SINUMERIK SINUMERIK 840D sl / 828DExtended Functions Function Manual Valid for Control system SINUMERIK 840D sl / 840DE sl SINUMERIK 828D Software Version NCU system software 2.6 SP1 03/2010 6FC5397-1BP20-1BA0 Preface A4: Digital and analog NCK I/Os 1B3: Several operator panels connected to several NCUs, distributed systems - only 840D sl 2B4: Operation via PG/PC - only 840D sl 3H1: Manual travel and handwheel travel 4K3: Compensation 5K5: Mode groups, channels, axis interchange 6M1: Kinematic transformation 7M5: Measuring 8N3: Software cams, position switching cycles - only 840D sl 9N4: Punching and nibbling - only 840D sl 10P2: Positioning axes 11P5: Oscillation - only 840D sl 12R2: Rotary axes 13S3: Synchronous spindle 14S7: Memory configuration 15T1: Indexing axes 16W3: Tool change 17W4: Grinding-specific tool offset and monitoring functions - only 840D sl 18Z2: NC/PLC interface signals 19Appendix A Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. DANGER indicates that death or severe personal injury will result if proper precautions are not taken. WARNING indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken. CAUTION without a safety alert symbol, indicates that property damage can result if proper precautions are not taken. NOTICE indicates that an unintended result or situation can occur if the corresponding information is not taken into account. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. Qualified Personnel The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation for the specific task, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems. Proper use of Siemens products 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. The permissible ambient conditions must be adhered to. The information in the relevant documentation must be observed. Trademarks All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG Industry Sector Postfach 48 48 90026 NRNBERG GERMANY Order number: 6FC5397-1BP20-1BA0 04/2010 Copyright Siemens AG 2010. Technical data subject to change Extended Functions Function Manual, 03/2010, 6FC5397-1BP20-1BA0 3 Preface SINUMERIK Documentation The SINUMERIK documentation is organized in three parts: General documentation User documentation Manufacturer/service documentation Information on the following topics is available at http://www.siemens.com/motioncontrol/docu: Ordering documentation Here you can find an up-to-date overview of publications. Downloading documentation Links to more information for downloading files from Service & Support. Researching documentation online Information on DOConCD and direct access to the publications in DOConWEB. Compiling individual documentation on the basis of Siemens contents with the My Documentation Manager (MDM), refer to http://www.siemens.com/mdm. My Documentation Manager provides you with a range of features for generating your own machine documentation. Training and FAQs Information on our range of training courses and FAQs (frequently asked questions) is available via the page navigation. 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. It provides the target group with the information required to implement the functions. Preface Extended Functions 4 Function Manual, 03/2010, 6FC5397-1BP20-1BA0 Standard version This documentation only describes the functionality of the standard version. Extensions or changes made by the machine tool manufacturer are documented by the machine tool manufacturer. Other functions not described in this documentation might be executable in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing. Further, for the sake of simplicity, this documentation does not contain all detailed information about all types of the product and cannot cover every conceivable case of installation, operation or maintenance. Installation Structure of this Function Manual: Inner title (page 3) with the title of the Function Manual, the SINUMERIK controls as well as the software and the version for which this version of the Function Manual is applicable and the overview of the individual functional descriptions. Description of the functions in alphabetical order (e.g. A2, A3, B1 etc.) Appendix with: List of abbreviations Fax template for feedback for documentation 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; NC/PLC Interface Signals (Z1) Function Manual Extended Functions; NC/PLC Interface Signals (Z2) Function Manual Special Functions; NC/PLC Interface Signals (Z3) Alarms: Diagnostics Manual Preface Extended Functions Function Manual, 03/2010, 6FC5397-1BP20-1BA0 5 Notation of system data The following notation is applicable for system data in this documentation: Signal/Data Notation Example NC/PLC interface signals ... NC/PLC interface signal: () When the new gear step is engaged, the following NC/PLC interface signals are set by the PLC program: DB31, ... DBX16.0-2 (actual gear stage A to C) DB31, ... DBX16.3 (gear is changed) Machine data ... machine data: () Master spindle is the spindle stored in the machine data: MD20090 $MC_SPIND_DEF_MASTER_SPIND (Position of deletion of the master spindle in the channel). Setting Data ... Setting data: () The logical master spindle is contained in the setting data: SD42800 $SC_SPIND_ASSIGN_TAB[0] (Spindle number converter) Note Signal address The description of functions include as of an NC/PLC interface signal, only the address valid for SINUMERIK 840D sl. The signal address for SINUMERIK 828D should be taken from the data lists "Signals to/from ..." at the end of the particular description of functions. Quantity structure Explanations concerning the NC/PLC interface are based on the absolute maximum number of sequential components: Mode groups (DB11) Channels (DB21, etc.) Axes/spindles (DB31, etc.) Preface Extended Functions 6 Function Manual, 03/2010, 6FC5397-1BP20-1BA0 Data types The following elementary data types are used in the control system: Type Meaning Value range INT Signed integers -2147483648 ... +2147483647 REAL Figures with decimal point acc. to IEEE (2.2*10-308 1.8*10+308) BOOL Truth values TRUE (1) and FALSE (0) 1, 0 CHAR ASCII characters Corresponding to code 0 to 255 STRING Character string, number of characters in [...] Maximum of 200 characters (no special characters) AXIS Axis names only All axis identifiers in the channel FRAME Geometrical parameters for moving, rotating, scaling, and mirroring Arrays can only be formed from similar elementary data types. Up to 3-dimensional arrays are possible. Technical Support If you have any questions, please contact our hotline: Europe/Africa Phone +49 180 5050 - 222 Fax +49 180 5050 - 223 0.14/min. from German landlines, cell phone prices may differ Internet http://www.siemens.de/automation/support-request America Phone +1 423 262 2522 Fax +1 423 262 2200 E-mail mailto:techsupport.sea@siemens.com Asia/Pacific Phone +86 1064 757575 Fax +86 1064 747474 E-mail mailto:support.asia.automation@siemens.com Note You will find telephone numbers for other countries for technical support on the Internet: http://www.automation.siemens.com/partner Preface Extended Functions Function Manual, 03/2010, 6FC5397-1BP20-1BA0 7 Questions about the manual If you have any queries (suggestions, corrections) in relation to this documentation, please send a fax or e-mail to the following address: Fax: +49 9131- 98 2176 Email: mailto:docu.motioncontrol@siemens.com A fax form is available in the appendix of this document. SINUMERIK Internet address http://www.siemens.com/sinumerik SINUMERIK 828D system performance (region) PPU 260 / 261 PPU 280 / 281 T M T M System performance Basic quantity of axes/spindles 3 4 3 4 Max. number of axes/spindles 6 6 8 6 Max. number of interpolating axes 4 4 4 4 Max. number of channels/mode groups 1/1 1/1 1/1 1/1 Min. block change time 6 ms 2 ms 6 ms 1 ms Speed/current control cycle 125 s 125 s 125 s 125 s CNC user memory (buffered) 3 MB 3 MB 5 MB 5 MB CNC functions Tool Management Number of tools/cutting edges 128/256 128/256 256/512 256/512 Safety Integrated: Safe Torque Off, Safe Brake Control Safety Integrated: Safe velocity Max. number of ASUBs (permanently set) 2 2 2 2 TRANSMIT / TRACYL Inclined Y axis - - - Synchronous spindle for counterspindle - - - Synchronous spindle for polygon machining - - Gantry Temperature compensation Preface Extended Functions 8 Function Manual, 03/2010, 6FC5397-1BP20-1BA0 PPU 260 / 261 PPU 280 / 281 T M T M HMI, CNC programming ShopMill/ShopTurn HMI functions DIN/ISO programming with programGUIDE Online ISO dialect interpreter ShopMill/ShopTurn machining step programming Measuring cycles Simulation in surface display Simulation in 3D display PLC SIMATIC S7-200 (integrated) Basic I/O modules: PP 72/48D PN PP 72/48D 2/2A PN (being prepared) PLC cycle time 6 ms 6 ms 6 ms 6 ms Max. number of PLC operations 24000 24000 24000 24000 Servo-synchronous high-speed PLC task Reaction time to process interrupts (terminal to terminal) 7.5 ms 7.5 ms 4.5 ms 4.5 ms Max. number of digital inputs/outputs 288/192 288/192 360/240 360/240 Max. number of analog inputs/outputs 8/8 8/8 10/10 10/10 Commissioning functions Service Planner (maintenance scheduler) Easy Extend (for managing machine units) Easy Archive (data archiving) T Turning M Milling Standard (basic scope) CNC option - Not available Extended Functions Function Manual, 03/2010, 6FC5397-1BP20-1BA0 9 Contents Preface...................................................................................................................................................... 3 1 A4: Digital and analog NCK I/Os.............................................................................................................. 27 1.1 Brief description ...........................................................................................................................27 1.2 NCK I/O via PLC..........................................................................................................................28 1.2.1 General functionality ....................................................................................................................28 1.2.2 NCK digital inputs/outputs............................................................................................................33 1.2.2.1 NCK digital inputs ........................................................................................................................33 1.2.2.2 NCK digital outputs ......................................................................................................................35 1.2.3 Connection and logic operations of fast NCK inputs/outputs ......................................................39 1.2.4 NCK analog inputs/outputs ..........................................................................................................41 1.2.4.1 NCK analog inputs.......................................................................................................................41 1.2.4.2 NCK analog outputs.....................................................................................................................44 1.2.5 Direct PLC I/Os, addressable from the NC..................................................................................48 1.2.6 Analog-value representation of the NCK analog input/output values..........................................51 1.2.7 Comparator inputs .......................................................................................................................52 1.3 NCK I/O via PROFIBUS - only 840D sl .......................................................................................56 1.3.1 Functionality.................................................................................................................................56 1.3.2 Parameter assignment.................................................................................................................57 1.3.3 Programming................................................................................................................................59 1.3.3.1 Communication via part programs/synchronous actions.............................................................59 1.3.3.2 Communication via compile cycles..............................................................................................62 1.4 Constraints...................................................................................................................................64 1.4.1 NCK I/O via PLC..........................................................................................................................64 1.4.2 NCK I/O via PROFIBUS - only 840D sl .......................................................................................65 1.5 Examples .....................................................................................................................................66 1.5.1 NCK I/O via PLC..........................................................................................................................66 1.5.1.1 Writing to PLC-I/Os ......................................................................................................................66 1.5.1.2 Reading from PLC-I/Os................................................................................................................67 1.5.2 NCK I/O via PROFIBUS - only 840D sl .......................................................................................68 1.5.2.1 PROFIBUS-I/O in write direction..................................................................................................68 1.5.2.2 PROFIBUS-I/O in read direction..................................................................................................70 1.5.2.3 Query of the RangeIndex in case of "PROFIBUS-I/O in write direction" .....................................72 1.6 Data lists ......................................................................................................................................74 1.6.1 Machine data................................................................................................................................74 1.6.1.1 General machine data..................................................................................................................74 1.6.1.2 Channel-specific machine data....................................................................................................75 1.6.2 Setting data..................................................................................................................................75 1.6.2.1 General setting data.....................................................................................................................75 1.6.3 Signals .........................................................................................................................................75 1.6.3.1 Signals to NC...............................................................................................................................75 1.6.3.2 Signals from NC...........................................................................................................................76 Contents Extended Functions 10 Function Manual, 03/2010, 6FC5397-1BP20-1BA0 2 B3: Several operator panels connected to several NCUs, distributed systems - only 840D sl ................. 77 2.1 Brief description .......................................................................................................................... 77 2.1.1 Topology of distributed system configurations............................................................................ 77 2.1.2 Several operator panels and NCUs with control unit management (option)............................... 82 2.1.2.1 General information..................................................................................................................... 82 2.1.2.2 System features .......................................................................................................................... 83 2.1.2.3 Hardware..................................................................................................................................... 84 2.1.2.4 Functions..................................................................................................................................... 86 2.1.2.5 Configurability ............................................................................................................................. 88 2.1.3 Several operator panel fronts and NCUs, standard functionality................................................ 88 2.1.3.1 System features .......................................................................................................................... 88 2.1.3.2 Functions..................................................................................................................................... 89 2.1.3.3 Configurability ............................................................................................................................. 92 2.1.3.4 MPI/OPI network rules ................................................................................................................ 96 2.1.4 NCU link ...................................................................................................................................... 97 2.1.4.1 General information..................................................................................................................... 97 2.1.4.2 Technological description.......................................................................................................... 100 2.1.4.3 Link axes ................................................................................................................................... 102 2.1.4.4 Axis container............................................................................................................................ 103 2.1.4.5 User-specification link communication via link variables .......................................................... 103 2.1.4.6 Lead-link axes ........................................................................................................................... 104 2.2 Several operator panel fronts and NCUs with control unit management option....................... 105 2.2.1 Hardware structure.................................................................................................................... 105 2.2.2 Properties.................................................................................................................................. 105 2.2.3 Configuration file NETNAMES.INI ............................................................................................ 107 2.2.4 Structure of the configuration file .............................................................................................. 107 2.2.5 Creating and using the configuration file................................................................................... 112 2.2.6 Power up................................................................................................................................... 113 2.2.7 HMI switchover.......................................................................................................................... 116 2.2.8 Suppression .............................................................................................................................. 116 2.2.9 Connection and switchover conditions...................................................................................... 118 2.2.10 Implementation of control unit switchover................................................................................. 119 2.2.11 Operator interface ..................................................................................................................... 119 2.2.12 Operating mode switchover ...................................................................................................... 121 2.2.13 MCP switchover ........................................................................................................................ 123 2.3 Several operator panel fronts and NCUs, standard functionality.............................................. 124 2.3.1 Configurations ........................................................................................................................... 124 2.3.2 Switchover of connection to another NCU................................................................................ 128 2.3.3 Creating and using the configuration file................................................................................... 129 2.3.4 Power up................................................................................................................................... 129 2.3.5 NCU replacement...................................................................................................................... 130 2.4 Restrictions for switchover of operator components................................................................. 132 2.5 Link communication .................................................................................................................. 133 2.5.1 General information................................................................................................................... 133 2.5.2 Parameter assignment: NC system cycles ............................................................................... 134 2.5.3 Parameter assignment: Link communication............................................................................ 135 2.5.4 Configuration............................................................................................................................. 136 2.5.5 Wiring the NCUs ....................................................................................................................... 137 2.5.6 Activation................................................................................................................................... 137 2.6 Link axes ................................................................................................................................... 138 2.6.1 Configuration of link axes and container axes .......................................................................... 140 2.6.2 Axis data and signals ................................................................................................................ 144 Contents Extended Functions Function Manual, 03/2010, 6FC5397-1BP20-1BA0 11 2.6.3 Output of predefined auxiliary functions in the case of an NCU link..........................................146 2.6.4 Supplementary conditions for link axes .....................................................................................147 2.6.5 Programming with channel and machine axis identifiers...........................................................149 2.6.6 Flexible configuration.................................................................................................................149 2.7 Axis container.............................................................................................................................150 2.7.1 System variables for axis containers .........................................................................................156 2.7.2 Machining with axis container (schematic) ................................................................................158 2.7.3 Axis container behavior after Power ON....................................................................................159 2.7.4 Axis container response to mode switchover ............................................................................159 2.7.5 Axis container behavior in relation to ASUBs ............................................................................159 2.7.6 Axis container response to RESET ...........................................................................................159 2.7.7 Axis container response to block searches ...............................................................................159 2.7.8 Supplementary conditions for axis container rotations ..............................................................159 2.8 User-specific link variables ........................................................................................................163 2.8.1 Link variables .............................................................................................................................163 2.8.2 Reading drive data via link variables .........................................................................................168 2.9 System of units within a link grouping........................................................................................173 2.10 Supplementary conditions..........................................................................................................174 2.10.1 Several operator panels and NCUs with control unit management option................................174 2.10.2 Several operator panel fronts and NCUs, standard functionality...............................................174 2.10.3 Link axes....................................................................................................................................175 2.10.4 Axis container.............................................................................................................................175 2.10.5 Lead-link axis .............................................................................................................................175 2.11 Examples ...................................................................................................................................176 2.11.1 Configuration file NETNAMES.INI with control unit management option..................................176 2.11.2 User-specific reconfiguring of PLC program control unit switchover .........................................179 2.11.2.1 Description of operational sequences (overview) ......................................................................179 2.11.2.2 Description of operational sequences (details)..........................................................................180 2.11.2.3 Defined logical functions/defines ...............................................................................................189 2.11.2.4 Graphical representation of function sequences .......................................................................190 2.11.3 Configuration file NETNAMES.INI, standard functionality .........................................................197 2.11.3.1 Two operator panel fronts and one NCU...................................................................................197 2.11.3.2 One operator panel front and three NCUs.................................................................................198 2.11.4 Quick M:N commissioning based on examples.........................................................................199 2.11.4.1 Example 1 ..................................................................................................................................199 2.11.4.2 Example 2 ..................................................................................................................................202 2.11.4.3 Example 3 ..................................................................................................................................208 2.11.4.4 Description of FB9 .....................................................................................................................212 2.11.4.5 Example of calling FB9 ..............................................................................................................215 2.11.4.6 Example of override switchover .................................................................................................216 2.11.4.7 Switchover between MCP and HT6...........................................................................................218 2.11.4.8 General Information ...................................................................................................................219 2.11.5 Link axis .....................................................................................................................................221 2.11.6 Axis container coordination........................................................................................................222 2.11.6.1 Axis container rotation without a part program wait...................................................................222 2.11.6.2 Axis container rotation with an implicit part program wait..........................................................223 2.11.6.3 Axis container rotation by one channel only (e.g. during power up)..........................................223 2.11.7 Evaluating axis container system variables...............................................................................223 2.11.7.1 Conditional branch.....................................................................................................................223 2.11.7.2 Static synchronized action with $AN_AXCTSWA......................................................................223 2.11.7.3 Wait for certain completion of axis container rotation................................................................224 2.11.8 Configuration of a multi-spindle turning machine.......................................................................225 Contents Extended Functions 12 Function Manual, 03/2010, 6FC5397-1BP20-1BA0 2.11.9 Lead-link axis ............................................................................................................................ 234 2.11.9.1 Configuration............................................................................................................................. 234 2.11.9.2 Programming............................................................................................................................. 236 2.12 Data lists.................................................................................................................................... 237 2.12.1 Machine data............................................................................................................................. 237 2.12.1.1 General machine data............................................................................................................... 237 2.12.1.2 Channel-specific machine data................................................................................................. 237 2.12.1.3 Axis/spindle-specific machine data........................................................................................... 238 2.12.2 Setting data............................................................................................................................... 238 2.12.2.1 General setting data.................................................................................................................. 238 2.12.2.2 Axis/spindle-specific setting data.............................................................................................. 238 2.12.3 Signals....................................................................................................................................... 238 2.12.3.1 Signals from NC........................................................................................................................ 238 2.12.3.2 Signals from HMI/PLC............................................................................................................... 239 2.12.3.3 General online interface............................................................................................................ 239 2.12.3.4 Signals from axis/spindle .......................................................................................................... 241 2.12.4 System variables....................................................................................................................... 241 2.12.4.1 System variables....................................................................................................................... 241 3 B4: Operation via PG/PC - only 840D sl ................................................................................................ 243 3.1 Brief description ........................................................................................................................ 243 3.2 Software installation.................................................................................................................. 245 3.2.1 System requirements ................................................................................................................ 245 3.2.2 Installation................................................................................................................................. 246 3.2.3 Supplementary software conditions.......................................................................................... 251 3.2.4 Start program............................................................................................................................ 251 3.2.5 Close program........................................................................................................................... 251 3.3 Operation via PG/PC................................................................................................................. 253 3.3.1 General operation ..................................................................................................................... 253 3.3.2 Additional information................................................................................................................ 256 3.3.3 Operation of operator panel fronts............................................................................................ 257 3.4 Simulation of part programs...................................................................................................... 257 3.5 Marginal conditions ................................................................................................................... 258 3.6 Data lists.................................................................................................................................... 258 4 H1: Manual travel and handwheel travel ................................................................................................ 259 4.1 Brief description ........................................................................................................................ 259 4.1.1 Overview ................................................................................................................................... 259 4.1.2 General characteristics of manual travel in JOG...................................................................... 260 4.1.3 Control of manual-travel functions via PLC interface................................................................ 263 4.1.4 Control-system response to power ON, mode change, RESET, block search, REPOS.......... 265 4.2 Continuous travel ...................................................................................................................... 266 4.2.1 General functionality ................................................................................................................. 266 4.2.2 Distinction between inching mode continuous mode................................................................ 267 4.2.3 Special features of continuous travel ........................................................................................ 268 4.3 Incremental travel (INC) ............................................................................................................ 269 4.3.1 General functionality ................................................................................................................. 269 4.3.2 Distinction between inching mode and continuous mode......................................................... 270 4.3.3 Special features of incremental travel ....................................................................................... 271 Contents Extended Functions Function Manual, 03/2010, 6FC5397-1BP20-1BA0 13 4.4 Handwheel travel in JOG...........................................................................................................272 4.4.1 General functionality ..................................................................................................................272 4.4.2 Travel request ............................................................................................................................277 4.4.3 Double use of the handwheel ....................................................................................................281 4.5 Handwheel override in automatic mode ....................................................................................283 4.5.1 General functionality ..................................................................................................................283 4.5.2 Programming and activating handwheel override......................................................................287 4.5.3 Special features of handwheel override in automatic mode......................................................289 4.6 Contour handwheel/path input using handwheel (option) .........................................................291 4.7 DRF offset ..................................................................................................................................293 4.8 Start-up: Handwheels ................................................................................................................297 4.8.1 General information ...................................................................................................................297 4.8.2 Connection via PPU - only 828D ...............................................................................................298 4.8.3 Connected via PROFIBUS - only 840D sl .................................................................................299 4.8.4 Connected via Ethernet - only 840D sl ......................................................................................302 4.9 Special features of manual travel ..............................................................................................305 4.9.1 Geometry-axis manual travel .....................................................................................................305 4.9.2 Special features of spindle manual travel ..................................................................................307 4.9.3 Monitoring functions...................................................................................................................308 4.9.4 Other ..........................................................................................................................................310 4.10 Approaching a fixed point in JOG..............................................................................................311 4.10.1 Introduction ................................................................................................................................311 4.10.2 Functionality...............................................................................................................................312 4.10.3 Parameter setting.......................................................................................................................314 4.10.4 Programming..............................................................................................................................315 4.10.5 Supplementary conditions..........................................................................................................315 4.10.6 Application example...................................................................................................................316 4.11 Data lists ....................................................................................................................................318 4.11.1 Machine data..............................................................................................................................318 4.11.1.1 General machine data................................................................................................................318 4.11.1.2 Channel-specific machine data..................................................................................................318 4.11.1.3 Axis/spindle-specific machine data............................................................................................319 4.11.2 Setting data................................................................................................................................319 4.11.2.1 General setting data...................................................................................................................319 4.11.3 Signals .......................................................................................................................................320 4.11.3.1 Signals from NC.........................................................................................................................320 4.11.3.2 Signals to mode group...............................................................................................................320 4.11.3.3 Signals from mode group...........................................................................................................320 4.11.3.4 Signals to channel......................................................................................................................320 4.11.3.5 Signals from channel .................................................................................................................321 4.11.3.6 Signals to axis/spindle ...............................................................................................................321 4.11.3.7 Signals from axis/spindle ...........................................................................................................322 5 K3: Compensation ................................................................................................................................. 323 5.1 Introduction ................................................................................................................................323 5.2 Temperature compensation.......................................................................................................324 5.2.1 Description of functions..............................................................................................................324 5.2.2 Commissioning...........................................................................................................................327 5.2.2.1 Temperature-dependent parameters.........................................................................................327 5.2.2.2 Temperature compensation type and activation........................................................................328 5.2.2.3 Maximum compensation value per IPO clock cycle ..................................................................328 Contents Extended Functions 14 Function Manual, 03/2010, 6FC5397-1BP20-1BA0 5.2.3 Example .................................................................................................................................... 329 5.2.3.1 Commissioning the temperature compensation for the Z axis of a lathe.................................. 329 5.3 Backlash compensation ............................................................................................................ 332 5.3.1 Description of functions............................................................................................................. 332 5.3.2 Commissioning.......................................................................................................................... 333 5.3.2.1 Backlash.................................................................................................................................... 333 5.3.2.2 Weighting factor for backlash.................................................................................................... 333 5.3.2.3 Applying the backlash compensation step-by-step................................................................... 334 5.4 Interpolatory compensation....................................................................................................... 334 5.4.1 General properties .................................................................................................................... 334 5.4.2 Compensation of leadscrew errors and measuring system errors ........................................... 338 5.4.2.1 Measuring system error compensation (MSEC) ....................................................................... 338 5.4.2.2 Commissioning.......................................................................................................................... 339 5.4.2.3 Example .................................................................................................................................... 342 5.4.3 Compensation of sag and angularity errors.............................................................................. 343 5.4.3.1 Description of functions............................................................................................................. 343 5.4.3.2 Commissioning.......................................................................................................................... 348 5.4.3.3 Examples................................................................................................................................... 352 5.4.4 Direction-dependent leadscrew error compensation ................................................................ 361 5.4.4.1 Description of functions............................................................................................................. 361 5.4.4.2 Commissioning.......................................................................................................................... 362 5.4.4.3 Example .................................................................................................................................... 366 5.4.5 Extension of the sag compensation with NCU link - only 840D sl ............................................ 370 5.4.6 Special features of interpolatory compensation........................................................................ 378 5.5 Dynamic feedforward control (following error compensation)................................................... 379 5.5.1 General properties .................................................................................................................... 379 5.5.2 Speed feedforward control ........................................................................................................ 382 5.5.3 Torque feedforward control - only 840D sl (option) .................................................................. 384 5.5.4 Dynamic response adaptation .................................................................................................. 386 5.5.5 Forward feed control for command and PLC axes ................................................................... 387 5.5.6 Secondary conditions................................................................................................................ 388 5.6 Friction compensation (quadrant error compensation) ............................................................. 389 5.6.1 General properties .................................................................................................................... 389 5.6.2 Conventional friction compensation.......................................................................................... 391 5.6.2.1 Conventional friction compensation.......................................................................................... 391 5.6.2.2 Commissioning of conventional friction compensation............................................................. 393 5.6.3 Quadrant error compensation using neural networks - only 840D sl........................................ 402 5.6.3.1 Fundamentals ........................................................................................................................... 402 5.6.3.2 Parameterization of neural QEC............................................................................................... 405 5.6.3.3 Learning the neural network...................................................................................................... 411 5.6.3.4 Commissioning of neural QEC.................................................................................................. 415 5.6.3.5 Further optimization and intervention options........................................................................... 419 5.6.3.6 Quick commissioning ................................................................................................................ 425 5.7 Circularity test ........................................................................................................................... 428 5.8 Measures for hanging (suspended) axes.................................................................................. 433 5.8.1 Electronic counterweight ........................................................................................................... 433 5.8.2 Reboot delay ............................................................................................................................. 435 5.9 Data lists.................................................................................................................................... 437 5.9.1 Machine data............................................................................................................................. 437 5.9.1.1 General machine data............................................................................................................... 437 5.9.1.2 Channel-specific machine data................................................................................................. 437 5.9.1.3 Axis/spindle-specific machine data........................................................................................... 438 Contents Extended Functions Function Manual, 03/2010, 6FC5397-1BP20-1BA0 15 5.9.2 Setting data................................................................................................................................439 5.9.2.1 General setting data...................................................................................................................439 5.9.2.2 Axis/spindle-specific setting data...............................................................................................439 5.9.3 Signals .......................................................................................................................................440 5.9.3.1 Signals from NC.........................................................................................................................440 5.9.3.2 Signals from mode group...........................................................................................................440 5.9.3.3 Signals from channel .................................................................................................................440 5.9.3.4 Signals from axis/spindle ...........................................................................................................440 6 K5: Mode groups, channels, axis interchange ....................................................................................... 441 6.1 Brief description .........................................................................................................................441 6.2 Mode groups - only 840D sl .......................................................................................................443 6.3 Channels - only 840D sl .............................................................................................................444 6.3.1 Channel synchronization (program coordination) ......................................................................444 6.3.2 Conditional wait in continuous path mode WAITMC .................................................................447 6.3.3 Running-in channel-by-channel .................................................................................................451 6.4 Axis/spindle replacement ...........................................................................................................457 6.4.1 Introduction ................................................................................................................................457 6.4.2 Example of an axis replacement................................................................................................460 6.4.3 Axis replacement options...........................................................................................................461 6.4.4 Replacement behavior NC program..........................................................................................462 6.4.5 Axis transfer to neutral state (release).......................................................................................463 6.4.6 Transferring axis or spindle in the part program........................................................................464 6.4.7 Automatic axis replacement.......................................................................................................466 6.4.8 Axis replacement via PLC..........................................................................................................468 6.4.9 Set axis replacement behavior variable.....................................................................................471 6.4.10 Axis replacement via axis container rotation .............................................................................472 6.4.11 Axis replacement with and without preprocessing stop.............................................................473 6.4.12 Axis exclusively controlled from the PLC...................................................................................474 6.4.13 Axis permanently assigned to the PLC......................................................................................475 6.4.14 Geometry axis in rotated frame and axis replacement ..............................................................476 6.4.15 Axis replacement from synchronized actions ............................................................................478 6.4.16 Axis interchange for leading axes (gantry) ................................................................................480 6.5 Marginal conditions....................................................................................................................481 6.6 Data lists ....................................................................................................................................483 6.6.1 Machine data..............................................................................................................................483 6.6.1.1 General machine data................................................................................................................483 6.6.1.2 Channel-specific machine data..................................................................................................483 6.6.1.3 Axis/spindle-specific machine data............................................................................................485 6.6.2 Setting data................................................................................................................................486 6.6.2.1 Channel-specific setting data.....................................................................................................486 6.6.3 Signals .......................................................................................................................................486 6.6.3.1 Signals to/from BAG ..................................................................................................................486 6.6.3.2 Signals to/from channel .............................................................................................................486 7 M1: Kinematic transformation ................................................................................................................ 487 7.1 Brief description .........................................................................................................................487 7.1.1 TRANSMIT (option) ...................................................................................................................487 7.1.2 TRACYL (option)........................................................................................................................488 7.1.3 TRAANG (option).......................................................................................................................489 7.1.4 Chained transformations............................................................................................................489 7.1.5 Activating transformation machine data via parts program/softkey...........................................490 Contents Extended Functions 16 Function Manual, 03/2010, 6FC5397-1BP20-1BA0 7.2 TRANSMIT (option)................................................................................................................... 490 7.2.1 Preconditions for TRANSMIT.................................................................................................... 492 7.2.2 Settings specific to TRANSMIT................................................................................................. 495 7.2.3 Activation of TRANSMIT........................................................................................................... 499 7.2.4 Deactivation of the TRANSMIT function ................................................................................... 499 7.2.5 Special system reactions with TRANSMIT ............................................................................... 500 7.2.6 Machining options for TRANSMIT ............................................................................................ 504 7.2.7 Working area limitations............................................................................................................ 511 7.2.8 Overlaid motions with TRANSMIT ............................................................................................ 512 7.2.9 Monitoring of rotary axis rotations over 360 ............................................................................ 512 7.2.10 Constraints ................................................................................................................................ 513 7.3 TRACYL (option)....................................................................................................................... 514 7.3.1 Preconditions for TRACYL........................................................................................................ 518 7.3.2 Settings specific to TRACYL..................................................................................................... 522 7.3.3 Activation of TRACYL ............................................................................................................... 527 7.3.4 Deactivation of the TRACYL function ....................................................................................... 528 7.3.5 Special system reactions with TRACYL.................................................................................... 528 7.3.6 Jog............................................................................................................................................. 531 7.4 TRAANG (option) ...................................................................................................................... 532 7.4.1 Preconditions for TRAANG (inclined axis) ................................................................................ 534 7.4.2 Settings specific to TRAANG.................................................................................................... 536 7.4.3 Activation of TRAANG............................................................................................................... 539 7.4.4 Deactivation of TRAANG.......................................................................................................... 540 7.4.5 Special system reactions with TRAANG................................................................................... 540 7.4.6 Inclined axis programming (G05, G07) ..................................................................................... 542 7.5 Chained transformations........................................................................................................... 543 7.5.1 Activating chained transformations........................................................................................... 546 7.5.2 Switching off a chained transformation..................................................................................... 546 7.5.3 Special characteristics of chained transformations................................................................... 547 7.5.4 Persistent transformation .......................................................................................................... 547 7.5.5 Axis positions in the transformation chain................................................................................. 553 7.6 Cartesian PTP travel ................................................................................................................. 556 7.6.1 Programming of position ........................................................................................................... 559 7.6.2 Overlap areas of axis angles..................................................................................................... 560 7.6.3 Examples of ambiguities of position.......................................................................................... 561 7.6.4 Example of ambiguity in rotary axis position............................................................................. 562 7.6.5 PTP/CP switchover in JOG mode............................................................................................. 562 7.7 Cartesian manual travel (optional) ............................................................................................ 563 7.8 Activating transformation machine data via parts program/softkey .......................................... 572 7.8.1 Functionality .............................................................................................................................. 572 7.8.2 Constraints ................................................................................................................................ 573 7.8.3 Control response to power ON, mode change, RESET, block search, REPOS ...................... 575 7.8.4 List of machine data affected.................................................................................................... 575 7.9 Constraints ................................................................................................................................ 579 7.9.1 Chained transformations........................................................................................................... 579 7.10 Examples................................................................................................................................... 580 7.10.1 TRANSMIT................................................................................................................................ 580 7.10.2 TRACYL.................................................................................................................................... 582 7.10.3 TRAANG................................................................................................................................... 587 7.10.4 Chained transformations........................................................................................................... 589 7.10.5 Activating transformation MD via a parts program.................................................................... 593 Contents Extended Functions Function Manual, 03/2010, 6FC5397-1BP20-1BA0 17 7.10.6 Axis positions in the transformation chain .................................................................................594 7.11 Data lists ....................................................................................................................................598 7.11.1 Machine data..............................................................................................................................598 7.11.1.1 TRANSMIT.................................................................................................................................598 7.11.1.2 TRACYL.....................................................................................................................................599 7.11.1.3 TRAANG....................................................................................................................................601 7.11.1.4 Chained transformations............................................................................................................602 7.11.1.5 Non transformation-specific machine data ................................................................................602 7.11.2 Signals .......................................................................................................................................602 7.11.2.1 Signals from channel .................................................................................................................602 8 M5: Measuring....................................................................................................................................... 603 8.1 Brief description .........................................................................................................................603 8.2 Hardware requirements .............................................................................................................604 8.2.1 Probes that can be used............................................................................................................604 8.2.2 Measuring probe connection......................................................................................................606 8.3 Channel-specific measuring.......................................................................................................611 8.3.1 Measuring mode ........................................................................................................................611 8.3.2 Measurement results .................................................................................................................612 8.4 Setting zeros, workpiece measuring and tool measuring..........................................................613 8.4.1 Preset actual value memory and scratching..............................................................................613 8.4.2 Workpiece measuring ................................................................................................................614 8.4.2.1 Input values................................................................................................................................614 8.4.2.2 Measurement selection..............................................................................................................622 8.4.2.3 Output values.............................................................................................................................623 8.4.2.4 Calculation method ....................................................................................................................623 8.4.2.5 Units of measurement and measurement variables for the calculation.....................................626 8.4.2.6 Diagnostics.................................................................................................................................628 8.4.3 Types of workpiece measurement .............................................................................................628 8.4.3.1 Measurement of an edge (measurement type 1, 2, 3) ..............................................................628 8.4.3.2 Measurement of an angle (measurement type 4, 5, 6, 7)..........................................................633 8.4.3.3 Measurement of a hole (measurement type 8)..........................................................................637 8.4.3.4 Measurement of a shaft (measurement type 9).........................................................................640 8.4.3.5 Measurement of a groove (measurement type 12)....................................................................641 8.4.3.6 Measurement of a web (measurement type 13) ........................................................................644 8.4.3.7 Measurement of geo axes and special axes (measurement type 14, 15).................................645 8.4.3.8 Measurement of an oblique edge (measurement type 16)........................................................647 8.4.3.9 Measurement of an oblique angle in a plane (measurement type 17) ......................................649 8.4.3.10 Redefine measurement around a WCS reference frame (measurement type 18)....................653 8.4.3.11 Measurement of a 1-, 2- and 3-dimensional setpoint selection (measurement type 19, 20, 21) ..............................................................................................................................................656 8.4.3.12 Measurement of an oblique angle (measurement type 24) .......................................................661 8.4.3.13 Measurement of a rectangle (measurement type 25)................................................................665 8.4.3.14 Measurement for saving data management frames (measurement type 26)............................667 8.4.3.15 Measurement for restoring backed-up data management frames (measurement type 27) ......668 8.4.3.16 Measurement for defining an additive rotation for taper turning (measurement type 28)..........669 8.4.4 Tool measuring ..........................................................................................................................670 8.4.5 Types of workpiece measurement .............................................................................................671 8.4.5.1 Measurement of tool lengths (measurement type 10) ...............................................................671 8.4.5.2 Measurement of tool diameter (measurement type 11).............................................................673 8.4.5.3 Measurement of tool lengths with zoom-in function (measurement type 22) ............................674 8.4.5.4 Measuring a tool length with stored or current position (measurement type 23).......................675 8.4.5.5 Measurement of a tool length of two tools with orientation........................................................677 Contents Extended Functions 18 Function Manual, 03/2010, 6FC5397-1BP20-1BA0 8.5 Measurement accuracy and functional testing.......................................................................... 688 8.5.1 Measurement accuracy............................................................................................................. 688 8.5.2 Probe functional testing............................................................................................................. 689 8.6 Simulated measuring ................................................................................................................ 690 8.6.1 General functionality ................................................................................................................. 690 8.6.2 Position-related switch request ................................................................................................. 690 8.6.3 External switch request ............................................................................................................. 692 8.6.4 System variable......................................................................................................................... 693 8.7 Examples - only 840D sl ........................................................................................................... 693 8.7.1 Measuring mode 1 .................................................................................................................... 693 8.7.2 Measuring mode 2 .................................................................................................................... 694 8.7.3 Continuous measurement ......................................................................................................... 695 8.7.3.1 Continous measurement on completion of programmed traversing motion............................. 695 8.7.3.2 Continuous measurements with deletion of distance-to-go...................................................... 695 8.7.3.3 Continuous measurements modally over several blocks.......................................................... 696 8.7.4 Functional test and repeat accuracy......................................................................................... 697 8.8 Data lists.................................................................................................................................... 699 8.8.1 Machine data............................................................................................................................. 699 8.8.1.1 General machine data............................................................................................................... 699 8.8.1.2 Channel-specific machine data................................................................................................. 699 8.8.2 System variables....................................................................................................................... 699 9 N3: Software cams, position switching cycles - only 840D sl ................................................................. 701 9.1 Brief description ........................................................................................................................ 701 9.2 Cam signals and cam positions ................................................................................................ 702 9.2.1 Generation of cam signals for separate output ......................................................................... 702 9.2.2 Generation of cam signals with gated output............................................................................ 706 9.2.3 Cam positions ........................................................................................................................... 711 9.2.4 Lead/delay times (dynamic cam) .............................................................................................. 712 9.3 Output of cam signals ............................................................................................................... 714 9.3.1 Activating................................................................................................................................... 714 9.3.2 Output of cam signals to PLC................................................................................................... 714 9.3.3 Output of cam signals to NCK I/Os in position control cycle..................................................... 715 9.3.4 Timer-controlled cam signal output ........................................................................................... 717 9.3.5 Independent, timer-controlled output of cam signals................................................................ 718 9.4 Position-time cams.................................................................................................................... 720 9.5 Supplementary conditions......................................................................................................... 722 9.6 Data lists.................................................................................................................................... 723 9.6.1 Machine data............................................................................................................................. 723 9.6.1.1 General machine data............................................................................................................... 723 9.6.2 Setting data............................................................................................................................... 724 9.6.2.1 General setting data.................................................................................................................. 724 9.6.3 Signals....................................................................................................................................... 724 9.6.3.1 Signals to axis/spindle............................................................................................................... 724 9.6.3.2 Signals from axis/spindle .......................................................................................................... 724 Contents Extended Functions Function Manual, 03/2010, 6FC5397-1BP20-1BA0 19 10 N4: Punching and nibbling - only 840D sl .............................................................................................. 725 10.1 Brief description .........................................................................................................................725 10.2 Stroke control .............................................................................................................................725 10.2.1 General information ...................................................................................................................725 10.2.2 High-speed signals ....................................................................................................................726 10.2.3 Criteria for stroke initiation .........................................................................................................728 10.2.4 Axis start after punching ............................................................................................................730 10.2.5 PLC signals specific to punching and nibbling...........................................................................731 10.2.6 Punching and nibbling-specific reactions to standard PLC signals ...........................................731 10.2.7 Signal monitoring .......................................................................................................................732 10.3 Activation and deactivation ........................................................................................................732 10.3.1 Language commands ................................................................................................................732 10.3.2 Functional expansions ...............................................................................................................737 10.3.3 Compatibility with earlier systems..............................................................................................742 10.4 Automatic path segmentation ....................................................................................................744 10.4.1 General information ...................................................................................................................744 10.4.2 Operating characteristics with path axes...................................................................................746 10.4.3 Response in connection with single axes..................................................................................750 10.5 Rotatable tool .............................................................................................................................754 10.5.1 General information ...................................................................................................................754 10.5.2 Coupled motion of punch and die..............................................................................................755 10.5.3 Tangential control ......................................................................................................................756 10.6 Protection zones ........................................................................................................................760 10.7 Supplementary conditions..........................................................................................................760 10.8 Examples ...................................................................................................................................761 10.8.1 Examples of defined start of nibbling operation.........................................................................761 10.9 Data lists ....................................................................................................................................766 10.9.1 Machine data..............................................................................................................................766 10.9.1.1 General machine data................................................................................................................766 10.9.1.2 Channel-specific machine data..................................................................................................766 10.9.2 Setting data................................................................................................................................767 10.9.2.1 Channel-specific setting data.....................................................................................................767 10.9.3 Signals .......................................................................................................................................767 10.9.3.1 Signals to channel......................................................................................................................767 10.9.3.2 Signals from channel .................................................................................................................767 10.9.4 Language commands ................................................................................................................768 11 P2: Positioning axes .............................................................................................................................. 769 11.1 Brief description .........................................................................................................................769 11.2 Own channel, positioning axis or concurrent positioning axis ...................................................771 11.2.1 Own channel - only 840D sl .......................................................................................................772 11.2.2 Positioning axis (posAxis) ..........................................................................................................773 11.2.3 Concurrent positioning axis........................................................................................................775 11.3 Motion behavior and interpolation functions ..............................................................................777 11.3.1 Path interpolator and axis interpolator .......................................................................................777 11.3.2 Interpolation response of path axis in G0 ..................................................................................777 11.3.3 Autonomous single-axis operations...........................................................................................779 11.3.4 Autonomous single-axis functions with NC-controlled ESR......................................................787 11.4 Velocity.......................................................................................................................................789 Contents Extended Functions 20 Function Manual, 03/2010, 6FC5397-1BP20-1BA0 11.5 Programming............................................................................................................................. 790 11.5.1 General...................................................................................................................................... 790 11.5.2 Revolutional feed rate in external programming....................................................................... 793 11.6 Block change............................................................................................................................. 793 11.6.1 Settable block change time....................................................................................................... 797 11.6.2 End of motion criterion with block search ................................................................................. 805 11.7 Control by the PLC.................................................................................................................... 806 11.7.1 Starting concurrent positioning axes from the PLC .................................................................. 808 11.7.2 PLC-controlled axes...........................................................