Beckhoff TF5200 User manual

Functional description | EN
TF5200 | TwinCAT 3 CNC
Online tool compensation
6/8/2021 | Version: 1.02

Notes on the documentation
TF5200 | TwinCAT 3 CNC
Online tool compensation
3Version: 1.02
Notes on the documentation
This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the documentation and the following notes and explanations are followed when installing
and commissioning the components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.
The responsible staff must ensure that the application or use of the products described satisfy all the
requirements for safety, including all the relevant laws, regulations, guidelines and standards.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
No claims for the modification of products that have already been supplied may be made on the basis of the
data, diagrams and descriptions in this documentation.
Trademarks
Beckhoff®, TwinCAT®, TwinCAT/BSD®, TC/BSD®, EtherCAT®, EtherCAT G®, EtherCAT G10®, EtherCAT P®,
Safety over EtherCAT®, TwinSAFE®, XFC®, XTS® and XPlanar® are registered trademarks of and licensed by
Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties for their own
purposes could violate the rights of the owners.
Patent Pending
The EtherCAT technology is patent protected, in particular by the following applications and patents:
EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702
with corresponding applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilisation of this document as well as the communication of its contents to
others without express authorisation are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.

General and safety instructions
TF5200 | TwinCAT 3 CNC
Online tool compensation
4 Version: 1.02
General and safety instructions
Icons used and their meanings
This documentation uses the following icons next to the safety instruction and the associated text. Please
read the (safety) instructions carefully and comply with them at all times.
Icons in explanatory text
1. Indicates an action.
ðIndicates an action statement.
DANGER
Acute danger to life!
If you fail to comply with the safety instruction next to this icon, there is immediate danger to human life and
health.
CAUTION
Personal injury and damage to machines!
If you fail to comply with the safety instruction next to this icon, it may result in personal injury or damage to
machines.
NOTE
Restriction or error
This icon describes restrictions or warns of errors.
Tips and other notes
This icon indicates information to assist in general understanding or to provide additional informa-
tion.
General example
Example that clarifies the text.
NC programming example
Programming example (complete NC program or program sequence) of the described function or NC com-
mand.
Specific version information
Optional or restricted function. The availability of this function depends on the configuration and the
scope of the version.

Table of contents
TF5200 | TwinCAT 3 CNC
Online tool compensation
5Version: 1.02
Table of contents
Notes on the documentation ....................................................................................................................3
General and safety instructions...............................................................................................................4
1 Overview.....................................................................................................................................................8
2 Description.................................................................................................................................................9
2.1 Programming .....................................................................................................................................9
2.2 Wear compensation of tool radius ...................................................................................................11
2.3 Wear compensation of tool length ...................................................................................................15
2.3.1 Inclined grinding disc ....................................................................................................... 18
2.4 Wear compensation in tool direction ...............................................................................................19
2.5 Wear compensation in direction of surface normal .........................................................................22
2.6 Special settings in tool data.............................................................................................................25
2.7 Connection to PLC ..........................................................................................................................26
2.7.1 Channel-specific connection............................................................................................ 26
2.7.2 Axis-specific connection .................................................................................................. 28
2.8 Special V.G. variables for OTC .......................................................................................................30
2.9 Connecting to external tool management........................................................................................31
3 Parameter .................................................................................................................................................32
3.1 Overview..........................................................................................................................................32
3.2 Description.......................................................................................................................................32
4 Support and Service................................................................................................................................34
Index .........................................................................................................................................................35

Table of contents
TF5200 | TwinCAT 3 CNC
Online tool compensation
6 Version: 1.02

List of figures
TF5200 | TwinCAT 3 CNC
Online tool compensation
7Version: 1.02
List of figures
Figure 1 Grinding a contour ....................................................................................................................... 9
Figure 2 Wear compensation of tool radius ............................................................................................... 11
Figure 3 Contour of the NC program wr_quad_disc.nc ............................................................................. 13
Figure 4 Description of RADIUS function................................................................................................... 15
Figure 5 Wear compensation of tool length ............................................................................................... 16
Figure 6 Description of LENGTH function.................................................................................................. 17
Figure 7 Inclined grinding disc ................................................................................................................... 18
Figure 8 Wear compensation in tool direction............................................................................................ 19
Figure 9 Grinding disc setting B=0............................................................................................................. 20
Figure 10Grinding disc setting B=90........................................................................................................... 20
Figure 11Description of TOOL_DIR function .............................................................................................. 21
Figure 12Wear in surface normal direction ................................................................................................. 22
Figure 13Description of SURF_NORM_DIR function ................................................................................. 24

Overview
TF5200 | TwinCAT 3 CNC
Online tool compensation
8 Version: 1.02
1 Overview
Task
With certain processes such as grinding, the length or the radius of the tool must be continuously corrected
to compensate for wear.
Wear compensation depends on the path travelled.
Properties
Wear compensation can only be enabled with tool type 2 (grinding tool). If a different tool type is used, error
message P-ERR-21391 is output.
Wear compensation can be used for 4 processing types and 3 different modes.
Parametrisation
Wear compensation is activated and deactivated from the NC program. The wear constant can be
parameterised both from the NC program and using preset parameters in the tool list P-TOOL-00030.
Further parameters in this context are described in the section Parameter [}32].
Programming
The following NC command is provided to program online tool compensation in the NC program.
Parametrisation can be programmed in advance or in combination with #OTC ON .
For further details on the above command, see the section Programming [}9].
Links to other documents
For the sake of clarity, links to other documents and parameters are abbreviated, e.g. [PROG] for the
Programming Manual or P-AXIS-00001 for an axis parameter.
For technical reasons, these links only function in the Online Help (HTML5, CHM) but not in pdf files since
pdfs do not support cross-linking.

Description
TF5200 | TwinCAT 3 CNC
Online tool compensation
9Version: 1.02
2 Description
Task
With certain processes such as grinding, the length or the radius of the tool must be continuously corrected
to compensate for wear.
Wear compensation depends on the path covered. In addition, compensation can be influenced by the PLC.
Wear compensation is activated and deactivated from the NC program. The wear constant can be
parameterised both from the NC program and using preset parameters in the tool list P-TOOL-00030.
Rapid traversing blocks have no wear.
It is assumed that the entire width of the lateral surface of the grinding disc is in contact.
Workpiece
Tool
holder
Figure1: Grinding a contour
Tool type
Wear compensation can only be enabled with tool type 2 (grinding tool). If a different tool type is used, error
message P-ERR-21391 is output.
Processing types
Online wear compensation can be used for 4 processing types and 3 different modes.
1. Radius compensation (only in combination with active TRC) for processing contours in the plane (2.5
D)
2. Length compensation for processing surfaces (surface grinding, 2.5 D)
3. Compensation in tool direction for any orientation (5-axis)
4. Compensation in direction of surface normal (5-axis)
Modes
1. Continuous (dependent on motion path traversed)
2. Discrete (discrete wear compensation via PLC)
3. Automatic, combination of discrete and continuous
Discrete additive wear values which are assigned by the PLC are adjusted over several cycles.
2.1 Programming
The following NC command is provided to program online tool compensation in the NC program.
Parametrisation can be programmed in advance or in combination with #OTC ON:
#OTC ON | OFF [ [ RADIUS | LENGTH | TOOL_DIR | SURF_NORM_DIRDISC | CONT | AUTO

Description
TF5200 | TwinCAT 3 CNC
Online tool compensation
10 Version: 1.02
WEAR_CONST<expr> | WEAR_CONST_TOOL ACC_WEIGHT<expr> ] ]

RADIUS Radius compensation processing type
LENGTH Length compensation processing type (default)
TOOL_DIR Compensation in tool direction (5-axis) processing type
SURF_NORM_DIR Compensation in direction of surface normal (5-axis) processing type
DISC Discrete mode: input only via PLC, external presetting
CONT Continuous mode: Presetting values only by calculating the motion path
traversed and the wear constant, internal calculation
AUTO Automatic mode: Adding the external presetting and internal calculation
(default)
WEAR_CONST<expr> User-specific definition of wear constant; it acts modally, this means that
with #OTC ON the programmed wear constant is used and not the default
wear constant defined in the current tool data. Defining the valid wear
constant is optional.
Unit: 0,1 µm/m
WEAR_CONST_TOOL Switch to the default wear constant defined in the current tool data; it acts
modally, this means that with #OTC ON the default wear constant (default)
defined in the current tool data is used and not the user-specific definition of
the wear constant.
ACC_WEIGHT<expr> Acceleration weighting in percent [1;100], default: 100%
When OTC is deselected with #OTC OFF, the amount of wear (discrete and/or continuous) is in-
cluded in the calculation for the current tool.

Description
TF5200 | TwinCAT 3 CNC
Online tool compensation
11Version: 1.02
2.2 Wear compensation of tool radius
Grinding a contour
Use tool radius wear compensation (radius compensation) by preference to grind a contour at the same time
as tool radius compensation.
Grinding disc wear in the direction of the disc radius can be compensated continuously or discretely.
In the radius compensation processing type, wear is only considered for active tool radius compensation
(TRC).
The figure below shows the tool radius wear:
Workpiece
R1
R2
R1 > R2
Figure2: Wear compensation of tool radius
The start-up movement in relation to the equidistant path after selecting TRC (G41/G42) is con-
sidered without wear.
Motion after deselecting TRC (G40) is also without wear.

Description
TF5200 | TwinCAT 3 CNC
Online tool compensation
12 Version: 1.02
General #OTC programming example
N10 F10000
N20 D1(Data set selection for grinding wheel)
N30 G0 X0 Y0 Z0
N40 #OTC[RADIUS, AUTO] (OTC operation mode + define mode)
N50 #OTC ON(Select OTC)
N60 G41 G01 X50(Select TRC, wear-free movement)
N70 X1000
N80 G40 X50(Deselect TRC with path motion to reduce TRC)
N90 #OTC OFF(Deselect OCP)
N100 G00 X50
N199 M30

Description
TF5200 | TwinCAT 3 CNC
Online tool compensation
13Version: 1.02
OTC with discrete compensation
%wr_quad_disc.nc
N20 G17G90
N22 D1 G25(Linear transition block)
N40 G1 X0Y0Z0 F600
N50 #OTC ON[RADIUS DISC]
N55 G42
N60 G1 X2
N70 G1 X102
N80 G26 Y100(Circular transition block)
N90 X2
N95 Y0
N100 G40 G1 X0
N110 #OTC OFF
N99999 M30
Legend:
Green: Path contour with active TRC without OTC offset
Black: Path contour with negative value for OTC radius offset
Red:Path contour with positive value for OTC radius offset
Figure3: Contour of the NC program wr_quad_disc.nc

Description
TF5200 | TwinCAT 3 CNC
Online tool compensation
14 Version: 1.02
Explanation to the figure above (the discrete OTC offset applied is 2 mm)
1. G25 is active. The contour is not continuous. The predefined OTC offset is applied to another axis
over several cycles.
2. The TRC inserts a circular transition because of G26. But the OTC offset is so large that the increase
in offset is unable to keep up with the continuous change in the contour.
3. The OTC offset lags behind considerably.
4. Increase the OTC offset
5. Decrease the positive OTC offset and increase the negative OTC offset
The tool radius is influenced by the PLC.
Requirements: After the ControlUnit OTCRadiusOffset is active, the OTC radius offset can then be
programmed for the build in use accordingly. This value is then added to each cycle perpendicular to the
programmed contour.
For CNC Version >= V2.11.2800:
gpCh[channel_idx]^.bahn_mc_control.otc_radius_offset
where channel_idx = [0..HLI_SYS_CH_MAXIDX]
For CNC Version < V2.11.2800:
pMC[channel_idx]^.addr^.MCControlBahn_Data.MCControlSGN32Unit_OTCRadiusOffset
where channel_idx = [1.. HLI_SYS_CHNMAX]
PLC access for CNC Build >= V2.11.2800
(* enable online tool compensation control unit *)
gpCh[0]^.bahn_mc_control.otc_radius_offset.enable_w := TRUE;
(* write radius offset in the first channel *)
gpCh[0]^.bahn_mc_control.otc_radius_offset.command_w := OTC_Offset;
PLC access for CNC build < V2.11.2800
(* enable online tool compensation control unit *)
pMC[1]^.addr^.MCControlBahn_Data.MCControlSGN32Unit_OTCRadiusOffset.X_Enable := TRUE;
(* write radius offset in the first channel *)
pMC[1]^.addr^.MCControlBahn_Data.MCControlSGN32Unit_OTCRadiusOffset.D_Command := OTC_Offset;
A continuous contour path is recommended because changing the orientation of the predefined off-
set is not applied to the axis all at once but is distributed over several cycles.
On selection, the commands G41/G42 and #OTC ON can be swapped. On deselection, the se-
quence G40 before #OTC OFF must be maintained. The TRC modes G138/G139 make a path mo-
tion between the two commands absolutely necessary.
If error 90050 is output, the path motion does not exist when deselected with G138/G139.
The functionality of the RADIUS type is shown by the example of the G17 plane:

Description
TF5200 | TwinCAT 3 CNC
Online tool compensation
15Version: 1.02
Figure4: Description of RADIUS function
2.3 Wear compensation of tool length
Grinding a surface
When the tool length is compensated (length compensation), wear is compensated in the direction of the 3rd
main axis. This can take place both continuously and discretely. This procedure is used in particular for
processing surfaces (surface grinding).

Description
TF5200 | TwinCAT 3 CNC
Online tool compensation
16 Version: 1.02
Work piece
Z
X
Y
L1
L2
L1 > L2
Figure5: Wear compensation of tool length
Tool length wear
...
N30 D1(Select data set for grinding disc)
N40 G00 X0 Y0 Z0
N50 #OTC ON [LENGTH] (Select OTC)
N60 G1 X1000 F10000
N70 #OTC OFF(Deselect OTC)
...

Description
TF5200 | TwinCAT 3 CNC
Online tool compensation
17Version: 1.02
Distributing continuous wear on 2 main axes depends on the inclination of the grinding disc as described in
Section Inclined grinding disc [}18].
The LENGTH operation mode is shown in the figure below:
IPO
Decoder
TRC
BAVO
Planning
Online
OTC
PLC
Covered
distance and tilt
angle of disc
G17/G18/G19
CONT
DISC
#OTC [ LENGTH CONT/ DISC/AUTO]
X Y Z
+
+
+
+Axis offset
+
+
+
W
Figure6: Description of LENGTH function

Description
TF5200 | TwinCAT 3 CNC
Online tool compensation
18 Version: 1.02
2.3.1 Inclined grinding disc
Inclined grinding
The incline of the grinding disc is only entered in the tool list (P-TOOL-00138) to grind inclined surfaces.
Here the complete lateral surface of the grinding disc is also in contact.
The figure below shows the orientation of the tilt angle using the example of the G17 plane:
X/Y plane with G17
ori_vec
Z
X
a
a
ori_vec
ori_vec
a negative
a positive
a is 0
Turning point of disc
Figure7: Inclined grinding disc

Description
TF5200 | TwinCAT 3 CNC
Online tool compensation
19Version: 1.02
Tool orientation is determined by the disc tilt angle. This tool orientation can then be used to apply the
resulting wear proportionately to the main axes.
In the figure above, wear is included in the calculation of the X and Z axes.
2.4 Wear compensation in tool direction
Grinding a surface
This compensation type is used to compensate for wear in the tool direction. This can take place both
continuously and discretely.
Grinding disc
Workpiece tool wear
X
Z
Figure8: Wear compensation in tool direction
OTC grinding with kinematic type 4
...
N30 D1(Select record for grinding disc)
N40 G00 X0 Y0 Z300 B0
N50 #KIN ID[4]
N50 #TRAFO ON
N60 G00 B45
N70 G01 X100 Z50 F1000
N80 #OTC ON [TOOL_DIR, DISC](Select OTC)
N90 $FOR P1=0, 20, 1
N100 G91 G01 X10 Z-10 F2000
N110X-10 Z10
N120 $ENDFOR
N120 #OTC OFF(deselect OTC)
N130 #TRAFO OFF
...

Description
TF5200 | TwinCAT 3 CNC
Online tool compensation
20 Version: 1.02
Programming kinematic parameters
B-
+
TCP
B=0°
Tool 1
HD3
HD1 Grinding wheel
Figure9: Grinding disc setting B=0
-
+
TCP
BB=90°
Tool 2
HD1
HD10=-90°
Grinding wheel
Figure10: Grinding disc setting B=90