRS(...) and ESRR(...) are overwritten with the parameter values saved in the drive when the drive powers-up or for a drive warm restart.
Page 396 R3: Extended stop and retract 6.3 ESR executed autonomously in the drive • MD36963 $MA_SAFE_VELO_STOP_REACTION (stop response, safely reduced speed) • MD10089 $MN_SAFE_PULSE_DIS_TIME_BUSFAIL (wait time pulse cancellation when the bus fails) Delay times in the drive are configured using the following drive parameters: •...
Page 397: Esr And Safety Integrated (828D)
R3: Extended stop and retract 6.3 ESR executed autonomously in the drive 6.3.12 ESR and Safety Integrated (828D) No feedback signal of the safety stop reaction Within the scope of SINUMERIK 828D, the safety stop reaction currently active in the drive is not signaled back to the control.
Page 398: Boundary Conditions
R3: Extended stop and retract 6.4 Boundary conditions Boundary conditions Operational performance of the components The drive components involved in the extended stopping and retraction must be capable of functioning. If one of these components fails, the full scope of the described reaction no longer applies.
Page 399: Examples
R3: Extended stop and retract 6.5 Examples Examples 6.5.1 NC-controlled reactions Example using NC-controlled reactions. The important details are specified. Exercise The A axis is to operate as the generator drive, while the X axis should retract 10 mm at maximum speed in the event of a fault, and axes Y and Z should stop after a delay of 100 ms so that the retraction axis has time to cancel the mechanical coupling.
Page 400: Retraction While Thread Cutting
R3: Extended stop and retract 6.5 Examples Trigger conditions and static synchronized actions Example 1: Trigger condition is the occurrence of alarms, which activate the follow-up (tracking) mode: Program code IDS=02 WHENEVER ($AC_ALARM_STAT B_AND 'H2000')>0 DO $AC_ESR_TRIGGER=1 Example 2: Trigger condition is when the ELG synchronous monitoring responds, if, e.g. Y is defined as ELG following axis and the max.
Page 401: Rapid Lift, Absolute And Incremental
R3: Extended stop and retract 6.5 Examples Program code Comment N80 POLFMASK(Z) Disable retraction, axis X Y and Enable retraction, axis Z N90 Y10 ; Retraction response, axial: Z (abs.) N100 POLFMASK() ; Disable retraction of all axes 6.5.4 Rapid lift, absolute and incremental Retraction to absolute positions and through an incremental distance: Program code Comment...
Page 402 R3: Extended stop and retract 6.5 Examples Program code Comment N90 Z100 G1 F1000 Retraction response: - linear relation: X (inc.), Y (abs.) - axial: Z (abs.) N95 POLF[X]=10 ; Retraction position axis X, absolute N100 Y0 G1 F1000 Retraction response: - linear relation: X (inc.), Y (abs.) - axial: Z (abs.) N110 POLFMLIN()
Page 403: Data Lists
R3: Extended stop and retract 6.6 Data lists Data lists 6.6.1 Machine data 6.6.1.1 Channelspecific machine data Number Identifier: $MC_ Description 21204 LIFTFAST_STOP_COND Stop characteristics for rapid lift 21380 ESR_DELAY_TIME1 Delay time (STOPBYALARM, NOREAD) for ESR axes 21381 ESR_DELAY_TIME2 Time for interpolatory braking of ESR axes 6.6.1.2 Axis/spindlespecific machine data Number...
Page 404: Signals To Axis/Spindle
R3: Extended stop and retract 6.6 Data lists 6.6.3.2 Signals to axis/spindle DB number Byte.Bit Name 31, ... Feed stop 6.6.3.3 Signals from axis/spindle DB number Byte.bit name 31, ... 95.0 VDC link < alarm threshold 31, ... 95.3 Generator operation – minimum speed fallen below 31, ...
Page 405: S9: Setpoint Switchover
S9: Setpoint switchover Brief description Function The "setpoint exchange" function is used in applications in which the same motor is used to traverse different machine axes. Replacing the technology function "setpoint changeover" (TE5) The "setpoint changeover" function replaces the technology function "setpoint changeover" (TE5).
Page 406: Startup
S9: Setpoint switchover 7.2 Startup Startup 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 407 S9: Setpoint switchover 7.2 Startup Figure 7-3 Setpoint exchange with 2 axes Activation 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.
Page 408 S9: Setpoint switchover 7.2 Startup Transfer conditions • Axis standstill of all axes involved. • Special functions such as reference point approach, measuring, travel to fixed stop, function generator, star/delta changeover, drive parameter set changeover are not active in the axis with drive control. •...
Page 409: Interface Signals
S9: Setpoint switchover 7.3 Interface signals Interface signals Axisspecific signals Despite assignment of a drive to several machine axes, the use of NC/PLC interface signals remains unchanged. This requires an explicit coordination of access operations to the NC/ PLC interface signals in the PLC user program. Status signals The status signals contained in the following bytes are always displayed in the same way for all of the machine axes involved in the changeover:...
Page 410 S9: Setpoint switchover 7.3 Interface signals Figure 7-4 Schematic setpoint changeover from machine axes AX1 to AX2 Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 411: Interrupts
S9: Setpoint switchover 7.4 Interrupts Interrupts Drive alarms are only displayed for axes with drive control Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 412: Position Control Loop
S9: Setpoint switchover 7.5 Position control loop 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. The use of a single drive means that only one of the control loops can be closed at any one time.
Page 413: Reference Points
S9: Setpoint switchover 7.6 Reference points Reference points The use of load-side encoders does not affect the axial reference points of a setpoint exchange. However, the mechanical reference to the load can be lost following setpoint exchange for a load-side position derived solely from the motor encoder. These types of axis must be referenced again after every setpoint exchange.
Page 414: Constraints
S9: Setpoint switchover 7.7 Constraints Constraints "Parking" operating status The "parking" operating state can only be exited using the axis with the drive checking function. Service display drive The "Drive Service Display" HMI diagnostics screen does not take into account changes in assignments between the machine axes and the drive.
Page 415: Data Lists
S9: Setpoint switchover 7.8 Data lists Data lists 7.8.1 Machine data 7.8.1.1 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:...
Page 416 S9: Setpoint switchover 7.8 Data lists Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 417: T3: Tangential Control
T3: Tangential control 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).
Page 418 T3: Tangential control 8.1 Brief description Applications The tangential control function can be used for example for the following applications: • Tangential positioning of a rotatable tool for nibbling operations. • Follow-up control of tool alignment for a bandsaw. • Positioning a dressing tool on a grinding wheel.
Page 419: Characteristics Of Tangential Follow-Up Control
T3: Tangential control 8.2 Characteristics of tangential follow-up control 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 8-1 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 420 T3: Tangential control 8.2 Characteristics of tangential follow-up control Special cases • G641 rounding is possible between two blocks, both of which move at least one of the two leading axes of the tangentially following axis. • G641 rounding is possible between two blocks, both of which do not move either of the leading axes of the tangentially following axis.
Page 421: Using Tangential Follow-Up Control
T3: Tangential control 8.3 Using tangential follow-up control Using tangential follow-up control Activation 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 422: Assignment Between Leading Axes And Following Axis
T3: Tangential control 8.3 Using tangential follow-up control Cross-channel block search The cross-channel block search in the program test mode (SERUPRO "Search-Run by Program test") can be used to simulate the tangential tracking of axes. Further information about the multi-channel block search function SERUPRO, see: References: Function Manual, Basic Functions;...
Page 423: Switching On Corner Response
T3: Tangential control 8.3 Using tangential follow-up control following axes made beforehand with TANG. Refer to Section "Assignment between leading axes and following axis". An angle between the tangent and the position of the following axis can be specified optionally when follow-up is activated. This angle is maintained by the control for as long as the following axis is made to follow.
Page 424: Termination Of Follow-Up Control
T3: Tangential control 8.3 Using tangential follow-up control System variable $AC_TLIFT_BLOCK The system variable $AC_TLIFT_BLOCK indicates whether the current block is an intermediate block generated by TLIFT. If the value of the system variable is 1, TLIFT inserted the current block as an intermediate block. 8.3.4 Termination of follow-up control Programming...
Page 425: Canceling The Definition Of A Follow-Up Axis Assignment
T3: Tangential control 8.3 Using tangential follow-up control 8.3.6 Canceling the definition of a follow-up axis assignment. A follow-up axis assignment specified by TANG() remains active after TANGOF. This inhibits a plane change or geometry axis switchover. The predefined subprogram TANGDEL is used to cancel the definition of a follow-up axis assignment so that the follow-up axis can be operated dependent on new leading axes when a new follow-up axis assignment is defined.
Page 426 T3: Tangential control 8.3 Using tangential follow-up control Geometry axis switchover with TANGDEL The following example shows how TANGDEL is used correctly in association with an axis switchover. N10 GEOAX(2,Y1) ; Geo axis group is determined N20 TANG(A,X, Y) ; Channel axis Y1 is being assigned N30 TANGON(A, 90) ;...
Page 427: Limit Angle
T3: Tangential control 8.4 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.
Page 428: Supplementary Conditions
T3: Tangential control 8.5 Supplementary conditions Supplementary conditions Block search with active coupling Note For an active coupling, it is recommended to only use block search type 5, "Block search via program test" (SERUPRO) for a block search. Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 429: Examples
T3: Tangential control 8.6 Examples Examples Positioning of workpiece Figure 8-4 Tangential positioning of a workpiece on a bandsaw Positioning of tool Figure 8-5 Positioning of a dressing tool on a grinding wheel Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 430 T3: Tangential control 8.6 Examples Example Corner in area Programming 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.
Page 431: Data Lists
T3: Tangential control 8.7 Data lists Data lists 8.7.1 Machine data 8.7.1.1 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 8.7.2 System variables Identifier Description $AC_TLIFT_BLOCK Current block is an intermediate block generated by TLIFT Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 432 T3: Tangential control 8.7 Data lists Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 433: Te01: Installation And Activation Of Loadable Compile Cycles
Contents A description is provided in the following chapters as to how technology functions, available from Siemens, can be installed and activated in the control as individual loadable compile cycles. Technology functions The description is a general description and applies to all the following technology functions: •...
Page 434 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 435: Loading Compile Cycles
TE01: Installation and activation of loadable compile cycles 9.1 Loading compile cycles Loading compile cycles 9.1.1 Loading a compile cycle with HMI sl Precondition • The compile cycle to be transferred to the control must be saved on a storage medium which can be directly connected to the control, such as a USB-FlashDrive.
Page 436: Loading A Compile Cycle With Hmi Advanced
TE01: Installation and activation of loadable compile cycles 9.1 Loading compile cycles 9.1.2 Loading a compile cycle with HMI Advanced Precondition To transfer a 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 437 TE01: Installation and activation of loadable compile cycles 9.1 Loading compile cycles Execution Perform the following operation to load a compile cycle from an external computer into the NCK: 1. Start the "WinSCP3" program on the external computer (programming device / PC) 2.
Page 438: Interface Version Compatibility
TE01: Installation and activation of loadable compile cycles 9.2 Interface version compatibility Interface version compatibility The compile cycle and the NCK system software communicate via a SINUMERIK-specific interface. The interface version used by the loaded compile cycle must be compatible with the interface version of the NCK system software.
Page 439 TE01: Installation and activation of loadable compile cycles 9.2 Interface version compatibility Interface versions The relevant interface versions are displayed under: • Interface version of the NCK system software HMI Advanced: Diagnosis > Service Display > Version > NCU Version Display (excerpt) ------------------------------------------- CC Interface Version:...
Page 440 TE01: Installation and activation of loadable compile cycles 9.2 Interface version compatibility Dependencies The following dependencies exist between the interface versions of a compile cycle and the NCK system software: • 1. Position 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 441: Software Version Of A Compile Cycle
TE01: Installation and activation of loadable compile cycles 9.3 Software version of a compile cycle Software version of a compile cycle The SW version of a compile cycle is displayed under: HMI Advanced: Diagnosis > Service Display > Version > NCU Version Display (excerpt) ------------------------------------------- CC Interface Version:...
Page 442: Activating The Technological Functions In The Nck
TE01: Installation and activation of loadable compile cycles 9.4 Activating the technological functions in the NCK Activating the technological functions in the NCK Requirement The corresponding option must be enabled 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 443: Function-Specific Startup
TE01: Installation and activation of loadable compile cycles 9.5 Function-specific startup Function-specific startup Further function-specific installation routines are described in the corresponding function description (TE1 - TEn). Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 444: Creating Alarm Texts
<BaseName_02 type="QString" value="xxx"/> </BaseNames> 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 Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 445: Creating Alarm Texts With Hmi Advanced
German. 5.Restart HMI Advanced. For more information about creating alarm texts with HMI Advanced, please refer to: References: /IAM/ SINUMERIK 840D sl/840Di sl/840D/840Di Startup CNC Part 2 (HMI); Startup HMI Advanced (IM4), Chapter: Creating user alarm texts Note HMI reinstallation Retain the added alarm texts in the text files of the F:\oem even after a reinstallation of HMI.
Page 446: Creating Alarm Texts With Hmi Embedded
4. Restart HMI Embedded. For more information about creating alarm texts with HMI Embedded, please refer to: References: /IAM/ SINUMERIK 840D sl/840Di sl/840D/840Di Commissioning CNC Part 2 (HMI); Commissioning HMI Embedded (IM2), Chapter: Creating In-House Texts Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 447: Upgrading A Compile Cycle
TE01: Installation and activation of loadable compile cycles 9.7 Upgrading a compile cycle Upgrading a compile cycle To upgrade a compile cycle installed in the control, under no circumstances is it sufficient to just exchange the corresponding ELF file. If only the ELF file is replaced, then this can result in undefined behavior of the NCK software due to inconsistent data of the memory and data management.
Page 448: Deleting A Compile Cycle
TE01: Installation and activation of loadable compile cycles 9.8 Deleting a compile cycle Deleting a compile cycle If a loaded compile cycle is to be completely deleted in the control, it is not enough to only delete the corresponding ELF file. With this procedure, the following data is kept in the retentive memory of the control: •...
Page 449: Data Lists
TE01: Installation and activation of loadable compile cycles 9.9 Data lists Data lists 9.9.1 Machine data 9.9.1.1 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:...
Page 450 TE01: Installation and activation of loadable compile cycles 9.9 Data lists Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 451: Te02: Simulation Of Compile Cycles
TE02: Simulation of compile cycles 10.1 Brief description 10.1.1 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 452: Oem Transformations
TE02: Simulation of compile cycles 10.2 OEM transformations 10.2 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 "<...
Page 453 TE02: Simulation of compile cycles 10.2 OEM transformations 6. In the directory for the manufacturer cycles, create the file "TRAORI.SPF" with the following contents: PROC TRAORI(INT II) 7. In the directory for the manufacturer cycles, create the file "TRACON.SPF" with the following contents: PROC TRACON(INT II) Note...
Page 454 TE02: Simulation of compile cycles 10.2 OEM transformations Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 455: Te1: Clearance Control
TE1: Clearance control 11.1 Brief description 11.1.1 General information 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 456 TE1: Clearance control 11.1 Brief description 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. Typical focal lengths are from 5 to 20 cm. The position of the focal point in relation to the workpiece is an extremely critical process parameter in laser cutting operations and must be kept constant within a tolerance of ≤...
Page 457 TE1: Clearance control 11.1 Brief description 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 11-2 System components for clearance control with SINUMERIK 840Di 1D/ 3D machining Clearance control can be used for 1D and 3D machining with up to five interpolatory axes.
Page 458: Clearance Control
TE1: Clearance control 11.2 Clearance control 11.2 Clearance control 11.2.1 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 459 TE1: Clearance control 11.2 Clearance control From the point of view of the control, the unit for the closed-loop control gain is [(mm/min)/V]. In the same way as the setpoint clearance in standardized in [mm], values can only be standardized in [(mm/min)/mm] by using the sensor electronics. Max.
Page 460: Velocity Feedforward Control
TE1: Clearance control 11.2 Clearance control • Conversion time, channel cycle time: ET 200 S with "2 AI U high-speed" analog electronics module produces the following times: Conversion time: 0.1 ms Channel cycle time: 1 ms (both channels) → Average control deadtime of 0.5 ms •...
Page 461 TE1: Clearance control 11.2 Clearance control (840Di) The velocity filters of the SIMODRIVE 611 universal/ E and POSMO SI, CD, CA drives provide an additional means of damping: • Parameter 1502: (time constant for speed setpoint filter 1) • Parameter 1503: (time constant for speed setpoint filter 2) CAUTION Every damping measure implemented contributes to increasing the overall time constant of the control loop!
Page 462: Control Loop Structure
TE1: Clearance control 11.2 Clearance control 11.2.3 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.
Page 463: Compensation Vector
TE1: Clearance control 11.2 Clearance control Figure 11-5 Control structure, clearance control (principle) 11.2.4 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 464 TE1: Clearance control 11.2 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 465 TE1: Clearance control 11.2 Clearance control Figure 11-8 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 466 TE1: Clearance control 11.2 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 467: Technological Features Of Clearance Control
TE1: Clearance control 11.3 Technological features of clearance control 11.3 Technological features of clearance control Clearance control is characterized by the following technological features: • Dynamic Response The overlaid sensor motion uses the current residual dynamic response that is still in reserve after the programmed axis motion (velocity and acceleration).
Page 468 TE1: Clearance control 11.3 Technological features of clearance control • 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: - Path override for sensor movement active •...
Page 469: Sensor Collision Monitoring
TE1: Clearance control 11.4 Sensor collision monitoring 11.4 Sensor collision monitoring Sensor signal If the clearance sensor used has an additional "sensor collision" signal for detecting a collision between the sensor and the workpiece being machined, this signal can be made available to the clearance control function via a digital NCK peripheral input.
Page 470: Startup
TE1: Clearance control 11.5 Startup 11.5 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 11.5.1 Activating the technological function...
Page 471: Parameter Settings For Input Signals (840D)
TE1: Clearance control 11.5 Startup 11.5.3 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 472: Parameter Settings For Input Signals (840Di)
TE1: Clearance control 11.5 Startup 11.5.4 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 473: Parameters Of The Programmable Compensation Vector
TE1: Clearance control 11.5 Startup 11.5.5 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).
Page 474: Parameter Settings For Clearance Control
TE1: Clearance control 11.5 Startup Each machine data bit corresponds to a channel axis. • Coordinate X = channel axis corresponding to bit a • Coordinate Y = channel axis corresponding to bit b • Coordinate Z = channel axis corresponding to bit c with a <...
Page 475 TE1: Clearance control 11.5 Startup 1D/ 3D clearance control The following machine data is used to select 1D or 3D clearance control: • MD62500 $MC_CLC_AXNO = x (axis assignment for clearance control) x > 0: 1D clearance control where x = axis number of clearance-controlled channel axis x = -1: 1.
Page 476: Starting Up Clearance Control
TE1: Clearance control 11.5 Startup 11.5.7 Starting up clearance control Clearance sensor The clearance sensor outputs should be connected to the I/O modules that were activated using the following machine data: • MD10362 $MN_HW_ASSIGN_ANA_FASTIN (I/O address of the I/O module) (hardware assignment for the fast analog NCK inputs) •...
Page 477 TE1: Clearance control 11.5 Startup MD10366 $MN_CLC_OFFSET_ASSIGN_ANAOUT = 6 (hardware assignment for the external digital NCK inputs) Note Before the clearance control function is activated for the first time, check that the entire working range enabled for clearance control is collision-free: •...
Page 478 TE1: Clearance control 11.5 Startup Completion A data backup is recommended once the start-up procedure has been completed. References: /IDsl/ Commissioning Manual IBN CNC: NCK, PLC, drive /HBisl/ SINUMERIK 840Di sl Manual, User Data Backup/Series Commissioning Note A data backup is recommended once the start-up procedure has been completed. Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 479: Programming
TE1: Clearance control 11.6 Programming 11.6 Programming 11.6.1 Activating and deactivating clearance control (CLC) Syntax Mode CLC( Mode • Format: Integer • Range of values: -1, 0, 1, 2, 3 CLC(...) is a procedure call and must therefore be programmed in a dedicated part program block.
Page 480 TE1: Clearance control 11.6 Programming RESET response CLC(0) is executed implicitly on a reset (NC RESET or end of program). Parameterizable RESET response The reset response of a 1D clearance control function can be determined via the channel- specific NCK OEM machine data: •...
Page 481 TE1: Clearance control 11.6 Programming Sensor collision monitoring A digital input for an additional collision signal can be configured by the sensor using the following machine data: MD62504 $MC_CLC_SENSOR_TOUCHED_INPUT (assignment of the input signal for the "sensor collision" signal) This collision monitor can be activated and deactivated block-synchronously through alternate programming of CLC(1)/CLC(2).
Page 482 TE1: Clearance control 11.6 Programming Compensation vector Actual position of the direction axes If the clearance control is activated with a programmable compensation vector at a position of 0 on all 3 direction axes, a compensation vector cannot be calculated from this information. The following alarm is then displayed: number •...
Page 483 TE1: Clearance control 11.6 Programming Figure 11-11 Interpolation of the compensation vector The compensation vector must be oriented by programming the direction axes at [1, 0, 0] before part program block N100. In part program block N100, the end position of the compensation vector is oriented by programming the direction axes at [0, 0, -1].
Page 484: Closed-Loop Control Gain (Clc_Gain)
TE1: Clearance control 11.6 Programming In the case of a re-orientation (rotation) of the compensation vector, it is also necessary to note the ratio between the programmed traversing path and the configured dynamic response of the direction axes. The ratio should be chosen such that the programmed traversing path is not traversed in one or a small number of interpolation cycles, due to the dynamic response of the axis.
Page 485 TE1: Clearance control 11.6 Programming Functionality The current closed-loop control gain for clearance control is produced by the active characteristic specified via machine data: • MD62510 $MC_CLC_SENSOR_VOLTAGE_TABLE1 (coordinate voltage of interpolation points sensor characteristic 1) • MD62511 $MC_CLC_SENSOR_VELO_TABLE1 (coordinate velocity of interpolation points sensor characteristic 1) •...
Page 486: Limiting The Control Range (Clc_Lim)
TE1: Clearance control 11.6 Programming Figure 11-12 Response of the CLC offset vector when CLC_GAIN=0.0 Reset Within a part program, a modified gain factor must be reset by means of explicitly programming CLC_GAIN=1.0. RESET response CLC_GAIN=1.0 becomes effective after a power on reset, NC RESET or end of program. 11.6.3 Limiting the control range (CLC_LIM) Syntax...
Page 487 TE1: Clearance control 11.6 Programming Functionality The maximum control range for clearance control can be modified on a block-specific basis using CLC_LIM. The maximum programmable lower/upper limit is limited by the limit value preset in the relevant machine data: • MD62505 $MC_CLC_SENSOR_LOWER_LIMIT[1] (lower clearance control motion limit) •...
Page 488: Direction-Dependent Traversing Motion Disable
TE1: Clearance control 11.6 Programming Error messages The following programming errors are displayed with an alarm: • Programming more than 2 arguments number number CLC alarm "75005 Channel Block CLC_LIM: general programming error" • Programming arguments outside the permissible limits number number CLC alarm "750010 Channel...
Page 489 TE1: Clearance control 11.6 Programming Parameterization The following machine data is used to parameterize the digital outputs: • MD62523 $MC_CLC_LOCK_DIR_ASSIGN_DIGOUT[n] (assignment of the digital outputs for disabling the CLC movement) n = 0 → Digital output for disabling the negative traversing direction n = 1 →...
Page 490: Voltage Offset, Can Be Set On A Block-Specific Basis (Clc_Voff)
TE1: Clearance control 11.6 Programming 11.6.5 Voltage offset, can be set on a block-specific basis (CLC_VOFF) Syntax oltage offset CLC_VOFF = V Voltage offset • Format: Real • Unit: Volts • Range of values: No restrictions CLC_VOFF is an NC address and can therefore be written together with other instructions in a part program block.
Page 491: Voltage Offset Definable By Synchronized Action
TE1: Clearance control 11.6 Programming 11.6.6 Voltage offset definable by synchronized action Syntax number oltage offset $A_OUTA[ ] = V Number Number of the parameterized analog output (see below: Parameterization) • Format: Integer • Range of values: 1, 2, . . .max. number of analog outputs oltage offset Just like the voltage offset for CLC_VOFF (see Chapter "Voltage offset, can be set on a block- specific basis (CLC_VOFF) [Page 490]").
Page 492: Selection Of The Active Sensor Characteristic (Clc_Sel)
TE1: Clearance control 11.6 Programming 11.6.7 Selection of the active sensor characteristic (CLC_SEL) Syntax characteristic number CLC_SEL( Characteristic number • Format: Integer • Range of values: 1, 2 CLC_SEL(...) is a procedure call and must therefore be programmed in a dedicated part program block.
Page 493: Function-Specific Display Data
TE1: Clearance control 11.7 Function-specific display data 11.7 Function-specific display data The "clearance control" technological function provides specific display data for supporting start-up and for service purposes. Possible applications Application options for display data include for example: • Determination of form variances and transient control errors via the variables for the maximum and minimum position offset/sensor voltage.
Page 494 TE1: Clearance control 11.7 Function-specific display data HMI Advanced Proceed as follows to create and display the GUD variables in HMI Advanced. 1. Setting the password Enter the password for protection level 1: (machine manufacturer). 2. Activate the "definitions" display. Operating area switchover >...
Page 495: Opi Variable
TE1: Clearance control 11.7 Function-specific display data SINUMERIK NCK The new GUD variables, which are already being displayed, will only be detected by the clearance control function and supplied with up-to-date values following an NCK POWER ON RESET. Note Once the GUD variables have been created, an NCK POWER ON RESET must be carried out in order for the clearance control function to update the GUD variables.
Page 496 TE1: Clearance control 11.7 Function-specific display data OPI variable Proceed as follows to define the OPI variables. 1. Create the CLC-specific definition file: CLC.NSK Note: We recommend that you create the file in the \OEM directory rather than in the \MMC2 directory so that it is not overwritten when a new software version is installed.
Page 497: Function-Specific Alarm Texts
TE1: Clearance control 11.8 Function-specific alarm texts 11.8 Function-specific alarm texts The procedure to be following while creating function-specific alarm texts is described in: References: /FB3/ Function Manual, Special Functions; Installation and Activation of Readable Compile Cycles (TE01), Section: "Creating alarm texts [Page 444]" Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 498: Boundary Conditions
TE1: Clearance control 11.9 Boundary conditions 11.9 Boundary conditions 11.9.1 I/O modules For A/D conversion, the analog output current of the clearance sensor must be connected to NC via an I/O module with analog input to the NC. 11.9.1.1 I/O modules (840D) The analog I/O module (DMP compact module) is connected to the drive bus via an NCU terminal block.
Page 499: I/O Modules (840Di)
TE1: Clearance control 11.9 Boundary conditions 11.9.1.2 I/O modules (840Di) On the SINUMERIK 840Di, the analog I/O module is connected via PROFIBUS-DP. Figure 11-15 Clearance sensor connection via analog S7 I/O module Suitable I/O modules As the A/D conversion time directly affects the deadtime of the clearance control servo loop, only one I/O module may be used with low conversion time.
Page 500: Function-Specific Boundary Conditions
TE1: Clearance control 11.9 Boundary conditions 11.9.2 Function-specific boundary conditions NC stop from PLC If, in addition to the programmed path motion, the traversing movement of the clearance- controlled axes is also to be stopped in connection with an NC stop, the "NC stop axes and spindles"...
Page 501 TE1: Clearance control 11.9 Boundary conditions Gantry axes Only one of the clearance-controlled axes may be configured as the master axis of a gantry grouping, defined via machine data: MD37100 $MA_GANTRY_AXIS_TYPE (gantry axis definition) Following axes in a gantry grouping may not be used in the context of clearance control. Displaying the axis position The actual current axis position of a clearance-controlled axis as the sum of an interpolatory axis position and the current position offset of clearance control is not displayed in the main...
Page 502 TE1: Clearance control 11.9 Boundary conditions Computing time requirements The additional computing time required for the "clearance control" technological function must be taken into account on control systems in which the cycle times set for the interpolator and position controller cycle have been substantially optimized in comparison with the default setting: The additional computing time required comes into effect when clearance control is activated in the part program (CLC(x)).
Page 503: Data Lists
TE1: Clearance control 11.10 Data lists 11.10 Data lists 11.10.1 Machine data 11.10.1.1 Drive-specific machine data (840D) Drive machine data (SIMODRIVE 611D) Number Identifier: $MD_ Description 1502 SPEED_FILTER_1_TIME [n] Time constant for setpoint speed filter 1 1503 SPEED_FILTER_2_TIME [n] Time constant for setpoint speed filter 2 11.10.1.2 Drive-specific machine data (840Di) Drive parameter (SIMODRIVE 611D;...
Page 504: 5Axis/Spindlespecific Machine Data
TE1: Clearance control 11.10 Data lists Number Identifier: $MC_ Description 28254 MM_NUM_AC_PARAM Number of parameters for synchronized actions Clearance control 62500 CLC_AXNO Axis assignment for clearance control 62502 CLC_ANALOG_IN Analog input for clearance control function 62504 CLC_SENSOR_TOUCHED_INPUT Input bit assignment for the "sensor collision" signal 62505 CLC_SENSOR_LOWER_LIMIT Lower motion limit of clearance control...
Page 505: Signals
TE1: Clearance control 11.10 Data lists Number Identifier: $MA_ Description 36000 STOP_LIMIT_COARSE Exact stop coarse 36010 STOP_LIMIT_FINE Exact stop fine 36040 STANDSTILL_DELAY_TIME Delay time zero speed monitoring 36060 STANDSTILL_VELO_TOL Axis/ spindle velocity stopped 36750 AA_OFF_MODE Value calculation mode for axial position override 11.10.2 Signals 11.10.2.1 Signals to channel...
Page 506 TE1: Clearance control 11.10 Data lists Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 507: Te3: Speed/Torque Coupling, Master-Slave
TE3: Speed/torque coupling, master-slave 12.1 Brief description A master-slave coupling is a speed setpoint coupling between a master and slave axis - performed at the position controller level - with and without torque equalization control. The coupling can be permanently closed or can be dynamically closed and opened and reconfigured.
Page 508: Coupling Diagram
TE3: Speed/torque coupling, master-slave 12.2 Coupling diagram 12.2 Coupling diagram If the coupling is closed, the slave axis is traversed only with the load-side setpoint speed of the master axis. It is therefore only speed-controlled, not position-controlled. There is no differential position control between the master and slave axis.
Page 509: Configuring A Coupling
TE3: Speed/torque coupling, master-slave 12.3 Configuring a coupling 12.3 Configuring a coupling Static assignment For a speed setpoint coupling and torque equalization control, the static assignment of master and slave axis is defined separately in the following machine data: • Speed setpoint coupling MD37250 $MA_MS_ASSIGN_MASTER_SPEED_CMD[<slave axis>] = <machine axis number of the master axis for the speed setpoint coupling>...
Page 510 TE3: Speed/torque coupling, master-slave 12.3 Configuring a coupling Boundary conditions The following boundary conditions must be observed for the dynamic assignment: • When the coupling is closed, a change to the assignment using MASLDEF has no effect. The change only becomes effective the next time that the coupling is opened. •...
Page 511 TE3: Speed/torque coupling, master-slave 12.3 Configuring a coupling General boundary conditions The following boundary condition must be observed: • A slave axis can only be assigned to one master axis • One master axis can be assigned several slave axes •...
Page 512: Torque Compensatory Controller
TE3: Speed/torque coupling, master-slave 12.4 Torque compensatory controller 12.4 Torque compensatory controller The torque equalization controller (PI control) calculates a load-side initial speed setpoint. The additional speed setpoint can be differently entered via the following machine data: MD37254 $MA_MS_TORQUE_CTRL_MODE[<slave axis>] = <value> <value>...
Page 513 TE3: Speed/torque coupling, master-slave 12.4 Torque compensatory controller Gain factor (P component) The gain factor of the torque equalization controller is set in the following machine data as a percentage of the ratio of the maximum load-side axis velocity of the slave axis (MD32000 $MA_MAX_AX_VELO) to its rated torque (SINAMICS S120: p2003): MD37256 $MA_MS_TORQUE_CTRL_P_GAIN[<slave axis>] Note: Scaling via MD37253 $MA_MS_FUNCTION_MASK[<slave axis>], bit 0...
Page 514 TE3: Speed/torque coupling, master-slave 12.4 Torque compensatory controller NOTICE Mechanical coupling When using the torque equalization controller, it is absolutely necessary to have a mechanical coupling between the master and slave axis. Otherwise, the two drives involved could accelerate in an uncontrollable fashion. Activating/deactivating via the NC/PLC interface The torque equalization controller can be activated on an axis-for-axis basis via the NC/PLC interface:...
Page 515: Tension Torque
TE3: Speed/torque coupling, master-slave 12.5 Tension torque 12.5 Tension torque The tension torque is a supplementary torque which is switched to the active torque equalization controller. This means that a mechanical tension can be established between axes within a master-slave grouping. Establishing a tension is not only possible between the master and a slave axis, but also between two slave axes by declaring one of the slave axes the reference axis for the torque equalization controller.
Page 516 TE3: Speed/torque coupling, master-slave 12.5 Tension torque Reference axis of the speed Reference axis of the torque Input of the torque equalization setpoint coupling equalization controller contr. Axis MD37250 = value MD37252 = value MD37254 = value Value Description Value Description Value Description...
Page 517 TE3: Speed/torque coupling, master-slave 12.5 Tension torque Reference axis of the speed Reference axis of the torque Input of the torque equalization setpoint coupling equalization controller contr. Axis MD37250 = value MD37252 = value MD37254 = value Value Description Value Description Value Description...
Page 518 TE3: Speed/torque coupling, master-slave 12.5 Tension torque Figure 12-5 Example 2: alternating coupling with 1x4 and 2x2 axes Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 519: Activating A Coupling
TE3: Speed/torque coupling, master-slave 12.6 Activating a coupling 12.6 Activating a coupling Default After the control has booted, the following machine data defines whether the coupling is permanently closed (static) or can be dynamically closed/opened and reconfigured: MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[<slave axis>] = <close mode> Statically closing a coupling MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[<slave axis>] = 1 After the control boots, the coupling is statically closed.
Page 520 TE3: Speed/torque coupling, master-slave 12.6 Activating a coupling • Machine data MD37262 Writing the machine data to close ( = 1) or open ( = 0) in the part program or synchronized action. The change becomes active immediately. • NC/PLC interface DB31, ...
Page 521: Response On Activation/Deactivation
TE3: Speed/torque coupling, master-slave 12.7 Response on activation/deactivation 12.7 Response on activation/deactivation Activating/deactivating during axis standstill A request to close/open the coupling only becomes effective when the master and slave axis are at a standstill (zero speed): DB31,... DBX.61.4 == 1 (axis/spindle stationary) In this case, the coupled axes must be in the closed-loop controlled mode.
Page 522 TE3: Speed/torque coupling, master-slave 12.7 Response on activation/deactivation Phase 2 The following synchronous signals are generated from the actual speed difference between the master and slave spindle(s): DB31, ... DBX96.3 (speed tolerance, coarse) DB31, ... DBX96.2 (speed tolerance, fine) The associated limits are set using the following machine data: MD37270 $MA_MS_VELO_TOL_COARSE ("Tolerance coarse") MD37272 $MA_MS_VELO_TOL_FINE ("Tolerance fine").
Page 523 TE3: Speed/torque coupling, master-slave 12.7 Response on activation/deactivation Deactivation during motion Opening the coupling without braking If the coupling is opened using the programmed commandMASLOF, then for spindles in the open-loop speed controlled mode, the coupling is immediately opened. The slave spindles maintain their speeds at the time that the coupling is opened until a new speed is programmed.
Page 524: Constraints
TE3: Speed/torque coupling, master-slave 12.8 Constraints 12.8 Constraints 12.8.1 Speed/torque coupling (SW 6 and higher) General • Master and slave axes must be on the same NCU. • A coupling is closed or opened independent of the channel state the next time that the axis is at a standstill.
Page 525: Axial Nc/Plc Interface Signals
TE3: Speed/torque coupling, master-slave 12.8 Constraints Modulo rotary axes • For slave axes, when the coupling is closed, the actual value displayed in the service display is not modulo 360°. Independent of the setting in machine data: MD30310 $MA_ROT_IS_MODULO[<slave axis>] Spindles •...
Page 526: Interaction With Other Functions
TE3: Speed/torque coupling, master-slave 12.8 Constraints • If, for the master or slave axis, one of the following drive status signals is not set: DB31, ... DBX61.7 (current controller active) == 0 OR DB31, ... DBX61.6 (speed controller active) == 0 then, when the slave axis is at a standstill, the status signal is reset: DB31, ...
Page 527 TE3: Speed/torque coupling, master-slave 12.8 Constraints Dynamic stiffness control The Kv factor of the master axis is copied to the slave axis for an existing coupling and is thus also active in the slave drive. This is an attempt to achieve the same control response in the drive of the master and slave axis as far as possible.
Page 528 TE3: Speed/torque coupling, master-slave 12.8 Constraints Safety Integrated (new 840D sl) As the slave axis is traversed via the master axis speed setpoint, the axial setpoint limit MD36933 $MA_SAFE_DES_VELO_LIMIT is inactive in the coupled slave axes. All safety monitoring functions remain active in the slave axes however. Weight counterbalance The additional torque for the electronic counterweight MD32460 $MA_TORQUE_OFFSET is computed in the following axis, irrespective of the coupling status.
Page 529 TE3: Speed/torque coupling, master-slave 12.8 Constraints Example for cyclic coupling sequence (position=3/container=CT1) MASLDEF(AUX,SPI(3)) ; S3 master for AUX MASLON(AUX) ; Coupling in for AUX M3=3 S3=4000 ; Machining ... MASLDEL(AUX) ; Clear configuration and release coupling AXCTSWE(CT1) ; Container rotation Figure 12-8 Coupling between container spindle S3 and auxiliary motor AUX (prior to rotation) Figure 12-9...
Page 530 TE3: Speed/torque coupling, master-slave 12.8 Constraints The master axis controls the movement away from the limit switch, since the coupling cannot be disconnected until the cause of the alarm has been eliminated. Block search Static coupling The "block search with calculation" function (SERUPRO) can be used without any restrictions in conjunction with a static master-slave coupling.
Page 531 TE3: Speed/torque coupling, master-slave 12.8 Constraints Table 12-1 PROGEVENT.SPF: Example 1 Program code Comment N70 ENDIF N80 REPOSA Table 12-2 PROGEVENT.SPF: Example 2 Program code Comment N10 IF $P_PROG_EVENT==5 ; Block search active IF (($P_SEARCH_MASLC[SPI(2)]<>0) AND In the block search, ($AA_MASL_STAT[SPI(2)]==0)) the coupling state of the second spindle has changed...
Page 532: Examples
TE3: Speed/torque coupling, master-slave 12.9 Examples 12.9 Examples 12.9.1 Master-slave coupling between AX1=Master and AX2=Slave. Configuration Master-slave coupling between AX1=Master and AX2=Slave. 1. Machine axis number of master axis for speed setpoint coupling MD37250 $MA_MS_ASSIGN_MASTER_SPEED_CMD[AX2] = 1 2. Master axis with torque distribution identical to master axis with speed setpoint coupling MD37252 $MA_MS_ASSIGN_MASTER_TORQUE_CTR[AX2] = 0 3.
Page 533: Close/Separate Coupling Via Part Program
TE3: Speed/torque coupling, master-slave 12.9 Examples Typical sequence of operations Action Effect/comment • Approach coupling position Each axis moves to the coupling position. • Close coupling mechanically Both axes are mechanically coupled to one another. • Request to close the coupling PLC interface signal "Master/slave on"...
Page 534 TE3: Speed/torque coupling, master-slave 12.9 Examples Preconditions • Master-slave coupling is configured. • Axes are stationary. • No servo enable signals. Typical sequence of operations Action Effect/comment • Request to close the coupling The following PLC interface signal is set: DB31, ...
Page 535: Data Lists
TE3: Speed/torque coupling, master-slave 12.10 Data lists 12.10 Data lists 12.10.1 Machine data 12.10.1.1 Axis/spindlespecific machine data Number Identifier: $MA_ Description 37250 MS_ASSIGN_MASTER_SPEED_CMD Leading axis for speed setpoint coupling 37252 MS_ASSIGN_MASTER_TORQUE_CTR Leading axis for torque distribution 37254 MS_TORQUE_CTRL_MODE Connection of torque control output 37255 MS_TORQUE_CTRL_ACTIVATION Activate torque compensatory control...
Page 536: Signals
TE3: Speed/torque coupling, master-slave 12.10 Data lists 12.10.3 Signals 12.10.3.1 Signals to axis/spindle DB number Byte.bit Description 31, ... 24.4 Activate torque compensatory controller 31, ... 24.7 Activate master-slave coupling 12.10.3.2 Signals from axis/spindle DB number Byte.bit Description 31, ... 96.2 Differential speed "Fine"...
Page 537: Te4: Transformation Package Handling
TE4: Transformation package handling 13.1 Brief description The handling transformation package has been designed for use on manipulators and robots. The package is a type of modular system, which enables the customer to configure the transformation for his machine by setting machine data (provided that the relevant kinematics are included in the handling transformation package).
Page 538: Kinematic Transformation
TE4: Transformation package handling 13.2 Kinematic transformation 13.2 Kinematic transformation Task of a transformation The purpose of a transformation is to transform movements in the tool tip, which are programmed in a Cartesian coordinate system, into machine axis positions. Fields of application The handling transformation package described here has been designed to cover the largest possible number of kinematic transformations implemented solely via parameter settings in machine data.
Page 539: Definition Of Terms
TE4: Transformation package handling 13.3 Definition of terms 13.3 Definition of terms 13.3.1 Units and directions Lengths and angles In the transformation machine data, all lengths are specified in millimeters or inches and, unless otherwise stated, all angles in degrees at intervals of [ -180°, 180° ]. Direction of rotation In the case of angles, arrows in the drawings always indicate the mathematically positive direction of rotation.
Page 540: Definition Of A Joint
TE4: Transformation package handling 13.3 Definition of terms The definitions of the RPY angles are as follows: • Angle A: 1. rotation about the Z axis of the initial system • B angle: 2. Rotation through the rotated Y axis •...
Page 541 TE4: Transformation package handling 13.3 Definition of terms Figure 13-2 Joint identifying letters Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 542: Configuration Of A Kinematic Transformation
TE4: Transformation package handling 13.4 Configuration of a kinematic transformation 13.4 Configuration of a kinematic transformation Meaning In order to ensure that the kinematic transformation can convert the programmed values into axis motions, it must have access to some information about the mechanical construction of the machine.
Page 543: Parameterization Using Geometry Data
TE4: Transformation package handling 13.4 Configuration of a kinematic transformation 13.4.2 Parameterization using geometry data Modular principle The machine geometry is parameterized according to a type of modular principle. With this method, the machine is successively configured in geometry parameters from its base center point to the tool tip, thereby producing a closed kinematic loop.
Page 544 TE4: Transformation package handling 13.4 Configuration of a kinematic transformation MD62612, MD62613 The frame T_IRO_RO links the base center point of the machine (BCS = RO) with the first internal coordinate system (IRO) determined by the transformation. MD62613 $MC_TRAFO6_TIRORO_RPY (frame between base center point and internal coordinate system (rotation component), n = 0...2) MD62612 $MC_TRAFO6_TIRORO_POS (frame between base center point and internal coordinate system (position component), n = 0...2)
Page 545 TE4: Transformation package handling 13.4 Configuration of a kinematic transformation MD62604 The hand type is specified in machine data: MD62604 $MC_TRAFO6_WRIST_AXES (wrist axis identifier) The term wrist axes generally refers to axes four to six. MD62610, MD62611 Frame T_FL_WP links the last hand coordinate system with the flange coordinate system. MD62610 $MC_TRAFO6_TFLWP_POS (frame between wrist point and flange coordinate system (position component), n = 0...2) MD62611 $MC_TRAFO6_TFLWP_RPY (frame between wrist point and flange coordinate...
Page 546 TE4: Transformation package handling 13.4 Configuration of a kinematic transformation Figure 13-4 Overview of basic axis configuration The handling transformation package contains the following basic axis kinematics: • SS: Gantry (3 linear axes, rectangular) • CC: SCARA (1 linear axis, 2 rotary axes (in parallel)) •...
Page 547 TE4: Transformation package handling 13.4 Configuration of a kinematic transformation Wrist axes included in every transformation MD62604 The fourth axis and all further axes are generally referred to as "wrist axes". The handling transformation package can only identify hands with rotary axes. The wrist axis identifier for three-axis hands is entered in machine data: MD62604 $MC_TRAFO6_WRIST_AXES (wrist axis identifier) In the case of hands with fewer than three axes, the identifier for a beveled hand with elbow...
Page 548 TE4: Transformation package handling 13.4 Configuration of a kinematic transformation Central hand (CH) On a central hand, all wrist axes intersect at one point. All parameters must be set as shown in Table "Configuring data for a central hand". Figure 13-6 Central hand Table 13-1 Configuring data for a central hand...
Page 549 TE4: Transformation package handling 13.4 Configuration of a kinematic transformation Table 13-2 Configuring data for a beveled hand with elbow (5-axis Machine data Value MD62604 $MC_TRAFO6_WRIST_AXES MD62614 $MC_TRAFO6_DHPAR4_5A [a4, 0.0] MD62615 $MC_TRAFO6_DHPAR4_5D [0.0, d5] MD62616 $MC_TRAFO6_DHPAR4_5ALPHA [α4, 0.0] Figure 13-8 Link frames T_IRO_RO Frame T_IRO_RO provides the link between the base center point coordinate system (RO)
Page 550 TE4: Transformation package handling 13.4 Configuration of a kinematic transformation • In the case of type CC, CS or SC basic axes, no further restrictions apply provided that the 4th axis is parallel to the last rotary basic axis. • With respect to all other basic axes, and basic axes of type CC, CS or SC if the 4th axis is perpendicular to the last rotary basic axis, the Z axis of RO must be parallel to the Z axis of IRO.
Page 551 TE4: Transformation package handling 13.4 Configuration of a kinematic transformation Changing the axis sequence MD62620 Note With certain types of kinematics, it is possible to transpose axes without changing the behavior of the kinematic transformation. Machine data: MD62620 $MC_TRAFO6_AXIS_SEQ (rearrangement of axes) The axes on the machine are numbered consecutively from 1 to 5 and must be entered in the internal sequence in machine data: MD62620 $MC_TRAFO6_AXIS_SEQ[0] ...[4]...
Page 552 TE4: Transformation package handling 13.4 Configuration of a kinematic transformation Example 2 This example involves a SCARA kinematic transformation as illustrated in Fig. "Rearrangement of axes (example 2)", in which the axes can be freely transposed. Kinematic 1 is directly included in the handling transformation package. It corresponds to a CC kinematic.
Page 553 TE4: Transformation package handling 13.4 Configuration of a kinematic transformation Example The example (Fig. "Matching mathematical and mechanical zero points") shows an articulated arm kinematic. The mathematical zero point for axis 2 is 90º. This value must be set for axis 2 in machine data: MD62617 $MC_TRAFO6_MAMES[1] (offset between mathematical and mechanical zero points) Axis 3 is counted relative to axis 2 and therefore has a value of -90º...
Page 554 TE4: Transformation package handling 13.4 Configuration of a kinematic transformation MD62629 The velocities for individual translational motion directions for axis traversal with G00 can be preset in machine data: MD62629 $MC_TRAFO6_VELCP[i] (Cartesian velocity [no.]: 0...2) Index i = 0 : X component of basic system Index i = 1 : Y component of basic system Index i = 2 : Z component of basic system MD62630...
Page 555: Descriptions Of Kinematics
TE4: Transformation package handling 13.5 Descriptions of kinematics 13.5 Descriptions of kinematics The following descriptions of kinematics for transformations involving 2 to 5 axes explain the general configuring procedure first before describing how the machine data need to be configured, using a configuring example for each kinematic type. These examples do not include all possible lengths and offsets.
Page 556 TE4: Transformation package handling 13.5 Descriptions of kinematics 10.Define frame T_IRO_RO and enter the offset in machine data: MD62612 $MC_TRAFO6_TIRORO_POS (frame between base center point and internal system (position component)) Enter the rotation in machine data: MD62613 $MC_TRAFO6_TIRORO_RPY (frame between base center point and internal system (rotation component)) 11.Determine the flange coordinate system.
Page 557 TE4: Transformation package handling 13.5 Descriptions of kinematics 3-axis CC kinematics Figure 13-12 3-axis CC kinematics Table 13-4 Configuration data for 3-axis CC kinematics Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62601 $MC_TRAFO6_AXES_TYPE [3, 1, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [2, 1, 3, 4, 5, 6] MD62618 $MC_TRAFO6_AXES_DIR...
Page 558 TE4: Transformation package handling 13.5 Descriptions of kinematics 3-axis SC kinematics Figure 13-13 3-axis SC kinematics Table 13-5 Configuration data for 3-axis SC kinematics Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62601 $MC_TRAFO6_AXES_TYPE [1, 1, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6] MD62618 $MC_TRAFO6_AXES_DIR...
Page 559 TE4: Transformation package handling 13.5 Descriptions of kinematics 3-axis CS kinematic Figure 13-14 3-axis CS kinematic Table 13-6 Configuration data for 3-axis CS kinematics Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62601 $MC_TRAFO6_AXES_TYPE [3, 1, 1, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6] MD62618 $MC_TRAFO6_AXES_DIR...
Page 560 TE4: Transformation package handling 13.5 Descriptions of kinematics Articulated-arm kinematics 3-axis NR kinematics Figure 13-15 3-axis NR kinematics Table 13-7 Configuration data 3-axis NR kinematic Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62601 $MC_TRAFO6_AXES_TYPE [3, 3, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6] MD62618 $MC_TRAFO6_AXES_DIR...
Page 561 TE4: Transformation package handling 13.5 Descriptions of kinematics 3-axis RR kinematics Figure 13-16 3-axis RR kinematics Table 13-8 Configuration data for 3-axis RR kinematics Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62601 $MC_TRAFO6_AXES_TYPE [3, 1, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6] MD62618 $MC_TRAFO6_AXES_DIR...
Page 562 TE4: Transformation package handling 13.5 Descriptions of kinematics 3-axis NN kinematics Figure 13-17 3-axis NN kinematics Table 13-9 Configuration data for 3-axis NN kinematics Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62601 $MC_TRAFO6_AXES_TYPE [3, 3, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6] MD62618 $MC_TRAFO6_AXES_DIR...
Page 563: 4-Axis Kinematics
TE4: Transformation package handling 13.5 Descriptions of kinematics 13.5.2 4-axis kinematics 4-axis kinematics usually imply 3 translational degrees of freedom and one degree of freedom for orientation. Restrictions The following restrictions apply to 4-axis kinematics: The frame T_FL_WP is subject to the following condition: •...
Page 564 TE4: Transformation package handling 13.5 Descriptions of kinematics 9. Enter the mechanical zero offset in the machine data: MD62617 $MC_TRAFO6_MAMES (offset between mathematical and mechanical zero points) 10.Enter the basic axis lengths in the machine data: MD62607 $MC_TRAFO6_MAIN_LENGTH_AB (basic axis lengths A and B) 11.Define frame T_IRO_RO and enter the offset in the machine data: MD62612 $MC_TRAFO6_TIRORO_POS (frame between base center point and internal system (position component))
Page 565 TE4: Transformation package handling 13.5 Descriptions of kinematics SCARA kinematics 4-axis CC kinematics Figure 13-18 4-axis CC kinematics Table 13-10 Configuration data for 4-axis CC kinematics Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62606 $MC_TRAFO6_A4PAR MD62601 $MC_TRAFO6_AXES_TYPE [3, 1, 3, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [2, 1, 3, 4, 5, 6]...
Page 566 TE4: Transformation package handling 13.5 Descriptions of kinematics 4-axis SC kinematics Figure 13-19 4-axis SC kinematics Table 13-11 Configuration data for 4-axis SC kinematics Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62606 $MC_TRAFO6_A4PAR MD62601 $MC_TRAFO6_AXES_TYPE [1, 1, 3, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6] MD62618 $MC_TRAFO6_AXES_DIR...
Page 567 TE4: Transformation package handling 13.5 Descriptions of kinematics 4-axis CS kinematic Figure 13-20 4-axis CS kinematic Table 13-12 Configuration data for 4-axis CS kinematics Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62606 $MC_TRAFO6_A4PAR MD62601 $MC_TRAFO6_AXES_TYPE [3, 1, 1, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6] MD62618 $MC_TRAFO6_AXES_DIR...
Page 568 TE4: Transformation package handling 13.5 Descriptions of kinematics Articulated-arm kinematics 4-axis NR kinematics Figure 13-21 4-axis NR kinematics Table 13-13 Configuration data 4-axis NR kinematic Machine data Value MD62600 $MC_TRAFO6_ KINCLASS MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62606 $MC_TRAFO6_A4PAR MD62601 $MC_TRAFO6_AXES_TYPE [3, 3, 3, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6]...
Page 569: 5-Axis Kinematics
TE4: Transformation package handling 13.5 Descriptions of kinematics 13.5.3 5-axis kinematics 5-axis kinematics usually imply 3 degrees of freedom for translation and 2 for orientation. Restrictions The following restrictions apply to 5-axis kinematics: 1. There are restrictions for the flange coordinate system because the X flange axis must intersect the 5th axis, nevertheless, it must not be parallel to it.
Page 570 TE4: Transformation package handling 13.5 Descriptions of kinematics 5. ID specification for the wrist axes. If axis 4 and 5 intersect, a central hand (ZEH) is present. In all other cases, the ID for beveled hand with elbow (BHE) must be entered in the machine data: MD62604 $MC_TRAFO6_WRIST_AXES (wrist axis identifier) 6.
Page 571 TE4: Transformation package handling 13.5 Descriptions of kinematics SCARA kinematics 5-axis CC kinematics Figure 13-22 5-axis CC kinematics Table 13-14 Configuration data for 5-axis CC kinematics Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62606 $MC_TRAFO6_A4PAR MD62601 $MC_TRAFO6 _AXES_TYPE [3, 1, 3, 3, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [2, 1, 3, 4, 5, 6]...
Page 572 TE4: Transformation package handling 13.5 Descriptions of kinematics 5-axis NR kinematics Figure 13-23 5-axis NR kinematics Table 13-15 Configuration data 5-axis NR kinematic Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62606 $MC_TRAFO6_A4PAR MD62601 $MC_TRAFO6_AXES_TYPE [3, 3, 3, 3, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6] MD62618 $MC_TRAFO6_AXES_DIR...
Page 573: 6-Axis Kinematics
TE4: Transformation package handling 13.5 Descriptions of kinematics 13.5.4 6-axis kinematics 6-axis kinematics usually imply 3 degrees of freedom for translation and 3 more for orientation. This allows for the tool direction to be manipulated freely in space. Also, the tool can be rotated along its own axis to the machining surface or inclined with a tilting angle.
Page 574 TE4: Transformation package handling 13.5 Descriptions of kinematics Table 13-16 Configuring data for a special 2-axis SC kinematic Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62602 $MC_TRAFO6_SPECIAL_KIN MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62601 $MC_TRAFO6_AXES_TYPE [1, 3, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6] MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1] MD62617 $MC_TRAFO6_MAMES...
Page 575 TE4: Transformation package handling 13.5 Descriptions of kinematics Table 13-17 Configuring data for a special 3-axis SC kinematic Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62602 $MC_TRAFO6_SPECIAL_KIN MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62601 $MC_TRAFO6_AXES_TYPE [1, 3, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6] MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1] MD62617 $MC_TRAFO6_MAMES...
Page 576 TE4: Transformation package handling 13.5 Descriptions of kinematics Table 13-18 Configuring data for a special 4-axis SC kinematic Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62602 $MC_TRAFO6_SPECIAL_KIN MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62601 $MC_TRAFO6_AXES_TYPE [3, 3, 1, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6] MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]...
Page 577 TE4: Transformation package handling 13.5 Descriptions of kinematics Table 13-19 Configuration data for special 2-axis NR kinematics Machine data Value MD62600 $MC_TRAFO6_KINCLASS MD62602 $MC_TRAFO6_SPECIAL_KIN MD62605 $MC_TRAFO6_NUM_AXES MD62603 $MC_TRAFO6_MAIN_AXES MD62604 $MC_TRAFO6_WRIST_AXES MD62601 $MC_TRAFO6_AXES_TYPE [3, 3, ...] MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6] MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1] MD62617 $MC_TRAFO6_MAMES...
Page 578: Tool Orientation
TE4: Transformation package handling 13.6 Tool orientation 13.6 Tool orientation 13.6.1 Tool orientation Figure 13-1 Workpieces with 5-axis transformation Programming Three possible methods can be used to program the orientation of the tool: • Directly as "orientation axes" A, B and C in degrees •...
Page 579 TE4: Transformation package handling 13.6 Tool orientation Euler angle via machine data: MD10620 $MN_EULER_ANGLE_NAME_TAB (name of Euler angle) Direction vectors via machine data: MD10640 $MN_DIR_VECTOR_NAME_TAB (name of normal vectors) The tool orientation can be located in any block. Above all, it can be programmed alone in a block, resulting in a change of orientation in relation to the tool tip which is fixed in its relationship to the workpiece.
Page 580 TE4: Transformation package handling 13.6 Tool orientation GCODE_RESET_VALUES [24] = 1 → ORIWKS is initial setting GCODE_RESET_VALUES [24] = 2 → ORIMKS is initial setting GCODE_RESET_VALUES [24] = 3 → ORIPATH When ORIPATH is active, the orientation is calculated from the lead and side angles relative to the path tangent and surface normal vector.
Page 581: Orientation Programming For 4-Axis Kinematics
TE4: Transformation package handling 13.6 Tool orientation 13.6.2 Orientation programming for 4-axis kinematics Tool orientation for 4-axis kinematic 4-axis kinematics possess only one degree of freedom for orientation. When the orientation is programmed using RPY angles, Euler angles or direction vectors, it is not generally possible to guarantee that the specified orientation can be approached.
Page 582 TE4: Transformation package handling 13.6 Tool orientation Figure 13-29 Orientation angle for 5-axis kinematic It is possible to define orientation axes for the handling transformation package. Note Additional information can be found in: /FB3/ Function Manual, Special Functions, "Orientation Axes" /PGA/ Programming Guide Advanced, "Orientation Axes".
Page 583: Singular Positions And How They Are Handled
TE4: Transformation package handling 13.7 Singular positions and how they are handled 13.7 Singular positions and how they are handled The calculation of the machine axes to a preset position, i.e. position with orientation, is not always clear. Depending on the machine kinematic, there may be positions with an infinite number of solutions.
Page 584: Call And Application Of The Transformation
TE4: Transformation package handling 13.8 Call and application of the transformation 13.8 Call and application of the transformation Powering-up The transformation is activated by means of the TRAORI(1) command. Once the TRAORI(1) command has been executed and the transformation thus activated, the interface signal switches to "1": DB21, …...
Page 585 TE4: Transformation package handling 13.8 Call and application of the transformation Bit 7: Reset behavior of "active kinematic transformation" Bit 7 = 0 For this reason, the initial setting is defined for active transformation after the end of part program or RESET, according to the following machine data: MD20140 $MC_TRAFO_RESET_VALUE (transformation data block run-up (reset/part program end)) Meaning:...
Page 586: Actual Value Display
TE4: Transformation package handling 13.9 Actual value display 13.9 Actual value display MCS machine coordinate system The machine axes are displayed in mm/inch and/or degrees in MCS display mode. WCS workpiece coordinate system If the transformation is active, the tool tip (TCP) is specified in mm/inch and the orientation by the RPY angles A, B and C in WCS display mode.
Page 587: Tool Programming
TE4: Transformation package handling 13.10 Tool programming 13.10 Tool programming Meaning The tool lengths are specified in relation to the flange coordinate system. Only 3-dimensional tool compensations are possible. Depending on the kinematic type, there are additional tool restrictions for 5-axis and 4-axis kinematics. For a kinematic as illustrated in Fig. "5-axis NR kinematic", only a 1-dimensional tool with lengths in the x direction is permitted.
Page 588: Cartesian Ptp Travel With Handling Transformation Package
TE4: Transformation package handling 13.11 Cartesian PTP travel with handling transformation package 13.11 Cartesian PTP travel with handling transformation package It is possible to use the "Cartesian PTP travel" function with the handling transformation package. For this purpose the following machine data must be set to 4100: MD24100 $MC_TRAFO_TYPE_1 (definition of transformation 1 in the channel) = 4100 References For additional information on the function "Cartesian PTP travel"...
Page 589: Function-Specific Alarm Texts
TE4: Transformation package handling 13.12 Function-specific alarm texts 13.12 Function-specific alarm texts The procedure to be following while creating function-specific alarm texts is described in: References: /FB3/ Function Manual, Special Functions; Installation and Activation of Readable Compile Cycles (TE01), Section: "Creating alarm texts [Page 444]" Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 590: Boundary Conditions
TE4: Transformation package handling 13.13 Boundary conditions 13.13 Boundary conditions 13.13.1 Function-specific boundary conditions NCU 572.2 The handling transformation package can be utilized on NCU 572.2 hardware only on condition that is has been specifically enabled for the customer. Clearance control The handling transformation package cannot be operated together with the technology function: "clearance control", as generally the three basic axes are not arranged perpendicular to one another.
Page 591: Interaction With Other Functions
TE4: Transformation package handling 13.13 Boundary conditions Singularities A pole cannot be crossed when a transformation is active. Singular positions can cause axis overloads. The feedrate is not automatically adjusted. The user must reduce the feedrate appropriately at the relevant points. 13.13.2 Interaction with other functions Block search...
Page 592: Examples
TE4: Transformation package handling 13.14 Examples 13.14 Examples 13.14.1 General information about start-up Note The compile cycles are supplied as loadable modules. The general start up of such compile cycles is described in TE01. The specific installation measures for this compile cycle can be found from Section "Starting up a kinematic transformation"...
Page 593: Starting Up A Kinematic Transformation
TE4: Transformation package handling 13.14 Examples Inserting the PC card 1. Deactivate the control. 2. Insert the PC card with the new firmware (technology card) in the PCMCIA slot of the NCU. 3. Turn switch S3 on the front panel of the NCU to 1. 4.
Page 594 TE4: Transformation package handling 13.14 Examples Configure the transformation 1. Enter transformation type 4099 or 4100 (if PTP travel is active) in the machine data: MD24100 $MC_TRAFO_TYPE_1 (definition of channel transformation 1) 2. Enter the assignment of the channel axes involved in the transformation in the machine data: MD24110 $MC_TRAFO_AXES_IN_1[0 to 5] (axis assignment for transformation) Axis numbers beginning with 1.
Page 595 TE4: Transformation package handling 13.14 Examples 10.Enter the data which define the hand: Wrist axis identifier in the machine data: MD62604 $MC_TRAFO6_WRIST_AXES (wrist axis identifier) Parameters for hand in the machine data: MD62614 $MC_TRAFO6_DHPAR4_5A (parameter A for configuring the hand) MD62615 $MC_TRAFO6_DHPAR4_5D (parameter D for configuring the hand) MD62616 $MC_TRAFO6_DHPAR4_5ALPHA (parameter ALPHA for configuring the hand)
Page 596: Data Lists
TE4: Transformation package handling 13.15 Data lists 13.15 Data lists 13.15.1 Machine data 13.15.1.1 General machine data Number Identifier: $MN_ Description 10620 EULER_ANGLE_NAME_TAB[n] Name of Euler angle 19410 TRAFO_TYPE_MASK, bit 4 Option data for OEM transformation 13.15.1.2 Channelspecific machine data Number Identifier: $MC_ Description...
Page 597: Signals
TE4: Transformation package handling 13.15 Data lists Number Identifier: $MC_ Description 62616 TRAFO6_DHPAR4_5ALPHA Parameter ALPHA for configuring the hand 62617 TRAFO6_MAMES Offset between mathematical and mechanical zero points 62618 TRAFO6_AXES_DIR Matching of physical and mathematical directions of rotation 62619 TRAFO6_DIS_WRP Mean distance between wrist point and singularity 62620 TRAFO6_AXIS_SEQ...
Page 598 TE4: Transformation package handling 13.15 Data lists Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 599: Te6: Mcs Coupling
TE6: MCS coupling 14.1 Brief description If a machine tool has 2 or more mutually independent traversing machining heads (in this case K1 (Y/ Z/ C/ A/ W or K2 (Y2/ Z2/ C2/ A2/ W2)), and if a transformation needs to be activated for the machining operation, the orientation axes cannot be coupled by means of the standard coupling functions (COPON, TRAILON).
Page 600 TE6: MCS coupling 14.1 Brief description CC_Master, CC_Slave There are CC_Master and CC_Slave axes. A CC_Master axis can have several CC_Slave axes, but a CC_Slave axis cannot be a CC_Master axis (error message). The coupling between these pairs is activated and deactivated by means of an OEM-specific language command and can thus be active in all operating modes.
Page 601: Description Of Mcs Coupling Functions
TE6: MCS coupling 14.2 Description of MCS coupling functions 14.2 Description of MCS coupling functions 14.2.1 Defining coupling pairs A CC_Slave axis is matched to its CC_Master axis via the following axial machine data: MD63540 $MA_CC_MASTER_AXIS (specifies the CC_Master axis assigned to a CC_Slave axis) The coupling's axes can only be changed when the coupling is not active.
Page 602: Tolerance Window
TE6: MCS coupling 14.2 Description of MCS coupling functions A coupling can be disabled via the CC_Slave axis in axial VDI-Out byte: DB31, … DBX24.2 (disable CC_Slave axis coupling) This does not generate an alarm. CC_COPOFF() CC_COPOFF([A1][A2][A3][A4][A5]) As CC_COPON or CC_COPONM() except for the fact that no alarm is generated if A1 to A5 is used to program an axis that is not involved in a coupling.
Page 603: Description Of Collision Protection
TE6: MCS coupling 14.3 Description of collision protection 14.3 Description of collision protection 14.3.1 Defining protection pairs A ProtecSlave axis (PSlave) is matched to its ProtecMaster (PMaster) axis via the following axial machine data: MD63542 $MA_CC_PROTECT_MASTER (specifies the PMaster axis assigned to a PSlave axis) The protection pairs can thus be defined independently of the coupling pairs.
Page 604: Configuring Example
TE6: MCS coupling 14.3 Description of collision protection WARNING If the axes are forced to brake, the positions displayed in the workpiece coordinate system are incorrect! These are not re-synchronized again until a system RESET. If the axes are already violating the minimum clearance when collision protection is activated, they can only be traversed in one direction (retraction direction).
Page 605: User-Specific Configurations
TE6: MCS coupling 14.4 User-specific configurations 14.4 User-specific configurations Parking the machining head In this context, "parking" means that the relevant machining head is not involved in workpiece machining. All axes are operating under position control and positioned at exact stop. Even if a machining head is being used in production, coupling should be active! This is essential primarily if only the second head (Y2..) is being used.
Page 606: Special Operating States
TE6: MCS coupling 14.5 Special operating states 14.5 Special operating states Reset The couplings can remain active after a RESET. Reorg No non-standard functionalities. Block search During a block search, the last block containing an OEM-specific language command is always stored and then output with the last action block. This feature is illustrated in the following examples.
Page 607 TE6: MCS coupling 14.5 Special operating states After block search to TARGET: no coupling is active! Single block There are no nonstandard functionalities. Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 608: Boundary Conditions
TE6: MCS coupling 14.6 Boundary conditions 14.6 Boundary conditions Validity The function is configured only for the first channel. Braking behavior Braking behavior at the SW limit with path axes The programmable acceleration factor ACC for braking at the SW limit corresponds to the path axes.
Page 609: Data Lists
TE6: MCS coupling 14.7 Data lists 14.7 Data lists 14.7.1 Machine data 14.7.1.1 Channelspecific machine data Number Identifier: $MC_ Description 28090 NUM_CC_BLOCK_ELEMENTS Number of block elements for compile cycles. 28100 NUM_CC_BLOCK_USER_MEM Total size of usable block memory for compile cycles 14.7.1.2 Axis/spindlespecific machine data Number...
Page 610 TE6: MCS coupling 14.7 Data lists Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 611: Te7: Continue Machining - Retrace Support
TE7: Continue machining - retrace support 15.1 Brief description Function The "Continue machining - Retrace support (RESU)" technological function supports the retracing of uncompleted 2-dimensional machining processes such as laser cutting, water jet cutting, etc. In the event of a fault during the machining process, e.g. loss of the laser, RESU can be used even by machine operators who do not have specific knowledge of the active part program to interrupt machining and travel back along the contour from the interruption point to a program continuation point necessary for machining purposes.
Page 612 TE7: Continue machining - retrace support 15.1 Brief description Function code The code for the "Continue Machining - Retrace support" technological function for function- specific identifiers of program commands, machine data, etc. is: RESU (= REtrace SUpport) Restrictions The use of the "Continue Machining Retrace support" technological function is subject to the following restrictions: •...
Page 613: Functional Description
TE7: Continue machining - retrace support 15.2 Functional description 15.2 Functional description 15.2.1 Function Block search with calculation on contour To be able to resume interrupted machining at a specific point in a part program, a block search can be carried out using the "Block search with calculation on contour" standard function.
Page 614: Definition Of Terms
TE7: Continue machining - retrace support 15.2 Functional description Contour ranges which are not logged are bridged by straight lines between the starting and end points during reverse/forward travel. Figure 15-2 Retraceable contour range 15.2.2 Definition of terms Interruption point The interruption point is the point of the contour at which the traversing movement comes to a standstill following an NC stop and reverse travel is activated.
Page 615 TE7: Continue machining - retrace support 15.2 Functional description Preconditions A part program with traversing blocks in the configured RESU working plane (e.g. 1st and 2nd geometry axis of the channel) as well as the part program command for the RESU start has been started in the 1st channel.
Page 616 TE7: Continue machining - retrace support 15.2 Functional description 8. Retrace support: Continue machining is initiated via PLC interface signal: DB21, … DBX0.2 = 1 (start retrace support) For retrace support, RESU automatically selects the original machining program and launches a block search with calculation as far as the program continuation point. 9.
Page 617 TE7: Continue machining - retrace support 15.2 Functional description Signal chart for interface signals The principle sequence of the RESU function is illustrated in the following figure as a signal chart of the interface signals involved: ① Reverse travel is started. ②...
Page 618: Maximum Retraceable Contour Area
TE7: Continue machining - retrace support 15.2 Functional description 15.2.4 Maximum retraceable contour area In multiple machining continuation within a contour area, the reverse travel on the contour is always possible only up to the last machining continuation point (W). In first-time reverse travel after RESU start, reverse travel up to the start of the contour range is possible.
Page 619: Startup
TE7: Continue machining - retrace support 15.3 Startup 15.3 Startup 15.3.1 Activation Before starting up the technological function, make sure that the corresponding compile cycle has been loaded and activated. See also "TE01: Installation and activation of loadable compile cycles [Page 433]". Activation The "Continue machining - Retrace support"...
Page 620 TE7: Continue machining - retrace support 15.3 Startup For RESU, the already existing machine data value (x) is adjusted as follows: MD28090 $MC_MM_NUM_CC_BLOCK_ELEMENTS = x + 4 Size of the block memory The size of the block memory in KB that can be used by the user for compile cycles is defined via the memory configuring channel-specific machine data: MD28100 $MC_MM_NUM_CC_BLOCK_USER_MEM For RESU, the already existing machine data value (x) is adjusted as follows:...
Page 621: Memory Configuration: Heap Memory
TE7: Continue machining - retrace support 15.3 Startup 15.3.4 Memory configuration: Heap memory Memory requirements RESU requires compile cycles heap memory for the following function-specific buffers: • Block buffer The larger the block buffer (see Fig. "RESU program structure") the more part program blocks can be traversed in reverse.
Page 622: Resu Main Program Memory Area
TE7: Continue machining - retrace support 15.3 Startup For RESU, the already existing machine data value (x) is adjusted as follows: MD28105 $MC_MM_NUM_CC_HEAP_MEM = x + 50 Size of the block buffer The size of the block buffer is adjusted via the machine data: MD62571 $MC_RESU_RING_BUFFER_SIZE Default setting: MD62571 $MC_RESU_RING_BUFFER_SIZE = 1000...
Page 623: Storage Of The Resu Subroutines
TE7: Continue machining - retrace support 15.3 Startup Storage in the dynamic NC memory (default) If the RESU main program is created in the dynamic NC memory, the memory area available to the user for file storage must be increased as follows: MD18351 $MN_MM_DRAM_FILE_MEM_SIZE = x + 100 already available machine data value...
Page 624: Asub Enable
TE7: Continue machining - retrace support 15.3 Startup 15.3.7 ASUB enable Note A requirement for using ASUBs is that the "Cross-mode actions" option must be available. The following machine data must be set for the start enable for the RESU-specific ASUB CC_RESU_ASUP.SPF while the channel is in the NC STOP state: MD11602 $MN_ASUP_START_MASK, bit 0 = 1 (ignore stop reason for ASUB) MD11604 $MN_ASUP_START_PRIO_LEVEL = 1 (priorities from which MD11602 is...
Page 625 TE7: Continue machining - retrace support 15.3 Startup Program example The following program extract implements the changes described above: DB21, … DBX32.2 // IF "Retrace support active" == 1 DB21, … DBX0.1 // THEN "Forward/Reverse" = 0 DB21, … DBX0.2 "Start retrace support"...
Page 626: Programming
TE7: Continue machining - retrace support 15.4 Programming 15.4 Programming 15.4.1 RESU Start/Stop/Reset (CC_PREPRE) Start / stop / reset / of RESU is done with the program instruction: CC_PREPRE (Prepare Retrace) Programming Syntax: CC_PREPRE(<mode>) Parameters: Mode: Type: INTEGER Range of values: -1, 0, 1 CC_PREPRE(...) is a procedure call and must therefore be programmed in a dedicated part program block.
Page 627 TE7: Continue machining - retrace support 15.4 Programming RESET response In reset events: • NCK POWER ON RESET (warm start) • NCK Reset • End of program (M30) CC_PREPRE(-1) is executed implicitly. Error messages The following programming errors are detected and displayed with alarms: •...
Page 628: Resu-Specific Part Programs
TE7: Continue machining - retrace support 15.5 RESU-specific part programs 15.5 RESU-specific part programs 15.5.1 Overview RESU uses the following, automatically generated and partially adjustable part programs: Program Name Main program CC_RESU.MPF INI program CC_RESU_INI.SPF END program CC_RESU_END.SPF Continue machining ASUB CC_RESU_BS_ASUP.SPF RESU ASUB CC_RESU_ASUP.SPF...
Page 629: Main Program (Cc_Resu.mpf)
TE7: Continue machining - retrace support 15.5 RESU-specific part programs 15.5.2 Main program (CC_RESU.MPF) Function In addition to the calls for the RESU-specific subroutines, the RESU main program "CC_RESU.MPF" contains the traversing blocks generated from the traversing blocks logged in the block buffer for reverse/forward travel along the contour. The program is always regenerated by the RESU function if, once the part program has been interrupted, the status of the following interface signal changes: DB21, …...
Page 630: Ini Program (Cc_Resu_Ini.spf)
TE7: Continue machining - retrace support 15.5 RESU-specific part programs 15.5.3 INI program (CC_RESU_INI.SPF) Function The RESU-specific subroutine "CC_RESU_INI.SPF" contains the defaults required for the reverse travel: • Metric input system: • Absolute dimensions: • To switch off the adjustable zero-point offsets / G500 frames (refer to Frames [Page 643] ): •...
Page 631 TE7: Continue machining - retrace support 15.5 RESU-specific part programs Program structure CC_RESU_INI.SPF has the following content by default: PROC CC_RESU_INI G71 G90 G500 T0 G40 F200 ;system frames that are present are deactivated ;actual value and scratching if $MC_MM_SYSTEM_FRAME_MASK B_AND 'H01' $P_SETFRAME = ctrans() endif ;external zero point offset...
Page 632: End Program (Cc_Resu_End.spf)
TE7: Continue machining - retrace support 15.5 RESU-specific part programs 15.5.4 END program (CC_RESU_END.SPF) Function The task of the RESU-specific subroutine "CC_RESU_END.SPF" is to stop reverse travel once the end of the retraceable contour is reached. If the RESU function is parameterized appropriately, this scenario will not arise under normal circumstances.
Page 633: Resu Asub (Cc_Resu_Asup.spf)
ASUB is initiated if the following RESU interface signal is switched over in the ? NC Stop state: DB21, … DBX0.1 (Forward/Reverse) Program structure CC_RESU_ASUP.SPF has the following content: PROC CC_RESU_ASUP ; siemens system asub - do not change G4 F0.001 REPOSA Note CC_RESU_ASUP.SPF must not be changed. Special Functions...
Page 634: Retrace Support
TE7: Continue machining - retrace support 15.6 Retrace support 15.6 Retrace support 15.6.1 General Retrace support refers to the entire operation from initiation of retracing through the interface signal DB21, … DBX0.2 = 1 (start machining continuation) up to to the continuation of the part program processing of the programmed contour.
Page 635: Reposition
TE7: Continue machining - retrace support 15.6 Retrace support • Synchronized actions • M functions References The complete description of the Block search is available in: /FB1/ Basic Functions Function Manual; Mode Group, Channel, Program Mode (K1), Program test 15.6.3 Reposition Function Following the end of the last action block (last traversing block before repositioning), NC...
Page 636: Temporal Conditions Concerning Nc Start
TE7: Continue machining - retrace support 15.6 Retrace support Channel axes All other channel axes programmed in the part program travel to the relevant position calculated in the block search. 15.6.4 Temporal conditions concerning NC start NC start should be initiated twice by the machine operator within the framework of continue machining (refer to Functional sequence (principle) [Page 614]).
Page 637 TE7: Continue machining - retrace support 15.6 Retrace support Main block All instructions required for processing the subsequent section of the part program must be programmed in one main block. The main blocks are to be designated with a Main Block No. consisting of the sign ":" and a positive whole number (block number).
Page 638: Function-Specific Display Data
TE7: Continue machining - retrace support 15.7 Function-specific display data 15.7 Function-specific display data 15.7.1 Channel-specific GUD variables As display data for the size of the block search buffer, RESU provides the following channel- specific GUD variables: GUD variable Meaning Value Access CLC_RESU_LENGTH_BS_BUFFER...
Page 639: Function-Specific Alarm Texts
TE7: Continue machining - retrace support 15.8 Function-specific alarm texts 15.8 Function-specific alarm texts The procedure to be following while creating function-specific alarm texts is described in: References: /FB3/ Function Manual, Special Functions; Installation and Activation of Readable Compile Cycles (TE01), Section: "Creating alarm texts [Page 444]" Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 640: Boundary Conditions
TE7: Continue machining - retrace support 15.9 Boundary conditions 15.9 Boundary conditions 15.9.1 Function-specific boundary conditions 15.9.1.1 Continue machining within subroutines Subroutine call outside or inside a program loop Clear retrace support within subroutines depends on whether the subroutine call is made outside or inside a program loop: •...
Page 641: Machining Continuation On Full Circles
TE7: Continue machining - retrace support 15.9 Boundary conditions 15.9.1.3 Machining continuation on full circles In full circles, the block starting and end points coincide at one contour point. As no clear differentiation is possible in this case, one always starts from the block start point during machining continuation on this kind of a contour point.
Page 642: Traversing Movements Of The Channel Axes
TE7: Continue machining - retrace support 15.9 Boundary conditions 15.9.2.2 Traversing movements of the channel axes Other channel axes, except the two geometry axes of the RESU working plane, are not considered by RESU. If traversing movements in other channel axes are required for machining continuation or reverse travel, these can either be undertaken by the machined operator manually, or programmed as travel block in the RESU-specific subroutine "CC_RESU_INI.SPF".
Page 643: Compensation
TE7: Continue machining - retrace support 15.9 Boundary conditions Transformation changeover While RESU is active, no transformation changes are permitted to take place and transformation must not be activated/deactivated. The RESU activity: • Starts: with the part program command CC_PREPRE(1) •...
Page 644: Tool Offsets
TE7: Continue machining - retrace support 15.9 Boundary conditions 15.9.2.8 Tool offsets RESU can be used in conjunction with tool offsets. However, as the traversing movements of the two geometry axes of the RESU working plane are recorded in the basic coordinate system (BCS) and therefore after the tool offsets have been taken into account, the tool offsets must be deactivated during retrace support (reverse / forward travel).
Page 645: Data Lists
TE7: Continue machining - retrace support 15.10 Data lists 15.10 Data lists 15.10.1 Machine data 15.10.1.1 General machine data Number Identifier: $MN_ Meaning 11602 ASUP_START_MASK Ignore stop reasons if an ASUB is running. 11604 ASUP_START_PRIO_LEVEL Defines the ASUB priority from which MD11602 is effective.
Page 646 TE7: Continue machining - retrace support 15.10 Data lists Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 647: Te8: Cycle-Independent Path-Synchronous Switching Signal Output
TE8: Cycle-independent path-synchronous switching signal output 16.1 Brief description Function The "Cycle-independent path synchronized switching signal output" technological function serves the purpose of switching time-critical, position-based machining processes on and off quickly, e.g. high speed laser cutting (HSLC; High Speed Laser Cutting). The switching signal output can be block-related or path length-related: •...
Page 648 TE8: Cycle-independent path-synchronous switching signal output 16.1 Brief description References The "cycle-independent path-synchronous switching signal output" technological function is a compile cycle. For the handling of compile cycles, see "TE01: Installation and activation of loadable compile cycles [Page 433]". Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 649: Functional Description
TE8: Cycle-independent path-synchronous switching signal output 16.2 Functional description 16.2 Functional description 16.2.1 General Note The functionality is described with examples, with the help of the "High speed laser cutting technology (HSLC, High Speed Laser Cutting). 16.2.2 Calculating the switching positions 16.2.2.1 Block-related switching signal output Switching criteria...
Page 650 TE8: Cycle-independent path-synchronous switching signal output 16.2 Functional description Example: The following block positions function as switching positions: • Position X30 for G0-edge change from N10 to N20 • Position X100 for G0-edge change from N30 to N40 Freely programmable velocity threshold value as switching criterion A freely programmable velocity threshold value is used to define the setpoint velocity programmed in the part program block at and above which the switching signal is activated/ deactivated.
Page 651: Path Length-Related Switching Signal Output
TE8: Cycle-independent path-synchronous switching signal output 16.2 Functional description • Position X30 for edge change from N10 to N20 • Position X70 for edge change from N20 to N30 Note G0 always deactivates the switching signal, regardless of the threshold value. 16.2.2.2 Path length-related switching signal output Programmable paths as the switching criterion...
Page 652: Calculating The Switching Instants
TE8: Cycle-independent path-synchronous switching signal output 16.2 Functional description 16.2.3 Calculating the switching instants In order for the switching to be as precise as possible at the switching positions calculated, the control calculates the positional difference between the actual position of the geometry axes involved and the switching difference in every position controller cycle.
Page 653: 16.2.5 Approaching Switching Position
TE8: Cycle-independent path-synchronous switching signal output 16.2 Functional description Value below minimum switching position distance For path length-related switching signal output, the value may fall below the minimum switching position distance, e.g. due to: • Increase in feed rate • Decrease in programmable switching position distance s and s The following reactions take place if the value falls below the minimum:...
Page 654: Programmed Switching Position Offset
TE8: Cycle-independent path-synchronous switching signal output 16.2 Functional description 16.2.6 Programmed switching position offset Programmed switching position offset For block-related switching signal output, a positional offset of the switching position can be programmed : • Offset distance negative = lead With a negative offset distance, the switching position is offset before the set point position programmed in the part program block.
Page 655: Response To Part Program Interruption
TE8: Cycle-independent path-synchronous switching signal output 16.2 Functional description 16.2.7 Response to part program interruption Following an interruption in the part program (NC-STOP) and subsequent change to JOG mode, the technological function is deactivated or switching signals cease to be output. The technology function is reactivated or switching signals are output again only after switching to the AUTOMATIC mode and continuing the part program (NC-START).
Page 656: Start-Up
TE8: Cycle-independent path-synchronous switching signal output 16.3 Start-up 16.3 Start-up 16.3.1 Activation Before starting up the technological function, make sure that the corresponding compile cycle has been loaded and activated. See also "TE01: Installation and activation of loadable compile cycles [Page 433]". Activation The "Cycle-independent path synchronized switching signal output"...
Page 657: Parameterizing The Digital On-Board Outputs
TE8: Cycle-independent path-synchronous switching signal output 16.3 Start-up 16.3.3 Parameterizing the digital on-board outputs Parameter assignment A digital output from the local I/O is required for the switching signal. For this, at least 1 digital output byte must be defined through the following machine data: MD10360 $MN_FASTIO_DIG_NUM_OUTPUTS ≥...
Page 658: Parameterization Of The Geometry Axes
TE8: Cycle-independent path-synchronous switching signal output 16.3 Start-up 16.3.5 Parameterization of the geometry axes Standard setting Machines for high-speed laser cutting normally have two geometry axes that are configured in the following two machine data: MD20050_$MC_AXCONF_GEOAX_ASSIGN_TAB[0] MD20050_$MC_AXCONF_GEOAX_ASSIGN_TAB[1] The calculation of the switching instants is derived from these two geometry axes. Note The configured axis selection for calculating the switching instants can be changed by redefining the first and second geometry axes in the part program with the help of program...
Page 659: Programming
TE8: Cycle-independent path-synchronous switching signal output 16.4 Programming 16.4 Programming 16.4.1 Activating the block-related switching signal output (CC_FASTON) Syntax CC_FASTON (DIFFON, DIFFOFF [,FEEDTOSWITCH]) CC_FASTON() is a procedure call and must therefore be programmed in a dedicated part program block. Parameter The parameters for the CC_FASTON() procedure have the following meaning: Parameter Meaning...
Page 660: Activating The Path Length-Related Switching Signal Output (Cc_Faston_Cont)
TE8: Cycle-independent path-synchronous switching signal output 16.4 Programming Changing parameters The parameters for the CC_FASTON() procedure can be modified at any time during the execution of the part program. To do this, enter the procedure call again with the new parameter values.
Page 661: Deactivation (Cc_Fastoff)
TE8: Cycle-independent path-synchronous switching signal output 16.4 Programming Reset response A reset (NC RESET or end of program) deactivates the function. 16.4.3 Deactivation (CC_FASTOFF) Syntax CC_FASTOFF CC_FASTOFF is a procedure call and must therefore be programmed in a dedicated part program block.
Page 662: Function-Specific Alarm Texts
TE8: Cycle-independent path-synchronous switching signal output 16.5 Function-specific alarm texts 16.5 Function-specific alarm texts The procedure to be following while creating function-specific alarm texts is described in: References: /FB3/ Function Manual, Special Functions; Installation and Activation of Readable Compile Cycles (TE01), Section: "Creating alarm texts [Page 444]" Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 663: Boundary Conditions
TE8: Cycle-independent path-synchronous switching signal output 16.6 Boundary conditions 16.6 Boundary conditions 16.6.1 Block search Switching signal output for block search If a block search is on a part program block which lies after a CC_FASTON() procedure call for activating the technology function, then the switching signal is activated with the next traversing motion.
Page 664: Transformations
TE8: Cycle-independent path-synchronous switching signal output 16.6 Boundary conditions Figure 16-5 Switching signal after block search Suppressing the switching signal output The user (machine manufacturer) must take appropriate measures, e.g. disable the switching signal, in order to suppress the activation of the switching signal in the REPOS block in the constellation described above.
Page 665: Compensation
TE8: Cycle-independent path-synchronous switching signal output 16.6 Boundary conditions 16.6.3 Compensation The following compensations are considered while calculating the switching positions: • Temperature compensation • Sag compensation A description of the compensations can be found in: References: /FB2/ Function Manual, Extended Functions; Compensations (K3) 16.6.4 Tool radius compensation (TRC) As part of tool radius compensation, control-internal part program blocks (compensation...
Page 666: Software Cams
TE8: Cycle-independent path-synchronous switching signal output 16.6 Boundary conditions 16.6.6 Software cams Because the hardware timer is also used for the "software cam" function, it is not possible to use the "clock-independent switching signal output" function with software cams at the same time.
Page 667: Data Lists
TE8: Cycle-independent path-synchronous switching signal output 16.7 Data lists 16.7 Data lists 16.7.1 Machine data 16.7.1.1 General machine data Number Identifier: $MN_ Description 10360 FASTO_NUM_DIG_OUTPUTS Number of digital output bytes 16.7.1.2 Channelspecific machine data Number Identifier: $MC_ Description 20050 AXCONF_GEOAX_ASSIGN_TAB Assignment of geometry axis to channel axis 28090 MM_NUM_CC_BLOCK_ELEMENTS...
Page 668 TE8: Cycle-independent path-synchronous switching signal output 16.7 Data lists Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 669: Te9: Axis Pair Collision Protection
TE9: Axis pair collision protection 17.1 Brief description 17.1.1 Brief description Function The "axis pair collision protection" technology function enables machine axes which are arranged on the same guide element of a machine to be monitored in pairs to ensure that no collisions occur and that the maximum distance between the two axes is not exceeded.
Page 670: Functional Description
TE9: Axis pair collision protection 17.2 Functional description 17.2 Functional description The "axis pair collision protection" function is a protection function for machine axes which are arranged in a machine tool in such a way (on the same guide rail, for example) that incorrect operation or programming could cause them to collide with one another.
Page 671: Startup
TE9: Axis pair collision protection 17.3 Startup 17.3 Startup 17.3.1 Enabling the technology function (option) The technology function is enabled via the following optional item of data: MD19610 $ON_TECHNO_EXTENSION_MASK[6], BIT4 = 1 17.3.2 Activating the technology function Before starting up the technology function, make sure that the corresponding compile cycle has been loaded and activated.
Page 672: Retraction Direction
TE9: Axis pair collision protection 17.3 Startup NOTICE Same axis types The machine axes in an axis pair must be of the same axis type: • Linear axis • Rotary axis Modulo rotary axes The machine axes in an axis pair must not be of the "modulo rotary axis" axis type. 17.3.4 Retraction direction The direction of travel for retracting the corresponding machine axis is entered in the following...
Page 673: Protection Window
TE9: Axis pair collision protection 17.3 Startup 17.3.6 Protection window The protection window is used to define the minimum distance, which the two machine axes specified in $MN_...PAIRS[n] must not undershoot. Parameters are assigned for the protection window in the following item of machine data: MD61519 $MN_CC_PROTECT_WINDOW[n] = <minimum distance>...
Page 674: Activating The Protection Function
TE9: Axis pair collision protection 17.3 Startup 17.3.9 Activating the protection function The protection function is active if the following conditions are met: • A valid pair of machine axes has been entered in machine data item $MN_...PAIRS[n] • Machine data item $MN_...PAIRS[n] is active •...
Page 675: Limitations And Constraints
TE9: Axis pair collision protection 17.4 Limitations and constraints 17.4 Limitations and constraints 17.4.1 Precedence of function-specific acceleration The protection function only uses the function-specific acceleration of the machine axes MD63514 .$MA_CC_PROTECT_ACCEL to calculate the time at which deceleration should be performed.
Page 676 TE9: Axis pair collision protection 17.4 Limitations and constraints Real machine axes: machine axis identifiers AX1 and AX13 • MD10000 $MN_AXCONF_MACHAX_NAME_TAB[ x ] = "AX1" • MD10000 $MN_AXCONF_MACHAX_NAME_TAB[ y ] = "AX13" Assigning parameters for the protection function prior to the axis container rotation •...
Page 677: Examples
TE9: Axis pair collision protection 17.5 Examples 17.5 Examples 17.5.1 Collision protection The figure shows the arrangement of 3 machine axes and the offset and orientation of the machine coordinate systems (machine). Figure 17-2 Collision protection for 2 axis pairs Parameter assignment: Protection function 1 Axis pair: 1st machine axis A3, 2nd machine axis A1 •...
Page 678: Collision Protection And Distance Limiter
TE9: Axis pair collision protection 17.5 Examples Retraction direction: A12 in positive direction, A1 in positive direction • MD61517 $MN_CC_PROTECT_SAFE_DIR[1] = 01 01 Offset vector from machine coordinate system machine_A12 to machine_A1 with reference to machine_A1 • MD61518 $MN_CC_PROTECT_OFFSET[1] = 32.0 Example protection window, 5.0 mm •...
Page 679 TE9: Axis pair collision protection 17.5 Examples Retraction direction: A1 in negative direction, A3 in positive direction • MD61517 $MN_CC_PROTECT_SAFE_DIR[0] = 01 00 Offset vector from machine coordinate system machine_A3 to machine_A1 with reference to machine_A1 • MD61518 $MN_CC_PROTECT_OFFSET[0] = -100.0 Example protection window, 40.0 mm •...
Page 680: Data Lists
TE9: Axis pair collision protection 17.6 Data lists 17.6 Data lists 17.6.1 Option data Number Identifier: $ON_ Description 19610 TECHNO_EXTENSION_MASK[6] Enable the technology function via BIT4 = 1 17.6.2 Machine data 17.6.2.1 NC-specific machine data Number Identifier: $MN_ Description 60972 CC_ACTIVE_IN_CHAN_PROT[n] Channel-specific activation of the technology function BIT0 = 1 =>...
Page 681: V2: Preprocessing
V2: Preprocessing 18.1 Brief description Preprocessing The programs stored in the directories for standard and user cycles can be preprocessed to reduce runtimes. Preprocessing is activated via machine data. Standard and user cycles are preprocessed when the power is switched on, i.e. as an internal control function, the part program is translated (compiled) into a binary intermediate code optimized for processing purposes.
Page 682 V2: Preprocessing 18.1 Brief description Memory is required for preprocessing cycles. You can optimize your memory in two ways: • The program to be executed can be shortened with the command DISPLOF (display off). • MD10700 $MN_PREPROCESSING_LEVEL has been expanded by bit 2 and 3. This allows selective cycle preprocessing of the individual directories (e.g.
Page 683 V2: Preprocessing 18.1 Brief description CPU time intensive programs and programs with symbolic names are processed faster. Runtime-critical sections (e.g. continuation of processing after deletion of distance-to-go or preprocessing stop in cycles) can be processed faster. If the interrupt routine is available as a preprocessed cycle, processing can be continued more rapidly after the program interrupt.
Page 684: Program Handling
This is a sensible setting when no cycles with call parameters are used. During control power-up, the call description of the cycles is generated. All user cycles (_N_CUS_DIR directory) and Siemens cycles (_N_CST_DIR directory) with transfer parameters can be called up without external statement. Changes to the cycle-call interface do not take effect until the next POWER ON.
Page 685 V2: Preprocessing 18.2 Program handling Compiling Subroutines (_SPF file extension) located in the directories for standard cycles (_N_CST_DIR, _N_CMA_DIR) and user cycles (_N_CUS_DIR) and any subroutines marked with PREPRO are compiled. The name of the compilation corresponds to the original cycle with extension _CYC.
Page 686 V2: Preprocessing 18.2 Program handling In order to execute this program normally, the following machine data must specify at least 3 names: MD28020 $MC_MM_NUM_LUD_NAMES_TOTAL Six names are required to compile this program after POWER ON. Preprocessed programs/cycles are stored in the dynamic NC memory. The space required for each program must be flashed over unmodified as outlined above.
Page 687: Program Call
V2: Preprocessing 18.3 Program call 18.3 Program call Overview Figure 18-1 Generation and call of preprocessed cycles without parameters Figure 18-2 Generation and call of preprocessed cycles with parameters Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 688 SPF program. • The change to an external language mode with G291 is rejected and an alarm issued. When the pre-compiled cycle is called, an explicit change is made to the Siemens language mode. • When the subroutine is called, it is checked whether the compiled file is older than the cycle.
Page 689 V2: Preprocessing 18.3 Program call Syntax check All program errors that can be corrected by means of a compensation block are detected during preprocessing. In addition, when the program includes branches and check structures, a check is made to ensure that the branch destinations are present and that structures are nested correctly.
Page 690: Constraints
V2: Preprocessing 18.4 Constraints 18.4 Constraints Availability of the "preprocessing" function The function is an option ("Program pre-processing"), which must be assigned to the hardware via the license management. Vocabulary The full vocabulary of the NC language is available in the part program. There are no restrictions on the calculation of measured process variables and in the reaction to signals from the process and other channels (override, deletion of distance-to-go, motion- synchronous actions, channel coordination, interrupt processing, etc.).
Page 691 V2: Preprocessing 18.4 Constraints • Indirect axis programming: IF $AA_IM[AXNAME($MC_AXCONF_CHANAX_NAME_TAB[4])] > 5 ; This branch will pass through if the actual value of the 5th channel axis ; with reference to the machine coordinate system is greater than 5. G1 AX[AXNAME($MC-AXCONF-GEOAX-NAME-TAB[0])] = 10 F1000 G90.
Page 692: Examples
V2: Preprocessing 18.5 Examples 18.5 Examples 18.5.1 Preprocessing individual files PROC UP1 PREPRO ; Preprocessing if bit 5 = 1 ; in PREPROCESSING_LEVEL N1000 DEF INT COUNTER N1010 TARGET: G1 G91 COMPON N1020 G1 X0.001 Y0.001 Z0.001 F100000 N1030 COUNTER=COUNTER+1 N1040 COUNTER=COUNTER-1 N1050 COUNTER=COUNTER+1 N1060 IF COUNTER<=10 GOTOB TARGET...
Page 693: Preprocessing In The Dynamic Nc Memory
V2: Preprocessing 18.5 Examples Subroutine UP2 is not pretranslated, but the call description is generated. b) Bit 5 = 0 MD10700 $MN_PREPROCESSING_LEVEL=13 ; bit 0, 2, 3, Both subroutines are pretranslated, and the call description is generated. c) Example of an invalid subroutine with activated compiling: PROC SUB1 PREPRO ;...
Page 694: Data Lists
V2: Preprocessing 18.6 Data lists 18.6 Data lists 18.6.1 Machine data 18.6.1.1 General machine data Number Identifier: $MN_ Description 10700 PREPROCESSING_LEVEL Program preprocessing level 18242 MM_MAX_SIZE_OF_LUD_VALUE Maximum LUD-variable array size 18.6.1.2 Channelspecific machine data Number Identifier: $MC_ Description 28010 MM_NUM_REORG_LUD_MODULES Number of blocks for local user variables for REORG (DRAM) 28020...
Page 695: W5: 3D Tool Radius Compensation
W5: 3D tool radius compensation 19.1 Brief description 19.1.1 General Why 3D TRC? 3D tool radius compensation is used to machine contours with tools that can be controlled in their orientation independently of the tool path and shape. Note This description is based on the specifications for 2D tool radius compensation. References: Function Manual Basic Functions;...
Page 696 W5: 3D tool radius compensation 19.1 Brief description Circumferential milling, face milling The following diagram shows the differences between 2 D and 3D TRC with respect to circumferential milling operations. Figure 19-1 21/2D and 3D tool radius compensation The parameters for display in the "Face milling" screen are described in detail in Chapter "Face milling [Page 709]".
Page 697: Machining Modes
W5: 3D tool radius compensation 19.1 Brief description 19.1.2 Machining modes There are two modes for milling spatial contours: • Circumferential milling • Face milling Circumferential milling mode is provided for machining so-called ruled surfaces (e.g. taper, cylinder, etc.) while face milling is used to machine curved (sculptured) surfaces. Circumferential milling Tools will be applied as follows for circumferential milling: •...
Page 698: Circumferential Milling
W5: 3D tool radius compensation 19.2 Circumferential milling 19.2 Circumferential milling Circumferential milling The variant of circumferential milling used here is implemented through the definition of a path (directrix) and the associated orientation. In this machining mode, the tool shape is irrelevant on the path and at the outside corners.
Page 699: Corners For Circumferential Milling
W5: 3D tool radius compensation 19.2 Circumferential milling Figure 19-4 Insertion depth 19.2.1 Corners for circumferential milling Outside corners/inside corners Outside corners and inside corners must be treated separately. The terms inside corner and outside corner are dependent on the tool orientation. When the orientation changes at a corner, for example, the corner type may change while machining is in progress.
Page 700: Behavior At Outer Corners
W5: 3D tool radius compensation 19.2 Circumferential milling Figure 19-6 Change of corner type during machining 19.2.2 Behavior at outer corners In the same manner as 21/2D tool radius compensation procedures, a circle is inserted at outer corners for G450 and the intersection of the offset curves is approached for G451. With nearly tangential transitions, the procedure for active G450 is as with G451 (limit angle is set via machine data).
Page 701 W5: 3D tool radius compensation 19.2 Circumferential milling The ORIC and ORID program commands are used to determine whether changes in orientation programmed between two blocks are executed before the inserted circle block is processed or at the same time. When the orientation needs to be changed at outside corners, the change can be implemented in parallel to interpolation or separately from the path motion.
Page 702 W5: 3D tool radius compensation 19.2 Circumferential milling Example: N10 A0 B0 X0 Y0 Z0 F5000 ; Radius=5 N20 T1 D1 ; Transformation selection N30 TRAORI(1) ;3D TRC selection N40 CUT3DC N50 ORIC ; TRC selection N60 G42 X10 Y10 N70 X60 ;...
Page 703 W5: 3D tool radius compensation 19.2 Circumferential milling ORID If ORID is active, then all blocks between the two traversing blocks are executed at the end of the first traversing block. The circle block with constant orientation is executed immediately before the second traversing block.
Page 704: Behavior At Inside Corners
W5: 3D tool radius compensation 19.2 Circumferential milling G451 The intersection is determined by extending the offset curves of the two participating blocks and defining the intersection of the two blocks at the corner in the plane perpendicular to the tool orientation.
Page 705 W5: 3D tool radius compensation 19.2 Circumferential milling Figure 19-9 The contact points of the tool must not cross the limits of block N70 or N90 as a result of the change in orientation in block N80 Example: N10 A0 B0 X0 Y0 Z0 F5000 N20 T1 D1 ;...
Page 706 W5: 3D tool radius compensation 19.2 Circumferential milling Figure 19-10 Path end position and change in orientation at inside corners Change in insertion depth Generally speaking, the contour elements that form an inside corner are not positioned on the plane perpendicular to the tool. This means that the contact points between the two blocks and the tool are at different distances from the tool tip.
Page 707 W5: 3D tool radius compensation 19.2 Circumferential milling Figure 19-11 Change in insertion depth Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 708 W5: 3D tool radius compensation 19.2 Circumferential milling Example of inside corners Figure 19-12 Change in orientation at an inside corner Example: N10 A0 B0 X0 Y0 Z0 F5000 N20 T1 D1 ; Radius=5 N30 TRAORI(1) ; Transformation selection N40 CUT3DC ;3D TRC selection N50 ORID N60 G42 X10 Y10 G451...
Page 709: Face Milling
W5: 3D tool radius compensation 19.3 Face milling 19.3 Face milling The face milling function allows surfaces with any degree or form of curvature to be machined. In this case, the longitudinal axis of the tool and the surface normal vector are more or less parallel.
Page 710 W5: 3D tool radius compensation 19.3 Face milling The shaft characteristics are not taken into account on any of the tool types. For this reason, the two tool types 120 (end mill) and 155 (bevel cutter), for example, have an identical machining action since only the section at the tool tip is taken into account.
Page 711: Orientation
W5: 3D tool radius compensation 19.3 Face milling 19.3.2 Orientation The options for programming the orientation have been extended for 3D face milling. The tool offset for face milling cannot be calculated simply by specifying the path (e.g. a line in space).
Page 712: Compensation On Path
W5: 3D tool radius compensation 19.3 Face milling In addition to the usual methods of programming orientation, it is also possible to refer the tool orientation to the surface normal vector and path tangent vector using the addresses LEAD (lead or camber angle) and TILT (side angle). The lead angle is the angle between the tool orientation and the surface normal vector.
Page 713 W5: 3D tool radius compensation 19.3 Face milling Figure 19-15 Change in the machining point on the tool surface close to a point in which surface normal vector and tool orientation are parallel The problem is basically solved as follows: If the angle d between the surface normal vector and tool orientation w is smaller than a limit value (machine data) δ...
Page 714: Corners For Face Milling
W5: 3D tool radius compensation 19.3 Face milling 19.3.4 Corners for face milling Two surfaces which do not merge tangentially form an edge. The paths defined on the surfaces make a corner. This corner is a point on the edge. The corner type (inside or outside corner) is determined by the surface normal of the surfaces involved and by the paths defined on them.
Page 715: Behavior At Outer Corners
W5: 3D tool radius compensation 19.3 Face milling 19.3.5 Behavior at outer corners Outside corners are treated as if they were circles with a 0 radius. The tool radius compensation acts on these circles in the same way as on any other programmed path. The circle plane extends from the final tangent of the first block to the start tangent of the second block.
Page 716: Behavior At Inside Corners
W5: 3D tool radius compensation 19.3 Face milling 19.3.6 Behavior at inside corners The position of the tool in which it is in contact with the two surfaces forming the corner must be determined at an inside corner. The contact points must be on the paths defined on both surfaces.
Page 717: Monitoring Of Path Curvature
W5: 3D tool radius compensation 19.3 Face milling If the tool orientation at an inside corner is not constant, the change in orientation is implemented in the same way as described in Subsection "Behavior at inside corners" for 3D circumferential milling, i.e. the tool is moved in the corner so that it contacts the two adjacent surfaces at the block start, block end and at two points of the change in orientation.
Page 718: Selection/Deselection Of 3D Trc
W5: 3D tool radius compensation 19.4 Selection/deselection of 3D TRC 19.4 Selection/deselection of 3D TRC The following commands are used to select/deselect 3D tool radius compensation for circumferential milling or face milling: • CUT3DC (circumferential milling) • CUT3DFS (face milling) •...
Page 719: Deselection Of 3D Trc
W5: 3D tool radius compensation 19.4 Selection/deselection of 3D TRC N50 G42 X10 Y10 ; TRC selection N60 X60 N70 ... Intermediate blocks Intermediate blocks are permitted when 3D TRC is active. The specifications for 2D TRC apply equally to 3D TRC. 19.4.2 Deselection of 3D TRC Deselection...
Page 720: Constraints
W5: 3D tool radius compensation 19.5 Constraints 19.5 Constraints Availability of the "3D tool radius compensation" function The function is an option ("3D tool radius compensation"), which must be assigned to the hardware via the license management. Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 721: Examples
W5: 3D tool radius compensation 19.6 Examples 19.6 Examples Example program for 3D circumferential milling: ; Definition of tool D1 $TC_DP1[1,1]=120 ; Type (end mill) $TC_DP3[1,1] = ; Length offset vector $TC_DP6[1.1] =8 ; Radius N10 X0 Y0 Z0 T1 D1 F12000 ;...
Page 722 W5: 3D tool radius compensation 19.6 Examples N200 X-20 Y-20 Z10 ; Inside corner with previous block N210 X-30 Y10 A4=1 C4=1 ; Inside corner, new plane definition N220 A3=1 B3=0.5 C3=1.7 ; Change in orientation with ORIC N230 X-20 Y30 A4=1 B4=-2 C4=3 ORID N240 A3 = 0.5 B3=-0.5 C3=1 ;...
Page 723: Data Lists
W5: 3D tool radius compensation 19.7 Data lists 19.7 Data lists 19.7.1 General machine data Number Identifier: $MN_ Description 18094 MM_NUM_CC_TDA_PARAM Number of TDA data 18096 MM_NUM_CC_TOA_PARAM Number of TOA data, which can be set up per tool and evaluated by the CC 18100 MM_NUM_CUTTING_EDGES_IN_TOA Tool offsets per TOA module...
Page 724 W5: 3D tool radius compensation 19.7 Data lists Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 725: W6: Path Length Evaluation
W6: Path length evaluation 20.1 Brief description Function With the "Path length evaluation" function, the NCK specific machine axis data is made available as the system and OPI variables, with whose help it is possible to assess the strain on the machine axes and thereby make an evaluation on the state of the machine's maintenance.
Page 726: Data
W6: Path length evaluation 20.2 Data 20.2 Data The following data is available: OPI variable Meaning System variable $AA_TRAVEL_DIST aaTravelDist Total traverse path: sum of all set position changes in MCS in [mm] or [deg.]. $AA_TRAVEL_TIME aaTravelTime Total travel time: sum of IPO clock cycles from set position changes in MCS in [s] (solution: 1 IPO clock cycle)
Page 727: Parameterization
W6: Path length evaluation 20.3 Parameterization 20.3 Parameterization 20.3.1 General activation The function is generally activated via the NCK-specific machine data: MD18860 $MN_MM_MAINTENANCE_MON (Activate recording of maintenance data) 20.3.2 Data groups The data has been collected into data groups. The data groups are activated via the axis-specific machine data: MD33060 $MA_MAINTENANCE_DATA (configuration to record maintenance data) Value Activation of the following data: System variable / OPI variable...
Page 728: Examples
W6: Path length evaluation 20.4 Examples 20.4 Examples 20.4.1 Traversal per part program Three geometry axes AX1, AX2 and AX3 exist in a machine. For geometry axis AX1, the part program-driven total traverse path, total travel time and travel count should be calculated. Parameter assignment Activation of the overall function: MD18860 $MN_MM_MAINTENANCE_MON = TRUE...
Page 729: Data Lists
W6: Path length evaluation 20.5 Data lists 20.5 Data lists 20.5.1 Machine data 20.5.1.1 NC-specific machine data Number Identifier: $MN_ Description 18860 MM_MAINTENANCE_MON Activate recording of maintenance data 20.5.1.2 Axis/spindlespecific machine data Number Identifier: $MA_ Description 33060 MAINTENANCE_DATA Configuration, recording maintenance data Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 730 W6: Path length evaluation 20.5 Data lists Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 731: Z3: Nc/Plc Interface Signals
Z3: NC/PLC interface signals 21.1 3-Axis to 5-Axis Transformation (F2) 21.1.1 Signals from channel (DB21, ...) DB21, ... DBX29.4 activate PTP traversal Edge evaluation: Yes Signal(s) updated: Signal state 1 or edge activate PTP traversal. change 0 → 1 Signal state 0 or edge Activate CP traversal.
Page 732 Z3: NC/PLC interface signals 21.1 3-Axis to 5-Axis Transformation (F2) DB21, … DBX318.2 TOFF active Edge evaluation: Yes Signal(s) updated: Signal state 1 or edge Activate online tool length offset. change 0 → 1 Signal state 0 or edge Reset online tool length offset. change 1 ...
Page 733: Gantry Axes (G1)
Z3: NC/PLC interface signals 21.2 Gantry Axes (G1) 21.2 Gantry Axes (G1) 21.2.1 Signals to axis/spindle (DB31, ...) DB31, ... DBX29.4 Start gantry synchronization Edge evaluation: No Signal(s) updated: Cyclic Signal state 1 or edge Request from PLC user program to synchronize the leading axis with the assigned change 0 ...
Page 734: Signals From Axis/Spindle (Db31
Z3: NC/PLC interface signals 21.2 Gantry Axes (G1) 21.2.2 Signals from axis/spindle (DB31, ...) DB31, ... DBX101.2 Gantry trip limit exceeded Edge evaluation: No Signal(s) updated: Cyclic Signal state 1 or edge The difference between the position actual values of the leading and synchronized axes has change 0 ...
Page 735 Z3: NC/PLC interface signals 21.2 Gantry Axes (G1) DB31, ... DBX101.4 Gantry synchronization ready to start Edge evaluation: No Signal(s) updated: Cyclic Signal state 1 or edge After gantry axis referencing, the monitoring function has detected that the position actual change 0 ...
Page 736 Z3: NC/PLC interface signals 21.2 Gantry Axes (G1) DB31, ... DBX101.5 Gantry grouping is synchronized Application example(s) Machining should be enabled only if the gantry axes are already synchronized. This can be implemented in the PLC user program by combining NC Start with IS "Gantry grouping is synchronized".
Page 737: Axis Couplings And Esr (M3)
Z3: NC/PLC interface signals 21.3 Axis Couplings and ESR (M3) 21.3 Axis Couplings and ESR (M3) 21.3.1 Signals to axis (DB31, ...) DB31, … Active following axis overlay DBX26.4 Edge evaluation: No Signal(s) updated: Cyclic Signal state 1 or edge An additional traversing motion can be overlaid on the following axis.
Page 738 Z3: NC/PLC interface signals 21.3 Axis Couplings and ESR (M3) DB31, … DBX98.6 Acceleration warning threshold Signal irrelevant ... Without electronic gear. Corresponding to ... The following machine data: MD37550 $MA_EG_VEL_WARNING (threshold value velocity alarm threshold) MD32300 $MA_MAX_AX_ACCEL (axis acceleration) DB31, …...
Page 739: Extended Stop And Retract (R3)
Z3: NC/PLC interface signals 21.4 Extended stop and retract (R3) 21.4 Extended stop and retract (R3) 21.4.1 Signals from axis/spindle (DB31, ...) DB31, ... DBX95.0 VDC link < alarm threshold Edge evaluation: No Signal(s) updated: Cyclic Signal state 1 The drive signals that the DC link voltage VDC link is lower than the "lower DC link voltage threshold"...
Page 740: Setpoint Exchange (S9)
Z3: NC/PLC interface signals 21.5 Setpoint Exchange (S9) 21.5 Setpoint Exchange (S9) 21.5.1 Signals to axis/spindle (DB31, ...) DB31, ... DBX24.5 Activate setpoint exchange Edge evaluation: No Signal(s) updated: Cyclic Signal state = 1 Request to axis to take over drive control. Signal state = 0 Request to axis to relinquish drive control.
Page 741: Tangential Control (T3)
Z3: NC/PLC interface signals 21.6 Tangential Control (T3) 21.6 Tangential Control (T3) 21.6.1 Special response to signals The movement of the axis under tangential follow-up control to compensate for a tangent jump at a corner of the path (defined by the movements of the leading axis) can be stopped by the following signals (e.g.
Page 742: Clearance Control (Te1)
Z3: NC/PLC interface signals 21.7 Clearance Control (TE1) 21.7 Clearance Control (TE1) 21.7.1 Signals to channel (DB21, ...) DB21, ... DBX1.4 CLC stop Edge evaluation: No Signal(s) updated: Cyclic Signal state 1 or Clearance control is deactivated in the same way as the part program command edge change 0 ...
Page 743 Z3: NC/PLC interface signals 21.7 Clearance Control (TE1) DB21, ... DBX37.4 CLC motion at lower motion limit Edge evaluation: No Signal(s) updated: Cyclic Signal state 1 or The traversing movement of the clearance-controlled axes based on clearance control has edge change 0 → 1 been stopped at the upper movement limit set in MD62505 $MC_CLC_SENSOR_LOWER_LIMIT (Lower motion limit of clearance control) or programmed with CLC_LIM(..).
Page 744 Z3: NC/PLC interface signals 21.7 Clearance Control (TE1) DB21, ... DBX37.4-5 CLC motion has stopped Signal state 0 or Clearance control generates traversing movements directly in the clearance-controlled axes. edge change 1 → 0 As long as the axes are traversing due to clearance control, the axial interface signals cannot be set: DB31, …...
Page 745: Speed/Torque Coupling, Master-Slave (Te3)
Z3: NC/PLC interface signals 21.8 Speed/Torque Coupling, Master-Slave (TE3) 21.8 Speed/Torque Coupling, Master-Slave (TE3) 21.8.1 Signals to axis/spindle (DB31, ...) DB31, ... DBX24.4 Torque compensatory controller on Edge evaluation: Yes Signal(s) updated: Cyclically Signal state 1 or edge Torque compensatory controller is to be activated. change 0 ...
Page 746 Z3: NC/PLC interface signals 21.8 Speed/Torque Coupling, Master-Slave (TE3) DB31, ... DBX96.3 Master/slave coarse Edge evaluation: No Signal(s) updated: Cyclic Signal state 1 or The differential speed is in the range defined by the following item of machine data: edge change 0 → 1 MD37270 $MA_MS_VELO_TOL_COARSE Signal state 0 or The differential speed has not reached the range defined in MD37270.
Page 747: Handling Transformation Package (Te4)
Z3: NC/PLC interface signals 21.9 Handling Transformation Package (TE4) 21.9 Handling Transformation Package (TE4) 21.9.1 Signals from channel (DB21, ...) DB21, ... DBX29.4 Activate PTP traversal Edge evaluation: Yes Signal(s) updated: Signal state 1 or Activate PTP traversal. edge change 0 → 1 Signal state 0 or Activate CP traversal.
Page 748: Mcs Coupling (Te6)
Z3: NC/PLC interface signals 21.10 MCS Coupling (TE6) 21.10 MCS Coupling (TE6) 21.10.1 Signals to axis/spindle (DB31, ...) DB31, … DBX24.2 Deactivate or disable coupling Edge evaluation: No Signal(s) updated: Signal state 1 An active coupling is not deactivated until the relevant axes are stationary. If CC_COPON is programmed for this axis, no error message is generated.
Page 749 Z3: NC/PLC interface signals 21.10 MCS Coupling (TE6) DB31, … DBX97.1 Activate coupling Edge evaluation: No Signal(s) updated: Signal state 1 Coupling active Signal state 0 Coupling not active Signal irrelevant for ... Application example(s) Displayed only for the CC_Slave axis. DB31, …...
Page 750: Retrace Support (Te7)
Z3: NC/PLC interface signals 21.11 Retrace Support (TE7) 21.11 Retrace Support (TE7) 21.11.1 Signals to channel DB21, ... DBX0.1 Reverse/Forward Edge evaluation: Yes Signal(s) updated: Signal state 1 or edge Activate reverse travel. change 0 → 1 The RESU main program CC_RESU.MPF is generated from the traversing blocks recorded in the RESU-internal block buffer in order to initiate travel back along the contour on the next NC START.
Page 751 Z3: NC/PLC interface signals 21.11 Retrace Support (TE7) DB21, ... DBX32.2 Retrace support active Edge evaluation: No Signal(s) updated: Signal state 1 The "retrace support active" signal is set as soon as signal state 1 is detected for the "start retrace support"...
Page 752 Z3: NC/PLC interface signals 21.11 Retrace Support (TE7) Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 753: Appendix
Appendix List of abbreviations Output ADI4 Analog Drive Interface for 4 Axes Adaptive Control Active Line Module Rotating induction motor ASCII American Standard Code for Information Interchange: American Standard Code for Information Interchange ASUB Asynchronous subroutine AUXFU Auxiliary Function: auxiliary function User program Mode Mode group...
Page 754 Appendix A.1 List of abbreviations Compiler Projecting Data: Configuring data of the compiler Control Unit Communication Processor Central Processing Unit: Central processing unit Carriage Return Clear To Send: Ready to send signal for serial data interfaces CUTCOM Cutter radius Compensation: Tool radius compensation Digital-to-Analog Converter Data Block (PLC) Data Block Byte (PLC)
Page 755 Appendix A.1 List of abbreviations Engineering System Extended Stop and Retract ETC key ">"; Softkey bar extension in the same menu Function Block (PLC) Function Call: Function block (PLC) FEPROM Flash EPROM: Read and write memory FIFO First In First Out: Memory that works without address specification and whose data are read in the same order in which they were stored.
Page 756 Appendix A.1 List of abbreviations Commissioning Interpolatory compensation Increment: Increment Interpolator Jogging: Setup mode Gain factor of control loop Proportional gain Transformation ratio Ü LADder diagram Logical Machine Axis Image Local Area Network LEDs Light Emitting Diode: Light Emitting Diode Line Feed Position Measuring System Position Controller...
Page 757 Appendix A.1 List of abbreviations Main Program File: NC part program (main program) Multi Port Interface: Multiport Interface Machine Control Panel Numerical Control: Numerical control Numerical Control Kernel Numerical Control Unit Name for the operating system of the NCK Interface Signal Work Offset Numerical eXtension (axis extension module) Organization block in the PLC...
Page 758 Appendix A.1 List of abbreviations POSMO CA Positioning Motor Compact AC: Complete drive unit with integrated power and control module as well as positioning unit and program memory; AC infeed POSMO CD Positioning Motor Compact DC: Like CA but with DC infeed POSMO SI Positioning Motor Servo Integrated: Positioning motor, DC infeed Parameter Process data Object;...
Page 759 Appendix A.1 List of abbreviations SKiP: Function for skipping a part program block Synchronous Linear Motor Stepper motor Sensor Module Cabinet Mounted Sensor Module Externally Mounted Sub Program File: Subprogram Programmable Logic Controller SRAM Static RAM (non-volatile) TNRC Tool Nose Radius Compensation Synchronous Rotary Motor Leadscrew Error Compensation Synchronous Serial Interface (interface type)
Page 760 Appendix A.1 List of abbreviations Verein Deutscher Ingenieure [Association of German Engineers] Verband Deutscher Elektrotechniker [Association of German Electrical Engineers] Voltage Input Voltage Output Feed Drive Workpiece coordinate system Tool Tool Length Compensation Workshop-Oriented Programming WorkPiece Directory: Workpiece directory Tool Radius Compensation Tool Tool Offset Tool Management...
Page 761: Overview
Appendix A.2 Overview Overview Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 762 Appendix A.2 Overview Special Functions Function Manual, 09/2011, 6FC5397-2BP40-2BA0...
Page 763: Glossary
Glossary Absolute dimensions A destination for an axis movement is defined by a dimension that refers to the origin of the currently active coordinate system. See → Incremental dimension Acceleration with jerk limitation In order to optimize the acceleration response of the machine whilst simultaneously protecting the mechanical components, it is possible to switch over in the machining program between abrupt acceleration and continuous (jerk-free) acceleration.
Page 764 Glossary Auxiliary functions Auxiliary functions enable → part programs to transfer → parameters to the → PLC, which then trigger reactions defined by the machine manufacturer. Axes In accordance with their functional scope, the CNC axes are subdivided into: • Axes: interpolating path axes •...
Page 765 Glossary Basic Coordinate System Cartesian coordinate system which is mapped by transformation onto the machine coordinate system. The programmer uses axis names of the basic coordinate system in the → part program. The basic coordinate system exists parallel to the → machine coordinate system if no → transformation is active.
Page 766 Glossary See → NC Component of the NC for the implementation and coordination of communication. Compensation axis Axis with a setpoint or actual value modified by the compensation value Compensation memory Data range in the control, in which the tool offset data are stored. Compensation table Table containing interpolation points.
Page 767 Glossary Coordinate system See → Machine coordinate system, → Workpiece coordinate system Central processing unit, see → PLC C-Spline The C-Spline is the most well-known and widely used spline. The transitions at the interpolation points are continuous, both tangentially and in terms of curvature. 3rd order polynomials are used.
Page 768 Glossary Differential Resolver Function: NC function which generates an incremental zero offset in Automatic mode in conjunction with an electronic handwheel. Drive The drive is the unit of the CNC that performs the speed and torque control based on the settings of the NC.
Page 769 Glossary Feed override The programmed velocity is overriden by the current velocity setting made via the → machine control panel or from the → PLC (0 to 200%). The feedrate can also be corrected by a programmable percentage factor (1-200%) in the machining program. Finished-part contour Contour of the finished workpiece.
Page 770 Glossary High-level CNC language The high-level language offers: → user-defined variables, → system variables, → macro techniques. High-speed digital inputs/outputs The digital inputs can be used for example to start fast CNC program routines (interrupt routines). The digital CNC outputs can be used to trigger fast, program-controlled switching functions (SINUMERIK 840D).
Page 771 Glossary Intermediate blocks Motions with selected → tool offset (G41/G42) may be interrupted by a limited number of intermediate blocks (blocks without axis motions in the offset plane), whereby the tool offset can still be correctly compensated for. The permissible number of intermediate blocks which the control reads ahead can be set in system parameters.
Page 772 Glossary Servo gain factor, a control variable in a control loop. Leading axis The leading axis is the → gantry axis that exists from the point of view of the operator and programmer and, thus, can be influenced like a standard NC axis. Leadscrew error compensation Compensation for the mechanical inaccuracies of a leadscrew participating in the feed.
Page 773 Glossary Machine coordinate system A coordinate system, which is related to the axes of the machine tool. Machine zero Fixed point of the machine tool to which all (derived) measuring systems can be traced back. Machining channel A channel structure can be used to shorten idle times by means of parallel motion sequences, e.g.
Page 774 Glossary Mirroring Mirroring reverses the signs of the coordinate values of a contour, with respect to an axis. It is possible to mirror with respect to more than one axis at a time. Mode group Axes and spindles that are technologically related can be combined into one mode group. Axes/spindles of a BAG can be controlled by one or more →...
Page 775 Glossary The scope for implementing individual solutions (OEM applications) for the SINUMERIK 840D has been provided for machine manufacturers, who wish to create their own operator interface or integrate process-oriented functions in the control. Operator Interface The user interface (UI) is the display medium for a CNC in the form of a screen. It features horizontal and vertical softkeys.
Page 776 Glossary Path axis Path axes include all machining axes of the → channel that are controlled by the → interpolator in such a way that they start, accelerate, stop, and reach their end point simultaneously. Path feedrate Path feed affects → path axes. It represents the geometric sum of the feed rates of the → geometry axes involved.
Page 777 Glossary Polar coordinates A coordinate system, which defines the position of a point on a plane in terms of its distance from the origin and the angle formed by the radius vector with a defined axis. Polynomial interpolation Polynomial interpolation enables a wide variety of curve characteristics to be generated, such as straight line, parabolic, exponential functions (SINUMERIK 840D).
Page 778 Glossary Programming key Character and character strings that have a defined meaning in the programming language for → part programs. Protection zone Three-dimensional zone within the → working area into which the tool tip must not pass. Quadrant error compensation Contour errors at quadrant transitions, which arise as a result of changing friction conditions on the guideways, can be virtually entirely eliminated with the quadrant error compensation.
Page 779 Glossary Safety Functions The control is equipped with permanently active montoring functions that detect faults in the → CNC, the → PLC, and the machine in a timely manner so that damage to the workpiece, tool, or machine is largely prevented. In the event of a fault, the machining operation is interrupted and the drives stopped.
Page 780 Glossary Transformation ratio Standard cycles Standard cycles are provided for machining operations, which are frequently repeated: • Cycles for drilling/milling applications • for turning technology The available cycles are listed in the "Cycle support" menu in the "Program" operating area. Once the desired machining cycle has been selected, the parameters required for assigning values are displayed in plain text.
Page 781 Glossary Synchronized axis A synchronized axis is the → gantry axis whose set position is continuously derived from the motion of the → leading axis and is, thus, moved synchronously with the leading axis. From the point of view of the programmer and operator, the synchronized axis "does not exist". System memory The system memory is a memory in the CPU in which the following data is stored: •...
Page 782 Glossary Tool nose radius compensation Contour programming assumes that the tool is pointed. Because this is not actually the case in practice, the curvature radius of the tool used must be communicated to the control which then takes it into account. The curvature center is maintained equidistantly around the contour, offset by the curvature radius.
Page 783 Glossary User-defined variable Users can declare their own variables for any purpose in the → part program or data block (global user data). A definition contains a data type specification and the variable name. See → System variable. Variable definition A variable definition includes the specification of a data type and a variable name.
Page 784 Glossary Workpiece coordinate system The workpiece coordinate system has its starting point in the → workpiece zero-point. In machining operations programmed in the workpiece coordinate system, the dimensions and directions refer to this system. Workpiece zero The workpiece zero is the starting point for the → workpiece coordinate system. It is defined in terms of distances to the →...
Page 785 Index Symbols Example Kinematics $AA_COUP_ACT $AA_COUP_CORR $AA_COUP_CORR_DIST $AA_ESR_ENABLE $AA_ESR_STAT aaJerkCount $AA_IN_SYNC aaJerkTime $AA_JERK_COUNT aaJerkTotal $AA_JERK_TIME aaTravelCount $AA_JERK_TOT aaTravelCountHS $AA_LEAD_P aaTravelDist $AA_LEAD_P_TURN aaTravelDistHS $AA_LEAD_SP aaTravelTime $AA_LEAD_SV aaTravelTimeHS $AA_LEAD_V Acceleration $AA_SYNC Channel-specific $AA_SYNCDIFF Function-specific $AA_TRAVEL_COUNT Acceleration mode $AA_TRAVEL_COUNT_HS Acceleration time constant $AA_TRAVEL_DIST Acceleration warning threshold $AA_TRAVEL_DIST_HS Access rights...
Page 786 Index Compressor Continue machining ASUB Basic orientation Contour accuracy Basic system clock cycle Programmable 840Di Contour tunnel Basic system cycle -radius Basic version Control system dynamics Behavior at inside corners Coordinate reference Behavior at outer corners Coordinate system Behavior at pole Corner Block change criterion Corner in area...
Page 787 Index CPLINSC CPLINTR DB 31, ... CPLNUM DBB101 CPLOF DBX1.4 CPLON DBX101.3 CPLOUTSC DBX101.5 CPLOUTTR DBX2.1 CPLPOS DBX24.3 CPLSETVAL DBX24.5 CPMBRAKE DBX29.4 CPMPRT DBX29.5 CPMRESET DBX4.3 CPMSTART DBX66.0 CPMVDI DBX96.7 CPOF DBX97.0 CPOF+CPFPOS DBX97.1 CPON DBX97.2 CPRECOF DBX97.3 CPRECON DBX98.0 CPRES DBX98.1 CPSETTYPE...
Page 788 Index DBX1.0 DBX61.6 DBX1.4 DBX61.7 DBX317.6 DBX64.6 DBX318.0 DBX64.7 DBX318.2 DBX95.0 DBX318.3 DBX96.2 DBX32.1 DBX96.3 DBX32.2 DBX96.4 DBX32.6 DBX96.5 DBX33.4 DBX96.7 DBX33.6 DBX98.0 DBX37.4 DBX98.1 DBX37.5 DBX98.4 DBX7.7 DBX98.5 DB31, ... DBX98.6 DBX 99,1 DBX98.7 DBX0.0 DBX99.0 DBX0.1 DBX99.1 DBX0.2 DBX99.2 DBX0.3 DBX99.3...
Page 789 Index Deactivate or disable coupling Definition G0 edge change EG axis group G450 Definition of an axis pair G451 Dependent coupled motion axis G91 extension Detailed description Zero point offset Determining permissible axis limits Gantry axes Diagnosing and optimizing utilization of resources Differences in comparison with coupled motion Differential speed "Coarse"...
Page 790 Index Interpolator cycle Maximum switching frequency Interruption point MCS coupling Intersection procedure for 3D compensation Brief description MD10000 MD10002 MD10050 MD10059 MD10060 Keywords MD10061 Kinematic transformation MD10062 Kinematics MD10070 swivelling linear axis MD10089 Kinematics of machines MD10300 MD10350 MD10360 MD10362 MD10366 Large circle interpolation Laser cutting...
Page 791 Index MD20060 MD24520 MD20080 MD24530 MD20110 MD24540 MD20112 MD24550 MD20140 MD24558 MD20150 MD24560 MD20178 MD24561 MD20470 MD24567 MD20482 MD2457 MD20610 MD24570 MD20900 MD24572 MD20905 MD24573 MD21050 MD24574 MD21060 MD24576 MD21070 MD24580 MD21084 MD24582 MD21094 MD24585 MD21100 MD24590 MD21102 MD24620 MD21104 MD24630 MD21106 MD24640...
Page 792 Index MD32430 MD37500 MD32434 MD37500 $MA_ESR_REACTION MD32610 MD37550 $MA_EG_VEL_WARNING MD32620 MD37560 $MA_EG_ACC_TOL MD32650 MD43108 MD32800 MD60900+i MD32810 MD60940 MD32900 MD60948 MD32910 MD60972 MD33000 MD61516 MD33060 MD61517 MD33100 MD61518 MD34040 MD61519 MD34070 MD61532 MD34080 MD62500 MD34090 MD62502 MD34100 MD62504 MD34110 MD62505 MD34330 MD62506 MD36000...
Page 793 Index MD62614 Opening angle MD62615 Opening angle of the cone MD62616 Operating modes MD62617 MD62618 Option MD62620 ORIC MD62629 ORICONCCW MD62630 ORICONCW MD62631 ORICONIO MD62632 ORICONTO MD63514 ORICURVE MD63540 ORID MD63541 Orientation MD63542 Orientation axes MD63543 Modulo display MD63544 Orientation direction MD63545 Orientation direction and rotation MD65520...
Page 794 Cartesian position SD43104 Orientation SD43106 Polynomial SD43108 Protection window Series machine startup PTP traversal active Shutting down Extended Siemens compile cycles Simulated master value Singular positions r9721 Singularities r9723 Slot Rapid stop Smoothing Reaction to Stop Of the orientation characteristic...
Page 795 Index Correction Deviation Universal milling head Synchronism difference Applications Synchronization Following axis Parameterization Synchronization difference Synchronization mode Synchronous axis Synchronous operation -difference V2 preprocessing -monitoring Brief description Synchronous position Velocity threshold value Following axis Velocity warning threshold Leading axis Versions Synchronous traverse difference Virtual leading axis - scanning...

This manual is also suitable for:

Sinumerik 840de sl

Siemens SINUMERIK 840D sl Function Manual

1 F2: Multi-Axis Transformations

2 G1: Gantry Axes

3 G3: Cycle Times

4 K6: Contour Tunnel Monitoring

5 M3: Coupled Axes

6 R3: Extended Stop and Retract

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