Siemens Sinumerik 840d sl Parts list manual



SINUMERIK

SINUMERIK 840D sl

Special Functions

Function Manual

Validfor

Control

SINUMERIK840Dsl/840DEsl

Software Version

CNCsoftware 4.4

09/2011

6FC5397-2BP40-2BA0

Preface

F2: Multi-axis transformations 1

G1: Gantry axes 2

G3: Cycle times 3

K6: Contour tunnel monitoring 4

M3: Coupled axes 5

R3: Extended stop and retract 6

S9: Setpoint switchover 7

T3: Tangential control 8

TE01: Installation and activation

of loadable compile cycles 9

TE02: Simulation of compile

cycles 10

TE1: Clearance control 11

TE3: Speed/torque coupling,

master-slave 12

TE4: Transformation package

handling 13

TE6: MCS coupling 14

TE7: Continue machining -

retrace support 15

TE8: Cycle-independent path-

synchronous switching signal output 16

TE9: Axis pair collision

protection 17

V2: Preprocessing 18

W5: 3D tool radius

compensation 19

W6: Path length evaluation 20

Z3: NC/PLC interface signals 21

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.

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 for the specific task, in particular its warning notices and

safety instructions. Qualified personnel are those who, based on their training and experience, are capable of

identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens products

Note the following:

Trademarks

All names identified by ® are registered trademarks of the SiemensAG. The remaining trademarks in this

publication may be trademarks whose use by third parties for their own purposes could violate the rights of the

owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software

described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the

information in this publication is reviewed regularly and any necessary corrections are included in subsequent

editions.

DANGER

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

WARNING

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

CAUTION

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

CAUTION

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

NOTICE

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

account.

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 adhered to. The information in the relevant documentation must be observed.

Siemens AG

Industry Sector

Postfach 48 48

90026 NÜRNBERG

GERMANY

order number:6FC5397-2BP40-2BA0

Ⓟ 02.2011

Technical data subject to change

Special Functions

Function Manual 09/2011, 6FC5397-2BP40-2BA0 3

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:

docu.motioncontrol@siemens.com

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

Preface

Special Functions

4Function Manual, 09/2011, 6FC5397-2BP40-2BA0

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 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

Function Manual, 09/2011, 6FC5397-2BP40-2BA0 5

• Appendix with:

- List of abbreviations

- Overview

• Index of terms

Notation of system data

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

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.)

Note

For detailed descriptions of data and alarm see:

• machine and setting data:

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

• NC/PLC interface signals:

Function Manual Basic Functions; NC/PLC Interface Signals (Z1)

Function Manual Basic Functions; NC/PLC Interface Signals (Z2)

Function Manual Special Functions; NC/PLC Interface Signals (Z3)

•alarms:

Diagnostics Manual

Signal/Data Notation Example

NC/PLC interface

signals

... NC/PLC interface signal:

<signal address> (<signal name>)

When the new gear step is engaged, the following NC/PLC

interface signals are set by the PLC program:

DB31, ... DBX16.0-2 (actual gear stage A to C)

DB31, ... DBX16.3 (gear is changed)

Machine data ... machine data:

<Type><Number> <Complete

Designator> (<Meaning>)

Master spindle is the spindle stored in the machine data:

MD20090 $MC_SPIND_DEF_MASTER_SPIND (Position of

deletion of the master spindle in the channel).

Setting Data ... Setting data:

<Type><Number> <Complete

Designator> (<Meaning>)

The logical master spindle is contained in the setting data:

SD42800 $SC_SPIND_ASSIGN_TAB[0] (Spindle number

converter)

Preface

Special Functions

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

Data types

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

Type Meaning Range of values

INT Signed integers -2147483648 ... +2147483647

REAL Figures with decimal point acc. to IEEE ±(2,2*10-308 … 1,8*10+308)

BOOL Truth values TRUE (1) and FALSE (0) 1, 0

CHAR ASCII characters Corresponding to code 0 to 255

STRING Character string, number of characters in [...] Maximum of 200 characters (no special

characters)

AXIS Axis names only All axis identifiers in the channel

FRAME Geometrical parameters for moving, rotating, scaling, and

mirroring

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

Special Functions

Function Manual 09/2011, 6FC5397-2BP40-2BA0 7

Table of contents

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

1 F2: Multi-axis transformations ...................................................................................................................23

1.1 Brief description......................................................................................................................... 23

1.1.1 5-axis Transformation ................................................................................................................ 23

1.1.2 3-axis and 4-axis transformation ............................................................................................... 25

1.1.3 Orientation transformation with a swivelling linear axis. ............................................................ 26

1.1.4 Universal milling head ............................................................................................................... 28

1.1.5 Orientation axes ........................................................................................................................ 29

1.1.6 Cartesian manual travel ............................................................................................................. 30

1.1.7 Cartesian PTP travel ................................................................................................................. 30

1.1.8 Generic 5-axis transformation ................................................................................................... 30

1.1.9 Online tool length offset ............................................................................................................. 31

1.1.10 Activation via parts/program/softkey .......................................................................................... 31

1.1.11 Orientation compression ............................................................................................................ 31

1.2 5-axis transformation ................................................................................................................. 32

1.2.1 Kinematic transformation ........................................................................................................... 32

1.2.2 Machine types for 5-axis transformation .................................................................................... 32

1.2.3 Configuration of a machine for 5-axis transformation ................................................................ 34

1.2.4 Tool orientation .......................................................................................................................... 38

1.2.5 Singular positions and handling ................................................................................................. 43

1.3 3-axis and 4-axis transformations.............................................................................................. 46

1.4 Transformation with swivelled linear axis .................................................................................. 48

1.5 Universal milling head ............................................................................................................... 54

1.5.1 Fundamentals of universal milling head .................................................................................... 54

1.5.2 Parameterization ....................................................................................................................... 56

1.5.3 Traverse of universal milling head in JOG mode ....................................................................... 58

1.6 Activation and application of 3-axis to 5-axis transformation..................................................... 59

1.7 Generic 5-axis transformation and variants............................................................................... 61

1.7.1 Functionality .............................................................................................................................. 61

1.7.2 Description of machine kinematics ............................................................................................ 62

1.7.3 Generic orientation transformation variants ............................................................................... 63

1.7.4 Parameterization of orientable tool holder data ......................................................................... 65

1.7.5 Extension of the generic transformation to 6 axes .................................................................... 69

1.7.6 Extension of the generic transformation to 7 axes .................................................................... 72

1.7.7 Cartesian manual travel with generic transformation ................................................................ 77

1.8 Restrictions for kinematics and interpolation ............................................................................. 80

1.8.1 Singularities of orientation ......................................................................................................... 80

1.9 Orientation ................................................................................................................................. 83

1.9.1 Basic orientation ........................................................................................................................ 83

1.9.2 Orientation movements with axis limits ..................................................................................... 85

1.9.3 Orientation compression ............................................................................................................ 86

1.9.4 Smoothing of orientation characteristic ..................................................................................... 90

Table of contents

Special Functions

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

1.9.5 Orientation relative to the path ................................................................................................... 92

1.9.6 Programming of orientation polynominals ................................................................................. 96

1.9.7 Tool orientation with 3-/4-/5-axis transformations ...................................................................... 99

1.9.8 orientation vectors with 6-axis transformation ...........................................................................99

1.10 Orientation axes....................................................................................................................... 101

1.10.1 JOG mode ............................................................................................................................... 102

1.10.2 Programming for orientation transformation ............................................................................ 103

1.10.3 Programmable offset for orientation axes ................................................................................106

1.10.4 Orientation transformation and orientable tool holders ............................................................ 107

1.10.5 Modulo display of orientation axes .......................................................................................... 107

1.11 Orientation vectors................................................................................................................... 109

1.11.1 Polynomial interpolation of orientation vectors ........................................................................ 109

1.11.2 Rotations of orientation vector ................................................................................................. 113

1.11.3 Extended interpolation of orientation axes ............................................................................... 117

1.12 Online tool length offset........................................................................................................... 122

1.13 Examples................................................................................................................................. 126

1.13.1 Example of a 5-axis transformation ......................................................................................... 126

1.13.2 Example of a 3-axis and 4-axis transformation ........................................................................ 128

1.13.2.1 Example of a 3-axis transformation ......................................................................................... 128

1.13.2.2 Example of a 4-axis transformation ......................................................................................... 129

1.13.3 Example of a universal milling head ........................................................................................ 129

1.13.4 Example for orientation axes ................................................................................................... 130

1.13.5 Examples for orientation vectors ............................................................................................. 132

1.13.5.1 Example for polynomial interpretation of orientation vectors ................................................... 132

1.13.5.2 Example of rotations of orientation vector ............................................................................... 133

1.13.6 Examples for generic axis transformations .............................................................................. 134

1.13.6.1 Example of a generic 6-axis transformation ............................................................................135

1.13.6.2 Example of a generic 7-axis transformation ............................................................................136

1.13.6.3 Example for the modification of rotary axis motion .................................................................. 137

1.13.7 Example: Compression of an orientation ................................................................................. 137

1.14 Data lists.................................................................................................................................. 139

1.14.1 Machine data ........................................................................................................................... 139

1.14.1.1 General machine data ............................................................................................................. 139

1.14.1.2 Channelspecific machine data ................................................................................................ 139

1.14.2 Setting data ............................................................................................................................. 143

1.14.2.1 General setting data ................................................................................................................ 143

1.14.2.2 Channelspecific setting data ................................................................................................... 143

1.14.3 Signals ..................................................................................................................................... 143

1.14.3.1 Signals from channel ............................................................................................................... 143

2 G1: Gantry axes ......................................................................................................................................145

2.1 Brief description....................................................................................................................... 145

2.2 "Gantry axes" function ............................................................................................................. 146

2.3 Referencing and synchronization of gantry axes..................................................................... 151

2.3.1 Introduction .............................................................................................................................. 151

2.3.2 Automatic synchronization ....................................................................................................... 157

2.3.3 Points to note ........................................................................................................................... 158

2.4 Start-up of gantry axes ............................................................................................................ 161

Special Functions

Function Manual, 09/2011, 6FC5397-2BP40-2BA0 9

Table of contents

2.5 PLC interface signals for gantry axes...................................................................................... 167

2.6 Miscellaneous points regarding gantry axes ........................................................................... 169

2.7 Examples................................................................................................................................. 172

2.7.1 Creating a gantry grouping ...................................................................................................... 172

2.7.2 Setting of NCK PLC interface .................................................................................................. 173

2.7.3 Commencing start-up .............................................................................................................. 174

2.7.4 Setting warning and trip limits .................................................................................................. 176

2.8 Data lists.................................................................................................................................. 179

2.8.1 Machine data ........................................................................................................................... 179

2.8.1.1 Axis/spindlespecific machine data .......................................................................................... 179

2.8.2 Signals ..................................................................................................................................... 180

2.8.2.1 Signals from mode group ........................................................................................................ 180

2.8.2.2 Signals from channel ............................................................................................................... 180

2.8.2.3 Signals to axis/spindle ............................................................................................................. 180

2.8.2.4 Signals from axis/spindle ......................................................................................................... 180

3 G3: Cycle times .......................................................................................................................................181

3.1 Brief description....................................................................................................................... 181

3.2 Startup ..................................................................................................................................... 182

3.3 SINUMERIK 840D ................................................................................................................... 183

3.4 SINUMERIK 840Di with PROFIBUS DP ................................................................................. 185

3.4.1 Description of a DP cycle ........................................................................................................ 185

3.4.2 Clock cycles and position-control cycle offset ......................................................................... 187

3.5 Data lists.................................................................................................................................. 191

3.5.1 Machine data ........................................................................................................................... 191

3.5.1.1 General machine data ............................................................................................................. 191

3.5.1.2 Axis/spindlespecific machine data .......................................................................................... 191

4 K6: Contour tunnel monitoring ................................................................................................................193

4.1 Brief description....................................................................................................................... 193

4.1.1 Contour tunnel monitoring ....................................................................................................... 193

4.1.2 Programmable contour accuracy ............................................................................................. 194

4.2 Contour tunnel monitoring ....................................................................................................... 195

4.3 Programmable contour accuracy............................................................................................. 197

4.4 Constraints .............................................................................................................................. 199

4.5 Examples................................................................................................................................. 200

4.5.1 Programmable contour accuracy ............................................................................................. 200

4.6 Data lists.................................................................................................................................. 201

4.6.1 Machine data ........................................................................................................................... 201

4.6.1.1 Channelspecific machine data ............................................................................................... 201

4.6.1.2 Axis/spindlespecific machine data .......................................................................................... 201

4.6.2 Setting data ............................................................................................................................. 201

4.6.2.1 Channelspecific setting data .................................................................................................. 201

5 M3: Coupled axes ...................................................................................................................................203

5.1 Coupled motion ....................................................................................................................... 203

Table of contents

Special Functions

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

5.1.1 Product brief ............................................................................................................................ 203

5.1.1.1 Function ................................................................................................................................... 203

5.1.1.2 Preconditions ........................................................................................................................... 203

5.1.2 General functionality ................................................................................................................ 204

5.1.3 Programming ........................................................................................................................... 208

5.1.3.1 Definition and switch on of a coupled axis grouping (TRAILON) ............................................. 208

5.1.3.2 Switch off (TRAILOF) ............................................................................................................... 209

5.1.4 Effectiveness of PLC interface signals .................................................................................... 209

5.1.5 Status of coupling .................................................................................................................... 211

5.1.6 Dynamics limit .......................................................................................................................... 211

5.2 Curve tables............................................................................................................................. 212

5.2.1 Product brief ............................................................................................................................ 212

5.2.1.1 Function ................................................................................................................................... 212

5.2.1.2 Preconditions ........................................................................................................................... 212

5.2.2 General functionality ................................................................................................................ 213

5.2.3 Memory organization ............................................................................................................... 214

5.2.4 Commissioning ........................................................................................................................ 216

5.2.4.1 Memory configuration .............................................................................................................. 216

5.2.4.2 Tool radius compensation ........................................................................................................ 216

5.2.4.3 Specification of memory type ................................................................................................... 217

5.2.5 Programming ........................................................................................................................... 217

5.2.6 Access to table positions and table segments ......................................................................... 224

5.2.7 Activation/deactivation ............................................................................................................. 228

5.2.8 Modulo-leading axis special case ............................................................................................ 229

5.2.9 Behavior in AUTOMATIC, MDA and JOG modes ................................................................... 230

5.2.10 Effectiveness of PLC interface signals .................................................................................... 230

5.2.11 Diagnosing and optimizing utilization of resources .................................................................. 231

5.3 Master value coupling.............................................................................................................. 235

5.3.1 Product brief ............................................................................................................................ 235

5.3.1.1 Function ................................................................................................................................... 235

5.3.1.2 Preconditions ........................................................................................................................... 235

5.3.2 General functionality ................................................................................................................ 235

5.3.3 Programming ........................................................................................................................... 239

5.3.4 Behavior in AUTOMATIC, MDA and JOG modes ................................................................... 243

5.3.5 Effectiveness of PLC interface signals .................................................................................... 245

5.3.6 Special characteristics of the axis master value coupling function .......................................... 245

5.4 Electronic gearbox (EG) .......................................................................................................... 247

5.4.1 Product brief ............................................................................................................................ 247

5.4.1.1 Function ................................................................................................................................... 247

5.4.1.2 Preconditions ........................................................................................................................... 248

5.4.2 Performance Overview of EG (Summary) ............................................................................... 255

5.4.3 Definition of an EG axis group ................................................................................................. 258

5.4.4 Activating an EG axis group .................................................................................................... 259

5.4.5 Deactivating an EG axis group ................................................................................................ 264

5.4.6 Deleting an EG axis group ....................................................................................................... 264

5.4.7 Interaction between rotation feedrate (G95) and electronic gearbox ....................................... 265

5.4.8 Response to POWER ON, RESET, operating mode change, block search ............................ 265

5.4.9 System variables for electronic gearbox ..................................................................................266

5.5 Generic coupling...................................................................................................................... 268

5.5.1 Product brief ............................................................................................................................ 268

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