Siemens SINUMERIK 840D sl Parts list manual

SINUMERIK
SINUMERIK 840D sl / 828D
Extended Functions
Function Manual
CNC Software 4.7 SP2
Software Version
SINUMERIK 828D
SINUMERIK 840D sl / 840DE sl
Control
Valid for
10/2015
6FC5397-1BP40-5BA3
Preface
Fundamental safety
instructions 1
A4: Digital and analog NC I/O
for SINUMERIK 840D sl 2
B3: Distributed systems -
840D sl only 3
H1: Manual and handwheel
travel 4
K3: Compensations 5
K5: Channel synchronization,
axis interchange 6
M1: Kinematic transformation 7
M5: Measurement 8
N3: Software cams, position
switching cycles - only 840D
sl 9
N4: Own channel - only 840D
sl 10
P2: Positioning axes 11
P5: Oscillation 12
R2: Rotary axes 13
S3: Synchronous spindle 14
S7: Memory configuration 15
T1: Indexing axes 16
W3: Tool change 17
W4: Grinding-specific tool
offset and tool monitoring 18
Z2: NC/PLC interface signals 19
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: 6FC5397-1BP40-5BA3
Ⓟ 11/2015 Subject to change
Copyright © Siemens AG 1994 - 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
Extended Functions
Function Manual, 10/2015, 6FC5397-1BP40-5BA3 3

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
Structure
This Function Manual is structured as follows:
● 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
Extended Functions
4Function Manual, 10/2015, 6FC5397-1BP40-5BA3

● 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, Extension 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
Extended Functions
Function Manual, 10/2015, 6FC5397-1BP40-5BA3 5

Quantity structure
Explanations concerning the NC/PLC interface are based on the absolute maximum number
of the following 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
---
Arrays
Arrays can only be formed from similar elementary data types. Up to 3-dimensional arrays are
possible.
Example: DEF INT ARRAY[2, 3, 4]
Number systems
The following number systems are available:
● Decimal: DEF INT number = 1234 or DEF REAL number = 1234.56
● Hexadecimal: DEF INT number = 'H123ABC'
● Binary: DEF INT number = 'B10001010010'
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
Preface
Extended Functions
6Function Manual, 10/2015, 6FC5397-1BP40-5BA3

ELSE
... <> AXPOS
ENDIF
Preface
Extended Functions
Function Manual, 10/2015, 6FC5397-1BP40-5BA3 7

Preface
Extended Functions
8Function Manual, 10/2015, 6FC5397-1BP40-5BA3

Table of contents
Preface.........................................................................................................................................................3
1Fundamental safety instructions.................................................................................................................27
1.1 General safety instructions.....................................................................................................27
1.2 Industrial security...................................................................................................................27
2 A4: Digital and analog NC I/O for SINUMERIK 840D sl.............................................................................29
2.1 Introduction............................................................................................................................29
2.2 Indirect I/O access via PLC....................................................................................................30
2.2.1 Brief description.....................................................................................................................30
2.2.2 Parameterization....................................................................................................................31
2.2.3 System variables....................................................................................................................34
2.2.4 Comparator inputs..................................................................................................................34
2.2.5 Digital NC I/Os.......................................................................................................................34
2.2.5.1 Digital inputs...........................................................................................................................34
2.2.5.2 Digital outputs........................................................................................................................36
2.2.5.3 Connection and logic operations of fast digital I/Os...............................................................39
2.2.6 Analog NC I/Os......................................................................................................................41
2.2.6.1 Analog inputs.........................................................................................................................41
2.2.6.2 Analog outputs.......................................................................................................................44
2.2.6.3 Representation of the analog I/O values................................................................................48
2.2.7 Comparator inputs..................................................................................................................49
2.3 Direct I/O access via PLC......................................................................................................54
2.3.1 Parameterization....................................................................................................................54
2.3.2 Reading/writing: System variables.........................................................................................56
2.3.3 Supplementary conditions......................................................................................................57
2.3.4 Examples...............................................................................................................................57
2.3.4.1 Writing to PLC-I/Os................................................................................................................57
2.3.4.2 Reading from PLC-I/Os..........................................................................................................58
2.4 Direct I/O access without PLC...............................................................................................59
2.4.1 Brief description.....................................................................................................................59
2.4.2 Parameter assignment...........................................................................................................61
2.4.3 Reading/writing......................................................................................................................62
2.4.3.1 System variables....................................................................................................................62
2.4.3.2 Bindings (compile cycles).......................................................................................................64
2.4.4 Supplementary conditions......................................................................................................66
2.4.5 Examples...............................................................................................................................66
2.4.5.1 Writing to the NC I/O..............................................................................................................66
2.4.5.2 Reading from the NC I/O........................................................................................................68
2.4.5.3 Writing of the NC I/O with status query..................................................................................69
2.5 Data lists................................................................................................................................71
2.5.1 Machine data..........................................................................................................................71
2.5.1.1 General machine data............................................................................................................71
2.5.1.2 Channelspecific machine data...............................................................................................72
Extended Functions
Function Manual, 10/2015, 6FC5397-1BP40-5BA3 9

2.5.2 Setting data............................................................................................................................72
2.5.2.1 General setting data...............................................................................................................72
2.5.3 System variable......................................................................................................................72
2.5.4 Signals...................................................................................................................................73
2.5.4.1 Signals to NC.........................................................................................................................73
2.5.4.2 Signals from NC.....................................................................................................................73
3 B3: Distributed systems - 840D sl only.......................................................................................................75
3.1 Brief description.....................................................................................................................75
3.1.1 Several operator panels on several NCUs (T:M:N)................................................................75
3.1.2 NCU link.................................................................................................................................78
3.1.2.1 Link communication...............................................................................................................78
3.1.2.2 Link variables.........................................................................................................................79
3.1.2.3 Link axes................................................................................................................................79
3.1.2.4 Lead link axes........................................................................................................................80
3.1.2.5 Dependencies........................................................................................................................80
3.1.2.6 Application example: Rotary indexing machine.....................................................................81
3.2 NCU link.................................................................................................................................83
3.2.1 Link communication...............................................................................................................83
3.2.1.1 General information................................................................................................................83
3.2.1.2 Link module............................................................................................................................87
3.2.1.3 Parameter assignment: NC system cycles............................................................................87
3.2.1.4 Parameter assignment: Link communication.........................................................................89
3.2.1.5 Configuration..........................................................................................................................90
3.2.1.6 Wiring the NCUs....................................................................................................................90
3.2.1.7 Activation................................................................................................................................90
3.2.2 Link variables.........................................................................................................................91
3.2.2.1 Properties of the link variables memory.................................................................................92
3.2.2.2 Properties of the link variables...............................................................................................92
3.2.2.3 Write elements.......................................................................................................................93
3.2.2.4 Dynamic response during write..............................................................................................93
3.2.2.5 System variable......................................................................................................................94
3.2.2.6 Synchronization of a write request.........................................................................................95
3.2.2.7 Example: Structure of the link variables memory...................................................................95
3.2.2.8 Example: Read drive data......................................................................................................97
3.2.3 Link axes................................................................................................................................98
3.2.3.1 General information................................................................................................................98
3.2.3.2 Name of a link axis...............................................................................................................100
3.2.3.3 Parameterization..................................................................................................................100
3.2.3.4 Auxiliary function output for spindles....................................................................................101
3.2.3.5 Supplementary conditions....................................................................................................102
3.2.4 Axis container.......................................................................................................................104
3.2.4.1 General information..............................................................................................................104
3.2.4.2 Parameterization..................................................................................................................107
3.2.4.3 Programming........................................................................................................................113
3.2.4.4 System variable....................................................................................................................115
3.2.4.5 Machining with axis container (schematic)...........................................................................116
3.2.4.6 Behavior in different operating states...................................................................................116
3.2.4.7 Behavior when withdrawing the release for axis container rotation.....................................117
3.2.4.8 Supplementary conditions....................................................................................................119
3.2.5 Lead link axes......................................................................................................................121
3.2.5.1 General information..............................................................................................................121
Table of contents
Extended Functions
10 Function Manual, 10/2015, 6FC5397-1BP40-5BA3

3.2.5.2 Parameterization..................................................................................................................122
3.2.5.3 System variables to enter a leading value...........................................................................124
3.2.5.4 Supplementary conditions....................................................................................................124
3.2.5.5 Example...............................................................................................................................124
3.2.6 System of units within a link group.......................................................................................124
3.3 Examples.............................................................................................................................125
3.3.1 Link axis...............................................................................................................................125
3.3.2 Axis container coordination..................................................................................................126
3.3.2.1 Axis container rotation without a part program wait.............................................................127
3.3.2.2 Axis container rotation with an implicit part program wait....................................................127
3.3.2.3 Axis container rotation by one channel only (e.g. during power up)....................................127
3.3.3 Evaluating axis container system variables.........................................................................127
3.3.3.1 Conditional branch...............................................................................................................127
3.3.3.2 Static synchronized action with $AN_AXCTSWA................................................................128
3.3.3.3 Wait for certain completion of axis container rotation..........................................................128
3.3.4 Configuration of a multi-spindle turning machine.................................................................129
3.3.5 Lead link axis.......................................................................................................................138
3.3.5.1 Configuration........................................................................................................................138
3.3.5.2 Programming........................................................................................................................139
3.4 Data lists..............................................................................................................................141
3.4.1 Machine data........................................................................................................................141
3.4.1.1 General machine data..........................................................................................................141
3.4.1.2 Channelspecific machine data.............................................................................................141
3.4.1.3 Axis/spindlespecific machine data.......................................................................................141
3.4.2 Setting data..........................................................................................................................142
3.4.2.1 General setting data.............................................................................................................142
3.4.2.2 Axis/spindle-specific setting data.........................................................................................142
3.4.3 Signals.................................................................................................................................142
3.4.3.1 Signals from NC...................................................................................................................142
3.4.3.2 Signals from HMI/PLC..........................................................................................................142
3.4.3.3 General online interface.......................................................................................................143
3.4.3.4 Signals from axis/spindle.....................................................................................................144
3.4.4 System variables..................................................................................................................144
4 H1: Manual and handwheel travel............................................................................................................147
4.1 Overview..............................................................................................................................147
4.2 Control via the PLC interface...............................................................................................150
4.3 Parameter assignment (general)..........................................................................................151
4.4 Continuous manual travel....................................................................................................157
4.4.1 Function...............................................................................................................................157
4.4.2 Parameter assignment.........................................................................................................160
4.4.3 Supplementary conditions....................................................................................................160
4.5 Incremental manual travel....................................................................................................161
4.5.1 Function...............................................................................................................................161
4.5.2 Parameter assignment.........................................................................................................164
4.5.3 Supplementary conditions....................................................................................................165
4.6 Handwheel travel.................................................................................................................165
4.6.1 Function...............................................................................................................................165
4.6.2 Parameter assignment.........................................................................................................173
Table of contents
Extended Functions
Function Manual, 10/2015, 6FC5397-1BP40-5BA3 11

4.6.3 Travel request......................................................................................................................178
4.7 Manual traversing of the spindle..........................................................................................181
4.8 Manual traversing of geometry axes/orientation axes..........................................................183
4.9 Approaching a fixed point in JOG........................................................................................185
4.9.1 Function...............................................................................................................................185
4.9.2 Parameterization..................................................................................................................188
4.9.3 Programming........................................................................................................................190
4.9.4 Supplementary Conditions...................................................................................................191
4.9.5 Application example.............................................................................................................191
4.10 Position travel in JOG..........................................................................................................192
4.10.1 Function...............................................................................................................................192
4.10.2 Parameter setting.................................................................................................................195
4.10.3 Supplementary Conditions...................................................................................................196
4.10.4 Application example.............................................................................................................196
4.11 Circular travel in JOG...........................................................................................................197
4.11.1 Function...............................................................................................................................197
4.11.2 Parameter setting.................................................................................................................203
4.11.3 Supplementary Conditions...................................................................................................206
4.11.4 Application example.............................................................................................................206
4.12 Retraction in the tool direction (JOG retract)........................................................................207
4.12.1 Overview..............................................................................................................................207
4.12.2 Parameterization..................................................................................................................209
4.12.2.1 Automatic selection of JOG retract after Power On.............................................................209
4.12.2.2 Enable of the traversing direction.........................................................................................209
4.12.2.3 Measuring system status.....................................................................................................209
4.12.3 Selection..............................................................................................................................210
4.12.4 Tool retraction......................................................................................................................211
4.12.5 Deselection..........................................................................................................................213
4.12.6 Repeated selection..............................................................................................................213
4.12.7 Continuing machining...........................................................................................................214
4.12.8 State diagram.......................................................................................................................215
4.12.9 System data.........................................................................................................................215
4.12.10 Supplementary conditions....................................................................................................216
4.13 Use of handwheels in automatic mode................................................................................217
4.13.1 Handwheel override in automatic mode...............................................................................217
4.13.1.1 General functionality............................................................................................................217
4.13.1.2 Programming and activating handwheel override................................................................221
4.13.1.3 Special features of handwheel override in automatic mode.................................................223
4.13.2 Contour handwheel/path input using handwheel (option)....................................................224
4.13.3 DRF offset............................................................................................................................226
4.13.4 Double use of the handwheel...............................................................................................229
4.14 Monitoring functions.............................................................................................................230
4.15 Start-up: Handwheels...........................................................................................................231
4.15.1 General information..............................................................................................................231
4.15.2 Connection via PPU (only 828D).........................................................................................233
4.15.3 Connection via PROFIBUS (828D)......................................................................................233
4.15.4 Connection via PROFIBUS (840D sl)..................................................................................235
4.15.5 Connected via Ethernet (only 840D sl)................................................................................237
Table of contents
Extended Functions
12 Function Manual, 10/2015, 6FC5397-1BP40-5BA3

4.16 Data lists..............................................................................................................................241
4.16.1 Machine data........................................................................................................................241
4.16.1.1 General machine data..........................................................................................................241
4.16.1.2 Channel-specific machine data............................................................................................241
4.16.1.3 Axis/spindlespecific machine data.......................................................................................242
4.16.2 Setting data..........................................................................................................................243
4.16.2.1 General setting data.............................................................................................................243
4.16.2.2 Channel-specific setting data...............................................................................................243
4.16.2.3 Axis/spindle-specific setting data.........................................................................................243
4.16.3 Signals.................................................................................................................................243
4.16.3.1 Signals from NC...................................................................................................................243
4.16.3.2 Signals to mode group.........................................................................................................244
4.16.3.3 Signals from mode group.....................................................................................................244
4.16.3.4 Signals to channel................................................................................................................245
4.16.3.5 Signals from channel............................................................................................................246
4.16.3.6 Signals to axis/spindle..........................................................................................................248
4.16.3.7 Signals from axis/spindle.....................................................................................................248
4.16.4 System variable....................................................................................................................249
4.16.4.1 System variable....................................................................................................................249
4.16.5 OPI variable.........................................................................................................................249
4.16.5.1 OPI variable.........................................................................................................................249
5 K3: Compensations..................................................................................................................................251
5.1 Introduction..........................................................................................................................251
5.2 Temperature compensation.................................................................................................252
5.2.1 Description of functions........................................................................................................252
5.2.2 Commissioning.....................................................................................................................255
5.2.3 Example...............................................................................................................................256
5.2.3.1 Commissioning the temperature compensation for the Z axis of a lathe.............................256
5.3 Backlash compensation.......................................................................................................259
5.3.1 Mechanical backlash compensation....................................................................................259
5.3.1.1 Description of functions........................................................................................................259
5.3.1.2 Commissioning: Axis-specific machine data........................................................................260
5.3.2 Dynamic backlash compensation.........................................................................................262
5.3.2.1 Description of functions........................................................................................................262
5.3.2.2 Commissioning: Axis-specific machine data........................................................................263
5.3.3 Dual position feedback.........................................................................................................263
5.3.3.1 Commissioning: Axis-specific machine data........................................................................264
5.3.3.2 Supplementary conditions....................................................................................................264
5.4 Interpolatory compensation..................................................................................................265
5.4.1 General properties...............................................................................................................265
5.4.2 Leadscrew error and measuring system error compensation..............................................267
5.4.2.1 Measuring system error compensation (MSEC)..................................................................267
5.4.2.2 Commissioning.....................................................................................................................268
5.4.2.3 Example...............................................................................................................................271
5.4.3 Sag and angularity error compensation...............................................................................272
5.4.3.1 Description of functions........................................................................................................272
5.4.3.2 Commissioning.....................................................................................................................276
5.4.3.3 Examples.............................................................................................................................279
5.4.4 Extension of the sag compensation with NCU link - only 840D sl........................................288
Table of contents
Extended Functions
Function Manual, 10/2015, 6FC5397-1BP40-5BA3 13

5.4.5 Direction-dependent leadscrew error compensation............................................................297
5.4.5.1 Description of functions........................................................................................................297
5.4.5.2 Commissioning.....................................................................................................................298
5.4.5.3 Example...............................................................................................................................301
5.4.6 Cylinder error compensation................................................................................................304
5.4.6.1 Function...............................................................................................................................304
5.4.6.2 Commissioning.....................................................................................................................305
5.4.6.3 Examples.............................................................................................................................308
5.4.7 Supplementary conditions....................................................................................................312
5.5 Dynamic feedforward control (following error compensation)..............................................313
5.5.1 General properties...............................................................................................................313
5.5.2 Speed feedforward control...................................................................................................315
5.5.3 Torque feedforward control..................................................................................................317
5.5.4 Dynamic response adaptation..............................................................................................318
5.5.5 Forward feed control for command- and PLC axes.............................................................319
5.5.6 Secondary conditions...........................................................................................................320
5.6 Friction compensation overview...........................................................................................321
5.7 Friction compensation with a constant compensation value................................................322
5.7.1 Description of functions........................................................................................................322
5.7.2 Commissioning.....................................................................................................................323
5.7.2.1 Circularity test......................................................................................................................324
5.7.3 Supplementary conditions....................................................................................................328
5.8 Friction compensation with adaptive characteristic..............................................................328
5.8.1 Description of functions........................................................................................................328
5.8.2 commissioning.....................................................................................................................329
5.8.3 Supplementary conditions....................................................................................................331
5.9 Friction compensation with adaptive characteristics............................................................331
5.9.1 Description of the function....................................................................................................331
5.9.2 Commissioning.....................................................................................................................333
5.9.2.1 Activating the function..........................................................................................................333
5.9.2.2 Commissioning functions of the SINUMERIK Operate user interface.................................334
5.9.2.3 Parameterization of the acceleration at the characteristic interpolation points....................336
5.9.2.4 Velocity setpoint pulse.........................................................................................................338
5.9.2.5 Torque setpoint pulse...........................................................................................................340
5.10 Compensation functions for suspended axes......................................................................344
5.10.1 Electronic counterweight......................................................................................................344
5.10.2 Special function: Reboot delay.............................................................................................345
5.11 Data lists..............................................................................................................................347
5.11.1 Machine data........................................................................................................................347
5.11.1.1 General machine data..........................................................................................................347
5.11.1.2 Channelspecific machine data.............................................................................................347
5.11.1.3 Axis/spindlespecific machine data.......................................................................................348
5.11.2 Setting data..........................................................................................................................349
5.11.2.1 General setting data.............................................................................................................349
5.11.2.2 Axis/spindle-specific setting data.........................................................................................349
5.11.3 Signals.................................................................................................................................349
5.11.3.1 Signals from NC...................................................................................................................349
5.11.3.2 Signals from mode group.....................................................................................................349
5.11.3.3 Signals from channel............................................................................................................349
Table of contents
Extended Functions
14 Function Manual, 10/2015, 6FC5397-1BP40-5BA3

5.11.3.4 Signals to axis/spindle..........................................................................................................350
5.11.3.5 Signals from axis/spindle.....................................................................................................350
6 K5: Channel synchronization, axis interchange........................................................................................351
6.1 Channel synchronization......................................................................................................351
6.1.1 Channel synchronization (program coordination)................................................................351
6.1.2 Channel synchronization: Conditional wait in path controlled operation..............................354
6.1.3 Running-in channel-by-channel...........................................................................................358
6.1.4 Supplementary conditions....................................................................................................363
6.2 Axis replacement..................................................................................................................363
6.2.1 Overview..............................................................................................................................363
6.2.2 Commissioning.....................................................................................................................364
6.2.3 Programming: Releasing an axis (RELEASE).....................................................................365
6.2.4 Programming: Fetching an axis (GET, GETD).....................................................................365
6.2.5 Automatic axis replacement.................................................................................................367
6.2.6 Axis replacement via PLC....................................................................................................369
6.2.7 Axis interchange via axis container rotation.........................................................................371
6.2.8 Axis replacement with and without preprocessing stop.......................................................372
6.2.9 Axis exclusively controlled from the PLC.............................................................................373
6.2.10 Axis permanently assigned to the PLC................................................................................374
6.2.11 Geometry axis in rotated frame and axis replacement.........................................................375
6.2.12 Axis replacement from synchronized actions.......................................................................376
6.2.13 Axis interchange for leading axes (gantry)...........................................................................379
6.2.14 State diagram.......................................................................................................................379
6.2.15 Example...............................................................................................................................381
6.3 Data lists..............................................................................................................................383
6.3.1 Machine data........................................................................................................................383
6.3.1.1 General machine data..........................................................................................................383
6.3.1.2 Channel-specific machine data............................................................................................383
6.3.1.3 Axis/spindlespecific machine data.......................................................................................385
6.3.2 Setting data..........................................................................................................................386
6.3.2.1 Channelspecific setting data................................................................................................386
6.3.3 Signals.................................................................................................................................386
6.3.3.1 Signals to/from BAG.............................................................................................................386
6.3.3.2 Signals to/from Channel.......................................................................................................386
7 M1: Kinematic transformation...................................................................................................................387
7.1 TRANSMIT face end transformation (option).......................................................................387
7.1.1 Function...............................................................................................................................387
7.1.1.1 Introduction..........................................................................................................................387
7.1.1.2 Machining options................................................................................................................388
7.1.1.3 Working area limitations.......................................................................................................394
7.1.1.4 Overlaid motions with TRANSMIT.......................................................................................395
7.1.1.5 Monitoring of rotary axis rotations over 360º........................................................................395
7.1.2 Parameter assignment.........................................................................................................396
7.1.2.1 Overview..............................................................................................................................396
7.1.2.2 Axis configuration.................................................................................................................397
7.1.2.3 Specific settings...................................................................................................................399
7.1.3 Programming........................................................................................................................401
7.1.4 Constraints...........................................................................................................................401
7.1.5 Example...............................................................................................................................403
Table of contents
Extended Functions
Function Manual, 10/2015, 6FC5397-1BP40-5BA3 15

7.2 TRACYL cylinder surface transformation (option)................................................................406
7.2.1 Function...............................................................................................................................406
7.2.2 Parameter assignment.........................................................................................................410
7.2.2.1 Overview..............................................................................................................................410
7.2.2.2 Axis configuration.................................................................................................................411
7.2.2.3 Specific settings...................................................................................................................413
7.2.3 Programming........................................................................................................................417
7.2.4 Boundary conditions.............................................................................................................420
7.2.5 Examples.............................................................................................................................423
7.2.5.1 Machining grooves on a cylinder surface with X-Y-Z-C kinematics.....................................423
7.2.5.2 Machining grooves on a cylinder surface with X-Y-Z-A-C kinematics..................................428
7.3 TRAANG oblique angle transformation (option)...................................................................431
7.3.1 Function...............................................................................................................................431
7.3.2 Parameter assignment.........................................................................................................432
7.3.2.1 Overview..............................................................................................................................432
7.3.2.2 Axis configuration.................................................................................................................434
7.3.2.3 Specific settings...................................................................................................................436
7.3.3 Programming........................................................................................................................437
7.3.3.1 Activate skew angle transformation (TRAANG)...................................................................437
7.3.3.2 Oblique plunge-cutting on grinding machines (G5, G7).......................................................438
7.3.4 Boundary conditions.............................................................................................................439
7.3.5 Example...............................................................................................................................441
7.4 Chained transformations......................................................................................................444
7.4.1 Function...............................................................................................................................444
7.4.1.1 Introduction..........................................................................................................................444
7.4.1.2 System variables..................................................................................................................446
7.4.2 Programming........................................................................................................................449
7.4.3 Examples.............................................................................................................................450
7.4.3.1 Application example of chained transformations..................................................................450
7.4.3.2 Determining the axis positions in the transformation chain..................................................454
7.5 Persistent transformation.....................................................................................................457
7.6 Cartesian PTP travel............................................................................................................462
7.6.1 Function...............................................................................................................................462
7.6.2 Commissioning.....................................................................................................................464
7.6.2.1 Response after POWER ON................................................................................................464
7.6.2.2 Response after reset/part program end...............................................................................464
7.6.2.3 Consideration of the SW limits during PTP travel................................................................465
7.6.3 Programming........................................................................................................................466
7.6.3.1 Activating/deactivating Cartesian PTP travel (PTP, PTPG0, PTPWOC, CP)......................466
7.6.3.2 Specify the position of the joints (STAT)..............................................................................467
7.6.3.3 Specify the sign of the axis angle (TU)................................................................................470
7.6.3.4 Example 1: PTP and TRAORI..............................................................................................472
7.6.3.5 Example 2: PTPG0 and TRANSMIT....................................................................................473
7.6.4 Supplementary conditions....................................................................................................474
7.7 Cartesian manual travel (optional).......................................................................................476
7.8 Activating transformation machine data via part program/softkey.......................................484
7.8.1 Function...............................................................................................................................484
7.8.2 Constraints...........................................................................................................................484
7.8.3 Control response to power ON, mode change, RESET, block search, REPOS..................486
Table of contents
Extended Functions
16 Function Manual, 10/2015, 6FC5397-1BP40-5BA3

7.8.4 List of machine data affected...............................................................................................487
7.8.5 Example...............................................................................................................................489
7.9 Data lists..............................................................................................................................490
7.9.1 Machine data........................................................................................................................490
7.9.1.1 TRANSMIT...........................................................................................................................490
7.9.1.2 TRACYL...............................................................................................................................491
7.9.1.3 TRAANG..............................................................................................................................493
7.9.1.4 Chained transformations......................................................................................................494
7.9.1.5 Non transformation-specific machine data...........................................................................494
7.9.2 Signals.................................................................................................................................495
7.9.2.1 Signals from channel............................................................................................................495
8 M5: Measurement.....................................................................................................................................497
8.1 Brief description...................................................................................................................497
8.2 Hardware requirements........................................................................................................498
8.2.1 Probes that can be used......................................................................................................498
8.3 Channel-specific measuring.................................................................................................499
8.3.1 Measurement.......................................................................................................................499
8.3.2 Measurement results............................................................................................................500
8.4 Axial measurement..............................................................................................................501
8.4.1 Measurement.......................................................................................................................501
8.4.2 Telegram selection...............................................................................................................505
8.4.3 Measurement results............................................................................................................505
8.5 Setting zeros, workpiece measuring and tool measuring.....................................................507
8.5.1 Preset actual value memory and scratching........................................................................507
8.5.2 Workpiece measuring..........................................................................................................508
8.5.2.1 Input values..........................................................................................................................508
8.5.2.2 Measurement selection........................................................................................................515
8.5.2.3 Output values.......................................................................................................................516
8.5.2.4 Calculation method..............................................................................................................516
8.5.2.5 Units of measurement and measurement variables for the calculation...............................520
8.5.2.6 Diagnostics...........................................................................................................................521
8.5.3 Types of workpiece measurement.......................................................................................522
8.5.3.1 Measurement of an edge (measurement type 1, 2, 3).........................................................522
8.5.3.2 Measurement of an angle (measurement type 4, 5, 6, 7)....................................................526
8.5.3.3 Measurement of a hole (measurement type 8)....................................................................529
8.5.3.4 Measurement of a shaft (measurement type 9)...................................................................532
8.5.3.5 Measurement of a groove (measurement type 12)..............................................................533
8.5.3.6 Measurement of a web (measurement type 13)..................................................................536
8.5.3.7 Measurement of geo axes and special axes (measurement type 14, 15)............................537
8.5.3.8 Measurement of an oblique edge (measurement type 16)..................................................539
8.5.3.9 Measurement of an oblique angle in a plane (measurement type 17).................................540
8.5.3.10 Redefine measurement around a WCS reference frame (measurement type 18)...............544
8.5.3.11 Measurement of a 1-, 2- and 3-dimensional setpoint selection (measurement type 19,
20, 21)..................................................................................................................................547
8.5.3.12 Measuring a measuring point in any coordinate system (measurement type 24)................551
8.5.3.13 Measurement of a rectangle (measurement type 25)..........................................................555
8.5.3.14 Measurement for saving data management frames (measurement type 26)......................556
8.5.3.15 Measurement for restoring backed-up data management frames (measurement type 27)....557
8.5.3.16 Measurement for defining an additive rotation for taper turning (measurement type 28) ....558
Table of contents
Extended Functions
Function Manual, 10/2015, 6FC5397-1BP40-5BA3 17

8.5.4 Tool measuring....................................................................................................................559
8.5.5 Types of workpiece measurement.......................................................................................559
8.5.5.1 Measurement of tool lengths (measurement type 10)..........................................................559
8.5.5.2 Measurement of tool diameter (measurement type 11).......................................................562
8.5.5.3 Measurement of tool lengths with zoom-in function (measurement type 22).......................563
8.5.5.4 Measuring a tool length with stored or current position (measurement type 23).................564
8.5.5.5 Measurement of a tool length of two tools with the following orientation:............................565
8.6 Measurement accuracy and functional testing.....................................................................577
8.6.1 Measurement accuracy........................................................................................................577
8.6.2 Probe function test...............................................................................................................577
8.7 Simulated measuring...........................................................................................................578
8.7.1 General functionality............................................................................................................578
8.7.2 Position-related switch request............................................................................................579
8.7.3 External switch request........................................................................................................580
8.7.4 System variable....................................................................................................................581
8.8 Channels - only 840D sl.......................................................................................................582
8.8.1 Measuring mode 1...............................................................................................................582
8.8.2 Measuring mode 2...............................................................................................................583
8.8.3 Continuous measurement....................................................................................................583
8.8.4 Functional test and repeat accuracy....................................................................................584
8.9 Data lists..............................................................................................................................586
8.9.1 Machine data........................................................................................................................586
8.9.1.1 General machine data..........................................................................................................586
8.9.1.2 Channel-specific machine data............................................................................................586
8.9.2 System variables..................................................................................................................587
9 N3: Software cams, position switching cycles - only 840D sl...................................................................589
9.1 Brief Description...................................................................................................................589
9.2 Cam signals and cam positions...........................................................................................590
9.2.1 Generation of cam signals for separate output....................................................................590
9.2.2 Generation of cam signals with gated output.......................................................................594
9.2.3 Cam positions......................................................................................................................598
9.2.4 Lead/delay times (dynamic cam).........................................................................................600
9.3 Output of cam signals..........................................................................................................601
9.3.1 Activating..............................................................................................................................601
9.3.2 Output of cam signals to PLC..............................................................................................602
9.3.3 Output of cam signals to NCK I/Os in position control cycle................................................602
9.3.4 Timer-controlled cam signal output......................................................................................604
9.3.5 Independent, timer-controlled output of cam signals...........................................................605
9.4 Position-time cams...............................................................................................................606
9.5 Supplementary Conditions...................................................................................................607
9.6 Data lists..............................................................................................................................608
9.6.1 Machine data........................................................................................................................608
9.6.1.1 General machine data..........................................................................................................608
9.6.2 Setting data..........................................................................................................................608
9.6.2.1 General setting data.............................................................................................................608
9.6.3 Signals.................................................................................................................................609
9.6.3.1 Signals to axis/spindle..........................................................................................................609
Table of contents
Extended Functions
18 Function Manual, 10/2015, 6FC5397-1BP40-5BA3

9.6.3.2 Signals from axis/spindle.....................................................................................................609
10 N4: Own channel - only 840D sl...............................................................................................................611
10.1 Brief Description...................................................................................................................611
10.2 Stroke control.......................................................................................................................611
10.2.1 General information..............................................................................................................611
10.2.2 High-speed signals...............................................................................................................612
10.2.3 Criteria for stroke initiation...................................................................................................613
10.2.4 Axis start after punching.......................................................................................................616
10.2.5 PLC signals specific to punching and nibbling.....................................................................617
10.2.6 Punching and nibbling-specific reactions to standard PLC signals......................................617
10.2.7 Signal monitoring.................................................................................................................618
10.3 Activation and deactivation..................................................................................................618
10.3.1 Language commands...........................................................................................................618
10.3.2 Functional expansions.........................................................................................................622
10.3.3 Compatibility with earlier systems........................................................................................626
10.4 Automatic path segmentation...............................................................................................628
10.4.1 General information..............................................................................................................628
10.4.2 Operating characteristics with path axes.............................................................................630
10.4.3 Response in connection with single axes............................................................................634
10.5 Rotatable tool.......................................................................................................................639
10.5.1 General information..............................................................................................................639
10.5.2 Coupled motion of punch and die........................................................................................640
10.5.3 Tangential control.................................................................................................................641
10.6 Protection zones..................................................................................................................644
10.7 Supplementary conditions....................................................................................................644
10.8 Examples.............................................................................................................................645
10.8.1 Examples of defined start of nibbling operation...................................................................645
10.9 Data lists..............................................................................................................................650
10.9.1 Machine data........................................................................................................................650
10.9.1.1 General machine data..........................................................................................................650
10.9.1.2 Channelspecific machine data.............................................................................................650
10.9.2 Setting data..........................................................................................................................651
10.9.2.1 Channelspecific setting data................................................................................................651
10.9.3 Signals.................................................................................................................................651
10.9.3.1 Signals to channel................................................................................................................651
10.9.3.2 Signals from channel............................................................................................................651
10.9.4 Language commands...........................................................................................................651
11 P2: Positioning axes.................................................................................................................................653
11.1 Product brief.........................................................................................................................653
11.2 Own channel, positioning axis or concurrent positioning axis..............................................655
11.2.1 Own channel........................................................................................................................655
11.2.2 Positioning axis....................................................................................................................656
11.2.3 Concurrent positioning axis..................................................................................................659
11.3 Motion behavior and interpolation functions.........................................................................660
11.3.1 Path interpolator and axis interpolator.................................................................................660
Table of contents
Extended Functions
Function Manual, 10/2015, 6FC5397-1BP40-5BA3 19

11.3.2 Interpolation response of path axis in G0.............................................................................660
11.3.3 Autonomous singleaxis operations......................................................................................663
11.3.4 Autonomous single-axis functions with NC-controlled ESR.................................................667
11.4 Positioning axis dynamic response......................................................................................669
11.5 Programming........................................................................................................................671
11.5.1 General................................................................................................................................671
11.5.2 Revolutional feed rate in external programming..................................................................673
11.6 Block change........................................................................................................................674
11.6.1 Settable block change time..................................................................................................676
11.6.2 End of motion criterion with block search.............................................................................681
11.7 Control by the PLC...............................................................................................................682
11.7.1 Starting concurrent positioning axes from the PLC..............................................................684
11.7.2 PLC-controlled axes.............................................................................................................684
11.7.3 Control response of PLC-controlled axes............................................................................686
11.8 Response with special functions..........................................................................................687
11.8.1 Dry run (DRY RUN)..............................................................................................................687
11.8.2 Single block..........................................................................................................................687
11.9 Examples.............................................................................................................................688
11.9.1 Motion behavior and interpolation functions.........................................................................688
11.9.1.1 Traversing path axes without interpolation with G0.............................................................689
11.10 Data lists..............................................................................................................................689
11.10.1 Machine data........................................................................................................................689
11.10.1.1 NC-specific machine data....................................................................................................689
11.10.1.2 Channelspecific machine data.............................................................................................689
11.10.1.3 Axis/spindlespecific machine data.......................................................................................690
11.10.2 Setting data..........................................................................................................................690
11.10.2.1 Axis/spindle-specific setting data.........................................................................................690
11.10.3 Signals.................................................................................................................................690
11.10.3.1 Signals to channel................................................................................................................690
11.10.3.2 Signals from channel............................................................................................................690
11.10.3.3 Signals to axis/spindle..........................................................................................................691
11.10.3.4 Signals from axis/spindle.....................................................................................................691
12 P5: Oscillation...........................................................................................................................................693
12.1 Brief description...................................................................................................................693
12.2 Asynchronous oscillation......................................................................................................694
12.2.1 Influences on asynchronous oscillation................................................................................695
12.2.2 Asynchronous oscillation under PLC control........................................................................701
12.2.3 Special reactions during asynchronous oscillation...............................................................701
12.3 Oscillation controlled by synchronized actions.....................................................................704
12.3.1 Infeed at reversal point 1 or 2..............................................................................................707
12.3.2 Infeed in reversal point range...............................................................................................708
12.3.3 Infeed at both reversal points...............................................................................................709
12.3.4 Stop oscillation movement at the reversal point...................................................................710
12.3.5 Oscillation movement restarting...........................................................................................711
12.3.6 Do not start partial infeed too early......................................................................................712
12.3.7 Assignment of oscillation and infeed axes OSCILL.............................................................713
12.3.8 Definition of infeeds POSP...................................................................................................713
Table of contents
Extended Functions
20 Function Manual, 10/2015, 6FC5397-1BP40-5BA3