sinumerik 840d sl/828d extended functions sinumerik 840d sl / 828d extended functions function...

SINUMERIK

SINUMERIK 840D sl / 828DExtended Functions

Function Manual

Validfor ControlsystemSINUMERIK840Dsl/840DEslSINUMERIK828D Software VersionCNCsoftware 4.4

09/20116FC5397-1BP40-2BA0

Preface

A4: Digital and analog NCK I/Os 1B3: Several operator panels connected to several NCUs, distributed systems - only 840D sl 2B4: Operation via PG/PC - only 840D sl 3H1: Manual travel and handwheel travel 4K3: Compensation 5K5: Mode groups, channels, axis interchange 6M1: Kinematic transformation 7M5: Measuring 8N3: Software cams, position switching cycles - only 840D sl 9N4: Own channel - only 840D sl10P2: Positioning axes 11P5: Oscillation - only 840D sl 12R2: Rotary axes 13S3: Synchronous spindle 14S7: Memory configuration 15T1: Indexing axes 16W3: Tool change 17W4: Grinding-specific tool offset and monitoring functions - only 840D sl 18Z2: NC/PLC interface signals 19Appendix A

Legal informationWarning notice system

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

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 PersonnelThe product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation for the specific task, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens productsNote the following:

TrademarksAll names identified by are registered trademarks of the SiemensAG. 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 LiabilityWe 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.

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

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

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

CAUTIONwithout a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

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

WARNINGSiemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be adhered to. The information in the relevant documentation must be observed.

Siemens AGIndustry SectorPostfach 48 4890026 NRNBERGGERMANY

Order number:6FC5397-1BP40-2BA0 02.2011

Copyright SiemensAG2011.Technical data subject to change

Extended FunctionsFunction Manual 09/2011, 6FC5397-1BP40-2BA0 3

Preface

SINUMERIK documentationThe SINUMERIK documentation is organized in the following categories:

General documentation

User documentation

Manufacturer/service documentation

Additional informationYou can find information on the following topics at www.siemens.com/motioncontrol/docu:

Ordering documentation/overview of documentation

Additional links to download documents

Using documentation online (find and search in manuals/information)

Please send any questions about the technical documentation (e.g. suggestions for improvement, corrections) to the following address:

[email protected]

My Documentation Manager (MDM)Under the following link you will find information to individually compile OEM-specific machine documentation based on the Siemens content:

www.siemens.com/mdm

Training For information about the range of training courses, refer under:

www.siemens.com/sitrain

SITRAIN - Siemens training for products, systems and solutions in automation technology

www.siemens.com/sinutrain

SinuTrain - training software for SINUMERIK

FAQsYou can find Frequently Asked Questions in the Service&Support pages under Product Support. http://support.automation.siemens.com

http://www.siemens.com/motioncontrol/docu:mailto:[email protected]://www.siemens.com/mdmhttp://www.siemens.com/sitrainhttp://www.siemens.com/sinutrainhttp://support.automation.siemens.com

Preface

Extended Functions4 Function Manual, 09/2011, 6FC5397-1BP40-2BA0

SINUMERIKYou can find information on SINUMERIK under the following link:

www.siemens.com/sinumerik

Target groupThis publication is intended for:

Project engineers

Technologists (from machine manufacturers)

System startup engineers (Systems/Machines)

Programmers

BenefitsThe 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.

Standard versionThis 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.

Technical Support You will find telephone numbers for other countries for technical support in the Internet under http://www.siemens.com/automation/service&support

http://www.siemens.com/automation/service&supporthttp://www.siemens.com/sinumerik

Preface

Extended FunctionsFunction Manual, 09/2011, 6FC5397-1BP40-2BA0 5

Information on structure and contents

InstallationStructure 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- Overview

Index of terms

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

NoteFor 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

Signal/Data Notation ExampleNC/PLC interface signals

... NC/PLC interface signal: ()

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

Machine data ... machine data: ()

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

Setting Data ... Setting data: ()

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

Preface


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.)

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

NoteSignal addressThe description of functions include as of an NC/PLC interface signal, only the address valid for SINUMERIK 840D sl. The signal address for SINUMERIK 828D should be taken from the data lists "Signals to/from ..." at the end of the particular description of functions.

Type Meaning Value rangeINT Signed integers -2147483648 ... +2147483647REAL Figures with decimal point acc. to IEEE (2,2*10-308 1,8*10+308)BOOL Truth values TRUE (1) and FALSE (0) 1, 0CHAR ASCII characters Corresponding to code 0 to 255STRING Character string, number of characters in [...] Maximum of 200 characters (no special

characters)AXIS Axis names only All axis identifiers in the channelFRAME Geometrical parameters for moving, rotating, scaling, and

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

Preface


SINUMERIK 828D system performance (region)

PPU240.2 / 241.2 PPU 260.2 / 261.2 PPU 280.2 / 281.2BASIC T BASIC M T M T M

System performanceBasic quantity of axes/spindles 3 4 3 4 3 4Max. number of axes/spindles 5 5 6 6 8 6Max. number of interpolating axes 4 4 4 4 4 4Max. number: Channels / mode groups 1/1 1/1 1/1 1/1 1/1 1/1Min. block change time 9ms 9ms 6ms 6ms 6ms 3msSpeed/current control cycle 125s 125s 125s 125s 125s 125sCNC user memory (buffered) 1 MB 1 MB 3MB 3MB 5MB 5MB

CNC functionsTool Management Number of tools/cutting edges 80/160 80/160 128/256 128/256 256/512 256/512Max. number of ASUBs (permanently set)

2 2 2 2 2 2

TRANSMIT / TRACYL Inclined Y axis - - - - -Synchronous spindle for counterspindle - - - - -Synchronous spindle for polygon machining

- - -

Gantry Temperature compensation

Drive functionsSafety Integrated: Safe Torque Off, Safe Brake Control

Safety Integrated: Safe velocity

HMI, CNC programmingShopMill/ShopTurn HMI functions DIN/ISO programming with programGUIDE

Online ISO dialect interpreter ShopMill/ShopTurn machining step programming

Measuring cycles Simulation in surface display Simulation in 3D display

Preface


PLCSIMATIC S7-200 (integrated) Basic I/O modules:PP 72/48D PNPP 72/48D 2/2A PN (being prepared)

PLC cycle time 9ms 9ms 6ms 6ms 6ms 6msMax. number of PLC operations 24000 24000 24000 24000 24000 24000Servo-synchronous high-speed PLC task

Reaction time to process interrupts (terminal to terminal)

7.5ms 7.5ms 7.5ms 7.5ms 4.5ms 4.5ms

Max. number of digital inputs/outputs 216/144 216/144 288/192 288/192 360/240 360/240Max. number of analog inputs/outputs 6/6 6/6 8/8 8/8 10/10 10/10

Commissioning functionsService Planner (maintenance scheduler)

Easy Extend (for managing machine units)

Easy Archive (data archiving)

PPU240.2 / 241.2 PPU 260.2 / 261.2 PPU 280.2 / 281.2BASIC T BASIC M T M T M

T TurningM Milling Standard (basic scope) Option- Not available

Extended FunctionsFunction Manual 09/2011, 6FC5397-1BP40-2BA0 9

Table of contents

Preface.........................................................................................................................................................3

1 A4: Digital and analog NCK I/Os ...............................................................................................................27

1.1 Brief Description ........................................................................................................................ 27

1.2 NCK I/O via PLC........................................................................................................................ 281.2.1 General functionality .................................................................................................................. 281.2.2 NCK digital inputs/outputs ......................................................................................................... 331.2.2.1 NCK digital inputs ...................................................................................................................... 331.2.2.2 NCK digital outputs .................................................................................................................... 351.2.3 Connection and logic operations of fast NCK inputs/outputs .................................................... 381.2.4 NCK analog inputs/outputs ........................................................................................................ 401.2.4.1 NCK analog inputs ..................................................................................................................... 401.2.4.2 NCK analog outputs .................................................................................................................. 431.2.5 Direct PLC I/Os, addressable from the NC ................................................................................ 471.2.6 Analog-value representation of the NCK analog input/output values ........................................ 501.2.7 Comparator inputs ..................................................................................................................... 51

1.3 NCK I/O via PROFIBUS - only 840D sl ..................................................................................... 551.3.1 Functionality .............................................................................................................................. 551.3.2 Parameter assignment .............................................................................................................. 561.3.3 Programming ............................................................................................................................. 581.3.3.1 Communication via part programs/synchronous actions ........................................................... 581.3.3.2 Communication via compile cycles ............................................................................................ 61

1.4 Constraints ................................................................................................................................ 631.4.1 NCK I/O via PLC ........................................................................................................................ 631.4.2 NCK I/O via PROFIBUS - only 840D sl ..................................................................................... 64

1.5 Examples................................................................................................................................... 651.5.1 NCK I/O via PLC ........................................................................................................................ 651.5.1.1 Writing to PLC-I/Os .................................................................................................................... 651.5.1.2 Reading from PLC-I/Os ............................................................................................................. 661.5.2 NCK I/O via PROFIBUS - only 840D sl ..................................................................................... 671.5.2.1 PROFIBUS-I/O in write direction ............................................................................................... 671.5.2.2 PROFIBUS-I/O in read direction ................................................................................................ 691.5.2.3 Query of the RangeIndex in case of "PROFIBUS-I/O in write direction" ................................... 71

1.6 Data lists.................................................................................................................................... 731.6.1 Machine data ............................................................................................................................. 731.6.1.1 General machine data ............................................................................................................... 731.6.1.2 Channelspecific machine data ................................................................................................. 741.6.2 Setting data ............................................................................................................................... 741.6.2.1 General setting data .................................................................................................................. 741.6.3 Signals ....................................................................................................................................... 741.6.3.1 Signals to NC ............................................................................................................................. 741.6.3.2 Signals from NC ........................................................................................................................ 74

Table of contents


2 B3: Several operator panels connected to several NCUs, distributed systems - only 840D sl .................75

2.1 Brief Description ........................................................................................................................ 752.1.1 Topology of distributed system configurations ........................................................................... 752.1.2 Several operator panels and NCUs with control unit management (option) .............................. 802.1.2.1 General information ................................................................................................................... 802.1.2.2 System Features ........................................................................................................................ 812.1.2.3 Hardware ................................................................................................................................... 822.1.2.4 Functions ................................................................................................................................... 842.1.2.5 Configurability ............................................................................................................................ 852.1.3 Several operator panel fronts and NCUs, standard functionality ............................................... 862.1.3.1 System Features ........................................................................................................................ 862.1.3.2 Functions ................................................................................................................................... 872.1.3.3 Configurability ............................................................................................................................ 892.1.3.4 MPI/OPI network rules ............................................................................................................... 932.1.4 NCU link ..................................................................................................................................... 942.1.4.1 General information ................................................................................................................... 942.1.4.2 Technological description .......................................................................................................... 972.1.4.3 Link axes ................................................................................................................................... 992.1.4.4 User-specification link communication via link variables ......................................................... 1002.1.4.5 Lead link axes .......................................................................................................................... 100

2.2 Several operator panel fronts and NCUs with control unit management option ...................... 1022.2.1 Hardware structure .................................................................................................................. 1022.2.2 Properties ................................................................................................................................ 1022.2.3 Configuration file NETNAMES.INI ........................................................................................... 1042.2.4 Structure of the configuration file ............................................................................................. 1042.2.5 Creating and using the configuration file ................................................................................. 1092.2.6 Power up ................................................................................................................................. 1102.2.7 HMI switchover ........................................................................................................................ 1132.2.8 Suppression ............................................................................................................................. 1132.2.9 Connection and switchover conditions .................................................................................... 1152.2.10 Implementation of control unit switchover ................................................................................ 1162.2.11 Operator interface .................................................................................................................... 1162.2.12 Operating mode switchover ..................................................................................................... 1182.2.13 MCP switchover ....................................................................................................................... 120

2.3 Several operator panel fronts and NCUs, standard functionality............................................. 1212.3.1 Configurations .......................................................................................................................... 1212.3.2 Switchover of connection to another NCU ............................................................................... 1252.3.3 Creating and using the configuration file ................................................................................. 1262.3.4 Power up ................................................................................................................................. 1262.3.5 NCU replacement .................................................................................................................... 127

2.4 Restrictions for switchover of operator components................................................................ 129

2.5 Link communication................................................................................................................. 1302.5.1 General information ................................................................................................................. 1302.5.2 Parameter assignment: NC system cycles .............................................................................. 1312.5.3 Parameter assignment: Link communication ........................................................................... 1332.5.4 Configuration ........................................................................................................................... 1332.5.5 Wiring the NCUs ...................................................................................................................... 1342.5.6 Activation ................................................................................................................................. 134

2.6 Link axes ................................................................................................................................. 135


Table of contents

2.6.1 Configuration of link axes and container axes ......................................................................... 1372.6.2 Axis data and signals ............................................................................................................... 1412.6.3 Output of predefined auxiliary functions in the case of an NCU link ........................................ 1432.6.4 Supplementary conditions for link axes ................................................................................... 1442.6.5 Programming with channel and machine axis identifiers ......................................................... 1462.6.6 Flexible configuration ............................................................................................................... 146

2.7 Axis container .......................................................................................................................... 1472.7.1 System variables for axis containers ....................................................................................... 1532.7.2 Machining with axis container (schematic) .............................................................................. 1542.7.3 Axis container behavior after Power ON ................................................................................. 1552.7.4 Axis container response to mode switchover .......................................................................... 1552.7.5 Axis container behavior in relation to ASUBs .......................................................................... 1552.7.6 Axis container response to RESET ......................................................................................... 1552.7.7 Axis container response to block searches ............................................................................. 1552.7.8 Behavior when withdrawing the release for axis container rotation ......................................... 1552.7.9 Supplementary conditions for axis container rotations ............................................................ 157

2.8 User-specific link variables ...................................................................................................... 1602.8.1 Link variables ........................................................................................................................... 1602.8.2 Reading drive data via link variables ....................................................................................... 165

2.9 Lead link axis........................................................................................................................... 167

2.10 System of units within a link grouping ..................................................................................... 170

2.11 Supplementary conditions ....................................................................................................... 1712.11.1 Several operator panels and NCUs with control unit management option .............................. 1712.11.2 Several operator panel fronts and NCUs, standard functionality ............................................. 1712.11.3 Link axes ................................................................................................................................. 1722.11.4 Axis container .......................................................................................................................... 1722.11.5 Lead link axis ........................................................................................................................... 172

2.12 Examples................................................................................................................................. 1732.12.1 Configuration file NETNAMES.INI with control unit management option ................................ 1732.12.2 User-specific reconfiguring of PLC program control unit switchover ....................................... 1762.12.2.1 Description of operational sequences (overview) .................................................................... 1762.12.2.2 Description of operational sequences (details) ........................................................................ 1772.12.2.3 Defined logical functions/defines ............................................................................................. 1862.12.2.4 Graphical representation of function sequences ..................................................................... 1872.12.3 Configuration file NETNAMES.INI, standard functionality ....................................................... 1942.12.3.1 Two operator panel fronts and one NCU ................................................................................. 1942.12.3.2 One operator panel front and three NCUs ............................................................................... 1952.12.4 Quick M:N commissioning based on examples ....................................................................... 1972.12.4.1 Example 1 ................................................................................................................................ 1972.12.4.2 Example 2 ................................................................................................................................ 2002.12.4.3 Example 3 ................................................................................................................................ 2052.12.4.4 Description of FB9 ................................................................................................................... 2092.12.4.5 Example of calling FB9 ............................................................................................................ 2122.12.4.6 Example of override switchover ............................................................................................... 2132.12.4.7 Switchover between MCP and HT6 ......................................................................................... 2142.12.4.8 General Information ................................................................................................................. 2152.12.5 Link axis ................................................................................................................................... 2172.12.6 Axis container coordination ..................................................................................................... 2192.12.6.1 Axis container rotation without a part program wait ................................................................. 219

Table of contents


2.12.6.2 Axis container rotation with an implicit part program wait ........................................................ 2192.12.6.3 Axis container rotation by one channel only (e.g. during power up) ........................................ 2192.12.7 Evaluating axis container system variables ............................................................................. 2202.12.7.1 Conditional branch ................................................................................................................... 2202.12.7.2 Static synchronized action with $AN_AXCTSWA .................................................................... 2202.12.7.3 Wait for certain completion of axis container rotation .............................................................. 2202.12.8 Configuration of a multi-spindle turning machine ..................................................................... 2222.12.9 Lead link axis ........................................................................................................................... 2302.12.9.1 Configuration ........................................................................................................................... 2302.12.9.2 Programming ........................................................................................................................... 232

2.13 Data lists .................................................................................................................................. 2332.13.1 Machine data ........................................................................................................................... 2332.13.1.1 General machine data ............................................................................................................. 2332.13.1.2 Channelspecific machine data ................................................................................................ 2332.13.1.3 Axis/spindlespecific machine data .......................................................................................... 2332.13.2 Setting data ............................................................................................................................. 2342.13.2.1 General setting data ................................................................................................................ 2342.13.2.2 Axis/spindle-specific setting data ............................................................................................. 2342.13.3 Signals ..................................................................................................................................... 2342.13.3.1 Signals from NC ....................................................................................................................... 2342.13.3.2 Signals from HMI/PLC ............................................................................................................. 2342.13.3.3 General online interface ........................................................................................................... 2352.13.3.4 Signals from axis/spindle ......................................................................................................... 2362.13.4 System variables ..................................................................................................................... 237

3 B4: Operation via PG/PC - only 840D sl .................................................................................................239

3.1 Brief Description ...................................................................................................................... 239

3.2 Software installation................................................................................................................. 2413.2.1 System requirements ............................................................................................................... 2413.2.2 Installation ............................................................................................................................... 2423.2.3 Supplementary software conditions ......................................................................................... 2473.2.4 Start program ........................................................................................................................... 2473.2.5 Close program ......................................................................................................................... 248

3.3 Operation via PG/PC ............................................................................................................... 2493.3.1 General operation .................................................................................................................... 2493.3.2 Additional information .............................................................................................................. 2513.3.3 Operation of operator panel fronts ........................................................................................... 252

3.4 Simulation of part programs..................................................................................................... 253

3.5 Marginal conditions.................................................................................................................. 253

3.6 Data lists .................................................................................................................................. 253

4 H1: Manual travel and handwheel travel .................................................................................................255

4.1 product brief............................................................................................................................. 2554.1.1 Overview .................................................................................................................................. 2554.1.2 General characteristics of manual travel in JOG ..................................................................... 2564.1.3 Control of manual-travel functions via PLC interface ............................................................... 2604.1.4 Control-system response to power ON, mode change, RESET, block search, REPOS ......... 261

4.2 Continuous travel..................................................................................................................... 2624.2.1 General functionality ................................................................................................................ 262


Table of contents

4.2.2 Distinction between inching mode continuous mode ............................................................... 2634.2.3 Special features of continuous travel ....................................................................................... 264

4.3 Incremental travel (INC) .......................................................................................................... 2654.3.1 General functionality ................................................................................................................ 2654.3.2 Distinction between inching mode and continuous mode ........................................................ 2664.3.3 Special features of incremental travel ..................................................................................... 267

4.4 Handwheel travel in JOG......................................................................................................... 2684.4.1 General functionality ................................................................................................................ 2684.4.2 Travel request .......................................................................................................................... 2764.4.3 Double use of the handwheel .................................................................................................. 280

4.5 Handwheel override in automatic mode .................................................................................. 2824.5.1 General functionality ................................................................................................................ 2824.5.2 Programming and activating handwheel override ................................................................... 2874.5.3 Special features of handwheel override in automatic mode .................................................... 289

4.6 Contour handwheel/path input using handwheel (option) ....................................................... 290

4.7 DRF offset ............................................................................................................................... 293

4.8 Start-up: Handwheels .............................................................................................................. 2964.8.1 General information ................................................................................................................. 2964.8.2 Connection via PPU - only 828D ............................................................................................. 2974.8.3 Connected via PROFIBUS - only 840D sl ............................................................................... 2984.8.4 Connected via Ethernet - only 840D sl .................................................................................... 301

4.9 Special features of manual travel ............................................................................................ 3054.9.1 Geometry-axis manual travel ................................................................................................... 3054.9.2 Special features of spindle manual travel ................................................................................ 3064.9.3 Monitoring functions ................................................................................................................ 3084.9.4 Other ........................................................................................................................................ 309

4.10 Approaching a fixed point in JOG............................................................................................ 3104.10.1 Introduction .............................................................................................................................. 3104.10.2 Functionality ............................................................................................................................ 3114.10.3 Parameter setting .................................................................................................................... 3134.10.4 Programming ........................................................................................................................... 3154.10.5 Supplementary Conditions ...................................................................................................... 3154.10.6 Application example ................................................................................................................ 316

4.11 Data lists.................................................................................................................................. 3174.11.1 Machine data ........................................................................................................................... 3174.11.1.1 General machine data ............................................................................................................. 3174.11.1.2 Channelspecific machine data ............................................................................................... 3174.11.1.3 Axis/spindlespecific machine data .......................................................................................... 3184.11.2 Setting data ............................................................................................................................. 3184.11.2.1 General setting data ................................................................................................................ 3184.11.3 Signals ..................................................................................................................................... 3194.11.3.1 Signals from NC ...................................................................................................................... 3194.11.3.2 Signals to mode group ............................................................................................................. 3194.11.3.3 Signals from mode group ........................................................................................................ 3194.11.3.4 Signals to channel ................................................................................................................... 3204.11.3.5 Signals from channel ............................................................................................................... 3214.11.3.6 Signals to axis/spindle ............................................................................................................. 3224.11.3.7 Signals from axis/spindle ......................................................................................................... 322

Table of contents


5 K3: Compensation ...................................................................................................................................323

5.1 Introduction.............................................................................................................................. 323

5.2 Temperature compensation..................................................................................................... 3245.2.1 Description of functions ........................................................................................................... 3245.2.2 Commissioning ........................................................................................................................ 3275.2.2.1 Temperature-dependent parameters ....................................................................................... 3275.2.2.2 Temperature compensation type and activation ...................................................................... 3285.2.2.3 Maximum compensation value per IPO clock cycle ................................................................ 3285.2.3 Example ................................................................................................................................... 3295.2.3.1 Commissioning the temperature compensation for the Z axis of a lathe ................................. 329

5.3 Backlash compensation........................................................................................................... 3325.3.1 Description of functions ........................................................................................................... 3325.3.2 Commissioning ........................................................................................................................ 3335.3.2.1 Backlash .................................................................................................................................. 3335.3.2.2 Weighting factor for backlash .................................................................................................. 3335.3.2.3 Applying the backlash compensation step-by-step .................................................................. 333

5.4 Interpolatory compensation ..................................................................................................... 3345.4.1 General information ................................................................................................................. 3345.4.2 Compensation of leadscrew errors and measuring system errors .......................................... 3375.4.2.1 Measuring system error compensation (MSEC) ...................................................................... 3375.4.2.2 Commissioning ........................................................................................................................ 3385.4.2.3 Example ................................................................................................................................... 3415.4.3 Compensation of sag and angularity errors ............................................................................. 3425.4.3.1 Description of functions ........................................................................................................... 3425.4.3.2 Commissioning ........................................................................................................................ 3475.4.3.3 Examples ................................................................................................................................. 3515.4.4 Direction-dependent leadscrew error compensation ............................................................... 3605.4.4.1 Description of functions ........................................................................................................... 3605.4.4.2 Commissioning ........................................................................................................................ 3615.4.4.3 Example ................................................................................................................................... 3655.4.5 Extension of the sag compensation with NCU link - only 840D sl ........................................... 3695.4.6 Special features of interpolatory compensation ....................................................................... 378

5.5 Dynamic feedforward control (following error compensation).................................................. 3805.5.1 General properties ................................................................................................................... 3805.5.2 Speed feedforward control ....................................................................................................... 3825.5.3 Torque feedforward control ...................................................................................................... 3845.5.4 Dynamic response adaptation ................................................................................................. 3865.5.5 Forward feed control for command- and PLC axes ................................................................. 3875.5.6 Secondary conditions .............................................................................................................. 388

5.6 Friction compensation (quadrant error compensation) ............................................................ 3905.6.1 General properties ................................................................................................................... 3905.6.2 Conventional friction compensation ......................................................................................... 3915.6.2.1 Description of functions ........................................................................................................... 3915.6.2.2 commissioning ......................................................................................................................... 3935.6.3 Quadrant error compensation using neural networks - only 840D sl ....................................... 4005.6.3.1 Fundamentals .......................................................................................................................... 4005.6.3.2 Parameterization of neural QEC .............................................................................................. 4035.6.3.3 Learning the neural network .................................................................................................... 4105.6.3.4 Commissioning of neural QEC ................................................................................................ 414


Table of contents

5.6.3.5 Further optimization and intervention options .......................................................................... 4175.6.3.6 Quick commissioning ............................................................................................................... 423

5.7 Circularity test.......................................................................................................................... 426

5.8 Measures for hanging (suspended axes) ................................................................................ 4315.8.1 Electronic counterweight ......................................................................................................... 4315.8.2 Reboot delay ........................................................................................................................... 433

5.9 Data lists.................................................................................................................................. 4355.9.1 Machine data ........................................................................................................................... 4355.9.1.1 General machine data ............................................................................................................. 4355.9.1.2 Channelspecific machine data ............................................................................................... 4355.9.1.3 Axis/Spindle-specific machine data ......................................................................................... 4365.9.2 Setting data ............................................................................................................................. 4375.9.2.1 General setting data ................................................................................................................ 4375.9.2.2 Axis/spindle-specific setting data ............................................................................................. 4375.9.3 Signals ..................................................................................................................................... 4375.9.3.1 Signals from NC ...................................................................................................................... 4375.9.3.2 Signals from mode group ........................................................................................................ 4375.9.3.3 Signals from channel ............................................................................................................... 4375.9.3.4 Signals from axis/spindle ......................................................................................................... 437

6 K5: Mode groups, channels, axis interchange ........................................................................................439

6.1 Brief description....................................................................................................................... 439

6.2 Mode groups - only 840D sl..................................................................................................... 441

6.3 Channels - only 840D sl .......................................................................................................... 4426.3.1 Channel synchronization (program coordination) .................................................................... 4426.3.2 Conditional wait in continuous path mode WAITMC ............................................................... 4456.3.3 Running-in channel-by-channel ............................................................................................... 449

6.4 Axis/spindle replacement......................................................................................................... 4556.4.1 Introduction .............................................................................................................................. 4556.4.2 Example of an axis replacement ............................................................................................. 4586.4.3 Axis replacement options ........................................................................................................ 4596.4.4 Replacement behavior NC program ........................................................................................ 4606.4.5 Transition the axis into the neutral state (RELEASE) .............................................................. 4616.4.6 Transferring an axis or spindle into the part program (GET, GETD) ....................................... 4626.4.7 Automatic axis replacement .................................................................................................... 4636.4.8 Axis replacement via PLC ....................................................................................................... 4656.4.9 Set axis replacement behavior variable. .................................................................................. 4686.4.10 Axis interchange via axis container rotation ............................................................................ 4696.4.11 Axis replacement with and without preprocessing stop ........................................................... 4706.4.12 Axis exclusively controlled from the PLC ................................................................................. 4716.4.13 Axis permanently assigned to the PLC .................................................................................... 4726.4.14 Geometry axis in rotated frame and axis replacement ............................................................ 4736.4.15 Axis replacement from synchronized actions .......................................................................... 4756.4.16 Axis interchange for leading axes (gantry) .............................................................................. 477

6.5 Marginal conditions.................................................................................................................. 478

6.6 Data lists.................................................................................................................................. 4806.6.1 Machine data ........................................................................................................................... 4806.6.1.1 General machine data ............................................................................................................. 480

Table of contents


6.6.1.2 Channel-specific machine data ................................................................................................ 4806.6.1.3 Axis/spindlespecific machine data .......................................................................................... 4826.6.2 Setting data ............................................................................................................................. 4836.6.2.1 Channelspecific setting data ................................................................................................... 4836.6.3 Signals ..................................................................................................................................... 4836.6.3.1 Signals to/from BAG ................................................................................................................ 4836.6.3.2 Signals to/from Channel .......................................................................................................... 483

7 M1: Kinematic transformation .................................................................................................................485

7.1 Brief description....................................................................................................................... 4857.1.1 TRANSMIT (option) ................................................................................................................. 4857.1.2 TRACYL (option) ..................................................................................................................... 4867.1.3 TRAANG (option) ..................................................................................................................... 4877.1.4 Chained transformations .......................................................................................................... 4887.1.5 Activating transformation machine data via parts program/softkey ......................................... 488

7.2 TRANSMIT (option) ................................................................................................................. 4897.2.1 Preconditions for TRANSMIT .................................................................................................. 4907.2.2 Settings specific to TRANSMIT ............................................................................................... 4937.2.3 Activation of TRANSMIT .......................................................................................................... 4977.2.4 Deactivation of the TRANSMIT function .................................................................................. 4977.2.5 Special system reactions with TRANSMIT .............................................................................. 4987.2.6 Machining options for TRANSMIT ........................................................................................... 5027.2.7 Working area limitations .......................................................................................................... 5097.2.8 Overlaid motions with TRANSMIT ........................................................................................... 5107.2.9 Monitoring of rotary axis rotations over 360 ........................................................................... 5107.2.10 Constraints ............................................................................................................................... 511

7.3 TRACYL (option) ..................................................................................................................... 5137.3.1 Preconditions for TRACYL ....................................................................................................... 5167.3.2 Settings specific to TRACYL .................................................................................................... 5207.3.3 Activation of TRACYL .............................................................................................................. 5257.3.4 Deactivation of the TRACYL function ...................................................................................... 5257.3.5 Special system reactions with TRACYL .................................................................................. 5267.3.6 Jog ........................................................................................................................................... 529

7.4 TRAANG (option)..................................................................................................................... 5307.4.1 Preconditions for TRAANG (inclined axis) ............................................................................... 5327.4.2 Settings specific to TRAANG ................................................................................................... 5347.4.3 Activation of TRAANG ............................................................................................................. 5377.4.4 Deactivation of TRAANG ......................................................................................................... 5387.4.5 Special system reactions with TRAANG .................................................................................. 5387.4.6 Inclined axis programming (G05, G07) .................................................................................... 540

7.5 Chained transformations.......................................................................................................... 5427.5.1 Activating chained transformations .......................................................................................... 5457.5.2 Switching off a chained transformation .................................................................................... 5457.5.3 Special characteristics of chained transformations .................................................................. 5467.5.4 Persistent transformation ......................................................................................................... 5467.5.5 Axis positions in the transformation chain ............................................................................... 552

7.6 Cartesian PTP travel................................................................................................................ 5557.6.1 Programming of position .......................................................................................................... 5597.6.2 Overlap areas of axis angles ................................................................................................... 5607.6.3 Examples of ambiguities of position ........................................................................................ 560


Table of contents

7.6.4 Example of ambiguity in rotary axis position ........................................................................... 5627.6.5 PTP/CP switchover in JOG mode ........................................................................................... 562

7.7 Cartesian manual travel (optional)........................................................................................... 563

7.8 Activating transformation machine data via parts program/softkey ......................................... 5717.8.1 Functionality ............................................................................................................................ 5717.8.2 Constraints .............................................................................................................................. 5727.8.3 Control response to power ON, mode change, RESET, block search, REPOS ..................... 5747.8.4 List of machine data affected ................................................................................................... 574

7.9 Constraints .............................................................................................................................. 5787.9.1 Chained transformations ......................................................................................................... 578

7.10 Examples................................................................................................................................. 5797.10.1 TRANSMIT .............................................................................................................................. 5797.10.2 TRACYL .................................................................................................................................. 5817.10.3 TRAANG .................................................................................................................................. 5867.10.4 Chained transformations ......................................................................................................... 5887.10.5 Activating transformation MD via a parts program .................................................................. 5927.10.6 Axis positions in the transformation chain ............................................................................... 593

7.11 Data lists.................................................................................................................................. 5977.11.1 Machine data ........................................................................................................................... 5977.11.1.1 TRANSMIT .............................................................................................................................. 5977.11.1.2 TRACYL .................................................................................................................................. 5987.11.1.3 TRAANG .................................................................................................................................. 6007.11.1.4 Chained transformations ......................................................................................................... 6017.11.1.5 Non transformation-specific machine data .............................................................................. 6017.11.2 Signals ..................................................................................................................................... 6017.11.2.1 Signals from channel ............................................................................................................... 601

8 M5: Measuring ........................................................................................................................................603

8.1 Brief description....................................................................................................................... 603

8.2 Hardware requirements ........................................................................................................... 6048.2.1 Probes that can be used .......................................................................................................... 604

8.3 Channel-specific measuring .................................................................................................... 6068.3.1 Measuring mode ...................................................................................................................... 6068.3.2 Measurement results ............................................................................................................... 607

8.4 Setting zeros, workpiece measuring and tool measuring ........................................................ 6088.4.1 Preset actual value memory and scratching ............................................................................ 6088.4.2 Workpiece measuring .............................................................................................................. 6098.4.2.1 Input values ............................................................................................................................. 6098.4.2.2 Measurement selection ........................................................................................................... 6178.4.2.3 Output values .......................................................................................................................... 6188.4.2.4 Calculation method .................................................................................................................. 6188.4.2.5 Units of measurement and measurement variables for the calculation ................................... 6218.4.2.6 Diagnostics .............................................................................................................................. 6238.4.3 Types of workpiece measurement ........................................................................................... 6238.4.3.1 Measurement of an edge (measurement type 1, 2, 3) ............................................................ 6238.4.3.2 Measurement of an angle (measurement type 4, 5, 6, 7) ........................................................ 6288.4.3.3 Measurement of a hole (measurement type 8) ........................................................................ 6328.4.3.4 Measurement of a shaft (measurement type 9) ....................................................................... 635

Table of contents


8.4.3.5 Measurement of a groove (measurement type 12) .................................................................. 6368.4.3.6 Measurement of a web (measurement type 13) ...................................................................... 6398.4.3.7 Measurement of geo axes and special axes (measurement type 14, 15) ............................... 6408.4.3.8 Measurement of an oblique edge (measurement type 16) ...................................................... 6428.4.3.9 Measurement of an oblique angle in a plane (measurement type 17) ..................................... 6448.4.3.10 Redefine measurement around a WCS reference frame (measurement type 18) .................. 6488.4.3.11 Measurement of a 1-, 2- and 3-dimensional setpoint selection

(measurement type 19, 20, 21) ................................................................................................ 6518.4.3.12 Measurement of an oblique angle (measurement type 24) ..................................................... 6568.4.3.13 Measurement of a rectangle (measurement type 25) .............................................................. 6608.4.3.14 Measurement for saving data management frames (measurement type 26) .......................... 6628.4.3.15 Measurement for restoring backed-up data management frames (measurement type 27) ..... 6638.4.3.16 Measurement for defining an additive rotation for taper turning (measurement type 28) ........ 6648.4.4 Tool measuring ........................................................................................................................ 6658.4.5 Types of workpiece measurement ........................................................................................... 6668.4.5.1 Measurement of tool lengths (measurement type 10) ............................................................. 6668.4.5.2 Measurement of tool diameter (measurement type 11) ........................................................... 6688.4.5.3 Measurement of tool lengths with zoom-in function (measurement type 22) .......................... 6698.4.5.4 Measuring a tool length with stored or current position (measurement type 23) ..................... 6708.4.5.5 Measurement of a tool length of two tools with the following orientation: ................................ 671

8.5 Measurement accuracy and functional testing ........................................................................ 6828.5.1 Measurement accuracy ........................................................................................................... 6828.5.2 Probe functional testing ........................................................................................................... 683

8.6 Simulated measuring............................................................................................................... 6848.6.1 General functionality ................................................................................................................ 6848.6.2 Position-related switch request ................................................................................................ 6848.6.3 External switch request ............................................................................................................ 6868.6.4 System variable ....................................................................................................................... 687

8.7 Channels - only 840D sl........................................................................................................... 6888.7.1 Measuring mode 1 ................................................................................................................... 6888.7.2 Measuring mode 2 ................................................................................................................... 6898.7.3 Continuous measurement ........................................................................................................ 6898.7.3.1 Continous measurement on completion of programmed traversing motion ............................ 6898.7.3.2 Continuous measurements with deletion of distance-to-go ..................................................... 6908.7.3.3 Continuous measurements modally over several blocks ......................................................... 6908.7.4 Functional test and repeat accuracy ........................................................................................ 691

8.8 Data lists .................................................................................................................................. 6938.8.1 Machine data ........................................................................................................................... 6938.8.1.1 General machine data ............................................................................................................. 6938.8.1.2 Channel-specific machine data ................................................................................................ 6938.8.2 System variables ..................................................................................................................... 693

9 N3: Software cams, position switching cycles - only 840D sl ..................................................................695


9.2 Cam signals and cam positions ............................................................................................... 6969.2.1 Generation of cam signals for separate output ........................................................................ 6969.2.2 Generation of cam signals with gated output ........................................................................... 6999.2.3 Cam positions .......................................................................................................................... 7039.2.4 Lead/delay times (dynamic cam) ............................................................................................. 705


Table of contents

9.3 Output of cam signals.............................................................................................................. 7069.3.1 Activating ................................................................................................................................. 7069.3.2 Output of cam signals to PLC .................................................................................................. 7069.3.3 Output of cam signals to NCK I/Os in position control cycle ................................................... 7079.3.4 Timer-controlled cam signal output ......................................................................................... 7089.3.5 Independent, timer-controlled output of cam signals ............................................................... 710

9.4 Position-time cams .................................................................................................................. 711

9.5 Supplementary Conditions ...................................................................................................... 713

9.6 Data lists.................................................................................................................................. 7149.6.1 Machine data ........................................................................................................................... 7149.6.1.1 General machine data ............................................................................................................. 7149.6.2 Setting data ............................................................................................................................. 7149.6.2.1 General setting data ................................................................................................................ 7149.6.3 Signals ..................................................................................................................................... 7159.6.3.1 Signals to axis/spindle ............................................................................................................. 7159.6.3.2 Signals from axis/spindle ......................................................................................................... 715

10 N4: Own channel - only 840D sl .............................................................................................................717


10.2 Stroke control .......................................................................................................................... 71810.2.1 General information ................................................................................................................. 71810.2.2 High-speed signals .................................................................................................................. 71910.2.3 Criteria for stroke initiation ....................................................................................................... 72110.2.4 Axis start after punching .......................................................................................................... 72310.2.5 PLC signals specific to punching and nibbling ........................................................................ 72410.2.6 Punching and nibbling-specific reactions to standard PLC signals ......................................... 72410.2.7 Signal monitoring ..................................................................................................................... 725

10.3 Activation and deactivation...................................................................................................... 72610.3.1 Language commands .............................................................................................................. 72610.3.2 Functional expansions ............................................................................................................. 73110.3.3 Compatibility with earlier systems ........................................................................................... 735

10.4 Automatic path segmentation .................................................................................................. 73710.4.1 General information ................................................................................................................. 73710.4.2 Operating characteristics with path axes ................................................................................. 73910.4.3 Response in connection with single axes ................................................................................ 743

10.5 Rotatable tool .......................................................................................................................... 74810.5.1 General information ................................................................................................................. 74810.5.2 Coupled motion of punch and die ............................................................................................ 74910.5.3 Tangential control .................................................................................................................... 750

10.6 Protection zones...................................................................................................................... 754

10.7 Supplementary conditions ....................................................................................................... 755

10.8 Examples................................................................................................................................. 75610.8.1 Examples of defined start of nibbling operation ....................................................................... 756

10.9 Data lists.................................................................................................................................. 76110.9.1 Machine data ........................................................................................................................... 76110.9.1.1 General machine data ............................................................................................................. 76110.9.1.2 Channelspecific machine data ............................................................................................... 761

Table of contents


10.9.2 Setting data ............................................................................................................................. 76110.9.2.1 Channelspecific setting data ................................................................................................... 76110.9.3 Signals ..................................................................................................................................... 76210.9.3.1 Signals to channel ................................................................................................................... 76210.9.3.2 Signals from channel ............................................................................................................... 76210.9.4 Language commands .............................................................................................................. 762

11 P2: Positioning axes ................................................................................................................................763

11.1 Product brief ............................................................................................................................ 763

11.2 Own channel, positioning axis or concurrent positioning axis ................................................. 76611.2.1 Own channel - only 840D sl ..................................................................................................... 76611.2.2 Positioning axis (posAxis) ........................................................................................................ 76711.2.3 Concurrent positioning axis ..................................................................................................... 770

11.3 Motion behavior and interpolation functions ............................................................................ 77111.3.1 Path interpolator and axis interpolator ..................................................................................... 77111.3.2 Interpolation response of path axis in G0 ................................................................................ 77111.3.3 Autonomous singleaxis operations ......................................................................................... 77311.3.4 Autonomous single-axis functions with NC-controlled ESR .................................................... 779

11.4 Velocity .................................................................................................................................... 781

11.5 Programming ........................................................................................................................... 78211.5.1 General .................................................................................................................................... 78211.5.2 Revolutional feed rate in external programming ...................................................................... 785

11.6 Block change ........................................................................................................................... 78611.6.1 Settable block change time ...................................................................................................... 78811.6.2 End of motion criterion with block search ................................................................................ 793

11.7 Control by the PLC .................................................................................................................. 79411.7.1 Starting concurrent positioning axes from the PLC ................................................................. 79611.7.2 PLC-controlled axes ................................................................................................................ 79611.7.3 Control response of PLC-controlled axes .................................................................

sinumerik 840d sl/828d extended functions sinumerik 840d sl / 828d extended functions function...

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