sinumerik 840d sl - siemens...memory configuration (s7) 15 indexing axes (t1) 16 tool change (w3) 17...

SINUMERIK 840D sl Extended Functions

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Preface

Digital and analog NCK I/Os (A4)

1Several Operator Panels on Several NCUs, Distributed Systems (B3)

2

Operation via PG/PC (B4) 3

Manual and Handwheel Travel (H1)

4

Compensations (K3) 5

Mode Groups, Channels, Axis Replacement (K5)

6Kinematic Transformation (M1)

7

Measurement (M5) 8

Software cams, position switching signals (N3)

9

Punching and Nibbling (N4) 10

Positioning Axes (P2) 11

Oscillation (P5) 12

Rotary Axes (R2) 13

Synchronous Spindles (S3) 14

Memory Configuration (S7) 15

Indexing Axes (T1) 16

Tool Change (W3) 17

Grinding-specific tool offset and tool monitoring (W4)

18NC/PLC interface signals (Z2)

19

Appendix A

SINUMERIK 840D sl

Extended Functions

Function Manual

01/2008 6FC5397-1BP10-3BA0

Valid for Controller SINUMERIK 840D sl / 840DE sl Software VersionNCU system software for 840D sl/840DE sl 1.5/2.5

Safety Guidelines Safety Guidelines This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGER indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.

CAUTION without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

NOTICE indicates that an unintended result or situation can occur if the corresponding information is not taken into account.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel The device/system may only be set up and used in conjunction with this documentation. Commissioning and operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage Note the following:

WARNING This device may only be used for the applications described in the catalog or the technical description and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly as well as careful operation and maintenance.

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

Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG Automation and Drives Postfach 48 48 90327 NÜRNBERG GERMANY

Order number: 6FC5397-1BP10-3BA0 Ⓟ 02/2008

Copyright © Siemens AG 2008. Technical data subject to change

Extended Functions Function Manual, 01/2008, 6FC5397-1BP10-3BA0 3

Preface

SINUMERIK® Documentation The SINUMERIK documentation is organized in three parts: ● General documentation ● User documentation ● Manufacturer/service documentation A monthly updated publications overview with respective available languages can be found in the Internet under: http://www.siemens.com/motioncontrol Select the menu items "Support" → "Technical Documentation" → "Overview of Publications". The Internet version of DOConCD (DOConWEB) is available under: http://www.automation.siemens.com/doconweb Information on the range of training courses and FAQs (frequently asked questions) are available on the Internet under: http://www.siemens.com/motioncontrol under menu item "Support".

Target group This publication is intended for: ● Project engineers ● Technologists (from machine manufacturers) ● System startup engineers (Systems/Machines) ● Programmers

Benefits The function manual describes the functions so that the target group knows them and can select them. It provides the target group with the information required to implement the functions.

http://www.siemens.com/motioncontrolhttp://www.automation.siemens.com/doconwebhttp://www.siemens.com/motioncontrol

Preface

Extended Functions 4 Function Manual, 01/2008, 6FC5397-1BP10-3BA0

Standard version This documentation only describes the functionality of the standard version. Extensions or changes made by the machine tool manufacturer are documented by the machine tool manufacturer. Other functions not described in this documentation might be executable in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing. Further, for the sake of simplicity, this documentation does not contain all detailed information about all types of the product and cannot cover every conceivable case of installation, operation or maintenance.

Installation Structure of this Function Manual: ● Inner title (page 3) with the title of the Function Manual, the SINUMERIK controls as well

as the software and the version for which this version of the Function Manual is applicable and the overview of the individual functional descriptions.

● Description of the functions in alphabetical order (e.g. A2, A3, B1 etc.) ● Appendix with:

– List of abbreviations – Fax template for feedback for documentation – Overview

● Index of terms

Note For detailed descriptions of data and alarm see: • machine and setting data:

Detailed description of machine data (only electronically on DOConCD or DOConWEB)

• NC/PLC interface signals: Function Manual Basic Functions; NC/PLC Interface Signals (Z1) Function Manual Basic Functions; NC/PLC Interface Signals (Z2) Function Manual Special Functions; NC/PLC Interface Signals (Z3)

• alarms: Diagnostics Manual

Preface


Notation of system data The following notation is applicable for system data in this documentation:

Signal/Data Notation Example NC/PLC interface signals

... NC/PLC interface signal: Signal data (signal name)

When the new gear step is engaged, the following NC/PLC interface signals are set by the PLC program: DB31, ... DBX16.0-2 (actual gear stage A to C) DB31, ... DBX16.3 (gear is changed)

Machine data ... machine data: ()

Master spindle is the spindle stored in the machine data: MD20090 $MC_SPIND_DEF_MASTER_SPIND (Position of deletion of the master spindle in the channel).

Setting Data ... setting data: ()

The logical master spindle is contained in the setting data: SD42800 $SC_SPIND_ASSIGN_TAB[0] (Spindle number converter)

Data types The following elementary data types are used in the control system:

Type Meaning Value range INT Signed integers -2147483646 ... +2147483647 REAL Figures with decimal point acc. to IEEE ±(2,2*10-308 … 1,8*10+308) BOOL Boolean values: TRUE/FALSE TRUE ≠ 0; FALSE = 0 CHAR 1 ASCII character corresponding to the code 0 … 255 STRING Character string, number of characters in [...], maximum of

200 characters Sequence of values with 0 ... 255

AXIS Axis identifier Axis identifier for all channel axes FRAME Geometrical parameters for translation, rotation, scaling,

and mirroring

Arrays can only be formed from similar elementary data types. Up to 3-dimensional arrays are possible.

Quantity structure Explanations concerning the NC/PLC interface are based on the absolute maximum number of sequential components: ● Mode groups (DB11) ● Channels (DB21, etc.) ● Axes/spindles (DB31, etc.)

Preface


Technical Support If you have any technical questions, please contact our hotline:

Europe / Africa Phone +49 180 5050 222 Fax +49 180 5050 223 Internet http://www.siemens.com/automation/support-request

America Phone +1 423 262 2522 Fax +1 423 262 2200 E-Mail mailto:[email protected]

Asia/Pacific Phone +86 1064 719 990 Fax +86 1064 747 474 E-mail mailto:[email protected]

Note Country specific telephone numbers for technical support are provided under the following Internet address: http://www.siemens.com/automation/service&support Calls from the German fixed line network are charged (e.g. at 0.14 €/min). Charges of other phone services may be different and may vary.

Questions about the manual If you have any queries (suggestions, corrections) in relation to this documentation, please send a fax or e-mail to the following address:

Fax: +49 9131 - 98 63315 Email: mailto:[email protected]

A fax form is available in the appendix of this document.

SINUMERIK Internet address http://www.siemens.com/sinumerik

http://www.siemens.com/automation/service&supporthttp://www.siemens.com/automation/support-requestmailto:[email protected]:[email protected]:[email protected]://www.siemens.com/sinumerik


Contents Preface ...................................................................................................................................................... 3 1 Digital and analog NCK I/Os (A4) ............................................................................................................ 25

1.1 Brief Description...........................................................................................................................25 1.2 NCK I/O via PLC ..........................................................................................................................26 1.2.1 General functionality ....................................................................................................................26 1.2.2 NCK digital inputs/outputs............................................................................................................33 1.2.2.1 NCK digital inputs ........................................................................................................................33 1.2.2.2 NCK digital outputs ......................................................................................................................35 1.2.3 Connection and logic operations of fast NCK inputs/outputs ......................................................38 1.2.4 NCK analog inputs/outputs ..........................................................................................................40 1.2.4.1 NCK analog inputs .......................................................................................................................40 1.2.4.2 NCK analog outputs.....................................................................................................................43 1.2.5 Direct PLC I/Os, addressable from the NC..................................................................................46 1.2.6 Analog-value representation of the NCK analog input/output values..........................................49 1.2.7 Comparator inputs .......................................................................................................................51 1.3 NCK I/O via PROFIBUS...............................................................................................................54 1.3.1 Functionality .................................................................................................................................54 1.3.2 Parameter assignment.................................................................................................................55 1.3.3 Programming................................................................................................................................57 1.3.3.1 Communication via part programs/synchronous actions.............................................................57 1.3.3.2 Communication via compile cycles..............................................................................................59 1.4 Constraints ...................................................................................................................................61 1.4.1 NCK I/O via PLC ..........................................................................................................................61 1.4.2 NCK I/O via PROFIBUS...............................................................................................................62 1.5 Examples .....................................................................................................................................63 1.5.1 NCK I/O via PLC ..........................................................................................................................63 1.5.1.1 Writing to PLC-I/Os ......................................................................................................................63 1.5.1.2 Reading from PLC-I/Os................................................................................................................64 1.5.2 NCK I/O via PROFIBUS...............................................................................................................65 1.5.2.1 PROFIBUS-I/O in write direction..................................................................................................65 1.5.2.2 PROFIBUS-I/O in read direction..................................................................................................67 1.5.2.3 Query of the RangeIndex in case of "PROFIBUS-I/O in write direction" .....................................68 1.6 Data lists ......................................................................................................................................70 1.6.1 Machine data................................................................................................................................70 1.6.1.1 General machine data..................................................................................................................70 1.6.1.2 Channel-specific machine data....................................................................................................71 1.6.2 Setting data ..................................................................................................................................71 1.6.2.1 General setting data.....................................................................................................................71 1.6.3 Signals .........................................................................................................................................71 1.6.3.1 Signals to NC ...............................................................................................................................71 1.6.3.2 Signals from NC...........................................................................................................................72

Contents


2 Several Operator Panels on Several NCUs, Distributed Systems (B3).................................................... 73 2.1 Brief Description.......................................................................................................................... 73 2.1.1 Topology of distributed system configurations............................................................................ 73 2.1.2 Several operator panels and NCUs with control unit management (option)............................... 78 2.1.2.1 General information..................................................................................................................... 78 2.1.2.2 System Features ......................................................................................................................... 79 2.1.2.3 Hardware..................................................................................................................................... 80 2.1.2.4 Functions..................................................................................................................................... 82 2.1.2.5 Configurability ............................................................................................................................. 84 2.1.3 Several operator panel fronts and NCUs, standard functionality................................................ 84 2.1.3.1 System Features ......................................................................................................................... 84 2.1.3.2 Functions..................................................................................................................................... 85 2.1.3.3 Configurability ............................................................................................................................. 87 2.1.3.4 MPI/OPI network rules ................................................................................................................ 92 2.1.4 NCU link ...................................................................................................................................... 93 2.1.4.1 General information..................................................................................................................... 93 2.1.4.2 Types of distributed machines .................................................................................................... 94 2.1.4.3 Link axes ..................................................................................................................................... 96 2.1.4.4 Flexible configuration .................................................................................................................. 97 2.1.4.5 User communication across the NCUs ....................................................................................... 98 2.1.4.6 Lead link axes ............................................................................................................................. 99 2.1.4.7 NCU link with different interpolation cycles............................................................................... 100 2.2 Several operator panel fronts and NCUs with control unit management option....................... 102 2.2.1 Hardware structure.................................................................................................................... 102 2.2.2 Properties.................................................................................................................................. 102 2.2.3 Configuration file NETNAMES.INI ............................................................................................ 104 2.2.4 Structure of the configuration file .............................................................................................. 105 2.2.5 Creating and using the configuration file................................................................................... 109 2.2.6 Power up ................................................................................................................................... 110 2.2.7 HMI switchover.......................................................................................................................... 113 2.2.8 Suppression .............................................................................................................................. 113 2.2.9 Connection and switchover conditions...................................................................................... 115 2.2.10 Implementation of control unit switchover................................................................................. 116 2.2.11 Operator interface ..................................................................................................................... 116 2.2.12 Operating mode switchover ...................................................................................................... 117 2.2.13 MCP switchover ........................................................................................................................ 119 2.2.14 PLC program "Control Unit Switchover" ................................................................................... 120 2.3 Several operator panel fronts and NCUs, standard functionality.............................................. 125 2.3.1 Configurations ........................................................................................................................... 125 2.3.2 Switchover of connection to another NCU................................................................................ 129 2.3.3 Creating and using the configuration file................................................................................... 130 2.3.4 Power up ................................................................................................................................... 130 2.3.5 NCU replacement...................................................................................................................... 131 2.4 Restrictions for switchover of operator components................................................................. 133 2.5 NCU link .................................................................................................................................... 134 2.5.1 Introduction ............................................................................................................................... 134 2.5.2 Technological description.......................................................................................................... 135 2.6 Link axes ................................................................................................................................... 137 2.6.1 Configuration of link axes and container axes .......................................................................... 139 2.6.2 Axis data and signals ................................................................................................................ 143 2.6.3 Output of predefined auxiliary functions in the case of an NCU link......................................... 146 2.6.4 Supplementary conditions for link axes .................................................................................... 147

Contents


2.6.5 Programming with channel and machine axis identifiers...........................................................149 2.6.6 Flexible configuration .................................................................................................................149 2.7 Axis container.............................................................................................................................150 2.7.1 System variables for axis containers .........................................................................................156 2.7.2 Machining with axis container (schematic) ................................................................................158 2.7.3 Axis container behavior after Power ON....................................................................................159 2.7.4 Axis container response to mode switchover ............................................................................159 2.7.5 Axis container behavior in relation to ASUBs ............................................................................159 2.7.6 Axis container response to RESET ...........................................................................................159 2.7.7 Axis container response to block searches ...............................................................................159 2.7.8 Supplementary conditions for axis container rotations ..............................................................159 2.8 Cross-NCU user communication, link variables ........................................................................163 2.8.1 Link variables .............................................................................................................................163 2.8.2 System variables of the link memory .........................................................................................167 2.8.3 Link axis drive information .........................................................................................................168 2.9 Configuration of a link grouping .................................................................................................170 2.10 Communication in link grouping.................................................................................................173 2.11 Lead link axis .............................................................................................................................176 2.11.1 Programming a lead link axis.....................................................................................................180 2.12 NCU link with different interpolation cycles................................................................................181 2.12.1 Diagram of general solution .......................................................................................................183 2.12.2 Different position control cycles .................................................................................................186 2.12.3 Supplementary conditions..........................................................................................................188 2.12.4 Activating NCU links with different interpolation cycles .............................................................188 2.12.5 Different IPO cycles, behavior at power ON, RESET, etc. ........................................................188 2.12.6 System variable with different interpolation cycles ....................................................................189 2.13 Link grouping system of units ....................................................................................................190 2.14 Supplementary conditions..........................................................................................................191 2.14.1 Several operator panels and NCUs with control unit management option................................191 2.14.2 Several operator panel fronts and NCUs, standard functionality...............................................191 2.14.3 Link axes ....................................................................................................................................192 2.14.4 Axis container.............................................................................................................................192 2.14.5 Lead link axis .............................................................................................................................192 2.14.6 NCU link with different interpolation cycles................................................................................193 2.15 Examples ...................................................................................................................................194 2.15.1 Configuration file NETNAMES.INI with control unit management option ..................................194 2.15.2 User-specific reconfiguring of PLC program control unit switchover .........................................197 2.15.2.1 Description of operational sequences (overview)......................................................................197 2.15.2.2 Description of operational sequences (details)..........................................................................198 2.15.2.3 Defined logical functions/defines ...............................................................................................206 2.15.2.4 Graphical representation of function sequences .......................................................................206 2.15.3 Configuration file NETNAMES.INI, standard functionality .........................................................214 2.15.3.1 Two operator panel fronts and one NCU...................................................................................214 2.15.3.2 One operator panel front and three NCUs.................................................................................215 2.15.4 Quick M:N commissioning based on examples .........................................................................216 2.15.4.1 Example 1 ..................................................................................................................................216 2.15.4.2 Example 2 ..................................................................................................................................219 2.15.4.3 Example 3 ..................................................................................................................................225 2.15.4.4 Description of FB9 .....................................................................................................................229 2.15.4.5 Example of calling FB9 ..............................................................................................................232 2.15.4.6 Example of override switchover .................................................................................................233

Contents


2.15.4.7 Switchover between MCP and HT6 .......................................................................................... 234 2.15.4.8 General Information .................................................................................................................. 235 2.15.5 Link axis .................................................................................................................................... 237 2.15.6 Axis container coordination....................................................................................................... 238 2.15.6.1 Axis container rotation without a part program wait .................................................................. 238 2.15.6.2 Axis container rotation with an implicit part program wait......................................................... 239 2.15.6.3 Axis container rotation by one channel only (e.g. during power up)......................................... 239 2.15.7 Evaluating axis container system variables .............................................................................. 239 2.15.7.1 Conditional branch .................................................................................................................... 239 2.15.7.2 Static synchronized action with $AN_AXCTSWA ..................................................................... 239 2.15.7.3 Wait for certain completion of axis container rotation ............................................................... 240 2.15.8 Configuration of a multi-spindle turning machine...................................................................... 241 2.15.9 Lead link axis ............................................................................................................................ 250 2.15.9.1 Configuration............................................................................................................................. 250 2.15.9.2 Programming............................................................................................................................. 252 2.15.10 NCU link with different interpolation cycles............................................................................... 253 2.15.10.1 Example of eccentric turning..................................................................................................... 253 2.16 Data lists.................................................................................................................................... 254 2.16.1 Machine data............................................................................................................................. 254 2.16.1.1 General machine data............................................................................................................... 254 2.16.1.2 Channel-specific machine data................................................................................................. 254 2.16.1.3 Axis/spindle-specific machine data ........................................................................................... 255 2.16.2 Setting data ............................................................................................................................... 255 2.16.2.1 General setting data.................................................................................................................. 255 2.16.2.2 Axis/spindle-specific setting data .............................................................................................. 255 2.16.3 Signals....................................................................................................................................... 255 2.16.3.1 Signals from NC ........................................................................................................................ 255 2.16.3.2 Signals from HMI/PLC............................................................................................................... 256 2.16.3.3 General online interface ............................................................................................................ 256 2.16.3.4 Signals to axis/spindle............................................................................................................... 257

3 Operation via PG/PC (B4)...................................................................................................................... 259 3.1 Brief Description........................................................................................................................ 259 3.2 Software installation .................................................................................................................. 261 3.2.1 System requirements ................................................................................................................ 261 3.2.2 Installation ................................................................................................................................. 262 3.2.3 Supplementary software conditions .......................................................................................... 268 3.2.4 Start program ............................................................................................................................ 268 3.2.5 Close program........................................................................................................................... 269 3.3 Operation via PG/PC................................................................................................................. 270 3.3.1 General operation ..................................................................................................................... 270 3.3.2 Additional information................................................................................................................ 272 3.3.3 Operation of operator panel fronts ............................................................................................ 273 3.4 Simulation of part programs...................................................................................................... 273 3.5 Marginal conditions ................................................................................................................... 274 3.6 Data lists.................................................................................................................................... 274

4 Manual and Handwheel Travel (H1) ...................................................................................................... 275 4.1 Product brief.............................................................................................................................. 275 4.1.1 Overview ................................................................................................................................... 275 4.1.2 General characteristics of manual travel in JOG ...................................................................... 276 4.1.3 Control of manual-travel functions via PLC interface................................................................ 279

Contents


4.1.4 Control-system response to power ON, mode change, RESET, block search, REPOS...........280 4.2 Continuous travel .......................................................................................................................281 4.2.1 General functionality ..................................................................................................................281 4.2.2 Distinction between inching mode continuous mode.................................................................282 4.2.3 Special features of continuous travel.........................................................................................283 4.3 Incremental travel (INC).............................................................................................................284 4.3.1 General functionality ..................................................................................................................284 4.3.2 Distinction between inching mode and continuous mode..........................................................285 4.3.3 Special features of incremental travel........................................................................................286 4.4 Handwheel travel in JOG...........................................................................................................287 4.4.1 General functionality ..................................................................................................................287 4.4.2 Travel request ............................................................................................................................291 4.4.3 Double use of the handwheel ....................................................................................................295 4.5 Handwheel override in automatic mode ....................................................................................297 4.5.1 General functionality ..................................................................................................................297 4.5.2 Programming and activating handwheel override......................................................................301 4.5.3 Special features of handwheel override in automatic mode ......................................................303 4.6 Third handwheel via SIMODRIVE 611D (SINUMERIK 840D)...................................................305 4.7 Contour handwheel/path default using handwheel (optional for SINUMERIK 840D)................307 4.8 DRF offset ..................................................................................................................................309 4.9 Start-up: Handwheels ................................................................................................................312 4.9.1 General information ...................................................................................................................312 4.9.2 Connection via cable distributor.................................................................................................313 4.9.3 Connection via SIMODRIVE 611D (SINUMERIK 840D) ...........................................................314 4.9.4 Connection via PROFIBUS........................................................................................................315 4.9.5 Connection via Ethernet.............................................................................................................317 4.10 Special features of manual travel ..............................................................................................319 4.10.1 Geometry-axis manual travel .....................................................................................................319 4.10.2 Special features of spindle manual travel ..................................................................................320 4.10.3 Monitoring functions...................................................................................................................322 4.10.4 Other ..........................................................................................................................................323 4.11 Approaching a fixed point in JOG ..............................................................................................325 4.11.1 Introduction ................................................................................................................................325 4.11.2 Functionality ...............................................................................................................................326 4.11.3 Parameter setting.......................................................................................................................329 4.11.4 Programming..............................................................................................................................329 4.11.5 Supplementary Conditions.........................................................................................................330 4.11.6 Application example...................................................................................................................331 4.12 Data lists ....................................................................................................................................332 4.12.1 Machine data..............................................................................................................................332 4.12.1.1 General machine data................................................................................................................332 4.12.1.2 Channel-specific machine data..................................................................................................332 4.12.1.3 Axis/spindle-specific machine data............................................................................................333 4.12.2 Setting data ................................................................................................................................333 4.12.2.1 General setting data...................................................................................................................333 4.12.3 Signals .......................................................................................................................................334 4.12.3.1 Signals to NC .............................................................................................................................334 4.12.3.2 Signals from NC.........................................................................................................................334 4.12.3.3 Signals to mode group ...............................................................................................................334 4.12.3.4 Signals from mode group...........................................................................................................334

Contents


4.12.3.5 Signals to channel..................................................................................................................... 335 4.12.3.6 Signals from channel................................................................................................................. 335 4.12.3.7 Signals to axis/spindle............................................................................................................... 336 4.12.3.8 Signals from axis/spindle .......................................................................................................... 336

5 Compensations (K3) .............................................................................................................................. 337 5.1 Brief Description........................................................................................................................ 337 5.2 Temperature compensation ...................................................................................................... 339 5.2.1 General information................................................................................................................... 339 5.2.2 Temperature compensation parameters................................................................................... 341 5.3 Backlash compensation ............................................................................................................ 346 5.4 Interpolatory compensation....................................................................................................... 349 5.4.1 General information................................................................................................................... 349 5.4.2 Measuring system error compensation (MSEC)....................................................................... 353 5.4.3 Sag compensation and angularity error compensation ............................................................ 357 5.4.4 Extension of the sag compensation with NCU link ................................................................... 373 5.4.5 Special features of interpolatory compensation........................................................................ 381 5.5 Dynamic feedforward control (following error compensation)................................................... 383 5.5.1 General information................................................................................................................... 383 5.5.2 Forward feed control for command- and PLC axes .................................................................. 386 5.5.3 Speed feedforward control ........................................................................................................ 388 5.5.4 Torque feedforward control ....................................................................................................... 391 5.6 Friction compensation (quadrant error compensation) ............................................................. 394 5.6.1 General information................................................................................................................... 394 5.6.2 Conventional friction compensation .......................................................................................... 396 5.6.3 Commissioning of conventional friction compensation ............................................................. 398 5.7 Neural quadrant error compensation ........................................................................................ 405 5.7.1 Fundamentals ........................................................................................................................... 405 5.7.2 Parameterization of neural QEC ............................................................................................... 407 5.7.3 Learning the neural network...................................................................................................... 414 5.7.4 Commissioning of neural QEC.................................................................................................. 418 5.7.5 Further optimization and intervention options........................................................................... 421 5.7.6 Quick commissioning ................................................................................................................ 426 5.8 Circularity test ........................................................................................................................... 429 5.9 Electronic weight compensation (vertical axis) ......................................................................... 434 5.9.1 Electronic counterweight function ............................................................................................. 434 5.9.2 Effect on electronic counterweight function of rebooting from HMI .......................................... 436 5.9.3 Electronic weight compensation with travel to fixed stop.......................................................... 438 5.10 Supplementary conditions......................................................................................................... 441 5.10.1 Availability ................................................................................................................................. 441 5.11 Data lists.................................................................................................................................... 443 5.11.1 Machine data............................................................................................................................. 443 5.11.1.1 SIMODRIVE 611D machine data.............................................................................................. 443 5.11.1.2 General machine data............................................................................................................... 443 5.11.1.3 Channel-specific machine data................................................................................................. 443 5.11.2 Setting data ............................................................................................................................... 444 5.11.2.1 General setting data.................................................................................................................. 444 5.11.2.2 Axis/spindle-specific setting data .............................................................................................. 444 5.11.3 Signals....................................................................................................................................... 445 5.11.3.1 Signals from NC ........................................................................................................................ 445

Contents


5.11.3.2 Signals from mode group...........................................................................................................445 5.11.3.3 Signals from channel .................................................................................................................445 5.11.3.4 Signals to axis/spindle ...............................................................................................................445

6 Mode Groups, Channels, Axis Replacement (K5).................................................................................. 447 6.1 Brief description .........................................................................................................................447 6.2 Mode groups ..............................................................................................................................449 6.3 Channels ....................................................................................................................................450 6.3.1 Channel synchronization (program coordination) ......................................................................450 6.3.2 Conditional wait in continuous path mode WAITMC .................................................................453 6.4 Axis/spindle replacement ...........................................................................................................457 6.4.1 Introduction ................................................................................................................................457 6.4.2 Example of an axis replacement................................................................................................459 6.4.3 Axis replacement options...........................................................................................................460 6.4.4 Replacement behavior NC program ..........................................................................................461 6.4.5 Axis transfer to neutral state (release).......................................................................................462 6.4.6 Transferring axis or spindle in the part program........................................................................463 6.4.7 Automatic axis replacement.......................................................................................................464 6.4.8 Axis replacement via PLC..........................................................................................................466 6.4.9 Set axis replacement behavior variable.....................................................................................469 6.4.10 Axis replacement via axis container rotation .............................................................................470 6.4.11 Axis replacement with and without preprocessing stop.............................................................471 6.4.12 Exclusively PLC controlled axis and permanently assigned PLC axis ......................................472 6.4.13 Geometry axis in rotated frame and axis replacement ..............................................................474 6.4.14 Axis replacement from synchronized actions ............................................................................475 6.5 Marginal conditions ....................................................................................................................477 6.6 Data lists ....................................................................................................................................479 6.6.1 Machine data..............................................................................................................................479 6.6.1.1 General machine data................................................................................................................479 6.6.1.2 Channel-specific machine data..................................................................................................479 6.6.1.3 Axis/spindle-specific machine data............................................................................................481 6.6.2 Setting data ................................................................................................................................482 6.6.2.1 Channel-specific setting data.....................................................................................................482 6.6.3 Signals .......................................................................................................................................482 6.6.3.1 Signals to/from BAG ..................................................................................................................482 6.6.3.2 Signals to/from Channel.............................................................................................................482

7 Kinematic Transformation (M1).............................................................................................................. 483 7.1 Brief description .........................................................................................................................483 7.1.1 TRANSMIT.................................................................................................................................483 7.1.2 TRACYL.....................................................................................................................................484 7.1.3 TRAANG ....................................................................................................................................485 7.1.4 Chained transformations............................................................................................................485 7.1.5 Activating transformation machine data via parts program/softkey ...........................................485 7.2 TRANSMIT.................................................................................................................................486 7.2.1 Preconditions for TRANSMIT.....................................................................................................487 7.2.2 Settings specific to TRANSMIT..................................................................................................490 7.2.3 Activation of TRANSMIT ............................................................................................................494 7.2.4 Deactivation of the TRANSMIT function ....................................................................................494 7.2.5 Special system reactions with TRANSMIT ................................................................................494 7.2.6 Machining options for TRANSMIT .............................................................................................498 7.2.7 Working area limitations.............................................................................................................504

Contents


7.2.8 Overlaid motions with TRANSMIT ............................................................................................ 505 7.2.9 Monitoring of rotary axis rotations over 360º ............................................................................ 505 7.2.10 Constraints ................................................................................................................................ 506 7.3 TRACYL .................................................................................................................................... 507 7.3.1 Preconditions for TRACYL........................................................................................................ 509 7.3.2 Settings specific to TRACYL..................................................................................................... 513 7.3.3 Activation of TRACYL ............................................................................................................... 518 7.3.4 Deactivation of the TRACYL function ....................................................................................... 518 7.3.5 Special system reactions with TRACYL.................................................................................... 519 7.3.6 Jog............................................................................................................................................. 521 7.4 TRAANG ................................................................................................................................... 522 7.4.1 Preconditions for TRAANG (inclined axis) ................................................................................ 523 7.4.2 Settings specific to TRAANG .................................................................................................... 526 7.4.3 Activation of TRAANG............................................................................................................... 529 7.4.4 Deactivation of TRAANG .......................................................................................................... 529 7.4.5 Special system reactions with TRAANG................................................................................... 530 7.4.6 Inclined axis programming (G05, G07) ..................................................................................... 531 7.5 Chained transformations ........................................................................................................... 533 7.5.1 Activating chained transformations ........................................................................................... 535 7.5.2 Switching off a chained transformation ..................................................................................... 535 7.5.3 Special characteristics of chained transformations................................................................... 535 7.5.4 Persistent transformation .......................................................................................................... 536 7.5.5 Axis positions in the transformation chain................................................................................. 541 7.6 Cartesian PTP travel ................................................................................................................. 544 7.6.1 Programming of position ........................................................................................................... 547 7.6.2 Overlap areas of axis angles..................................................................................................... 548 7.6.3 Examples of ambiguities of position.......................................................................................... 548 7.6.4 Example of ambiguity in rotary axis position............................................................................. 549 7.6.5 PTP/CP switchover in JOG mode............................................................................................. 550 7.7 Cartesian manual travel (optional) ............................................................................................ 551 7.8 Activating transformation machine data via parts program/softkey .......................................... 560 7.8.1 Functionality .............................................................................................................................. 560 7.8.2 Constraints ................................................................................................................................ 560 7.8.3 Control response to power ON, mode change, RESET, block search, REPOS ...................... 562 7.8.4 List of machine data affected .................................................................................................... 563 7.9 Constraints ................................................................................................................................ 566 7.9.1 TRANSMIT................................................................................................................................ 566 7.9.2 TRACYL (peripheral surface transformation)............................................................................ 566 7.9.3 TRAANG (inclined axis) ............................................................................................................ 566 7.9.4 Chained transformations ........................................................................................................... 567 7.10 Examples................................................................................................................................... 568 7.10.1 TRANSMIT................................................................................................................................ 568 7.10.2 TRACYL .................................................................................................................................... 569 7.10.3 TRAANG ................................................................................................................................... 574 7.10.4 Chained transformations ........................................................................................................... 576 7.10.5 Activating transformation MD via a parts program.................................................................... 580 7.10.6 Axis positions in the transformation chain................................................................................. 581 7.11 Data lists.................................................................................................................................... 584 7.11.1 Machine data............................................................................................................................. 584 7.11.1.1 TRANSMIT................................................................................................................................ 584 7.11.1.2 TRACYL .................................................................................................................................... 585

Contents


7.11.1.3 TRAANG ....................................................................................................................................587 7.11.1.4 Chained transformations............................................................................................................588 7.11.1.5 Non transformation-specific machine data ................................................................................588 7.11.2 Signals .......................................................................................................................................589 7.11.2.1 Signals from channel .................................................................................................................589

8 Measurement (M5) ................................................................................................................................ 591 8.1 Brief description .........................................................................................................................591 8.2 Hardware requirements .............................................................................................................593 8.2.1 Probes that can be used ............................................................................................................593 8.2.2 Measuring probe connection......................................................................................................595 8.3 Channel-specific measuring.......................................................................................................600 8.3.1 Measuring mode ........................................................................................................................600 8.3.2 Measurement results .................................................................................................................601 8.4 Setting zeros, workpiece measuring and tool measuring ..........................................................602 8.4.1 Preset actual value memory and scratching..............................................................................602 8.4.2 Workpiece measuring ................................................................................................................603 8.4.2.1 Input values................................................................................................................................603 8.4.2.2 Measurement selection..............................................................................................................610 8.4.2.3 Output values.............................................................................................................................611 8.4.2.4 Calculation method ....................................................................................................................612 8.4.2.5 Units of measurement and measurement variables for the calculation.....................................615 8.4.2.6 Diagnostics.................................................................................................................................616 8.4.3 Types of workpiece measurement.............................................................................................617 8.4.3.1 Measurement of an edge (measurement type 1, 2, 3) ..............................................................617 8.4.3.2 Measurement of an angle (measurement type 4, 5, 6, 7)..........................................................621 8.4.3.3 Measurement of a hole (measurement type 8)..........................................................................624 8.4.3.4 Measurement of a shaft (measurement type 9).........................................................................627 8.4.3.5 Measurement of a groove (measurement type 12)....................................................................628 8.4.3.6 Measurement of a web (measurement type 13) ........................................................................631 8.4.3.7 Measurement of geo axes and special axes (measurement type 14, 15).................................632 8.4.3.8 Measurement of an oblique edge (measurement type 16)........................................................634 8.4.3.9 Measurement of an oblique angle in a plane (measurement type 17) ......................................635 8.4.3.10 Redefine measurement around a WCS reference frame (measurement type 18)....................639 8.4.3.11 Measurement of a 1-, 2- and 3-dimensional setpoint selection

(measurement type 19, 20, 21)..................................................................................................642 8.4.3.12 Measurement of an oblique angle (measurement type 24) .......................................................647 8.4.3.13 Measurement of a rectangle (measurement type 25)................................................................650 8.4.3.14 Measurement for saving data management frames (measurement type 26)............................652 8.4.3.15 Measurement for restoring backed-up data management frames (measurement type 27) ......653 8.4.3.16 Measurement for defining an additive rotation for taper turning (measurement type 28)..........654 8.4.4 Tool measuring ..........................................................................................................................655 8.4.5 Types of workpiece measurement.............................................................................................656 8.4.5.1 Measurement of tool lengths (measurement type 10) ...............................................................656 8.4.5.2 Measurement of tool diameter (measurement type 11).............................................................658 8.4.5.3 Measurement of tool lengths with zoom-in function (measurement type 22) ............................659 8.4.5.4 Measuring a tool length with stored or current position (measurement type 23).......................660 8.4.5.5 Measurement of a tool length of two tools with the following orientation: .................................661 8.5 Axial measurement (optional) ....................................................................................................672 8.5.1 Constraints .................................................................................................................................672 8.5.2 Measuring mode ........................................................................................................................673 8.5.3 Programming..............................................................................................................................674 8.5.4 Measurement results .................................................................................................................676

Contents


8.5.5 Continuous measurement (cyclic measurement)...................................................................... 677 8.6 Measurement accuracy and functional testing.......................................................................... 679 8.6.1 Measurement accuracy............................................................................................................. 679 8.6.2 Probe functional testing............................................................................................................. 679 8.7 Marginal conditions ................................................................................................................... 680 8.8 Examples................................................................................................................................... 680 8.8.1 Measuring mode 1 .................................................................................................................... 680 8.8.2 Measuring mode 2 .................................................................................................................... 681 8.8.3 Continuous measurement ......................................................................................................... 681 8.8.3.1 Continous measurement on completion of programmed traversing motion ............................. 681 8.8.3.2 Continuous measurements with deletion of distance-to-go ...................................................... 682 8.8.3.3 Continuous measurements modally over several blocks.......................................................... 682 8.8.4 Functional test and repeat accuracy ......................................................................................... 683 8.9 Data lists.................................................................................................................................... 685 8.9.1 Machine data............................................................................................................................. 685 8.9.1.1 General machine data............................................................................................................... 685 8.9.1.2 Channel-specific machine data................................................................................................. 685 8.9.2 System variables....................................................................................................................... 685

9 Software cams, position switching signals (N3) ..................................................................................... 687 9.1 Brief Description........................................................................................................................ 687 9.2 Cam signals and cam positions ................................................................................................ 688 9.2.1 Generation of cam signals for separate output ......................................................................... 688 9.2.2 Generation of cam signals with gated output............................................................................ 691 9.2.3 Cam positions ........................................................................................................................... 694 9.2.4 Lead/delay times (dynamic cam) .............................................................................................. 696 9.3 Output of cam signals ............................................................................................................... 697 9.3.1 Activating................................................................................................................................... 697 9.3.2 Output of cam signals to PLC ................................................................................................... 697 9.3.3 Output of cam signals to NCK I/Os in position control cycle..................................................... 698 9.3.4 Timer-controlled cam signal output........................................................................................... 699 9.3.5 Independent, timer-controlled output of cam signals ................................................................ 701 9.4 Position-time cams.................................................................................................................... 702 9.5 Supplementary Conditions........................................................................................................ 704 9.6 Data lists.................................................................................................................................... 705 9.6.1 Machine data............................................................................................................................. 705 9.6.1.1 General machine data............................................................................................................... 705 9.6.2 Setting data ............................................................................................................................... 706 9.6.2.1 General setting data.................................................................................................................. 706 9.6.3 Signals....................................................................................................................................... 706 9.6.3.1 Signals to axis/spindle............................................................................................................... 706 9.6.3.2 Signals from axis/spindle .......................................................................................................... 706

10 Punching and Nibbling (N4) ................................................................................................................... 707 10.1 Brief Description........................................................................................................................ 707 10.2 Stroke control ............................................................................................................................ 708 10.2.1 General information................................................................................................................... 708 10.2.2 High-speed signals.................................................................................................................... 709 10.2.3 Criteria for stroke initiation ........................................................................................................ 711 10.2.4 Axis start after punching............................................................................................................ 713

Contents


10.2.5 PLC signals specific to punching and nibbling...........................................................................714 10.2.6 Punching and nibbling-specific reactions to standard PLC signals ...........................................714 10.2.7 Signal monitoring .......................................................................................................................715 10.3 Activation and deactivation ........................................................................................................716 10.3.1 Language commands ................................................................................................................716 10.3.2 Functional expansions ...............................................................................................................720 10.3.3 Compatibility with earlier systems..............................................................................................725 10.4 Automatic path segmentation ....................................................................................................727 10.4.1 General information ...................................................................................................................727 10.4.2 Operating characteristics with path axes ...................................................................................729 10.4.3 Response in connection with single axes ..................................................................................733 10.5 Rotatable tool .............................................................................................................................738 10.5.1 General information ...................................................................................................................738 10.5.2 Coupled motion of punch and die ..............................................................................................739 10.5.3 Tangential control ......................................................................................................................740 10.6 Protection zones ........................................................................................................................744 10.7 Supplementary conditions..........................................................................................................744 10.8 Examples ...................................................................................................................................745 10.8.1 Examples of defined start of nibbling operation.........................................................................745 10.9 Data lists ....................................................................................................................................750 10.9.1 Machine data..............................................................................................................................750 10.9.1.1 General machine data................................................................................................................750 10.9.1.2 Channel-specific machine data..................................................................................................750 10.9.2 Setting data ................................................................................................................................751 10.9.2.1 Channel-specific setting data.....................................................................................................751 10.9.3 Signals .......................................................................................................................................751 10.9.3.1 Signals to channel......................................................................................................................751 10.9.3.2 Signals from channel .................................................................................................................751 10.9.4 Language commands ................................................................................................................752

11 Positioning Axes (P2) ............................................................................................................................ 753 11.1 Product brief...............................................................................................................................753 11.2 Own channel, positioning axis or concurrent positioning axis ...................................................755 11.2.1 Own channel ..............................................................................................................................755 11.2.2 Positioning axis (posAxis) ..........................................................................................................756 11.2.3 Concurrent positioning axis........................................................................................................758 11.3 Motion behavior and interpolation functions ..............................................................................760 11.3.1 Path interpolator and axis interpolator .......................................................................................760 11.3.2 Interpolation response of path axis in G0 ..................................................................................760 11.3.3 Autonomous single-axis operations...........................................................................................762 11.3.4 Autonomous single-axis functions with NC-controlled ESR ......................................................770 11.4 Velocity.......................................................................................................................................772 11.5 Programming..............................................................................................................................773 11.5.1 General ......................................................................................................................................773 11.5.2 Revolutional feed rate in external programming........................................................................776 11.6 Block change..............................................................................................................................777 11.6.1 Settable block change time........................................................................................................780 11.6.2 End of motion criterion with block search ..................................................................................787

Contents


11.7 Control by the PLC.................................................................................................................... 788 11.7.1 Starting concurrent positioning axes from the PLC .................................................................. 789 11.7.2 PLC-controlled axes.................................................................................................................. 790 11.7.3 Control response PLC-controlled axes ..................................................................................... 792 11.8 Response with special functions............................................................................................... 793 11.8.1 Dry run (DRY RUN)................................................................................................................... 793 11.8.2 Single block............................................................................................................................... 793 11.9 Examples................................................................................................................................... 794 11.9.1 Motion behavior and interpolation functions ............................................................................. 794 11.9.1.1 Traversing path axes without interpolation with G0 .................................................................. 795 11.10 Data lists.................................................................................................................................... 796 11.10.1 Machine data............................................................................................................................. 796 11.10.1.1 Channel-specific machine data................................................................................................. 796 11.10.1.2 Axis/spindle-specific machine data ........................................................................................... 796 11.10.2 Setting data ............................................................................................................................... 796 11.10.2.1 Axis/spindle-specific setting data .............................................................................................. 796 11.10.3 Signals......................................................................................

sinumerik 840d sl - siemens...memory configuration (s7) 15 indexing axes (t1) 16 tool change (w3) 17...

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