Siemens SINUMERIK 840D sl Parts list manual

SINUMERIK
SINUMERIK 840D sl / 828D
Special functions
Function Manual
01/2015
6FC5397-2BP40-5BA2
Preface
Fundamental safety
instructions 1
F2: Multi-axis transformations 2
G1: Gantry axes 3
K6: Contour tunnel monitoring 4
K7: Kinematic chain - only
840D sl 5
K8: Geometric machine
modeling - only 840D sl 6
K9: Collision avoidance - only
840D sl 7
M3: Coupled axes 8
R3: Extended stop and retract 9
S9: Setpoint exchange -
840D sl only 10
T3: Tangential control - 840D
sl only 11
T4: Automatic retuning with
AST - only 840D sl 12
TE01: Installation and
activation of loadable
compile cycles 13
TE02: Simulation of Compile
Cycles (only HMI Advanced) 14
TE1: Clearance control -
840D sl only 15
Continued on next page
CNC software 4.7 SP1
Software Version
Controllers
SINUMERIK 828D
SINUMERIK 840D sl / 840DE sl
Valid for

Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5397-2BP40-5BA2
Ⓟ 02/2015 Subject to change
Copyright © Siemens AG 1995 - 2015.
All rights reserved

SINUMERIK 840D sl / 828D
Special functions
Function Manual
Continuation
TE3: Speed/torque coupling,
master-slave 16
TE4: Handling transformation
package - 840D sl only 17
TE6: MCS coupling - 840D sl
only 18
TE7: Continue machining at
the contour (retrace support)
- 840D sl only 19
TE8: Cycle-independent
path-synchronous switching
signal output - 840D sl only 20
TE9: Axis pair collision
protection 21
V2: Preprocessing 22
W5: 3D tool radius
compensation - 840D sl only 23
W6: Path length evaluation -
840D sl only 24
Z3: NC/PLC interface signals 25
Appendix A

Legal information
Warning 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.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, 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 products
Note the following:
WARNING
Siemens 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 complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in
this publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5397-2BP40-5BA2
Ⓟ 02/2015 Subject to change
Copyright © Siemens AG 1995 - 2015.
All rights reserved

Preface
SINUMERIK documentation
The SINUMERIK documentation is organized in the following categories:
● General documentation
● User documentation
● Manufacturer/service documentation
Additional information
You 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
FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support. http://support.automation.siemens.com
Special functions
Function Manual, 01/2015, 6FC5397-2BP40-5BA2 5

SINUMERIK
You can find information on SINUMERIK under the following link:
www.siemens.com/sinumerik
Target group
This publication is intended for:
● Project engineers
● Technologists (from machine manufacturers)
● System startup engineers (Systems/Machines)
● Programmers
Benefits
The function manual describes the functions so that the target group knows them and can
select them. It provides the target group with the information required to implement the
functions.
Standard version
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine tool manufacturer are documented by the machine tool
manufacturer.
Other functions not described in this documentation might be executable in the control. This
does not, however, represent an obligation to supply such functions with a new control or when
servicing.
Further, for the sake of simplicity, this documentation does not contain all detailed information
about all types of the product and cannot cover every conceivable case of installation, operation
or maintenance.
Technical Support
You will find telephone numbers for other countries for technical support in the Internet under
http://www.siemens.com/automation/service&support
Information on the structure and contents
Installation
Structure of this Function Manual:
● Inner title (page 3) with the title of the Function Manual, the SINUMERIK controls as well
as the software and the version for which this version of the Function Manual is applicable
and the overview of the individual functional descriptions.
● Description of the functions in alphabetical order (e.g. A2, A3, B1, etc.)
Preface
Special functions
6Function Manual, 01/2015, 6FC5397-2BP40-5BA2

● Appendix with:
– List of abbreviations
– Documentation overview
● Index of terms
Note
For detailed descriptions of data and alarms see:
● For machine and setting data:
Detailed description of machine data (only electronically on DOConCD or DOConWEB)
● For 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)
● For alarms:
Diagnostics Manual
Notation of system data
The following notation is applicable for system data in this documentation:
Signal/Data Notation Example
NC/PLC interface
signals
... NC/PLC interface signal:
<signal address> (<signal name>)
When the new gear stage 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:
<Type><Number> <Complete Des‐
ignator> (<Meaning>)
Master spindle is the spindle stored in the machine data:
MD20090 $MC_SPIND_DEF_MASTER_SPIND (position of de‐
letion of the master spindle in the channel)
Setting data ... setting data:
<Type><Number> <Complete Des‐
ignator> (<Meaning>)
The logical master spindle is contained in the setting data:
SD42800 $SC_SPIND_ASSIGN_TAB[0] (spindle number con‐
verter)
Note
Signal address
The description of functions include as <signal address> 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.
Preface
Special functions
Function Manual, 01/2015, 6FC5397-2BP40-5BA2 7

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 types
The control provides the following data types that can be used for programming in part
programs:
Type Meaning Value range
INT Signed integers -2.147.483.648 ... +2.147.483.647
REAL Numbers with decimal point ≈ ±5,0*10-324 … ≈ ±1,7*10+308
BOOL Boolean values TRUE (≠0) , FALSE (0)
CHAR ASCII characters and bytes 0 ... 255 or -128 ... 127
STRING Character string, null-terminated Maximum of 400 characters + /0
(no special characters)
AXIS Axis names All axis names available in the control
system
FRAME Geometrical parameters for moving, rotating, scaling, and
mirroring
---
Note
Arrays can only be formed from similar elementary data types. Up to 3-dimensional arrays are possible.
Querying REAL variables
We recommend that querying REAL or DOUBLE variables in NC programs and synchronized
actions is programmed as limit value evaluation.
Example: Querying the actual value of an axis for a specific value
DEF REAL AXPOS = 123.456
IF ($VA_IM[<axis>] - 1ex-6) <= AXPOS <= ($VA_IM[<axis>] + 1ex-6) ; actual position
... == AXPOS
ELSE
... <> AXPOS
ENDIF
Preface
Special functions
8Function Manual, 01/2015, 6FC5397-2BP40-5BA2

Table of contents
Preface.........................................................................................................................................................5
1Fundamental safety instructions.................................................................................................................29
1.1 General safety instructions.....................................................................................................29
1.2 Industrial security...................................................................................................................29
2 F2: Multi-axis transformations....................................................................................................................31
2.1 Brief description.....................................................................................................................31
2.1.1 5-axis Transformation............................................................................................................31
2.1.2 3-axis and 4-axis transformation............................................................................................33
2.1.3 Orientation transformation with a swiveling linear axis..........................................................34
2.1.4 Universal milling head............................................................................................................36
2.1.5 Orientation axes.....................................................................................................................37
2.1.6 Cartesian manual travel.........................................................................................................38
2.1.7 Cartesian PTP travel..............................................................................................................38
2.1.8 Generic 5-axis transformation................................................................................................38
2.1.9 Online tool length offset.........................................................................................................38
2.1.10 Activation via parts/program/softkey......................................................................................39
2.1.11 Orientation compression........................................................................................................39
2.2 5-axis transformation..............................................................................................................39
2.2.1 Kinematic transformation.......................................................................................................39
2.2.2 Machine types for 5-axis transformation................................................................................40
2.2.3 Configuration of a machine for 5-axis transformation............................................................41
2.2.4 Tool orientation......................................................................................................................46
2.2.5 Singular positions and handling.............................................................................................50
2.3 3-axis and 4-axis transformations..........................................................................................53
2.4 Transformation with swiveled linear axis................................................................................54
2.5 Cardan milling head...............................................................................................................60
2.5.1 Fundamentals of cardan milling head....................................................................................60
2.5.2 Parameterization....................................................................................................................62
2.5.3 Traverse of the cardan milling head in JOG mode.................................................................63
2.6 Programming of the 3- to 5-axis transformation.....................................................................64
2.7 Generic 5-axis transformation and variants...........................................................................65
2.7.1 Functionality...........................................................................................................................65
2.7.2 Description of machine kinematics.........................................................................................66
2.7.3 Generic orientation transformation variants...........................................................................67
2.7.4 Parameterization of orientable toolholder data......................................................................69
2.7.5 Extension of the generic transformation to six axes - 840D sl only........................................73
2.7.6 Extension of the generic transformation to seven axes - 840D sl only..................................76
2.7.7 Cartesian manual travel with generic transformation.............................................................80
2.8 Restrictions for kinematics and interpolation..........................................................................82
2.8.1 Singularities of orientation......................................................................................................83
Special functions
Function Manual, 01/2015, 6FC5397-2BP40-5BA2 9

2.9 Orientation..............................................................................................................................85
2.9.1 Basic orientation.....................................................................................................................85
2.9.2 Orientation movements with axis limits..................................................................................87
2.9.3 Orientation compression........................................................................................................88
2.9.4 Smoothing of orientation characteristic..................................................................................92
2.9.5 Orientation relative to the path...............................................................................................94
2.9.6 Programming of orientation polynominals..............................................................................98
2.9.7 System variable for tool orientation......................................................................................101
2.10 Orientation axes...................................................................................................................103
2.10.1 JOG mode............................................................................................................................105
2.10.2 Programming for orientation transformation.........................................................................106
2.10.3 Programmable offset for orientation axes............................................................................108
2.10.4 Orientation transformation and orientable tool holders........................................................109
2.10.5 Modulo display of orientation axes.......................................................................................109
2.11 Orientation vectors...............................................................................................................110
2.11.1 Polynomial interpolation of orientation vectors.....................................................................110
2.11.2 Rotations of orientation vector.............................................................................................114
2.11.3 Extended interpolation of orientation axes...........................................................................118
2.12 Online tool length offset.......................................................................................................122
2.13 Examples.............................................................................................................................126
2.13.1 Example of a 5-axis transformation......................................................................................126
2.13.2 Example of a 3-axis and 4-axis transformation....................................................................129
2.13.2.1 Example of a 3-axis transformation......................................................................................129
2.13.2.2 Example of a 4-axis transformation......................................................................................129
2.13.3 Example of a universal milling head.....................................................................................129
2.13.4 Example for orientation axes................................................................................................131
2.13.5 Examples for orientation vectors..........................................................................................133
2.13.5.1 Example for polynomial interpretation of orientation vectors...............................................133
2.13.5.2 Example of rotations of orientation vector............................................................................134
2.13.6 Examples for generic axis transformations..........................................................................134
2.13.6.1 Example of a generic 6-axis transformation.........................................................................136
2.13.6.2 Example of a generic 7-axis transformation.........................................................................137
2.13.6.3 Example for the modification of rotary axis motion..............................................................138
2.13.7 Example: Compression of an orientation.............................................................................138
2.14 Data lists..............................................................................................................................139
2.14.1 Machine data........................................................................................................................139
2.14.1.1 General machine data..........................................................................................................139
2.14.1.2 Channelspecific machine data.............................................................................................139
2.14.2 Setting data..........................................................................................................................143
2.14.2.1 General setting data.............................................................................................................143
2.14.2.2 Channelspecific setting data................................................................................................143
2.14.3 Signals.................................................................................................................................144
2.14.3.1 Signals from channel............................................................................................................144
3 G1: Gantry axes.......................................................................................................................................145
3.1 Brief description...................................................................................................................145
3.2 "Gantry axes" function..........................................................................................................146
3.2.1 Definition of a gantry grouping.............................................................................................146
3.2.2 Monitoring the synchronism difference................................................................................147
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3.2.3 Extended monitoring of the synchronism difference............................................................148
3.2.4 Referencing and synchronization of gantry axes.................................................................148
3.2.5 Control dynamics.................................................................................................................149
3.2.6 Opening the gantry grouping................................................................................................149
3.3 Referencing and synchronization of gantry axes.................................................................150
3.3.1 Introduction..........................................................................................................................150
3.3.2 Automatic synchronization...................................................................................................156
3.3.3 Points to note.......................................................................................................................157
3.4 Start-up of gantry axes.........................................................................................................160
3.5 Parameter assignment: Response to faults.........................................................................164
3.6 PLC interface signals for gantry axes..................................................................................165
3.7 Miscellaneous points regarding gantry axes........................................................................167
3.8 Examples.............................................................................................................................169
3.8.1 Creating a gantry grouping...................................................................................................169
3.8.2 Setting of NCK PLC interface...............................................................................................171
3.8.3 Commencing start-up...........................................................................................................171
3.8.4 Setting warning and trip limits..............................................................................................173
3.9 Data lists..............................................................................................................................174
3.9.1 Machine data........................................................................................................................174
3.9.1.1 Axis/spindlespecific machine data.......................................................................................174
3.9.2 Signals.................................................................................................................................175
3.9.2.1 Signals from mode group.....................................................................................................175
3.9.2.2 Signals from channel............................................................................................................175
3.9.2.3 Signals to axis/spindle..........................................................................................................176
3.9.2.4 Signals from axis/spindle.....................................................................................................176
4 K6: Contour tunnel monitoring..................................................................................................................177
4.1 Brief description...................................................................................................................177
4.1.1 Contour tunnel monitoring - 840D sl only.............................................................................177
4.1.2 Programmable contour accuracy.........................................................................................178
4.2 Contour tunnel monitoring - 840D sl only.............................................................................179
4.3 Programmable contour accuracy.........................................................................................180
4.4 Constraints...........................................................................................................................183
4.5 Data lists..............................................................................................................................184
4.5.1 Machine data........................................................................................................................184
4.5.1.1 Channelspecific machine data.............................................................................................184
4.5.1.2 Axis/spindlespecific machine data.......................................................................................184
4.5.2 Setting data..........................................................................................................................184
4.5.2.1 Channelspecific setting data................................................................................................184
5 K7: Kinematic chain - only 840D sl...........................................................................................................185
5.1 Function description.............................................................................................................185
5.1.1 Characteristics.....................................................................................................................185
5.2 Commissioning.....................................................................................................................188
5.2.1 General................................................................................................................................188
5.2.1.1 Overview..............................................................................................................................188
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Function Manual, 01/2015, 6FC5397-2BP40-5BA2 11

5.2.1.2 Structure of the system variables.........................................................................................188
5.2.2 Machine data........................................................................................................................190
5.2.2.1 Maximum number of elements.............................................................................................190
5.2.2.2 Root element........................................................................................................................190
5.2.3 System variables..................................................................................................................190
5.2.3.1 Overview..............................................................................................................................190
5.2.3.2 $NK_NAME..........................................................................................................................191
5.2.3.3 $NK_NEXT...........................................................................................................................192
5.2.3.4 $NK_PARALLEL..................................................................................................................193
5.2.3.5 $NK_TYPE...........................................................................................................................194
5.2.3.6 $NK_OFF_DIR, $NK_AXIS, $NK_A_OFF (parameterization for $NK_TYPE = AXIS_LIN)....195
5.2.3.7 $NK_OFF_DIR, $NK_AXIS, $NK_A_OFF (parameterization for $NK_TYPE =
AXIS_ROT)..........................................................................................................................198
5.2.3.8 $NK_OFF_DIR, $NK_AXIS, $NK_A_OFF (parameterization for $NK_TYPE =
ROT_CONST)......................................................................................................................201
5.2.3.9 $NK_OFF_DIR, $NK_AXIS, $NK_A_OFF (parameterization for $NK_TYPE = OFFSET)....203
5.3 Programming........................................................................................................................205
5.3.1 Deletion of components (DELOBJ)......................................................................................205
5.3.2 Index determination by means of names (NAMETOINT).....................................................207
5.4 Data lists..............................................................................................................................208
5.4.1 Machine data........................................................................................................................208
5.4.1.1 NC-specific machine data....................................................................................................208
5.4.2 System variables..................................................................................................................208
6 K8: Geometric machine modeling - only 840D sl.....................................................................................211
6.1 Function description.............................................................................................................211
6.1.1 Features...............................................................................................................................211
6.1.2 Automatic tool protection areas............................................................................................214
6.2 Commissioning.....................................................................................................................217
6.2.1 General................................................................................................................................217
6.2.1.1 Overview..............................................................................................................................217
6.2.1.2 Structure of the system variables.........................................................................................217
6.2.1.3 Color chart............................................................................................................................219
6.2.2 Machine data........................................................................................................................220
6.2.2.1 Maximum number of protection areas..................................................................................220
6.2.2.2 Maximum number of protection area elements for machine protection areas.....................220
6.2.2.3 Maximum number of protection area elements for automatic tool protection areas............220
6.2.2.4 Maximum number of NC/PLC interface signals for the preactivation of protection areas....220
6.2.2.5 Maximum number of triangles for machine protection areas...............................................220
6.2.2.6 Maximum number of triangles for automatic tool protection areas......................................220
6.2.2.7 Creation mode for automatic tool protection areas..............................................................221
6.2.3 System variables: Protection areas......................................................................................221
6.2.3.1 Overview..............................................................................................................................221
6.2.3.2 $NP_PROT_NAME..............................................................................................................222
6.2.3.3 $NP_CHAIN_ELEM..............................................................................................................223
6.2.3.4 $NP_PROT_TYPE...............................................................................................................224
6.2.3.5 $NP_1ST_PROT..................................................................................................................225
6.2.3.6 $NP_PROT_COLOR............................................................................................................226
6.2.3.7 $NP_PROT_D_LEVEL.........................................................................................................227
6.2.3.8 $NP_BIT_NO........................................................................................................................228
6.2.3.9 $NP_INIT_STAT...................................................................................................................230
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6.2.3.10 $NP_INDEX.........................................................................................................................231
6.2.4 System variables: Protection area elements for machine protection areas.........................232
6.2.4.1 Overview..............................................................................................................................232
6.2.4.2 $NP_NAME..........................................................................................................................233
6.2.4.3 $NP_NEXT...........................................................................................................................234
6.2.4.4 $NP_NEXTP........................................................................................................................235
6.2.4.5 $NP_COLOR........................................................................................................................237
6.2.4.6 $NP_D_LEVEL.....................................................................................................................238
6.2.4.7 $NP_USAGE........................................................................................................................239
6.2.4.8 $NP_TYPE...........................................................................................................................240
6.2.4.9 $NP_FILENAME..................................................................................................................243
6.2.4.10 $NP_PARA...........................................................................................................................245
6.2.4.11 $NP_OFF.............................................................................................................................246
6.2.4.12 $NP_DIR..............................................................................................................................247
6.2.4.13 $NP_ANG.............................................................................................................................249
6.2.5 System variables: Protection area elements for automatic tool protection areas................250
6.2.6 Boundary conditions.............................................................................................................251
6.3 Data lists..............................................................................................................................252
6.3.1 Machine data........................................................................................................................252
6.3.1.1 NC-specific machine data....................................................................................................252
6.3.2 System variables..................................................................................................................252
7 K9: Collision avoidance - only 840D sl.....................................................................................................255
7.1 Function description.............................................................................................................255
7.1.1 Characteristics.....................................................................................................................255
7.1.2 Reaction of the control to a risk of collision..........................................................................257
7.1.3 State diagram: Protection area............................................................................................260
7.1.4 Tools....................................................................................................................................261
7.1.5 Boundary conditions.............................................................................................................263
7.2 Commissioning.....................................................................................................................265
7.2.1 General................................................................................................................................265
7.2.1.1 Overview..............................................................................................................................265
7.2.1.2 Structure of the system variables.........................................................................................265
7.2.2 Machine data........................................................................................................................266
7.2.2.1 Enable..................................................................................................................................266
7.2.2.2 Collision tolerance................................................................................................................267
7.2.2.3 Safety clearance..................................................................................................................267
7.2.2.4 Maximum memory space.....................................................................................................268
7.2.2.5 Maximum number of collision pairs......................................................................................268
7.2.2.6 Protection levels for collision avoidance On/Off...................................................................269
7.2.3 System variables..................................................................................................................269
7.2.3.1 Overview..............................................................................................................................269
7.2.3.2 $NP_COLL_PAIR.................................................................................................................270
7.2.3.3 $NP_SAFETY_DIST............................................................................................................271
7.2.4 Extend system variables......................................................................................................273
7.2.4.1 Overview..............................................................................................................................273
7.2.4.2 State data.............................................................................................................................273
7.2.4.3 Memory requirement............................................................................................................274
7.2.4.4 Braking distance estimations...............................................................................................274
7.3 Programming........................................................................................................................275
7.3.1 Check for collision pair (COLLPAIR)....................................................................................275
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7.3.2 Request recalculation of the machine model of the collision avoidance (PROTA)..............277
7.3.3 Setting the protection area state (PROTS)..........................................................................278
7.3.4 Determining the clearance of two protection areas (PROTD)..............................................278
7.4 Example...............................................................................................................................280
7.4.1 Specifications.......................................................................................................................280
7.4.2 Part program of the machine model.....................................................................................284
7.5 Data lists..............................................................................................................................292
7.5.1 Machine data........................................................................................................................292
7.5.1.1 NC-specific machine data....................................................................................................292
7.5.2 System variables..................................................................................................................292
7.5.3 Signals.................................................................................................................................293
7.5.3.1 Signals to NC.......................................................................................................................293
7.5.3.2 Signals from NC...................................................................................................................293
7.5.3.3 Signals from channel............................................................................................................294
7.5.3.4 Signals from axis..................................................................................................................294
8 M3: Coupled axes.....................................................................................................................................295
8.1 Coupled motion....................................................................................................................295
8.1.1 Brief description...................................................................................................................295
8.1.1.1 Function...............................................................................................................................295
8.1.1.2 Preconditions.......................................................................................................................295
8.1.2 General functionality............................................................................................................296
8.1.3 Programming........................................................................................................................300
8.1.3.1 Definition and switch on of a coupled axis grouping (TRAILON).........................................300
8.1.3.2 Switch off (TRAILOF)...........................................................................................................300
8.1.4 Effectiveness of PLC interface signals.................................................................................301
8.1.5 Status of coupling.................................................................................................................302
8.1.6 Dynamics limit......................................................................................................................303
8.1.7 Supplementary conditions....................................................................................................304
8.1.8 Examples.............................................................................................................................304
8.2 Curve tables - 840D sl only..................................................................................................305
8.2.1 Product brief.........................................................................................................................305
8.2.1.1 Function...............................................................................................................................305
8.2.1.2 Preconditions.......................................................................................................................306
8.2.2 General functionality............................................................................................................306
8.2.3 Memory organization............................................................................................................307
8.2.4 Commissioning.....................................................................................................................309
8.2.4.1 Memory configuration...........................................................................................................309
8.2.4.2 Tool radius compensation....................................................................................................310
8.2.4.3 Specification of memory type...............................................................................................310
8.2.5 Programming........................................................................................................................311
8.2.6 Access to table positions and table segments.....................................................................317
8.2.7 Activation/deactivation.........................................................................................................321
8.2.8 Modulo-leading axis special case........................................................................................322
8.2.9 Behavior in AUTOMATIC, MDA and JOG modes................................................................322
8.2.10 Effectiveness of PLC interface signals.................................................................................323
8.2.11 Diagnosing and optimizing utilization of resources..............................................................323
8.2.12 Supplementary conditions....................................................................................................327
8.2.13 Examples.............................................................................................................................327
8.3 Master value coupling - 840D sl only...................................................................................329
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8.3.1 Product brief.........................................................................................................................329
8.3.1.1 Function...............................................................................................................................329
8.3.1.2 Preconditions.......................................................................................................................329
8.3.2 General functionality............................................................................................................329
8.3.3 Programming........................................................................................................................333
8.3.4 Behavior in AUTOMATIC, MDA and JOG modes................................................................337
8.3.5 Effectiveness of PLC interface signals.................................................................................339
8.3.6 Special characteristics of the axis master value coupling function......................................339
8.3.7 Supplementary conditions....................................................................................................340
8.4 Electronic gear (EG).............................................................................................................340
8.4.1 Product brief.........................................................................................................................340
8.4.1.1 Function...............................................................................................................................340
8.4.1.2 Preconditions.......................................................................................................................341
8.4.2 Definition of an EG axis group.............................................................................................349
8.4.3 Activating an EG axis group.................................................................................................350
8.4.4 Deactivating an EG axis group.............................................................................................355
8.4.5 Deleting an EG axis group...................................................................................................355
8.4.6 Interaction between rotation feedrate (G95) and electronic gearbox...................................356
8.4.7 Response to POWER ON, RESET, operating mode change, block search........................356
8.4.8 System variables for electronic gearbox..............................................................................357
8.4.9 Examples.............................................................................................................................358
8.4.9.1 Example using linear couplings............................................................................................358
8.4.9.2 Extended example with non-linear components..................................................................362
8.5 Generic coupling..................................................................................................................368
8.5.1 Brief description...................................................................................................................368
8.5.1.1 Function...............................................................................................................................368
8.5.1.2 Requirements.......................................................................................................................368
8.5.2 Fundamentals......................................................................................................................372
8.5.2.1 Coupling module..................................................................................................................372
8.5.2.2 Keywords and coupling characteristics................................................................................373
8.5.2.3 System variables..................................................................................................................376
8.5.3 Creating/deleting coupling modules.....................................................................................376
8.5.3.1 Creating a coupling module (CPDEF)..................................................................................376
8.5.3.2 Delete coupling module (CPDEL)........................................................................................377
8.5.3.3 Defining leading axes (CPLDEF or CPDEF+CPLA)............................................................378
8.5.3.4 Delete leading axes (CPLDEL or CPDEL+CPLA)................................................................379
8.5.4 Switching coupling on/off.....................................................................................................381
8.5.4.1 Switching on a coupling module (CPON).............................................................................381
8.5.4.2 Switch off coupling module (CPOF).....................................................................................381
8.5.4.3 Switching on leading axes of a coupling module (CPLON)..................................................382
8.5.4.4 Switching off leading axes of a coupling module (CPLOF)..................................................383
8.5.4.5 Implicit creation and deletion of coupling modules...............................................................384
8.5.5 Programming coupling characteristics.................................................................................384
8.5.5.1 Coupling rule (CPLNUM, CPLDEN, CPLCTID)...................................................................384
8.5.5.2 Coupling relationship (CPLSETVAL)...................................................................................386
8.5.5.3 Co-ordinate reference (CPFRS):..........................................................................................387
8.5.5.4 Block change behavior (CPBC)...........................................................................................388
8.5.5.5 Synchronized position of the following axis when switching on (CPFPOS+CPON).............390
8.5.5.6 Synchronized position of the leading axis when switching on (CPLPOS)............................391
8.5.5.7 Synchronization mode (CPFMSON)....................................................................................392
8.5.5.8 Behavior of the following axis at switch-on (CPFMON).......................................................394
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8.5.5.9 Behavior of the following axis at switch-off (CPFMOF)........................................................395
8.5.5.10 Position of the following axis when switching off (CPFPOS+CPOF)...................................396
8.5.5.11 Condition at RESET (CPMRESET)......................................................................................396
8.5.5.12 Condition at parts program start (CPMSTART)...................................................................398
8.5.5.13 Status during part program start in search run via program test (CPMPRT).......................399
8.5.5.14 Offset / scaling (CPLINTR, CPLINSC, CPLOUTTR, CPLOUTSC)......................................400
8.5.5.15 Synchronism monitoring stage 1 (CPSYNCOP, CPSYNFIP, CPSYNCOV, CPSYNFIV) ....403
8.5.5.16 Synchronous operation monitoring stage 2 (CPSYNCOP2, CPSYNFIP2)..........................407
8.5.5.17 Reaction to stop signals and commands (CPMBRAKE)......................................................411
8.5.5.18 Response to certain NC/PLC interface signals (CPMVDI) ..................................................412
8.5.5.19 Alarm suppression (CPMALARM)........................................................................................416
8.5.6 Coupling cascading..............................................................................................................417
8.5.7 Compatibility.........................................................................................................................418
8.5.7.1 Adaptive cycles....................................................................................................................418
8.5.7.2 Coupling types (CPSETTYPE).............................................................................................419
8.5.7.3 Projected coupling (CPRES)................................................................................................424
8.5.8 Cross-channel coupling, axis replacement..........................................................................425
8.5.9 Behavior with rotary axes.....................................................................................................425
8.5.10 Behavior during POWER ON, .............................................................................................427
8.5.11 CP SW limit monitoring........................................................................................................428
8.5.11.1 Function...............................................................................................................................428
8.5.11.2 Parameterization..................................................................................................................430
8.5.11.3 Programming........................................................................................................................431
8.5.11.4 Boundary conditions.............................................................................................................431
8.5.11.5 Examples.............................................................................................................................432
8.5.12 Disturbance characteristic....................................................................................................433
8.5.12.1 Rapid stop............................................................................................................................433
8.5.13 Tracking the deviation from synchronism.............................................................................434
8.5.13.1 Fundamentals......................................................................................................................434
8.5.13.2 Measuring the deviation from synchronism..........................................................................435
8.5.13.3 Entering the deviation from synchronism directly.................................................................438
8.5.13.4 Synchronism correction........................................................................................................438
8.5.13.5 Diagnostics for synchronism correction...............................................................................439
8.5.13.6 Resetting synchronism correction........................................................................................440
8.5.13.7 Limitations and constraints...................................................................................................441
8.5.14 Examples.............................................................................................................................443
8.5.14.1 Programming examples.......................................................................................................443
8.5.14.2 Adapt adaptive cycle............................................................................................................444
8.6 Dynamic response of following axis.....................................................................................445
8.6.1 Parameterized dynamic limits..............................................................................................445
8.6.2 Programmed dynamic limits.................................................................................................446
8.6.2.1 Programming (VELOLIMA, ACCLIMA)................................................................................446
8.6.2.2 Examples.............................................................................................................................448
8.6.2.3 System variables..................................................................................................................449
8.7 General supplementary conditions.......................................................................................449
8.8 Data lists..............................................................................................................................450
8.8.1 Machine data........................................................................................................................450
8.8.1.1 NC-specific machine data....................................................................................................450
8.8.1.2 Channelspecific machine data.............................................................................................450
8.8.1.3 Axis/spindlespecific machine data.......................................................................................451
8.8.2 Setting data..........................................................................................................................451
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8.8.2.1 Axis/spindle-specific setting data.........................................................................................451
8.8.3 System variables..................................................................................................................451
8.8.4 Signals.................................................................................................................................454
8.8.4.1 Signals to axis/spindle..........................................................................................................454
8.8.4.2 Signals from axis/spindle.....................................................................................................455
9 R3: Extended stop and retract..................................................................................................................457
9.1 Brief description...................................................................................................................457
9.2 Control-managed ESR - 840D sl only..................................................................................457
9.2.1 Extended stop and retract (ESR).........................................................................................457
9.2.2 Drive-independent reactions................................................................................................459
9.2.3 Power failure detection and bridging....................................................................................459
9.2.4 NC-controlled extended stop................................................................................................460
9.2.5 Retract..................................................................................................................................462
9.2.6 Trigger sources....................................................................................................................467
9.2.7 Logic gating functions: Source and reaction linking.............................................................468
9.2.8 Activation..............................................................................................................................468
9.2.9 Configuring aids for ESR......................................................................................................469
9.2.10 Control system response.....................................................................................................472
9.2.10.1 Axis behavior depending on the enable signals...................................................................472
9.2.10.2 POWER OFF/POWER ON..................................................................................................474
9.2.10.3 Operating mode change, NC Stop, reset.............................................................................474
9.2.10.4 Part program start, NC start.................................................................................................475
9.2.10.5 Alarm behavior.....................................................................................................................475
9.2.10.6 Block search, REPOS..........................................................................................................475
9.3 ESR executed autonomously in the drive............................................................................476
9.3.1 Fundamentals......................................................................................................................476
9.3.2 Configuring stopping in the drive..........................................................................................477
9.3.3 Configuring retraction in the drive........................................................................................478
9.3.4 Configuring generator operation in the drive........................................................................479
9.3.5 ESR is enabled via system variable.....................................................................................481
9.3.6 Triggering ESR via system variable.....................................................................................481
9.3.7 Feedback of the ESR status................................................................................................481
9.3.8 Acknowledge ESR reactions................................................................................................482
9.3.9 Configuring ESR in the part program...................................................................................483
9.3.9.1 Stopping (ESRS)..................................................................................................................484
9.3.9.2 Retraction (ESRR)...............................................................................................................484
9.3.9.3 Boundary conditions.............................................................................................................486
9.3.10 ESR and Safety Integrated (840D sl)...................................................................................487
9.3.11 ESR and Safety Integrated (828D)......................................................................................488
9.4 Boundary conditions.............................................................................................................489
9.5 Examples.............................................................................................................................490
9.5.1 NC-controlled reactions........................................................................................................490
9.5.2 Retraction while thread cutting.............................................................................................492
9.5.3 Rapid lift using ASUB and fast input....................................................................................492
9.5.4 Rapid lift, absolute and incremental.....................................................................................493
9.5.5 Lift fast with linear relation of axes.......................................................................................493
9.6 Data lists..............................................................................................................................494
9.6.1 Machine data........................................................................................................................494
9.6.1.1 Channelspecific machine data.............................................................................................494
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9.6.1.2 Axis/spindlespecific machine data.......................................................................................494
9.6.2 System variables..................................................................................................................494
9.6.3 Signals.................................................................................................................................495
9.6.3.1 Signals to channel................................................................................................................495
9.6.3.2 Signals to axis/spindle..........................................................................................................495
9.6.3.3 Signals from axis/spindle.....................................................................................................495
10 S9: Setpoint exchange - 840D sl only......................................................................................................497
10.1 Brief description...................................................................................................................497
10.2 Startup..................................................................................................................................497
10.3 Interface signals...................................................................................................................500
10.4 Interrupts..............................................................................................................................503
10.5 Position control loop.............................................................................................................503
10.6 Reference points..................................................................................................................503
10.7 Supplementary conditions....................................................................................................503
10.8 Data lists..............................................................................................................................504
10.8.1 Machine data........................................................................................................................504
10.8.1.1 Axis/spindlespecific machine data.......................................................................................504
11 T3: Tangential control - 840D sl only........................................................................................................505
11.1 Brief description...................................................................................................................505
11.2 Characteristics of tangential follow-up control......................................................................506
11.3 Using tangential follow-up control........................................................................................508
11.3.1 Assignment between leading axes and following axis.........................................................509
11.3.2 Activation of follow-up control..............................................................................................509
11.3.3 Switching on corner response..............................................................................................510
11.3.4 Termination of follow-up control...........................................................................................511
11.3.5 Switching off intermediate block generation.........................................................................511
11.3.6 Canceling the definition of a follow-up axis assignment.......................................................511
11.4 Limit angle............................................................................................................................513
11.5 Supplementary conditions....................................................................................................514
11.6 Examples.............................................................................................................................515
11.7 Data lists..............................................................................................................................516
11.7.1 Machine data........................................................................................................................516
11.7.1.1 Axis/spindlespecific machine data.......................................................................................516
11.7.2 System variables..................................................................................................................516
12 T4: Automatic retuning with AST - only 840D sl.......................................................................................517
12.1 Function...............................................................................................................................517
12.2 Commissioning.....................................................................................................................518
12.3 Programming........................................................................................................................518
12.3.1 CYCLE751 - Open/execute/close optimization session.......................................................518
12.3.2 CYCLE752 - Add axis to an optimization session................................................................519
12.3.3 CYCLE753 - Select optimization mode................................................................................521
12.3.4 CYCLE754 - Add/remove data set.......................................................................................522
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12.3.5 CYCLE755 - Backup/restore data........................................................................................523
12.3.6 CYCLE756 - Activate optimization results...........................................................................524
12.3.7 CYCLE757 - Save optimization data....................................................................................525
12.3.8 CYCLE758 - Change a parameter value.............................................................................527
12.3.9 CYCLE759 - Read parameter value....................................................................................527
12.3.10 List of the parameters for the automatic servo optimization.................................................529
12.3.11 Manufacturer-defined identifier for cycle calls and parameters............................................532
12.4 Supplementary conditions....................................................................................................536
12.5 Examples.............................................................................................................................536
12.5.1 Example 1: Measuring an axis with AST default settings....................................................536
12.5.2 Example 2: Reoptimize the speed controller of an axis.......................................................537
12.5.3 Example 3: Reoptimize the speed controller and the position controller of an axis.............539
12.5.4 Example 4: Reoptimization of the path interpolation............................................................542
12.5.5 Example 5: Reoptimize the speed control loop to eliminate known periodic disturbance
frequencies...........................................................................................................................546
13 TE01: Installation and activation of loadable compile cycles....................................................................549
13.1 Loading compile cycles........................................................................................................550
13.1.1 Loading a compile cycle with SINUMERIK Operate............................................................550
13.1.2 Loading a compile cycle with HMI Advanced.......................................................................551
13.1.3 Loading a compile cycle from an external computer with WinSCP3....................................552
13.2 Interface version compatibility..............................................................................................552
13.3 Software version of a compile cycle.....................................................................................554
13.4 Activating the technological functions in the NCK................................................................554
13.5 Function-specific startup......................................................................................................555
13.6 Creating alarm texts.............................................................................................................555
13.6.1 Creating alarm texts with SINUMERIK Operate...................................................................555
13.6.2 Creating alarm texts with HMI Advanced.............................................................................556
13.7 Upgrading a compile cycle...................................................................................................557
13.8 Deleting a compile cycle......................................................................................................558
13.9 Data lists..............................................................................................................................559
13.9.1 Machine data........................................................................................................................559
13.9.1.1 NC-specific machine data....................................................................................................559
14 TE02: Simulation of Compile Cycles (only HMI Advanced)......................................................................561
14.1 Brief description...................................................................................................................561
14.1.1 Function...............................................................................................................................561
14.2 OEM transformations...........................................................................................................561
15 TE1: Clearance control - 840D sl only......................................................................................................563
15.1 Brief description...................................................................................................................563
15.1.1 General................................................................................................................................563
15.1.2 Function description.............................................................................................................564
15.2 Clearance control.................................................................................................................565
15.2.1 Control dynamics.................................................................................................................565
15.2.2 Velocity feedforward control.................................................................................................567
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15.2.3 Control loop structure...........................................................................................................568
15.2.4 Compensation vector...........................................................................................................569
15.3 Technological features of clearance control.........................................................................572
15.4 Sensor collision monitoring..................................................................................................573
15.5 Startup..................................................................................................................................574
15.5.1 Activating the technological function....................................................................................574
15.5.2 Configuring the memory.......................................................................................................574
15.5.3 Parameter settings for input signals (840D sl).....................................................................574
15.5.4 Parameters of the programmable compensation vector......................................................575
15.5.5 Parameter settings for clearance control.............................................................................577
15.5.6 Starting up clearance control...............................................................................................578
15.6 Programming........................................................................................................................580
15.6.1 Activating and deactivating clearance control (CLC)...........................................................580
15.6.2 Closed-loop control gain (CLC_GAIN).................................................................................585
15.6.3 Limiting the control range (CLC_LIM)..................................................................................587
15.6.4 Direction-dependent traversing motion disable....................................................................589
15.6.5 Voltage offset, can be set on a block-specific basis (CLC_VOFF).......................................591
15.6.6 Voltage offset definable by synchronized action..................................................................591
15.6.7 Selection of the active sensor characteristic (CLC_SEL).....................................................592
15.7 Function-specific display data..............................................................................................593
15.7.1 Channel-specific GUD variables..........................................................................................594
15.7.2 OPI variable.........................................................................................................................596
15.8 Function-specific alarm texts................................................................................................597
15.9 Supplementary conditions....................................................................................................597
15.9.1 I/O modules..........................................................................................................................597
15.9.1.1 External smoothing filters.....................................................................................................598
15.9.2 Function-specific supplementary conditions........................................................................598
15.10 Data lists..............................................................................................................................601
15.10.1 Machine data........................................................................................................................601
15.10.1.1 NC-specific machine data....................................................................................................601
15.10.1.2 Channelspecific machine data.............................................................................................601
15.10.1.3 Axis/spindlespecific machine data.......................................................................................602
15.10.2 Drive parameters (SINAMICS S120)...................................................................................602
15.10.3 Signals.................................................................................................................................603
15.10.3.1 Signals to channel................................................................................................................603
15.10.3.2 Signals from channel............................................................................................................603
16 TE3: Speed/torque coupling, master-slave..............................................................................................605
16.1 Brief description...................................................................................................................605
16.2 Coupling diagram.................................................................................................................606
16.3 Configuring a coupling.........................................................................................................607
16.4 Torque compensatory controller..........................................................................................609
16.5 Tension torque.....................................................................................................................611
16.6 Closing/opening a coupling..................................................................................................615
16.7 Response on activation/deactivation....................................................................................617
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20 Function Manual, 01/2015, 6FC5397-2BP40-5BA2