840d and ncfunctions

Traceability NC-functions in 840 D G-Code (DRAFT)Julio Garrido Campos ([email protected])

Vigo University

get_time()Siemens840D Could translate directly into a write operation dumping (WRITE code o Procedure) into a LOG file the appropriate text, and any of the following 840D Variables (CNC internal variables) according with the standard definition of the function:

$A_YEAR $A_MONTH $A_DAY $A_HOUR $A_MINUTE $A_SECOND $A_MSECOND.

Validated and tested example code : WRITE(ERROR,"LOGFILE", "WS2 START TIME :" << $A_HOUR << ":" << $A_MINUTE << ":" << $A_SECOND << ":" << $A_MSECOND )

(Using the write function or any external-defined file writing procedure)

(Sinutrain 840 Screenshot)

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start_getting_max_deviaton_along_toolpath()Siemens840D Could be translated with the aid of a Siemens Synchronous Motion Action code, using several user variables (R parameters) to store user-defined values.

In the examples, R[1], R[2],R[3] have been used to store X,Y,Z positions of the measured value as given by the encoders variables: $VA_IM[X], $VA_IM[Y] & $VA_IM[Z]

R[5] , used to store the actual max deviation path ( following error ), calculated as:SQRT( POT($VA_LAG_ERROR[X])+POT($VA_LAG_ERROR[Y])^2+POT($VA_LAG_ERROR[Z])))

For each tool path segments, during its interpolation cycles, the previously stored R[5] value is compared with the new calculated deviation value, and if it is greater, R[5] and X,Y,Z positions are updated and recorded. This is done with the following sample code:

ID=1 WHENEVER ($R[5]<SQRT(POT($VA_LAG_ERROR[X])+POT($VA_LAG_ERROR[Y])+POT($VA_LAG_ERROR[Z]))) DO TCICLO

1. ID=1, identifies the synchronous action as number 1, to be cancelled with the corresponding stop function. WHENEVER is the vocabulary word to indicate that that the action alter DO word should be performed each time the condition (in green is fulfilled)

2. TCICLO is a procedure/subroutine, programmed to store the current variables in the corresponding R-Parameters.

3. After each G-code block corresponding to a tool path segment and before the next motion G-code, recorded values are DUMPED to the log File (1 value per segment), via a WRITE command and the used variables (R-parameters) are reset to 0 to prepare the measure of the next tool path segment deviation value Validated and Tested example code (software tested, so no ability to obtain non cero $VA_LAG_ERROR[]):

G2X-27.299979Y-90.799979Z-84.74075CR=38.608WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION VALUE :" << R[5] << "POSITION: X" << R[1] << “ Y ” << R[2] << “ Z “ << R[3])R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0MSG("SEGMENT-1 DEVIATION VALUE RECORDED")

- 2 -

G1X-90.799979Y-27.299979WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION VALUE : ...")R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0

4. It would be necessary to add AP-238 information in the log to macth these values with the corresponding Ap-238 toolpath geometry.

stop_getting_max_deviaton_along_toolpath()Siemens840D Could translate directly into cancelling the previously started synchronous action

CANCEL (ID NUMBER)

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Sample Code executed in Sinutrain Sinumerik 840d.

;Sample Program (with M00 inserted to pause simulation at several points …);AP-238 STEP-NC MAIN PROGRAM;N01 EXTERN WSSPINDL( INT, REAL );N02 EXTERN WSTOOL( INT )N03 DEF INT ERROR; VARIABLE INITIALIZATIONN04 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0N10 T="PF25"N10 G17 G40 G53 G90N11 MSG("TOOLCHANGEBEGINNING ")N12 MSG("TOOLCHANGEEND ")N13 MSG("FACE TOP OF PART")N14 MSG("BLANK STATEMENT for NC_COMPENSATION ")N15 MSG("")N16 M00; Workingstep 1: line 33 WS 1;N15 WSMODEON;N17 WSTOOL( 1 )N17 G70;N19 WSSPINDL( 3, 2000.00 );N20 WS_FLOODN18 G0X0Y0Z-2.54N19 X-184.15Y143.51Z-55.88N20 Z-80.772N21 G1X-152.4F1016N22 X152.4N23 Y124.46N24 X-152.4N25 Y105.41N26 X152.4N27 Y86.36N28 X-152.4N29 Y67.31N30 X152.4Y67.31N31 Y48.26N32 X-152.4Y48.26N33 Y29.21N34 X152.4Y29.21N35 Y10.16N36 X-152.4N37 Y-8.89N38 X152.4Y-8.89N39 Y-27.94N40 X-152.4Y-27.94N41 Y-46.99N42 X152.4N43 Y-66.04N44 X-152.4Y-66.04N45 Y-85.09N46 X152.4N47 Y-104.14N48 X-152.4

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N49 Y-123.19N50 X152.4N51 Y-142.24N52 X-152.4N53 Y-161.29N54 X152.4N55 X177.8N56 G0Z-55.88

; Workingstep: line 123 WS 2

; WRITE IN LOG FILE WS3 START TIME; WRITE COMMAND (N59)N57 WRITE(ERROR,"LOGFILE", "WS2 START TIME :" << $A_HOUR << ":" << $A_MINUTE << ":" << $A_SECOND << ":" << $A_MSECOND ); Display The log messageN58 MSG("WS2 START TIME :" << $A_HOUR << ":" << $A_MINUTE << ":" << $A_SECOND << ":" << $A_MSECOND ); STOP AFTER TO PAUSE SIMULATIONN59 M00N61 MSG("EXECUTING TOOLPATH 1 - TP4"); WS2 TOOLPATH 1 POLYLINE (TP4)N62 X175.980235Y-18.319722N63 Z-82.20075N64 MSG("EXECUTING TOOLPATH 2 - TP5"); WS2 TOOLPATH 2 POLYLYNE (TP5)N65 G1Z-84.74075F1016N66 X99.780235N67 X90.799979Y-27.299979N68 X27.299979Y-90.799979; WS3 TOOLPATH 3 COMPOSITE CURVE (TP6); START MONITORING MAX DEVIATION POSITION ALONG TOOLPATHN69 MSG("ACTIVATING MONITORING OF MAX DEVIATION ALONG TOOLPATH for TP6"); COMO LLAMADA A CICLON69 ID=1 WHENEVER ($R[5]<SQRT(POT($VA_LAG_ERROR[X])+POT($VA_LAG_ERROR[Y])+POT($VA_LAG_ERROR[Z]))) DO TCICLO

N70 G2X-27.299979Y-90.799979Z-84.74075CR=38.608; EJEMPLO PARA EL LOGN71 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION VALUE :" << R[5] << "POSITION" << $VA_IM[X] << $VA_IM[Y] << $VA_IM[Z]); EJEMPLO DE SALIDA POR PANTALLAN72 MSG("SEGMENT-1 DEVIATION VALUE RECORDED")N73 G1X-90.799979Y-27.299979N74 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION VALUE : ...")N75 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0N76 MSG("SEGMENT-2 DEVIATION VALUE RECORDED")N77 G2X-90.799979Y27.299979Z-84.74075CR=38.608N78 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION VALUE : ...")N79 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0N80 MSG("SEGMENT-3 DEVIATION VALUE RECORDED")N81 G1X-27.299979Y90.799979N82 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION VALUE : ...")N83 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0N84 MSG("SEGMENT-4 DEVIATION VALUE RECORDED")N85 G2X27.299979Y90.799979Z-84.74075CR=38.608N86 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION VALUE : ...")N87 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0N88 MSG("SEGMENT-5 DEVIATION VALUE RECORDED")N89 G1X90.799979Y27.299979N90 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION VALUE : ...")N91 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0N92 MSG("SEGMENT-6 DEVIATION VALUE RECORDED")N93 X99.780235Y18.319722N94 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION VALUE : ...")N95 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0N96 MSG("SEGMENT-7 DEVIATION VALUE RECORDED")N97 X175.980235

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N98 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION VALUE : ...")N99 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0N100 MSG("SEGMENT-8 DEVIATION VALUE RECORDED"); STOP MONITORING MAX DEVIATION POSITION ALONG TOOLPATHN101 MSG ("TP6 END AND STOP TOOLPATH MONITRING")N102 CANCEL(1)N103 M00N105 MSG("COMPLETING THE REST OF WORKINGSTEP 2")N106 G0X166.999979Y-9.339466N107 G1X90.799979F1016N108 X81.819722Y-18.319722N109 X18.319722Y-81.819722N110 G2X-18.319722Y-81.819722Z-84.74075CR=25.908N111 G1X-81.819722Y-18.319722N112 G2X-81.819722Y18.319722Z-84.74075CR=25.908N113 G1X-18.319722Y81.819722N114 G2X18.319722Y81.819722Z-84.74075CR=25.908N115 G1X81.819722Y18.319722N116 X90.799979Y9.339466N117 X166.999979N118 G0X158.019722Y-0.35921N119 G1X81.819722F1016N120 X72.839466Y-9.339466N121 X9.339466Y-72.839466N122 G2X-9.339466Y-72.839466Z-84.74075CR=13.208N123 G1X-72.839466Y-9.339466N124 G2X-72.839466Y9.339466Z-84.74075CR=13.208N125 G1X-9.339466Y72.839466N126 G2X9.339466Y72.839466Z-84.74075CR=13.208N127 G1X72.839466Y9.339466N128 X81.819722Y0.35921N129 X158.019722N130 G0X175.980235Y-18.319722N131 Z-88.9635N132 G1X99.780235F1016N133 X90.799979Y-27.299979N134 X27.299979Y-90.799979N135 G2X-27.299979Y-90.799979Z-88.9635CR=38.608N136 G1X-90.799979Y-27.299979N137 G2X-90.799979Y27.299979Z-88.9635CR=38.608N138 G1X-27.299979Y90.799979N139 G2X27.299979Y90.799979Z-88.9635CR=38.608N140 G1X90.799979Y27.299979N141 X99.780235Y18.319722N142 X175.980235N143 G0X166.999979Y-9.339466N144 G1X90.799979F1016N145 X81.819722Y-18.319722N146 X18.319722Y-81.819722N147 G2X-18.319722Y-81.819722Z-88.9635CR=25.908N148 G1X-81.819722Y-18.319722N149 G2X-81.819722Y18.319722Z-88.9635CR=25.908N150 G1X-18.319722Y81.819722N151 G2X18.319722Y81.819722Z-88.9635CR=25.908N152 G1X81.819722Y18.319722N153 X90.799979Y9.339466N154 X166.999979N155 G0X158.019722Y-0.35921N156 G1X81.819722F1016N157 X72.839466Y-9.339466N158 X9.339466Y-72.839466N159 G2X-9.339466Y-72.839466Z-88.9635CR=13.208N160 G1X-72.839466Y-9.339466N161 G2X-72.839466Y9.339466Z-88.9635CR=13.208N162 G1X-9.339466Y72.839466N163 G2X9.339466Y72.839466Z-88.9635CR=13.208N164 G1X72.839466Y9.339466N165 X81.819722Y0.35921

- 6 -

N166 X158.019722N167 Z-86.4235N168 G0Z-55.88; WRITE IN LOG FILE WS3 END TIMEN169 WRITE(ERROR,"LOGFILE", "WS2 END TIME :" << $A_HOUR << ":" << $A_MINUTE << ":" << $A_SECOND << ":" << $A_MSECOND ); If we want to display a log messageN170 MSG("WS2 END TIME :" << $A_HOUR << ":" << $A_MINUTE << ":" << $A_SECOND << ":" << $A_MSECOND )N171 M00N172 MSG("CONTINUE WITH THE REST of WSTEPs"); Workingstep: line 337 WS 3N173 X171.958Y0N174 Z-90.51925N175 G1Z-93.05925F1016; PROGRAM STOP FOR THE SIMULATION PART

...

;Sample Technological Cycle

; CALCULATE DEVIATION VALUEN000 $R[5] = SQRT(POT($VA_LAG_ERROR[X]) + POT($VA_LAG_ERROR[Y]) + POT($VA_LAG_ERROR[Z]))N030 $R[1]=$AA_IM[X] N040 $R[2]=$AA_IM[Y] N050 $R[3]=$AA_IM[Z] N020 M17

Operation and Programming 10/2002 Edition

Turning SINUMERIK 802D

Valid for

Control SystemSoftware Version SINUMERIK 802D2

10.02 Edition

SINUMERIK 802D

Operation and Programming Turning

Introduction 1

Turning On an Reference-Point

Approach 2

Setting Up3

Manually Controlled Mode4

Automatic Mode5

Part Programming6

System 7

Programming 8 Cycles 9

SINUMERIKDocumentation

- 7 -

ANew documentationBUnrevised reprint with new Order NoCRevised edition with new statusPrinting history Brief details of this edition and previous editions are listed below. IThe status of each edition is shown by the code in the ”Remarks” column. Status code in the “Remarks” column:

If actual changes have been made on the page since the last edition, this is indicated by a new edition coding in the header on the page.

10.02 6FC5698–2AA00–0BP2 CEdition Order–No. Remark 1.0 6FC5698–2AA0–0BP0 A 07.01 6FC5698–2AA00–0BP1 C

This Manual is included on the documentation on CD–ROM (DOCONCD) Edition Order–No. Remark 1.02 6FC5298–6CA00–0BG3 C

Trademarks SIMATIC , SIMATIC HMI , SIMATIC NET , SIMOTION , SINUMERIK and SIMODRIVE are registered trademarks of Siemens. Third parties using for their own purposes any other names in this document which refer to trademarks might infringe upon the rights of trademark owners.

Further information is available on the Internet under: http://w.ad.siemens.de/sinumerik

This publication was produced with Interleaf V 7

The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for demages. All rights, including rights created by patent grant or registration of utility model or design, are reserved.

Siemens AG 2002. All rights reserved.

Other functions not described in this documentation might be executable in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing.

We have checked that the contents of this document correspond to the hardware and software described. Nonetheless, differences might exist and therefore we cannot guarantee that they are completely identical. The information contained in this document is, however, reviewed regularly and any necessary changes will be included in the next edition. We welcome suggestions for improvement.

Subject to change without prior notice.

Siemens–AktiengesellschaftBestell–Nr. 6FC5 698–2AA00–0BP2 Printed in the Federal Republic of Germany

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T)

Safety notices

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This Manual contains notices intended to ensure your personal safety and to avoid material damage. The notices are highlighted by a warning triangle and, depending on the degree of hazard, represented as shown below:

! Danger indicates that loss of life, severe personal injury or substantial material damage will result if the appropriate precautions are not taken.

indicates that loss of life, severe personal injury or substantial material damage may result if the appropriate precautions are not taken.

! Caution indicates that minor personal injury or material damage may result if the appropriate precautions are not taken.

Caution eithout a warning triangle means that material damage can occur if the appropriate precautions are not taken.

Attention means that an undesired event or status can occur if the appropriate note is not observed.

Note is used to draw your special attention to an important information on the product, the handling of the product or the corresponding part of the documentation.

Qualified personnel

Start-up and operation of a device may only be carried out by qualified personnel. Qualified personnel as referred to in the safety notices provided in this Manual are persons who are authorized to start up, ground and tag devices, systems and circuits according to the relevant safety standards.

Usage as per intended purpose Please observe the following:

The device may only be used for the cases of application, as intended by the Catalog, and only in conjunction with third-party devices and components recommended or approved by Siemens.

The proper and safe operation of the product requires transport, storage and installation according to the relevant instructions and qualified operation and maintenance at the prescribed intervals.

Contents viSINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T)

1Introduction1-131.1Screen Layout1-131.2Operating Areas1-161.3Accessibility Options1-171.3.1Calculator1-171.3.2Editing Chinese Characters1-21.3.3Hotkeys1-21.4The Help System1-231.5Coordinate Systems1-242Turning on and Reference Point Approach2-273Setting Up3-293.1Entering Tools and Tool Offsets3-293.1.1Creating a New Tool3-313.1.2Determining Tool Offsets (manually)3-32

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3.1.3Determining the Tool Compensations Using a Probe3-353.1.4Determining the tool compensations values using an optical measuring system3-363.1.5Probe Settings3-363.2Tool monitoring3-393.3Entering/Modifying Zero Offset3-403.3.1Determining Zero Offset3-413.4Programming Setting Data - Operating Area “Parameters”3-423.5R Parameters - Operating Area “Offset/Parameters”3-454Manually Controlled Operation4-474.1Jog Mode - Operating Area “Position”4-484.1.1Assigning Handwheels4-514.2Operating Mode MDA (Manual Input)4-524.2.1Face Turning4-55Automatic Mode5-595.1Selecting and Starting a Part Program5-635.2Block Search - Operating Area “Machine”5-645.3Stopping/Aborting a Part Program5-655.4Re-approach after abortion 5-65.5Re-approach after Interruption - Operating Area “Machine”5-65.6Program Execution from External (RS232 Interface)5-676Part Programming6-696.1Entering a New Program - Operating Area ”Program”6-726.2Editing a Part Program - Operating Mode “Program”6-736.3Blueprint programming6-756.4Simulation6-93Contents 6.5Data Transfer via the RS232 Interface6-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents viiSINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T)

7System7-977.1PLC diagnosis using the ladder diagram representation7-1187.1.1Screen layout7-1187.1.2Operating options7-1198Programming8-1298.1Fundamentals of NC Programming8-1298.1.1Program Names8-1298.1.2Program Structure8-1298.1.3Word Structure and Address8-1308.1.4Block Structure8-1318.1.5Character Set8-1328.1.6List of Statements8-1348.2Positional Data8-149

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8.2.1Absolute / Incremental Data Input: G90, G91, AC, IC8-1498.2.2Metric and Inch Dimensions: G71, G70, G710, G7008-1508.2.3Radius / Diameter Programming: DIAMOF, DIAMON8-1518.2.4Programmable Zero Offset: TRANS, ATRANS8-1528.2.5Programmable Scaling Factor: SCALE, ASCALE8-153G54 to G59, G500, G53, G1538-154G25, G26, WALIMON, WALIMOF8-1558.3Axis Movements8-1578.3.1Linear Interpolation at Rapid Traverse: G08-1578.3.2Linear Interpolation with Feed: G18-1588.3.3Circular Interpolation: G2, G38-1598.3.4Circular Interpolation via Intermediate Point: CIP8-1628.3.5Circle with Tangential Transition: CT8-1628.3.6Thread Cutting with Constant Lead: G338-1638.3.7Thread cutting with variable lead: G34, G358-1668.3.8Thread interpolation: G331, G3328-1678.3.9Fixed-Point Approach: G758-1688.3.10Reference Point Approach: G748-1688.3.11Measuring with Switching Tracer: MEAS, MEAW8-1698.3.12Feed F8-1708.3.13Exact Stop / Continuous-Path Control Mode: G9, G60, G648-1718.3.14Acceleration Behavior: BRISK, SOFT8-1738.3.15Percentage Acceleration Compensation: ACC8-1748.3.16Traversing with Feedforward Control: FFWON, FFWOF8-1758.3.173rd and 4th Axes8-1758.3.18Dwell Time: G48-1768.3.19Travel to fixed stop8-1778.4Spindle Motions8-1808.4.1Spindle Speed S; Directions of Rotation8-1808.4.2Spindle Speed Limiting: G25, G268-1808.4.3Positioning the Spindle: SPOS8-1818.4.4Gear stages8-1828.4.52nd spindle8-1828.5Special Turning Functions8-1848.5.1Constant Cutting Speed: G96, G978-1848.5.2Rounding, Chamfer8-1868.5.3Contour Definition Programming8-1878.6Tool and Tool Compensation8-1908.6.1General Notes8-1908.6.2Tool T8-190

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8.2.6Workpiece Clamping - Settable Zero Offset: 8.2.7Programmable Working Area Limitation: 8.6.3Tool Offset Number D8-191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents viiiSINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T)

8.6.4Selection of Tool Radius Compensation: G41, G428-1948.6.5Corner Behavior: G450, G4518-1968.6.6Tool Radius Compensation OFF: G408-1978.6.7Special Cases of Tool Radius Compensation8-1988.6.8Example of Tool Radius Compensation8-1998.6.9Using milling tools8-2008.6.10Tool compensation special cases8-2028.7Miscellaneous Function M8-2038.8H function8-2048.9Arithmetic parameters R, LUD and PLC variables8-2058.9.1Arithmetic parameters R8-2058.9.2Local user data (LUD)8-2078.9.3Reading and writing PLC variables8-2088.10Program Jumps8-2098.10.1Jump Destination for Program Jumps8-2098.10.2Unconditional Program Jumps8-2098.10.3Conditional Program Jumps8-2108.10.4Programming Example of Jumps8-2128.11Subroutine Technique8-2138.1.1General8-2138.1.2Calling Machining Cycles8-2158.12Timer and Workpiece Counter8-2168.12.1Runtime Timer8-2168.12.2Workpiece Counter8-2178.13Language commands for tool monitoring8-2198.13.1Overview: Tool monitoring8-2198.13.2Tool life monitoring8-2208.13.3Count monitoring8-2218.14Milling on turning machines8-2248.14.1Milling face ends - TRANSMIT8-2248.14.2Milling of peripheral surfaces - TRACYL8-2268.15Equivalent G Functions with SINUMERIK 802S - Turning8-2319Cycles9-2339.1Overview of cycles9-2339.2Programming cycles9-2349.3Graphical cycle support in the program editor9-2369.4Drilling cycles9-238

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9.4.1General9-2389.4.2Preconditions9-2399.4.3Drilling, centering – CYCLE819-2409.4.4Center drilling – CYCLE829-2439.4.5Deep hole drilling – CYCLE839-2459.4.6Rigid tapping – CYCLE849-2499.4.7Tapping with compensation chuck – CYCLE8409-2529.4.8Reaming 1 (boring 1) – CYCLE859-2569.4.9Boring (boring 2) – CYCLE869-2599.4.10Reaming 2 (boring 3) – CYCLE879-2629.4.11Drilling with stop 1 (boring 4) – CYCLE889-2659.4.12Drilling with stop 2 (boring 5) – CYCLE899-2679.4.13Row of holes – HOLES19-2699.4.14Circle of holes – HOLES29-273Contents ixSINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T)

9.5.1Preconditions9-2769.5.2Grooving – CYCLE939-278

9.5.3Undercut form EF – CYCLE949-286. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5.4Stock removal – CYCLE959-2909.5.5Thread undercut – CYCLE969-3039.5.6Thread cutting – CYCLE979-3079.5.7Chaining of threads – CYCLE989-3139.6Error Messages and Error Handling9-3209.6.1General notes9-3209.6.2Error handling in the cycles9-3209.6.3Overview of cycle alarms9-3209.6.4Messages in the cycles9-322. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

xSINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T)

SINUMERIK 802D Key Definition &

Recall key ETC key

Acknowledge Alarm key Not assigned Info key Shift key Control key Alt key SPACE (INSERT)

Deletion key (Backspace) Deletion key Insertion key Tabulator

- 13 -

ENTER / Input key Position operating area key

Program operating area key Parameters operating area key Program Manager operating area key Alarm/System operating area key

Not assigned Paging keys

Cursor keys Selection key/toggle key

Alphanumeric keys Double assignment on the Shift level

Numerical keys Double assignment on the Shift level


External machine control panel

Reset NC STOP NC START emergency stop %Spindle override

User-defined key with LED User-defined key with LED INCREMENT JOG REFERENCE POINT AUTOMATIC SINGLE BLOCK

SPINDLE START CCW rotation

SPINDLE START CW rotation

RAPID TRAVERSE OVERRIDE Rapid traverse override

X axis Z axis

%Feed override xii

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) notice

1-13SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T)

Introduction 1.1Screen Layout

Status area Application area

Tip and softkey area

G function

Fig. 1-1 Screenlayout

The screen is divided into the following main areas:

Status area Application area Tip and softkey area



Status area

Fig. 1-2Status area

Table 1-1Explanation of the display elements in the status area

DisplayElement Display Meaning

Active operating area, active mode Position

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JOG; 1 INC, 10 INC, 100 INC, 1000 INC, VAR INC (incremental evaluation in JOG mode)

MDA1 MDA AUTOMATIC

Offset ProgramProgram Program Manager SystemSystem Alarm Marked as an ”external language” using G291

Alarm and message line

Thflliidild(ith/)2The following is displayed (either/or): 1. Alarm number with alarm text1. Alarm number with alarm text

2. Message text

Program status RESETProgram aborted / basic status 3RUNProgram running STOPProgram stopped

4Program controls in Automatic mode

5 Reserved 6NC messages 7Selected part program (main program)



Tip and softkey area

Fig. 1-3Tip and softkey area

Table 1-2Explanation of the display elements in the tip and softkey area

DisplayElement Display Meaning

1 Recall symbol

Pressing the Recall key lets you return to the next higher level.

Displays tips for the operator

MMC status information

ETC is possible (If you press this key, the horizontal softkey bar will display further functions.)

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Mixed notation active Data transfer running Link with the PLC programming tool active

4Softkey bar vertical and horizontal

Standard softkeys

Use this softkey to quit the screen form. Use this softkey to cancel input; the window will be quitted. Pressing this softkey will complete your input and start the calculation.

Introduction 1.2Operating Areas


Pressing this softkey will complete your input and accept the entered values.

This function is used to switch over the screen form from diameter programming to radius programming.

1.2Operating Areas The functions of the control system can be carried out in the following operating areas:

Position Machine operation Offset/ParametersInput of compensation values and setting data ProgramCreation of part programs Program ManagerPart program directory System Diagnosis, start-up AlarmAlarm and message lists

To switch to a different operating area, press the appropriate key (hardkey).

Protection levels

The input or modification of data in the control system is password-protected in sensible places.

In the menus listed below the input or modification of data depends on the protection level set.

Tool offsets Zero offsets Setting data RS232 settings Program creation / program correction

Introduction 1.3 Accessibility Options


1.3 Accessibility Options

1.3.1 Calculator

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To calculate terms, the four basic arithmetic operations can be used, as well as the functions “sine”, “cosine”, “squaring” and “square root”. A bracket function is provided to calculate nested terms. The bracketing depth is unlimited.

If the input field is already occupied by a value, the function will accept this value into the input line of the calculator.

When you press the Input key, the result is calculated and displayed in the calculator.

Pressing the Accept softkey enters the result in the input field at the current cursor position of the part program editor and closes the calculator automatically.

Fig. 1-4Calculator

Characters permitted for input

SSine function The X value (in degrees) before the input cursor is replaced by the value sin(X).

CCosine function The X value (in degrees) before the input cursor is replaced by the value cos(X).

QSquare function

RSquare root function The X value before the input cursor is replaced by the value √X.

( )Bracket function (X+Y)*Z



Calculation examples

TaskInput -> Result 100 + (67*3)100+67*3-> 301 sin(45)45 S -> 0.707107 cos(45)45 C -> 0.707107 424 Q -> 16 √4 R -> 2 (34+3*2)*10 (34+3*2)*10 -> 400

To calculate auxiliary points on a contour, the calculator provides the following functions:

Calculating the tangential transition between a circle sector and a straight line Moving a point in the plane Converting polar coordinates to Cartesian coordinates

Adding the second end point of a straight line/straight line contour section given from an angular relation

Softkeys

This function is used to calculate a point on a circle. The point results from the angle of the tangent created, the radius and the direction of rotation of the circle.

Fig. 1-5 Enter the circle center, the angle of the tangent and the circle radius.

Use the softkey G2 / G3 to define the direction of rotation of the circle.

When you press this softkey, the abscissa and ordinate values are calculated. The abscissa is the first axis, and the ordinate is the second axis of the plane. The value of the abscissa is copied into the input box from which the calculator function has been called, and the value of the ordinate is copied into the next following input box. If the

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function has been called from the part program editor, the coordinates are saved with the axis names of the selected basic plane.

G2/G3



in plane G18.Example: Calculate the intersection point between circle sector and straight line

Given:Radius: 10

Circle center: Z 147 X103 Connection angle of the straight line: -45

Result:Z = 154.071 X = 110.071

This function calculates the Cartesian coordinates of a point in the plane, which is to be linked with a point (P) on a straight line. For calculation, the distance between the points and the slope angle (A2) of the new straight line to be created with reference to the slope (A1) of the given straight line must be known.

Fig. 1-6

Enter the following coordinates or angles:

the coordinates of the given point (P) the rise angle of the straight line (A1) the distance of the new point with reference to P the rise angle of the connecting straight line (A2) with reference to A1

When you press this softkey, the Cartesian coordinates are calculated, which are then copied into two input fields following another to one. The value of the abscissa is copied into the input box from which the calculator function has been called, and the value of the ordinate is copied into the next following input box. If the function has been called from the part program editor, the coordinates are saved with the axis names of the selected basic plane.

- 18 -



This function converts the given polar coordinates into Cartesian coordinates.

Fig. 1-7

Enter reference point, vector length and slope angle.

When you press this softkey, the Cartesian coordinates are calculated, which are then copied into two input fields following another to one. The value of the abscissa is copied into the input box from which the calculator function has been called, and the value of the ordinate is copied into the next following input box. If the function has been called from the part program editor, the coordinates are saved with the axis names of the selected basic plane.

This function is used to calculate the missing end point of the straight line/straight line contour section whereby the second straight line stands vertically on the first straight line.

The following values of the straight line are known:

Straight line 1:

Start point and slope angle

Straight line 2:

Length and one end point in the Cartesian coordinate system

Fig. 1-8

This function is used to select the given coordinate of the end point. The ordinate value or the abscissa value is given.


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The second straight line is rotated in CW direction or in counter-clockwise direction by 90 degrees relative to the first straight line.

The missing end point is calculated. The value of the abscissa is copied into the input box from which the calculator function has been called, and the value of the ordinate is copied into the next following input box. If the function has been called from the part program editor, the coordinates are saved with the axis names of the selected basic plane.

Example

Fig. 1-9

Add the drawing above by the value of the center circle in order to be able to calculate then the intersection point between the circle sector of the straight line. The missing coordinate of the center point is calculated using the calculator function , since the radius in the tangential transition stands vertically on the straight line.

Fig. 1-10

Calculating M1 in section 1:

Der Radius steht 90° im Uhrzeigersinn gedreht auf der durch den Winkel festgelegten Gerade.

Use the softkeyto select the appropriate direction of rotation. Use the softkey

to define the given end point.

Enter the coordinates of the pole, the slope angle of the straight line, the ordinate angle of the end point and the circle radius as the length.

Accept

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Fig. 1-1

Result:X = 60 Z = -4.601

1.3.2Editing Chinese Characters

This function is only available in the Chinese language version.

The control system provides a function for editing Chinese characters in the program editor and in the PLC alarm text editor. After activation, type the phonetic alphabet of the searched character in the input box. The editor will then offer various characters for this sound, from which you can choose the desired one by entering either of the digits 1 to 9.

Fig. 1-12Chinese editor AltSis used to turn on/turn off the editor

1.3.3 Hotkeys

This operator control can be used to select, copy, cut and delete texts using special key commands. This functions are available both for the part program editor and for input fields.

CTRL C Copy CTRL B Select CTRL X Cut CTRL V Paste AltLis used to switch to mixed notation

AltHHelp system or Info key

Introduction 1.4The Help System


1.4The Help System

To activate the help system, use the Info key. It offers a brief description for all essential operating functions.

Further, the help feature contains the following topics:

Overview of the NC commands with a brief description Cycle programming Explanation of the drive alarms

Fig. 1-13Table of contents of the help system This function opens the topic selected.

Fig. 1-14Description with regard to a help topic

“>> <<”. This softkey is only unhidden if a cross reference is displayed in the

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application area.Use this function to select cross references. A cross reference is marked by the characters

If you select a cross reference, in addition, the Back to topic softkey is displayed. This function lets you return to the previous screen form.

Show

Go to topic

Back to topic

Introduction 1.5 Coordinate Systems


Use this function to search for a term in the table of contents. Type the term you are looking for and start the search process.

Help in the Program Editor area

The system offers an explanation for each NC instruction. To display the help text directly, position the cursor behind the instruction and press the Info key.

1.5 Coordinate Systems

For machine tools, right-handed, right-angled coordinate systems are used. The movements on the machine are described as a relative movement between tool and workpiece.

Fig. 1-15Determination of the axis directions another to one; coordinate system for programming on turning

Find



Machine coordinate system (MCS)

How the coordinate system is located with reference to the machine, depends on the machine type concerned. It can be rotated in different positions.

Fig. 1-16Machine coordinates/machine axes using the example of a turning machine

The origin of this coordinate system is the machine zero. In this point, all axes have the position ’zero’. This point represents only a reference point defined by the machine manufacturer. It need not be approachable.

The traversing range of the machine axes can be in the negative range.

Workpiece coordinate system (WCS)

The coordinate system described above (see Fig. 1-15) is also used to describe the geometry of a workpiece in the workpiece program. The workpiece zero can be freely selected by the programmer in the Z axis. In the X axis, it is in the turning center.

X Workpiece

Z Workpiece

W Workpiece

- 22 -

W - workpiece zero Fig. 1-17Workpiece coordinate system



Relative coordinate system

Apart from the machine and workpiece coordinate systems, the control system provides a relative coordinate system. This coordinate system is used for setting reference points that can be freely selected and have no influence on the active workpiece coordinate system. All axis movements are displayed relative to these reference points.

Clamping the workpiece

For machining, the workpiece is clamped in the machine. The workpiece must be aligned such that the axes of the workpiece coordinate system run in parallel with those of the machine. Any resulting offset of the machine zero with reference to the workpiece zero is determined along the Z axis and entered in a data area intended for the settable zero offset. In the NC program this offset is activated, e.g. using a programmed G54.

XMachine X Workpiece

Z Workpiece e.g.Z G54

Workpiece Machine

Fig. 1-18Workpiece on the machine

Current workpiece coordinate system

The programmed zero offset TRANS can be used to generate an offset with reference to the workpiece coordinate system resulting in the current workpiece coordinate system (see Section ”Programmable Zero Offset: TRANS”).


Turning on and Reference Point Approach

Note

When you turn on the SINUMERIK 802D and the machine, please also observe the Machine Documentation, since turning on and reference point approach are machine-dependent functions.

This documentation assumes an 802D standard machine control panel (MCP). Should you use a different MCP, the operation may be other than described herein.

Operating sequence

First turn on the power supply of CNC and machine. After the control system has booted, you are in the Position operating area, Jog mode.

The window “Reference-point approach” is active.

Fig. 2-1The Jog-Ref start screen

Use the Ref key on the machine control panel to activate “reference-point approach”.

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The Reference-Point Approach window (Fig. 2-1) will display whether the axes have a reference point or not.

Axis has to be referenced

Axis has reached its reference point

Turning on and Reference Point Approach


Select a direction key.

If you select the wrong approach direction, no movement will be carried out.

Approach the reference point one after the other for each axis. Quit the function by selecting a different mode (MDA, Automatic or Jog).

Note ”Reference-point approach“ is only possible in Jog mode.


Setting Up

Preliminary remarks Before you can work with the CNC, set up the machine, the tools, etc. on the CNC as follows:

Enter the tools and the tool offsets. Enter/modify zero offset. Enter setting data.

3.1Entering Tools and Tool Offsets

Functionality

The tool offsets consist of several data describing the geometry, the wear and the tool type. Depending on the tool type, each tool is assigned a defined number of parameters. Tools are identified by a number (T number).

See also Section 8.6 “Tool and Tool Offset“

Operating sequence

Use this softkey to open the Tool Offset Data window that contains a list of the tools created. Use the cursor keys and the Page Up/PageDown keys to navigate in this list.

Fig. 3-1Tool list

Offset Param

Tool List

- 24 -

Setting Up 3.1Entering Tools and Tool Offsets


Use the following operating sequence to enter the compensation values:

Position the cursor bar on the input box you want to modify, enter the desired value(s) and confirm your input by pressing Input or by a cursor movement.

For special tools, the softkey function Extend is provided, which offers a complete parameter list, which can be filled in.

Softkeys

Use this softkey to determine the tool offset data. Use this softkey to determine the tool offset data manually (see section 3.1.2). Use this softkey to determine the tool offset data semi-automatically (see Section 3.1.3). Use this softkey to calibrate the probe. Use this softkey to delete the tool offset data of all cutting edges of the tool. Use this softkey to display all parameters of a tool.

Fig. 3-2Screen form for entering special tools

Use this softkey to open a lower-level menu bar offering all functions required to create and display further cutting edges.

Use this softkey to select the next higher cutting edge number.

Tool measure

Measure manual

Measure auto

Calibrate probe

Delete tool

Extend

Activate change

Edges

- 25 -



Use this softkey to select the next lower cutting edge number. Use this softkey to create a new edge. Use this softkey to reset all offset values of the cutting edge to zero.

Use this function to change the tool type. Use the relevant softkey to select the appropriate tool type.

Type the number of the tool you are looking for and start the search using the OK softkey. If the tool you are looking for exists, the cursor is positioned on the corresponding line.

Use this softkey to create tool offset data for a new tool. Note: Max. 32 tools can be created.

3.1.1Creating a New Tool

Operating sequence

This function provides another two softkey functions required to select the tool type. After selection, type the desired tool number in the input box.

Fig. 3-3The New Tool windowInput of tool number For milling and drilling tools, the operator must select the machining direction.

Fig. 3-4Selection of the machining direction for a milling tool

New tool edge

Reset edge

Change type

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Find

New tool

New tool



Use OK to confirm your input. A data record loaded with zero by default will be accepted into the tool list.

3.1.2Determining Tool Offsets (manually)

Functionality This function can be used to determine the unknown geometry of a tool T.

Prerequisite

The respective tool is changed. In JOG mode, use the cutting edge of the tool to approach a point on the machine with known machine coordinate values. This can be a workpiece with a known position.

Procedure Enter the reference point in the appropriate field Ø or Z0.

Please observe: The assignment of length 1 or 2 to the axis depends on the tool type (turning tool, drill). With a turning tool, the reference point for the X axis is a diameter dimension!

Using the actual position of the point F (machine coordinate) and the reference point, the control system can calculate the compensation value assigned to length 1 or length 2 for the axis preselected.

Note: You can also use a zero offset already determined (e.g. value of G54) as the known machine coordinate. In this case, use the edge of the tool to approach the workpiece zero point. If the edge is positioned directly at workpiece zero, the reference point is zero.

XMachine Z

Workpiece

Machine

Length 2=? Actual position Z

F - tool carrier reference point

Length 1 =? Actual position X

OffsetM

M - machine zero The offset value in the X axis is a diameter value.

W - workpiece zero

Gxx Fig. 3-5Determination of length compensation values using the example of a cutting tool



XMachine

Workpiece

- 27 -

Machine Length 1=?

Actual position Z

F - tool carrier reference point M - machine zero

FW Gxx

W - workpiece zero

Fig. 3-6Determining the length compensation using the example of a drill: Length 1 / Z axis

Note

The diagram 3-6 is only applicable if the variables 42950 TOOL_LENGTH_TYPE and TOOL_LENGHT_CONST!=0; otherwise, length tool will apply for the milling and drilling tools.

Operating sequence Use this softkey to open the selection window for manual or semi-automatic measurement.

Fig. 3-7Selection of manual or semi-automatic measurement Use this softkey to open the Measure tool window.

Measure tool

Measure manual



Fig. 3-8The “Measure tool” window

In the field Z0, type the workpiece diameter or in the Z0 field, type a value you wish to have for the tool at the current position. This can be either the current machine coordinate or a value from the zero offsets. If any other values are used, the compensation value will refer to the specified position.

After the softkeys Set length 1 or Set length 2 have been pressed, the control system will determine the searched geometry length 1 or length 2 according to the preselected axis. The compensation value determined will be stored.

- 28 -

Pressing this softkey wiull save the position of the X axis. The X axis can be moved from the workpiece away.It is thus possible, e.g. to determine the workpiece diameter. The saved value of the axis position will then be used for calculating the length compensation.

The behavior of the softkey is determined by the display machine data 373 MEAS_SAVE_POS_LENGTH2 (see also Manufacturer Documentation “SINUMERIK 802D Start-Up”)

Save position



3.1.3Determining the Tool Compensations Using a Probe

Operating sequence

Select this softkey and then: the Measure Tool window appears.

Fig. 3-9The “Measure Tool” window

This intercative screen form can be used to enter tool and edge number. In addition, the tool point direction is displayed after the symbol.

After the screen form has been opened, the boxes of the interactive screen form are filled with the tool currently being in mesh.

The tool can be either the active tool of the NC (loaded via a part program) or a tool loaded via the PLC.

If the tool has been loaded by the PLC, the tool number in the interactive screen form can differ from the tool number in the window T,F,S.

If you change the tool number, no automatic tool change is carried out. The measurement results, however, are assigned to the entered tool.

Measuring process Approach the probe using either the traversing keys or the handwheel.

- 29 -

After the symbol “Probe triggered”

has appeared, release the traversing key and wait

until the end of the measuring process. During the automatic measurement, a gauge is displayed, symbolizing that the measuring process is in progress.

Measure tool

Measure auto



Note

If several axes are moved simultaneously, no calculation of the compensation data is carried out.

3.1.4Determining the tool compensations values using an optical measuring system

Fig. 3-10Measuring using an optical measuring system (input fields T and D, see measuring using a sensing probe)

Measuring process

For measuring, position the tool tip of a chisel or of a drilling tool into the crosshair. With a milling tool, use the highest point of the cutting edge to determine the tool length.

Then, press the Set length softkey to calculate the compensation values.

3.1.5Probe Settings

This screen form is used to store the probe coordinates and to set the axis feedrate for the automatic measuring process.

All position values refer to the machine coordinate system.

Settings Data probe



Fig. 3-11The “Probe Data” screen form

Table 3-1

Parameter Meaning

- 30 -

Absolute position P1Absolute position of the probe in the Z direction Absolute position P2Absolute position of the probe in the X+ direction Absolute position P3Absolute position of the probe in the Z+ direction Absolute position P4Absolute position of the prober in the X- direction FeedrateFeedrate at which the tool is moved towards the probe

Calibrating the probe

The calibration of the probe can be carried out either in the Settings menu or in the Measure tool menu. To do so, approach four points of the probe.

For calibration, use a tool of the type 500 with tool tip position 3 or 4.

The appropriate parameters to determine the four probe positions can be written to the data records of two cutting edges.

Calibrate probe



Fig. 3-12Calibrating the probe

After the screen form has opened, an animation signaling the current step to be carried out appears next to the current positions of the probe. This position must be approached with the appropriate axis.

After the symbol “Probe triggered” has appeared, release the traversing key and wait until the end of the measuring process. During the automatic measuring process, a gauge is displayed, symbolizing the progress of the measuring process.

The position provided by the measuring program serves to calculate the real probe position.

It is possible to quit the measuring function without all positions having approached. The points already captured remain stored.

Note

If several axes are moved simultaneously, no calculation of the compensation data is carried out.

To skip a point not needed for measuring, use the Next Step function.

Setting Up 3.2Tool monitoring

- 31 -


Each monitoring type is displayed in 4 columns.

Setpoint Prewarning limit Residual value active Use the checkbox in the 4th column to activate/deactivate the monitoring type.

life Work

Fig. 3-13Tool monitoring

Use this softkey to reset the monitoring values of the selected tool.

Fig. 3-14 Use this softkey to change the enable status of the selected tool.

Toollife

Reset monitor

After enable

Setting Up 3.3Entering/Modifying Zero Offset


3.3Entering/Modifying Zero Offset

Functionality

After reference-point approach, the actual-value memory and thus also the actual-value display are referred to the machine zero. A machining program, however, is always referred to the workpiece zero. This offset must be entered as the zero offset.

Operating sequence

Select “Zero Offset” via Parameters and Zero Offset.

A list of settable zero offsets will appear on the screen. The screen form also displays the values of the programmed zero offset, the active scaling factors, the status display “Mirroring active”, and the total of all active zero offsets.

- 32 -

Fig. 3-15The Zero Offset window

Position the cursor bar on the input box you wish to modify, enter value(s). The values are accepted into the zero offsets either by a cursor movement or using the Input key.

The offset values of the cutting edge come into effect immediately.

Zero Offset

Change activated

Setting Up 3.3Entering/Modifying Zero Offset


3.3.1Determining Zero Offset

Prerequisite

You have selected the window with the corresponding zero offset (e.g. G54) and the axis for which you wish to determine the offset.

XMachine

Workpiece

Machine Zero offset Z=?

Length 2

Actual position Z

F-tool carrier reference point M-machine zero

W W-workpiece zero

Fig. 3-16Determining the zero offset - Z axis

Procedure

Press the softkey Zero Offs Measur. The control system will switch to the operating area “Position” and open the dialog box for measuring the zero offsets. The axis selected will appear as a softkey with a black shadow.

Then scratch the workpiece using the tool tip. In the box Set position to:, type the position you wish to have for the workpiece edge in the workpiece coordinate system.

Fig. 3-17Screen form Determine zero offset in XScreen form Determine zero offset in Z

- 33 -

The softkey will calculate the offset and will display the result in the “Offset” box. Press Abort to quit the window.

Measure workpiece

Set zero offset

Abort

Setting Up 3.4Programming Setting Data - Operating Area “Parameters”


3.4Programming Setting Data - Operating Area “Parameters”

Functionality

The setting data are used to make the settings for the operating states. These can be modified if necessary.

Operating sequence

Use the Offset Parameters and Setting Data softkeys to open the Setting Data window.

The Setting Data softkey will branch into another menu level where various control options can be set.

Fig. 3-18Main screen Setting data

Jog feed

Feed value in Jog mode If the feed value is zero, the control system will use the value stored in the machine data.

Spindle

Spindle speed Min. / max.

A limitation of the spindle speed in the max. (G26)/min. (G25) fields can therefore only be carried out within the limit values specified in the machine data.

Programmed (LIMS)

Programmable upper speed limiting (LIMS) at constant cutting speed (G96). Dry run feed (DRY)

The feed that can be entered here will be used instead of the programmed feed in automatic mode if the function “Dry run feed” is selected.

Start angle for thread cutting (SF)

For thread cutting, a start position for the spindle is displayed as the start angle. If the thread cutting operation is repeated, a multiple thread can be cut by modifying the angle.

Setting data

- 34 -



Position the cursor bar on the input box you wish to modify, enter value(s). Use the Input key or carry out a cursor movement to confirm your input.

Softkeys

The work area limiting is active for the geometry and for additional axes. Enter the values for the work area limiting. The softkey Set Active enables/disables the values for the axis selected using the cursor.

User data

Fig. 3-19

Fig. 3-20

Work area limit.

Time counter



Meaning:

Parts required: Number of workpieces required ( required workpieces ) Parts total: Number of workpieces manufactured in total ( actual total )

Part count: This counter logs the number of all workpieces produced beginning from the starting time.

Run time: Total runtime of NC programs in the AUTOMATIC mode ( in seconds )

The AUTOMATIC mode counts the runtimes of all programs executed between NC START and end of program / RESET. The timer is reset to zero with every power-up of the control system; runtime of the selected NC program ( in seconds )

Cycle time: Tool action time ( in seconds )

In the NC program selected, the runtime between NC START and end of program / RESET is measured. Starting a new NC program will clear the timer.

Cutting time

The runtime of the path axes is measured in all NC programs between NC START and end of program, without rapid traverse active and the tool active. With the dwell time active, the measurement is additionally interrupted.

- 35 -

If the control system is booted with the default values, the timer is reset to zero automatically.

Use this softkey to display a complete list of all setting data of the control system. The data are divided into general, axis-specific and channel setting data.

Channel specific spec.

Fig. 3-21

Misc

Setting Up 3.5R Parameters - Operating Area “Offset/Parameters”


Functionality

The main screen R Parameters displays a complete list of all R parameters of the control system (see also Section 8.9 “Arithmetic Parameters R”). These can be modified if necessary.

Find

User data

Fig. 3-22The R Parameters window

Operating sequence Select the softkeys Parameters and R Parameters, position the cursor bar on the input box you wish to modify, and enter value(s). Use the Input key or carry out a cursor movement to confirm your input. Use this softkey to search for R parameters.

R Para. meter

Find

Setting Up 3.5R Parameters - Operating Area “Offset/Parameters”


For your notes


Manually Controlled Operation

Preliminary remark Manually controlled operation is possible in Jog and MDA modes.

SettingsSetbase Measureworkpiece Measure tool

Back <<

Switch m>inch.

Back <<

Set rel x=0 z=0 x=z=0

Delete base W0

Measuremanual Data probe

- 36 -

Measure auto

Calibrate probe

Back <<

Set work offset

Work offset

Back << Fig. 4-1Jog menu tree

Face Settings

Abort OK

Set basis

Back << Set rel x=0 z=0 x=z=0

Delete base W0

Back <<

Switch m>inch.

Dataprobe

Peripher. surface

Fig. 4-2MDA menu tree

Manually Controlled Operation 4.1Jog Mode - Operating Area “Position”


Operating sequence Use the Jog key on the machine control panel to select Jog mode.

To traverse the axes, press the appropriate key of the X or Z axis.

As long as this key is hold down, the axes will traverse continuously at the rate defined in the setting data. If the value in the setting data is zero, the value stored in the machine data will be used.

Set the speed using the override switch.

If you also press the Rapid Traverse Override key, the selected axis will be traversed at rapid traverse velocity as long as the keys are hold down.

In Incremental Dimension mode, you can use the same operating sequence to traverse settable increments. The set increment is displayed in the display area. To cancel, simply press Jog once more.

- 37 -

The Jog main screen displays position, feed and spindle values, as well as the current tool.

Fig. 4-3The Jog main screen



Parameters Table 4-1 Description of the parameters displayed in the Jog main screen

Parameters Explanation

Display of addresses of existing axes in the machine coordinate system (MCS).

+X- ZIf you traverse an axis in the positive (+) or negative (-) direction, a plus or minus sign is displayed in the corresponding field.

If the axis is already in the desired position, no sign will be displayed.

Position m These fields display the current position of the axes in the MCS or WCS.

Repos offsetIf the axes are traversed in the state ”Program interrupted” in Jog mode, this column displays the distance traversed by each axis with reference to the break point.

G functionDisplay of important G functions

Spindle Srpm Display of actual and set values of spindle speed

Feed Fmm/min Display of feedrate actual and set values

ToolDisplay of the currently engaged tool and of the current edge number

Note

If a second spindle is integrated into the system, the workspindle is displayed using a lower font size. The window will always display only the data of one spindle.

The control system displays the spindle data, taking into account the following aspects:

The master spindle is displayed: -in the idle condition,

-at spindle start,

-if both spindles are active. The workspindle is displayed: -at spindle start of the workspindle.

In all cases, the power bar applies to the spindle currently active.

Softkeys

This softkey is used to set the basic zero offset or a temporary reference point in the relative coordinate system. After opening, this function can be used to set the basic zero offset.Set base


- 38 -


The following subfunctions are offered:

Direct input of the axis position desired In the position window, position the input cursor on the desired axis and enter the new position. Complete your input either by pressing the Input key or by a cursor movement.

Setting all axes to zero The softkey function X=Y=Z=0 will overwrite the current position of the corresponding axis with zero.

Setting individual axes to zero If you select either of the softkeys X=0, Y=0 or Z=0, the current position will be overwritten with zero.

Pressing the Set Rel softkey switches the display to the relative coordinate system. The following inputs will modify the reference point in this coordinate system.

Note A modified basic zero offset will act regardless of any other zero offsets.

Determining the zero offset (see Chapter 3)

Use this softkey to determine the tool compensation values (see Chapter 3)

In MDA mode, this screen form is used to set the retraction level, the safety distance and the direction of rotation for part programs generated automatically.

In addition, this screen form can be used to set the values for JOG feed and for the variable incremental dimension.

Fig. 4-4

Retraction plane: The “Face” function will retract the tool to the specified position (Z position) after execution.

Safety distance: Clearance to the workpiece surface. defines the minimum distance between workpiece surface and workpiece. It is used by the functions “Face” and “Automatic tool gauging”.

Overview

Acceleration with jerk limitation

To achieve optimum acceleration with reduced wear on the machine's mechanical parts, you can select SOFT in the part program to ensure continuous, jerk-free acceleration.

When you select "acceleration with jerk limitation", the velocity characteristic over the

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path is generated as a sinusoidal curve.

Access protection

Protectionlevel

Type Users Access to (examples)

0 Password Siemens All functions, programs, data

1 Password Machine manufacturers:Development

Defined functions, programs and data (options)

2 Password Machine manufacturers:Start-up engineers

Defined functions, programs and data (machine data)

3 Password End user: Servicing Assigned functions, programs and data

4 Key redSwitch position 3

End user:Programmers, machine-setters

< Protection level 0 to 3Machine manufacturer/end user

5 Key greenSwitch position 2

End user:Qualified users who do not program

< Protection level 0 to 3End user

6 Key blackSwitch position 1

End user:Trained users who do not program

Program selection only, tool wear entries, and work offset entries

7 Switch position 0

End user:Semi-skilled users

No input and program selection possible, only the machine control panel can be operated

Access to programs, data and functions is protected in a user-oriented hierarchical system of eight access levels.

These are subdivided into four password levels (protection level 0 to 3) for Siemens, machine manufacturers and end users.

SINUMERIK controls thus provide a multistage concept for controlling access privileges. Protection level 0 has the highest, protection level 7 the lowest access privileges. A higher protection level automatically includes all protection levels below it.

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Access privileges for protection levels 1 to 3 are preprogrammed by Siemens as default.

Access privileges for protection levels 4 to 7 can be assigned by the machine manufacturer or end user.

Actual-value system for workpiece

The term "actual-value system for workpiece" is used to designate functions which allow the SINUMERIK user to:

begin machining in a workpiece coordinate system defined via machine data in JOG and AUTOMATIC mode without any additional manipulations after powering up the control

retain the valid settings relating to active level, settable frames (G54-G59), kinematic transformations, and active tool compensation at the end of the part program for use in the next part program

to change back and forth between the workpiece coordinate system and the machine coordinate system

to change the workpiece coordinate system per operator input (e.g. change the adjustable frames or the tool offset)

Alarms and messages

All "alarms and messages" are output on the operator panel in plain text with a graphic symbol indicating the clear criterion. The alarm texts are stored on the control.

"Alarms and messages" from the machine can be displayed in plain text from the PLC program. A distinction is made between status messages and fault messages. While status messages are immediately cleared, fault messages must always be acknowledged.

The control's response to alarms or messages is configurable, and the required texts are stored on the control.

"Alarms and messages" in the part program: Messages can be programmed to give the user information on the current processing status while the program is executing.

Analog spindles

Unipolar or bipolar 10 V interfaces can be used. In the case of SINUMERIK 802D sl, the MCPA module is additionally required.

Auxiliary function output

Auxiliary function output informs the PLC when the part program wants the PLC to handle certain machine switching operations. This is accomplished by transfering the appropriate auxiliary functions and their parameters to the PLC interface. The transferred values and signals must be processed by the PLC user program. The following functions can be forwarded to the PLC:

Tool selection T

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Tool offset Feed F/FA Spindle speed S H functions M functions

Auxiliary function output may be carried out either with velocity reduction and PLC acknowledgement up to the next block, or before and during travel without velocity reduction and without block change delay. Following blocks are then retracted without a time-out.

Axes/spindles

→ Spindle functions

AxesThree or four of the four simultaneously operating axes are interpolating axes.

SpindlesSpindle drives can be speed-controlled or position-controlled.

Backlash compensation

With positive backlash (normal case), the encoder actual value is ahead of the true actual value (table): The table does not travel far enough.

During power transmission between a moving machine part and its drive (e.g. ball screw), there is normally a small amount of backlash because setting mechanical parts so that they are completely free of backlash would result in too much wear and tear on the machine. In the case of axes/spindles with indirect measuring systems, mechanical backlash results in corruption of the traverse path. For example, when the direction of movement is reversed, an axis will travel too much or too little by the amount of the backlash.

To compensate for backlash, the axis-specific actual value is corrected by the amount of the backlash every time the axis/ spindle reverses its direction of movement.

Following reference-point approach, backlash compensation is always active in all modes.

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Block search

The block search function allows any point in the part program to be selected, at which machining must start or be continued. The function is provided for the purpose of testing part programs or continuing machining after a program abort.

Three types of search are available:

Block search with calculation at the contour line:during the block search, the same calculations are executed as during normal program operation. The target block is then traversed true-to-contour until the end position is reached. Using this function it is possible to approach the contour again from any situation.

Block search with calculation at the block end point:this function allows you to approach a target position (such as tool change position). Once again, all calculations are executed as during normal program operation. The approach targets the end position of the target block or the next programmed position using the method of interpolation valid in the destination block.

Block search without calculation:this method is used for high-speed searches in the main program. No calculation are carried out during the search. The internal control values remain the same as before the block search.

In order to execute an CNC program without faults, the target block must be included as relevant block information.

You can specify the target of the search by

Directly positioning the cursor on the destination block, or By specifying a block number, a jump label, any string, a program name or a

line number.

CNC program messages

→ Alarms and messages

CNC user memory

All programs and data, such as part programs, subroutines, comments, tool offsets, zero offsets and program user data can be stored in the shared, battery-backed CNC user memory.

Circle via center point and end point

Circular interpolation causes the tool to move along a circular path in a clockwise or counter-clockwise direction. The required circle is described by:

Starting point of circular path (actual position in the block before the circle) Direction of rotation of circle Circle end position (target defined in circular block)

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Circle center point

The circle center can be programmed as an absolute value with reference to the current zero point or as an incremental value with reference to the starting point of the circular path. If the opening angle is apparent from the drawing, then it can be directly programmed. In many cases, the dimensioning of a drawing is chosen so that it is more convenient to program the radius to define the circular path. In the case of a circular arc of more than 180 degrees, the radius specification is given a negative sign.

Circle via intermediate point and end point

If a circle is to be programmed which does not lie in a paraxial plane but obliquely in space, an intermediate point can be used to program it instead of the circle center point. Three points are required to program the circle: the starting point, the intermediate point, and the end point.

Clamping monitoring

→ Position monitoring, standstill monitoring

"Clamping monitoring" is one of the many extensive monitoring mechanisms for axes. When an axis is to be clamped following conclusion of the positioning action, you can activate clamping monitoring with the PLC interface signal "clamping in progress". This may become necessary because it is possible for the axis to be pushed beyond the standstill tolerance from the position setpoint during the clamping procedure. The amount of deviation from the position setpoint is set via the machine data. During the clamping procedure, the clamping monitor replaces the standstill monitor, and is effective for linear axes, rotary axes, and position-controlled spindles. The clamping monitor is not active in follow-up mode. When the monitor responds, its reactions are the same as those of the standstill monitor.

Contour definition programming

"Contour definition programming" enables fast input of simple contours.

With the aid of help displays in the editor, your can program 1-point, 2-point or 3-point definitions with the transition elements chamfer or rounding easily and clearly by entering Cartesian coordinates and/or angles.

Contour monitoring

The following error is monitored within a definable tolerance band as a measure of contour accuracy. An impermissibly high following error might be caused by a drive overload, for example. If an error occurs, the axes/spindles are stopped. "Contour monitoring" is always enabled when a channel is active and in position-controlled mode. In the case of an interrupted channel/channel with reset status, the contour will not be monitored.

Cycle support

→ Technological cycles

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Data backup

The following data backup methods are available for your system software and user data:

Integrated FEPROM Serial interface (RS 232 C) (point-to-point interface) CF card

Diagnostic functions

For service purposes, a self-diagnostics program and testing aids have been integrated in the controls. The status is displayed on the operator panel for:

Interface signals between the CNC and the PLC and between the PLC and the machine

Variables PLC bit memories, timers and counters PLC inputs/outputs

For test purposes, the user can set combinations of output signals, input signals, and memory bits. Alarms and messages also provide valuable diagnostic information. In the "service display" menu, it is possible to call up important information about the axis and spindle drives, such as:

Absolute actual position Position setpoint Following error Speed setpoint/ Speed actual value

Dimensions in metric and inches

Depending on the measuring system used in the production drawing, you can program workpiece-related geometrical data in either metric measure (G71) or inches (G70). The control can be set to a basic system regardless of the programmed dimensional notation. You can enter the following geometrical data directly and let the control convert them into the other measuring system (examples):

Position data X, Y, Z, etc. Interpolation parameters I, J, K and circle radius CR Pitch Programmable zero offset (TRANS) Polar radius RP

With the G700/G710 programming expansion, all feedrates are also interpreted in the programmed measuring system (inch/min or mm/min). In the "Machine" operating area, you can switch back and forth between inch and metric dimensional notation using a softkey.

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Display functions

All current information can be displayed on the operator panel's screen, such as:

Block currently being executed Previous and following block Actual position, distance-to-go Current feedrate Spindle speed G Functions Auxiliary functions Workpiece designation Main program/subroutine name All data entered, such as part programs, user data and machine data Help texts

Important operating states are displayed in plain text, for example

Alarms and messages Position not reached Feed stop Program in process Data input/output in progress

Drives

The SINUMERIK 802D sl offers a DRIVE-CLiQ interface for the SINAMICS drive system.

Electronic handwheels

Using electronic handwheels, it is possible to move selected axes simultaneously in manual mode. The handwheel clicks are analyzed by the increment analyzer. If coordinate offset or coordinate rotation is selected, it is also possible to move the axes manually in the transformed workpiece coordinate system. The maximum input frequency of the handwheel inputs is 500 kHz.

Ethernet interface

→ RCS 802 remote diagnostics (option)

Files, programs and data of all types can be transferred via the Ethernet interface. The interface is parameterized on the control. Both the control itself and the customer CF codes can be accessed. If the control is to be integrated into a network, the RCS 802 remote diagnostics tool (option) is additionally required.

Execution of large CNC programs

Part programs that are too large for CNC memory can be read in via the Ethernet interface and executed while the read-in is in progress (Version Pro). The CNC executes the program from circulating buffer. Part programs are automatically reloaded into circulating buffer as soon as free memory space becomes available.

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It is much more convenient to execute programs from a plug-in customer CF card. The CF card can be linked directly to the control via insertion in a PC or via an RS 232 C or Ethernet port. This ensures that there is enough memory for the program to be executed directly.

Feedforward control

Feedforward control allows you to reduce axial following errors almost to zero. For this reason, feedforward control is often referred to as "following error compensation".

Particularly during acceleration in contour curvatures, e.g. circles and corners, this following error leads to undesirable, velocity-dependent contour violations.

For compensation of contour violations, the SINUMERIK 802D sl features velocity-dependent feedforward speed control.

Feedrate override

The programmed velocity is overridden by the current velocity setting via the machine control panel or by the PLC.

0 to 200 % with SINUMERIK 802D sl

Follow-up mode

If an axis/spindle is in follow-up mode, it can be moved externally, and the actual value can still be recorded. The traverse paths are updated in the display. Standstill, clamping and positioning monitoring functions are not effective in follow-up mode. A new reference-point procedure for the axes is not required when follow-up mode is cancelled.

Frame concept

With the Frame concept, it is possible to transform rectangular coordinate systems very simply by translating, rotating, scaling and mirroring. The following instructions are used to program these options:

TRANS programmable zero offset ROT rotation in space or in a plane SCALE scaling (scale factor) MIRROR mirroring

The instructions can also be used several times within one and the same program. Existing offsets can either be overwritten or new ones can be added. Additive frame instructions:

ATRANS AROT ASCALE AMIRROR

If swiveling tools or workpieces are available, machining can be extremely flexible.

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Helical interpolation

Helical interpolation: Thread milling with form cutter

The helical interpolation function is ideal for machining internal and external threads using form milling cutters and for milling lubrication grooves. The helix comprises two movements:

Circular movement in one plane A linear movement perpendicular to this plane

The programmed feedrate F either refers only to the circular motion or to the total path velocity of the three CNC axes involved.

In addition to the two CNC axes performing circular interpolation, other linear motions can be performed synchronously. The programmed feedrate F refers to the axes specially selected in the program.

High-level CNC language

To meet the various technological demands of modern machine tools, a CNC high-level language has been implemented that provides a high degree of programming freedom.

Indirect programming

One option for universal use of a program is indirect programming. Here, the addresses of axes, spindles, R parameters, etc., are not directly programmed, but are addressed via a variable in which their required address is then entered.

Program jumps

The inclusion of program jumps allows extremely flexible control of the machining process. Conditional and unconditional jumps are available as well as program branches that depend on a current value. Labels that are written at the beginning of the block are used as jump destinations. The jump destination can be before or after the exit jump block.

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Arithmetic and trigonometric functions

Extensive arithmetic functions can be implemented with user variables and arithmetic variables. In addition to the four basic arithmetic operations, there are also:

Sine, cosine, tangent Arc sine, arc cosine, arc tangent Square root Absolute value 2nd power (square) Integer component Round to integer Natural logarithm Exponential function Offset Rotation Scale modification Mirroring

Comparison operations and logic combinations

Comparison operations with variables can be used to formulate jump conditions. The comparison functions that can be used are:

Equal to, not equal to Greater than, less than Greater than or equal to Less than or equal to Concatenation of strings

The following logic combinations are also available: AND, OR, NOT, EXOR. These logic operations can also be performed bit by bit.

I/O interfacing via PROFIBUS DP

PROFIBUS DP represents the protocol profile for distributed I/O. It enables high-speed cyclic communication with aggregates of 12 Mbit/s and offers the following advantages: high availability, data integrity and standard message structure.

Intermediate blocks for tool radius compensation

Traversing movements with tool offset selected can be interrupted by a limited number of intermediate blocks (block without axis movements in the compensation plane).

Languages/language expansions

The user interface for the SINUMERIK controls is available in almost any required language. The user interface can be switched between two languages when online.

Leadscrew error/measuring system error compensation

The principle of "indirect measuring" on CNC-controlled machines is based on the

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assumption that the leadscrew pitch is constant at every point within the traversing range, so that the actual position of the axis can be derived from the position of the drive spindle (ideal situation). Tolerances in ball screw production, however, result in large dimensional deviations to a lesser or greater extent (referred to as leadscrew error). Added to this are the dimensional deviations caused by the measuring system as well as its installation tolerances on the machine (so-called measuring system errors), plus any machine-dependent error sources.

Because these dimensional deviations directly affect the accuracy of workpiece machining, they must be compensated for by the relevant position-dependent compensation values.

The compensation values are derived from measured error curves and entered in the control in the form of compensation tables during commissioning.

Limit switch monitoring

Overview of travel limits

Preceding the EMERGENCY STOP switch, hardware limit switches, which take the form of digital inputs controlled via the PLC interface, limit the traversing range of the machine axes. Deceleration is effected either as quick stop with setpoint zero or in accordance with a braking characteristic. The axes must be retracted in the opposite direction in JOG mode.

Software limit switches precede the hardware limit switches, are not overtraveled, and are not active until reference-point approach has been completed.

A second pair of plus/minus software limit switches can be activated via the PLC.

Linear interpolation

Up to 4 axes can interpolate linearly.

Look Ahead

During the machining of complex contours, most of the program blocks describe very short paths and often feature sharp changes in direction. If a contour of this type is processed with a fixed programmed path velocity, an optimum result cannot be obtained.

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In short traversing blocks with tangential block transitions, the drives cannot attain the required final velocity because of the short path distances. Corners are cut off.

"Look Ahead" enables the optimum machining velocity to be achieved. On tangential block transitions, the axis is accelerated and decelerated beyond block boundaries, so that no drops in velocity occur. On sharp changes of direction, smoothing of the contour is reduced to a programmable path dimension.

Measuring system error compensation

→ Leadscrew error/measuring system error compensation

Monitoring functions

The controls contain watchdog monitors which are always active. These monitors detect problems in the CNC, PLC or machine in time to prevent damage to workpiece, tool or machine. When a problem occurs, machining is interrupted and the drives brought to a standstill. The cause of the fault is saved, and displayed as an alarm. At the same time, the PLC is notified that a CNC alarm has been triggered. Monitoring functions exist for the following areas:

Read in Format Encoder and drive Contour Position Standstill Clamping Speed setpoint Actual velocity Enabling signals Voltage Temperatures Microprocessors Serial interfaces Transfer between CNC and PLC System memory and user memory

Monitoring of tool life and workpiece count

This function permits monitoring of tool life and/or workpiece count. If the monitoring time of a cutting edge expires during machining, an alarm is output, and a VDI signal is issued. The service life of the active cutting edge of the loaded tool is monitored. Monitoring of the workpiece count covers all tool cutting edges which are used to manufacture a workpiece.

Online ISO dialect interpreter

With the online ISO dialect interpreter, part programs in other ISO dialects such as G codes from other manufacturers can be read into, edited and processed in the SINUMERIK 802D sl. Part programs can also be written in the normal manner. G290/G291 can be used to also swap between the two programming languages within

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a part program.

Operating modes

In the "Machine" operating area, you have a choice of three modes:

JOGJOG mode is intended for the manual movement of axes and spindles as well as for setting up the machine. The setting-up functions are reference-point approach, repositioning, handwheel control or incremental mode, and redefinition of control zero (preset/set actual value)

MDAIn MDA mode, you can enter individual program blocks or sequences of blocks, then execute them immediately via CNC Start. The tested blocks can then be saved in part programs.

AUTOIn AUTO mode, your part programs are executed automatically once they have been selected from the workpiece, part program or subprogram directories (normal operation). During AUTO mode it is possible to generate and correct another part program. The Teach-in submode allows you to transfer movements to the AUTO program by returning and storing positions.

In MDA and AUTO mode, you can modify the sequence of a program using the following "program control" functions:

SKP Skip block DRY Dry run feedrate ROV Rapid traverse override SBL1 Single block with stop after machine function blocks SBL2 Single block with stop after every block SBL3 Stop in cycle M01 Programmed stop PRT Program test

PLC status

In its "diagnostics" area, the user interface allows you to check and/or change PLC status signals.

This allows you to do the following on site without a programming device:

Check the input and output signals from the PLC's I/O Troubleshoot Check the interface signals for diagnostic purposes

The status of the following data items can be displayed on the operator panel:

Interface signals from/to the machine control panel NCK/PLC and MMC/PLC interface signals Data blocks, memory bits, timers, counters, inputs and outputs

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The status of the above signals can be changed for testing purposes. Signal combinations are also possible, and as many as ten operands can be modified simultaneously.

PLC user memory

The PLC user program, the user data and the basic PLC program are stored together in the PLC user memory.

Part program management

Part programs can be organized according to workpieces. This permits clear allocation of programs and data to the respective workpieces.

Polar coordinates

When programming in polar coordinates, it is possible to define positions with reference to a defined center point by specifying the radius and angle. The center point can be defined by an absolute dimension or incremental dimension.

Position monitoring

To protect the machine, SINUMERIK controls provide extensive monitoring mechanisms for axis monitoring:

Motion monitoring:Contour monitoring, position monitoring, standstill monitoring, clamping monitoring, speed setpoint monitoring, actual speed monitoring, encoder monitoring

Static limits monitoring:Limit switch monitoring, working area limitation

Position monitoring is always activated after termination of motion blocks "according to the setpoint". To ensure that an axis is in position within a specified period of time, the timer programmed in the machine data is started when a traversing block terminates; when the timer expires, a check is made to ascertain whether the following error fell below the limit value (machine data). When the specified "fine exact stop limit" has been reached or following output of a new position setpoint other than zero (e.g. after positioning to "coarse exact stop" and subsequent block change), the positioning monitor is deactivated and replaced by the standstill monitor.

The positioning monitor is effective for linear and rotary axes as well as for position-controlled spindles.

Programmable acceleration

With the "programmable acceleration" function it is possible, for example, to modify the axis acceleration in the program in order to limit mechanical vibration in critical program sections.

The path or positioning axis is then accelerated at the programmed value. The maximum acceleration value stored in the control is not exceeded. This limitation is

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active in AUTOMATIC mode and in all interpolation modes. As part of intelligent motion control, this function provides a more precise workpiece surface.

Programming language

The CNC programming language is based on DIN 66025.

RCS 802 remote diagnostics (option)

This function enables you to observe the control online. The RCS 802 remote diagnostics function makes the entire control accessible from the PC for the purpose of:

Monitoring Operator control Creating snap shots Commissioning Loading/saving data NC/PLC Loading/saving user programs

This function enables the control to also be integrated into a network.

Reference point approach

When using a machine axis in program-controlled mode, it is important to ensure that the actual values supplied by the measuring system agree with the machine coordinate values.

Reference point approach (limit switch) is performed separately for each axis at a defined velocity either using the direction keys, in a sequence that can be defined in the machine data, or automatically via program command G74.

Reference point approach for an axis with absolute value encoders is carried out automatically when the control is switched on (without axis motion) if the corresponding axis is recognized as being calibrated.

Repos

Following a program interruption in AUTOMATIC mode (e.g. to take a measurement on the workpiece and correct the tool wear values or because of tool breakage), manual repositioning of the tool is possible after changing to JOG mode. In this case, the control stores the interruption point coordinates and displays the differential travel of the axes in JOG mode in the actual-value window as Repos (repositioning) offset.

Repositioning can also be performed in JOG mode using the axis- and direction keys. It is not possible to overshoot the interruption point; the feedrate override switch is effective.

Rotary axis, turning endlessly

Depending on the application, the traversing range of a rotary axis can be limited by a software switch (e.g. operating range between 0° and 60°) or to a corresponding

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number of rotations (e.g. 1000°), or unlimited (endlessly turning in both directions).

Serial interface (RS 232 C)

A serial interface (RS 232 C) is provided for data input/output. This interface can be used to load and archive programs and data. The interface can be parameterized and operated with menu assistance via the operator panel.

Series machine startup

In order to transfer a specific configuration as easily as possible to other controls on the same type of machine, you can create so-called series machine startup files.

Series machine startup is then extremely easy and user-friendly, and can even be accomplished without a programming device by using an IBM-compatible PC.

Store a startup file on CF card in the control, plug the CF card into the next control, and start the series machine startup there.

Skip blocks

CNC blocks that are not to be executed in every program run, e.g. execute a trial program run, can be skipped. Skip blocks are identified by placing a "/" character in front of the block number. The statements in the skip blocks are not executed, and the program resumes with the next block that is not identified as a skip block.

Spindle functions

Spindle speed

analog (±10 V) digital

Spindle speed override 0 to 200 %; gear stages with default setting via:

part program (commands M41 to M45) or automatically via programmed spindle speed (M40) or Oriented spindle stop (positioning mode) with SPOS 1)

Spindle monitoring with the functions 1)

Axis/spindle stationary (n < nmin)

Spindle in setpoint range Max. spindle speed Programmable lower (G25) and upper (G26) spindle speed limitation Min./max. speed of the gear stage Max. encoder limit frequency Target point monitoring for SPOS

Constant cutting speed with G96 (in m/min or inch/min) at the tool tip for uniform turning finish and thus better surface quality.

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Thread cutting with constant lead: 1)

The following types of thread can be produced with G33: Cylindrical, conical or face threads, single or multiple, right-hand or left-hand threads. In addition, multiple-block threads can be produced by concatenating threading blocks.

Tapping with compensating chuck/rigid tapping:

When tapping with compensating chuck (G63), the compensating chuck takes up differences between spindle movement and drilling axis. Prerequisite for rigid tapping (G331/G332) is a position-controlled spindle with position decoding system.

The traversing range of the drilling axis is therefore not restricted. By using the method whereby the spindle, as a rotary axis, and the drilling axis interpolate, threads can be cut to a precise final drilling depth (e.g. for blind hole thread).

1) Prerequisite: Position actual value encoder (measuring system) with appropriate parameter substitution (directly mounted spindle).

Spindle speed limitation


Standstill monitoring

The standstill monitor checks whether the axis moves further out of its position than the value specified as standstill tolerance in the machine data. The standstill monitoring function is always active following expiration of the "standstill monitoring delay time" or upon reaching the "fine exact stop" limit as long as no new traversing command is pending. When the monitor responds, an alarm is generated and the relevant axis/spindle brought to standstill with rapid stop via a speed setpoint ramp. The standstill monitor is effective for linear and rotary axes as well as for position-controlled spindles. The standstill monitor is inactive in follow-up mode.

Subroutines

If machining operations recur frequently, it is advisable to store them in a subroutine. The subroutine is called from a main program (number of passes ≤9999).

The SIMUMERIK 802D sl supports seven subroutine levels within a main program. Subroutines can be completely protected against unauthorized readouts and displays (cycles). A main program can also be called from within another main program or subroutine.

Tapping with compensating chuck/rigid tapping


Teach In

"Teach-in" is the transfer of current positions to the CNC program.

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When teach-in is used in AUTOMATIC mode, it is possible not only to transfer the program but also to test and correct it immediately. The program is stopped and the axes are moved into the desired position with the JOG keys using the MCP or handwheel. This position is transferred to the program as a traversing block and can then be started again at any point. A reset is not required. Positions already taught in the program can be corrected and new positions can be inserted.

Technology cycles

Technology cycles (standard cycles) for drilling/milling and turning are available for frequently repeated machining tasks. You can store these technology cycles together with your user cycles in the control as protected subroutine. The parameters are initialized via graphically supported input screen forms in plain text.

Thread cutting


Tool change via T number

In chain, rotary-plate and box magazines, a tool change normally takes place in two stages. A T command locates the tool in the magazine, and an M command inserts it in the spindle. In circular magazines on turning machines, the T command carries out the entire tool change, that is, locates and inserts the tool. You can preselect the type of tool change in the machine data.

Tool offsets

Tool offsets

When generating programs, you do not need to take tool dimensions such as cutter diameter, cutting edge position or tool length into account. You program the workpiece dimensions directly, for example following the production drawing. When a workpiece goes into production, the tool paths are controlled in dependence on the relevant tool geometry in such a way that the programmed contour can be produced with any tool used.

You enter the tool data separately in the control's tool table, and in the program you

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call only the required tool with its offset data. During program execution, the control fetches the required offset data from the tool files and corrects the tool path for various tools automatically.

By programming a T function (5-figure integer number) in the block, you can select the tool. Each T number can be assigned a corresponding tool offset (D addresses). The number of tools to be managed in the control is set at the configuration stage. A tool offset block comprises 25 parameters, e.g.:

Tool type Up to three tool length offsets Radius compensation Wear dimension for length and radius Tool base dimension

The wear and the tool base dimension are added to the corresponding offset.

Tool radius compensation

Bypassing the outside corners with transition circle/transition ellipse

When tool radius compensation is enabled, the control automatically computes the equidistant tool paths for different tools. To do so, it requires the tool number T, the tool offset number D (with cutter number), the machining direction G41/G42, and the relevant working plane G17 to G19.

The path is offset in two axes in dependence on the selected tool radius.

The control can also automatically insert a circle or a straight line in the block with the tool radius compensation when no intersection with the preceding block is possible.

The process of tool radius compensation may be interrupted only by a certain number of successive blocks or M commands containing no traversing commands or path

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specifications in the compensating plane.

Tool types

Example: Geometry of turning tool

The tool type determines which geometric data are needed for the tool offset memory and how they are to be used. The control combines these geometric data into a result value (e.g. total length, total radius).

The calculated overall value comes into effect when the offset memory is activated. The use of these values in the axes is determined by the tool type and current machining level G17, G18 or G19.

The following tool types can be parameterized:

Group 1xy: milling cutters (from spherical head cutter to bevel cutter) Group 2xy: drills (from twist drill to reamer) Group 5xy: turning tools (from roughing tool to threading tool)

The storing of all tool data is supported by input screen forms.

Travel to fixed stop

With this function, tailstocks or sleeves can be traversed to a fixed stop to clamp workpieces. The pressure applied can be defined in the part program. "Travel to fixed stop" is possible simultaneously for several axes, and parallel to the movement of other axes.

Traversing range

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The range of values for the traversing ranges depends on the selected computational resolution. The default value for "computational resolution for linear or angle positions" in the machine data (1000 increments per mm or per degree) can be used to program the value ranges (see Table). The traversing range can be restricted by software limit switches and operating ranges.

G70 [inches, degrees] G71 [mm, degrees]

Linear axes X, Y, Z, ... ± 399.999,999 ± 999.999,999

Rotary axes A, B, C, ... ± 999.999,999 ± 999.999,999

Interpolation parameters I, J, K

± 399.999,999 ± 999.999,999

User interface

The user interface is divided into six operating areas:

Machine Offset/parameters Program manager Program editor System Alarm Custom

This makes it possible, for example, to write a new part program while parts production is in progress.

On changing the operating area, the last active menu is always stored. "Hot keys" are provided for switching from one operating area to another. 8 horizontal and 8 vertical softkeys as well as Windows-type technology ensure easy, user-friendly machine operation.

User machine data

The NCK makes machine data available for configuring the CNC. These data make it possible to activate specific machine configurations, machine expansions, and user "options".

Velocity

The maximum path velocity, axis velocity and spindle speed are affected by the dynamic response of machine and drive and by the limit frequency of actual-value acquisition.

The minimum velocity must not fall below 10-3 units/IPO cycle.

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The maximum velocity of the axis is generally limited by the mechanics or by the limit frequency of the encoder.

Working area limitation

→ Zero offsets

In addition to the limit switches, "working area limitations" limit the traversing range of the axes. Protection zones are thus set up within the working area of the machine. These prevent tool movements and protect surrounding equipment such as tool turrets and measuring stations from damage.

The limitations refer to the basic coordinate system. Monitoring consists of ascertaining whether the tool tip penetrates the protected working area while taking into account the tool radius.

Zero offsets

You can define "zero offsets" which can then be called in the part programs.

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840d and ncfunctions

Documents