operation application

DiagnosisOperation, Application

Typ1 osa / CC 220

101Version

Typ1 osa / CC 220

DiagnosisOperation, Application1070 073 306-101 (91.10) GB

(V25)

E 1991

by Robert Bosch GmbH,All rights reserved, including applications for protective rights.

Reproduction or handing over to third parties are subject to our written permission.

Discretionary charge 10.– DM

CC 220 / 320DiagnosisFlexible Automation

Contents

C – 1

Contents

1. General 1 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Safety instructions − 1 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Calling the diagnostic programs 1 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Description of the diagnostic programs

D1 Logbook − D1 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5 Internal reference point offset D5 – 1. . . . . . . . . . . . . . . . . . . . . . . D6 Interface data D6 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D7 Communication store display D7 – 1. . . . . . . . . . . . . . . . . . . . . . . D9 EEPROM management − D9 – 1. . . . . . . . . . . . . . . . . . . . . . . . . D21 Logic analyzer − D21 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D22 Axis oscilloscope − D22 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D23 Contour display − D23 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D24 Axis optimization D24 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D25 Lead screw error compensation − D25 – 1. . . . . . . . . . . . . . . . . D26 CNC remote diagnosis (information) D26 – 1. . . . . . . . . . . . . . . . D27 Putting into operation for circular compensation ‘ D27 – 1. . . D28 Tapping ‘ D28 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Notes: Diagnostic programs which are not available in the CC 200/300 are identified byan ‘ in front of the page number.If a diagnostic program contains new or modified functions – compared with thecontrols of the Type CC 200/300 –, this is indicated by a − in front of the page num-ber.

The following diagnostic programs are intended exclusively for BOSCH servicepersonnel and are not described in this manual:D2 Reloading the operating programD3 Cancelling all memory

Separate manuals are available for the diagnostic programs D4 and D26:D4 Machine parameter program CC 220 M/T: P. No.: 4201

CC 320 M: P. No.: 4180D26 CNC remote diagnosis P. No.: 4184

The diagnostic programs D8 Change languageD10 Library managementimplemented in the CC 220/320 are no longer present as special diagnostic pro-grams in controls of the type CC 220/320, but can now be called directly by wayof softkey. Please refer to the appropriate operating manual for operating instruc-tions.


Contents

C – 2


General

1 – 1

1. General

This manual refers to the software version V25 for the controls CC 220/320.

The diagnostic programs D21 to D28 are options which are subject to charge.

2. Safety instructions

Diagnostic programs permit critical changes to be made in the interaction of CNC,machine and drives right up to complete deletion of the CNC memory.If they are used by insufficiently trained or untrained personnel, this may thus resultin serious damage to the machine and drives, loss of software or even injury!For this reason, diagnostic programs must be started and operated only bycorrespondingly trained expert personnel.In this context, please note our extensive range of training courses. You will findan overview of the available seminars on the inner cover of this manual. Our train-ing center will gladly provide you with further information.

In some diagnostic programs, axes have to be traversed in order to optimize CNCservo loops and drives.For this reason, make sure that no one enters the machine’s danger area dur-ing execution of such diagnostic programs.

The following symbols are used in this manual in order to point out certain thingswhich are relevant to safety:

Axis movement possible!For this reason, make sure that there are no persons or objects in the machine’sdanger area.Make sure that no collisions are possible in the axis traversing range.

Machine parameter record is modified! This is followed by a CNC restart. The modi-fied machine parameters are active after this.Is there a backup of the original machine parameters?BOSCH will not be liable for damaging resulting from incorrectly calculated, pro-grammed or optimized machine parameters or non–observance of limit data!

Active axis processor data is modified!This effects the axis response.

Data loss possible!Data in the user RAM (part programs, tables etc.) may possibly be deleted or over-written.Do you possess a backup of this data?

3. Calling the diagnostic programs

MOVE

MP

SERVO

DATA


General

1 – 2

The following monitor display appears after selection of group operating mode

(DIAGNOSTIC):

The control displays all available diagnostic programs after operation of the softkeySERVICE FUNCTION (possibly only after input of a code number; refer to the sec-tion ”Notes”):

The system asks for the number of the desired program when the softkey STARTis pressed. Input of the program number is acknowledged with the ENTER key. TheCNC then starts the corresponding diagnostic program.

No CP0ACT

NC0STOP

DIAGNOSTIC12. 5 16:53PROGRAM

ERROR CONDITION ON STATUS

DIAGNOSTICCONTROL

DIAGNOSTICMACHINE

RESETFUNCTION

SERVICEFUNCTION

GGGGGGGGGG

GGGGGGGGGG

GGGGGGGGGG

9094141580

1533965

146994

16640

829

1302536268

115

71140

7277953679799

167

DRIVE ON

AT LAST PROGR.F 0.0 M 0T 0

No CP0ACT

NC0WAIT

DIAGNOSTIC14.10 8:28PROGRAM

NUMBER PROGRAM NAME LENGTH

DATA IN DATA OUT START DELETE

SERVICE FUNCTION

ACCESSDDDDDDDDDDDDDD

12345679

212223242527

LOGBOOK MONITORRELOAD OPERATING PROGRAMCANCEL ALL MEMORYMACHINE PARAMETER PROGRAMINTERNAL REF. POINT OFFSETINTERFACE DATACOMMUNICATION STORE DISPLAYMANAGE EEPROMLOGIC–ANALYZERAXIS OSCILLOSCOPECONTOUR DISPLAYAXIS OPTIMIZATIONLEAD SCREW ERROR COMPENSATIONPUTTING INTO OPERATION FOR CIRCULAR COMPENSATION

MEMORY USED BY DIAG.:MEMORY AVAILABLE:

44384 OTHERS: 2658

EEEEEEEEEEEEEE

2574398


General

1 – 3

Notes:

‘ If the softkey RESET FUNCTION and then softkey CLEAR ALL LOGIC arepressed in group operating mode DIAGNOSTIC, it is possible to enter thesoftkey level SERVICE FUNCTION only by input of a code number as fromthis point in time.When a correct code number has been entered, the softkey level SERVICEFUNCTION is accessible without input of the code number until renewed op-eration of the softkey sequence DIAGNOSTIC, RESET FUNCTION, CLEARALL LOGIC.

‘ Some diagnostic programs create files with the group identifier ”L” or ”D” forrecording data. This reduces the memory space which is available for partprograms.

‘ Data recordings can be repeated any number of times within diagnostic pro-grams, since the previous recording is overwritten by each new recording. All other operating modes of the control can be used during recording of databy a diagnostic program.Exception: CONTROL RESET and selection of a different diagnostic pro-gram cancel the currently active diagnostic program (except for D21).


General

1 – 4


D1 Logbook

D1 – 5

4. Description of the diagnostic programs

D1 – Logbook

General

The diagnostic program D1 is used for management of one or more ”logbooks”. Alogbook is a file with the identifier ”D” which contains various data for reconstructionof operating sequences, error messages or warnings etc. This file is divided into5 ring memories which store warnings, errors, system errors, other messages andoperating steps in the order of their occurrence.

Activating/deactivating a logbook

There are two possibilities for activation of a logbook:

‘ Input of a logbook file number in machine parameter P 9914. Then ACTI-VATE the machine parameters. The logbook is automatically initialized withthe specified file number after control start–up and is active as from this pointin time. The ring memories are created with the following sizes: R1 to R4:512 bytes, R5: 0 byte.

‘ Operation of softkey INIT in diagnostic program D1.

An already active logbook can be deactivated in diagnostic program D1 by pressingsoftkey INIT, input of ”0” and acknowledgement with the ENTER key or by selectionof a different logbook (also refer to softkey LOGBOOK SELECTION). A logbookcannot be activated again once it has been deactivated. Only deactivated logbookscan be deleted.

User interface/softkey assignments

The following display appears if no logbook is yet active when D1 is selected:

No CP0ACT

NC0STOP


LOGBOOK NOT INITIALIZED!

DISPLAYRING STORE INIT

LOGBOOKSELECTION

LOGBOOKPUNCHOUT

12. 5 16:59


D1 Logbook

D1 – 6

The following monitor display is shown if a logbook is already active:

INIT

Initialization of a logbook (creation of a new logbook file). When the softkey INIT is pressed, the CNC expects input of a logbook file number(value range 0.3000–999999999).Input of ”0” deactivates a currently active logbook (”active” means that recordingstake place in this logbook). A logbook cannot be activated again once it has beendeactivated. Only deactivated logbooks can be deleted.Two test points are interrogated after input of the file number. However, these areof importance only for service purposes. Skip test point input by pressing the EN-TER key twice.The system then asks for the memory size for the individual ring stores. Reserva-tion of approx. 500 bytes per ring store will already permit a sensible recording tobe made. After this, the logbook is initialized and automatically activated. Any events whichoccur are recorded from this point in time onwards.

The number of logbooks which can be created is limited by the available memoryspace. Only one logbook can be active at any time.

In order to use the file number of a deactivated logbook again for an active logbook,it is first necessary to delete the deactivated logbook in the softkey level SERVICEFUNCTION and to then create a logbook again in D1 under softkey INIT.

LOGBOOKSELECTION

Selection of any existing deactivated logbooks for display on the monitor.

No CP0ACT

NC0STOP

DIAGNOSTICPROGRAM

LOGBOOK D 11000 ACTIVE

DISPLAYRING STORE INIT

LOGBOOKSELECTION

LOGBOOKPUNCHOUT

RING STORE FOR WARNINGRING STORE 2 FOR ERRORSRING STORE 3 FOR SYSTEM ERRORSRING STORE 4 FOR OTHER MESSAGESRING STORE 5 FOR OPERATING STEPS

TEST POINT 1 ADDRESS 0000064TEST POINT 2 ADDRESS 00000000

TOTAL LOGBOOK SIZE: 605 BYTES

SIZE = 100 BYTESSIZE = 100 BYTESSIZE = 100 BYTESSIZE = 100 BYTESSIZE = 100 BYTES

12. 5 16:59


D1 Logbook

D1 – 7

LOGBOOKPUNCHOUT

The currently displayed logbook is output on an external data medium. The currentsetting in group operating mode DATA I/O, softkey DATA OUT, determines viawhich interface output takes place. A change in operating mode aborts active out-put. Output via the DNC interface is not possible.

DISPLAYRING STORE

This softkey results in display of the contents of the individual ring stores. The storecontents are displayed in plain text with data, time and message.

Example: Ring store 1 (warnings):

Example: Ring store 5 (operating steps):

The last–pressed key is shown at the top left in the uppermost data line of the moni-tor (”ENTR” here in the example).

No CP0ACT

NC0STOP

DIAGNOSTICPROGRAM

PAGEFORWARDS

PAGEBACK

LASTKEY

SOFTKEYMASK

LOG 11 23.05 09:31 WARNING: DATA PROTECTEDKEYING: DATA SK1+ SK1− 0 ENTRTEST POINT: 1=00000000 2=00000000 MODE: DATA

1

LOG 7 16.05 11:34 WARNING: AXIS MOVINGKEYING: SK5+TEST POINT: 1=00000000 2=00000000 MODE: DIAGNOSTIC

SK5− DIAG SK3+ SK3− SK3+

DISPLAY END

No CP0ACT

NC0STOP

DIAGNOSTIC12. 5 17: 5PROGRAM

PAGEFORWARDS

PAGEBACK

SK4−ERETSK4−DIAGSK4+SK3+SK4+SK5−SK5+2SK3+ENTRSK2+SK4−

SK4+ERETSK4+SK4−2SK4−SK3−SK5+ERETSK1−DATA5SK1−SK4+

ERETSK4−SK4+5SK4+SK3+ENTRSK4−SK1+SK2−SK1−SK1+ENTR

ERETSK4+ENTR2SK4−DIAG0SK4+SK3−SK2+SK1+ENTR2

RESETENTR

6SK4−SK4+ERET2SK3−SK3+SK1−ERET1SK4−

SK3+6

5SK4+DIAGSK5−SK1−SK3+SK5−SK1+SK2−SK1−SK4+

SK3−5RESET2DIAGDATASK5+SK1+SK5−SK5+SK1−SK2+SK1+ERET

ENTRSK3+2SK3+7SK3−RESETENTRSK1−SK5+SK1−SK1+SK1−ENTRSK4−

1DIAG7SK3−2SK3+SK5+0SK1+ENTRSK1+SK1−SK1+3SK4+

SK4−ERET2SK3+SK4−SK3−SK4−1SK5−0SK3−SK1+SK2−3SK4−

SK4+


D1 Logbook

D1 – 8

The following abbreviations are used for display of the keys:

ABAR, MDI, MASC, DATA, DIAG, KORR Group operating modesCUP+, CDN+, CRI+, CLE+ Cursor keys pressedCUP–, CDN–, CRI–, CLE– Cursor keys releasedLPE+ Magnifier pressedLPE– Magnifier releasedSK1+, SK2+, SK3+, SK4+, SK5+ Softkey pressedSK1–, SK2–, SK3–, SK4–, SK5– Softkey releasedERET Level returnDEL Delete keyENTR Enter key1 ... 0 Numeric keys: * – + = Arithmetic operation keys+/– Sign change. Decimal pointRESET Stands for Control Reset,

CAL = System error 1NC reset, switching on/off,Logbook Init

?? Unknown key code

SOFTKEYMASK

The softkey mask present at the time of the entry is displayed. If the key assignmentis displayed by a number, this indicates variable softkey designations, such as oc-cur, for example, for wool sub–tables.


D5 Internal reference point offset

D5 – 9

D5 – Internal reference point offset

The currently active axis offset values are displayed after selection of the programD5. These may have been generated by G92 or by ZERO SET. Zero offsets by way ofG54 – G59, G154 – G159, G254 – G259, G60 or G160 are not taken into accounthere.

No CP0ACT

NC0WAIT


AXIS

X

Y

Z

OFFSET VALUE

767.766 MM

MM

MM

− 715.692

124.423


D5 Internal reference point offset

D5 – 10


D6 Interface data

D6 – 11

D6 – Interface data

General

Data arriving at the standard interfaces can be displayed with D6. The data is notstored during this operation.No check is made of the data (e.g. with respect to correct file header, program end,ECODE etc.). Reading–in is not subject to any time monitoring function. No mes-sage is issued if data transfer is faulty.


The following functions are offered after program selection:

DEVICESELECT

STATUS DFSSEARCH

DFS–NO.SEARCH

START

DEVICESELECT

Selection of the data interface and definition of the connected peripheral device.

STATUS

The following softkey bar appears when STATUS is pressed:

SWCONTROL

HEX CHAR/HEX CHAR/SYMB

SWCONTROL

Activation/deactivation of the XON/XOFF protocol.Softkey is shown inverted: software handshake active (Xon/Xoff).Softkey is displayed normally: hardware handshake active (DTR/DSR).

HEX

Display of the incoming data in HEX format.

CHAR/HEX

Incoming data is displayed as ASCII characters. Exception: display of control char-acters occurs in HEX format.

CHAR/SYMB

Incoming data is shown as ASCII characters. Exception: control characters are dis-played symbolically (e.g. <SP> = Space, <LF> = Line Feed).


D6 Interface data

D6 – 12

START

Start of the reading–in operation. This operation continues until the screen is full.Half of the screen is filled again in each case by repeated operation of this key.

DFSSEARCH

Reading–in is started by pressing the softkeys DFS SEARCH and START and isthen continued until a correct DFS identifier is found. After this, a maximum of 17lines of the program/table are displayed. The rest of the incoming program/tabledata of this file is skipped after renewed operation of DFS SEARCH and thenSTART. The control displays the first 17 lines of the program/table again only afterthe next DFS identifier has been found.Note: ”DFS search” is active as long as the softkey is shown inverted. The functionis executed only if the DFS identifier is correctly received.

DFS–NO.SEARCH

The system asks for the file number for which a search is to be made after operationof this softkey. After input of this number and subsequent operation of the softkeySTART, reading–in takes place until the specified file number (DFS identifier) isfound. The incoming data is displayed only after this has occurred.

Note: ”DFS search” is active as long as the softkey is displayed inverted. Thefunction is executed only if the DFS identifier is received correctly.

Example: Display of read–in data in the format CHAR/HEX:

No CP0ACT

NC0WAIT


DEVICESELECT. STATUS

DFS−SEARCH

DFS−No.SEARCH START

INTERFACE DATA

<00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00 <00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00 <00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><14><12 <00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00 <00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00 <00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00 <00><00><02><0D><0A><14><12>(DFS,P 55555,TEACH IN 18.08,RWED)<D><0A><14><12>1 A%=3:REM NUMBER OF AXES <0D><0A>1 A1$="X":REM AXIS ADDRESS<0D><0A>1 A2$="Y"<0D><0A>1 A3$="Z"<0D><0A>1 A4$="B"<0D><0A>1 A5$="B"<0D><0A>1 <14><12>B%=250:REM INTERFACE OUTPUT FOR SETTING MODEACTIVATION <0D><0A>

<13><12><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00


D7 Communication store display

D7 – 13

D7 – Communication store display

General

The content of the communication store from the point of view of the PLC can bedisplayed on the monitor of the CNC in hexadecimal format using the diagnosticprogram D7. D7 is offered only if word coupling exists between the CNC and PLC.

The communication store is a 128 KByte dual port RAM area on the NC–PLC–wordmodule (WK3). Both the CNC and the PLC (PC 600) have read and write accessto this area.


After D7 is started, the control always displays the communication store contentfrom address C000 H to C07F H (address information as hexadecimal numbersfrom the point of view of the PLC):

128 data words (256 bytes) can be displayed on one screen page. The data is dis-played in a table form (8 columns of 16 lines each). It is possible to see the assign-

8000 H.....

FFFF H

8000 H.....

FFFF H

Start address Page 0

End address Page 0

Start address Page 1

End address Page 1

Page 0

Page 1

No CP0ACT

NC0WAIT

DIAGNOSTIC17.10 14: 0PROGRAM

*000 0*00 00*0 BACKUP PAGE 1

C000 COMMUNICATION STORE DISPLAY

0002E752E852E010E73EE746E952F000EA26F006F026F0BAE0000000F092BB00

C400F212F24CF04EE95E00000000000000000000000000000000000000000000

0000000000000000000000000000000000000000000000000000000000000000

0000000000000000000000000000000000000000000000000000000000000000

BC34BC3400000000000000000000000000000000000000000000000000000000

0000000000000000000000000000000000000000000000000000000000000000

0000000000000000000000000000000000000000000000000000000000000000

0000000000000000000000000000000000000000000000000000000000000000

0123456789ABCDEF

C00 C01 C02 C03 C04 C05 C06 C07

PAGE 0*ADVANCE



D7 – 14

ment between the displayed data words and their addresses in the communicationstore by way of the inversely displayed bars above and on the right of the table.

The three most significant positions of an address (e.g. ”C02” of address ”C02F”)are shown in the top, highlighted bar, while the least significant position is shownin the bar on the right of the table (e.g. ”F” of the address ”C02F”).

The address of the top left data word is displayed in the prompt line (here in theexample: ”C000 COMMUNICATION STORE DISPLAY”).

Example:

Search for an arbitrary address

Select the required memory area by means of the softkey PAGE 0/PAGE1. The cur-rently displayed memory area is shown inverted on the softkey. The individual digits of the address displayed in the prompt line can be incrementedor decremented by means of the three softkeys *000,0*00 and 00*0. The asteriskon the softkey indicates the position which is changed.The least significant address need not be specified, since all 16 possible addressesare displayed underneath each other in one column.

It is possible to switch between incrementation and decrementation of the corre-sponding position by means of the softkey ADVANCE/BACKUP. The active condi-tion is shown inverted.

No CP0ACP

NC0WAIT

DIAGNOSTIC17.10 14: 0PROGRAM

*000 0*00 00*0 BACKUP PAGE 1

C000 COMMUNICATION STORE DISPLAY

0002E752E852E010E73EE746E952F000EA26F006F026F0BAE0000000F092BB00

C400F212F24CF04EE95E00000000000000000000000000000000000000000000

00000000000000000000

0000000000000000000000000000000000000000

0000000000000000000000000000000000000000000000000000000000000000

BC34BC34000000000000

000000000000000000000000000000000000

0000000000000000000000000000000000000000000000000000000000000000

0000000000000000000000000000000000000000000000000000000000000000

0000000000000000000000000000000000000000000000000000000000000000

0123456789ABCDEF

C00 C01 C02 C03 C04 C05 C06 C07

0000 00000000

Address C025 H Address C046 H

PAGE 0*ADVANCE



D7 – 15

Example:

You are on Page 0. The prompt line shows the address C000 H.You are looking for the content of the address D123 H on Page 0.Switch to ”Increment” (the field ADVANCE on the softkey ADVANCE/BACKUP isthen shown inverted).Press the softkey *000 once.Press the softkey 0*00 once.Press the softkey 00*0 twice.The 4th data value (from the top) in the left column now shows the content of ad-dress D123 H.



D7 – 16


D9 EEPROM management

D9 – 17

D9 – EEPROM management

General

The MEM5 memory module (or CP/MEM4 in the case of CC220) contains a 32KByte EEPROM area as standard (optionally 64 KBytes).Important data should be saved in the EEPROM since the content of the EEPROMarea is not lost – in contrast to the RAM area – after a total power failure on the MEMmodule or after forced backup loading.

The following files can be written into the EEPROM area and read out again usingthe diagnostic program D9:Part programsLSEC tablesW tablesZero offset tablesCompensation tablesMachine parameters.

For example, it is then possible to choose whether machine parameters and tablesare to be copied back from the EEPROM to the RAM when the control is put intooperation again.

User interface/softkey assignment

After D9 has been started, the monitor displays a list of all files stored in the EE-PROM area.Each entry in the list additionally contains information as to whether a file with thesame name already exists in the RAM area (column ”IN RAM”) and whether thisfile also contains the same data (column ”EQUAL”).

This list can now be extended by new entries or be shortened by deleting entries.

The functions PROGRAM EEPROM and COPY (from EEPROM to RAM) referto the files displayed here!If it is wished to store files in addition to the files which are already contained in theEEPROM, it is not necessary for files which are already stored in the EEPROM toalso be present in the RAM for programming of the EEPROM.

No CP0ACT

NC0WAIT


MACHINEPARAMETER

PROGRAMSELECTION DELETE COPY

EEPROMPROGR.

MANAGE EEPROM

LIST OF PROGRAMS TO BE SPECIFIEDNo PROGRAM NAME IN RAM EQUAL01234

PPPP

3000300130021131

MACHINE PARAMETERMAIN PROGRAM MOD. DIA 18.08SR SELECT MODULESR TEST DIAGNOSTIC CHANNELSR CP

22.0602.0722.01

YESYESYESYESYES

NONONONONO

MEMORY USED BY PROGRAM:MEMORY AVAILABLE: :

540922239

OTHERS: 3224



D9 – 18

The following functions can be initiated by means of the softkeys:

MACHINEPARAMETER

The currently active machine parameter record (not file L444!) is incorporated inthe list under number ”0”. A machine parameter record stored in the EEPROM can be copied into the RAMarea again only if the softkey FROM EEPROM is selected when reloading the com-plete operating system (diagnostic program D2).File L444 must be stored in the EEPROM (by means of the softkey PROGRAMSELECTION) if it is wished to permit restoration of machine parameters without re-loading the complete operating system.

PROGRAMSELECTION

PROGRAM ALLPROGRAMS

NEXTGROUP

PREVIOUSGROUP

Files can be entered in the list from the groups P, L, V, K, W after pressing PRO-GRAM SELECTION.To do this, first select the desired file group with the softkeys NEXT GROUP orPREVIOUS GROUP. The control then shows you all existing files of the selectedgroup.All files of this group can be included in the list by pressing the softkey ALL PRO-GRAMS.The softkey PROGRAM permits selection of a single file.

Notes:

‘ When programs are entered in the list, the CNC checks whether the size ofthe EEPROM area is sufficient for later programming. If not, the error mes-sage ”MEMORY FULL” appears in the prompt line.

‘ Link files cannot be included in the list.

‘ The K1 table must not be stored in the EEPROM.

DELETE

DELETE LIST ENTRIES

PROGRAM ALLPROGRAMS



D9 – 19

It is possible to delete either individual entries or all entries in the list. This functionrelates only to modification of the displayed list! If it is wished to delete a filein the EEPROM, it is first necessary to delete the corresponding file in this list. TheEEPROM must then be reprogrammed with the thus modified list. Files existing inthe EEPROM are then possibly overwritten by newer file versions (which are con-tained in the RAM).

If an individual list entry is deleted (by means of the softkey PROGRAM), it is neces-sary to enter not the file number but the list number of the corresponding file (col-umn ”NO”) and confirm this with the ENTER key.

COPY

COPY FILES FROM EEPROM

PROGRAM ALLPROGRAMS

Files can be copied from the EEPROM area to the RAM area of the control bymeans of the function COPY. All files entered in the list are copied into the RAM after operation of the softkey ALLPROGRAMS.If you wish to copy an individual file (by means of the softkey PROGRAM), you mustenter the list number of the corresponding file (column ”NO”) after operation of thesoftkey PROGRAM and then confirm this with the ENTER key.

Notes:

‘ Copying of the machine parameter record (list entry ”0”) to the RAM areais not possible using this function. A machine parameter record stored in theEEPROM can be copied into the RAM area again only if the softkey FROMEEPROM was selected when reloading the operating system.

‘ The function COPY is protected by a code.

EEPROM PROGR.

Programming the EEPROM area with the files entered in the list.The system first asks for input of a code in order to prevent unintentional program-ming.After this, the operator can enter an identifier consisting of a maximum of 50 ASCIIcharacters. This identifier is of no significance in the current software version. If itis wished to start programming, skip input of the identifier by pressing the ENTERkey. However, if it is wished to abort the function EEPROM PROGRAMMING at thispoint, simply press the level return key.

DATA



D9 – 20

The softkey EEPROM PROGR. is displayed inversely during programming. CNCoperation is not possible during this time. The message ”PROGRAMMING IS AC-TIVE!” flashes in the prompt line. The number of programmed bytes is displayedcontinuously. An asterisk appears in front of the list number of a file as soon as thisfile has been completely programmed.

The list is moved up on the screen if not all previously programmed files can be dis-played on one screen page.

DATA


D21 Logic analyzer

D21 – 21

D21 – Logic analyzer

General

The logic analyzer permits recording of a maximum of 16 signals of the CNC–PLCinterface.

During a recording, 500 sampling operations of all selected signals (refer to softkeyCHANNEL SELECTION) are always stored. The interval between two samplingsteps is adjustable. File D121 is used to record the data. If this file does not yet exist, the system createsit automatically before a recording (file size: approx. 2 – 2.5 KByte part programmemory). An existing file D121 is overwritten by each new recording. In addition, recorded data (including the current logic analyzer settings at the timeof recording) or arbitrary logic analyzer settings can also be stored in separate filesfor possible subsequent use (refer to softkey FILE SELECTION).

Functional principle of the logic analyzer:

Trigger condition Comparator Clock

ClockMemory

Data stream

DelayTrigger

position

0 ...................500 (Sampling steps)


D21 Logic analyzer

D21 – 22


The following display appears after selection of D21:

STARTINGVALUES

STARTING VALUES

CHANNELS8 OR 16

TRIGGERPOSITION

CLOCK

The functions of the logic analyzer can be adapted to the respective task by meansof these softkeys:

CHANNELS8 OR 16

It is possible to record 8 or 16 channels simultaneously. The number of channelscan be set to 8 or 16 by means of this softkey.

TRIGGERPOSITION

You define here how many sampling steps are to be stored before occurrence ofthe trigger event. 500 sampling steps are always stored in total in the recording file.

Examples:

Trigger position = 250:The sampling step executed when the trigger event occurs is assigned the ”num-ber” 250. A further 250 sampling steps (500 – 250) are then stored additionally asfrom this point.

Trigger position = 10:The sampling step executed when the trigger event occurs is assigned the ”num-ber” 10. A further 490 sampling steps (500 – 10) are then stored additionally as fromthis point.

No CP0ACT

NC0WAIT


DISPLAYCHANNELSELECTION

STARTINGVALUES

FILESELECTION

STARTRECORDING

WAITING0 I 40.7 11 O2 O3 O4 O5 O6 O7 O

36.036.136.236.336.436.536.6

*******

CHANNELS 8STORECLOCKTRIGGER−POS.

500 CLOCKS1 PLC−CY

250 CLOCKS

LOGIC−ANALYZER STATUS

LOGIC−ANALYZERNo TYPE ADDR. BIT TRIGGER COND.

CHANNELS

STARTING VALUES


D21 Logic analyzer

D21 – 23

CLOCK

Specification of the time interval between two sampling steps. It is possible to setthree different types of time interval here. In addition, it is necessary to enter thesize of an individual time interval. The following table provides an overview of thepossible inputs:

Interval type Size Meaning

1 (MS) 1 ms – 50 ms Channels can be sampled at ms inter-vals.Possible interval size: 1 ms to 50 ms, depending on set size.

2 (TASKS) 1 – 9999 The channels can be sampled on thebasis of task changes. This type of in-terval is relevant only for users whopossess extremely good system knowl-edge of the control.

3 (PLC CYCLES) 1 – 9999 The channels can be sampled eachtime the PLC performs a ”PE”.(Possible interval size: time from PE toPE.)(Possible only for PIC 250 or word–coupled PC 600).

CHANNELSELECTION

INPUT OF CHANNEL AND TRIGGER CONDITION

PLC INPUTI

PLC OUTPUTO

PLC MARKERM

STORES

TRIGGERCONDITION

Select the channel number to be changed (0 – 7 or 0 – 15) with the cursor keys

after operation of CHANNEL SELECTION. It is then possible to assign aninput, output, marker or memory address to the selected channel number by meansof softkey and numeric input. The input must be acknowledged with the ENTERkey.

Setting the trigger condition:

�

Selection of the channel number with the cursor keys . The active channelis shown inverted.

�Input of 0 results in low–level triggering,

1 results in high–level triggering,* (multiplication symbol) No trigger.

�An input, output, marker or memory bit is assigned to the active channel by press-ing the corresponding softkey (1 – 4) and subsequently making a numeric input.The following input values are permitted:

Input/output: bits 0.0 to 255.7Marker: markers 0.0 to 511.7


D21 Logic analyzer

D21 – 24

STARTRECORDING

The logic analyzer records. The message ”RECORDING” appears underneath theline ”LOGIC ANALYZER”. The condition ”WAITING” is displayed here when the re-cording has been completed.

Notes:

‘ The recording is aborted by selection of a different diagnostic program.

‘ CONTROL RESET does not normally interrupt recording. However, if activeremote diagnosis is aborted by selection of D21 and a restart then performedby CONTROL RESET, this operating sequence results in termination of therecording and of diagnostic program D21.

MOVE


D21 Logic analyzer

D21 – 25

FILESELECTION

LOGIC ANALYZER DIAGRAM/PARAMETER FILES

SAVE LOAD MODIFYHEADER FILE

PARAMETERONLY

COMPLETEDIAGRAM

The softkey FILE SELECTION permits access to a number of functions which areused for storage or loading of current logic analyzer settings or complete logic ana-lyzer recordings (time diagrams). The control displays all logic analyzer recordingor setting files which exist in the system on this softkey level.

SAVE

Using the softkey SAVE, it is possible to store current settings or the current record-ing (including settings) in a file of the group ”D”, depending on which softkey (PA-RAMETER ONLY or COMPLETE DIAGRAM) is shown inverted. File numbers from3101 to 3300 are permitted. A recording (time diagram) can be stored only aftercompletion of storage in one of these files.

LOAD

Loading of a stored setting or stored recording. Only the files which contain record-ings are displayed on the monitor after operation of LOAD if the softkey COM-PLETE DIAGRAM is shown inverted.

MODIFYHEADER FILE

The file header (text) can be modified after input of the file number. The text ”LOGICDIAGRAM” is entered as standard in the file header for recording files and the text”LOGIC PARAMETER” for setting files.

PARAMETERONLY

Only current settings of the logic analyzer are taken into account for LOAD or SAVEif this softkey is inverted. Settings should be understood as all parameters whichcan be influenced on the softkey levels INITIAL VALUES and CHANNEL SELEC-TION.

COMPLETEDIAGRAM

If this softkey is shown inverted, recordings (time diagrams) are also taken into ac-count in addition to settings (refer to SK PARAMETER only) for LOAD or SAVE.


D21 Logic analyzer

D21 – 26

DISPLAY

The current recording (time diagram) appears on the monitor:

The recording contains three markings in the form of vertical lines. These are identi-fied by C (cursor), T (trigger position) and R (reference mark).

The cursor is located at the cursor position ”0” (1st sampling step) in the initial dis-play condition. The mark T indicates the defined trigger position. The mark T ismoved to the respective sampling step if fewer sampling steps are performed thandefined under softkey TRIGGER POSITION after the start of recording before thetrigger condition occurs. The mark R is initially located at the cursor position 500.

The marks C and R can be moved – after corresponding softkey selection (CUR-

SOR or REFERENCE) – with the cursor keys or by input of a sampling stepnumber.

The positions of the marks C and R and the distance of the reference mark fromthe cursor mark (in sampling steps and seconds) are displayed in the message lineunder CUR, REF and REF–CUR. The current level (0 or 1) at the markings C andR is displayed at the right edge of the screen (under C and R) for each channel.The current signal assignment (input, output, marker, store) is shown for eachchannel at the left edge of the screen.

The time axis can be expanded by a factor of ten (*10) by softkey.

No CP0ACT

NC0STOP

DIAGNOSTICPROGRAM

*10 REFERENCESTART

RECORDING

CUR:

*1 CURSOR

O

I

I

I

I

I

I

O

5.4

0.0

0.1

2.0

0.2

0.3

2.1

36.6

0 REF: 500 REF−CUR: 500 ( 5.0005)

0 250 500

00

01

00

10

00

01

10

00

RC T CR


D22 Axis oscilloscope

D22 – 27

D22 – Axis oscilloscope

General

The diagnostic program allows the user to assess the dynamic response of theaxes. It is thus possible to establish sluggish movement, jamming or overshoot ofthe axes or excessively slow axis circling.

For this purpose, D22 offers the possibility of simultaneously recording axis move-ments and 2 logical signals and displaying these as diagrams on the CNC monitor.

The file D122 is used for data recording. If this file does not yet exist, the systemcreates it automatically before a recording (file size approx. 5 KByte part programmemory). An existing file D122 is overwritten by each new recording. In addition, recorded data (including the axis oscilloscope settings valid at the timeof recording) or arbitrary axis oscilloscope settings can also be stored in separatefiles for possible subsequent use (refer to softkey FILE SELECTION).

480 actual axis position values are always stored during a recording at the time in-terval defined in machine parameter P9901 (interpolation time in ms). From thesevalues, the control calculates the following:

‘ Setpoint/actual speed

‘ Setpoint/actual acceleration

‘ Setpoint speed/lag

This data can then be displayed on the monitor as diagrams.


The following display appears after selection of D22:

No CP0ACT

NC0STOP


DISPLAYSELECTDISPLAY

DISPLAYSPLITTING

OTHERCOMMANDS

STARTRECORDING

WAITING

AXIS: 1

OSCILLOSCOPE STATUSAXIS−OSCIL.

ADJUSTMENTS

2670

PC1PC2Y1:Y2:X:X−EXP.START =TRIGGER−POS.

AE

0.00.01.0000001.000000

240.0000

SCALE DIVISIONSSCALE DIVISIONS

M/S 2 PER SCALE DIVISION"

M/S 2 PER SCALE DIVISION"MS PER SCALE DIVISION

JOG BUTTON 1st AXISTRIGGER ACTIVATION



D22 – 28

SELECTDISPLAY

CMD. SPEEDACT. SPEED

CMD. ACCEL.ACT. ACCEL.

CMD. SPEEDLAG

Select the diagram which is desired after operation of the softkey DISPLAY here.It is possible to choose between setpoint and actual speed (CMD. SPEED/ACT.SPEED), setpoint and actual acceleration (CMD. ACCEL. ACT. ACCEL.) or setpoint speed and lag (CMD. SPEED/LAG). The inverted soft-key indicates the currently active setting. The settings can also still be changed after recording.

DISPLAYSPLITTING

X–DISPLAYSTART

EXPAND X*10

SCALE 1.Y–AXIS

SCALE 2.Y–AXIS

The diagram representation can be influenced by means of these functions:

X–DISPLAYSTART

The time axis of a diagram is divided into 20 scale divisions. Complete representa-tion of the diagram is not possible if the time axis is expanded by a factor of 10. Us-ing the softkey X–DISPLAY START, it is thus possible to specify as from which scaledivision the diagram is displayed on the monitor with an expanded time axis (inputs:0–18) (also refer to softkey EXPAND X*10). The scale division specified here ismarked on the non–expanded representation of the diagram with the character ”D”(also refer to softkey DISPLAY).

EXPAND X*10

This softkey allows the diagram to be expanded by a factor 10 in the X–axis (timeaxis). The softkey is shown inverted if axis expansion is active. It is possible toswitch back to the non–expanded diagram by pressing the softkey once more. The time axis of a diagram is subdivided into 20 scale divisions. Two scale divisionsare shown on the screen in the expanded diagram. One scale division of the timeaxis corresponds here to the time t = 2.4 x P9901.

SCALE1.Y–AXIS

SCALE2.Y–AXIS

The scale of the two Y–axes is set here. SCALE 1.Y–AXIS acts on the Y–AXIS of the top diagram, while SCALE 2.Y–AXISacts on the Y–AXIS of the bottom diagram (refer to softkey DISPLAY for diagramstructure).Input range: 0.0000001–9999999 m/min.



D22 – 29

Examples:

Input: 1 Setpoint speed of 1 m/min. corresponds to a Y–value of 1 scale divi-sion.

Input: 2 Setpoint speed of 1 m/min. corresponds to a Y–value of 1/2 scaledivision.

Input: 0.25 Setpoint speed of 1 m/min. corresponds to a Y–value of 4 scale divi-sions.

OTHERCOMMANDS

RECORDINGSELECTION

TRIGGERCONDITION

TRIGGERPOSITION

FILESELECTION

RECORDINGSELECTION

AXISNUMBER

PLC INPUTI

PLC OUTPUTO

STORES

The axis for which recording is desired is defined on this softkey level (softkey AXISNUMBER).

In addition, it is possible to use the cursor keys to select channels to whichan interface signal or, in the case of word coupling between CNC and PC 600, alsoa memory bit can be assigned with the softkeys PLC INPUT I, PLC OUTPUT O andSTORE S (maximum of 2 channels can be selected).These 2 channels are then recorded during recording and later displayed on theDISPLAY between the top and bottom diagrams. The bits 0.0 to 255.7 are per-mitted as input values for an input or output.



D22 – 30

TRIGGERCONDITION

JOGBUTTON

PROG.–NO.BLOCK NO.

PLC INPUTI

PLC OUTPUTO

STORES

Setting the trigger condition. When the softkey START RECORDING is pressed,the start of recording is delayed until the trigger event set here occurs. The activetrigger condition is identified by inverse display of the corresponding softkey. If thetrigger event does not occur, the axis oscilloscope must be reset by means of a con-trol reset.

Note:

If JOG BUTTON is selected as the trigger condition, jog mode must have been acti-vated in group operating mode MACHINE. If not, triggering is initiated by the jogbutton, but no axis movement takes place.

TRIGGERPOSITION

You define here how many actual axis position values are to be stored before thetrigger event occurs. 480 actual axis position values are always stored in total.The input must be made in the unit ”Scale divisions” (see example). The permittedvalue range for inputs lies within the limits 0.0 to 20.0. The time interval from scaledivision to scale division is calculated as follows:nt = Machine parameter P9901 * 24.

Example:

It is wished to store 252 actual axis position values before the trigger event occurs:

252 : 24 = 10.5 ! Input: 10.5

The recording thus consists of 252 values before the trigger event occurs plus 228values after this trigger event (always making up a total of 480 actual axis positionvalues).



D22 – 31

FILESELECTION

AXIS OSCILLOSCOPE DIAGRAM/PARAMETER FILES

SAVE LOAD MODIFYHEADER FILE

PARAMETERONLY

COMPLETEDIAGRAM

The softkey FILE SELECTION allows access to a number of functions which canbe used to store or load current axis oscilloscope settings or complete axis oscillo-scope recordings (time diagrams). The control displays all axis oscilloscope re-cording or setting files which exist in the system on this softkey level.

SAVE

The softkey SAVE allows current settings or the current recording (includingsettings) to be stored in a file of the group ”D”, depending on which softkey (PA-RAMETER ONLY or COMPLETE DIAGRAM) is shown inverted. File numbers from3301 to 3500 are permitted. A recording (time diagram) can be stored only afterinclusion in one of these files.Memory requirement of a recording: approx. 5 KByte.Memory requirement of a setting: approx. 100 Byte.

LOAD

Loading of a stored setting or stored recording. If the softkey COMPLETE DIA-GRAM is shown inverted, only the files which contain recordings are displayed onthe monitor after operation of LOAD.

MODIFYHEADER FILE

The header of a file (text) can be changed after input of the file number. The text”OSCIL–DIAGRAM” is entered in the file header as standard for recording files and”OSCIL–PARAMETER” for setting files.

PARAMETERONLY

If this softkey is shown inverted, only current settings of the axis oscilloscope aretaken into account for LOAD or SAVE.

COMPLETEDIAGRAM

Recordings, (time diagrams) are taken into account as well as settings (refer to SKPARAMETER ONLY) for LOAD or SAVE if this softkey is shown inverted.

DATA



D22 – 32

START RE-CORDING

The axis oscilloscope records. The message ”RECORDING” appears under theline ”AXIS OSCILLOSC.”. The status ”WAITING” is displayed here when the re-cording has been completed.

Notes:

‘ An ongoing recording is aborted by selection of a different diagnostic pro-gram or by CONTROL RESET.

‘ If the trigger event does not occur, the axis oscilloscope must be reset bymeans of a control reset.

‘ If JOG BUTTON was activated as the trigger condition, jog mode must havebeen activated in group operating mode MACHINE. Otherwise, no travers-ing movement occurs.

DISPLAY

The axis oscilloscope recording appears on the monitor. Once scale division of thetime axis corresponds to the time t = 24 x P9901 in non–expanded form andt = 2.4 x P9901 in expanded form.

The recording contains the marks D (for the expansion function) and T (trigger posi-

tion). The mark D can be moved with the cursor keys .

The display is expanded by a factor of 10 in the X–axis (time axis) by pressing theMAGNIFIER key. The starting point for the expanded display is the position of themark D in this case (refer to following monitor screen for an example of an ex-panded display). The display switches back to non–expanded form if ”MAG-NIFIER” is pressed again (same function as softkeys EXPAND X *10 and X–DIS-PLAY START).

COMMAND SPEED

T

D

ACTUAL SPEED



D22 – 33

The display can be quit by pressing the level return key.



D22 – 34


D23 Contour display

D23 – 35

D23 – Contour display

General

The contour display permits comparison of a programmed contour with the con-tour generated by the machine tool.Evaluation is performed by means of the measuring system feedback function withthe resolution set in the machine parameters (P 9901). The actual values are re-corded exactly to 1 increment for each sampling step.


If D23 is selected, the control first checks whether file D123 exists. This file is re-quired by D23 to store a recording. If D123 does not exist, it is necessary to enterthe number of desired sampling steps. Approx. 16 KByte of part program memoryis required for D123 for every 1000 sampling steps. The maximum number of sampling steps is restricted only by the available free partprogram memory. The recording duration depends on the number of defined sam-pling steps and on machine parameter P9901:

T [ms] = number of sampling steps * P9901

Example: Number of sampling steps = 2000; P9901 = 10. Duration of recording = 20 s;

required part program memory: approx. 32 KByte

Note:

D123 must be deleted if it is wished to change the number of sampling steps. Onlyafter this can the number of desired sampling steps be entered again when startingD23.

The following display appears when the number of sampling steps has been en-tered:

No CP0ACT

NC0STOP


DISPLAYSTARTINGVALUE TRIGGER

STARTRECORDING

WAITING

DISPLAY AXIS:

CONTOUR DISPLAY STATUS

CONTOUR DISPLAY

ADJUSTMENTS

X:Y:

TRIGGER:JOG BUTTON

SCALING FACTOR

XY

1st AXIS


D23 Contour display

D23 – 36

STARTINGVALUES

DISPLAYX–AXIS

DISPLAYY–AXIS

Y–AXISEXPANSION

X–AXISEXPANSION

The softkeys DISPLAY X–AXIS and DISPLAY Y–AXIS are used to assign an arbi-trary machine axis (axis number) to the abscissa (DISPLAY X–AXIS) and to the or-dinate (DISPLAY Y–AXIS) of the contour diagram.

The softkeys Y–AXIS EXPANSION and X–AXIS EXPANSION should be used onlyin conjunction with D27 (circular compensation).In order to optimize parameters set with D27, it is necessary to expand the repre-sentation of one axis involved in circular interpolation more than the other (e.g. Xand Y). This makes it possible to see the contour errors at quadrant transitions ofa circle more easily.The expansion factor can be entered separately for each axis (value range: 1 –1000).

In order to avoid a situation where the contour can no longer be completely dis-played on the monitor as a result of axis expansion, reduction of the non–expandedaxis by the specified factor occurs instead of an increase in the expanded axis. Thedisplayed proportions are thus correct.

Example:

Note:

If the function EXPANSION is active for an axis, the text ”AXIS” with the corre-sponding expansion factor appears on the display under the column ”MAGNIFI.FACTOR” (refer to softkey DISPLAY) in addition to ”DISPLAY” and ”MAGNIF.”.

Y

XNo expansion Y−axis expanded by

a factor of 2X−axis expanded bya factor of 2

Y

X

Y

X


D23 Contour display

D23 – 37

TRIGGER

JOG BUTTON PROGR. NO.BLOCK NO.

Definition of trigger condition. When the softkey START RECORDING is pressed,recording is delayed until the trigger event defined here occurs. The active triggercondition is indicated by inverted display of the corresponding softkey.

STARTRECORDING

After operation of START RECORDING, recording is started when the trigger con-dition occurs. The message ”RECORDING” appears under the line ”CONTOUR DISPLAY”. Thestatus ”WAITING” is displayed here when recording has been completed.

DISPLAY

The contour diagram can be called after the end of a recording by pressing the soft-key DISPLAY.The set and actual contours are shown (set contour: green; actual contour: red).

Two cross–hairs can be moved simultaneously along the contour with the cursor

keys . results in cross–hair movement opposite to the machining direc-

tion and in movement in machining direction.The values for axis position and axis speed (referred to the contour locationsmarked by the cross–hairs) are displayed on the left of the monitor.

The ”movement speed” of the cross–hairs can be preselected with the softkey

<<<

(see next monitor display). The active mode is shown inverted on the softkey:

<< Fast movement (step distance = 10 sampling steps)< Slow movement (step distance = 1 sampling step).

MOVE


D23 Contour display

D23 – 38

The whole display or part of it can be magnified with the MAGNIFIER key in orderto examine certain contour locations.

A frame appears on the screen after operation of the MAGNIFIER key. In addition,the following softkey bar is offered:

ON

Magnification of the displayed frame content to the complete display area of themonitor. The cross–hairs stay in their current position and may thus not be visibleinitially after magnification.

OFF

Deactivation of the magnifier function. The graphic display is built up again withoutmagnification. The cross–hairs stay in their current positions.

<

COMMAND−POS.CURSOR VALUE

MAGNIFI. FACTORDISPLAYMAGNIF.

1.00

X 47.88347.883Y

ACTUAL−POS.X 48.618

49.110YCOMMAND−SPEED

X −0.708−0.708Y

ACTUAL−SPEEDX −0.243

−0.531Y

Y

X

<<

ON OFF + − <



1.00

X 47.88347.883Y



X −0.708−0.708Y


−0.531Y

Y

X

<<

10.00


D23 Contour display

D23 – 39

+ –

Magnification or reduction in size of the displayed magnifier frame.The step distance by which the frame is magnified or reduced each time the soft-

keys ”+” or ”–” are pressed can be set by means of the softkey <<<

.

The frame can be moved arbitrarily with the cursor keys while the magnifier frameis displayed on the monitor.The step width by which the frame is moved can be adjusted by way of softkey

<<<

.

Example: Magnified display of the previously marked screen section.

Note:

‘ It is possible to perform magnification several times successively. However,when the displayed values under the column ”MAGNIFI. FACTOR” are re-placed by an asterisk, magnification should be stopped.

ON OFF + − <



10.00

X 47.88347.883Y



X −0.708−0.708Y


−0.531Y

Y

X

<<

10.00


D23 Contour display

D23 – 40


D24 Axis optimization

D24 – 41

D24 – Axis optimization

General

The servo loops of the control must be adapted to the drives used. The diagnosticprogram D24 offers the following functions for this purpose:

‘ Definition of a step function (speed) for each applied axis.

‘ Graphic representation of the axis reaction to the step function (as speedcharacteristic) and numeric display of the determined servo loop parame-ters.

‘ Display of position, lag, offset and required lag of all axes.

‘ Modification of the active required closed–loop gain.

‘ Offset adjustment of one axis.

‘ Acceptance of the optimized closed–loop gain and offset values in the ma-chine parameters.

The axis reaction is always measured by recording of 160 actual axis position val-ues. The time between 2 sampling operations corresponds to the value entered inmachine parameter P9901. The recording time is thus 1.6 s if P9901 = 10 ms.


The following monitor display appears after selection of D24:

AXISSELECTION

Selection of the machine axis which it is wished to optimize by input of the axis num-ber.

No CP0ACT

NC0WAIT


DISPLAYSTARTINGVALUES

MACHINEPARAMETER

AXISSELECTION

STARTRECORDING

WAITING

DISPLAY AXIS:

AXIS OPTIMIZATION STATUSAXIS OPTIMIZATION

ADJUSTMENTS

TIME SCALE (SEC):TRAVEL RANGE (MM):

X

TARGET VALUE (M/MIN):SERVO LOOP WITH SLOPEACCELERATE

0.501001.00



D24 – 42

STARTINGVALUES

SERVO O/PSERVO LOOP

DECELERATE/ACCELERATE

TARGETVALUE

TRAVELRANGE

SERVO O/PSERVO LOOP

Selection of the following operating modes is possible by repeated operation of thissoftkey:

‘ SERVO LOOP WITH SLOPE: The axis accelerates to the speed en-tered on the softkey TARGET VALUEwith a slope. The servo loop is closedduring this operation (refer to machineparameter P1002 for details of slope).

‘ SERVO LOOP WITHOUT SLOPE: The axis accelerates without slope tothe speed entered under the softkeyTARGET VALUE. The servo loop isclosed during this operation (refer tomachine parameter P1002 for details ofslope).

‘ SERVO OUTPUT: The servo loop is open. The axis tra-verses at the speed which was enteredunder the softkey TARGET VALUE.The measuring system is used only forspeed measurement.

DECELERATEACCELERATE

Selection of acceleration or deceleration.

TARGETVALUE

It is possible to define the desired axis speed in m/min. here. 10 % of the maximumspeed (refer to machine parameter P501) is stored as a default value for the modesSERVO LOOP with/without SLOPE. The entered value is interpreted in V inSERVO OUTPUT mode (default value: 1.5 V).

TRAVELRANGE

Input of the maximum distance which may be traversed for a single measurement(corresponds to an incremental value as from the starting position!). If the limitvalue entered here should be exceeded during the measurement, the axis will stopand a corresponding message is displayed.

Please note the maximum traversing range of your machine if you performseveral successive measurements!



D24 – 43

MACHINEPARAMETER

The following display appears:

Offset and required lag values of all axes can be changed on this operating level.

Select the axis where you wish to change the values with the cursor keys .

OFFSET–ADJAUTO

OFFSET–ADJMANUAL

Automatic or manual offset adjustment. The lag should set itself to zero whenthe offset has been entered or automatically adjusted. The changed offset valueis transferred directly to the axis processor and is thus active. The machine param-eter record is not yet changed at this point in time. Active offset values remain activeuntil they are overwritten by other offset values or until the control is reset.

REQUIREDLAG

Input of a new required lag value. This input must be made with care in order toexclude incorrect drive response.The required lag is calculated as follows:Required lag = max. axis speed (P501)/required closed loop gain (P1001).If the required lag is changed by means of this softkey, the new value becomes ac-tive for the corresponding axis when the ENTER key is pressed. For this purpose,the CNC adapts the currently active required closed loop gain in accordance withthe above relationship (the maximum axis speed remains constant).The entered value remains active until the control is reset or until a different valueis entered. The CNC modifies machine parameter P1001 correspondingly if the required lagis changed by means of the softkey REQUIRED LAG and this value then trans-ferred to the machine parameter record (by softkey ACTIVATE). P501 remainsconstant. The new values are then active after each control run–up.

No CP0ACT

NC0STOP

DIAGNOSTICPROGRAM

OFFSET−ADJAUTO

OFFSET−ADJMANUAL

REQUIREDLAG ACTIVATE

POSITION LAG OFFSET REQIRED LAG

XYZ

0.0000.0000.0000.000

XYZ

0.0000.0000.0000.000

XYZ

0.0020.0000.0000.000

XYZ

2000.0002000.00010000.00010000.000

SERVO

SERVO



D24 – 44

ACTIVATE

All currently active closed loop gain and offset values are immediately transferredto the machine parameter record when the softkey ACTIVATE is pressed. TheREADY 2 signal is cancelled and a new control run–up takes place.

Caution:The new values are not transferred to the file L444, if this file should exist. If youwish the file L444 to contain the modified values, you must first delete L444 aftertransfer and then regenerate it (with/without texts).

MP



D24 – 45

STARTRECORDING

When this softkey is pressed, the text under AXIS OPTIMIZATION changes from”WAITING” to ”RECORDING”. The instruction ”ACTIVATE JOG BUTTON” ap-pears in the message line.

The traversing movement starts after operation of the jog button (also withoutapproached reference point or active jog mode!)

DISPLAY

The step response of the corresponding axis can be displayed as a graph aftercompletion of a recording by pressing the softkey DISPLAY:

One scale division of the time axis (T) always corresponds to 50 sampling steps.Consequently, the corresponding time interval of a scale division is nt = 50*P9901(the time interval of a scale divisions is also displayed numerically in the startscreen of D24 under the column ADJUSTMENTS as ”TIME SCALE (SEC):”).One scale division of the absicissa (XI) always corresponds to 10 % of the currentlyset target value.

In addition to the graph, the CNC also displays the internally calculated characteris-tic servo loop values on the left side of the screen:

XI: Currently active target valueTU: Delay timeTA: Reaction timeUE: Overshoot (in % of XI)WO: Characteristic frequency (characterized by envelope curve A

in following figure)DA: Damping (characterized by n1/n2 in the following figure)I.S.E.: Quadratic control areaKVact: Actual closed loop gain factor

KVact = measured speed/measured lag (at last sampling step).

MOVE

DELAY TIMECHARACTERISTIC

ABSOLUTE VALUEXI

1.00

TUREACTION TIMETA 0.136

OVERSHOOTUE 44.600

CHAR.FREQ.WO 68.837

T

(M/MIN)

0.000 S

S

X

1/S

DAMPINGDA 0.320

I.S.E.3.7

KV 8.867

XI



D24 – 46

Notes:

‘ If the CNC cannot calculate characteristic values which are sufficiently accu-rate, question marks are displayed instead of the numbers.

‘ Range transgression of a calculated number (numeric value is greater thanthe display range) is indicated by the CNC by ”*****”.

Interrelationships of the servo loop characteristics:

Optimization instructions

While the setpoint speed should be reached as quickly as possible for pure posi-tioning operations (thus accepting overshoot), a compromise must be reached be-tween fast attainment of the setpoint speed and the minimum possible overshoot(contour violation by overshoot) in the case of machining operations (tool en-gaged).

5%−

WP

TU TAt

D1D2

limit

D1 Magnitude of the 1st overshoot

D2 Magnitude of the 2nd overshootWP Reversing pointA Envelope curve

A

SetV

SetV Setpoint speedTU Delay timeTA Reaction time

V


D25 Lead screw error compensation

D25 – 47

D25 – Lead screw error compensation

General

The lead screw error compensation function permits compensation of the mechan-ical inaccuracies of drive spindles or rack drives. It is possible to determine andcompensate both linearity errors as well as reversing backlash. In order to permit compensation, an error curve is recorded for each axis traversingdirection for each machine axis to be compensated. The actual axis position ismeasured exactly with an external device for this purpose. The established com-pensation data is entered in the files L101–L108 using this diagnostic program. Af-ter activation of the function (refer to the section ”General information” at the endof this chapter), the control corrects the corresponding machine positions automat-ically.

Note:

The machine parameter P1509 (reversing backlash) is no longer active if the leadscrew error compensation is active.


The following display is an example of the display which will appear on the screenafter selection of D25:

DATA IN DATA OUT

These keys are used to read the compensation files (L101–L108) in or out via thestandard interfaces of the CNC.Please refer to the operating manual for further information on reading data in/out.

No CP0ACT

NC0WAIT


EDIT DATA IN PRERUN DATA OUT MANAGE

AXIS LEAD SCREW ERROR POSITION

X

Y

Z

0 INCREMENTS

INCREMENTS

INCREMENTS

0

0

5

2

4

−

INCREMENTS

INCREMENTS

INCREMENTS



D25 – 48

MANAGE

Deletion of the displayed L files.

All compensation files (L101–L108) are deleted (if present) by the softkey DELETEALL. Other files are not deleted by this softkey.

It is possible to selectively delete individual files by means of the softkey DELETEand specification of a file number. It is thus possible to delete all displayed files indi-vidually.

EDIT

A compensation file can be created or modified by means of EDIT. After pressingthe key EDIT, enter the file number (101–108) and confirm this with the ENTER key.An L file is permanently assigned to each axis (X, Y, Z etc.). The following appliesin accordance with machine parameter P102: Axis 1: L101; Axis 2: L102...Axis 8:L108.

After selection of the required file, the control switches to the LSEC editor. All ASCIIcharacters required for programming of the compensation values are displayed inthe softkey bar:

EDIT L101

LF X S R P N OTHERCOMMANDS

The ASCII character is inserted at the current cursor position by operation of the1st or 2nd softkey (from the left). In the case of softkeys which possess 2 charac-ters, first select the character which it is wished to insert by repeatedly pressing thiskey (the selected character is shown inverted in the softkey). This character is theninserted at the current cursor position after operation of the ENTER key.

Notes:

‘ The 2nd softkey is always assigned the axis address valid for this com-pensation file.

‘ Refer to the section ”Programming compensation values” for the meaningof the ASCII characters.

‘ All required characters (except for the character LF!) can also be entered onthe ASCII keyboard.

OTHERCOMMANDS

Selection of further editor functions (refer to manual ”Operating instructions”.

DATA



D25 – 49

PRERUN

When the corresponding L–files have been created for all axes which are to becompensated, a test run can be started by way of the PRERUN function whichchecks the created L–files for errors.

Error–free files are provided with the identifier ”LSEC” instead of the date in the di-rectory display after the test run.The lead screw error compensation function can be activated by CLEAR ALLLOGIC only when all compensation files are error–free.The following error messages can occur during the test run:

LSEC–SYNTAX: Syntax error in the file.

LSEC–LOGIC: The file is not unambiguous.

LSEC–GRID: Entered compensation positions are not on the grid defined bythe step distance.

LSEC–OVER: Values outside the display range. The following rules apply:Positions: max. 8 positionsError values: max. +/– 32 767A maximum of 4000 compensation values are possible per tra-versing direction for all axes. This includes grid points whichare not programmed with a compensation value.

Refer to the handbook ”Error messages”, P. No. 3914 for detailed error descrip-tions.



D25 – 50

Determination of the error curve

The position errors must be determined for both the positive and negative travers-ing directions for each desired axis.

The unit of length for position and compensation values depends on the resolutionused. Normally, the resolution is 1 lm for linear and 1/100 of a degree for circularaxes.

First subdivide the traversing range of an axis into a number of equally large sec-tions (guide value, approx. 10–20 mm). This grid defines the positions in the tra-versing range at which position compensation values may be programmed lateron (refer to the section ”General information” for maximum number of position com-pensation values).

Travel the axis to the start of the traversing range (normally position 0) after refer-ence point travel.

Now define the actual axis position using an external measuring device. The differ-ence between the actual and setpoint positions (Pact – Pset) corresponds to thecompensation value which must be specified later on for this position.

First perform this measurement in positive traversing direction for arbitrary setpointpositions located on the grid. When you reach the end of the traversing range, per-form measurement in negative traversing direction for arbitrary setpoint positionson the grid.A maximum of 4000 compensation values can be entered in the control per travers-ing direction for all axes together.

Note:

It is not necessary to measure all positions defined by the grid in one traversing di-rection. If several grid points which are not measured lie between 2 positions in atraversing direction, the compensation value of the last–measured point applies tothese grid points (also refer to the section ”General information” at the end of thischapter). In this way, it is possible to perform compensation only in specific, particu-larly critical areas of the traversing path of an axis.

MOVE

Complete traversing range

Pos. traversing direction Neg. traversing direction

Measuring positions; the measuring position distribution may benon−uniform over the complete traversing range. The measuringpositions themselves must, however, all be located on the grid.

=



D25 – 51

Programming the compensation values

Several characters are used as well as numbers for programming a compensationfile. By means of these characters, the control recognizes the meaning of any nu-meric value which has been programmed after them.

Note:

All characters required are offered on the softkey level EDIT, but can also be en-tered on the ASCII keyboard. Exception: The character LF must be entered by wayof the softkey LF on the softkey level EDIT.

All numeric values must be programmed as integers in the unit of the positioningresolution (minimum traversable distance). The positioning resolution depends onmachine parameter P103:

Positioning resolution: (increment length)

Examples: Axis type P103 Positioning resolution

Linear 3 1 mLinear 2 10 mCircular 3 1/1000th degreeCircular 2 1/100th degree

Characters used for programming:

<LF>: (LINE FEED). Each programmed line of a compensation filemust be terminated with <LF>.

S: Step distance of the grid. The step distance must be pro-grammed in the first line of the compensation file. The reference point and all axis position values pro-grammed later on must lie on this grid. However, it is notnecessary to assign a compensation value to each gridpoint.

Examples:Linear axes:”S20000” means: compensation values may be pro-grammed every 20 mm (with 1 m positioning resolution).Circular axes: ”S1000” means: compensation values may be pro-grammed every 10 degrees (with 1/100th degree position-ing resolution).

<AXIS ADDRESS>: (e.g. ”X”, ”Y”, ”Z”). The position of the compensation valueis programmed by the axis address with subsequent nu-meric value. The compensation value itself (refer to charac-ter ”P or N”) must be programmed in the same line as theposition value.

1�10P103



D25 – 52

R: This identifies the following number as the position of thereference point. The compensation value itself (refer tocharacters ”P, N”) must be programmed in the same line asthe reference point position.

Examples:Linear axis:”R100000” means: reference point position at 100 mm(with 1 m positioning resolution).Circular axis:”R35000” means: reference point position at 350 degrees(with 1/100th degree positioning resolution).

P, N: ”P” identifies the following number as a compensation valuein positive traversing direction. ”N” identifies the followingnumber as a compensation value in negative traversing di-rection. The compensation value to be entered corre-sponds to the difference between the actually measuredposition and setpoint position in the unit of positioning reso-lution.

Examples:Setpoint position Actual position Compensation value10000 10002 210000 9998 –210000 10000 0

Programming for circular axes

Only compensation values for the position range 0° x X t 360° need be pro-grammed for circular or infinite axes.If a circular axis moves out of this range, a modulo calculation is performed withrespect to the axis position for access to the compensation values so that the com-pensation values for the position range 0° x X t 360° are active.

Examples:An initial position of 300° and an end position of 400° are defined, for example,when programming a circular axis in the part program. The compensation valuesprogrammed for the traversing range from 300° to < 360° are used for this range,while the compensation values programmed for the range 0° to 40° are used forthe traversing range from 360° to 400°.The same is true analogously, for example, for a traversing distance from +40° to–40°. The compensation values programmed for the range from < 360° to 320° areactive for the path from –0° to –40°.



D25 – 53

Programming example:

The traversing range of the X–axis (0–100 mm) has been subdivided into a grid witha step distance of 10 mm. Let the reference point position of the X–axis in this ex-ample be X = 100 [mm].

Programming:

The file L101 must be programmed for the compensation values of the X–axis.

S10000<LF> Step distance 10000 l; compensation value inputpossible every 10 mm.

X0P0<LF> No compensation in pos. travel direction at X0X10000P2<LF> Compensation by +2 l in pos. travel direction at X10X30000P2<LF> Compensation by +2 l in pos. travel direction at X30X40000P4<LF> Compensation by +4 l in pos. travel direction at X40X60000P1<LF> Compensation by +1 l in pos. travel direction at X60X70000P–4<LF> Compensation by –4 l in pos. travel direction at X70X80000P–2<LF> Compensation by –2 l in pos. travel direction at X80X90000P0<LF> No compensation in pos. travel direction at X90R100000P0<LF> No compensation in pos. travel direction at X100

(reference point)R100000N0<LF> No compensation in neg. travel direction (reversal point)

at X100 (reference point)X90000N0<LF> No compensation in neg. travel direction at X90X80000N–2<LF> Compensation by –2 l in neg. travel direction at X80X50000N6<LF> Compensation by +6 l in neg. travel direction at X50X20000N3<LF> Compensation by +3 l in neg. travel direction at X20X10000N2<LF> Compensation by +2 l in neg. travel direction at X10X0N0<LF> No compensation in neg. travel direction at X0M30 File end

8642

−2−4−6−8

10 20 30 40 5060

70

8090 100 110

Error[m]

[m * 103]Setpoint position

: Measuring points: Compensation char.in positive direction: Compensation char.in negative positionCompensation characteristic of the X−axis



D25 – 54

General information

‘ If there are several grid points which have not been programmed betweentwo programmed grid points in a traversing direction, the compensationvalue of the last–programmed grid point applies to these grid points whichhave not been programmed. Compensation values for machine positionsbetween two successive group points are calculated by the control by wayof linear interpolation.

‘ Error compensation starts to act at the first programmed position in a com-pensation file. Error compensation ends at the last programmed position in a compensa-tion file.

‘ A maximum of 4000 compensation values are possible per traversing direc-tion for all axes. The grid points which have not been ”filled out” are includedin this total.

‘ The position values for the positive traversing direction must be pro-grammed in ascending order and those for the negative traversing directionin descending order.

‘ Position information for circular axis compensation values must lie in therange 0° x X t 360°.

‘ The reference point must lie on the compensation grid; a compensationvalue can be entered here as well.


D26 CNC remote diagnosis (information)

D26 – 55

D26 – Remote diagnosis (information)

Fast and extensive information about failed installations is essential in order to sat-isfy the availability demands placed nowadays on modern machine concepts. Forthis purpose, BOSCH offers the user the ”remote diagnosis” option, which allowsthe service center to be informed by telephone about the type and scope of theproblems which have occurred at short notice.

For this purpose, the service or maintenance center possesses a remote diagnosiscomputer, a fully–configured CNC control equipped with special software. The op-tion ”remote diagnosis” must be applied to the machine (at the machine tool manufacturer or end customer) for the CNC to be diagnosed and RE-MOTE DIAGNOSIS (softkey) activated. D26 is activated directly by the remotediagnosis computer only for certain diagnostic functions such as local analyzer,axis oscilloscope, MSD etc. D26 automatically deactivates itself after completionof these functions.

Information is exchanged between the CNC and service center on a telephone lineusing an acoustic coupler or modem. The signalling rate can be set to 300, 1200,2400 or 4800 baud by means of machine parameter 5509.

When a connection has been established between the two controls, the servicecenter is in a position to inform itself about the following data of the connected CNC:

Error messagesAll pending error messages (from control and machine) are transmitted to the ser-vice center immediately after they occur and are displayed on the CNC.

DIAGNOSTIC mode, softkey CONTROLThe service center can receive information about the software version on this oper-ating level.

DIAGNOSTIC mode, softkey MACHINETransmission of the current MSD data (machine status display) and the input andoutput states present at the PLC at the time of transmission.

MessagesThe service center can output any message in plain text on the monitor of the con-nected CNC if it is wished to exchange all information (e.g. ”Please remove receiverfrom acoustic coupler”).

DIAGNOSTIC mode, softkey SERVICE FUNCTION

‘ Axis oscilloscope: Recording of axis data with subsequent transmission ofthe values to the service center for evaluation.

‘ Logic analyzer: Signal and trigger settings; after the end of recording, the re-corded data can be transmitted to the service center.

File transferThe following files can be transferred:Part programs (file group P), diagnostic programs (file group D), graphic programs(file group G), system data (file group L), offset tables (file group V), compensationtables (file group K) and W–tables (file group W).


D26 CNC remote diagnosis (information)

D26 – 56

Directory displayThe service center can have displayed all or specially selected directoriesof the individual file groups.

File transfer CNC ––> remote diagnosis computerAfter a certain file has been selected, this can be transmitted by the controlto the remote diagnosis computer and evaluated there.

File transfer remote diagnosis computer ––> CNCAny files can be transmitted to the user by the remote diagnosis computer(e.g. after correction of a part program at the service center).

File deletionIndividual files can be deleted from the service center.


D27 Putting into operationfor circular compensation

D27 – 57

D27 – Putting into operation for circular compensation

General

The diagnostic program acts as an aid for putting into operation the option CIRCU-LAR COMPENSATION.Other required commissioning aids: – D23 Contour display.

You will find further information on the option CIRCULAR COMPENSATION in thesection ”Circular compensation”.Please refer to the sections ”Preparations for optimization” and ”Optimizing the cir-cular compensation parameters” for preparations and procedure for optimization.

Notes:

‘ The option requires the servo loop board SERVO–i and the option CS–TABLES.

‘ Circular compensation is possible only for synchronous linear axes and issensible only in conjunction with a direct measuring system.

‘ If the option PILOT CONTROL is activated in the system, the pilot controlweighting factors (machine parameters P1016 and P1017) must have beenoptimized to minimize lag before circular compensation is activated and opti-mized.

Circular compensation

The option CIRCULAR COMPENSATION allows contour errors to be minimizedduring circular interpolation in the area of the quadrant transitions (at the reversalpoint of an axis).These contour errors occur with different degrees of severity on individual ma-chines owing to the respective mechanical design (static friction, torsion etc.).



D27 – 58

In order to avoid contour errors, a compensation pulse is generated at the reversalpoint of the respective axis in addition to the setpoint input. This ensures continu-ous movement of this axis through the standstill point (breakaway from static fric-tion at the right time).

The ideal pulse height is related non–linearly to the path velocity. When the optionis put into operation, this non–linear function must first be determined and graphi-cally plotted for the reversal points of all axes involved in circular interpolation onthe basis of measurements (with D27 and D23). This function is then approximatedby a maximum of three adjacent straight lines, thus providing a maximum of fourreference points (SP1–SP4) with the parameter pairs of pulse height (PH) and pathvelocity (VB) (refer to following figure).

Uy1

Uy1

Uy2

Ux1Ux2

Vy

t

Vx

Ux1Ux2

Circle contour display in diagnostic

X

Y

Uy1

Uy2

Ux1 = 1st reversal point X−axisUx2 = 2nd reversal point X−axisUy1 = 1st reversal point Y−axisUy2 = 2nd reversal point Y−axis

program D23 and assignment of thereversal points to the axes

Speed characteristic of bothaxes involved in circular interpolation

t

Vy

t

Magnifiedrepresentation ofthe point Uy1

Measured curve and its approximation by 3 straight lines

VB

PH

V1 V2 V3 V4

SP1

SP2

SP3SP4

Measured values=SP = Reference points



D27 – 59

The W–table W999999003 is used for recording all parameters necessary for cir-cular compensation (refer to the section ”Preparations for optimization” for the W–table definition program). The content of this table is read during every controlrun–up and is then active until a renewed run–up operation.On the basis of these values, the CNC calculates the required pulse height by linearinterpolation for arbitrary speeds.The pulse height is decreased linearly down to PH = 0 for path velocities below thefirst programmed reference point (SP1) down to the speed VB = 0. The pulse heightremains constant for path velocities above the last programmed reference point(SP4).



D27 – 60


The following monitor display appears after D27 has been started:

AXISNUMBER

Selection of the axis to be optimized (value range: 0–8).

COMPENSA-TION PULSE

1.Q

COMPENSA-TION PULSE

2.Q

Input of the compensation pulse height at the 1st and 2nd reversal points respec-tively of the selected axis in the unit lm (value range: 0 – 9999).

COMPENSA-TION TIME

Input of the compensation pulse duration in interpolation steps (value range: 0 –9999). The actual pulse duration is calculated as follows: T = input value *P9901.The parameter ”Compensation time” is preassigned the value 20 and should notnormally be changed.

ACTIVATE

The values displayed under ”ADJUSTMENTS” are transferred directly to the inter-polation processor for optimization when this softkey is pressed. Transfer of the val-ues to the W–table does not take place automatically.

Caution:

‘ The optimized circular compensation parameters have to be manually en-tered in the W–table W 999999003 (refer to the section ”Preparations for op-timization” for definition and structure of the W–table).This W–table is evaluated during every control run–up (if the option CIR-CULAR COMPENSATION is applied).

No CP0ACT

NC0STOP

DIAGNOSTIC30.11. 14: 8PROGRAM

AXISNUMBER

COMPENSATIONPULSE 1.Q

COMPENSATIONPULSE 2.Q

COMPENSATIONTIME ACTIVATE

AXIS:

CIRCULAR COMPENSATION

ADJUSTMENTS

COMPENSATION PULSE 1.Q:COMPENSATION PULSE 2.Q:COMPENSATION TIME: 20

001

SERVO



D27 – 61

‘ The values become active only if all parameters of the corresponding axishave been preassigned the value ”0” in the W–table before the last controlrun–up or if W 999999003 does not exist.

Preparations for optimization

Several preparations have to be made before optimization:

‘ Test program generation

Example: P110 N10 G0 X50 Y60 Z0N20 G17 G2 X60 Y50 R40N30 G0 X50 Y60M30

Since circular compensation is active only during circular interpolation and not atits start/end, the start and end points must not be programmed at a quadrant transi-tion in this test program.

‘ Generation of a definition program for W–table W999999003

(DFS, W999999003,COMPENSATION–TAB)$[8]$[A,W,40,0,COMPENSATION TIME]$[B,W,40,0,U1:.1.F–VALUE.]$[C,W,40,0,U1:.1.P–HEIGHT]$[D,W,40,0,U1:.2.F–VALUE.]$[E,W,40,0,U1:.2.P–HEIGHT]$[F,W,40,0,U1:.3.F–VALUE.]$[G,W,40,0,U1:.3.P–HEIGHT]$[H,W,40,0,U1:.4.F–VALUE.]$[I,W,40,0,U1:.4.P–HEIGHT]$[J,W,40,0,U2:.1.F–VALUE.]$[K,W,40,0,U2:.1.P–HEIGHT]$[L,W,40,0,U2:.2.F–VALUE.]$[M,W,40,0,U2:.2.P–HEIGHT]$[N,W,40,0,U2:.3.F–VALUE.]$[O,W,40,0,U2:.3.P–HEIGHT]$[P,W,40,0,U2:.4.F–VALUE.]$[Q,W,40,0,U2:.4.P–HEIGHT]$[@1,8,AXIS NUMBER]#*M30

Store the definition program on a data medium (Important: read out without DFSidentifier!).

The W–table is generated later on by reading this definition program into the con-trol.

The table contains 8 columns (axis number 1–8) of 17 lines each (circle parame-ters). The compensation time required for the respective axis will be entered laterunder address ”A”.A maximum of 4 parameter pairs (pulse height and path velocity) can be specifiedunder addresses B to I for the first reversal point (U1). The parameter pairs for thesecond reversal point (U2) should be entered in addresses J to Q. The addresses of the parameter pairs valid for a reversal point need not be com-



D27 – 62

pletely allocated in the W–table. It is thus also permitted, for example, to specifyonly two parameter pairs.

Optimizing the circular compensation parameters

D27 allows you to preallocate corresponding compensation values for the two re-versal points of each axis.Please note that the entered values are active only if the W–table values of the cor-responding axis have been preallocated the value ”0” and are active or ifW999999003 does not exist (also refer to the section ”User interface/software as-signments” under softkey ACTIVATE).Diagnostic program D23 can be used to check the contour after execution of acircle. For this purpose, setpoint and actual contours are displayed in D23. In order to per-mit the quadrant transition to be seen more easily, the respective axis can be ex-panded on the display (for instructions on operation of D23, refer to chapter ”D23Contour display”, softkey EXPANSION.

1. Define the radius which is to be used for optimization. Define the speedrange within which optimization is to take place. 9999 mm/min. is the maxi-mum permitted path feedrate.

2. Adapt the test program P110 (feedrate, radius) and then perform programselection.

3. Select D23 and set the trigger condition (e.g. program number = 110, blocknumber = 20).

4. Start D23 recording. Start test program.

5. Check quadrant transitions with contour display.

6. Select D27. Enter the corresponding axis number and compensation values(compensation pulse 1.Q/2.Q). Then press softkey ACTIVATE.

7. Select D23. Start recording. Start test program.

8. Check the quadrant positions. Optimize the compensation values if the com-pensation is too large or too small (repeat steps 6–8).

9. Determine the optimum compensation values for various speeds by adapt-ing the test program (feedrate). Note the found compensation values in atable (feedrate value, compensation path).Plot noted values graphically for each reversal point. Perform further mea-surements if necessary at critical points.

10. Approximate measured curves by maximum of 3 straight lines (refer to sec-tion ”Circular compensation”).

11. Generate W–table and plot parameter pairs of the reference points.

12. Transfer the W–table values by pressing the softkeys RESET FUNCTIONand CLEAR ALL LOGIC in group operating mode DIAGNOSTIC.

MOVE

SERVO

MOVE


D28 Tapping

D28 – 63

D28 – Tapping without compensation chuck

General

The diagnostic program D28 acts as a commissioning aid for the option ”TAPPINGWITHOUT COMPENSATION CHUCK” for correct adjustment of the pilot controlweighting factors for speed and acceleration (machine parameters P7203 andP7204).

Note:

The option requires the servo loop board SERVO i.


The following display appears after D28 is started:

DISPLAY

After the end of a recording (refer to softkey START RECORDING), you can haverecorded feedrate and lag values displayed as diagrams on the monitor by pressingthis softkey. The graphic display parameters are influenced by means of the func-tions offered by the softkey DISPLAY SPLITTING.

No CP0ACT

NC0STOP

DIAGNOSTIC30.11. 14: 8PROGRAM

DISPLAYAXISDATA

DISPLAYSPLITTING

OTHERCOMMANDS

STARTRECORDING

TAPPINGRECORDINGWAITING

ADJUSTMENTSAXIS:

Y1 :Y2 :X−EXPANSION:

1V−WEIGHTING:A−WEIGHTING:

X−EXP. START:

10001000100

MM/MINMM/MINMS

PER SCALE DIVISIONPER SCALE DIVISION

PER SCALE DIVISION

JOG BUTTON 1. AXISTRIGGER SETTING

00

0 SCALE DIVISION


D28 Tapping

D28 – 64

AXISDATA

AXISNUMBER

FEEDWEIGHTING

ACCELERA-TION

WEIGHTINGACTIVATE

On this softkey level, the axis to be optimized and the setpoints of the pilot controlvalues for feedrate and acceleration can be defined for an optimization step (referto the section ”Optimizing the pilot control weighting factors” for the optimizationprocedure).

In addition, it is possible to transfer the pilot control values to the machine parame-ters 7203 and 7204 after optimization by means of the softkey ACTIVATE, withoutthe option ”PILOT SPEED CONTROL” having to be activated in the system. A CNCreset automatically takes place after operation of the softkey ACTIVATE.

Caution:The values are entered only in the machine parameter record by operation of thesoftkey ACTIVATE. The file L444 is not modified.In order to keep L444 up to date, L444 must first be deleted after transfer and thenregenerated (with/without text) if necessary. Possibly save the machine parameterrecord in the EEPROM!

Note:

If it is wished to optimize several axes, it is not necessary to press the softkey ACTI-VATE after adjustment of an individual axis. First optimize all desired axes succes-sively and then press the softkey ACTIVATE.

SOFTKEYDISPLAY

SPLITTING

X–DISPLAYSTART

EXPAND X* 10

SCALEY1–AXIS

SCALEY2–AXIS

It is possible to manipulate the display parameters of the graphic display here (referto softkey DISPLAY). Both the right start point of the X–axis and expansion of the X–axis by a factor 10as well as scale factors for the Y–axes of the feedrate (Y1) and lag diagram (Y2)can be defined separately.

SERVO

MP


D28 Tapping

D28 – 65

OTHERCOMMANDS

TRIGGER JOGBUTTON

TRIGGERPROG./BLOCK

After activation of recording (refer to softkey START RECORDING), the start ofdata recording is delayed until a specific trigger event occurs. Both operation of a jog button and the start of execution of a specific program blockcan be defined as a trigger event. The set trigger condition is identified by inversedisplay of the corresponding softkey.

STARTRECORDING

Data recording is activated after operation of this softkey. At this point in time, thepilot control values entered on softkey level AXIS DATA are valid and not the ma-chine parameter values.

Recording starts when the trigger event occurs in accordance with the set triggercondition. During recording, the text ”RUNNING” is displayed on the monitor instead of thetext ”WAITING” (under the line ”RECORDING”).480 feedrate and lag values are always recorded. The recording time is calculatedas follows: T[ms] = 480 * P9901.The generated diagram can be called by means of the softkey DISPLAY only afterthe end of recording.

MOVE


D28 Tapping

D28 – 66

Preparations for optimization

Several preparations must be made before optimization:

‘ Adaption of the PLC program

The CNC output signal 16.5 is output for the duration of tapping. Feed enableis permitted by means of this signal although no M3, M4 is output.

‘ Adjustment of machine parameters

P7201 (gear speed–dependent spindle closed–loop gain):First take over the closed–loop gain value for the spindle axis from machineparameter P7014.The closed–loop gain must be set for each gear speed so that no spindleoscillations occur at the maximum speed which is to be used for tapping.

P7202 Gear speed–dependent spindle acceleration:Take over the value from machine parameter P7015. P7203 and P7204 (axis–specific pilot control weighting factors):First leave these values unchanged. The values determined later on duringoptimization can be transferred here directly from D28 by means of the soft-key ACTIVATE.

If the option ”PILOT CONTROL” is applied, it is additionally necessary totake into account the settings of P1014 and P1015 for optimization. Both pa-rameters define the maximum possible limit values for speed and accelera-tion pilot control weighting factors.

‘ Test program generation

Example: P111 N10 G1 X0 Y0 Z0 M19 S0N20 G32 F1000 M3 S1000 Z30N30 G32 F1000 M4 S1000 Z0M30

Before the start of tapping, the position servo loop of the spindle must beclosed. This is achieved, for example, by way of the function SPINDLE ORI-ENTATION or SPINDLE STOP (M5).

If drilling is to take place several times in a hole, the spindle must be posi-tioned with M19 before G32 (e.g. subsequent cutting after tool breakage).


D28 Tapping

D28 – 67

Optimizing the pilot control weighting factors

Aim of optimization: The lag of the drilling axis should be ”0” if possible during tap-ping. Realistic values here are a lag of less than 10 lm during constant speedphases and lag values of less than 20 lm during acceleration phases.The procedure for setting the pilot control parameters is described below.Since the magnitude of the remaining lag significantly effects the accuracyof the thread, careful adjustment of the pilot control parameters is essential.

1. Select D28.

2. Set the trigger condition (e.g. program number = 11, block number = 20).

3. Set the axis number (e.g. axis number = 3; Z–axis).

4. Start recording by means of the softkey START RECORDING then start testprogram (P111).

5. Evaluate recording. Calculate the active closed–loop gain from the recordedfeedrate and lag values.

6. Compare the active closed–loop gain (CLGact) with the value entered in ma-chine parameter P1001. Depending on the result, you can now enter therough value of the feedrate weighting factor in D28 under softkey level AXISDATA:

Result of comparison Feedrate weighting factor to be entered

CLGact ~ P1001 approx. 10000 (� 300) CLGact > P1001 significantly less than 10000 CLGact < P1001 greater than 10000

7. Start recording by means of the softkey START RECORDING. Then starttest program (P111).

8. Evaluate recording. The lag which occurred during unaccelerated travel isnow relevant (stationary lag).

Lag Entered feedrate weighting factor

became less increase; repeat as from step 7.has changed sign reduce; repeat as from step 7.(over–compensation)no reduction OK; continue with step 9.possible without sign change

Note:

It is possible to increase the resolution of the lag diagram in Y–direction by scaleswitchover on the softkey level DISPLAY SPLITTING in order to permit easy recog-nition of small lag values.

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D28 Tapping

D28 – 68

9. Increase the value of the acceleration weighting factor in D28 on the softkeylevel AXIS DATA in order to now minimize the lag during acceleration/decel-eration (recommendation: step distance 100).

10. Start recording by means of the softkey START RECORDING. Then starttest program (P111).

11. Evaluate recording. The lag which occurred during accelerated travel is now relevant.

Lag Entered acceleration weighting factor

became less increase; repeat as from step 10.changed sign reduce; repeat as from step 10.no reduction OK; continue with step 12.possible withoutsign change

Notes:

It is possible to increase the resolution of the lag diagram in Y–direction by switch-ing the scale on softkey level DISPLAY SPLITTING in order to permit easy recogni-tion of small lag values.The lag during an accelerated travel must not change.

12. Select the next axis to be optimized on softkey level AXIS DATA and adapttest program (P111). Then continue with step 4.

When the weighting factors have been set for all drilling axes, press the softkey AC-TIVATE on softkey level AXIS DATA. This transfers all optimized pilot controlweighting factors to the machine parameter record. The file L444 is not changedas a result. A CNC reset automatically takes place after this. In order to keep L444 up to date, you must first delete L444 after transfer and thenregenerate it (with/without text) again if necessary.

13. Check the optimized settings using the diagnostic program D23 CONTOURDISPLAY:The offset between spindle and drilling axis at the reversal point can be de-termined with D23. To do this, plot the spindle axis and drilling axis againsteach other (by means of the softkeys DISPLAY X/Y AXIS on the softkey levelSTARTING VALUES). In the ideal case, the ”ACTUAL CONTOUR” pro-duces a straight line for drilling in and out.

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MP

1070 073 306-101 (91.10) GB · HB NC · AT/VSP · Printed in Germany

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