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1. AROT additive programmable rotation AROT RPL add rotation in the current plane G17 G19 separate block AMIRROR additive programmable mirroring AMIRROR X0 coordinate axis whose direction is changed separate block G25 Lower spindle speed limiting G25 S separate block ee work area limiting G25 X Z separate block G26 Upper spindle speed limiting G26 S separate block e work area limiting G26 X Z separate block G17 X Y plane when center drilling TRANSMIT milling 6 Plane selection required G18 Z X plane G19 Y Z plane required for TRACYL milling G40 Tool radius compensation OFF 7 Tool radius compensation G41 Tool radius compensation left of the contour modal G42 Tool radius compensation right of the contour G500 Settable zero offset OFF 8 Settable zero offset G54 1st settable zero offset meen G55 2nd settable zero offset G56 3rd settable zero offset G57 4th settable zero offset G58 5th settable zero offset G59 6th settable zero offset G53 Non modal suppression of settable zero offset 9 Non modal suppression of settable zero offset G153 Non modal suppression of settable zero offset inclu ding basic frame G60 Exact stop 10 Approach behavior G64 Continuous path control mode modal buluwelsbold L dO 0 LL da0 00VVe 869 S049 aul seq AZ08 AZ08 MIYAWNNIS 6 L 8
2. G9 Non modal exact stop 11 Non modal exact stop non modal G601 Exact stop window fine at G60 G9 12 Exact stop window G602 Exact stop window rough at G60 G9 modal G70 Inch dimension data input 13 Inch metric dimension data input G71 Metric dimension data input modal G700 Inch dimension data input also for feed F G710 Metric dimension data input also for feed F G90 Absolute dimension data input 14 Absolute incremental data input G91 Incremental dimension data input modal G94 Feed F in mm min 15 Feed spindle G95 Feed F in mm spindle rev s modal G96 Constant cutting speed ON G96 S LIMS F F in mm rev S in m min G97 Constant cutting speed on turning OFF G450 Transition circle 18 Corner behavior at tool radius compensation G451 Intersection point modal BRISK Abrupt path acceleration 21 Acceleration profile SOFT Jerk limited path acceleration modal FFWOF Feedforward control OFF 24 Feedforward control FFWON Feedforward control ON modal WALIMON Work area limiting ON 28 Work area limiting applies to all axes activated by setting data values set modal using G25 G26 WALIMOF Work area limiting OFF DIAMOF Radius input 29 Dimension input radius diameter DIAMON Diameter input modal Oulwwesbold Or L 8 1 dO 0 LL dg0 00YYZ 869 S949 aul eseq AZ08 dZO8 MINAWNNIS G290 SIEMENS mode G291 External mod
3. 7 1 PLC diagnosis using the ladder diagram representation Table 7 4 Key combinations Key combination Action A to the first line of the row E or AIRE mE or E to the last line of the row up a screen een Sp US m down a screen one field to the left one field to the right up a field down a field SE O zm Se Eel a en to the first field of the first network to the last field of the first network a 8 CTRL END or CTRL opens the next program block in the same window CTRL PAGE E opens the previous program block in the same window PAGE e displays the complete text line in a table e displays the network comment when using network titles e displays the complete operands when using commands displays all information of the operand including comment when using commands iw QO zZz SINUMERIK 802D 802D base line 7 122 6FC5 698 2AA00 0BP3 11 03 OP T Softkeys PLC info Reset pro time PLC status Status list System 7 1 PLC diagnosis using the ladder diagram representation The PLC Info menu normally called About transl displays the PLC model the PLC system version cycle time and PLC user program runtime Project N
4. Servo trace System The softkeys Axis and Axis are additionally displayed You can use these softkeys to dis play the values for the next or previous axis The window displays information on the digital drive The window contains information regarding the PROFIBUS settings To optimize the axis an oscillograph function is implemented which provides graphical representa tion e of the velocity set value The velocity set value corresponds to the 10V interface e of the contour deviation e of the following error e of the actual position value e of the set position value e of exact stop fine coarse The start of recording can be linked with various criteria allowing the recording to be carried out synchronously to internal control states This setting must be made using the function Se lect Signal To analyze the result the following functions are provided e Changing of scaling of abscissa and ordinate e Measuring of a value using the horizontal or vertical marker e Measuring of abscissa and ordinate values as a difference between two marker positions e Storing of the result as a file in the part program directory Then it is possible to read out the file using WINPCIN and to edit the graphics using MS Excel Time scale Tine scale Vertical scale Vertical scale Auto scaling Marker steps File service Help P RH Select V Mark T Mark Fix Fix Show Move Star
5. lead K since path in Z axis longer G33 Ze Kee x Angle at taper greater than 45 degrees lead since path in X axis longer Transversal thread Fig 8 21 Lead assignment using the example of Z X axes Taper thread For taper threads 2 axes to be specified the required lead address or K with the longer path longer thread length must be used Another lead will not be specified SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 165 Programming 8 3 Axis Movements Start point offset SF A start point offset of the spindle is required to produce either threads using set cuts or multiple threads The start point offset is programmed in the thread block using G33 under the address SF absolute position If no start point offset is programmed the value from the setting data will be used Note In all cases a programmed value for SF will also be entered in the setting data Programming example Cylindrical thread double start point offset 180 degrees thread length including run in and run out 100 mm thread lead 4 mm rev RH thread cylinder already prepared N10 G54 GO G90 X50 Z0 S500 M3 start point approach CW spindle rotation N20 G33 Z 100 K4 SF 0 lead 4 mm rev N30 GO X54 N40 ZO N50 X50 N60 G33 Z 100 K4 SF 180 ond pitch offset by 180 degrees N70 GO X54 Multi block thread If several thread blocks are programmed one after the other mul
6. Fig 6 9 lf this function is selected the selected block is traversed at rapid traverse or with the programmed path feedrate SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 6 79 Part Programming 6 3 Blueprint programming Add functions OK 6 80 If necessary you can enter additional functions in the fields The commands can be separated from each other by spaces commas or semicolons PROGRAH Program editor DEMO1 MPF Not selected Input form line Fig 6 10 This interactive screenform is provided for all contour elements Pressing the OK softkey will accept all commands into the part program Select Abort to quit the interactive screenform without saving the values This function is intended to calculate the point of intersection between two straight lines Specify the coordinates of the end point of the second straight line and the angles of the straight lines PROGRAH Program editor DEHMO1 MPF Not selected Input form line line Fig 6 11 Calculating the point of intersection between two straight lines Table 6 1 Input in the interactive screenform End point of straight E Enter the end point of the straight line line 2 Angle of straight line 1 A1 The angle is specified in the counterclockwise direction from O to 360 degrees SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Part Programming
7. E jas ss E Tool Work R vari Setting User list offset able data data Fig 3 16 The Zero Offset window Position the cursor bar on the input box you wish to modify 0 9 enter value s The values are accepted into the zero offsets either by a cursor movement or using the Input key Change The offset values of the cutting edge come into effect immediately activated SINUMERIK 802D 802D base line 3 42 6FC5 698 2AA00 OBP3 11 03 OP T Setting Up 3 3 Entering Modifying Zero Offset 3 3 1 Determining Zero Offset Prerequisite You have selected the window with the corresponding zero offset e g G54 and the axis for which you wish to determine the offset F tool carrier reference point M machine zero W workpiece zero X Machine Workpiece Zero offset Z Fig 3 17 Determining the zero offset Z axis Procedure Measure Press the softkey Zero Offs Measur The control system will switch to the operating area Position workpiece and open the dialog box for measuring the zero offsets The axis selected will appear as a softkey with a black shadow Then scratch the workpiece using the tool tip In the box Set position to type the position you wish to have for the workpiece edge in the workpiece coordinate system SKP DRY ROY MO1 PRT SBL OSTORE1 SYF La Position Repos offset l Position Repos offset 8 00O H 8 00O taii D fa GQ
8. Example N10 T rill N20 G17 G1 F Z length compensation is effective in Z axis NSO Z N40 G8 drilling completed Fig 8 39 Drilling a center hole 8 6 4 Selection of Tool Radius Compensation G41 G42 Functionality A tool with a corresponding D number must be active The tool radius compensation cutter radius compensation is enabled by G41 G42 The control system will thus automatically cal culate the required equidistant tool paths for the programmed contour corresponding to the radius currently active G18 must be active Tool nose radius Fig 8 40 Tool radius compensation cutter radius compensation SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 195 Programming 8 6 Tool and Tool Compensation Programming G41 X Z tool radius compensation left of contour G42 X Z tool radius compensation right of contour Note The selection can only be carried out with linear interpolation GO G1 Program both axes If you specify only one axis the second axis will be added automatically by the value programmed last Fig 8 41 Compensation right left of the contour Start compensation The tool approaches the contour along a straight line and positions vertically to the path tan gent in the start point of the contour Select the start point such that collision free traversing is guaranteed Start contour Straight line Starting contour Circle
9. Parameters Table 9 14 Parameters of CYCLE94 O E Starting point in the transversal axis enter without sign Starting point in the transversal axis enter without sign in the transversal axis enter without sign real Starting point of the tool compensation in the longitudinal axis enter without sign Definition of the form Values E for form E F for form F Function Using this cycle you can program undercuts to DIN509 of the forms E and F for usual stress and with a finished part diameter gt 3 mm Form F Form E Fig 9 40 Operational sequence Position reached prior to cycle start The starting position can be any position from which the undercut can be approached wi thout collision SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 287 Cycles 9 5 Turning cycles The cycle creates the following sequence of motions e Approach of the starting point determined in the cycle by using GO e Selection of the cutter radius compensation according to the active tool point direction and traveling along the undercut contour at the feedrate programmed prior to the cycle call e Retraction to the starting point with GO and deselection of the cutter radius compensation with G40 Explanation of the parameters SPD and SPL starting point Use the parameter SPD to specify the finished part diameter for the undercut The finished part diameter in the longitudinal axis is defined us
10. 61 66 66 62 64 63 61 66 66 62 64 63 UNA A41 NA A FNA 449 Interface version 64 61 64 82 69 19 V64 61 04 02709713 V4 61 64 62 69 13 V4 61 62 62 66 24 UNA AA NA A FNA 749 PR SIH ARJ STARTUP ARJ Fig 7 14 Version language Order CP_ English second 1252 3 V64 61 64 62 69 13 64 61 64 62 69 7195 Defining the start program V64 61 64 62 69 13 64 61 64 62 69 19 After the system has booted the control system automatically starts the Machine operating area SK 1 If a different starting behavior is desired you can use this function to define a different starting behavior Type the number of the program you wish to be started after the system has booted Registry ini details DLL StartUp SK1i DLL arrangement Softkey DLL name SK1 ma dll pa dll pr dll pm dll dg dll Class name maschine parameter progrann progman diagnose alm d1ll alarn Start method Execute flag boty Ld 1 1 1 1 1 Change start DLL The start DLL is the first DLL to run after Power ON Changes to the start DLL alter the default window The current softkey SK1i maschine Change to skf Fig 7 15 Modifying the start up DLL SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T PLC STEP 7 connect System This softkey provides further functions for diagnosis
11. Functionality e Using the kinematic transformation function TRANSMIT provides a face end milling drilling ma chining of turned parts clamped in rotating chucks e To program this machining technology a Cartesian coordinate system is used e The control system transforms the programmed traversing motions of the Cartesian coordinate system into motions of the real machine axes In this case the main spindle works as a machine rotary axis e TRANSMIT must be configured via special machine data A tool center offset relative to the tur ning center is permissible and is also configured using these machine data e In addition to the tool length compensation it is also possible to use the tool radius compensa tion G41 G42 e The motions defined for rotary motions are taken into account by the velocity control Fig 8 55 Milling machining at a face end Programming TRANSMIT Activate TRANSMIT separate block TRAFOOF Deactivate Separate block SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 225 Programming 8 14 Milling on turning machines TRAFOOF will deactivate any active transformation function Programming example Information 8 226 Fig 8 56 Cartesian coordinate system X Y Z with its origin in the turning center when programming TRANS MIT Milling of a square eccentric and rotated N10 T1 F400 G94 G54 Milling tool feedrate feedrate type N20 GO X50 Z60 SPOS 0 Ap
12. Programming 8 12 Timer and Workpiece Counter Programming example Display N10 IF 4AC_TOTAL_PARTS R15 GOTOF SIST number of parts reached N80 SIST N90 MSG Required number of parts reached N100 MO The contents of the active system variables is displayed on the screen in the operating area OFFSET PARAM gt softkey Setting Data 2nd page Parts total AC_TOTAL_PARTS Parts required AC_REQUIRED_PARTS Part count AC_ACTUAL_PARTS AC_SPECIAL_PARTS is not displayed In addition Part count is displayed in AUTOMATIC mode in the operating area Position in the Tip line SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 219 Programming 8 12 Timer and Workpiece Counter 8 13 Language commands for tool monitoring 8 13 1 Overview Tool monitoring With SINUMERIK 802D this function is an option and available with software release 2 0 and hig her Functionality The tool monitoring is activated via machine data The following monitoring types are possible for the active cutting edge of the active tool e Monitoring of the tool life e Monitoring of the count All of the above mentioned monitoring functions can be activated for a tool at the same time The control data input of the tool monitoring is provided preferably via operation Additionally the functions can also be programmed Monitoring counter Monitoring counters are provided for every monitoring typ
13. Protocol Description e XON XOFF A possibility of controlling the transmission is the use of XON DC1 DEVICE CONTROL 1 and XOFF DEVICE CONTROL 2 control characters if the buffer of the peripheral device is full the device will send XOFF and once it is ready to receive data it will send XON e RTS CTS The signal RTS Request to Send controls the Send mode of the data transfer device Active Data are to be sent Passive The Send mode is only quitted after all data have been transmitted The CTS signal indicates the readiness to transmit data as the acknowledgment signal for RTS XON This is the character required to start a transmission It is only effective for the de vice type XON XOFF XOFF This is the character required to stop a transmission End of transmis sion This is the character signaling the end of transmission of a text file For transmitting binary data the special function Stop with end of transmission character may not be active Baud rate used to set the interface transmission rate 300 Baud 600 Baud 1200 Baud 2400 Baud 4800 Baud 9600 Baud 19200 Baud 38400 Baud 57600 Baud 115200 Baud Data bits Number of data bits with asynchronous transmission Input 7 data bits 8 data bits default setting Stop bits Number of stop bits with asynchronous transmission Input 1 stop bit default setting 2 stop bits Parity Parity bits are u
14. RESET Program aborted basic status RUN Program running STOP Program stopped Program controls in Automatic mode Reserved NC messages IOC Selected part program main program SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T Introduction 1 1 Screen Layout Tip and softkey area Fig 1 3 Tip and softkey area Table 1 2 Explanation of the display elements in the tip and softkey area Display Display Meaning Element Recall symbol Pressing the Recall key lets you return to the next higher level Tip line Displays tips for the operator MMC status information ETC is possible If you press this key the horizontal softkey bar will display further functions Mixed notation active Data transfer running Link with the PLC programming tool active 4 Softkey bar vertical and horizontal Standard softkeys K Use this softkey to quit the screen form Back Use this softkey to cancel input the window will be quitted Abort Pressing this softkey will complete your input and start the calculation iccep SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 1 15 Introduction 1 2 v OK Operating Areas 1 2 ma Ll POSITION OFFSET PARAM PROGRAM PROGRAM MANAGER SYSIEM IN SHIFT ALARM SYSTEM A ALARM Pressing this softkey will complete your input
15. Settings function aE Auxiliary functions Axis feedrate Delete MDI prog Save MDI prog MCS WCS REL 4 56 Use this softkey to set a basic zero offset see Section 4 1 Face milling see Section 4 2 1 see Section 4 1 The G function window provides G functions whereby each G function is assigned a group and has a fixed position in the window Use the PageUp and PageDown keys to display further G functions If you press this softkey seve ral times the window is closed This window displays the active auxiliary and M miscellaneous functions If you press this softkey several times the window is closed This softkey will unhide the Axis Feed window If you press this softkey several times the window is closed This function will delete all blocks displayed in the program window Type a name with which you want to save the MDA program in the program directory in the input field Alternatively you can select an existing program from the list To switch between the input field and the program list use the TAB key SKP DRY ROY H61 PRT SBL Back ok DEMO1 MPF Position Dist to go 6 666 mm D1 8 00A 8 00A 6 608 6 666 6 666 mn A Aaa aX 6 666 mm min AA O Save MDA Program Save as THP_HDA MPF Name LOAD1 MPF E LOAD2 MPF 4 LOADS MPF MDA Block E LOAD4 MPF Eq TEST1 M
16. DTB dwell time The dwell time at the groove base should be selected such that at least one spindle revolu tion is carried out It is programmed in seconds VARI machining type The machining type of the groove is defined with the units digit of the parameter VARI It can assume the values indicated in the illustration The tens digit of parameter VARI determines how the chamfers are taken into account VARI 1 8 The chamfers will be taken into account as CHF VARI 11 18 The chamfers will be taken into account as CHR SINUMERIK 802D 802D base line 9 284 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 5 Turning cycles X X TVARE Z T VARI 2 i2 Z X X T VARI Z3 13 Z T VARI 4 14 Z T VARI 5 15 Z T VARI 6 16 Z X X C T WARIE7 17 Z T VARIZ8 18 Z Fig 9 38 If the parameter has a different value the cycle will abort with alarm 61002 Machining type defined incorrectly The cycle carries out a contour monitoring such that a reasonable groove contour results This is not the case if the radii chamfers come into contact or intersect at the groove base or if you try to carry out a face grooving operation at a contour segment located parallel to the longitudinal axis In such cases the cycle will abort with alarm 61603 Groove form defined incorrectly Further notes Before calling the grooving cycle a double edged tool must be enabled The offset values for the two cuttin
17. Fig 8 35 Required length compensation values for turning tools Recessing F Tool holder refe tool rence point Z Two correction blocks required e g D1 cutting edge 1 D1 Length 1 Do Length 1 D2 cutting edge 2 X X Tool tip P ee cutting edge 1 D ool tip Length 1 in X cutting edge 2 Length 2 in Z D2 Fig 8 36 Turning tool with two edges length compensation SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 193 Programming 8 6 Tool and Tool Compensation Turning tool Z Length 1 X Tool tip P cutting edge R tool nose radius tool radius S position of cutting edge center point G18 Length 1 in X F tool holder reference point Length 2 in Z Edge position position values 1 through 9 are possible The specifications Length 1 Length 2 g are referred to point P at edge position 1 8 but at 9 S S P Fig 8 37 Required compensation data for turning tools with tool radius compensation F tool holder reference point Length 1 in Z G18 Turning tools Fig 8 38 Required compensation data for drill SINUMERIK 802D 802D base line 8 194 6FC5 698 2AA00 0BP3 11 03 OP T Programming 8 6 Tool and Tool Compensation Center hole To make a center hole switch to G17 The length compensation for the drill will thus be effec tive in the Z axis If drilling has been completed use G18 to switch back to normal compensa tion for turning tools
18. N100 RESETMOWN state 12 1 2 Updating the setpoint of the workpiece counter for T12 D1 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 223 Programming 8 12 Timer and Workpiece Counter Programming example DEF INT state Defining the variable for the status feedback of RESETMON GO X Retraction T7 Load a new tool possible via M6 TC_MOP3 P_TOOLNO P_TOOL 100 Prewarning limit 100 pcs TC_MOP4 P_TOOLNO P_TOOL 700 Residual count TC_MOP13 P_TOOLNO P_TOOL 700 Count setpoint Activation after setting TC_TP9 P_TOOLNO P_TOOL 2 Activation of the count monitoring active tool STOPRE ANF BEARBEIT Subroutine for workpiece machining SETPIECE 1 Update counter Mo Next workpiece press NC START to continue IF STC_MOP4 P_TOOLNO P_TOOL gt 1 GOTOB ANF MSG Tool T7 worn please change Mo after changing the tool press NC START to continue RESETMONWN state 7 1 2 Workpiece counter setpoint update IF state lt gt 0 GOTOF ALARM GOTOB ANF ALARM Display error MSG Error RESETMON lt lt state MO M2 SINUMERIK 802D 802D base line 8 224 6FC5 698 2AA00 0BP3 11 03 OP T Programming 8 14 Milling on turning machines 8 14 Milling on turning machines Note This function is only available with the 802D 8 14 1 Milling face ends TRANSMIT With SINUMERIK 802D this function is an option and available with software release 2 0 and hig her
19. Operation and Programming 11 03 Edition IUCN SINUMERIK 802D SIEMENS SINUMERIK 802D base line Turning SI E M z N S Introduction Turning On an Reference Point Approach Setting Up SINUMERIK 802D Manually Controlled Mode Operation and Programming Turning Automatic Mode Part Programming System Programming Cycles Valid for Control System Software Version SINUMERIK 802D 2 SINUMERIK 802D base line 1 11 03 Edition SINUMERIK Documentation Printing history Brief details of this edition and previous editions are listed below IThe status of each edition is shown by the code in the Remarks column Status code in the Remarks column Aix bale New documentation Be Unrevised reprint with new Order No Couris Revised edition with new status lf actual changes have been made on the page since the last edition this is indicated by a new edition coding in the header on the page Edition Order No 11 00 6FC5 698 2AA00 OBPO 07 01 6FC5 698 2AA00 O0BP1 10 02 6FC5 698 2AA00 OBP2 11 03 6FC5 698 2AA00 O0BP3 Remark A OOO This Manual is included on the documentation on CD ROM DOCONCD Trademarks SIMATIC SIMATIC HMI SIMATIC NET SIROTEC SINUMERIK and SIMODRIVE are registered trademarks of Siemens Third parties using for their own purposes any other names in this document which refer to trademarks might infringe upon the rights of trademark owners This publication was pr
20. The basic settings can be set in machine data All examples listed in these instructions start from the metric scaling G70 or G71 interprets all geometrical data specified directly with reference to the workpiece in inches or metrically e g e positional data X Z with GO G1 G2 G3 G33 CIP CT SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 151 Programming 8 2 Positional Data e interpolation parameters I K including pitch e circle radius CR e programmable zero offset TRANS ATRANS The remaining geometrical data that are no direct workpiece data such as feedrates tool off sets settable zero offsets are not affected by G70 G71 G700 G710 however additionally affects the feed F inch min inch rev or mm min mm rpm 8 2 3 Radius Diameter Programming DIAMOF DIAMON Functionality When machining parts on turning machines the positional data for the X axis traverse axis are usually programmed with diameter dimensions If necessary it is possible to switch over to radius programming DIAMOF and DIAMON will evaluate the end point specification for the X axis as a radius or diameter input The actual value will therefore be displayed in the workpiece coordinate sy stem Programming DIAMOF radius input DIAMON diameter input Diameter data input X Radius data input X DIAMON Transversal axis DIAMOF Transverse axis Longitudinal axis Fig 8 4 Diameter and radius data input f
21. cee eens Special Cases of Tool Radius Compensation 00 cc eee Example of Tool Radius Compensation 00 cee ene eee eens Using MINO TOOS oe aes eae terete hoes oooh oe oe A wees oe ee eee Fee cores re Tool compensation special cases 0 cc eee nnees Miscellaneous Function M 0 00 cee ee eee eee eee eee ene AL TUMCUON 6 2222 62460r85 eu coerce iow shee eee eee bee he ee eee eee eee RTA Arithmetic parameters R LUD and PLC variables Arithmetic parameters R a lt c0iccecae coded dand doeedaw bedvadendeecddaw de dedaad ee Local luserdata LUDI 2 veces des See noes irinn Foe hres Bee ee TEE oes Bee ee Reading and writing PLC variables 0 0 0 ccc ccc eee Program JUMPS seers odie rered Cain at cadena taone eee beanie EEE EER barton eine Jump Destination for Program Jumps Unconditional Program JUMPS 4 0002 eiseutetalwversaveiseeddbelaeededeisoudad es Conditional Program JUMPS 0 0 eee eee eens Programming Example of JUMPS 00 ccc eee eee e teen enas Subroutine Technique 0 teen een e eee een enees C ee ee ee a ee ee ee ee eee eee ee eee Calling Machining Cycles Timer and Workpiece Counter PUPS MIMD a5 ot tees Se eee 5a 4 6 bee beet ee Se obey Se ah oe 4 eee ees oo Workpiece Counter 0 ccc tent ee eee tenn e eee e ne eneenee Language commands for tool monitoring Overview Tool Monitoring 0 eee etna TOOMMEIMOMMN
22. gear stage selected automati for spindle n cally for spindle 1 M41 to M45 Gear stage 1 to gear step 5 Mn 41 to Gear stage 1 to n 10r 2 M2 41 1st gear stage for spindle 2 Mn 45 gear stage 5 for spindle n M70 M19 reserved do not use M Remaining M functions functionality is not defined on side of the control sy stem and is thus free for use by the machine manufac turer N Block number of auxiliary 0 9999 9999 can be used to mark blocks with a number is used in N20 block only integer no sign the beginning of a block Block number of main 0 9999 9999 special marking of blocks instead of N this block 20 block only integer no sign should contain all statements for the next following complete section of machining P Number of subroutine cy 1 9999 is used if the subroutine is run several times and is L781 P separate block cles only integer no sign contained in the same block as the call N10 L871 P3 passed three times RO Arithmetic parameters 0 0000001 R1 7 9431 R2 4 bto 9999 9999 R299 8 decimal places or with exponent specification 10 300 10 300 with exponent specification R1 1 9876EX9 R1 1 987 600 000 Arithmetic functions Apart from the 4 basic arithmetic operations using the operands there still are some other arithme tic functions SIN Sine specified in degrees e g R1 SIN 17 35 COS Cosine specified in degrees e g
23. 6 3 Blueprint programming Table 6 1 Input in the interactive screenform continued Angle of straight line 2 A2 The angle is specified in the counterclockwise direction from O to 360 degrees Feedrate F Feedrate G2 G3 OK Use this interactive screenform to create a circular block using the coordinates end point and center point PROGRAH Program editor DEHO1 MPF Not selected Form sector Center end point Fig 6 12 Enter the end point and center point coordinates in the input fields Input fields no longer nee ded are hidden Use this softkey to switch the direction of rotation from G2 to G3 G3 will appear on the display Pressing this softkey again will switch back the display to G2 Pressing the OK softkey will accept the block into the part program This function will calculate the tangential transition between a contour and a circle sector The straight line must be described by the starting point and the angle The circle must be described by the radius and the end point For calculating the points of intersection with any transition angles the POI softkey function will display the center point coordinates SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 6 81 Part Programming 6 3 Blueprint programming Program editor DEHMO1 MPF Not selected a Input form line circle G2 G3 Addit Functions 0 Fig 6 13 Straight line
24. 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Table of Contents 7 OVSICN correia tien res sue eceeuatesenecam cue eneesebabeeeEwtneraeasaeeneseecwen 7 1 PLC diagnosis using the ladder diagram representation 7 1 1 Creen ayoul suc cee Sa es oon See ER eee a ewes Be ee ee Ree eo es 7 1 2 Operating OpUONS cscac5s cane eee EN ee eh beh See AERA wh Odes e eee eee 8 Programming gencctnsc cece hocensceweacsagesenseeameneceuaseaeeecemaunee cee es 8 1 Fundamentals of NC Programming 000c cece cence eee tent n teen en eeas 8 1 1 PlOGhan NAICS te ceutecehous ae eeees es ce uee ne seen tet sree a ee eee set okeee es 8 1 2 Programi SIFUCIUING cca 2 2cecneceeneeceseudeen eee duets AE iNES ese e Ee EREE eases 8 1 3 Word Structure and Address 0 n eee e tenes 8 1 4 Silele Go lel ee ee ee ee 8 1 5 Character gel 2 4 0 4 4 oe snag ek EAA eho eee ees be eet ea eee eee eee 8 1 6 LISE GL DIGtCIMGUIS 6 24 08 be yee eroderen sot bees eek e a beeen eek bees sos beens 8 2 POSON DAT eese ee ee ee ee ee eee 8 2 1 Absolute Incremental Data Input G90 G91 AC IC 8 2 2 Metric and Inch Dimensions G71 G70 G710 G700 8 2 3 Radius Diameter Programming DIAMOF DIAMON 8 2 4 Programmable Zero Offset TRANS ATRANS 00 0c cece eee eee 8 2 5 Programmable Scaling Factor SCALE ASCALE 0 ees 8 2 6 Workpiece Clamping Settable Zero Offset G54 10 G59 G500 G53 Gls ariere rr bs hb wea eed
25. 9 4 14 Circle of holes HOLES2 Programming HOLES2 CPA CPO RAD STA1 INDA NUM Parameter Table 9 12 Parameters of HOLES2 Center point of circle of holes absolute 1st axis of the plane Center point of circle of holes absolute 2nd axis of the plane Radius of circle of holes enter without sign STA1 real Starting angle Range of values 180 lt STA1 lt 180 degrees INDA Incrementing angle NUM int Number of holes SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T 9 273 Cycles 9 4 Drilling cycles Function Use this circle to machine a circle of holes The machining plane must be defined before the cycle is called The type of hole is determined by the drilling hole cycle that has already been called modally oN OA 3 X Se ty Ni K Ros Sets 0 D 0 Fig 9 24 Operational sequence In the cycle the drilling positions are approached one after the other in the plane with GO Fig 9 25 SINUMERIK 802D 802D base line 9 274 6FC5 698 2AA00 O0BPS3 11 03 OP T Cycles 9 4 Drilling cycles Explanation of the parameters Y CPA CPO Fig 9 26 CPA CPO and RAD center point position and radius The position of the circle of holes in the machining plane is defined via center point parame ters CPA and CPO and radius parameter RAD Only positive values are permitted for the radius
26. 9 4 5 Cycles 9 4 Drilling cycles Deep hole drilling CYCLE83 Programming Parameters Function CYCLE83 RTP RFP SDIS DP DPR FDEP FDPR DAM DTB DTS FRF VARI Table 9 3 Parameters of CYCLE83 SDIS Safety clearance enter without sign DP real Final drilling depth absolute ee Final drilling depth relative to the reference plane enter wi thout sign FDEP First drilling depth absolute FDPR real First drilling depth relative to the reference plane enter wi thout sign DAM real Amount of degression enter without sign Dwell time at final drilling depth chip breaking Dwell time at starting point and for swarf removal FRF real Feedrate factor for the first drilling depth enter without sign Range of values 0 001 1 VARI int Machining type Chip breaking 0 Swart removal 1 The tool drills at the programmed spindle speed and feedrate to the entered final drilling depth Deep hole drilling is performed with a depth infeed of a maximum definable depth executed several times increasing gradually until the final drilling depth is reached The drill can either be retracted to the reference plane safety clearance after every infeed depth for swarf removal or retracted in each case by 1 mm for chip breaking Operational sequence Position reached prior to cycle start The drilling position is the position in the two axes of the selected plane SINUMERIK 802D 802D base line 6FC5 698 2AA0
27. AXIS1 Network symbol data table Signal to Axis Interface Messuring system 1 LS aS Tee A m al PLC Status CEUC GMES i Window S Cross info status list SBR32 SBR33 refs Fig 7 40 Network symbolic Giese softkey to display the list of cross references All operands used in the PLC project are dis refs prayed This list indicates in which networks an input output flag etc is used Absolute address Open in window 1 Open in 1119 M251 0 MAIN OBD Network 2 EMG SP 1134 FOVEPOS E HCPESTHUNCSBRS Netvork HOVM indov 2 1120 MS E E 2G STP 1135 MCP_LSIMU SBR3 Netuork 4 cmo Cross refs Cross refs Al a A a PLC PLC Status Window 1 Window 2 PLC PLC Status Window 1 Window 2 info status list OB1 SBR33 info status list SBR37 SBR33 Fig 7 41 The Cross references main menu absolute symbolic Furthermore it is possible to jump quickly to a desired position in the program in the windows 1 2 with reference to the selected operand s or symbol using the Open in function SINUMERIK 802D 802D base line 7 128 6FC5 698 2AA00 OBP3 11 03 OP T Symbolic address Absolute address Open in window 1 Open in window 2 Find System Z PLC diagnosis using the ladder diagram representation Depending on the active type of representation the elements are displayed either with absolute or symbolic iden
28. Programming example N10 SPOS 14 3 Spindle position 14 3 degrees N80 GO X89 Z300 SPOS 25 6 positioning of spindle with axis movements The block is only completed if all movements are completed N81 X200 Z300 Block N81 will only start if the spindle position programmed in N80 is reached SINUMERIK 802D 802D base line 8 182 6FC5 698 2AA00 OBP3 11 03 OP T 8 4 4 Function 8 4 5 Function Programming 8 4 Spindle Motions Gear stages Up to 5 gear stages can be configured for a spindle for speed torque adaptation The gear stage is selected in the program via M commands see Section 8 7 Miscellaneous function M e M40 automatic gear stage selection e M41 to M45 gear stages 1 to 5 2nd spindle With the SINUMERIK 802D with SW 2 0 and higher a 2nd spindle is provided Not with 802D bl With SW 2 0 and higher the kinematic transformation functions TRANSMIT and TRACYL are possi ble for the milling machining on turning machines These functions require a 2nd spindle for the driven milling tool When using these functions the main spindle is operated as a rotary axis See Section 8 14 Master spindle The master spindle results in various functions which are only possible with this spindle e G95 Revolutional feedrate e G96 G97 Constant cutting rate e LIMS Upper limit speed with G96 G97 e G33 G34 G35 Q331 Q332 Thread cutting thread interpolation e M3 M4 M5 S Simple specif
29. circle with tangential transition Table 6 2 Input in the interactive screenform End point of the circle E Enter the end point of the circle Angle of straight line A The angle is specified in the counterclockwise direction from 0 to 360 degrees Radius of the circle R Input field for the circle radius Feedrate F Input field for the interpolation feedrate Center point of the M If there is no tangential transition between the straight line and the circle circle the circle center point must be known The specification is performed depending on the type of calculation absolute incre mental or polar coordinates selected in the previous block Use this softkey to switch the direction of rotation from G2 to G3 G3 will appear on the display aaee Pressing this softkey again will switch back the display to G2 The display changes to G2 zG You can choose between tangential or any transition The screenform generates a straight line and a circle block from the data you have entered If several points of intersection exist the desired point of intersection must be selected from a dialog box If one coordinate was not entered the program tries to calculate it from the existing specifica tions If there are several possibilities a dialog box is provided to choose from This function will calculate the tangential transition between a straight line and a circle sector The circle
30. fields can therefore only be carried out within the limit values specified in the machine data Programmed LIMS Programmable upper speed limiting LIMS at constant cutting speed G96 Dry run feed DRY The feed that can be entered here will be used instead of the programmed feed in automa tic mode if the function Dry run feed is selected Start angle for thread cutting SF For thread cutting a start position for the spindle is displayed as the start angle If the thread cutting operation is repeated a multiple thread can be cut by modifying the angle SINUMERIK 802D 802D base line 3 44 6FC5 698 2AA00 OBP3 11 03 OP T Setting Up 3 4 Programming Setting Data Operating Area Parameters j 0 9 Position the cursor bar on the input box you wish to modify enter value s 2 Use the Input key or carry out a cursor movement to confirm your input Softkeys Worcs The work area limiting is active for the geometry and for additional axes Enter the values for the limit work area limiting The softkey Set Active enables disables the values for the axis selected using the cursor Axis Minimal Maximal Active Unit Set 9 688 iai active mm I E e Back R Setting parameter ELT Fig 3 20 Time counter OFFSET PARAH Timer Counter Part total Parts required Part count Run time Cycle time Cutting time Setup time Powe
31. grammed A compensating chuck is used in machining SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 255 Cycles 9 4 Drilling cycles N10 G90 GO G54 D1 T6 S500 M3 Specification of the technological values N20 G17 X0 Z60 Approaching the drill position N30 G1 F200 Determination of the path feed N40 CYCLE840 3 0 15 0 0 0 3 5 Cycle call no safety clearance N50 M30 End of program 9 4 8 Reaming 1 boring 1 CYCLE85 Programming CYCLE85 RTP RFP SDIS DP DPR DTB FFR RFF Parameters Table 9 6 Parameters of CYCLE85 Final drilling depth relative to the reference plane enter wi thout sign Dwell time at final drilling depth chip breaking Retraction feedrate Function The tool drills at the programmed spindle speed and feedrate to the entered final drilling depth The inward and outward movement is performed at the feedrate assigned to FFR and RFF respectively Operational sequence Position reached prior to cycle start The drilling position is the position in the two axes of the selected plane SINUMERIK 802D 802D base line 9 256 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 4 Drilling cycles Fig 9 11 The cycle creates the following sequence of motions e Approach of the reference plane brought forward by the safety clearance by using GO e Traversing to the final drilling depth with G1 and at the feedrate programmed under the parameter FFR e Dwel
32. no block number exists N100 the block number can be the jump destination 8 10 2 Unconditional Program Jumps Functionality NC programs execute their blocks in the order in which they have been allocated on writing The order of execution can be changed by inserting program jumps Jump destination can be a block with a label or with a block number This block must be in side the program The unconditional jump instruction GO TO statement requires a separate block SINUMERIK 802D 802D base line 8 210 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 10 Program Jumps Programming 8 10 3 GOTOF Label jump forward in the direction of the last block of the program GOTOB Label jump backwards in the direction of the first block of the program Label selected character sequence for label or block number Program execution N10 GOX Z Ee eae a ne EE N20 GOTOF LABELO_ jump to label LABELO 08088 E C eee rr N50 LABELO R1 R2 R3 N51 GOTOF LABEL1_ jump to label LABEL1 SSeS SS O S N100 M2 end of program LABEL X Z ee a N150 GOTOB LABEL2 jump to label LABEL2 LABEL2 X Z Fig 8 51 Unconditional jumps example Conditional Program Jumps Functionality After the IF statement jump conditions are programmed If the jump condition is not fulfilled value not zero the jump is carried out Jump destination can only be a block with a label or with a block number This block mus
33. the parameter INDA has been omitted N50 MCALL Deselect modal call N60 M2 End of program SINUMERIK 802D 802D base line 9 276 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 5 Turning cycles 9 5 Turning cycles 9 5 1 Preconditions The turning cycles are part of the configuration file setup_T cnf which is loaded into the user memory of the control system Call and return conditions The G functions effective prior to the cycle call remain active beyond the cycle Plane definition The machining plane must be defined prior to the cycle call With turning it is usually the G18 ZX plane The two axes of the current plane in turning will be called in the following longitu dinal axis first axis of this plane and transverse axis Second axis of this plane In the turning cycles with diameter programming active the second axis is taken into ac count as the transverse axis in all cases see Programming Guide Transverse axis Longitudinal axis Fig 9 28 Contour monitoring referred to the tool clearance angle Certain turning cycles in which traversing motions with relief cutting are generated monitor the clearance angle of the active tool for a possible contour violation This angle is entered in the tool compensation as a value in the D offset under the parameter DP24 A value bet ween 1 and 90 degrees O no monitoring without sign must be specified for the angle SINUMERIK 802D 802D base line 6FC5 6
34. values TRUE 1 FALSE 0 DEF CHAR varname2 TypeChar 1 character in the ASCII code a b code numerical value 0 255 DEF INT varname3 Type Integer integer values 32 bit range of values 2 147 483 648 to 2 147 483 648 decimal DEF REAL varname4 Type Real natural number as arithmetic parameter R Range of values 0 000 0001 9999 9999 8 decimals and sign and decimal points or Exponential notation 10 399 10 900 Each type requires a separate program line It is however possible to define several varia bles of the same type in a line Example DEF INT PVAR1 PVAR2 PVARS 12 PVAR4 4 variables of the type INT In addition to individual variables it is also possible to define one or two dimensional fields of variables of these data types DEF INT PVAR 5 n one dimensional field of the type INT n integer DEF INT PVAR6 n m two dimensional field of the type INT n m integer Example DEF INT PVAR7 3 field with 3 elements of the type INT Access to the individual field elements is granted in the program via the field index each indi vidual field element can be handled as an individual variable The field index ranges from 0 to less number of elements Example N10 PVAR7 2 24 The third field element with index 2 is assigned the value 24 Value assignment for the field that contains a SET statement N20 PVAR5 2 SET 1 2 3 From the 3rd field elemen
35. 000 Y8G 000 F658 9 B block CYCLE82 R12 1 666 12 666 1 666 1 8898 1 8990 N66 X166 296 F1i888u Copy Gi G96 X26 666 Y86 666 F656 666u block G2 G96 X46 666 Y86 666 116 666 J6 6606 F866 666u Gi X46 606 Y46 606u Tess CYCLE72 LOADi 1 666 1 606 15 600 1 660 46 866 1 600 2 6660 block 3 506 4 566 11 41 1 1 606 3 688 1 1 666 u G3 X660 666 Y46 666 116 666 J6 6000 Dolste N75 F856 260 block Gi G96 X26 066 Y86 660 F656 6600 N76 X 21660 N86 GOTOB ANAU Find N96 M2 eof Renumber Edit Contour Turning X A lation Fig 6 4 The Program Editor main screen Menu tree Zoom Mark To block origin Copy Show block oe Insert block Zoom Delete Z block oom Delete Find window Cursor co Fig 6 5 The Program menu tree 1 oe lt Zooms zom The softkeys marked with an gt k asterisk are only available with 802D bl with color display option SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 6 75 Part Programming 6 2 Editing a Part Program Operating Mode Program Operating sequence Softkeys Edit Execute Mark block Copy block Insert block Delete block Find Renumber Contour Drill Milling Turning Recompile Simulation 6 76 Use the Program manager to select the program yo
36. 1 5 9 Longitudinal int VARI 3 7 11 Longitudinal int VARI 3 7 11 Face internal VARI 4 8 12 or after rechucking Face external VARI 2 6 10 or after rechucking 9 298 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Cycles 9 5 Turning cycles DT and DAM dwell time and path length These parameters can be used to achieve an interruption of the individual roughing steps after certain distances traversed in order to carry out chip breaking These parameters are only relevant for roughing The parameter DAM is used to define the maximum distance after which chip breaking is to be carried out In DT an appropriate dwell time in seconds can be programmed which is carried out at each of the cut interruption points If no distance is speci fied for the cut interruption DAM 0 uninterrupted roughing steps without dwell times are created Uninterrupted paraxial cut i G1 Infeed motion y Fig 9 52 _VRT retraction travel Parameter _VRT can be used to program the amount by which the tool is retracted in both axes when roughing If _VRT 0 parameter not programmed the tool will retract by 1 mm Further notes Contour definition The contour must contain at least 3 blocks with motions in the two axes of the machining plane If the contour is shorter the cycle is aborted after the alarms 10933 Number of contour blocks contained
37. 10 gt 400 To calculate auxiliary points on a contour the calculator provides the following functions e Calculating the tangential transition between a circle sector and a straight line e Moving a point in the plane e Converting polar coordinates to Cartesian coordinates e Adding the second end point of a straight line straight line contour section given from an angular relation Softkeys R18 R1 R26 R21 R22 R23 R24 ate a point at CC absc G2 Acc ordi LIN aie A CC radius diamete Fig 1 5 circie issa M nate R r programming This function is used to calculate a point on a circle The point results from the angle of the tangent created the radius and the direction of rotation of the circle a Enter the circle center the angle of the tangent and the circle radius Use the softkey G2 G3 to define the direction of rotation of the circle SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T Introduction 1 3 Accessibility Options When you press this softkey the abscissa and ordinate values are calculated The abscissa is the first axis and the ordinate is the second axis of the plane The value of the abscissa is copied into the input box from which the calculator function has been called and the value of the ordinate is copied into the next following input box If the function has been called from the part program editor the coordinates are saved with the a
38. 186 N10 M3 direction of rotation of spindle N20 G96 S120 LIMS 2500 constant cutting speed ON 120 m min limit speed 2 500 rom N30 GO X150 no speed change because of block N31 with GO N31 X50 Z no speed change because of block N32 with GO N32 X40 contour approach new speed will automatically be set such as required for the start of block N40 N40 G1 FO 2 X32 Z Feed 0 2 mm rev N180 G97 X Z disable constant cutting speed N190 S new spindle speed rom The function G96 can also be switched off using either G94 or G95 same G group In this case the spindle speed S last programmed will also be effective for the further sequence of machining if no new S word is programmed The programmable offset TRANS or ATRANS see Chapter of the same name should not or only with small values be applied to the transversal axis X The workpiece zero point should be in the turning center Only thus the exact function of G96 is guaranteed SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 5 Special Turning Functions 8 5 2 Rounding Chamfer Functionality You can insert the elements chamfer or rounding into any contour corner The corresponding statement CHF or RND is programmed in the block containing the axis movements leading to the corner Programming CHF Insert chamfer value length of chamfer RND Insert rounding value radius of rounding Chamfer C
39. 5 5 Repositioning after interruption After a program interruption NC STOP you can retract the tool from the contour in the Ma nual mode Jog the coordinates of the interruption point are stored by the control system The path differences traversed by the axes are displayed Operating sequence Select the AUTOMATIC mode lt p gt Press NC START to continue the program execution Caution When reapproaching the interruption point all axes will traverse at the same time Make sure that the traversing area is not obstructed SINUMERIK 802D 802D base line 5 68 6FC5 698 2AA00 OBP3 11 03 OP T Automatic Mode 5 6 Program Execution from External RS232 Interface 5 6 Program Execution from External RS232 Interface Functionality An external program is transferred to the control system via the RS232 interface and executed immediately by pressing NC START While the buffer memory is processed reloading is carried out automatically For example a PC on which the PCIN tool for external data transfer is installed can be used as the external device Important Always connect and diconnect the V24 cable when the PCU and the PC are switched off Operating sequence Prerequisite The control system is in the RESET state The RS232 interface is parameterized correctly see Chapter 7 and not occupied by any other application Dataln DataOut STEP7 External Press this softkey progr Use the PCIN
40. 6FC5 698 2AA00 OBP3 11 03 OP T Manually Controlled Operation Manually controlled operation is possible in Jog and MDA modes The softkeys marked with an gt k asterisk are not available with the 802D bl Set Measure Measure base workpiece tool Settings x 0 Measure Data manual lt probe 7 0 Work Measure offset auto 4 os Ta Switch mm gt inch Delete Calibrate base WO probe gt k NN Set work a Fig 4 1 Jog menu tree Set Settings x 0 Peripher Data surface probe lt Ue UL Set rel Switch mm gt inch Delete base WO 0 O Fig 4 2 MDA menu tree SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 4 49 Manually Controlled Operation 4 1 Jog Mode Operating Area Position 4 1 Jog Mode Operating Area Position Operating sequence Ea Use the Jog key on the machine control panel to select Jog mode N X Z To traverse the axes press the appropriate key of the X or Z axis As long as this key is hold down the axes will traverse continuously at the rate defined in the setting data If the value in the setting data is zero the value stored in the machine data will be used Set the speed using the override switch If you also press the Rapid Traverse Override key the selected axis will be traversed at rapid tra verse velocity as long as the keys are hold down In Incremental Dimension mode you can use the same opera
41. 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 12 Timer and Workpiece Counter SETPIECE x x 1 32000 Number of workpieces produced since the last execution of the SETPIECE function The count for the residual count 6TC_MOP4 t d is reduced by this value X2 0 Deletion of all counters for the residual count S TC_MOP4Jt d for the tools D number involved in machining since then Alternatively the deletion via operation is recommended HMI Programming example N10 GO X100 N20 N30 T1 N40 M6 N50 D1 N60 SETPIECE 2 TC_MOP4 1 1 T1 D2 is decremented by 2 N70 T2 N80 M6 N90 SETPIECE 0 deletion of all tools above N91 D2 N100 SETPIECE 1 TC_MOP4 2 2 T2 D2 is decremented by 1 N110 SETPIECE 0 deletion of all tools above N120 M30 Notes The command SETPIECE does not act during block search Programming TC_MOP4 t d directly is only recommended in the simple case In this case a block that contains the STOPRE command must be programmed after this command Setpoint update As a rule updating of the setpoints i e setting of the residual workpiece quantity counters TC_MOP4 t d to the setpoint count 6TC_MOP1 3Jt d is carried out via operation HMI It is also possible however as described for the tool life monitoring via the function RESETMON state t d mon Example DEF INT state Defining a variable for the status feedback in the beginning of the program
42. 8B 8 008 mm oa Q 00A 8 008 mm 8 809 190 p 6 660 mm min 8 8 100 oe a a easure Tool Settings leasu re Tool PAYERS ia measure Mi Measure Fig 3 18 Screen form Determine zero offset in X Screen form Determine Zero offset in Z ee The softkey will calculate the offset and will display the result in the Offset box offset Press Abort to quit the window Abort SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 3 43 Setting Up 3 4 Programming Setting Data Operating Area Parameters 3 4 Programming Setting Data Operating Area Parameters Functionality The setting data are used to make the settings for the operating states These can be modi fied if necessary Operating sequence Use the Offset Parameters and Setting Data softkeys to open the Setting Data window OFFSET PARAM The Setting Data softkey will branch into another menu level where various control options Setting can be set data JOG feedrate nn min Spindle speed rpm Spindle data Limitation with G96 DRY Dry run feedrate nn min Start angle Start angle for thread Fig 3 19 Main screen Setting data Jog feed Feed value in Jog mode If the feed value is zero the control system will use the value stored in the machine data Spindle Spindle speed Min max A limitation of the spindle speed in the max G26 min G25
43. 9 3 Note If a value is entered both for DP and for DPR the final drilling depth is derived from DPR If this differs from the absolute depth programmed via DP the message Depth Corresponding to value for relative depth is output in the dialog line If the values for reference and retraction planes are identical a relative depth specification is not permitted The error message 61101 Reference plane not correctly defined and the cycle is not executed This error message is also output if the retraction plane is located after the reference plane i e its distance to the final drilling depth is smaller Programming example Drilling_centering Using this program you may produce 3 drill holes using the drilling cycle CYCLE81 whereby this is called using different parameters The drilling axis is always the Z axis SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 241 Cycles 9 4 Drilling cycles Fig 9 4 N10 GO G17 G90 F200 300 M3 N20 D3 T3 Z110 N30 X40 Y120 N40 CYCLE81 110 100 2 35 N50 Y30 N60 CYCLE81 110 102 35 N70 GO G90 F180 S300 M03 N80 X90 N90 CYCLE81 110 100 2 65 N100 M30 9 242 Specification of the technological values Approaching the retraction plane Approach of the first drilling position Cycle call with absolute final drilling depth safety clearance and incomplete parameter list Approach of next drill position Cycle call without safety
44. A_MONI FACT AA_FXS axis AA_MM ax is AA_MW a xis AC_MEAI1 Coordinate in incremental dimension Jump condition Upper limit speed of spindle with G96 Measuring with deleting the distance to go Measuring without dele ting the distance to go Data byte Data word Data double word Real data Factor for tool life monito ring Status travel to fixed stop Measurement result of an axis in the machine coor dinate system Measurement result of an axis in the workpiece coordinate system Measuring order state 0 001 99 999 999 1 1 1 1 gt 0 0 For certain blocks the dimensional specification for end or center point of a certain axis can be specified other than defined by G90 G91 If the GoTo condition is fulfilled the branch jump to the next block containing the label is carried out other wise next statement block several IF statements are possible in a block Comparison operands equal to lt gt not equal gt greater than lt less than greater than or equal to lt less than or equal to limits the spindle speed if the function G96 constant cutting speed for turning is enabled 1 Measuring input 1 rising edge 1 Measuring input 1 falling edge 1 Measuring input 1 rising edge 1 Measuring input 1 falling edge Reading and writing of PLC variables Initialization value 1 0 Values 0 5 axis machine axis identif
45. Absolute position P4 Absolute position of the prober in the X direction Feedrate Feedrate at which the tool is moved towards the probe Calibrating the probe Calibrate The calibration of the probe can be carried out either in the Settings menu or in the Measure tool robe menu To do so approach four points of the probe For calibration use a tool of the type 500 with tool tip position 3 or 4 SINUMERIK 802D 802D base line 3 38 6FC5 698 2AA00 OBP3 11 03 OP T Setting Up 3 1 Entering Tools and Tool Offsets The appropriate parameters to determine the four probe positions can be written to the data records of two cutting edges Position Repos offset Q l HBG 6 668 mn 6 066 mn og Next i 00A mm min Step 8 position P1 position P2 position P3 position P4 Approach probe with the following axis Z hemme Heasure TE workpiece Baal Fig 3 13 Calibrating the probe After the screen form has opened an animation signaling the current step to be carried out appears next to the current positions of the probe This position must be approached with the appropriate axis pote z After the symbol Probe triggered has appeared release the traversing key and wait e until the end of the measuring process During the automatic measuring process a gauge 2 is displayed symbolizing the progress of the measuring process The position provided by the measuring program serves to calculat
46. Corner behavior at an external corner Int corner Intersection point Fig 8 44 Corner behavior at an internal corner SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 197 Programming 8 6 Tool and Tool Compensation Transition circle G450 The tool center point traverses round the workpiece external corner with the tool radius along an arc From the point of view of data technology the transition circle belongs to the next block with traversing movements e g as far as the feed value is concerned Intersection point G451 With G451 intersection point of the equidistants the point intersection point is approa ched which results from the center point paths of the tool circle or straight line 8 6 6 Tool Radius Compensation OFF G40 Functionality To cancel compensation mode G41 G42 G40 is used This function is also the default posi tion when the program starts The tool completes the block prior to G40 in normal position compensation vector vertically to the tangent at the end point irrespective of the leaving angle If G40 is active the reference point is the tool tip When canceled the tool tips will thus appro ach the programmed point Always select the end point of the G40 block such that collision free traversing is guaranteed Programming G40 X Z tool radius compensation OFF Note Compensation mode can only be canceled with linear interpolation GO G1 Program
47. Corrected PO start point tool path PO starting point Circle i G42 Corrected ve o tool path R tool nose radius P1 starting point of contour Ic Tangent Fig 8 42 Start of tool radius compensation using the example G42 edge position 3 Information The block containing G41 G42 is usually followed by the first block containing the workpiece contour The contour description however may be interrupted by an intermediate block which does not contain any information on the contour path e g only an M command SINUMERIK 802D 802D base line 8 196 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 6 Tool and Tool Compensation Programming example N10 T F N15 X Z PO start point N20 G1 G42 X Z selection right of the contour P1 N30 X Z Start contour circle or straight line 8 6 5 Corner Behavior G450 G451 Functionality The functions G450 and G451 can be used to set the behavior in case of a non continuous transition from one contour element to another contour element corner behavior with G41 G42 enabled Internal and external corners are recognized by the control system itself With internal corners the intersection point of the equidistant path is approached in all cases Programming G450 transition circle G451 intersection point Ext corner G450 Transition circle Ext corner G451 Intersection radius tool radius point Fig 8 43
48. DIAHONG G2 G96 Z 202 54467 X88 85279 K 56 66606 I6 66660 G1 2 228 91667 X182 29441 amp G3 G96 Z 376 28925 X251 96644 K 87 68933 I 49 1472 G1 Z 391 2843 X224 81582 G2 Z 413 66606 X212 66666 K 21 7157 I33 59269 Pal a au ram ea Ag More Edit RV Drilling Milling Turning Seales E lation compile Fig 6 21 Result of step 2 The function calculates the tangential transition between two circle sectors Circle sector 1 must be described by the parameters starting point center point and radius and the circle sector 2 be des cribed by the parameters end point and radius PROGRAH Program editor TEST MPF Not selected Input form circle circle G31G2 G98 POI tang E 2 x Addition functions 0 Abort Value of ist axis of contour endpoint plane on circle 2 rrer ee eee eee Fig 6 22 Tangential transition Table 6 5 Input in the interactive screenform End point of circle 2 E 1st and 2nd geometry axes of the plane Center point of the M1 1st and 2nd geometry axes of the plane circle 1 Radius of circle 1 R1 Input field for the radius Center point of circle 2 M2 1st and 2nd geometry axes of the plane Radius of circle 1 R2 Input field for the radius Feedrate F Input field for the interpolation feedrate The specification of the points is performed depending on the type of calculation absolute incremental or polar coordinates selected before
49. Explanation Tool Input of the tool to be used The tool is changed prior to the machining To this aim the function will call a user cycle that will carry out all steps required This cycle is provided by the machine manufacturer Feed F Input of feedrate in mm min or mm rev Spindle S Input of spindle speed rpm Machining Determination of surface quality It is possible to choose between roughing and finishing Diameter Input of the coarse diameter of the part ZO Input of Z position Blank dimen sion Z1 Cutting dimension incremental Cutting dimension DZ Input of cutting length in Z direction Cutting dimension This dimension is always specified in increments and is referred to the workpiece edge UZ Allowance in Z direction Max infeed per cut UX Max infeed per cut Allowance in X direction surface Peripher 4 58 Longitudinal turning SKP DRY ROY MO1 PRT SBL DEMO1 HPF Peripher surface ool number T 1 0 000 mnm rev 6 666 rpm rough 1 909 abs 6 108 inc 1 809 abs 0 100 inc 8 188 inc 0 509 inc 0 500 inc Retract plane not defined a Fig 4 9 Longitudinal turning SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Manually Controlled Operation 4 2 Operating Mode MDA Manual Input Table 4 4 Description of the parameters in the Face Turning window Parameters Explanation Tool Input of the tool to be used The tool is
50. F value must be programmed X transversal axis Sp spindle speed D1 Do diameter D1 X Sp1 De x Sp2 Dp X Spn constant Fig 8 27 Constant cutting speed G96 Traversing at rapid traverse When traversing at rapid traverse GO the speed is not changed Exception If the contour is approached at rapid traverse and the next following block con tains either of the interpolation types G1 or G2 G3 CIP CT contour block the speed for the contour block is already set in the approach block using GO SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 185 Programming 8 5 Special Turning Functions Upper limit speed LIMS When machining from large to small diameters the spindle speed may increase substantially In this case it is recommended to specify the upper spindle speed limitation LIMS LIMS only applies with G96 and G97 If LIMS is programmed the value entered in the setting data is overwritten The upper limit speed either programmed via G26 or defined in the machine data cannot be exceeded if LIMS is programmed Disabling constant cutting speed G97 The function Constant cutting speed is disabled using G97 If G97 is enabled any S word programmed will be interpreted again as a spindle speed specified in revolutions per minute If no new S word is programmed the spindle will rotate at the speed last determined with the G96 function active Programming example Information 8
51. If the axis is programmed in a separate block with G1 it will traverse with the active feedrate F In case of a rotary axis the unit for F is degrees min with G94 or degrees spindle revolution with G95 The offsets for this axis can be set G54 G57 and programmed TRANS ATRANS Programming example 8 176 Supposed the 4th axis is a rotary axis with axis identifier A N5 G94 F in mm min or degrees min N10 GO X10 Z30 A45 traversing along X Z path at rapid traverse A at the same time N20 G1 X12 Z33 A60 F400 traversing along X Z path at 400mm min A at the same time N30 G1 A90 F3000 axis A traverses alone to the 90 degrees position at a traversing rate of 3 000 degrees min SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 3 Axis Movements Special statements for rotary axes DC ACP ACN e g for rotary axis A A DC absolute data input direct position approach using the shortest possible way A ACP absolute data input position approach in the positive direction A ACN absolute data input position approach in the negative direction Example N10 A ACP 55 7 approach absolute position 55 7 degrees in the positive direction 8 3 18 Dwell Time G4 Functionality You can interrupt the program execution for a defined time by inserting a separate block bet ween two NC blocks using G4 e g for relief cutting The words containing F or S are only used
52. MINAWNNIS TC_MOP3 t d TC_MOP4 t d TC_MOP1 1 t d TC_MOP1 3it d TC_TP8It TC_TPOt MSG OFFN RND RPL SET REP SETMS n SETMS SF Prewarning limit for the number of pieces not with 802D bl Residual number of work pieces not with 802D bl Required tool life not with 802D bl Residual number of work pieces not with 802D bl Tool status not with 802D bl Type of monitoring of the tool not with 802D bl Message Groove width with TRA CYL otherwise specification of stock allowance Rounding Angle of rotation with ROT AROT Set values for the variable fields Define spindle as master spindle Thread start point at G33 0 999 999 999 integer 0 999 999 999 integer 0 0 0 999 999 999 integer 0 2 max 65 characters 0 010 99 999 999 0 00001 359 9999 n 1 orn 2 0 001 359 999 writing or reading values for tool t D number d writing or reading values for tool t D number d in minutes writing or reading values for tool t D number d writing or reading values for tool t D number d default status coding by bits for tool t bit O to bit 4 Monitoring type for tool t writing or reading 0 No monitoring 1 Tool life 2 Count Message text in inverted commas Only effective with the tool radius compensation G41 G42 active inserts a rounding with the specified rad
53. OFFN Selection of the TRC Approach block approaching to the groove side taking into account the TRC Programming of the groove course via the groove center line 9 Deselection of the TRC 10 Retraction block retraction from the groove side taking into account the TRC 11 Positioning 12 Deletion of OFFN 13 TRAFOOF deselection of TRACYL 14 Re selection of the original zero offset see also the programming example below CONDO OF W DY SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 229 Programming 8 14 Milling on turning machines Information Guiding grooves Using a tool diameter that matches exactly the groove width it is possible to produce exact groo ves The tool radius compensation TRC is not disabled in this case Using TRACYL it is also possible to produce grooves with which the tool diameter is less than the groove width In this case the tool radius compensation G41 G42 and OFFN are used efficiently To avoid accuracy problems the tool diameter should be only slightly smaller than the groove width When working with TRACYL with groove side correction the axis used for the correction YM should stand on the turning center Thus the groove is produced centrally to the programmed groove center line Selection of the tool radius compensation TRC The TRC acts towards the programmed groove center line resulting in the groove side To cause the tool moving to the l
54. ON If you change a tool manually you must also enter the change into the control system so that the control system knows the appropriate tool For example you can start a block in MDA mode using the new T word Programming Ne tool number 1 32 000 Note A maximum of 32 tools can be stored in the CNC at a time SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 191 Programming 8 6 Tool and Tool Compensation Programming example 8 6 3 Tool change without M6 N10 T1 stool 1 N70 1588 tool 588 Tool Offset Number D Functionality A tool can be assigned 1 to 9 data fields each containing different tool offset data records for several cutting edges If a special cutting edge is necessary it can be programmed with D and an appropriate number If no D word is programmed D1 will be used by default DO will disable the tool offsets Programming Information D Tool offset numbers 1 9 DO no offsets effective Note A maximum of 64 data fields containing tool offset data records can be stored in the con trol system at a time Each tool has its own correction blocks max 9 Fig 8 34 Assignment of tool offset numbers to the tool example Tool length compensations come into effect immediately if the tool is active if no D number has been programmed the values of D1 are used The compensation is achieved with the first programmed traversing of the length c
55. Range of values 3 for M3 48 for M48 the sign determi nes the direction of rotation in the thread PIT real Pitch as a value signed Range of values 0 001 2000 000 mm the sign determines the direction of rotation in the thread POSS Spindle position for oriented spindle stop in the cycle in de grees SST1 Speed for retraction Function The tool drills at the programmed spindle speed and feedrate to the entered final thread depth CYCLE84 can be used to perform rigid tapping operations Note CYCLE84 can be used if the spindle to be used for the boring operation is technically able to go into position controlled spindle operation For tapping with compensating chuck a separate cycle CYCLE840 is provided SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 249 Cycles 9 4 Drilling cycles Operational sequence Position reached prior to cycle start The drilling position is the position in the two axes of the selected plane The cycle creates the following sequence of motions Approach of the reference plane brought forward by the safety clearance by using GO Oriented spindle stop value in the parameter POSS and switching the spindle to axis mode Tapping to final drilling depth and speed SST Dwell time at thread depth parameter DTB Retraction to the reference plane brought forward by the safety clearance speed SST1 and direction reversal Retraction to the retraction plane
56. SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T Table of Contents Table of Contents 1 INTROGUCHION esere roA A EEA aS 1 1 Seem Lay GUL P E E eee ese he E E E eeee 1 2 Peri leds s1dcetatec save ecetetee hee tes adte eo loae 1 3 Accessibility ODUONS 6 144260 st eectn sth beetc e6to0ehe 05d been bet eceta sed beeps 1 3 1 CCUA ser presene Aree EEEE EE EErEE EEE EEEE ERE REEE 1 3 2 Editing Chinese Characters 1 3 3 OL ee ee ee er en ee eee ee ee ee 1 4 The MeD OYEN seieuee sense bow cos aeeee eee ee eee eso eee ees ESTERA 1 5 Coordinate Systems 2 04012 austen doe deewddenciasd wast eed ewhetes 6eser edd ee Turning on and Reference Point Approach 00 cece eee eee ees 3 DCUING UD gaceacesdeee ese eaeseiweteee teeters nies age tease eetsee sates eases 3 1 Entering Tools and Tool Offsets 0 0 0 ccc eee eee 3 1 1 Creating a New Tool 00 e eee e enn nnees 3 1 2 Determining Tool Offsets Manually 0 0 cee eee tenes 3 1 3 Determining the Tool Compensations Using a Probe 0 0 cc eee eee 3 1 4 Determining the tool compensations values using an optical measuring system 3 1 5 Probe SCuINGS 4 ntcccceuegenssbecceseutaereres Es En ESE ne Ere reei SeS 3 2 TOOL MONRONING ss esst estrar ee eceeesee tebe ed ae ete bs ee betwee nea eke ages eee eats 3 3 Entering Modifying Zero Offset 00 eee eee enna 3 3 1 Determining Zero Offset 0 ccc nnana 3 4 Progr
57. STA1 and INDA starting and incremental angle These parameters define the arrangement of the holes on the circle of holes Parameter STA1 specifies the angle of rotation between the positive direction of the 1st axis abscissa in the workpiece coordinate system active before the cycle was called and the first hole Parameter INDA contains the angle of rotation from one hole to the next If parameter INDA is assigned the value zero the indexing angle is calculated internally from the number of holes which are positioned equally in a circle NUM number Parameter NUM defines the number of holes Programming example Circle of holes The program uses CYCLE82 to produce 4 holes having a depth of 30 mm The final drilling depth is specified as a relative value to the reference plane The circle is defined by the cen ter point X70 Y60 and the radius 42 mm in the XY plane The starting angle is 33 degrees The safety clearance along the drilling axis Z is 2 mm SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T 9 275 Cycles 9 4 Drilling cycles Fig 9 27 N10 G90 F140 S170 M3 T10 D1 Specification of the technological values N20 G17 GO X50 Y45 Z2 Approach starting position N30 MCALL CYCLE82 2 0 2 30 0 Modal call of the drilling cycle without dwell time DP is not programmed N40 HOLES2 70 60 42 33 0 4 Call of the circle of holes cycle the incre mental angle is calculated in the cycle since
58. _ WRITE_SLASH MPF L WRITE_Y MPF we on numa UDN gt p h H pd w N A eal STEP 7 PLC Status PLC Program Edit PLC connect status list program list alarm txt Fig 7 23 This dialog displays all files of the CUS directory and their assignment in the reference list PLCPROG LST in the form of a list You can use the TAB key to switch between the two columns The softkey functions Copy Insert and Delete are displayed with reference to a specific context If the cursor is positioned on the left hand side only the Copy function is available On the right hand side the functions Insert and Delete are offered to modify the reference list This function is not available with the 802D bl writes the selected file name to the clipboard pastes the file name at the current cursor position SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 7 113 System Delete deletes the selected file name from the assignment list Structure of the reference list file PLCPROG LST It is divided into 3 areas Number Area Degree of protection 1 100 User area User 101 200 Machine manufacturer Machine manufacturer 201 255 Siemens Siemens Edit PLC alarm txt Data I O 7 114 The notation is carried out for each program by lines Two columns are intended per line which must be separated from each other by TAB space o
59. aborted Further notes Depending on the settings in machine data MD30200 NUM_ENCS the cycle selects whether tapping is to be performed with or without encoder The direction of rotation for the spindle must be programmed with M3 or M4 before the cycle is called In thread blocks with G63 the values of the feedrate override switch and spindle speed over ride switch are frozen to 100 A longer compensating chuck is usually required for tapping without encoder Programming example Tapping without encoder Tapping is carried out without encoder at position XO the drilling axis is the Z axis The para meters SDR and SDAC for the direction of rotation must be assigned parameter ENC is assi gned the value 1 the value for the depth is the absolute value Pitch parameter PIT can be omitted A compensating chuck is used in machining N10 G90 GO G54 D1 T6 S500 M3 Specification of the technological values N20 G17 X0 Z60 Approaching the drill position N30 G1 F200 Determination of the path feed N40 CYCLE840 3 0 15 0 1 4 3 1 Cycle call dwell time 1 s direction of rotation for retraction M4 direction of rotation after cycle M3 no safety clearance Parameters MPIT and PIT are omitted N50 M2 End of program Example Tapping with encoder This program is used for tapping with encoder at position XO The tapping axis is the Z axis The pitch parameter must be defined automatic reversal of the direction of rotation is pro
60. also Section List of Statements Example SCALE scaling factor ON Extended address With the addresses R arithmetic parameter H H function J K interpolation parameters intermediate point the address is extended by 1 to 4 digits in order to achieve a larger number of addresses In this case the value must be assigned using an equality sign see also Section List of Sta tements Example R10 6 234 H5 12 1 11 32 67 SINUMERIK 802D 802D base line 8 132 6FC5 698 2AA00 0BP3 11 03 OP T Programming 8 1 Fundamentals of NC Programming 8 1 4 Block Structure Functionality A block should contain all data required to execute a step of machining Blocks generally consist of several words and are always completed with the end of block character Le new line This character is automatically generated when pressing the line space key or the Input key on writing IN Word1 Word2 n Wordn Comment Le FoF pe Py BLANK BLANK BLANK BLANK End of block character not visible eee only if necessary Block statements stands at the end separated from the remaining block bya Block number stands in front of the state ments only used if necessary instead of N cc aI i a colon is used in main blocks Skip block instruction only if necessary stands in the be ginning Total number of characters in a block 200 Fig 8 2 Block structure diagram Word
61. and start up of the PLC This softkey can be used to link the PLC with the external PLC 802 Programming Tool If the link is active an appropriate symbol appears in the status bar cf Table 1 2 If the RS232 interface is already occupied by the data transfer you can couple the control sy stem with the programming unit only if the transfer is completed The RS 232 interface is activated with activating the link Communication setup Hodem settings Active communication parameter Hodem active OFF Baud rate Stop bits Parity Data bits Fig 7 16 Enabling disabling RS232 for the Programming Tool The baud rate is set using the toggle field The following values are possible 9600 19200 38400 57600 115200 Communication setup Hodem settings Active communication parameter Hodem active Baud rate Stop bits Parity Data bits E ng Connect on STEP 7 PLC Status PLC Program Edit PLC connect status list progranm list alarm txt Fig 7 17 Settings with the modem active With the modem active ON you can additionally choose between the data formats 10 or 11 bits e Parity None with 10 bit format Even with 11 bit format e Stop bits 1 set by default active with initialization of the control system e Databits 8 set by default active with initialization of the control system SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 7 109 System Connec
62. base line 6FC5 698 2AA00 0BP3 11 03 OP T OFFSET PARAH Tool list 1 Cut edge Active tool no D Tool life min Quantity Setpt Prew 1lt Resid Activ Setpt Prew 1tResid Activ Ro A 1 1 566 666 558 000 557 978 pJ 6 6 8 6 2 1486 666 478 666 6 608 fJ 6 6 8 ead 161 6 666 6 666 96 666 6 6 8 Reset monitoring select parameter Selected tool T 1 All cutting edges Selected cutting edge D 1 All monitorings Selected monitoring Tool life min Fig 3 15 After enable SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T Use this softkey to change the enable status of the selected tool Setting Up Tool monitoring 3 41 Setting Up 3 3 Entering Modifying Zero Offset 3 3 Entering Modifying Zero Offset Functionality After reference point approach the actual value memory and thus also the actual value dis play are referred to the machine zero A machining program however is always referred to the workpiece zero This offset must be entered as the zero offset Operating sequence TA Select Zero Offset via Parameters and Zero Offset A list of settable zero offsets will appear on the screen The screen form also displays the va Ae lues of the programmed zero offset the active scaling factors the status display Mirroring active and the total of all active zero offsets e Sees al 0 BGG OU BO BOB m irie incd c O OBO
63. both axes If you specify only one axis the second axis will be added automatically by the value programmed last Final contour Straight line Final contour Circle f G40 Po Tangent py P1 Circle radiu R cutter radius P1 end point last block with G42 for example P2 end point block with G40 Fig 8 45 Quitting tool radius compensation with G40 using the example of G42 edge position 3 Programming example N100 X Z last block of contour circle or straight line P1 N110 G40 G1 X Z tool radius compensation OFF P2 SINUMERIK 802D 802D base line 8 198 6FC5 698 2AA00 0BP3 11 03 OP T Programming 8 6 Tool and Tool Compensation 8 6 7 Special Cases of Tool Radius Compensation Change of compensation direction The compensation direction G41 lt gt G42 can be changed without programming G40 The last block that contains the old compensation direction ends with the normal position of the compensation vector at the end point The new compensation direction is carried out as a compensation start normal position at start point Repetition G41 G41 or G42 G42 The same contour can be programmed once more without programming G40 The last block prior to the new compensation call ends with the normal position of the com pensation vector at the end point The new compensation is carried out as a compensation start behavior as described for the change of the compensation directio
64. change to continuous path control mode N100 GO G9 Z exact stop is only effective for this block N111 continuous path control mode again Note The command G9 will only create exact stop for the block in which it is programmed G60 however remains active until it is canceled by G64 Continuous path control mode G64 The objective of continuous path control mode is to avoid deceleration at the block borders and to change to the next block at the same tool path velocity if possible with tangential transitions This function uses the principle of look ahead velocity control over several next blocks With non tangential transitions corners the velocity is decreased if necessary such that none of the axes must perform a sudden velocity change or the jerk change in acceleration is limited if SOFT is active Programming example N10 G64 G1 Z F continuous path control mode N20 X continuous path control mode continued N180 G6O change to exact stop SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 173 Programming 8 3 Axis Movements Look ahead velocity control In continuous path control mode with G64 the control system determines the velocity control for several NC blocks automatically In case of approximately tangential transitions it is possi ble to accelerate or decelerate over several blocks In case of paths consisting of several short paths in the NC blocks it is possible t
65. contour the machining steps shown in the illustration result SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 295 Cycles 9 5 Turning cycles 8x4 875mm 2x3 5mm Fig 9 49 Example of calculating the current infeed depth Machining step 1 has a total depth of 39 mm Therefore 8 roughing steps are still required with a maximum infeed depth of 5 mm These are carried out with an infeed of 4 875 mm In machining step 2 8 roughing steps too are carried out with an infeed of 4 5 mm each to tal difference 36 mm In machining step 3 two roughing passes are carried out with a current infeed of 3 5 total difference 7 mm FAL FALZ and FALX finishing allowance A finishing allowance for roughing can be specified either using the parameters FALZ and FALX if you want to specify different finishing allowances axis specifically or via the parame ter FAL for a finishing allowance that follows the contour in this case this value is taken into account in both axes as a finishing allowance No plausibility check is carried out for the programmed values In other words If all three pa rameters are assigned values all these finishing allowances are taken into account by the cycle It is however reasonable to decide either on the one or other form of definition of a finishing allowance Roughing is always carried out up to these finishing allowances The resulting residual corner
66. direction Fig 8 11 Definition of direction of rotation of the circle using G2 G3 The description of the desired circle can be specified in different ways G2 G3 and center point spec end point G2 G3 and radius specification end point X X End point X Z End point X Z e g G2 X Z 1 K e g G2 X Z CRe Circle radiusGFR Center point I J Starting point X Z G2 G3 and aperture angle specification X center point End point X Z e g G2 AR I K e g G2 AR X Z Angle AR Angle AR Center point I K Starting point X Z Starting point X Z Fig 8 12 Possibilities of circle programming G2 G3 is active until it is canceled by another statement of this G group GO G1 For the tooth path velocity the programmed F word is decisive Note Further circle programming facilities are provided by CT circle with tangential connection and CIP circle via intermediate point see next following sections SINUMERIK 802D 802D base line 8 160 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 3 Axis Movements Input tolerances for circle Circles are only accepted by the control system within a certain dimensional tolerance To this aim the circle radius is compared in the starting and in the end points If the difference is wit hin the tolerance the internal setting of the center point will be carried out exactly Otherwise an alarm message is output The toler
67. example SINUMERIK 802D 802D base line 8 214 6FC5 698 2AA00 0BP3 11 03 OP T Programming 8 11 Subroutine Technique Subroutine name In order to be able to choose a certain subroutine from several subroutines offered the pro gram is assigned its own name The name can be freely selected when creating the program provided the following conventions are observed The same rules are applicable as for main program names Example SLEEVE7 In addition for subroutines it is possible to use the address word L 7 decimal places only integer are possible for the value Please note For address L leading zeros are significant for distinction Example L128 is not LO128 or L00128 These are 3 different subroutines Note The subroutine name LL6 is reserved for the tool change Calling subroutines Subroutines are called in a program main program or subroutine by their names This requires a separate block Example N10 L785 call of subroutine L785 N20 SHAFT7 call of subroutine SHAFT7 Program repetition P If you wish a subroutine to be executed several times in succession program the number of passes in the calling block after the subroutine name at address P Max 9 999 passes are possible P1 P9999 Example N10 L785 P3 _ call of subroutine L785 3 passes Nesting depth Subroutines cannot only be called in a main program but also in a subroutine For such a ne sted call 8 program levels inc
68. for monitoring of traveling to fixed stop in mm deg Note The machine axis identifier is preferably written as the axis identifier e g X1 Writing the channel axis identifier e g X is only permissible e g if no coordinate rotation is active and this axis is assigned directly to a machine axis The commands are modal The distance to be traversed and the selection of the function FXS axis 1 must be programmedin a separate block Programming example selection Notes 8 178 N10 G1 G94 N100 X250 Z100 F100 FXS Z1 1 FXST Z1 12 3 FXSW Z1 2 FXS function selected for machine axis Z1 clamping torque 12 3 width of the window 2 mm e When selecting the function make sure that the fixed stop is between starting and target posi tion e Torque FXST and window width FXSW may be specified optionally If they are not written the value of the existing setting data are used If there are any programmed values they are accepted into the setting data First the setting data are loaded with values from the ma chine data FXST or FXSW can be changed in the program at any time The changes come into effect prior to any traversing motions programmed in the block SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 3 Axis Movements Actual position after Travel to fixed stop Fixed stop cen monitoring window Fig 8 26 Example for traveling to f
69. for the first drilling depth is incompatible with the total depth the error mes sage 61107 First drilling depth defined incorrectly is output and the cycle is not execu ted The parameter FDPR has the same effect in the cycle as the parameter DPR If the values for the reference and retraction planes are identical the first drilling depth can be defined as a relative value If the first drilling depth is programmed larger than the final drilling depth the final drilling depth is never exceeded The cycle will reduce the first drilling depth automatically as far as the final drilling depth is reached when drilling only once and will therefore drill only once SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 247 Cycles 9 4 Drilling cycles DTB dwell time The dwell time to the final drilling depth chip breaking is programmed under DTB in se conds DTS dwell time The dwell time at the starting point is only performed if VARI 1 swarf removal FRF feedrate factor With this parameter you can enter a reduction factor for the active feedrate which only ap plies to the approach to the first drilling depth in the cycle VARI machining type If parameter VARI 0 is set the drill retracts 1 mm after reaching each drilling depth for chip breaking If VARI 1 for swarf removal the drill traverses in each case to the reference plane brought forward by the safety clearance Note The anticipati
70. for this block for time specification A previously programmed feed F and a previously programmed spindle speed S remain stored Programming G4 F dwell time in seconds G4 S dwell time in spindle revolutions Programming example N5 G1 F3 8 Z 50 S300 M3 feed F spindle speed S N10 G4 F2 5 dwell time 2 5s N20 Z70 N30 G4 S30 dwelling for 30 spindle revolutions corresponds to S 300 rpm and 100 speed override t 0 1 min N40 X feed and spindle speed are still effective Note G4 S is only possible in conjunction with a controlled spindle if the speed is also program med via S SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 177 Programming 8 3 8 3 19 Axis Movements Travel to fixed stop Functionality This function is an option and available as of SW 2 0 Using the function Travel to fixed stop FXS Fixed Stop it is possible to build up defined forces required for the clamping of workpieces such as they are required for quills and grippers Further more this function can also be used to approach mechanical reference points With a sufficiently reduced torque simple measuring processes are also possible without a probe connected Programming FXS axis 1 Select travel to fixed stop FXS axis 0 Deselect travel to fixed stop FXST axis Clamping torque specification in of the max torque of the drive FXSW axis width of the window
71. however will not wait until the spindle has stopped The spindle is stopped with program end or RESET At program start spindle speed zero SO is active Note Other settings can be configured via the machine data Programming example N10 G1 X70 Z20 F3 S270 M3 prior to traversing the axes X Z the spindle accelerates in CW direction to 270 rpm N80 S450 speed change N170 GO Z180 M5 Z movement in the block spindle stop 8 4 2 Spindle Speed Limiting G25 G26 Functionality If you program G25 or G26 and enter the speed limit value at spindle address S you can limit the limit values usually applicable to a controlled spindle This will at the same time overwrite the values entered in the setting data G25 and G26 each require a separate block Any values for the speed S programmed pre viously remain stored Programming G25 S slower spindle speed limiting G26 S upper spindle speed limiting SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 181 Programming 8 4 Spindle Motions Information The uppermost limits of the spindle speed are set in machine data Further setting data for limiting can be entered from the operator panel For the G96 function constant cutting speed an additional upper limit can be entered pro grammed Programming example N10 G25 12 slower spindle limit speed 12 rom N20 G26 S700 upper spindle limit speed 700 rom 8 4 3 Positioning the Spind
72. in the SINUMERIK archive format Time monito ring If any transmission problems occur the transmission is aborted after 5 se conds No abortion of the transmission SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 7 119 System 7 1 PLC diagnosis using the ladder diagram representation 7 1 PLC diagnosis using the ladder diagram representation Note This function is not available with the 802D bl Functionality Operating A PLC user program consists to a large degree of logical operations to realize safety functions and to support process sequences These logical operations include the linking of various contacts and relays As a rule the failure of a single contact or relay results in a failure of the whole system instal lation To locate causes of faults failures or of a program error various diagnostic functions are offered in the System operating area Note It is not possible here to edit the program sequence SYSIEM N AT PLC PLC program 7 1 1 7 120 Select the PLC softkey which is to be found in the System operating area The PLC main screen will appear The project stored in the permanent memory is opened Screen layout The division of the screen into the individual main areas is to a large degree as described in Section 1 1 of the User s Guide Any deviations and amendments pertaining to the PLC diagnos
73. is also removed parallel to the contour after each paraxial roughing process immediately so that no additional residual corner cut is required after completion of roughing If no finishing allowances are programmed stock is removed when roughing up to the final contour FF1 FF2 and FF3 feedrate Different feedrates can be specified for the individual machining steps as shown in the illu stration SINUMERIK 802D 802D base line 9 296 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 5 Turning cycles X GO FFI Roughing Finishing Fig 9 50 VARI machining type Table 9 16 Type of machining ace Bo a fom oO o o 3 L Roughing wing C a S a 7 ing ee Rricting eft Compitemachinng fo B Completing mf tft omenen ef emptor In longitudinal machining the infeed is always carried out along the transversal axis and in face machining along the longitudinal axis SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 297 Cycles 9 5 Turning cycles External machining means that the infeed is carried out in the direction of the negative axis With internal machining the infeed is carried out in the direction of the positive axis The parameter VARI is subjected to a plausibility check If its value is not in the range 1 12 when the cycle is called the cycle is aborted with alarm 61002 Machining type defined incor rectly Longitudinal ext VARI
74. is any position from which the contour starting point can be approa ched without collision The cycle creates the following sequence of motions The cycle starting point is calculated internally and approached with GO in both axes at the same time Roughing without relief cut elements e The paraxial infeed to the current depth is calculated internally and approached with GO e Approach of paraxial roughing intersection point with G1 and at feedrate FF1 e Rounding parallel to the contour along the contour finishing allowance with G1 G2 G3 and FF1 e Retraction by the amount programmed under _VRT in each axis and retraction with GO e This sequence is repeated until the total depth of the machining step is reached e When roughing without relief cut elements retraction to the cycle starting point is carried out axis by axis SINUMERIK 802D 802D base line 9 292 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 5 Turning cycles Fig 9 46 Roughing the relief cut elements e Approach of the starting point for the next relief cut axis by axis with GO When doing so an additional cycle internal safety clearance is observed e infeed along the contour finishing allowance with G1 G2 G3 and FF2 e Approach of paraxial roughing intersection point with G1 and at feedrate FF 1 e Rounding along the contour retraction and return are carried out as with the first machi ning step e lf there are further relief cut ele
75. main screen u _ m E Find nA Be at u Axis Axis specific machine data MD Open the Axis Specific Machine Data window The softkey bar will be added by the softkeys Axis and Axis Axis specific machine data CTRLOUT_SEGMENT_NRI CTRLOUT_MODULE_NRI 1 CTRLOUT_NRIO CTRLOUT_TYPE LO IS_VYIRTUAL_AXIO NUM_ENCS ENC_SEGMENT_NRI 1 ENC_MODULE_NRI 1 ENC_INPUT_NR ENC_TYPE ENC_IS_INDEPENDENTI 6 ACT_POS_ABS 1 IS_ROT_AX ROT_IS_MODULO DISPLAY_IS_MODULO MODULO_RANGE Refresh Find Continue Find Select group General i Chan spec Drive Display HD MD Degrees Fig 7 5 The data of the X axis are displayed Use Axis or Axis to switch to the machine data area of the next or previous axis Search Type the number or the name of the machine data you are looking for and press OK The cursor will jump to the data searched Use this softkey to continue searching for the next match SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 7 101 System Select group Channel MD Drive MD Display MD Service display Service Axes 7 102 This function provides various display filters for the active machine data group Further softkeys are provided The Expert setting displays all machine data of the active group The Filter active softke
76. menu area is intended for servicing access is granted via the user password All details programs of the operator terminal are displayed with their version numbers in the form of a list By reloading software components the version numbers may be different DLL Yersion 64 61 063 62 68 15 64 61 63 62 68 15 V4 61 03 802708715 61 66 66 62 64 83 64 61 63 62 68 15 64 61 63 802708715 64 61 63 802708715 64 61 63 62 08 15 64 61 63 62 68 15 64 61 63 82708715 64 61 63 62 08 15 64 61 63 8027808715 64 61 63 82708715 64 61 63 62 68 15 64 61 63 82708715 64 61 63 802708715 64 61 63 802708715 64 61 63 62 68 15 Interface version v64 61 03 62 68 15 64 61 63 82708715 64 61 62 62 66 24 64 61 63 82708715 64 61 63 82708715 64 61 63 62 68 15 64 61 63 82708715 64 61 63 82708715 64 61 63 62 68 15 64 61 63 82708715 64 61 63 82708715 64 61 63 82708715 64 61 63 82708715 64 61 63 82708715 64 61 63 82708715 64 61 63 82708715 64 61 63 82708715 64 61 63 82708715 Registry Details ane Zur ck z E MM Fig 7 12 The HMI version menu area SINUMERIK 802D 802D base line 7 106 6FC5 698 2AA00 0BP3 11 03 OP T registry details System This function displays the assignment of the hardkeys function keys Machine Offset Program for the programs to be started in the form of a list
77. name of starting label and press softkey con tour append Starting and end label are automatically created from the name you have entered then the program will jump to the contour editor To quit your input press the softkey Technol mask the program returns to the cycle support screenform SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Cycles 9 5 Turning cycles Fig 9 48 Examples NPP KONTUR_1 The rough turning contour is the complete program Kontur_1 NPP ANFANG ENDE The rough turning contour is defined as a section in the calling program which starts from the block containing label ANFANG to the block containing label ENDE MID infeed depth Parameter MID is used to define the maximum possible infeed depth for the roughing pro cess The cycle will automatically calculate the current infeed depth used for roughing With contours containing relief cut elements the roughing process is divided by the cycle into individual roughing sections The cycle calculates a new current infeed depth for each roug hing section This infeed depth is always between the programmed infeed depth and the half of its value The number of required roughing steps is determined on the basis of the total depth of a roughing section and of the programmed maximum infeed depth to which the total depth to be machined is distributed equally This provides optimum cutting conditions For roughing this
78. ohne Nutwandkorrektur Fig 8 59 Various grooves cross sectional view Programming TRACYL d Activate TRACYL separate block TRAFOOF Deactivate separate block d machining diameter of the cylinder in mm TRAFOOF will deactivate any active transformation function Address OFFN Distance of the groove side to the programmed path Usually the groove center line is programmed OFFN defines the half groove width when working with cutter radius compensation G41 G42 Programming OFFN distance in mm SINUMERIK 802D 802D base line 8 228 6FC5 698 2AA00 0BP3 11 03 OP T Programming 8 14 Milling on turning machines Note Set OFFN 0 after manufacturing the groove OFFN is used also beyond TRACYL for the pro gramming of the stock allowance in conjunction with G41 G42 Fig 8 60 Use of OFFN for the groove width Programming notes To be able to mill grooves using TRACYL the groove center line is programmed in the part program specifying the coordinates and the half groove width is programmed via OFFN OFFN will only come into effect after selecting tool radius compensation Furthermore it must be guaranteed that OFFN gt tool radius to avoid that the opposite groove side is damaged As a rule a part program for the milling of a groove consists of the following steps 1 Selection of the tool Selection of TRACYL Selection of the appropriate zero offset Positioning Programming of
79. order If a block contains several statements the following order is recommended N G X Z F S T D M H Note on block numbers First select the block numbers in steps of 5 or 10 You can thus later insert blocks and nevert heless observe the ascending order of block numbers Block skip Blocks of a program which are to be executed not with each program run can be marked by a slash in front of the block number The block skip operation itself is activated either via operation program control SKP or from the PLC signal It is also possible to skip a whole program section by skipping several blocks using the character If block skip is active during program execution all blocks marked with are skipped All statements contained in the blocks concerned will not be considered The program is conti nued with the next block without marking SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 133 Programming 8 1 Fundamentals of NC Programming Comment note Messages The statements contained in the blocks of a program can be explained by comments notes A comment starts with the character and ends with block end Comments are displayed in the current block display together with the remaining contents of the block Messages are programmed in a separate block A message is displayed in a special field and remains active until a block with a new
80. system will then automatically position the cursor on a program in which matching characters have been found SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 6 71 Part Programming Softkeys Programs Execute Copy Open Delete Rename Read out Read in Cycles Delete User cycles 6 72 Use this softkey to open the part program directory Use this softkey to choose the program for execution which you have selected using the cursor The program will be started with the next NC START Use the softkey New to create a new program A window appears which requests you to enter pro gram name and program type Use the softkey Copy to copy the selected program into another program with a new name Use this softkey to open the file for execution which you have selected using the cursor Use this softkey to delete the program or all part programs selected by means of the cursor Pressing the OK softkey will execute the deletion job and Abort will cancel it If you press the softkey Rename a window opens in which you can rename the program which you have selected first using the cursor Type the new name press OK to confirm the new order or use Abort to cancel Use this softkey to save programs via the RS232 interface Use this softkey to load part programs via the
81. the 802D bl Programming Parameter Function CYCLE86 RTP RFP SDIS DP DPR DTB SDIR RPA RPO RPAP POSS Table 9 7 Parameters of CYCLE86 RTP real Retraction plane neni SDIS ais clearance enter without sign real Final ae ae relative to the reference plane enter wi thout sign DTB real Dwell time at final drilling depth chip breaking SDIR int Direction of rotation Values 3 for M3 4 for M4 real Retraction path in the 1st axis of the plane incremental enter with sign real Retraction path in the 2nd axis of the plane incremental en ter with sign RPAP real Retraction path in the boring axis incremental enter with sign POSS Spindle position for oriented spindle stop in the cycle in de grees The cycle supports the boring of holes with a boring bar The tool drills at the programmed spindle speed and feedrate to the entered final drilling depth With boring 2 oriented spindle stop is activated once the drilling depth has been reached Then the programmed retraction positions are approached in rapid traverse and from there the retraction plane Operational sequence Position reached prior to cycle start SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 259 Cycles 9 4 Drilling cycles The drilling position is the position in the two axes of the selected plane The cycle creates the following sequence of motions Approach of the reference plane brought
82. the cycle Total of finishing allowance in Z _VF Fig 9 54 Cycle approach strategy In roughing the starting point determined by the cycle is always approached with both axes simultaneously and in finishing axis by axis In finishing the infeed axis traverses first SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 301 Cycles 9 5 Programming example 1 Stock removal cycle 9 302 Turning cycles The contour shown in the illustration to explain the defining parameters is to be machined longitudinally externally by complete machining Axis specific finishing allowances are speci fied Cutting will not be interrupted when roughing The maximum infeed is 5 mm The contour is stored in a separate program P6 35 76 P2 87 65 P4 52 44 P1 120 37 Fig 9 55 N10 T1 D1 GO G95 500 M3 Z125 X81 N20 CYCLE95 KONTUR_1 5 1 2 0 6 0 2 0 1 0 2 9 0 5 N30 GO G90 X81 N40 Z125 N50 M30 _N_KONTUR_1_SPF Approach position prior to the call Cycle call Reapproach of starting position Traversing by axes End of program Start of contour subroutine N100 Z120 X37 N110 Z117 X40 N120 Z112 RND 5 N130 Z95 X65 N140 287 N150 277 X29 N160 262 N170 258 X44 N180 252 N190 241 X37 N200 235 N210 X76 N220 M17 Traversing by axes Rounding with radius 5 Traversing by axes End of subroutine SINUMERIK 802D 802D base line
83. to 300 Example RO 0 1EX 5 Meaning RO 0 000 001 R1 1 874EX8 Meaning R1 187 400 000 Note Several assignments per block are permitted including the assignment of arithmetic terms Assignment to other addresses 8 206 The flexibility of an NC program is based on the fact that you assign other NC addresses these arithmetic parameters or arithmetic terms using arithmetic parameters It is possible to assign all addresses values arithmetic terms or arithmetic parameters with the following exception addresses N G and L When doing the assignment the address character must be followed by the character Assignments with a negative sign are possible SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 9 Arithmetic parameters R LUD and PLC variables lf assignments are to be made for axis addresses traversing commands a separate block is required Example N10 GO X R2 assignment to X axis Arithmetic operations functions When using the operands arithmetic functions make sure that the usual mathematical nota tion is observed Any priorities in the processing are defined by round brackets Otherwise the general rule whereby multiplication and division are performed before addition and sub traction will apply For the trigonometric functions specification in degrees should be used Admissible arithmetic functions see Section List of Statements Programming exampl
84. to the PLC A total of 10 of such function outputs per block are possible SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 205 Programming 8 9 8 9 8 9 1 Arithmetic parameters R LUD and PLC variables Arithmetic parameters R LUD and PLC variables Arithmetic parameters R Functionality If an NC program is desired to be applicable not only for values defined once or if you must calculate any values then use the arithmetic parameters You can have calculated any requi red values by the control system while the program is running or you can have set them by the control system Another possibility is to set arithmetic parameters by operation If the arithmetic parameters are already assigned values they can be assigned different NC addresses in the program which should be flexible in their values Programming RO to R299 Value assignment The arithmetic parameters can be assigned values in the following range 0 000 0001 9999 9999 8 decimal places and sign and decimal point For integer values the decimal point can be omitted A positive sign can always be omitted Example RO 3 5678 R1 37 3 R2 2 R3 7 R4 45678 123 The exponential notation can be used to assign an extended range of figures 107300 10 300 The value of the exponent is written after the EX character max number of characters 10 including signs and decimal point Range of values for EX 300
85. to the workpiece zero is deter mined along the Z axis and entered in a data area intended for the settable zero offset In the NC program this offset is activated e g using a programmed G54 Fig 1 18 Workpiece on the machine Current workpiece coordinate system The programmed zero offset TRANS can be used to generate an offset with reference to the workpiece coordinate system resulting in the current workpiece coordinate system see Sec tion Programmable Zero Offset TRANS SINUMERIK 802D 802D base line 1 26 6FC5 698 2AA00 OBP3 11 03 OP T Turning on and Reference Point Approach Note When you turn on the SINUMERIK 802D and the machine please also observe the Machine Documentation since turning on and reference point approach are machine dependent func tions This documentation assumes an 802D standard machine control panel MCP Should you use a different MCP the operation may be other than described herein Operating sequence b First turn on the power supply of CNC and machine After the control system has booted you are in the Position operating area Jog mode The window Reference point approach is active SKP DRY ROY MG 1 PRT SBL DEHO1 MPF Reference point A fre epee 8 BOA T 1 8 BOA 0 000 ox 8 808 6 666 mm min Fig 2 1 The Jog Ref start screen Use the Ref key on the machine control panel to activate reference point approach The Reference Point Appro
86. value the function will accept this value into the input line of the calculator When you press the Input key the result is calculated and displayed in the calculator Pressing the Accept softkey enters the result in the input field at the current cursor position of the part program editor and closes the calculator automatically Note If an input field is in the editing mode it is possible to restore the original status using the Toggle key SKP DRY ROY M61 PRT SBL HCS Reference point X1o 0 848 Z1o 8 B88 8 000 100 SP 8 908 6 606 mm min Je PCH A eal EA IS et ae Ea Fe EN ET Jy Ey Ee a Fig 1 4 Calculator Characters permitted for input Basic arithmetic operations ae S Sine function The X value in degrees before the input cursor is replaced by the value sin X C Cosine function The X value in degrees before the input cursor is replaced by the value cos X Q Square function The X value before the input cursor is replaced by the value X2 SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 1 17 Introduction 1 3 Accessibility Options R Square root funct ion The X value before the input cursor is replaced by the value VX Bracket function X Y Z Calculation examples Task Input gt Result 100 67 3 100 67 3 gt 301 sin 45 45 S gt 0 707107 cos 45 45 C gt 0 707107 42 4Q gt 16 V4 4R gt 2 34 3 2 10 344 3 2
87. with GO spindle mode is reinitiated by reprogramming the spindle speed active before the cycle was called and the direction of rotation program med under SDAC Explanation of the parameters For the parameters RTP RFP SDIS DP DPR see CYCLE82 pooo am a HAE UV AS rp Hoo A ae co OD LL a O O y LL 0 oO O Fig 9 8 DTB dwell time The dwell time is programmed in seconds When tapping blind holes it is recommended to omit the dwell time SDAC direction of rotation after end of cycle Under SDAC the direction of rotation after end of cycle is programmed The direction reversal when tapping is carried out automatically internally in the cycle 9 250 SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 4 Drilling cycles MPIT and PIT as a thread size and as a value The value for the thread pitch can be defined either as the thread size for metric threads bet ween M3 and M48 only or as a value distance from one thread turn to the next as a numeri cal value The parameter not required in each case is omitted in the call or is assigned the value zero RH or LH threads are defined by the sign of the pitch parameters e positive value gt RH as for M3 e negative value LH as for M4 If the two thread pitch parameters have conflicting values alarm 61001 Thread pitch wrong is generated by the cycle and cycle execution is aborted POSS spindle po
88. 0 0BP3 11 03 OP T 9 245 Cycles 9 4 Drilling cycles The cycle creates the following sequence of motions Deep hole drilling with swarf removal VARI 1 Approach of the reference plane brought forward by the safety clearance by using GO Traversing to the first drilling depth with G1 the feedrate for which is derived from the fee drate defined with the program call which is subject to parameter FRF feedrate factor Dwell time at final drilling depth parameter DTB Retraction to the reference plane brought forward by the safety clearance for swarf remo val by using GO Dwell time at the starting point parameter DTS Approach of the drilling depth last reached reduced by anticipation distance by using GO Traversing to the next drilling depth with G1 Sequence of motions is continued until the final drilling depth is reached Retraction to the retraction plane with GO tite Ht RFP DPR DP Fig 9 6 Deep hole drilling with swarf removal Deep hole drilling with chip breaking VARI 0 9 246 Approach of the reference plane brought forward by the safety clearance by using GO Traversing to the first drilling depth with G1 the feedrate for which is derived from the fee drate defined with the program call which is subject to parameter FRF feedrate factor Dwell time at final drilling depth parameter DTB Retraction by 1 mm from the current drilling depth with G1 and the feedrate prog
89. 0 OBP3 11 03 OP T Manually Controlled Operation 4 1 Jog Mode Operating Area Position JOG feedrate feedrate value in the JOG mode Dir of rot Direction of rotation of the spindle for programs generated automatically in the JOG and MDA modes Data Use this softkey to store the coordinates of the probe and to set the axis feedrate for the automatic tobe measuring process see Section 3 1 5 Switch to Use this softkey to switch between the metric and the inch system mm gt inch 4 1 1 Assigning Handwheels Operating sequence a Hand VL wheel In Jog mode display the Handwheel window After the window has been opened the column Axis will display all axis identifiers which simultaneously appear in the softkey bar Depending on the number of handwheels connec ted it is possible to switch from handwheel 1 to handwheel 2 or 3 Select the desired handwheel using the cursor Then press the axis softkey of the desired axis to assign or the desired axis The symbol will appear in the window J06 16666 INC RESET SKP DRY ROY HO1 PRT SBL DEMO1 MPF Position Repos offset a leo aBa om T 1 0 BAB 8 688 mm F 8 008 9 6 6660 mm min Measure Measure Settings workpiece tool Fig 4 5 The Handwhee l menu window Use the softkey MCS to select the axes from the machine or workpiece coordinate system which pee you wish to assign a handwheel The current setti
90. 0 RTP RFP SDIS DP DPR DTB SDR SDAC ENC MPIT PIT Parameters Table 9 5 Parameter of CYCLE840 Final drilling depth relative to the reference plane enter wi thout sign Dwell time at thread depth chip breaking Direction of rotation for retraction Values 0 automatic reversal of the direction of rotation 3 or 4 for M3 or M4 Direction of rotation after end of cycle Values 3 4 or 5 for M3 M4 or M5 Tapping with without encoder Values 0 with encoder 1 without encoder Thread pitch as the thread size signed Range of values 3 for M3 48 for M48 Pitch as a value signed Range of values 0 001 2000 000 mm Function The tool drills at the programmed spindle speed and feedrate to the entered final thread depth Using this cycle you can perform tapping with compensating chuck e without encoder and e with encoder Sequence of operations Tapping with compensating chuck without encoder Position reached prior to cycle start The drilling position is the position in the two axes of the selected plane SINUMERIK 802D 802D base line 9 252 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 4 Drilling cycles The cycle creates the following sequence of motions e Approach of the reference plane brought forward by the safety clearance by using GO e Tapping to the final drilling depth e Dwell time at tapping depth parameter DTB e Retraction to the reference plane brought forward by the saf
91. 02D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 175 Programming 8 3 8 3 16 Axis Movements Traversing with Feedforward Control FFWON FFWOF Functionality Feedforward control will reduce the following error to zero Traversing with feedforward control provides a higher traversing accuracy and thus better ma nufacturing results Programming FFWON feedforward control ON FFWOF feedforward control OFF Programming example 8 3 17 N10 FFWON feedforward control ON N20 G1 X Z F9 N80 FFWOF feedforward control OFF 3rd and 4th Axes Functionality Prerequisite Extended control system configuration for 4 axes Depending on the machine design a 3rd and 4th axes can be necessary These axes can be designed either as a linear or a rotary axis The identifier for these axes must be configured accordingly e g U or C or A etc With rotary axes the traversing range can be configured between 0 lt 360 degrees Modulo behavior A 3rd or 4th axis can be traversed as a linear axis together with the remaining axes if the ma chine is designed accordingly If the axis is traversed in a block that contains G1 or G2 G3 together with the remaining axes X Z it will not be assigned a component of the feedrate F Its velocity will then depend on the traversing rate of the axes X Z Its movement starts and ends with the remaining path axes However the velocity cannot be greater than the defined limit value
92. 1 CHR 1 N30 X3 Z3 ANG 2 CHR N40 X4 Z4 Fig 8 32 Examples for multi block contours SINUMERIK 802D 802D base line 8 190 6FC5 698 2AA00 0BP3 11 03 OP T Programming 8 6 Tool and Tool Compensation 8 6 Tool and Tool Compensation 8 6 1 General Notes Functionality When creating programs for workpiece machining you do not need to take into account tool length or cutter radius Program the workpiece dimensions directly e g using the drawing Enter the tool data separately in a special data area Simply call the required tool with its offset data in the program and enable the tool radius com pensation if necessary The control system will carry out the path corrections required to create the workpiece described F tool carrier reference point M machine zero W workpiece zero Fig 8 33 Machining of a workpiece with different tool dimensions 8 6 2 Tool T Functionality Programming of the T word will select the tool Whether it is a tool change or only a preselection is defined in machine data e Tool change tool call is carried out directly using the T word e g as usual for tool revol vers on turning machines or e the change is carried out after preselection using the T word and the miscellaneous func tion M6 see also Section 8 7 Miscellaneous Functions M Note If a certain tool has been activated it remains stored as the active tool even beyond program end and even after POWER
93. 1 Z112 Approaching the retraction plane N30 X70 Y50 Approaching the drill position N40 CYCLE86 112 110 77 0 2 3 1 1 1 45 Cycle call with absolute drilling depth N50 M2 End of program 9 4 10 Boring with Stop 1 boring 3 CYCLE87 Note This standard cycle is not available with the 802D bl Programming CYCLE87 RTP RFP SDIS DP DPR SDIR Parameter Table 9 8 Parameter CYCLE87 Retraction plane absolute Reference plane absolute Safety clearance enter without sign Final drilling depth absolute SINUMERIK 802D 802D base line 9 262 6FC5 698 2AA00 0BP3 11 03 OP T Function Cycles 9 4 Drilling cycles Table 9 8 Parameter CYCLE87 Fortsetzung DPR real Final drilling depth relative to the reference plane enter wi thout sign Direction of rotation Values 3 for M3 4 for M4 The tool drills at the programmed spindle speed and feedrate to the entered final drilling depth During boring 3 a spindle stop without orientation M5 is generated after reaching the final drilling depth followed by a programmed stop MO Pressing the NC START key continues the retraction movement at rapid traverse until the retraction plane is reached Operational sequence Position reached prior to cycle start The drilling position is the position in the two axes of the selected plane The cycle creates the following sequence of motions e Approach of the reference plane brought forward by the safet
94. 12 066 1 606 1 660 1 668 N6G vinan 7an Dninnn G1 Search key G2 c1 cor cyc Search direct S qUSi 0H E SoSH eH 3 5 G3 N75 F850 Z G1 G96 X20 000 Y80 666 F650 666 N76 X0 Z190 N86 GOTOB ANA N98 MZ eof F Program Correct control program Fig 5 6 Entering the searched term Result of search 5 3 Display of the desired block in the Current Block window Stopping Aborting a Part Program Operating sequence Use NC STOP to interrupt the execution of a part program Press NC START to continue Use RESET to abort the program currently running Automatic Mode Stopping Aborting a Part Program If you press NC START again the aborted program will be restarted and executed from the begin ning SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 5 67 Automatic Mode 5 4 Reapproach after Interruption 5 4 Reapproach after Interruption After program interruption RESET you can move away the tool from the contour in Manual mode Jog Operating sequence Select Automatic mode BlockSeare Open the Block Search window to load the interruption point h Interr The interruption point will be loaded Point To Pressing this softkey will start block search to the interruption point An adjustment to the start posi contour tion of the interrupted block will be carried out O Press NC START to continue the program execution
95. 2AA00 OBP3 11 03 OP T 9 305 Cycles 9 5 Turning cycles 9 306 If the parameter has a value other than A D the cycle aborts and creates alarm 61609 Form defined incorrectly Internally in the cycle the tool radius compensation is selected automatically The cycle uses only the tool point directions 1 4 If the cycle recognizes one of the tool point directions 5 9 or if the relevant undercut form cannot be machined using the selected tool point direction the alarm 61608 Wrong tool point direction programmed appears and the cycle is terminated The cycle will find the starting point determined by the tool point direction of the active tool and the thread diameter automatically The position of this starting point referred to the pro grammed coordinate values is determined by the tool point direction of the active tool For the forms A and B the undercut angle of the active tool is monitored in the cycle If it is detected that the form of the undercut cannot be machined using the selected tool the mes sage Changed form of undercut is displayed on the control system the machining however is continued FORMS A and B Fig 9 59 FORMS C and D SPL Fig 9 60 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Further notes Cycles 9 5 Turning cycles Before calling the cycle a tool compensation must be activated Otherwise the cycle is term
96. 2D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T PLC status SYSTEH Modem configuration Hoden settings Active modem parameters ISDN box Modem type Esc sequence Defaults Hang up OK CONNECT NO CARRIER Auto answer Accept call RING Fig 7 19 ATH AT init string AT amp FSO 18W4 OK CONNECT NO CARRIER Software QO ATA RING sy Settings for an ISDN box It is possible to display 16 operands at a time System Use this softkey to display the current states of the PLC memory cells listed below as necessary you can also modify them Inputs Input byte IBx input word Iwx input double word IDx Outputs Q Output byte Qbx output word Qwx output double word QDx Flags M Flag byte Mx flag word Mw flag double word MDx Timers T Timer Tx Counters C Counter Zx Data V Data byte Vbx data word Vwx data double word VDx Format B binary H hexadecimal D decimal timers are represented decimally The binary representation is not possible with double words Counters and PLC status display Operand Operand ormat Value ID1 6666 66686 F D QB1 B 6868 8888 Operand H1 0 B a T2 D 8 D a B Ci B19661666 4666 8868 L al les STEP 7 PLC Status PLC Progran Edit PLC connect status list progran list alarm txt Fig 7 20 PLC status display SINUMERIK 802D 802D base line 6FC5 6
97. 3 Functionality The function G33 can be used to machine threads with constant lead of the following type e threads on cylindrical bodies e threads on taper bodies e external and internal threads e single and multiple threads e multi block threads Sequencing of threads This function requires a spindle with position measuring system G33 is effective until it is canceled by another statement of this group GO G1 G2 G3 external internal Fig 8 19 External internal threads using the example of a cylindrical thread RH or LH thread RH or LH threads are defined with the direction of rotation of the spindle M3 CW rotation M4 CCW rotation see Section 8 4 Spindle Movement This requires the speed to be programmed under address S or a speed to be set Note For the thread length the run in and run out travels should be taken into account SINUMERIK 802D 802D base line 8 164 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 3 Axis Movements Side view Top view End point Thread length Start point Zero degree mark of spindle encoder Lead or K value is constant over Further start point the entire thread length possible for seve RH or LH thread of a G33 block ral threads M3 M4 Fig 8 20 Programmable parameters for thread with G33 Programming Cylinder thread G33 Z K Taper thread Angle at taper less Zaa Xa Kon aoe than 45 degrees
98. 3 OP T Cycles 9 5 Turning cycles Contour monitoring The cycle provides contour monitoring with regard to the following e Clearance angle of the active tool e Circle programming of arcs with an aperture angle gt 180 degrees With relief cut elements the cycle checks whether the machining is possible using the active tool If the cycle detects that this machining will result in a contour violation it will be aborted after alarm 61604 Active tool violates programmed contour has been output If the tool clearance angle is specified with zero in the tool compensation this monitoring will not be performed If too large arcs are found in the compensation alarm 10931 Incorrect machining contour appears Starting point The cycle determines the starting point for machining operation automatically The starting point is located in an axis in which the depth infeed is carried out by the finishing allowance retraction travel parameter _VRT from the contour away In the other axis it is by finishing allowance _VRT ahead of the contour starting point When the starting point is approached the cutter radius compensation is selected internally in the cycle The last point before the cycle is called must therefore be selected such that this approach is possible without collision and space enough is provided to carry out the appropriate compen satory motion Total of finishing i allowance in X _VRT STARTING Pour of
99. 50 JOG mode 4 50 L Longitudinal thread 9 313 M Machine zero 3 42 Machining parameters 9 238 Machining plane 9 234 Manual data input MDA mode 4 54 Messages 9 323 Index 325 Index O Operating area Machine Operating areas 1 16 Operating the cycle selection 9 236 Overview of cycle alarms 9 321 Overview of cycle files 9 236 P Part program selecting starting 5 65 _ stopping aborting 5 67 Plane definition 9 234 R R parameters 3 47 Re approach after interruption 5 68 Reference plane relative drilling depth Repositioning after interrupting 5 68 Retraction plane Return conditions Rigid tapping Row of holes S Safety clearance Screen layout 1 13 Setting data 3 44 Simulation of cycles Special functions 9 250 9 251 Index 326 Starting point Stock removal CYCLE95 9 291 T Tapping with compensating chuck 9 252 Tapping with compensating chuck with encoder Tapping with compensating chuck without enco der 9 252 Thread cutting CYCLE9 Thread undercut CYCLE96 9 304 tool clearance angle Tool zero 3 42 Transversal thread 9 313 Turning cycles 9 233 U Undercut CYCLE94 V V24 interface 6 97 W Word structure 8 132 Z Zero offset 3 42 SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Suggestions SIEMENS AG Corrections A amp D MC IS for Pub
100. 5mm rev Starting point at 15 degrees N40 G35 Z 150 K5 F0 16 Starting lead 5 mm rev lead decrease 0 16 mm rev 2 thread length 50 mm desired lead at block end 3 mm rev N50 GO X80 retraction in X N60 Z120 N100 M2 Thread interpolation G331 G332 Functionality This function requires a position controlled spindle with position measuring system G331 G332 can be used to tap threads without compensating chuck provided the dynamic properties of both the spindle and the axes are such that this is possible If nevertheless a compensating chuck is used the path differences to be compensated by the compensating chuck are getting smaller Thus tapping with higher spindle speed is possible G331 is used for drilling and G332 is used for retracting the drill The drilling depth is specified via the axis e g Z the thread lead is specified via the appro priate interpolation parameter here K When using G332 the same lead is programmed as with G331 The reversal of the direction of rotation of the spindle is performed automatically The spindle speed is programmed with S without M3 M4 Before tapping using G332 the spindle must be switched to the position controlled mode using SPOS see also Section 8 4 3 Positioning the spindle Right hand or left hand thread The direction of rotation of the spindle is determined by the sign of the thread lead positive CW rotation as with M3 negative CCW rotatio
101. 6FC5 698 2AA00 OBP3 11 03 OP T Programming example 2 Stock removal cycle 9 5 Cycles Turning cycles The stock removal contour is defined in the calling program and is traversed directly after the cycle for finishing has been called P5 50 50 P4 50 41 547 P3 70 21 547 P2 90 10 P1 100 10 Fig 9 56 N110 G18 DIAMOF G90 G96 F0 8 N120 S500 M3 N130 T1 D1 N140 GO X70 N150 Z160 N160 CYCLE95 ANFANG ENDE 2 5 0 8 0 8 0 0 8 0 75 0 6 1 N170 GO X70 Z160 N175 M02 ANFANG N180 G1 X10 Z100 F0 6 N190 Z90 N200 Z70 ANG 150 N210 Z50 ANG 135 N220 Z50 X50 ENDE N230 M02 SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Cycle call 9 303 Cycles 9 5 Turning cycles 9 5 5 Thread undercut CYCLE96 Programming CYCLE96 DIATH SPL FORM Parameter Table 9 17 Parameters of CYCLE94 DIATH Nominal diameter of the thread Starting point of the correction in the longitudinal axis FORM char Definition of the form Values A for form A B for form B C for form C D for form D Function Using this cycle you can perform thread undercuts to DIN76 for parts with metrical ISO thread tll Fig 9 57 Operational sequence Position reached prior to cycle start The starting position can be any position from which each thread undercut can be approa ched without collision SINUMERIK 802D 802D base line 9 304 6FC5 69
102. 8 2AA00 0BP3 11 03 OP T Cycles 9 5 Turning cycles The cycle creates the following sequence of motions e Approach of the starting point determined in the cycle by using GO e Selection of tool radius compensation according to the active tool point direction Traver sing along the undercut contour using the feedrate programmed before the cycle was cal led e Retraction to the starting point with GO and deselection of the tool radius compensation with G40 Explanation of the parameters DIATH nominal diameter Using this cycle you can perform thread undercuts for metric threads from M3 through M68 If a final diameter lt 3 mm results according to the value programmed for DIATH the cycle is terminated generating the alarm 61601 Finished part diameter too small If the parameter has a value other than specified in DIN76 Part 1 the cycle is also termina ted generated the alarm 61001 Thread pitch defined incorrectly SPL starting point The finished dimension in the longitudinal axis is defined using the parameter SPL SPL DIATH Fig 9 58 FORM definition Thread undercuts of the forms A and B are defined for external threads form A for standard run outs of threads and form B for short run outs of threads Thread undercuts of the forms C and D are used for internal threads form C for a standard run out of the thread and form D for a short run out SINUMERIK 802D 802D base line 6FC5 698
103. 9 Dwell time in spindle revolutions G4 S separate block taining G4 T Tool number 1 32 000 Tool change can only be carried either directly using T only integer no sign the T command or on M6 This can be set in machine data X Axis 0 001 99 999 999 Positional data X Axis not with 802D bl 0 001 99 999 999 Positional data e g with TRACYL TRANSMIT Yes Axis 0 001 99 999 999 Positional data Z AC Absolute coordinate For certain blocks the dimensional specification for N10 G91 X10 Z AC 20 _ X incr dimension end or center point of a certain axis can be entered other than defined by G91 Z abs dimension Ouluwesbold VVI 8 1 dO 0 LL da0 00VVe 869 S949 aul seq AZ08 AZ08 MIYAWNNIS Address Meaning Value Assignment Explanation Programming ACC axis Percentage acceleration 1 200 integer Acceleration compensation for an axis or spindle spe N10 ACC X 80 X incremental dimension compensation cification as percentage Z absolute dimension ACP Absolute coordinate ap For a rotary axis ACP can be used to specify the N10 A ACP 45 3 approach absolute proach position in the po unit for the end point can other than for G90 G91 can position in the positive sitive direction only rotary also be used for positioning the spindle direction axis N20 SPOS ACP 83 1 positioning the spindle ACN Absolute coordinate ap For a rotary axis
104. 98 2AA00 0BP3 11 03 OP T 9 277 Cycles 9 5 Turning cycles YY No contour violation Contour violation Fig 9 29 When entering the tool clearance angle note that this depends on the machining type longi tudinal or face If you want to use one tool for longitudinal and face machining two tool compensations must be used in the case of different tool clearance angles The cycle will check whether or not the programmed contour can be machined using the se lected tool If the machining is not possible using this tool then e the cycle will abort and an error message is output in stock removal or e the contour is continued to be machined and a message is output with undercut cycles In this case the contour is determined by the cutting edge geometry If the tool clearance angle is specified with zero in the tool compensation this monitoring will not be performed For details on the reactions please refer to the individual cycles No contour violation Contour violation Fig 9 30 SINUMERIK 802D 802D base line 9 278 6FC5 698 2AA00 0BP3 11 03 OP T 9 5 2 Cycles 9 5 Turning cycles Grooving CYCLE93 Programming Parameters Function CYCLE93 SPD SPL WIDG DIAG STA1 ANG1 ANG2 RCO1 RCO2 RCI1 RCI2 FAL1 FAL2 IDEP DTB VARI Table 9 13 Parameters of CYCLE93 DIAG Groove depth enter without sign STA1 real Angle between contour and longi
105. 98 2AA00 OBP3 11 03 OP T 7 111 System Operand Operand Delete Status list Change Change Edit 7 112 pad The operand address displays the value incremented by 1 The operand address displays the value decremented by 1 Use this softkey to delete all operands This softkey will cancel the cyclic update of the values Then you can modify the values of the ope rands Use the function PLC Status lists to locate PLC signals quickly as well as to watch and modify them The following areas are offered to choose from e Inputs default setting left list e Outputs default setting central list e Flags default setting right list e Variable B19661666 CEFA aagEEEEs aagEEEEs 100000008 66666668 a 5 5155 5 1515 6 5 1515 5 1515 aBBEEEEs 988e8888 bi s 2 2 2 2 4 5 96666888 bi 3 5 2 2 2 4 5 bi s 5 2 2 2 215 oe888888 U2 2 4 2 5 a68e8888 66868888 66666668 66666668 888G8888 6eaG8888 966666186 aBGG8888 lalalalalala lala oeee8EE8 66661668 aeeeEEEs bi s 2 2 2 2 4 5 66G88888 68688888 69686088 66666668 66686068 Eal STEP 7 PLC Status PLC Progran Edit PLC connect status list program list alarm txt Fig 7 21 The PLC Status List main screen alala lalals lela alala lalals lela als lslalals lsi bils o 2 2 4 213 bals o 2 2 2 215 aaeeEEEs oeeeeeei on numark WN eS O on numnh WN eS O
106. Alt H Help system or Info key The Help System To activate the help system use the Info key It offers a brief description for all essential ope rating functions Further the help feature contains the following topics e Overview of the NC commands with a brief description e Cycle programming e Explanation of the drive alarms JOG 16666 INC Table of contents Dperating areas Protection levels Input help Calculator Tangential transition calculation Point in the plane calculation Conversion of Polar coordinates into Cartesian coordinates Endpoint calculation Editing Chinese characters Hot Keys Coordinate systems Reference Point Approach Setting Up Entering tools and tool offsets Tool list Delete tool Find tool number Create offset data for a new tool Fig 1 13 Table of contents of the help system This function opens the topic selected JOG 16666 INC Helpsysten Editing a part progran A part program or sections of a part program can only be edited if the program is not being executed All changes in the part program are stored immediately gt gt Overview of instructions lt lt Edit Use this function to edit texts Select Use this softkey to select a text block up to the current cursor position Copy Use this softkey to copy a selected block into the clipboard ee ee ee Fig 1 14 Description with regard to a help topic Use this function to select cross references A
107. For the meanings of the individual columns please refer to the table below SYSTEH Registry ini details DLL StartUp SK1i DLL arrangement DLL name ma d1ll pa d1ll pr d1l pm dll dg d1ll alm d1ll Class name Start method Execute flag maschine wi parameter 1 progranmn 1 progman 4 s kaa 1 diagnose alarn Fig 7 13 Table 7 1 Meanings of the entries under DLL arrangement Designation Meaning Softkey SK1 to SK7 Hardkey assignment 1 to 7 DLL name Name of the program to be executed Class name This column defines the identifier for receiving messages Start method Number of the function executed after starting the program Execute flag kind of execution 0 The program is managed via the basic system 1 The basic system starts the program and transfers the control to the loa ded program Text file name Name of the text file without extension Softkey text ID SK ID reserved Password level The execution of the program depends on the password level Class SK reserved SK file reserved Font details SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T This function displays the data of the loaded character sets in the form of a list 7 107 System Change Start DLL 7 108 DLL version 64 61 64 8270 713 4 61 64 62 69 13
108. G331 Thread interpolation N10 SPOS Spindle in position control N20 G331 Z K S Tapping without compensa ting chuck e g along Z axis RH or LH thread is defined by the sign of the lead e g K as with M3 as with M4 G332 Thread interpolation retraction Q332 Z K Tapping without compensa ting chuck e g along Z axis Retraction movement sign of lead as with G331 G4 Dwell time 2 Special movements dwell time G4 F separate block F time in seconds non modal 9r SO G4 S separate block S in spindle revolutions G74 Reference point approach G74 X Z separate block machine axis identifier G75 Fixed point approach G75 X Z separate block machine axis identifier TRANS Programmable offset 3 Write memory TRANS X Z separate block SCALE Programmable scaling factor SCALE X Z scaling factor in the non modal direction of the specified axis separate block ROT programmable rotation ROT RPL rotation in the current plane G17 G19 separate block MIRROR programmable mirroring MIRROR X0 coordinate axis whose direction is changed separate block ATRANS Additive programmable offset ATRANS X Z separate block ASCALE Additive programmable scaling factor ASCALE X Z scaling factor in the direction of the specified axis separate block Oulwwesbold 8El 8 1 dO 0 LL da0 00VV2 869 S949 aul seq AZ08 AZ08 MIHINWNNIS
109. HF A linear section is inserted between linear and circle contours in any combination The edge will be broken N10 G1 CHF _ _ _ Fig 8 28 Inserting a chamfer between two straight lines example Programming example for chamfer N10 G1 Z CHF 5 Insert 5mm chamfer N20 X Z SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 187 Programming 8 5 Special Turning Functions Rounding RND A circular contour element is inserted between linear and circle contours in any combination with tangential connection Straight line straight line Straight line circle N10 G1 RND N50 G1 RND Rounding lt Rounding Nr N20 G1 Fig 8 29 Inserting roundings examples Programming example for rounding N10 G1 Z RND 8 Insert rounding with 8 mm radius N20 X Z N50 G1 Z RND 7 3 Insert radius with 7 3 mm radius N60 G3 X Z Information If the contour length programmed in a block involved is not sufficient the value programmed for chamfer and rounding will be reduced automatically No chamfer rounding will be inserted if more than three blocks are programmed which do not contain information for traversing in the plane 8 5 3 Contour Definition Programming Functionality If direct end point specifications for the contour cannot be seen from the machining drawing it is also possible to use angle specifications for the straight line determi
110. INUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 203 Programming 8 7 Miscellaneous Function M 8 7 Miscellaneous Function M Functionality The miscellaneous function M can be used for example to initiate switching actions such as Coolant ON OFF and other functions A minor part of the M functions is assigned a fixed functionality by the control manufacturer The remaining part is available to the machine manufacturer for free use Note For an overview of the M miscellaneous functions used and reserved in the control system please refer to the Section List of Statements Programming M max 5 M functions per block can be programmed Activation Activation in blocks with axis movements If the functions MO M1 and M2 are contained in a block with traversing movements of the axes these M functions come into effect after the traversing movements The functions M3 M4 and M5 are output to the internal PLC prior to the traversing movements The axis movements start only if the controlled spindle has accelerated at M3 M4 With M5 however the axes will not wait until the spindle has come to a standstill the axis movements will start already prior to the standstill The remaining M functions are output to the internal PLC with the traversing movements If you want to program an M function deliberately prior to or after an axis movement then in sert a separate block with this M function P
111. If you traverse an axis in the positive or negative direction a plus or minus sign is dis Z played in the corresponding field If the axis is in the desired position no sign is displayed Position These fields display the current position of the axes in the MCS or WCS mm Distance to This field displays the distance to go for the axes in MCS or WCS go G function Display of important G functions Spindle S Display of the actual and set values of the spindle speed rpm Feed F Display of the feedrate actual and set values in mm min or mm rev Tool Display of the currently active tool and of the current edge number T D Editing win In the program state Stop or Reset an editing window is used to enter part program blocks dow Note If a second spindle is integrated into the system the workspindle is displayed using a lower font size The window will always display only the data of one spindle The control system displays the spindle data taking into account the following aspects The master spindle is displayed inthe idle condition at spindle start if both spindles are active The workspindle is displayed at spindle start of the workspindle In all cases the power bar applies to the spindle currently active SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 4 55 Manually Controlled Operation 4 2 Operating Mode MDA Manual Input Softkeys Set base Face
112. LEY98 continued Pos frea Tweadendpointinthe longitudinals pm fen peresan O Run in path without on FOP et rtp eeoa IANG real Infeed angle Range of values for flank infeed at the flank for alternating flank infeed S Starting point offset for the first thread turn enter without sign Ce ee ae O eC re ee Thread pitch 3 as a value enter without sign VARI Determination of va aie type for the thread Range of values 1 NUMT int Number of thread starts enter without sign Function Using this cycle it is possible to produce several chained cylindrical or taper threads with constant pitch using in longitudinal and face traversing whereby the pitch may be different Me Fig 9 69 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 315 Cycles 9 5 Turning cycles Operational sequence Position reached prior to cycle start Starting position is any position from which the programmed thread starting point run in path can be approached without collision The cycle creates the following sequence of motions e Approach of the starting point determined in the cycle at the beginning of the run in path for the first thread turn with GO e Infeed for roughing according to the infeed type defined under VARI e Thread cutting is repeated according to the programmed number of roughing cuts e The finishing allowance is removed in the following step with G33
113. M130 1 M13 2 M130 1 Progran A OS CD stat OFF M130 0 M130 1 M130 2 V1i 9800 M130 2 e e ae M130 6 address S M130 M13 1 M13 2 Y1e 00 M130 2 Zoon eam FJ Fe 3 a M130 6 2 Zoom M130 7 a 3 Find Symbol Al info PLC PLC Status Window 1 Window 2 Cross info status list SBR37 refs Network 4 Line 7 Colum 4 Fig 7 38 Program status ON absolute representation Use this softkey to switch between the absolute and symbolic representation of the operands De pending on the selected type of representation the operands are displayed either with absolute or symbolic identifiers If no symbol exists for a variable this is automatically displayed absolutely The representation in the application area can be zoomed in or zoomed out step by step The follo wing zoom stages are provided 20 default 60 100 and 300 can be used to search for operands in the symbolic or absolute representation A dialog box is displayed from which various search criteria can be selected Using the Absolute symbolic address softkey you may search for a certain operand matching this criterion in both PLC windows When searching uppercase and lowercase letters are ignored Selection in the upper toggle field e Searching for constants only absolute e Search for absolute and symbolic operands e Go to network number e Find SBR command Further search criteria e Search direction down from th
114. MTH 4 Fig 9 73 Programming example Thread chain Using this program you may produce a thread chain starting with a cylindrical thread The infeed is performed vertically to the thread neither finishing allowance nor starting point off set are programmed 5 roughing cuts and one idle passes are executed The machining type specified is longitudinal external with constant cross sectional area of cut SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 319 Cycles 9 5 Turning cycles X 0 Fig 9 74 N10 G95 T5 D1 S1000 M4 Specification of the technological values N20 GO X40 Z10 Approach starting position N30 CYCLE98 0 30 30 30 60 36 80 50 10 Cycle call 10 0 92 5 1 1 5 2 2 3 1 N40 GO X55 Traversing by axes N50 Z10 N60 X40 N70 M2 End of program SINUMERIK 802D 802D base line 9 320 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 6 Error Messages and Error Handling 9 6 Error Messages and Error Handling 9 6 1 General notes If error conditions are detected in the cycles an alarm is generated and the execution of the cycle is aborted Furthermore the cycles display their messages in the message line of the control system These message will not interrupt the program execution The errors with their reactions and the messages in the message line of the control system are described in conjunction with the individual cycles 9 6 2 Error handli
115. Note The programmed position values for X1 Z1 here 0 are ignored but must be programmed Reference Point Approach G74 Functionality G74 can be used for reference point approach in the NC program Direction and speed of each axis are stored in machine data G74 requires a separate block and is effective block by block The machine axis identifier must be programmed In the block following G74 the previous G command of the interpolation type group GO G1 G2 is active again Programming example N10 G74 X1 0 Z1 0 Note The programmed position values for X1 Z1 here 0 are ignored but must be programmed SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 169 Programming 8 3 Axis Movements 8 3 11 Measuring with Switching Tracer MEAS MEAW Functionality If either the statement MEAS or MEAW is contained in a block for traversing move ments of axes the positions of the traversed axes are acquired at the switching edge of a con nected tracer and then stored The measuring result for each axis can be read from the pro gram With MEAS the movements of the axes are decelerated when the selected switching edge of the tracer comes in and the remaining distance to go will be deleted Programming MEAS 1 G1 X Z F measuring at the rising edge of the tracer deletion of distance to go MEAS 1 G1 X Z F measuring at the falling edge of the tracer deletion of dist
116. ONING oisi cote cree ternal s cet eee coated sbeebs coe a sc COUNT MONIIN 2 c0 2cccercantiadeeedbasedueaddnahea iiaeaa oe aes Raina eai Milling on turning machines 0 cece ee eee ees Milling face ends TRANSMIT 0 0 ccc teen enna Milling of peripheral surfaces TRACYL Equivalent G Functions with SINUMERIK 802S Turning OVCIVIEW OF CYCICS cnc ccd ccc attuseueadbdeeasabtaeeeeesideesesebeseeeatetecese Programming CY ClesS cand 2 tected ren reL Soe ie ee eee hoe ects heewee mee oas Graphical cycle support in the program editor 0 cece eee nes Drilling ec tae ee ee ee ee ee eee ee ee eee Ge Meals 2 d 44 2 teh eeh aeoe eh one aees oka nbee eee enek esa cera eae aeneneenasheeeues EES NO ELE 24 44 5 c5s2026 cone eter been et eheeme et ehebwees ceepes eteeeeee es cee Drilling centering CYCLE81 Center drilling CYCLE82 1 0 0 ene e eee e tenn nes Deep hole drilling CYCLE83 22 cciepisdbetebes Secterecbbat erereestecns cheeses Rigid tapping CYCLE84 0 een eee ene nnenas Tapping with compensation chuck CYCLE840 0 annaa annann nan Reaming 1 boring 1 CYCLE85 ccna Boring boring 2 CYCLE86 0 ccc ENERE ERE E EA tenes Boring with Stop 1 boring 3 CYCLE87 0 ccc eens Drilling with stop CYCLE88 0 ccc ete eee nee Reaming 2 boring 5 CYCLE89 cece eeee Row of holes HOLES1 Circle of
117. P3 11 03 OP T Programming 8 3 Axis Movements 8 3 4 Circular Interpolation via Intermediate Point CIP Functionality In this case the direction of the circle results from the position of the intermediate point bet ween start and end points CIP is effective until it is canceled by another statement from this G group GO G1 G2 Note The set dimension data input format G90 or G91 is applicable both to the end point and the intermediate point Intermediate point I1 Fig 8 17 Circle with end and intermediate point specification example with G90 Programming example N5 G90 Z30 X40 Starting point of circle for N10 N10 CIP Z50 X40 K1 40 l1 45 end and intermediate point 8 3 5 Circle with Tangential Transition CT Functionality CT and the programmed end point in the current plane G18 Z X plane will create a circle tangentially connected to the previous path section circle or straight line Radius and center point of the circle are derived from the geometrical relations of previous path section and programmed circle end point Programming N10 G1 Z20 F3 Straight line N20 CT N20 CT X Z Circle with tangential connection End point of circle X Z Fig 8 18 Circle with tangential transition to the previous path section SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 163 Programming 8 3 Axis Movements 8 3 6 Thread Cutting with Constant Lead G3
118. PF a a as sos s Settings The display of the actual values for MDA mode is carried out depending on the selected coordinate system SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Manually Controlled Operation 4 2 Operating Mode MDA Manual Input 4 2 1 Face Turning Functionality This function can be used to prepare the blank for the subsequent machining without creating a special part program Operating sequence In MDA mode open the input screen form using the Face softkey e Position the axes on their start points e Enter the values in the screen form lt p If you have filled in the screen form completely the function will create a part program which can be started using NC Start The screen form will be closed and the machine main screen appears where the progress of the program can be viewed Important First the retraction level and the safety distance must be defined in the Settings menu SKP DRY ROY M61 PRT SBL Turnin DEMO1 MPF 3 orkpiece edge Z Get curr position Di 8 980 mm rev 6 668 rpm rough 1 688 abs MERC b 8 188 inc 0 100 inc 8 508 inc 8 508 inc E e Fig 4 8 Face turning SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 4 57 Manually Controlled Operation 4 2 Operating Mode MDA Manual Input Table 4 3 Description of the parameters in the Face Turning window Parameters
119. Programming 8 6 Tool and Tool Compensation 8 6 8 Example of Tool Radius Compensation Fig 8 46 Example of tool radius compensation cutter edge radius enlarged Programming example N1 contour cut N2 T1 tool 1 with offset D1 N10 DIAMON F S M radius input technological values N15 G54 GO G90 X100 Z15 N20 X0 Z6 N30 G1 G42 G451 X0 ZO Start compensation mode N40 G91 X20 CHF 5 1 1223 insert chamfer 30 degrees N50 Z 25 N60 X10 Z 30 N70 Z 8 N80 G3 X20 Z 20 CR 20 N90 G1 Z 20 N95 X5 N100 Z 25 N110 G40 GO G90 X100 quit compensation mode N120 M2 SINUMERIK 802D 802D base line 8 200 6FC5 698 2AA00 OBP3 11 03 OP T 8 6 9 Function Programming 8 6 Tool and Tool Compensation Using milling tools The use of the kinematic transformation functions TRANSMIT and TRACYL is connected with the use of milling tools on turning machines see Section 8 14 The effect of the tool compensation when working with milling tools is different to that with tur ning tools F toolholder reference point G17 Length 1 in Z Radius in X Y 18 Length 1 in Y Radius in Z X 49 Length 1 in X Radius in Y Z Length 1 Fig 8 47 Effect of the tool compensations with tool type milling tool Length 1 in Z Length 2 in Y Length 3 in X Radius in X Y Length 1 in Y Length 2 in X Length 3 in Z Radius in Z X Length 1 in X Length 2 in Z Length 3 in Y Radius in Y Z Wit
120. R2 COS R3 TAN Tangens specified in degrees e g R4 TAN R5 buluwesbold L dO 0 LL da0 00VVe 869 S039 aul seq AZ08 AZ08 MIYAWNNIS t l 8 Address Meaning Value Assignment Explanation Programming ASIN Arcussinus R10 ASIN 0 35 R10 20 487 degrees ACOS Arcuscosinus R20 ACOS R2 R20 degrees ATAN2 Arcustangens2 The angle of the sum vector is calculated from 2 vec R40 ATAN2 380 5 80 1 R40 20 8455 degrees tors standing vertically one on another The 2nd vector specified is always used for angle reference Result in the range 180 to 180 degrees SQRT Square root e g R6 SQRT R7 POT Square e g R12 POT R13 ABS Amount e g R8 ABS R9 TRUNC Integer portion e g R10 TRUNC R11 LN Natural logarithm R12 LN R9 EXP Exponential function R13 EXP R1 RET End of subroutine is used instead of M2 to maintain continuous path RET separate block control mode S Spindle speed 0 001 99 999 999 Unit of spindle speed rom S 51 Spindle speed 0 001 99 999 999 Unit of measurement of the spindle r p m 1 725 speed 725 r p m for spindle 1 for spindle 1 S2 Spindle speed 0 001 99 999 999 Unit of measurement of the spindle r p m S2 730 speed 730 r p m for spindle 2 for spindle 2 S Cutting speed with G96 0 001 99 999 999 Unit of cutting speed with G96 m min G96 active S S Dwell time in a block con 0 001 99 999 99
121. RS232 interface For the interface settings please refer to the operating area System Chapter 7 The transfer of part programs must be carried out using the text format Use the softkey Cycles to display the Standard Cycles directory This softkey is only available if the operator has the required access authorization Use this softkey to delete the cycle highlighted by the cursor first a confirmation warning will ap pear Use the User cycles softkey to display the User cycles directory With the appropriate access right the softkeys New Copy Open Delete Rename Read out and Read in are displayed SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T Save data SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T A Name _N_COY_COM _N_CUS1_ SPF _N_CUS2_SPF _N_CUS3_SPF _N_UC_COM Free NC memory Length 163 163 163 163 163 j__ Copy Open Read in sas oe O O o ee Fig 6 2 Save data Part Programming This function will save the contents of the volatile memory into a nonvolatile memory area Prerequisite There is no program currently executed Do not carry out any operator actions while the data backup is running 6 73 Part Programming 6 1 6 1 Entering a New Program Operating Area Program Entering a New Program Operating Area Program Operating sequences PROGRAM MANAGER P
122. SKP DRY ROV M 1 PRT SBL G DEMO1 MPF function Position Distance to go T F S A BAB 8 000 m T 4 D4 same 8 088 mm 8 800 8 0 00A F 6 666 mm min l 1 S 8 8 Axis Application area 0 0 8 feedrate EL Progran Block display DEMO1 MPF oa ANF Gi G94 X78 F3000 Ti 1 Di 1 ANA X78 Z75 N51 Z M3 519000 Gi G98 X26 606 Y8 0 F656 6608 CYCLE82 R12 1 606 12 606 1 600 1 060 1 800 NGG X109 298 F100 pain Gi G96 X26 666 Y86 666 F656 666 Cycle time 990H 1M31S a l ax prograns Tip Progran Block Record Correct control search progran and softkey area Fig 1 1 Screen layout The screen is divided into the following main areas e Status area e Application area e Tip and softkey area SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 1 13 Introduction 1 7 Screen Layout Status area Q AUTOMATIC 3 RESET SKP DRY m4 PRT SBL DENO1 MPF Fig 1 2 Status area Table 1 1 Explanation of the display elements in the status area Display Display Meaning Element Active operating area active mode Position JOG 1 INC 10 INC 100 INC 1000 INC VAR INC incremental evaluation in JOG mode MDA AUTOMATIC Offset Program Program Manager System Alarm Marked as an external language using G291 Alarm and message line The following is displayed either or 1 Alarm number with alarm text 2 Message text Program status
123. Speed of spindle n which was last programmed e AA_S n Actual speed of spindle n e P_SDIR n Direction of spindle n which was last programmed e AC_SDIR n Current direction of rotation spindle n 2 spindles installed Using the system variable it is possible to interrogate the following in the program e P_NUM_SPINDLES Number of configured spindles channel e P_MSNUM Number of the programmed master spindle e AC_MSNUM Number of the active master spindle SINUMERIK 802D 802D base line 8 184 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 5 Special Turning Functions 8 5 Special Turning Functions 8 5 1 Constant Cutting Speed G96 G97 Functionality Prerequisite This function requires a controlled spindle With the function G96 enabled the spindle speed will be adapted to the diameter of the work piece currently machined face axis such that a programmed cutting speed S at the tool edge remains constant spindle speed by diameter constant From the block containing G96 the S word will be interpreted as the cutting speed G96 is modally active until it is disabled by another G function of the group G94 G95 G97 Programming G96 S LIMS F constant cutting speed ON G97 constant cutting speed OFF S cutting speed unit m min LIMS upper limit speed of spindle only active with G96 F feed in mm rev as with G95 Note If previously G94 was active instead of G95 a new suitable
124. Stop another group is provided to select a window with different accuracies For exact stop a modal statement is provided G9 You should take into account this option for adaptation to your particular positioning task SINUMERIK 802D 802D base line 8 158 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 3 Axis Movements 8 3 2 Linear Interpolation with Feed G1 Functionality The tool moves from the starting point to the end point along a straight path For the tool path feedrate the programmed F word is decisive All axes can be traversed at the same time G1 is effective until it is canceled by another statement from the same G group GO G2 G3 a Fig 8 10 Linear interpolation with G1 Programming example NO5 G54 GO G90 X40 Z200 S500 M3 tool traverses at rapid traverse spindle speed 500 rom CW rotation N10 G1 Z120 F0 15 linear interpolation with feed 0 15 mm rev N15 X45 Z105 N20 Z80 N25 GO X100 clearance at rapid traverse N30 M2 end of program Note Another possible way to program a straight line is to use the angle specification ANG see Section Contour Definition Programming SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 159 Programming 8 3 Axis Movements 8 3 3 Circular Interpolation G2 G3 Functionality The tool moves from the starting point to the end point on a circular path The direction is de termined by the G function CW direction CCW
125. T 9 243 Cycles 9 4 Drilling cycles x aA ne 2 ie Srnec ee vev TE Sp O ac i OMORO a X Q Fig 9 5 DTB dwell time The dwell time to the final drilling depth chip breaking is programmed under DTB in se conds Note If a value is entered both for DP and for DPR the final drilling depth is derived from DPR If this differs from the absolute depth programmed via DP the message Depth Corresponding to value for relative depth is output in the message line If the values for reference and retraction planes are identical a relative depth specification is not permitted The error message 61101 Reference plane defined incorrectly is output and the cycle is not executed This error message is also output if the retraction plane is located after the reference plane i e its distance to the final drilling depth is smaller Programming example Boring_counterboring The program machines a single hole of a depth of 20 mm at position XO with cycle CYCLE82 The dwell time programmed is 3 s the safety clearance in the drilling axis Z is 2 4 mm N10 GO G90 G54 F2 S300 M3 Specification of the technological values N20 D1 T6 Z50 Approaching the retraction plane N30 G17 X0 Approaching the drill position N40 CYCLE82 3 1 1 2 4 20 3 Cycle call with absolute final drilling depth and safety clearance N50 M2 End of program SINUMERIK 802D 802D base line 9 244 6FC5 698 2AA00 O0BP3 11 03 OP T
126. TIME The runtime between NC start and program end reset is measured in the selected NC program Starting a new NC program deletes the timer e Tool intervention time in seconds AC_CUTTING_TIME The runtime of the path axes without rapid traverse is measured between NC start and program end reset in all NC programs with the tool active The measurement is additionally interrupted with the dwell time active The timer is automatically reset to zero with each booting of the control system Programming example N10 IF AC_CUTTING_TIME gt R10 GOTOF WZZEIT tool intervention time limit value N80 WZZEIT N90 MSG Tool intervention time Limit value reached N100 MO SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 217 Programming 8 12 Timer and Workpiece Counter Display 8 12 2 The contents of the system variable is displayed after activation as necessary on the screen in the operating area OFFSET PARAM gt softkey Setting Data 2nd page Runtime AC_OPERATING_TIME Cycle time AC_CYCLE_TIME Cutting time AC_CUTTING_TIME Setup time AN_SETUP_TIME Power on time AN POWERON_TIME In addition Cycle time is displayed in AUTOMATIC mode in the operating area Position in the Tip line Workpiece Counter Functionality Counters 8 218 The Workpiece Counter function provides counters that can be used for counting workpieces These counters are provided as syste
127. TRANSMIT and TRACYL softkeys do not exist with the 802D bl Therefore in the interactive screenform it must only be defined whether the following contour sec tions are to be programmed using radius or diameter programming The Approach start point softkey function will generate an NC block approaching the ent ered coordinates SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T Set Pole GO G1 Part Programming 6 3 Blueprint programming Programming aid for the programming of straight line sections PROGRAH Program editor DEMO1 MPF Enter the end point of the straight line in absolute dimensions in incremental dimensions with reference to the starting point or in polar coordinates The current settings are displayed in the interactive screenform The end point can also be defined by a coordinate and the angle between an axis and the straight line If the end point is determined via polar coordinates you will need the length of the vector between the pole and the end point as well as the angle of the vector referred to the pole The prerequisite is that a pole was set beforehand This pole will be applicable until a new pole is set A dialog box will appear where the coordinates of the pole point must be entered The pole point will refer to the selected plane PROGRAH Program editor DEMO1 MPF Input form line Z 6 66068 x 6 66668 Value of ist axis of pole point plane
128. Use this program to machine a grid of holes consisting of 5 rows with 5 holes each which are arranged in the XY plane with a distance of 10 mm between them The starting point of the grid is at X30 Y20 The example uses R parameters as transfer parameters for the cycle Fig 9 23 SINUMERIK 802D 802D base line 9 272 6FC5 698 2AA00 O0BP3 11 03 OP T R10 102 R11 105 R12 2 R13 75 R14 30 R15 20 R16 0 R17 10 R18 10 R19 5 R20 5 R21 0 R22 10 N10 G90 F300 S500 M3 T10 D1 N20 G17 GO X R14 Y R15 Z105 N30 MCALL CYCLE82 R11 R10 R12 R13 0 1 N40 LABEL1 N41 HOLES1 R14 R15 R16 R17 R18 R19 N50 R15 R15 R22 N60 R21 R21 1 N70 IF R21 lt R20 GOTOB LABEL1 N80 MCALL N90 G90 GO X30 Y20 Z105 N100 M2 Cycles 9 4 Drilling cycles Reference plane Retraction plane Safety clearance Drilling depth Reference point Row of holes of the 1st axis of the plane Reference point Row of holes of the 2nd axis of the plane Starting angle Distance of the 1st hole to the reference point Distance between the holes Number of holes per row Number of rows Count of rows Distance between the rows Specification of the technological values Approach starting position Modal call of the drilling cycle Call of the row of holes cycle Calculate y value for the next line Increment line counter Return to LABEL1 if the condition is fulfilled Deselect modal call Approach starting position End of program
129. Use this softkey to modify the variable value Use this softkey to assign the active pad a new area The dialog screen form offers four areas to choose from For each area a start address can be assigned which must be entered in the corres ponding input box If you quit the input screen form the settings will be saved SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T PLC program Program list System CR_ONLY1 CR_ONLY1 awry nuh wWNnNe 8 1 2 3 4 5 6 7 8 9 m p a 4 PLC edit pad h Ovaoan OuMh WN SB O Fig 7 22 The Data Type screen form Use the cursor keys and the Page up Page Down keys to navigate in and between the pads PLC diagnosis using the Ladder Diagram representation see Section 7 1 This function is not available with the 802D bl Using the PLC you may select part programs and run them via the PLC To this end the PLC user program writes a program number to the PLC interface which is then converted to a program name using a reference list It is possible to manage max 255 programs SYSTEH PLC program selection MPF directory pi _j T C 5_10 MPF _1 T_C 95_HS MPF _ WRITE_ MPF WRITE_1 MPF i WRITE_2 MPF _ WRITE_3 MPF _ WRITE_4 MPF _ WRITE_S MPF E WRITE_6 MPF _ WRITE_ MPF WRITE_8 MPF _ WRITE_9 MPF WRITE_CYCLE MPF Jj WRITE_C MPF _ WRITE_E MPF WRITE_L MPF
130. YCLE93 The value of parameters VARI for the machining type incorrectly CYCLE95 is specified incorrectly and must be changed CYCLE97 61101 Reference plane defined CYCLE82 Either different values for reference and retraction incorrectly to plane must be selected in the case of relative specifi CYCLE88 _ cation of the depth or an absolute value must be speci CYCLE840 fied for the depth 61102 No spindle direction pro CYCLE88 Parameter SDIR or SDR in grammed CYCLE840 CYCLE840 must be programmed 61107 First drilling depth defi CYCLE83 First drilling depth is opposite to total drilling depth ned incorrectly 61601 Finished part diameter CYCLE94 No finished part diameter was programmed too small 61602 Too width defined incor CYCLE93 Cutting tool is larger than programmed groove width rectly 61603 Groove form defined in CYCLE93 e Radii chamfers at groove base do not match with correctly groove width e Face groove at a contour element running parallel to the longitudinal axis is not possible Active tool violates pro CYCLE95 Contour violation in relief cut elements due to the clea grammed contour rance angle of the tool used i e use a different tool or check the contour subroutine 61605 Contour programmed in CYCLE95 Illegal relief cut element detected correctly 61606 Error in contour prepara CYCLE95 An error has been found in the contour preparation tio
131. ach window Fig 2 1 will display whether the axes have a refe rence point or not O Axis has to be referenced e Axis has reached its reference point SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 2 217 Turning on and Reference Point Approach X 2 28 Z Select a direction key If you select the wrong approach direction no movement will be carried out Approach the reference point one after the other for each axis Quit the function by selecting a different mode MDA Automatic or Jog Note Reference point approach is only possible in Jog mode SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Setting Up Preliminary remarks Before you can work with the CNC set up the machine the tools etc on the CNC as follows e Enter the tools and the tool offsets e Enter modify zero offset e Enter setting data Menu tree Tool Tool Work R vari Setting User list life offset able data data Tool measure Delete tool Extend E E Em Work area limit Measure Time Tool workpiece counter measure Delete tool rm New tool Fig 3 1 The menu tree for the Parameters operating area Note The softkeys marked with gt lt in Fig 3 1 are not available in the 802D bl SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 3 29 Setting Up 3 1 Entering Tools and Tool Offsets 3 1 Entering Tool
132. ady been called modally Operational sequence To avoid unnecessary travel the cycle calculates whether the row of holes is machined star ting from the first hole or the last hole from the actual position of the plane axes and the geo metry of the row of holes The drilling positions are then approached one after the other at rapid traverse Explanation of the parameters Fig 9 21 SINUMERIK 802D 802D base line 9 270 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 4 Drilling cycles SPCA and SPCO reference point of 1st axis of the plane and 2nd axis of the plane One point along the straight line of the row of holes is defined as the reference point for de termining the distances between the holes The distance to the first hole FDIS is defined from this point STA1 angle The straight line can be in any position in the plane It is specified both by the point defined by SPCA and SPCO and by the angle contained by the straight line with the 1st axis of the plane of the workpiece coordinate system that is active when the cycle is called The angle is entered under STA1 in degrees FDIS and DBH distance The distance of the first hole and the reference point defined under SPCA and SPCO is pro grammed with FDIS The parameter DBH contains the distance between any two holes NUM number The NUM parameter is used to define the number of holes Programming example Row of holes Use this program to mac
133. al and set values of spindle speed rom Feed F Display of feedrate actual and set values mm min Tool Display of the currently engaged tool and of the current edge number Note If a second spindle is integrated into the system the workspindle is displayed using a lower font size The window will always display only the data of one spindle The control system displays the spindle data taking into account the following aspects The master spindle is displayed inthe idle condition at spindle start if both spindles are active The workspindle is displayed at spindle start of the workspindle In all cases the power bar applies to the spindle currently active This softkey is used to set the basic zero offset or a temporary reference point in the relative coordi nate system After opening this function can be used to set the basic zero offset SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 4 51 Manually Controlled Operation 4 1 Jog Mode Operating Area Position Measure workpiece Measure tool Settings 4 52 The following subfunctions are offered e Direct input of the axis position desired In the position window position the input cursor on the desired axis and enter the new po sition Complete your input either by pressing the Input key or by a cursor movement e Setting all axes to zero The softkey function X Y Z 0 will overwrite the current position of the co
134. all reset Furthermore it is possible to link the start with a debugging mode to follow Use OK to RESET the control system and to carry out a restart in the mode selected Press RECALL to return to the System main screen without any action Machine data The modification of machine data has a substantial influence on the machine Wrong parame terization may destroy the machine The machine data are divided into groups 16146 TIME_LIMIT_NETTO_DRIVE_TASK 4 888008 po a i 4 MD number Name Unit Effect Fig 7 3 Structure of a machine data line Activation SO Immediately cf With confirmation re Reset po Power on Caution Faulty parameterization may result in destruction of the machine General machine data Open the General Machine Data window Use the PageUp PageDown keys to leaf up and down SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T System General NC machine data AXCONF_MACHAX_NAME_TABI AXCONF_MACHAX_NAME_TAB 1 AXCONF_MACHAX_NAME_TABI 2 AXCONF_MACHAX_NAME_TABI 3 ASSIGN_CHAN_TO_MODE_GROUP 1 SYSCLOCK_CYCLE_TIME POSCTRL_SYSCLOCK_TIME_RATIO IPO_SYSCLOCK_TIME_RATIO PLC_IPO_TIME_RATIO SYSCLOCK_SAMPL_TIME_RATIO CTRLOUT_LEAD_TIME CTRLOUT_LEAD_TIME_MAX PLC_CYCLE_TIME_AVERAGE TIME_LIMIT_NETTO_COM_TASK MM_NUM_MMC_UNITS Continue TIME_LIMIT_NETTO_DRIVE_TASK Select group General Axis Chan spec Drive Display HD MD Fig 7 4 The Machine Data
135. ally Auto To Use this softkey if you wish to use the default setting for scaling origin SHOW Use this softkey to display the entire workpiece Use this softkey to zoom out the display cutout Zoom Zoom Use this softkey to zoom in the display cutout SINUMERIK 802D 802D base line 6 96 6FC5 698 2AA00 OBP3 11 03 OP T Part Programming 6 5 Data Transfer via the RS232 Interface Delete Use this softkey to clear the visible screen window Cursor Use this softkey to modify the step size of the cursor coarse fi 6 5 Data Transfer via the RS232 Interface Functionality The RS232 interface can be used to output data e g part programs to an external data back up device or to read in them from there The RS232 interface and your data back up device must be matched another to one File types e Part programs Part programs Subroutines e Cycles Standard cycles Operating sequence PROGRAM manas Programs You have selected the operating area Program Manager and are in the overview of NC programs already created Read oui Use this softkey to save part programs via the RS232 interface Length _N_MPF_DIR _N_DEMO1_MPF NC memory assignment in bytes 246540 Fig 6 37 Reading out a program SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 6 97 Part Programming 6 5 Data Transfer via the RS232 Interfa
136. ame it is also possible to select L separate block only integer no sign L1 L9999999 the subroutine will thus also be called in a separate block Note LO001 is not equal to L1 The name LL6 is reserved for the tool change sub routine M Miscellaneous function 0 99 e g for initiating switching operations such as Coo M only integer no sign lant ON max 5 M functions per block Mo Programmed stop Machining stops at the end of a block containing MO machining is continued by pressing NC START again M1 Optional stop as MO but stop is only carried out if a special signal is provided M2 End of program is contained in the last block of the sequence of opera tions M30 reserved do not use M17 reserved do not use M3 CW rotation of spindle M4 CCW rotation of spindle M5 Spindle stop Mn 3 CW rotation of spindle for spindle n n 10r 2 M2 3 CW rotation stop for spindle 2 bulwwelsbold CY l 8 1 dO 0 LL dg0 00YYZ 869 S949 aul seq AZ08 dzZO8 MINAWNNIS Address Meaning Value Assignment Explanation Programming Mn 4 CCW rotation of spindle for spindle n n 1or 2 M2 4 CCW rotation stop for spindle 2 Mn 5 Spindle stop for spindle n n 1or 2 M2 5 Spindle stop for spindle 2 M6 Tool change only if activated with M6 via machine data otherwise change directly with T command M40 Automatic gear stage switching Mn 40 Automatic gear stage switching n 1or 2 M1 40
137. ammed with SCALE ASCALE active these offset values will also be scaled Original workpiece Workpiece Z Workpiece Workpiece enlarged in X and Z Fig 8 6 Example of a programmable scaling factor Programming example 8 154 N20 L10 programmed contour original N30 SCALE X2 Z2 N40 L10 contour in X and Z enlarged twice Subroutine call see Section 8 11 Subroutine Technique SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 2 Positional Data Information In addition to the programmable shift and the scaling factor there are still some other func tions programmable rotation ROT AROT and programmable mirroring MIRROR AMIRROR These functions are intended mainly for milling On turning machines this is possible with TRANSMIT or TRACYL see Section 8 14 Milling on turning machines Examples for rotation and mirroring see Section 8 1 6 Overview of statements For detailed information see References Operation and Programming Milling SINUMERIK 802D 8 2 6 Workpiece Clamping Settable Zero Offset G54 to G59 G500 G53 G153 Functionality The settable zero offset specifies the position of the workpiece zero on the machine offset of workpiece zero with reference to the machine zero This offset is determined when clamping the workpiece on the machine and it is then entered in the relevant data field by operation The value is enabled by the
138. amming Setting Data Operating Area Parameters 0 0c eee eee 3 5 R Parameters Operating Area Offset Parameters nananana cece eee eee 4 Manually Controlled Operation 0c cece ees 4 1 Jog Mode Operating Area Position 0 cette eee eens 4 1 1 PSSIONING TahOWRCCls se eect ore nren teas eee or er eos teres eee heer eens eres cee eee 4 2 Operating Mode MDA Manual Input 0 0 c cece eens 4 2 1 Pace TUMMNG tcatescescnceates ERER REREPEN TEREPRE rE EREEREER E EES 5 PULOMatC MOJE lt ccceecc tice cect Giccdinaceveseevenens Na 5 1 Selecting and Starting a Part Program 6 eens 5 2 Block Search Operating Area Machine 0 00 cece ene 5 3 Stopping Aborting a Part Program ccc eens 5 4 Reapproach after Interruption 0 0 0 ccc eee teen eens 5 5 Repositioning after interruption nna aaa anaana aaaea 5 6 Program Execution from External R8232 Interface 0 cee 6 Part Programming 5 c ctc4ccevetawe tindir oe teen etre eee a a a a 6 1 Entering a New Program Operating Area Program 00 eee ee eens 6 2 Editing a Part Program Operating Mode Program 0c cece eee eee eens 6 3 Blueprint progra MMING 2 2326 sctcenadcctetae as clethen ceeds a a E E a an 6 4 SIMMUIGUOM E E soit EET A E E E 254 E A cee es ET 6 5 Data Transfer via the RS232 Interface 0 0 tenes Vi SINUMERIK 802D
139. ance to go MEAW 1 G1 X Z F measuring at the rising edge of the tracer without deleting the distance to go MEAW 1 G1 X Z F measuring at the falling edge of the tracer without deleting the distance to go Measuring order state If the tracer has switched the variable AC_MEA 1 after the measuring record has the value 1 otherwise it has the value 0 Starting of the measuring record will set the variable to O Measurement result The measurement result is available for the axes traversed using the measuring record with the variables listed below and specified after the measuring record if the tracer has switched successfully in the machine coordinate system AA_MM axis in the workpiece coordinate system AA_MW axis Axis stands for X or Z Programming example N10 MESA 1 G1 X300 Z 40 F4000 measuring with deleting the distance to go rising edge N20 IF AC_MEA 1 0 GOTOF MEASERR measuring error N30 R5 AA_MW X R6 AA_MW Z process measured values N100 MEASERR MO measuring error Note IF statement see Section Conditioned Program Jumps SINUMERIK 802D 802D base line 8 170 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 3 Axis Movements 8 3 12 Feed F Functionality The feed F constitutes the tool path feedrate and represents the amount of the geometrical total of the speed components of all axes involved The individual axis speeds therefore result from the position of
140. ance value can be set via machine data Programming example Center and end point specification Starting point N End point point Fig 8 13 Center and end point specification example N5 G90 Z30 X40 Start point of circle for N10 N10 G2 Z50 X40 K10 l 7 end point and center point Note The center point values are referred to the starting point of the circular path Programming example End point and radius specification Starting point oN End point Fig 8 14 End point and radius input example SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 161 Programming 8 3 Axis Movements N5 G90 Z30 X40 Start point of circle for N10 N10 G2 Z50 X40 CR 12 207 end point and radius Note A negative sign for the value of CR will select a circle segment greater than a semi circle Programming example End point and aperture angle Starting point Fig 8 15 End point and aperture angle specification example N5 G90 Z30 X40 Start point of circle for N10 N10 G2 Z50 X40 AR 105 end point and aperture angle Programming example of center point and aperture angle Fig 8 16 Center point and aperture angle specification example N5 G90 Z30 X40 Start point of circle for N10 N10 G2 K10 l 7 AR 105 center point and aperture angle Note The center point values are referred to the starting point of the circular path SINUMERIK 802D 802D base line 8 162 6FC5 698 2AA00 OB
141. and accept the entered values This function is used to switch over the screen form from diameter programming to radius program ming Operating Areas The functions of the control system can be carried out in the following operating areas Position Machine operation Offset Parameters Input of compensation values and setting data Program Creation of part programs Program Manager Part program directory System Diagnosis start up Alarm Alarm and message lists To switch to a different operating area press the appropriate key hardkey Protection levels The input or modification of data in the control system is password protected in sensible pla ces In the menus listed below the input or modification of data depends on the protection level set e Tool offsets e Zero offsets e Setting data e RS232 settings e Program creation program correction SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T 1 3 1 3 1 SHIFT Introduction 1 3 Accessibility Options Accessibility Options Calculator The calculator function can be activated from any operating area using SHIFT and To calculate terms the four basic arithmetic operations can be used as well as the functions sine cosine squaring and square root A bracket function is provided to calculate ne sted terms The bracketing depth is unlimited If the input field is already occupied by a
142. ane Last changed Version PLC PLC system Sit Cycle time ms Processing time us Last iON ininum Moxcinum Git Fig 7 30 PLCinfo Use this softkey to refresh the data in the window see Operation and Programming Turning p 7 72 in the PLC status menu it is possible to read write and monitor a certain number of variables during the program execution The existing function is accepted az a Pu e gt GQ 7 x 3 P rt lt Q p z a A a PLC PLC Status Window 1 Window 2 Cross info status list SBR37 SBR33 refs Fig 7 31 PLC status display Using the function PLC status lists you may quickly locate monitor and change PLC signals see Operation and Programming Turning p 7 73 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 7 123 System 7 1 PLC diagnosis using the ladder diagram representation Window 1 XXXX Window 2 XXXX Program block 7 124 gt p h Ovaoawy OMA WN FS O ae jad Ne ovooaoanoawmnshwN Pe 8 1 2 3 4 5 6 7 8 9 16 11 12 Ww w A j A ul ul a A PLC PLC Status Window 1 Window 2 Cross info status list SBR37 SBR33 refs Fig 7 32 Status list This window displays all logical and graphical information of the PLC program running in the appro priate program block The logic in the LAD ladder diagra
143. ange passvord linear axis linear axis Delete 3 g password linear axis Change language Hachine Service data display Fig 7 1 The System main screen Depending on the functions selected the horizontal and vertical softkey bars change The menu tree shown below shows only the horizontal functions Start up Machine Service PLC Data I O data display General Service Step 7 Data Ng MD ange connect selection PLC Axis Service PLC RS232 MD drives status settings Chan spec Service Status MD profibus list Drive PLC MD lprogram gt Program list Display MD Servo Servo trace trace Versi Edit PLC gagn alarm txt Fig 7 2 The System menu tree only horizontal level The softkeys marked with an gt k asterisk are not available with the 802D bl SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 7 99 System Softkey Start up NC PLC OK Machine data ZN General MD 7 100 Start up Use this softkey to select the power up mode of the NC Select the desired mode using the cursor e Normal power up System is restarted e Power up with default data Cold restart with default values will restore the default state as on delivery e Power up with saved data Cold restart with the data saved last The PLC can be started in the following modes e Restart Cold restart e Overall reset Over
144. asbadeedneeteusds 8 3 18 Dwell TIME OGA 25 ceed eek eat Bee BS d SL eee 6 oo ed Sek eed See Bee eee as 8 3 19 Travel to fixed SIOD 2 c0i c55a25 00 64 sce RETAANE ek hoe eee ees ae EARR eee eee ees 8 4 Spindle Motions 22 2 cca od predate ceae coened nnd lt a bad eaeeuedendesneadsadecaderdds 8 4 1 Spindle Speed S Directions of Rotation 8 4 2 Spindle Speed Limiting G25 G26 1 eee eee ene ees 8 4 3 Positioning the Spindle SPOS 0 ccc eee nee n eens 8 4 4 Cece ee e e eect cuter ohne teehee ees eee te see ne bers ae ete mae ec bee nates 8 4 5 2nd SOIC osccateceanaa ced osaaetehe nesses ceneeteeenedeneeesuaaeeeneaaaeaes 8 5 Special Turning Functions 0 0 ccc eee ene e eens 8 5 1 Constant Cutting Speed G96 G97 8 5 2 Rounding CNAME gee ae en ee ee ne EE ei EEEE EEn a EEE INE SANER 8 5 3 Contour Definition Programming 000 asana ananena 8 6 Tool and Tool Compensation 8 6 1 General NOS 25 ste e yi beste 2 ete rere so eeeet ete ese Eni Skaer ES vetesetoeeeens 8 6 2 WOO a oe eek boas cee noes ee ose eee eee ee ees eae ote eee ees eases 8 6 3 Tool Offset Number D 0 ccc teen een e nee e ene nneenee SINUMERIK 802D 802D base line P 6FC5 698 2AA00 0BP3 11 03 OP T VII Table of Contents viii 8 6 4 8 6 5 9 4 7 9 4 8 9 4 9 9 4 10 9 4 11 9 4 12 9 4 13 9 4 14 9 5 Selection of Tool Radius Compensation G41 G42 Corner Behavior G450 G451 Tool Radius Compensation OFF G40 1 1 0
145. ate must be defined in the beginning of the program using a DEF statement DEF INT state It is also possible to define a different name for the variable instead of state but max 15 characters starting with 2 letters The variable can only be used in the program in which it was defined This also applies to the monitoring type variable mon If any specification is required here at all it can also be transferred directly as a number 1 or 2 Count monitoring The active cutting edge of the active tool is monitored for the count The count monitoring includes all tool cutting edges used to manufacture a workpiece If the count changes due to any new values specified the monitoring data of all cutting edges that became ac tive since the last workpiece counting are adapted Updating of the count via operation or SETPIECE 8 222 The count can be adapted either via operation HMI or in the NC program using the language com mand SETPIECE Using the SETPIECE function the programmer may update the count monitoring data of the tools involved in the machining process All tools that became active since the last activation of SET PIECE are acquired with their D numbers If a tool is active at the time when SETPIECE is called it is also counted If a block containing path axis motions is programmed after SETPIECE the appropriate tool is also taken into account in the next SETPIECE call SINUMERIK 802D 802D base line
146. ated Stop was recognized 5 Travel to fixed stop will be deselected The deselection is not yet completed TO N The interrogation of the system variable in the part program triggers a preprocessing stop With the SINUMERIK 802D only the static states before selection deselection may be acquired Alarm suppression The output of the following alarms may be suppressed via machine data e 20091 Fixed stop not reached e 20094 Fixed stop broken References Description of Functions Section Travel to Fixed Stop SINUMERIK 802D 802D base line 8 180 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 4 Spindle Motions 8 4 Spindle Motions 8 4 1 Spindle Speed S Directions of Rotation Functionality The speed of the spindle is programmed in revolutions per minute under the address S provi ded the machine has a controlled spindle The direction of rotation and the beginning or the end of the movement are defined using M commands see also Section 8 7 Miscellaneous Function M M3 CW rotation of spindle M4 CCW rotation of spindle M5 Spindle Stop Note For integer S values the decimal point may be omitted e g S270 Information If you program M3 or M4 in a block with axis movements the M commands come into effect prior to the axis movements Default setting The axis movements start only if the controlled spindle has accelerated M3 M4 M5 is also output before the axis movement starts The axes
147. ation between TDEP FAL NRC and NID thread depth finishing allowance number of roughing and idle passes The programmed finishing allowance acts paraxially and is subtracted from the specified thread depth TDEP the remainder is divided into roughing cuts The cycle will calculate the individual infeed depth automatically depending on the parameter VARI When the thread depth is divided into infeeds with constant cutting cross section the cutting force will remain constant over all roughing cuts In this case the infeed will be performed using different va lues for the infeed depth A second variant is the distribution of the whole thread depth to constant infeed depths When doing so the cutting cross section becomes larger from cut to cut but with smaller values for the thread depth this technology can result in better cutting conditions The finishing allowance FAL is removed after roughing in one step Then the idle passes pro grammed under parameter NID are executed IANG infeed angle Infeed along Infeed with a flank alternating flanks IANG lt Fig 9 71 SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 317 Cycles 9 5 Turning cycles Using parameter IANG the angle is defined under which the infeed is carried out in the thread If you wish to infeed at a right angle to the cutting direction in the thread the value of this parameter must be set to zero In o
148. ay from the fixed stop otherwise the fixed stop or the machine may be damaged The block change is carried out after the retraction position has been reached If no retraction posi tion is specified the block change is carried out immediately after disabling the torque limitation Further notes e Measuring with deletion of the distance to go command MEAS and Travel to fixed stop cannot be programmed in the same block e No axis specific contour monitoring is carried out during Traveling to fixed stop e If the torque limit is reduced too far the axis may no longer follow the setpoint specification the position controller will activate the limiting and the contour deviation will increase In this opera ting state sudden motions may occur due to an increased torque limit To make sure that the axis may still follow make sure that the contour deviation is not greater than with unlimited tor que e Appropriate machine data are provided to define a new torque limit to prevent the torque limit from being set suddenly e g when pressing the quill onto the workpiece System variable for the status AA_FXS axis This system variable delivers the status of Traveling to fixed stop for the specified axis Value 0 Axis is not at the stop 1 The stop was approached successfully axis is in fixed stop monitoring window Fixed stop approach was not successful axis is not at the stop Travel to fixed stop activ
149. bebe eetbeee rei eekase 8 2 7 Programmable Working Area Limitation G25 G26 WALIMON WALIMOF 0 0 ccc cece eee tenes 8 3 Axis Movements 0 0 c cece ee eee eee eee e eee e eee enaes 8 3 1 Linear Interpolation at Rapid Traverse GO 0 ccc eens 8 3 2 Linear Interpolation with Feed G1 tenet eens 8 3 3 Circular Interpolation G2 G3 2 1 6 eee eee ea Prai DE 8 3 4 Circular Interpolation via Intermediate Point CIP 1 0 0 0 0 0 ccc ees 8 3 5 Circle with Tangential Transition CT 0 ccc teen eens 8 3 6 Thread Cutting with Constant Lead G33 6 tenes 8 3 7 Thread cutting with variable lead G34 G35 1 eens 8 3 8 Thread interpolation G331 G332 2 eee eee een eae 8 3 9 Fixed Point Approach G75 2 05 lt c0 ose seme ee eed eee cee eens ae ewe eee eee eee ees 8 3 10 Reference Point Approach G74 1 0 cc eee eee eee eee neeaee 8 3 11 Measuring with Switching Tracer MEAS MEAW 000 c eee 8 3 12 POCO gxeuceusadeeerapdens oxugene Sbecee be soe ce ted eene EERE E ERENER EF 8 3 13 Exact Stop Continuous Path Control Mode G9 G60 G64 0 000005 8 3 14 Acceleration Behavior BRISK SOFT 0 0 0 0 ccc cee eee eens 8 3 15 Percentage Acceleration Compensation ACC 0 ccc eens 8 3 16 Traversing with Feedforward Control FFWON FFWOF 000 c eee eee 8 3 17 OIG ANG AMIN AXGS 422 cenedvud daw eed dducddduedencedeGesedeiedd
150. bility Options Enter the coordinates of the pole the slope angle of the straight line the ordinate angle of the end point and the circle radius as the length 688888 688888 8888 688888 8 BBBBB 688888 8 BBBBBB MO calulat m e g ji gt rt e PP abscissa PP ordinate PP angle A SEAN L EP ordinate L length diameter programming Fig 1 11 Result X 60 Z 44 601 Editing Chinese Characters This function is only available in the Chinese language version The control system provides a function for editing Chinese characters in the program editor and in the PLC alarm text editor After activation type the phonetic alphabet of the searched character in the input box The editor will then offer various characters for this sound from which you can choose the desired one by entering either of the digits 1 to 9 OB 1 02 Spa pes BET FB 9M Ag Fig 1 12 Chinese editor Alt S is used to turn on turn off the editor Hotkeys This operator control can be used to select copy cut and delete texts using special key com mands This functions are available both for the part program editor and for input fields CTRL C Copy CTRL B Select CTRL X Cut CTRL V Paste Alt L is used to switch to mixed notation SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T 1 4 Show Go to topic Introduction 1 4 The Help System
151. block that contains motion commands Other cycles written by the user can also be called modally There are two types of parameters e Geometrical parameters and e machining parameters The geometrical parameters are identical with all drilling cycles They define the reference and retraction planes the safety clearance and the absolute or relative final drilling depth Geometrical parameters are assigned once during the first drilling cycle CYCLE82 The machining parameters have a different meaning and effect in the individual cycles They are therefore programmed in each cycle separately Geometrical parameters Final drilling depth Reference plane Retraction plane TI Ko an Preconditions Call and return conditions 9 238 Drilling cycles are programmed independently of the actual axis names The drilling position must be approached in the higher level program before the cycle is called SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Cycles 9 4 Drilling cycles The required values for feedrate spindle speed and direction of spindle rotation must be pro grammed in the part program if there are no defining parameters in the drilling cycle The G functions and the current data record active before the cycle was called remain active beyond the cycle Plane definition In the case of drilling cycles it is generally assumed that the current workpiece coordinate system in wh
152. by pressing the SELECT key Pressing this key opens the selected program block its name absolute is displayed on the Win dow 1 2 softkey Use this softkey to activate deactivate the display of the program status It is possible here to ob serve the current network states beginning from the end of the PLC cycle The states of all ope rands are displayed in the Program status ladder diagram This LAD acquires the values for the status display in several PLC cycles and then refreshes the status display SIMATIC LAD EMG_STP SBR33 Program block 2 2 Progran Network 4 Emergency Stop Quit Drive Power up stat OFF E_KEY T_48m T_63m T_64m N_EMG_ mami a 1 gt Absolute N_EMG_ address S 3 P_N_EM T_48m EZE Fies Zoom T_6 T_48m T_63m eA mM O a N ON Zoon DELAY HP a D_T48_ T_63m T_64m T_63m A SCS CD Find T_48m T_63m T_64m P_M_FDY T_64m e I s a s 3 D_T64m S Network 4 Line 4 Column 6 Symbol info Al a PLC PLC Status Window 1 ENET firme Cross info status list SBR37 SBR33 refs Fig 7 37 Program status ON symbolic representation SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T Symbolic address Absolute address Zoom Zoom Find System Z PLC diagnosis using the ladder diagram representation SIMATIC LAD EMG_STP SBR33 LU PI l Program block T29
153. ce All files Use this softkey to select all files All files in the part program directory will be selected and the data transfer started Start Use this softkey to start output One or several files from the part program directory will be output Press STOP to cancel the trans fer Read in Use this softkey to load part programs via the RS232 interface Error log Error log All files transferred are listed with status information 6 98 e For files to be output the file name an error acknowledgment e For files to be input the file name and the path specification an error acknowledgment Transfer messages OK Transfer completed without errors ERR EOF End of text character has been received but the archive file is incomplete Time Out The time monitoring reports an abortion of the transfer User Abort Transfer aborted by the Stop softkey Error Com Error at port COM 1 NC PLC Error Error message from NC Error Data Data error 1 Files read in with without leader or 2 Files in punched tape format sent without file name Error File Name The file name does not comply with the name convention of the NC SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T System Functionality The System operating area provides all functions required for parameterizing and analyzing the NCK and the PLC Set password Ch
154. changed prior to the machining To this aim the function will call a user cycle that will carry out all steps required This cycle is provided by the machine manufacturer Feed F Input of feedrate in mm min or mm rev Spindle S Input of spindle speed rom Machining Determination of surface quality It is possible to choose between roughing and finishing XO Input of the diameter of the blank Blank diame ter x1 Cutting length incremental in Z direction Cutting length ZO Input of the workpiece edge position in Z direction Position Z1 Cutting length incremental in Z direction Cutting length DX Input of infeed dimension Max infeed per cut UZ Input field for allowance on roughing UX Allowance Getcurr Use this function to accept the current position of the tool tip into the input field ZO or XO osition SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 4 59 Manually Controlled Operation 4 2 Operating Mode MDA Manual Input For your notes SINUMERIK 802D 802D base line 4 60 6FC5 698 2AA00 OBP3 11 03 OP T Automatic Mode Functionality In the Automatic mode you can execute part programs fully automatically i e this is the mode intended for normal operation of part machining Operating sequence Use the Automatic key to select Automatic mode The Automatic mode start screen appears which displays position spindle tool values and the curr
155. channel setting data Axis Specific setting data 1 ae SPIND_MIN_VELO_G25 rev min po i mise es oe WORKAREA_PLUS_ENABLE Eeo WORKAREA_MINUS_ENABLE Bo General WORKAREA_LIMIT_PLUS aaga RC Te il ta a TEMP_COMP_SLOPE 6 990086 H Channel meme ae a p OSCILL_DWELL_TIME1 a aaaaaa s OSCILL_DWELL_TIME2 8 900008 s OSCILL_NUM_SPARK_CYCLES Bo x g Back parameter mt SINUMERIK 802D 802D base line 3 46 6FC5 698 2AA00 OBP3 11 03 OP T Setting Up 3 5 R Parameters Operating Area Offset Parameters 3 5 R Parameters Operating Area Offset Parameters Functionality The main screen R Parameters displays a complete list of all R parameters of the control sy stem see also Section 8 9 Arithmetic Parameters R These can be modified if necessary 6 66606 Setting Eld uiia data ii Fig 3 23 The R Parameters window Operating sequence Select the softkeys Parameters and R Parameters R Para meter position the cursor bar on the input box you wish to modify and 0 9 enter value s FA Use the Input key or carry out a cursor movement to confirm your input E Use this softkey to search for R parameters In SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 3 47 Setting Up 3 5 R Parameters Operating Area Offset Parameters This sheet has been left empty for your notes SINUMERIK 802D 802D base line 3 48
156. cific variable identifier multiplication reserved do not use addition positive character reserved do not use subtraction negative sign Non printable special characters Le end of block character Blank separator between words blank Tabulator reserved do not use SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 135 9 L 8 L dO 0 LL dg0 00YYzZ 869 S949 aul seq AZ08 AZ08 AIHINWNNIS 8 1 6 List of Statements Address Meaning Value Assignment Explanation Programming D Tool offset number 0 9 only integer no contains compensation data for a particular tool T D sign DO gt offset value 0 max 9 D numbers per tool F Feed 0 001 99 999 999 traversing rate of tool workpiece Fess unit in mm min or mm rev depending on G94 or G95 F Dwell time in a block con 0 001 99 999 999 dwell time in seconds G4 F separate block taining G4 F Thread lead change 0 001 99 999 999 IN MM rey see with G34 G35 block containing G34 G35 G G function only integer given values The G functions are divided into G groups Only one G G preparatory function group of a group may be programmed in a block or symbolic name e g A G function can be either modal until it is canceled CIP by another function of the same group or only effec tive for the block in which it is programmed non mo dal G group GO Linear interpolatio
157. clearance Specification of the technological values Approach next position Cycle call with relative final drilling depth and safety clearance End of program SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Cycles 9 4 Drilling cycles 9 4 4 Center drilling CYCLE82 Programming CYCLE82 RTP RFP SDIS DP DPR DTB Parameters Table 9 2 Parameters of CYCLE82 e e eset B plane abealute SDIS Safety clearance enter without sign DP real Final drilling depth absolute ee Final aa depth relative to the reference plane enter wi thout sign DTB real Dwell time at final drilling depth chip breaking Function The tool drills at the programmed spindle speed and feedrate to the entered final drilling depth A dwell time can be allowed to elapse when the final drilling depth has been reached Operational sequence Position reached prior to cycle start The drilling position is the position in the two axes of the selected plane The cycle creates the following sequence of motions e Approach of the reference plane brought forward by the safety clearance by using GO e Traversing to the final drilling depth with the feedrate G1 programmed prior to the cycle Call e Dwell time at final drilling depth e Retraction to the retraction plane with GO Explanation of the parameters For the parameters RTP RFT SDIS DP DPR see CYCLE81 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP
158. coordinates of the end point of the second straight line and optionally the angle A2 The first straight line is described by the star ting point and the angle A1 The function inserts a circle sector with tangential transitions between two straight lines The circle S The screenform can be used if the following conditions are fulfilled Poit Ea E E coordinates on a aa point Both coordinates in a A ReO een a aaoo coordinate system Starting point as a polar coordinate Circle sector Both coordinates in the Cartesian coordinate system and the radius e Center point as a polar coordinate End point e Both coordinates in a Cartesian coordinate system e End point as a polar coordinate Poit Given coordinates coordinates Starting point Both coordinates in a Cartesian coordinate system e Circle sector One coordinate in the Cartesian coordinate system and the radius O e mgema O n End point e Both coordinates in a Cartesian coordinate system pee e emapomasapoeroooranoe oo OO If it is not possible to determine the starting point from the previous blocks the starting point must be set by the operator PROGRAH Program editor DEHO1 MPF Not selected Input screen form Line circle line 0 Fig 6 35 Straight line circle straight line Table 6 6 Input in the interactive screenform End point of straight line 2 Enter the end point of the straight line Center point of the circle Mio 1st and 2nd axes of the plane Angle
159. cross reference is marked by the characters gt gt lt lt This softkey is only unhidden if a cross reference is displayed in the application area SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 1 23 Introduction 1 5 Coordinate Systems Back to topic Find If you select a cross reference in addition the Back to topic softkey is displayed This function lets you return to the previous screen form Use this function to search for a term in the table of contents Type the term you are looking for and start the search process Help in the Program Editor area 1 5 The system offers an explanation for each NC instruction To display the help text directly po sition the cursor behind the instruction and press the Info key Coordinate Systems 1 24 For machine tools right handed right angled coordinate systems are used The movements on the machine are described as a relative movement between tool and workpiece Fig 1 15 Determinationof the axis directions another to one coordinate system for programming on turning SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Introduction 1 5 Coordinate Systems Machine coordinate system MCS How the coordinate system is located with reference to the machine depends on the machine type concerned It can be rotated in different positions Fig 1 16 Machine coordinates machine axes using the
160. dle n which was last programmed Current direction of rota tion of spindle n Direction of rotation of spindle n which was last programmed Number of the active tool T Active D number of the active tool Tool life prewarning limit not with 802D bl Residual tool life not with 802D bl 0 0 10 300 min read only value min read only value S S S 0 999 999 999 integer 0 0 0 0 System variables time since the control system has last booted Time since the control system has last booted nor mally Total runtime of all NC programs Runtime of NC program only of the selected one Tool intervention time System variables total actual number workpiece set number Current actual number Number of workpieces specified by the user read only read only read only Spindle number n 1 or 2 read only Spindle number n 1 or 2 read only Spindle number n 1 or 2 read only Spindle number n 1 or 2 read only read only read only in minutes writing or reading values for tool t D number d in minutes writing or reading values for tool t D number d N10 IF AC_CYCLE_TIME 50 5 N10 IF AC_ACTUAL_PARTS 15 N10 IF P_TOOLNO 12 GOTOF N10 IF P_TOOL 1 GOTOF N10 IF TC_MOP1 13 1 lt 15 8 GOTOF N10 IF TC_MOP2 13 1 lt 15 8 GOTOF Oulwwelsbold 8t L 8 1 dO 0 LL dG0 00VVZ 869 S949 aul seq AZ08 dZO8
161. dow manual SINUMERIK 802D 802D base line 3 34 6FC5 698 2AA00 OBP3 11 03 OP T Save osition Reset SKP DRY ROY M61 PRT SBL DEMO1 MPF Position Repos offset g 008 6 666 mn 2 i 088 6 666 mn A baa D 2 i 6 6 666 mm min 6 Tool list Length2 6 066 S 8 8 6 6 8 a 60 120 Pover x E _ T 1 R3 D 1 Save Saved Pos 6 666 mn position Distance 6 668 mn apsis mm Length1 9 888 mn Back Settings The Measure tool window Fig 3 9 Setting Up 3 1 Entering Tools and Tool Offsets Reset SKP DRY ROY M61 PRT SBL DEMO1 MPF Position Repos offset 2 B88 6 666 mn G 088 6 666 mn A BBA D 1 i 0 6 008 8 908 6 666 mm min 0 8 8 8 0 B ima Length1 a 68 120 er X Em Back Settings e Inthe field ZO type the workpiece diameter or in the ZO field type a value you wish to have for the tool at the current position This can be either the current machine coordinate or a value from the zero offsets If any other values are used the compensation value will refer to the specified position e After the softkeys Set length 1 or Set length 2 have been pressed the control system will determine the searched geometry length 1 or length 2 according to the preselected axis The compensation value determined will be stored Pressing this softkey will save the position of the X axis The X axis can be moved from the work piece awa
162. drilling cycle CYCLE89 is called with a safety clearance of 5 mm and specification of the final drilling depth as an absolute value The drilling axis is the Z axis SINUMERIK 802D 802D base line 9 268 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 4 Drilling cycles Fig 9 19 DEF REAL RFP RTP DP DTB Definition of the parameters RFP 102 RTP 107 DP 72 DTB 3 Value assignments N10 G90 G17 F100 S450 M4 Specification of the technological values N20 GO X80 Y90 Z107 Approach drilling position N30 CYCLE89 RTP RFP 5 DP DTB Cycle call N40 M2 End of program 9 4 13 Row of holes HOLES1 Programming HOLES1 SPCA SPCO STA1 FDIS DBH NUM Parameter Table 9 11 Parameters of HOLES1 SPCA real 1 axis of the plane abscissa of a reference point on the straight line absolute SPCO real 2 axis of the plane ordinate of this reference point abso lute STA1 real Angle to the 1st axis of the plane abscissa 180 lt STA1 lt 180 degrees FDIS real Distance from the first hole to the reference point enter wi thout sign DBH Distance between the holes enter without sign NUM int Number of holes SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 269 Cycles 9 4 Drilling cycles Function This cycle can be used to produce a row of holes i e a number of holes arranged along a straight line or a grid of holes The type of hole is determined by the drilling hole cycle that has alre
163. e 6FC5 698 2AA00 OBP3 11 03 OP T 8 213 Programming 8 11 Subroutine Technique 8 11 Subroutine Technique 8 11 1 General Application Generally there is no difference between a main program and a subroutine Subroutines are used to store often recurring machining sequences e g certain contour forms This subroutine is called and executed in the main program when required One form of the subroutine is the machining cycle Machining cycles contain generally appli cable cases of machining e g thread cutting stock removal etc By loading values using the intended arithmetic parameters you can achieve an adaptation to your particular applica tion see Section Machining Cycles Subroutine structure The structure of a subroutine is identical to that of a main program see Section 8 1 2 Pro gram Structure Like main programs subroutines are also programmed with the command M2 end of program in the last block of the program sequence In this case it means re turn to the calling program level End of program As a substitute for M2 end of program it is also possible to use the end statement RET in the subroutine RET requires a separate block Use the RET statement if G64 continuous path control mode is not to be interrupted by the return M2 will interrupt G64 and generate exact stop Subroutine L10 N10 R1 94 i ir JE i Fig 8 53 Sequence when calling the subroutine twice
164. e R parameters N10 R1 R1 1 the new R1 results from the old R1 plus 1 N20 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 N30 R13 SIN 25 3 R13 results in a sine of 25 3 degrees N40 R14 R1 R2 R3 multiplication and division before addition and subtraction R14 R1 R2 R3 N50 R14 R3 R2 R1 result as block N40 N60 R15 SQRT R1 R1 R2 R2 meaning R15 V R12 R22 Programming example Assignment to axes N10 G1 G91 X R1 Z R2 F3 N20 Z R3 N30 X R4 N40 Z R5 SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 207 Programming 8 9 8 9 2 Arithmetic parameters R LUD and PLC variables Local user data LUD Functionality The user programmer may define his her own variables of different data types in a program LUD Local User Data These variables exist only in the program in which they were defi ned The variables are defined immediately in the beginning of the program and can be linked with a value assignment Otherwise the initial value is zero The name of the variable can be defined by the programmer himself The naming is subject to the following rules e maximum length 32 characters e The first two characters must be letters for the characters left letters underscore or digits can be used e Names that have already been used in the control system may not be used NC addres ses keywords names of programs subroutines etc Programming Fields 8 208 DEF BOOL varnamet Type Bool
165. e TRANSMIT TRACYL not with 802D bl 0 0000 359 9999 d 1 000 99 999 999 n 1 orn 2 axis identifier e g SP1 or C specified in degrees the spindle stops at the specified position to achieve this the spindle must provide the appropriate technical prerequisites position control Spindle number n 1 or 2 special function the next block is only decoded if the block is completed prior to STOPRE kinematic transformation only available if the relevant option exists to be confi gured kinematic transformation only available if the relevant option exists to be confi gured disables all kinematic transformations N10 SPOS N10 SPOS ACP N10 SPOS ACN N10 SPOS IC N10 SPOS DC STOPRE TRACYL 20 4 TRACYL 20 4 1 TRANSMIT TRANSMIT 1 TRAFOOF separate block separate block Cylinder diameter 20 4 mm also possible separate block also possible separate block buluwelbold Programming 8 2 Positional Data 8 2 Positional Data 8 2 1 Absolute Incremental Data Input G90 G91 AC IC Functionality With the statements G90 G91 the programmed dimensional data X Z are interpreted either as a coordinate end point G90 or as a distance to be traversed by the axis G91 G90 G91 applies to all axes Deviating from the G90 G91 setting certain positional data can be speci fied in absolute incremental dimensions using AC IC Th
166. e The monitoring counters run from a set value gt 0 against zero If a monitoring counter reaches a value lt 0 the limit value is deemed to be reached an appropriate alarm message is generated System variable for monitoring type and status e TC_TP8 t status of the tool with number t Bit O 1 Tool is active 0 Tool not active Bit 1 1 Tool is enabled 0 not enabled Bit 2 1 Tool is disabled 0 not disabled Bit 3 reserved Bit 4 1 Prewarning limit reached 0 not reached e TC_TP9 t type of the monitoring function for the tool with number t 0 No monitoring 1 Tool monitored for the tool life 2 Tool monitored for the count number of workpieces These system variables can be read written in the NC program System variable for tool monitoring data Table 8 2 Tool monitoring data TC_MOP1 t d Prewarning limit Tool life in minutes REAL 00 TC_MOP2 t d Residual tool life in minutes REAL 00 STC MOPGR A _ Prewaringtint Count INTO STC MOPAR _ Restualcount INTO SINUMERIK 802D 802D base line 8 220 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 12 Timer and Workpiece Counter STC OPT Tea REAL OO TC_MOPTAILG Rewredcount m o t for tool number T d for D number System variable for the active tool The following can be read in the NC program using a system variable e P_TOOLNO number of the active tool T e P_TOOL active D number of the active tool 8 13 2 Tool life mon
167. e not with 802D bl 47 External NC languages modal 47 External NC languages modally effective The functions marked with an asterisk act on program start with factory setting and unless not otherwise programmed and the machine manufacturer has not changed the default technology setting Turning bulwwelbold L dO 0 LL da0 00VVe 869 S049 aul seq AZ08 AZ08 MIYAWNNIS LVL 8 Address Meaning Value Assignment Explanation Programming H H function 0 0000001 Value transfer to PLC HO H9999 9999 9999 Definition of meaning by machine manufacturer HO 8 decimal places or with e g H7 23 456 to exponent specification H9999 10 300 10 300 Interpolation parameter 0 001 99 999 999 relates to X axis meaning dependent on G2 G3 gt see G2 G3 and G33 Thread circle center point or G33 G331 G332 gt thread lead 0 001 2000 000 K Interpolation parameter 0 001 99 999 999 relates to Z axis otherwise as with see G2 G3 and G33 Thread 0 001 2000 000 li Intermediate point for cir 0 001 99 999 999 relates to X axis specification for circular interpolation see CIP cular interpolation with CIP K1 Intermediate point for cir 0 001 99 999 999 relates to Z axis specification for circular interpolation see CIP cular interpolation with CIP L Subroutine name and call 7 decimal places Instead of a random n
168. e This step is repeated according to the number of idle passes e The whole sequence of motions is repeated for each further thread turn Explanation of the parameters Fig 9 70 PO1 and DM1 starting point and diameter Using these parameters you determine the original starting point for the thread chain The starting point determined by the cycle itself and approached at the beginning using GO is lo cated by the run in path before the programmed starting point starting point A in the diagram on the previous page PO2 DM2 and PO3 DM3 intermediate point and diameter These parameters are used to define two intermediate points in the thread SINUMERIK 802D 802D base line 9 316 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 5 Turning cycles PO4 and DM4 end point and diameter The original end point of the thread is programmed using the parameters PO4 and DM4 In the case of internal threads DM1 DM4 are the tap hole diameter Interrelation between APP and ROP run in run out paths The starting point used in the cycle however is the starting point brought forward by the run in path APP and correspondingly the end point is the programmed end point brought back by the run out path ROP In the transversal axis the starting point defined by the cycle is always by 1 mm above the programmed thread diameter This retraction plane is generated in the internally control sy stem automatically Interrel
169. e current cursor position e Whole program block from the beginning e In one program block e Over all program blocks You can search for the operands and constants as whole words identifiers Depending on how the operand display is set an alternative search is possible either for symbolic or absolute representation Press the ok softkey to start the search The found search element is highlighted by the focus If nothing is found an appropriate error message will appear Use the Abort softkey to quit the dialog box no search is carried out SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 7 127 System 7 1 PLC diagnosis using the ladder diagram representation SIMATIC LAD MAIN COB1 SIMATIC LAD MAIN COB1 i ia a 7 go to i ae 7 go to Network 2 Find operand Network 2 Find operand iO SMO 0 i P_M_AUTO mj ol ol Network 3 SMO 0 MCFNCR m cia RT a a pal PLC Status VEUT GITES M Window 2 Cross El PLC Status Rema Window Z Cross info status list OB1 SBR refs info status list OB1 SBRO refs Fig 7 39 Searching for symbolic operands Searching for absolute operands lf the search object is found use the Continue search softkey to continue the search Syl Pressing this softkey displays all symbolic identifiers used in the highlighted network INTO Network 1 Override is effective to NCK channel SM8 0 V32000 e lt Ss Network 2 Initialization first axis
170. e have to be set up Make sure that the safety notes of the machine manufacturer are complied with Operating sequence Use the Automatic softkey to select Automatic mode An overview of all programs existing in the control system will be displayed PROGRAM MANAGER ae Position the cursor bar on the desired program eee Use the Execute softkey to select the desired program for execution The selected program name will appear in the display line Program name Progr As necessary make appropriate settings how you wish the program to be executed control DEHO1 MPF E a Reset SKP DRY ROY M 1 PRT SBL Program Position Dist to go 8 900 gt aa pes Line 4 888 BX Condit 6 B80 6 000 6 666 mm min stop A A 9 0 0 Skip 60 120 Power c3 J SBL Block display DEHO1 MPF fine ANF Gi G94 X78 F3066 T1 1 D1 1 ANA X70 Z75 amp ROV N51 26 M3 51000 active N66 X100 296 F1660 N75 F856 ZO N76 X68 Z160 N86 GOTOB ANAS Cycle time 00H 27M BOS lt Back 7 a lt Program Block Real time Correct control search simulat program Fig 5 4 Program control lf you press NC START the part program will be executed SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 5 65 Automatic Mode 52 Block Search Operating Area Machine 5 2 Block Search Operating Area Machine Operating sequence Prereq
171. e i allowance according to the contour enter without sign FF o real Feedrate for roughing without undercut FF2 real Feedrate for insertion into relief cut elements VARI real Machining type Range of values 1 12 Dwell time fore chip breaking when roughing DAM real Path length after which each roughing step is interrupted for chip breaking _VRT real Retraction travel from the contour when roughing incremental enter without sign Using the rough turning cycle you can produce a contour which has been programmed in a subroutine from a blank by paraxial stock removal The contour may contain relief cut ele ments It is possible to machine contours using longitudinal and face machining both exter nally and internally The technology can be freely selected roughing finishing complete ma chining When roughing the contour paraxial cuts from the maximum programmed infeed depth are programmed and burrs are also removed parallel to the contour after an intersec tion point with the contour has been reached Roughing is carried out up to the programmed finishing allowance Finishing is carried out in the same direction as roughing The tool radius compensation is selected and deselected by the cycle automatically SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 291 Cycles 9 5 Turning cycles Fig 9 45 Operational sequence Position reached prior to cycle start The starting position
172. e probe probe SINUMERIK 802D 802D base line 3 30 6FC5 698 2AA00 OBP3 11 03 OP T Delete tool Extend Activate change Edges D gt gt lt lt D New tool edge Reset edge Change type Find New tool Setting Up 3 1 Entering Tools and Tool Offsets Note With the 802D bl the Gauge tool softkey opens the Gauge tool window directly Use this softkey to delete the tool offset data of all cutting edges of the tool Use this function to display all parameters of a tool For the meanings of the parameters please refer to the Section Programming D gt gt lt lt D Length1 Length2 Length3 Length1 o 8008 Length2 6 808 Length3 6 688 Radius 6 808 DP 6 668 DP8 6 668 DP 6 668 DP16 8 888 DP11 8 8868 New tool edge Reset edge Change type Back Tool Tool Work R vari Setting User list life offset able data data Fig 3 3 Technology 6 668 DP24 6 668 DP25 6 660 Length1i Length2 Length3 Screen form for entering special tools For the meanings of the parameters please refer to the Chapter Programming Pressing this softkey will enable the compensation values of the cutting edge immediately Use this softkey to open a lower level menu bar offering all functions required to create and display further cutting edges Use this s
173. e sector you have inserted and sector 2 Center point of the circle 1 1st and 2nd geometry axes of the plane Radius of circle 1 Input field for radius 1 Center point of circle 2 1st and 2nd geometry axes of the plane Radius of circle 1 Input field for radius 2 Radius of circle 3 Input field for radius 3 Input field for the interpolation feedrate If it is not possible to determine the starting point from the previous blocks use the Starting point screenform to enter the appropriate coordinates Use this softkey to define the direction of rotation of the two circles You can choose between G2 G3 Center and end points can be acquired either in absolute dimensions incremental dimensions or using polar coordinates The current settings are displayed in the interactive screenform SINUMERIK 802D 802D base line 6 90 6FC5 698 2AA00 OBP3 11 03 OP T Part Programming 6 3 Blueprint programming Example DIAMON G23 Fig 6 27 Given R1 39mm R2 69mm R3 39mm R4 49 mm R5 39 mm M1 Z 111 X 196 M2 Z 233 X 260 M3 Z 390 X 162 The coordinates Z 72 X 196 will be selected as the starting point After you have confirmed the starting point use the screenform to calculate the contour section C 63 The end point is left open since the coordinates are not known Use softkey 1 to set the direction of rotation of the two circles G2 G2 G3 and to fill out the parameter list Enter confirn start
174. e the real probe position It is possible to quit the measuring function without all positions having approached The points already captured remain stored Note To create the measuring program the parameters safety clearance from the Settings screen form and feedrate from the Probe Data screen form are needed If several axes are moved simultaneously no calculation of the compensation data is carried out To skip a point not needed for measuring use the Next Step function SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 3 39 Setting Up 3 2 Tool monitoring 3 2 Tool monitoring Tool life Reset monitor 3 40 Note This function is only available with the 802D Each monitoring type is displayed in 4 columns e Setpoint e Prewarning limit e Residual value e active Use the checkbox in the 4th column to activate deactivate the monitoring type D Tool life min Quantity Setpt Prew 1lt Resid Activ Setpt Prew 1l1tResid Activ 1 1 553823 558 668 557 978 pJ 8 2 1486 666 478 666 6 668 fq 8 161 6 666 6 666 46 666 8 Tool Tool Work R vari Setting User list life offset able data data Fig 3 14 Tool monitoring Symbols in the T column provide information on the tool status paN Prewarning limit reached X Tool disabled Ti Tool is monitored Use this softkey to reset the monitoring values of the selected tool SINUMERIK 802D 802D
175. e this parameter to define a retraction movement in the 2nd axis ordinate which is ex ecuted after the final drilling depth has been reached and oriented spindle stop has been per formed RPAP retraction path in the boring axis Use this parameter to define a retraction movement in the boring axis which is executed after the final drilling axis has been reached and oriented spindle stop has been performed POSS spindle position Use POSS to program the spindle position for the oriented spindle stop in degrees which is performed after the final drilling depth has been reached Note It is possible to stop the active spindle with orientation The angular value is programmed using a transfer parameter Cycle CYCLE86 can be used if the spindle to be used for the boring operation is technically able to go into position controlled spindle operation Programming example Second boring pass CYCLE86 is called at position X70 Y50 in the ZX plane The drilling axis is the Z axis The final drilling depth is programmed as an absolute value no safety clearance is specified The dwell time at the final drilling depth is 2 s The workpiece upper edge is at Z110 In the cycle the spindle is to rotate with M3 and to stop at 45 degrees SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 261 Cycles 9 4 Drilling cycles Fig 9 14 N10 GO G17 G90 F200 S300 M3 Specification of the technological values N20 T11 D
176. e this program to correct false program passages Any changes will be stored immediately Use this softkey to open the G function window to display all G functions active The G function window contains all active G functions whereby each G function is assigned a ground and has a fixed place Use the PageUp or PageDown keys to display further G functions EE a Reset SKP DRY ROY M 1 PRT SBL G function DEMO1 MPF Position Repos offset Auxiliary function G functions G HAG 6 668 mn a S G HAG 6 608 mn ae 8 988 8 080 44 10 13 Axis 15 694 feedrate 17 Fig 5 3 The Active G functions window This window displays the auxiliary and M iscellaneous functions currently active Pressing this softkey several times will close the window Pressing this softkey will display the Axis Feed window If you press this softkey several times the window is closed Pressing this softkey will switch the display from 7 block to 3 block display Use this softkey to select the values for the machine workpiece or relative coordinate systems An external program is transferred to the control system via the RS232 interface and executed im mediately by pressing NC START SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Automatic Mode 5 1 Selecting and Starting a Part Program 5 1 Selecting and Starting a Part Program Functionality Before starting a program CNC and machin
177. ear blocks with tan gential connection see also Fig 8 28 Chamfer CHR Another linear contour element chamfer is inserted in the corner between two linear blocks The programmed angle is the leg length of the chamfer Contour Insert chamfer with leg length e g 5 mm N10 G1 Z CHR 5 N20 X Z Bisector Fig 8 31 Inserting a chamfer with CHR SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 189 Programming 8 5 Special Turning Functions Information e f Radius and chamfer are programmed in a block only the radius is inserted indepen dently of the programming order e In addition to the contour definition programming there is also the chamfer specification with CHF In this case the value constitutes the chamfer length instead of the leg length with CHR End point in N20 not known N10 G1 X1 Z1 N20 ANG 1 N30 X3 Z3 ANG 2 The values are only symbolically End point in N20 unknown insert rounding N10 G1 X1 Z1 N20 ANG 1 RND N30 X3 Z3 ANG 2 analogously Insert chamfer N10 G1 X1 Z1 N20 ANG 1 CHR N30 X3 Z3 ANG 2 End point in N20 unknown insert rounding N10 G1 X1 Z1 N20 X2 Z2 RNDe N30 X3 Z3 analogously Insert chamfer N10 G1 X1 Z1 N20 X2 Z2 CHR N30 X3 Z3 End point in N20 unknown insert roundings N10 G1 X1 Z1 N20 ANG 1 RND 1 N30 X3 Z3 ANG 2 RND N40 X4 Z4 analogously Insert chamfer N10 G1 X1 Z1 N20 ANG
178. eater than 1 go to the block with LABEL2 N150 LABEL2 N800 LABELS N1000 IF R45 R7 1 GOTOB LABEL3 if R45 equal to R7 plus 1 go to the block with LABEL3 several conditional jumps in the block N10 MA1 N20 IF R1 1 GOTOB MA1 IF R1 2 GOTOF MA2 N50 MA2 Note The jump is carried out at the first condition fulfilled SINUMERIK 802D 802D base line 8 212 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 10 Program Jumps 8 10 4 Programming Example of Jumps Task Approaching points on a circle segment Given Start angle 30 in R1 Circle radius 32 mm in R2 Distance of positions 10 in R3 Number of points 11 in R4 Circle center position in Z 50mm in R5 Circle center position in X 20mm in R6 R4 11 number of points o 0 Pt 10 AT a Fig 8 52 Approaching points on a circle segment Programming example N10 R1 30 R2 32 R38 10 R4 11 R5 50 R6 20 assignment of start values N20 MA1 GO Z R2 COS R1 R5 X R2 SIN R1 R6 calculation and assignment to axis addresses N30 R1 R1 R3 R4 R4 1 N40 IF R4 gt 0 GOTOB MA1 N50 M2 Explanation The initial conditions are assigned to the corresponding arithmetic parameters in block N10 N20 is used for the calculation of the coordinates in X and Z and its processing In block N30 R1 is increased by the distance angle R3 R4 is decreased by 1 If R4 gt 0 N20 is executed again otherwise N50 with end of program SINUMERIK 802D 802D base lin
179. ecified other than for G90 G91 can also be axis directly for rotary axis spindle used for positioning the spindle N20 SPOS DC 33 1 positioning the spindle DEF Definition instruction Defining a local user variable of the type DEF INT VARI1 24 VARI2 2 variables of the type INT BOOL CHAR INT REAL directly at the beginning of the name is defined by the the program user FXS Travel to fixed stop 1 Selection Axis Use the machine identifier N20 G1 X10 225 FXS Z1 1 FXST Z1 12 3 FXSW Z1 2 axis 0 Deselection Fea FXST axis Clamping torque gt 0 0 100 0 in max 100 from the max torque of the drive N30 FXST Z1 12 3 travel to fixed stop axis Use the machine identifier FXSW Monitoring window gt 0 0 Unit of measurement mm or degrees axis specific N40 FXSW Z1 2 4 axis travel to fixed stop axis Use the machine identifier GOTOB GoTo statement back In conjunction with a label a GoTo operation to the N10 LABEL41 wards selected block is done the jump destination is in the a direction of the program start N100 GOTO LABEL1 GOTOF GoTo statement forward In conjunction with a label a GoTo operation to the N10 GOTOF LABEL2 selected block is done the jump destination is in the direction of the program start N130 LABEL2 buluwelsbold 9t L 8 1 dO 0 LL dG0 00VVZ 869 S949 aul seq AZ08 dZO8 MINAWNNIS LIMS MEAS MEAW A_DBBin A_DBWIn A_DBDIn A_DBRIn
180. eft of the groove side to the right of the groove center line enter G42 Correspondingly G41 must be written for if you wish the tool moving right of the groove side left of the groove center line Alternatively for changing G41 lt gt G42 you may enter the groove width in OFFN with a negative sign Since OFFN is also taken into account without TRACYL with the TRC active after TRAFOOF OFFN should be reset to zero The effect of OFFN with TRACYL is other than that without TRA CYL It is not possible to change OFFN within the part program Thus it is possible to shift the real center line from the center References Description of Functions Section Kinematic Transformations Programming example Producing a hook style groove Fig 8 61 Example of producing a groove 8 230 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 14 Milling on turning machines D x Pi 35 0 x 3 1415 mm 110 100 Y Fig 8 62 Programming the groove values at the groove bottom Machining diameter of the cylinder at the groove bottom 35 0 mm Desired groove total width 24 8 mm cutter used at the radius 10 123 mm N10 T1 F400 G94 G54 Milling tool cutter feedrate feedrate type zero offset N30 GO X25 Z50 SPOS 200 Approach start position N35 SETMS 2 Master spindle is now the milling spindle N40 TRACYL 35 0 Activate TRACYL machining diameter 35 0 mm N50 G55 G19 Zero offset plane selec
181. emel Find go to Find operand 1 IB3 2 IB4 3 IBS 4 IB amp 5 IB7 6 IB8 716 8 816 1 916 2 16 16 3 11 16 4 12 16 5 13 16 6 14 16 7 15 11 6 Cross refs ime _i Colunn a zj HED ok PLC PLC Status Window 1 Window 2 info status list OB1 SBR38 Fig 7 43 Find Find all Whole word only Searching for an operand in cross references Network 7 Network 7 Network 7 Network 7 Network 7 Network 7 Context HCP_862D HCP_862D HCP_882D MCP_882D NCP_882D HCP_862D EMG_STOP AXIS_CTL AXIS_CTL AXIS_CTL AXIS_CTL AXIS_CTL AXIS_CTL AXIS_CTL AXIS_CTL The text you are looking for is to be found in the notes line If the text is not found an appropriate error message is displayed which must be confirmed with OK If the search object is found use the Continue search softkey to continue the search SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Programming 8 1 Fundamentals of NC Programming 8 1 1 Program Names When creating a program the program name can be freely selected if the following conven tions are observed e The first two characters must be letters e The remaining characters may be letters digits or underscore e Do not use any separators see Section Character Set e A maximum of 16 characters is permitted Example WELLE527 8 1 2 Program Structure Structure and contents The NC program consists of a sequence of blocks see Table 8 1 Each bloc
182. ent block SKP DRY ROY M61 PRT SBL G function DEMO1 MPF Position Dist to go LIEGE J OA omm T O O oa D 8 688 mm 0 008 9 8 088 avant F 6 666 mm min S 8 8 o Axis 6 6 8 feedrate 60 12060 C Power Program Block display DEHO1 MPF sequence ANF Gi G94 X78 F3666 Ti 1 D1i 1 ANA X70 Z75m N51 Z M3 51000 N66 X100 296 F1660 N75 F856 Zam MCS WCS N76 X Z100 REL N86 GOTOB ANA Cycle time 9 01H 3M 49S External Progran Block Real time Correct control search simulat program Fig 5 1 The Automatic start screen Note The Real time simulat softkey is only available with the 802D bl with the color dis play option Spindle power and load display are not implemented in the 802D bl SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 5 61 Automatic Mode Parameters 5 62 Program Block Real time Correct control search simulat progr Zoom Auto To origin display all em P em Delete window Cursor coarse fine Program To test contour Dry run To feedrate endpoint Condit Without stop calculate Skip Interr point a Fig 5 2 The Automatic menu tree Table 5 1 Description of the parameters in the working window Parameters Explanation MCS Display of the existing axes in MCS or WCS X Z X If you traverse an axis in the positive or negative direction a plus or minus sign will Z appear in the re
183. es With the SINUMERIK 802D with SW 2 0 and higher the following special cases are available for the tool compensation Influence of setting data Using the setting data specified in the following the operator programmer may influence how the length compensation values of the tool used are taken into account e SD 42940 TOOL_LENGTH_CONST assignment of the tool length components to the geometry axes e SD 42950 TOOL_LENGTH_TYPE assignment of the tool length components irrespective of the tool type Note The changed setting data come into effect with the next cutting edge selection Examples With SD 42950 TOOL_LENGTH_TYPE 2 a milling tool with length compensation is taken into account as a turning tool e G17 Length 1 in the Y axis length 2 in the X axis e G18 Length 1 in the X axis length 2 in the Z axis e G19 Length 1 in the Z axis length 2 in the Y axis With SD 42940 TOOL_LENGTH_CONST 18 a length assignment is carried out in all planes G17 G19 in the same manner as with G18 Length 1 in the X axis length 2 in the Z axis Setting data in the program Apart from defining setting data via the operation it is also possible to write them in the pro gram Example N10 MC_TOOL_LENGTH_TYPE 2 N20 MC_TOOL_LENGTH_CONST 18 Information For detailed information on tool compensation special cases please refer to References Description of Functions Section Tool compensation special cases S
184. ese statements will not define the path on which the end points are reached For this pur pose a G group is provided G0 G1 G2 G3 see Section 8 3 Axis Movements Programming G90 absolute data input G91 incremental data input Z AC absolute data input for a certain axis here Z axis non modal Z C incremental data input for a certain axis here Z axis non modal G90 abs dimension G91 incr dimension Fig 8 3 Different dimensions in one drawing Absolute dimensioning G90 With absolute data input the dimensions are specified with reference to the zero point of the currently active coordinate system workpiece or current workpiece coordinate system or machine coordinate system This is dependent on which offsets are currently active pro grammable settable or no offset With program start G90 is active for all axes and remains active until it is canceled in a later block by G91 incremental data input modally effective Incremental data input G91 With incremental data input the numerical value of the positional information corresponds to the distance to be traversed by the axis The sign specifies the traversing direction G91 applies to all axes and can be canceled by G90 absolute data input in a later block SINUMERIK 802D 802D base line 8 150 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 2 Positional Data Specification with AC IC After the end
185. ety clearance e Retraction to the retraction plane with GO E a VVWv A EO n O O Tog Oo 0 O 1 dp O a ma a a TE A Oo QO Fig 9 9 Sequence of operations Tapping with compensating chuck with encoder Position reached prior to cycle start The drilling position is the position in the two axes of the selected plane The cycle creates the following sequence of motions e Approach of the reference plane brought forward by the safety clearance by using GO e Tapping to the final drilling depth e Dwell time at thread depth parameter DTB e Retraction to the reference plane brought forward by the safety clearance e Retraction to the retraction plane with GO SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 253 Cycles 9 4 Drilling cycles v in N eV i ee TN A Ta i SG a i i A x QO Fig 9 10 Explanation of the parameters For the parameters RTP RFP SDIS DP DPR see CYCLE81 DTB dwell time The dwell time is programmed in seconds It is only effective in tapping without encoder SDR direction of rotation for retraction SDR 0 must be set if the spindle direction is to reverse automatically If the machine data are defined such that no encoder is set in this case machine data MD30200 NUM_ENCS is 0 the parameter must be assigned the value 3 or 4 for the direc tion of rotation otherwise alarm 61202 No spindle direction program
186. example of a turning machine The origin of this coordinate system is the machine zero In this point all axes have the position zero This point represents only a reference point defi ned by the machine manufacturer It need not be approachable The traversing range of the machine axes can be in the negative range Workpiece coordinate system WCS The coordinate system described above see Fig 1 15 is also used to describe the geometry of a workpiece in the workpiece program The workpiece zero can be freely selected by the programmer in the Z axis In the X axis it is in the turning center X Workpiece Workpiece Workpiece W workpiece zero Fig 1 17 Workpiece coordinate system SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 1 25 Introduction 1 5 Coordinate Systems Relative coordinate system Apart from the machine and workpiece coordinate systems the control system provides a re lative coordinate system This coordinate system is used for setting reference points that can be freely selected and have no influence on the active workpiece coordinate system All axis movements are displayed relative to these reference points Clamping the workpiece For machining the workpiece is clamped in the machine The workpiece must be aligned such that the axes of the workpiece coordinate system run in parallel with those of the ma chine Any resulting offset of the machine zero with reference
187. forward by the safety clearance by using GO Traversing to final drilling depth with G1 and the feedrate programmed prior to the cycle Call Dwell time to final drilling depth Oriented spindle stop at the spindle position programmed under POSS Traverse retraction path in up to three axes with GO Retraction in the boring axis to the reference plane brought forward by the safety clea rance by using GO Retraction to the retraction plane with GO initial drilling position in both axes of the plane Explanation of the parameters Parameter RTP RFP SDIS DP DPR see CYCLE81 O gt GO D G1 B gt G4 B SPOS RTP RFP SDIS _ RFP DP RFP DPR DTB dwell time The dwell time to the final drilling depth chip breaking is programmed under DTB in se conds SDIR direction of rotation With this parameter you determine the direction of rotation with which boring is performed in the cycle If values other than 3 or 4 M3 M4 are generated alarm 61102 No spindle direc tion programmed is generated and the cycle is not executed 9 260 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Cycles 9 4 Drilling cycles RPA retraction path in the 1st axis Use this parameter to define a retraction movement in the 1st axis abscissa which is ex ecuted after the final drilling depth has been reached and oriented spindle stop has been per formed RPO retraction path in the 2nd axis Us
188. function will insert a straight line tangentially between two circle sectors The sectors are deter mined by their center points and their radii Depending on the direction of rotation selected different tangential points of intersection result Use the displayed screenform to enter the parameters center point and radius for the sector 1 and the parameters end point center point and radius for the sector 2 Furthermore the direc tion of rotation of the circles must be selected A help screen is provided to display the current settings Pressing OK calculates three blocks from the entered values and inserts them into the part program SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 6 83 Part Programming 6 3 Blueprint programming G2 G3 6 84 PROGRAH Program editor DEHMO1 HPF Not selected G21G3 G96 POI tang Z C x Fig 6 15 Table 6 4 Input in the interactive screenform End point E 1 and 2nd geometry axes of the plane If no coordinates are entered this function provides the point of intersection between the circle sector you have inserted and sector 2 Center point of the circle 1 ws 1st and 2nd geometry axes of the plane absolute coordi nates Radius of circle 1 RO Input field for radius 1 Center point of circle 2 KE 1st and 2nd geometry axes of the plane absolute coordi nates Radius of circle 1 R20 Input field for radius 2 Input field for the interpolation feed
189. g edges must be stored in two successive D numbers of the tool whereby the first of which must be activated prior to the first cycle call The cycle itself defines for which machining step it will use which of the two tool compensation values and will also enable them automatically After completion of the cycle the tool compensation number programmed prior to the cycle call is active again If no D number is programmed for a tool compensation when the cycle is called the execution of the cycle is aborted with the alarm 61000 No tool compensation active Programming example Grooving This program is used to produce a groove externally at an oblique line in the longitudinal di rection The starting point is on the right hand side at X35 Z60 The cycle will use the tool compensations D1 and D2 of tool T5 The cutting tool must be defi ned accordingly SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 285 Cycles 9 5 Turning cycles Chamfer gine di Fig 9 39 N10 G0 G90 Z65 X50 T5 D1 S400 M3 Starting point prior to cycle start N20 G95 F0 2 Specification of the technological values N30 CYCLE93 35 60 30 25 5 10 20 0 0 2 2 Cycle call 1 1 10 1 5 N40 GO G90 X50 Z65 Next position N50 M02 End of program SINUMERIK 802D 802D base line 9 286 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 5 Turning cycles 9 5 3 Undercut form E F CYCLE94 Programming CYCLE94 SPD SPL FORM
190. h I mo Power Set Length3 length Lengthi Back Set Measure Measure Bortinge base workpiece Raual Fig 3 11 Measuring using an optical measuring system input fields T and D see measuring using a sensing probe Measuring process For measuring position the tool tip of a chisel or of a drilling tool into the crosshair With a mil ling tool use the highest point of the cutting edge to determine the tool length Then press the Set length softkey to calculate the compensation values SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 3 37 Setting Up 3 1 Entering Tools and Tool Offsets 3 1 5 Probe Settings Note This function is only available with the 802D Settings Bae robe This screen form is used to store the probe coordinates and to set the axis feedrate for the automatic measuring process All position values refer to the machine coordinate system Position Repos offset Q l ABA 6 6668 mn A l HAG 6 688 mn Calibrate position P1 Feedrate TAG nn min probe position P2 position P3 position P4 Heasure workpiece tool Fig 3 12 The Probe Data screen form Table 3 1 Parameter Meaning Absolute position P1 Absolute position of the probe in the Z direction Absolute position P2 Absolute position of the probe in the X direction Absolute position P3 Absolute position of the probe in the Z direction
191. h the type drill the radius is not taken into ac count F toolholder reference point Fig 8 48 Effect of the tool length compensations three dimensionally special case SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 201 Programming 8 6 Tool and Tool Compensation Cutter radius compensation G41 G42 Fig 8 49 Cutter radius compensation to the right left of the contour Starting the correction The tool approaches the contour along a straight line and positions itself vertically to the path tangent at the contour starting point Select the starting point such that collision free traversing is guaranteed P1 starting point of the contour Contour straight line Contour circle MP Circle radius Tangent Tool radius not corrected not corrected 7 DT G42 Corrected Corrected tool path tool path PO starting point PO starting point Fig 8 50 Starting the cutter radius compensation using the example with G42 Information In all the other concerns the behavior of the cutter radius compensation is as that of the ra dius compensation with the tuning tool see Sections 8 6 5 through 8 6 7 For detailed information please refer to References Operation and Programming Milling SINUMERIK 802D SINUMERIK 802D 802D base line 8 202 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 6 Tool and Tool Compensation 8 6 10 Tool compensation special cas
192. hand Input fields no longer needed are hid den If a value is omitted from the center point coordinates the radius must be entered SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 6 87 Part Programming 6 3 Blueprint programming Use this softkey to switch the direction of rotation from G2 to G3 G3 will appear on the display coa Pressing this softkey again will switch back the display to G2 The display changes to G2 a You can choose between tangential or any transition The screenform generates two circle blocks from the data you have entered Selecting the point of intersection If several points of intersection exist the desired point of intersection must be selected from a dialog box PROGRAH Program editor TEST MPF Not selected POI DIAMONS 1 eof Select a point of intersection Fig 6 23 Selecting the point of intersection sey lt The contour will be drawn using the point of intersection 1 PROGRAH Program editor TEST MPF Not selected POI DIAMON 1 i eof Select a point of intersection sore The contour will be drawn using the point of intersection 2 SINUMERIK 802D 802D base line 6 88 6FC5 698 2AA00 OBP3 11 03 OP T OK Part Programming 6 3 Blueprint programming PROGRAH Program editor TEST MPF Not selected POI DIAMONS 1 eof Select a point of inter
193. he tool compensation If it turns out that the form of the undercut cannot be machined using the selected tool since its tool clearance angle is too small the message Changed form of undercut is displayed on the control system The ma chining however is continued X SL 4 SL3 Fig 9 43 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 289 Cycles 9 5 Turning cycles Further notes Before you call the cycle a tool compensation must be activated Otherwise the cycle is ab orted after alarm 61000 No tool compensation active has been output Programming example Undercut_form_E This program can be used to program an undercut of form E Fig 9 44 N10 T1 D1 S300 M3 G95 F0 3 Specification of the technological values N20 GO G90 Z100 X50 Selection of the starting position N30 CYCLE94 20 60 E Cycle call N40 G90 GO Z100 X50 Approach next position N50 M02 End of program SINUMERIK 802D 802D base line 9 290 6FC5 698 2AA00 0BP3 11 03 OP T 9 5 4 Cycles 9 5 Turning cycles Stock removal CYCLE95 Programming Parameters Function CYCLE95 NPP MID FALZ FALX FAL FF1 FF2 FF3 VARI DT DAM _VRT Table 9 15 Parameters of CYCLE95 Name of contour subroutine MD freal Infeed depth enter without sign C Co allowance in the longitudinal axis enter without sign FALX Finishing allowance in the transverse axis enter without sign T
194. hich is decremented A_MONIFACT 5 1 minute of real time 5 minutes of tool life which are decremented Setpoint update using RESETMON The function RESETMON state t d mon sets the actual value to the setpoint either for all cutting edges or only for a certain cutting edge of a certain tool either for all monitoring type or only for a certain monitoring type SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 221 Programming 8 12 8 13 3 Timer and Workpiece Counter Transfer parameters INT state Status of command execution 0 Successful execution S The cutting edge with the specified D number d does not exist 2 The tool with the specified T number t does not exist 3 The specified tool t does not have a defined monitoring function 4 The monitoring function is not activated i e the command is not executed INT t Internal T number 0 for all tool lt gt 0 for this tool t lt O absolute value generation ltl INT d optional D number of the tool with number t gt 0 for this D number withoutd 0 all cutting edges of tool t INT mon optional bit coded parameter for the monitoring type values analogously to TC_TP9 1 tool life 2 count without mon or 0 All actual values of the monitoring functions active for tool t are set to the setpoints Notes RESETMON is not effective with Program test active The variable for the status checkback message st
195. hine a row of holes consisting of 5 threaded holes arranged parallel to the Z axis of the ZX plane and which have a distance of 20 mm one to another The star ting point of the row of holes is at Z20 and X30 whereby the first hole has a distance of 10 mm from this point The geometry of the row of holes is described by the cycle HOLES1 First drilling is carried out using CYCLE82 and then tapping is performed using CYCLE84 tapping without compensating chuck The holes are 80 mm in depth difference between reference plane and final drilling depth Fig 9 22 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 271 Cycles 9 4 Drilling cycles N10 G90 F30 S500 M3 T10 D1 Specification of the technological values for the machining step N20 G17 G90 X20 Z105 Y30 Approach starting position N30 MCALL CYCLE82 105 102 2 22 0 1 Modal call of the drilling cycle N40 HOLES1 20 30 0 10 20 5 Call of row of holes cycle the cycle starts with the first hole only the drill positions are approached in this cycle N50 MCALL Deselect modal call Tool change N60 G90 GO X30 Z110 Y105 Traverse to position next to the 5th hole N70 MCALL CYCLE84 105 102 2 22 0 3 4 2 Modal call of the tapping cycle 300 N80 HOLES1 20 30 0 10 20 5 call of the row of holes cycle started with the 5th hole in the row N90 MCALL Deselect modal call N100 M2 End of program Programming example Grid of holes
196. holes HOLES2 0 0c eee eee eeees MOMMINO CVSS ce 2ee 55 snare eh ease dade E eee ane Seee eee akan eases SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Table of Contents 9 5 1 F eCONCINONS a6 pews teeter bes coces Gee neues ees bees ee orer eee bores teehee 9 5 2 GrOoOvVING CY CLEO8 sce oe5 25 ches ace eSaeene ooh ace bees aenehen sacs eheu ence 9 5 3 Undercut form E F CYCLE94 c 6 cc seeee ee dew ese i ee eee etsy ese ete ied eee weds 9 5 4 Stock removal CYCLE95 o2ccscccccasiecenenteedeaGneiveeeestuncdewaseicdensaes 9 5 5 Thread undercut CYCLEQG 0 ete eee ee neeeeee 9 5 6 Thread cutting CYCLES 2s 056 6022 o0e8 obec oes ee eee eh ore eee bees eee ees 9 5 7 Chaining of threads CYCLE98 0 0 0 ccna 9 6 Error Messages and Error Handling 9 6 1 General MOIS a6 oe ceus ot ore ee ees Sat cee eee bee Eas st oe sk bao See ees 9 6 2 Error handling inthe cycleS 00 anaana 9 6 3 Overview of cycle alarMS 1 eee n ene e teen eens 9 6 4 Messages in the cycles cox ces cet nce weber ooh eet eee eee ees eee eect emer end SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T IX SINUMERIK 802D Key Definition E CS aoon aon U V W Q oan A epee Boe i Bone aa M e Recall key ETC key Acknowledge Alarm key Not assigned Info key Shift key Control key Alt key SPACE INSERT Deletion key Bac
197. i nated and the error message 61000 No tool compensation active is issued Programming example Thread_undercut_form_A This program can be used to program a thread undercut of form A Fig 9 61 N10 D3 T1 S300 M3 G95 F0 3 N20 GO G90 Z100 X50 N30 CYCLE96 40 60 A N40 G90 GO X30 Z100 N50 M30 SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Specification of the technological values Selection of the starting position Cycle call Approach next position End of program 9 307 Cycles 9 5 Turning cycles 9 5 6 Thread cutting CYCLE97 Programming Parameters Function 9 308 CYCLE97 PIT MPIT SPL FPL DM1 DM2 APP ROP TDEP FAL IANG NSP NRC NID VARI NUMT Table 9 18 Parameters of CYCLE97 Thread pitch as a value enter without sign Thread pitch as a thread size Range of values 3 for M3 60 for M60 Run in path enter without sign ROP real Run out path enter without sign IANG real Infeed angle Range of values for flank infeed at the flank for alternating flank infeed Starting point offset for the first thread turn enter without sign Number of roughing cuts enter without sign Number of idle passes enter without sign VARI int Determination of machining type for the thread Range of values 1 4 NUMT Number of thread starts enter without sign Using the thread cutting cycle you can produce cylind
198. ications for direction of rotation stop and speed The master spindle is defined by configuration machine data As a rule the main spindle spindle 1 is the master spindle It is also possible to define a different spindle as master spindle in the program e SETMS n Spindle n 1 or 2 is master spindle as of now Switching back is also possible via e SETMS Now the configured master spindle is master spindle again or e SETMS 1 Spindle 1 is master spindle again The definition of the master spindle which was changed in the program will only apply to the end of the program program abortion Then the configured master spindle is active again SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 183 Programming 8 4 Spindle Motions Programming via the spindle number Some spindle functions can also be selected via the spindle number Slan S2 Spindle speed for spindle 1 or 2 e M1 3 M1 4 M1 5 Specifications for direction of rotation stop for spindle 1 e M2 3 M2 4 M2 5 Specifications for direction of rotation stop for spindle 2 e M1 40 M1 45 Gear stages for spindle 1 if installed e M2 40 M2 45 Gear stages for spindle 2 if installed e SPOS n Position spindle n e SPI n Converts spindle number n to axis identifier e g SP1 or CC n must be a valid spindle number 1 or 2 As regards their functions spindle identifier SPI n and Sn are identical e P_S n
199. ich the machining operation is to be performed is to be defined by selecting plane G17 and activating a programmable offset The drilling axis is always the axis of this coordinate system which stands vertically to the current plane A tool length compensation must be selected before the cycle is called lts effect is always perpendicular to the selected plane and remains active even after the end of the cycle In turning the drilling axis is thus the Z axis Drilling is performed to the end face of the work piece Tool length comp Fig 9 2 Dwell time programming The parameters for dwell times in the drilling cycles are always assigned to the F word and must therefore be assigned with values in seconds Any deviations from this procedure must be expressly stated SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 239 Cycles 9 4 Drilling cycles 9 4 3 Drilling centering CYCLE81 Note This standard cycle is not available with the 802D bl Programming Function CYCLE81 RTP RFP SDIS DP DPR Table 9 1 Parameter CYCLE81 a a SDIS Safety clearance enter without sign DP fea Final drilling depth absolute real Final oe depth relative to the reference plane enter wi thout sign The tool drills at the programmed spindle speed and feedrate to the entered final drilling depth Operational sequence Position reached prior to cycle start The drilling position
200. ier Axis Identifier of an axis X Z traversing on mea suring Axis Identifier of an axis X Z traversing on mea suring default setting 0 Initial state pushbutton key has not switched 1 Pushbutton key has switched N10 G90 X10 Z IC 20 Z incremental dimension X absolute dimension N10 IF R1 gt 5 GOTOF LABEL3 N80 LABEL3 see G96 N10 MEAS 1 G1 X Z F N10 MEAW 1 G1 X Z F N10 A_DBR 5 16 3 write real variables with offset position 5 position type and meaning are agreed between NC and PLC N10 A_MONIFACT 5 0 _ tool life elapsed 5 times faster N10 IF AA_FXS X1 1 GOTOF N10 R1 AA_MM X N10 R2 AA_MWI X N10 IF AC_MEASJ 1 1 GOTOF continue program if tracer has switched bulwwelbold 1 dO 0 LL dG0 00VVZ 869 S949 aul seq AZ08 dzZO8 MINAWNNIS ZY l 8 A _ _ TIME AC_ _ PARTS AC_ MSNUM P_ MSNUM P_NUM_ SPINDLES AA_SIn P_S n AC_ SDIRIn P_ SDIRIn P_ TOOLNO P_TOOL TC_MOP1 t d TC_MOP2 t d Timer for runtime AN_SETUP_TIME AN_POWERON_TIME AC_OPERATING_TIME AC_CYCLE_TIME AC_CUTTING_TIME Workpiece counter AC_TOTAL_PARTS AC_REQUIRED _PARTS AC_ACTUAL_PARTS AC_SPECIAL_PARTS Number of the active ma ster spindle Number of the program med master spindle Number of configured spindles Actual speed of spindle n Speed of spin
201. in the contour program not sufficient and 61606 Error in contour prepara tion have been output Relief cut elements can be connected directly one after the other Blocks without motions in the plane can be written without restrictions In the cycle all traversing blocks are prepared for the first two axes of the current plane since only these are involved in the cutting process The contour program may contain any motions programmed for other axes their distances to be traversed however will not come into effect during the whole cycle SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 299 Cycles 9 5 Turning cycles Only straight line and circle programming with GO G1 G2 and G3 are permitted as the geo metry in the contour Furthermore it is also possible to program the commands for rounding and chamfer If any other motion commands are programmed in the contour the cycle is ab orted with the alarm 10930 Illegal type of interpolation in the stock removal contour The first block with traversing motion in the current machining plane must contain a motion command GO G1 G2 or G3 otherwise the cycle is aborted with alarm 15800 Illegal initial conditions for CONTPRON This alarm will also appear with active G41 42 The starting con dition of the contour is the first position in the machining plane which is programmed in the contour subroutine To process the programmed contour a cycle internal me
202. ince the target is determined by the data flow RS232 Use this function to display the interface parameters currently selected Appropriate softkey func setting tions are provided to switch between binary transmission and the transmission of text files Additionally it is possible to set the parameters directly in the window SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 7 115 System S Communication setup Parameter Special functions Text format Device Confirm overwrite Baud rate Block end w CR LF Binary f t Stop bits Stop with EOF en Parity Punch tape format Data bits End of transmis Default Settings a z r Save pal Data RS232 selection asat Fig 7 26 Any changes in the settings come into effect immediately Pressing the Save softkey will save the selected settings even beyond switching off The Default Data softkey will reset all settings to their default settings Set Setting the password password Four password levels are distinguished in the control system which provide different access rights e System password e Manufacturer password e User password Depending on the access levels see also Technical Manual the data can be changed Enter the password If you do not know the password access will be denied linear axis linear axis linear axis Please enter password Access level Expert Fig 7 27 Entering the password Af
203. ine 6 92 6FC5 698 2AA00 OBP3 11 03 OP T Part Programming 6 3 Blueprint programming PROGRAH Program editor DEMO1 MPF 3 Not selected G2 G96 Z 263 653 X211 776 K 53 184 I 43 960 G3 2 351 074 X157 208 K 38 513 I 38 294 i eof ka Pau ica ey Ag More Edit Contour Drilling Milling Turning sous foals F lation compile Fig 6 32 Result of step 2 The function provides the point of intersection between circle sector 4 and circle sector 5 as the end point To calculate the tangential transition between and use the screenform Circle Straight line Program editor DEMO1 MPF Not selected Input form circle line G2 G90 POI tang C G2 G3 Z lt 458 00000 ABSI adition x 188 0080A z functions M NEZ 396 66666 ABS E A R S 0 x 46 50008 Value of 2nd axis of circle center plane Fig 6 33 Screenform Circle straight line PROGRAH Program editor DEMO1 MPF 4 Not selected G2 G96 Z 263 653 X211 776 K 53 184 I 43 960 G3 Z 351 074 X157 208 K 38 513 I 30 294 G2 G96 Z 417 636 X166 951 K 38 926 2 396 G1 Z 458 000 X188 860 amp eof More Edit RT Drilling Milling Turning sinu e lation compile Fig 6 34 Result of step 3 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 6 93 Part Programming 6 3 Blueprint programming sector is described by the center point and the radius Specify the
204. ines e cyclest spf e steigung spf and e meldung spf These must always be loaded in the control 9 2 Programming cycles A standard cycle is defined as a subroutine with name and parameter list Call and return conditions The G functions effective prior to the cycle call and the programmable offsets remain active beyond the cycle The machining plane G17 for drilling cycles or G18 for turning cycles must be defined before the cycle is called With drilling cycles the drilling operation is carried out in the axis standing vertically to the current plane Messages output during execution of a cycle During some cycles messages that refer to the state of machining are displayed on the screen of the control system during program execution These message do not interrupt the program execution and continue to be displayed on the screen until the next message appears The message texts and their meaning are listed together with the cycle to which they refer A summary of all relevant messages is to be found in Section 9 4 Block display during execution of a cycle The cycle call is displayed in the current block display for the duration of the cycle Cycle call and parameter list The defining parameters for the cycles can be transferred via the parameter list when the cy cle is called SINUMERIK 802D 802D base line 9 234 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 2 Programming cycles Note Cycle calls must alwa
205. ing process such as tapping or pocket milling These cycles are adapted to indivi dual tasks by parameter assignment The cycles described here are the same as supplied for the SINUMERIK 840D 810D Drilling cycles and turning cycles With the SINUMERIK 802D control system the following cycles are possible With SINUMERIK 840D the boring cycles CYCLE85 CYCLE89 are called boring 1 Drilling cycles CYCLE81 CYCLE82 CYCLE83 CYCLE84 CYCLE840 CYCLE85 CYCLE86 CYCLE87 CYCLE88 amp CYCLE89 HOLES1 HOLES2 Drilling centering not with 802D bl Center drilling Deep hole drilling Rigid tapping Tapping with compensation chuck Reaming Boring boring 2 not with 802D bl Boring with Stop 1 boring 3 not with 802D bl Drilling with stop Reaming 2 boring 5 Row of holes Circle of holes ring 5 but are nevertheless identical in their function SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Turning cycles CYCLE93 CYCLE94 CYCLE95 CYCLE96 CYCLE97 CYCLE98 Grooving Undercut forms E and F to DIN Stock removal Thread undercut Thread cutting Chaining of threads not with 802D bl bo 9 233 Cycles 9 2 Programming cycles The cycles are supplied with the tool box They are loaded via the RS232 interface into the part program memory during the start up of the control system Auxiliary cycle subroutines The cycle package includes the following auxiliary subrout
206. ing the parameter SPL If a final diameter lt 3 mm results for the value programmed for SPD the cycle aborts with alarm 61601 Finished part diameter too small Fig 9 41 FORM definition Form E and form F are fixed in DIN509 and must be defined using this parameter If the parameter has a value other than E or F the cycle aborts and creates alarm 61609 Form defined incorrectly SINUMERIK 802D 802D base line 9 288 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 5 Turning cycles X For workpieces with one machined surface For workpieces with two SL3 machined surfaces standing one on another at right angles Fig 9 42 The tool point direction is determined by the cycle automatically from the active tool compen sation The cycle can operate with the tool point directions 1 4 If the cycle detects either of the tool point directions 5 9 the alarm 61608 Wrong tool point direction programmed and the cycle is aborted The cycle determines its starting point automatically This is by 2 mm away from the end dia meter and by 10 mm away from the finishing dimension in the longitudinal axis The position of this starting point referred to the programmed coordinate values is determined by the tool point direction of the active tool The clearance angle of the active tool is monitored in the cycle if an appropriate value is spe cified in the appropriate parameter of t
207. is are shown below SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T System Z PLC diagnosis using the ladder diagram representation Program block Network 1 Initialization SMO 1 fen Progran stat OFF Net k 2 Emergency control sane Symbolic N i address Zoon a dr_ Tt i i 12 1 4T_52 6 M251 M251 4SpStop Zoon Network 3 Transfer 802D MCP signals to interface area V1000 E SMO 8 Find Network 2 Line 1 Column 1 Synbol info Al G Lae PLC PLC Status elem Window 2 Cross info status list OB1i SBRG refs Fig 7 29 Screen layout Control Display Meaning Range of application Supported PLC program language Name of the active program block Representation Symbolic name absolute name Program status RUN Program running STOP Program stopped 2 Status of the range of application Sym Symbolic representation abs Absolute representation ao Display of the active keys Focus performs the tasks of the cursor Notes line QO CO contains notes for searching 7 1 2 Operating options In addition to the softkeys and the navigation keys this area provides still further key combinations Key combinations The cursor keys move the focus over the PLC user program When reaching the window borders it is scrolled automatically SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 7 121 System
208. is the position in the two axes of the selected plane The cycle creates the following sequence of motions Approach of the reference plane brought forward by the safety clearance by using GO e Traversing to the final drilling depth at the feedrate programmed in the calling program G1 e Retraction to the retraction plane with GO Explanation of the parameters RFP and RTP reference plane and retraction plane Normally reference plane RFP and return plane RTP have different values In the cycle it is assumed that the retraction plane is ahead of the reference plane This means that the di stance from the retraction plane to the final drilling depth is larger than the distance from the reference plane to the final drilling depth SDIS safety clearance 9 240 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Cycles 9 4 Drilling cycles The safety clearance SDIS acts with reference to the reference plane This is brought for ward by the safety clearance The direction in which the safety clearance acts is determined by the cycle automatically DP and DPR final drilling depth The final drilling depth can be specified either absolute DP or relative DPR to the refe rence plane With relative specification the cycle will calculate the resulting depth automatically using the positions of reference and retraction planes gt G1 gt GO PIL IMIOO0U001 DP RFP DPR Fig
209. itoring The tool life is monitored for the tool cutting edge currently being in use active cutting edge D of the active tool T Once the path axes traverse G1 G2 G3 but not with GO the residual tool life TC_MOP2 t d of this tool cutting edge is updated If during the machining the residual tool life of a cutting edge of a tool falls below the value of Prewarning limit Tool life TC_MOP1 t d an appropriate interface signal is provided to the PLC If the residual tool life is lt 0 an alarm is issued and another interface signal is set Following the tool changes to the disabled status and can no longer be programmed anew until the disabled status is canceled Now the operator must intervene He must change the tool and make sure that an operative tool is available for machining again System variable A_MONIFACT Using the system variable A_MONIFACT data type REAL it is possible to run the clock for the monitoring feature slower or faster This factor can be set before using the tool e g to take into ac count the different wear according to the used workpiece material After booting of the control system Reset end of program the factor A_MONIFACT has the value 1 0 The real time is effective Examples for taking into account the system variable A_MONIFACT 1 1 minute in real time 1 minute of tool life which is decremented A _MONIFACT 0 1 1 minute of real time 0 1 minute of tool life w
210. ity In certain program sections it can be necessary to modify the axis or spindle acceleration set in the machine data This programmable acceleration is a percentage acceleration compensation It is possible to program a percentage value gt 0 and lt 200 for each axis e g X or spindle S In this case the axis interpolation is carried out using this proportional acceleration The reference value 100 is the valid machine data value for the acceleration depending on axis or spindle for the spindle also dependent on gear stage and positioning mode or speed mode Programming ACC Axis name percentage value for the axis ACC S percentage value for the spindle Programming example N10 ACC X 80 80 acceleration for the X axis N20 ACC S 50 50 acceleration for the spindle N100 ACC X 100 disabling the compensation for the X axis Activation The limitation is effective in all kinds of interpolation in AUTOMATIC and MDA modes The limitation is not effective in JOG mode and on reference point approach The value assignment ACC 100 will disable the correction this also applies to RESET and end of program The programmed compensation value is also effective with dry run feedrate Note A programmed value greater than 100 can only be carried out if the machine mechanics is designed for such a load and the drives have the appropriate reserves otherwise alarm messages are output SINUMERIK 802D 8
211. ius value tan gentially between two contour blocks Specification in degrees angle for a programmable rotation in the current plane G17 to G19 SET Various values from the specified element up to according to the number of values REP the same value from the specified element up to the end of the field n Number of the spindle if only SETMS is set the default master spindle comes into effect specified in degrees the thread starting point at G33 is offset by the specified value not important for tap ping N10 IF TC_MOP3 13 1 lt 15 GOTOF N10 IF TC_MOP4 13 1 lt 8 GOTOF N10 TC_MOP11 13 1 247 5 N10 TC_MOP13 13 1 715 N10 IF TC_TP8 1 1 GOTOF N10 TC_TP9 1 2 Select count monitoring MSG MESSAGE TEXT separate block N150 MSG delete previous message N10 OFFN 12 4 N10 X Z RND N11 X Z see ROT AROT DEF REAL VAR2 12 REP 4 5 all elements value 4 5 N10 R10 SET 1 1 2 3 4 4 R10 1 1 R11 2 3 R4 4 4 N10 SETMS 2 master separate block 2nd spindle see G33 DulwweIbold L dO 0 LL da0 00VVe 869 S039 aul seq AZ08 AZ08 MIYAWNNIS 6Vl 8 SPI n SPOS SPOS n STOPRE TRACYL d TRANSMIT TRAFOOF converts the spindle num ber n into the axis identi fier Spindle position Block search stop Milling of peripheral sur face not with 802D bl Milling of end face not with 802D bl Disabl
212. ixed stop The quill is pressed onto the workpiece Further programming examples N10 G1 G94 N20 X250 Z100 F100 FXS X1 1 FXS selected for machine axis X1 Clamping torque and window width as specified in the SDs N20 Y250 Z100 F100 FXS X1 1 FXST X1 12 3 FXS selected for machine axis X1 Clamping torque 12 3 window width as specified in the SDs N20 X250 Y100 F100 FXS X1 1 FXST X1 2 FXS selected for machine axis X1 FXS Clamping torque 12 3 window width 2 mm N20 X250 Z100 F100 FXS X1 1 FXSW X1 2 FXS selected for machine axis X1 clamping torque as specified in the SD window width 2 mm Fixed stop reached After the fixed stop has been reached e the distance to go is deleted and the position setpoint is corrected accordingly e the driving torque increases up to the programmed limit value FXST or to the value speci fied in the SD then remaining constant e the fixed stop monitoring within the given window width becomes active FXSW or value specified in the SD Deselecting the function Deselecting the function results in a preprocessing stop The block that contains FXS X1 0 must contain traversing motions Example N200 G1 G94 X200 Y400 F200 FXS X1 0 The X1 axis is retracted to the position X 200 mm SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 179 Programming 8 3 Axis Movements Important The traversing motion to the retraction position must lead aw
213. k constitutes a machining step Statements in a block are written in the form of words The last block in the order of execution of blocks contains a special word for the program end M2 Table 8 1 NC program structure Block Word Word Word ve Comment Block N10 GO X20 Tst block Block N20 G2 ZS ee 2nd block Block N30 Een fan Ae eer Block N40 Block N50 M2 end of program SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 131 Programming 8 1 Fundamentals of NC Programming 8 1 3 Word Structure and Address Functionality structure A word is a block element and mainly constitutes a control command A word consists of e address character generally a letter e andanumerical value The numerical value consists of a sequence of digits which with certain addresses can be added by a sign in front of the value and a decimal point A positive sign may be omitted Address Value Address Value Address Value Example X 20 1 Explanation Traverse Travel or limit po using linear sition for the X 300 mm min interpolation axis 20 1 mm Fig 8 1 Example of a word structure Several address characters A word may also contain several address letters In this case however the numerical value must be assigned using the intermediate character Example CR 5 23 In addition G functions can also be called using a symbolic name see
214. kspace Deletion key Insertion key Tabulator ENTER Input key Position operating area key Program operating area key Parameters operating area key Program Manager operating area key Alarm System operating area key Not assigned Paging keys Cursor keys Selection key toggle key ra KN i Z Alphanumeric keys Double assignment on the Shift level 0 9 Numerical keys Double assignment on the Shift level SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T External machine control panel User defined key with LED User defined key with LED E L Lh INCREMENT G JOG REFERENCE POINT EJ 1 100 o zio EZ s ey JJC Z yy VW Z nd 60 70 SPINDLE START 40 80 m E o A 0 CCW rotation 6 S A 2 S110 AUTOMATIC 80 70 A l e H SINGLE BLOCK MANUAL DATA 3 SPINDLE START i AMW J CW rotation SPINDLE STOP BEH RAPID TRAVERSE OVERRIDE Rapid traverse override Reset X axis NC STOP z Z axis NC START Feed override emergency stop Spindle override SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T notice 7 SINUMERIK 802D 802D base line XII 6FC5 698 2AA00 0BP3 11 03 OP T Introduction Note In the present Manual SINUMERIK 802D base line is further referred to as 802D bl 1 1 Screen Layout AUTOMATIC Status area RESET
215. l time at final drilling depth e Retraction to the reference plane brought forward by the safety clearance with G1 and the retraction feedrate defined under the parameter RFF e Retraction to the retraction plane with GO Explanation of the parameters For the parameters RTP RFP SDIS DP DPR see CYCLE81 cc o Q D Ta o go 558 T ge fam 4 amp LD A Q A OO000001 X lt SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 257 Cycles 9 4 Drilling cycles DTB dwell time The dwell time to the final drilling depth is programmed under DTB in seconds FFR feedrate The feedrate value programmed under FFR is active in drilling RFF retraction feedrate The feedrate value programmed under RFF is active when retracting from the hole to the re ference plane safety clearance Programming example First boring pass CYCLE85 is called at Z70 XO The tapping axis is the Z axis The value for the final drilling depth in the cycle call is programmed as a relative value no dwell time is programmed The workpiece upper edge is at Z0 N10 G90 GO S300 M3 N20 T3 G17 G54 Z70 X0 Approaching the drill position N30 CYCLE85 10 2 2 25 300 450 Cycle call no dwell time programmed N40 M2 End of program SINUMERIK 802D 802D base line 9 258 6FC5 698 2AA00 0BP3 11 03 OP T 9 4 9 Cycles 9 4 Drilling cycles Boring boring 2 CYCLE86 Note This standard cycle is not available with
216. le SPOS Functionality Prerequisite The spindle must be technically designed for position control mode The function SPOS can be used to position the spindle on a certain angle position The spindle is fixed in position by the position control The velocity of the positioning process is stored in machine data With SPOS value from the M3 M4 movement the respective direction of rotation is kept up to the end of positioning When positioning from standstill the position is approached on the shortest way In this case the direction results from the corresponding start and end positions Exception first movement of spindle i e if the measuring system is not yet synchronized In this case the direction is defined in machine data It is also possible to specify other movements as with rotary axes for the spindle using SPOS ACP SPOS ACN see Section 3rd and 4th Axes The movement of the spindle is parallel to any axis movements programmed in the same block The block is completed if both movements are completed Programming SPOS absolute position 0 lt 360 degrees SPOS ACP absolute data input position approach in the positive direction SPOS ACN absolute data input position approach in the positive direction SPOS IC incremental data input the sign defines the traversing direction SPOS DC absolute data input direct position approach using the shortest possible way
217. lease take into account This block interrupts G64 continuous path control mode and generates exact stop Programming example N1085 N20 X M3 M function in a block with axis movement Spindle accelerates prior to movement of X axis N180 M78 M67 M10 M12 M37 max 5 M functions per block Note Apart from M and H functions T D and S functions can also be transferred to the PLC A total of 10 of such function outputs are possible per block Information With SW 2 0 and higher 2 spindles are possible This provides an extended programming possibility for M commands only for the spindle M1 3 M1 4 M1 5 M1 40 M3 M4 M5 M40 for spindle 1 M2 3 M2 4 M2 5 M2 40 M3 M4 M5 M40 for spindle 2 SINUMERIK 802D 802D base line 8 204 6FC5 698 2AA00 0BP3 11 03 OP T Programming 8 8 H function 8 8 H function Functionality The H functions can be used to transfer floating point data from the program to the PLC of the type such as arithmetic parameters see Section Arithmetic Parameters R The meanings of the values for a certain H function are defined by the machine manufacturer Programming HO to H9999 max 3 H functions per block Programming example N10 H1 1 987 H2 978 123 H3 4 max 3 H functions per block N20 GO X71 3 H99 8978 234 with axis movements in the block N30 H5 analogously to HO 5 0 Note Apart from M and H functions T D and S functions can also be transferred
218. levant window If the axis is positioned no sign is displayed Position These fields display the current position of the axes in MCS or WCS mm Distance to These fields display the distance to go for the axes in MCS or WCS go G function Display of important G functions Spindle S Display of spindle speed set and actual values rpm Feed F Display of feedrate actual and set values mm min or mm rev Tool Display of the currently engaged tool and of the current edge T D Current block The block display shows seven blocks of the active part program which follow one after another without spaces The display of each individual block is limited to the width of the window If blocks are quickly executed one after the other the display switches to the display of three blocks so that you can follow the program execution as best as possible Use the softkey Program sequence to return to 7 segment display SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Softkeys Progr control Program test Dry run feed rate Condit STOP Skip SBL fine ROV active Back lt lt Block Search To contour To endpoint Automatic Mode Note If a second spindle is integrated into the system the workspindle is displayed using a lower font size The window will alwa
219. lication Manual Postfach 3180 D 91050 Erlangen Tel 49 0 180 5050 222 hotline Fax 49 0 9131 2176 Documentation email motioncontrol docu erlf siemens de User Documentation SINUMERIK 802D Operation and Programming Turning From Order No 6FC5698 2AA00 OBP3 Name Edition 11 03 Pompany gent Should you come across any printing Street errors when reading this publication ERR 1 please notify us on this sheet Zip code Suggestions for improvement are also welcome Telephone Telefax Suggestions and or corrections Document Structure SINUMERIK 802D General Documentation Catalog SINUMERIK 802D Turning Milling User Manual Operation and Proaramming SINUMERIK 802D SINUMERIK 802D Turning Milling User Manual Diagnostics Guide SINUMERIK 802D Turning Milling Technical Manual Start up SINUMERIK 802D Documentation Turning SIM bee a VE Milling Technical Manual Descriptions of Functions SINUMERIK 802D Turning Milling Siemens AG Automatisierungs und Antriebstechnik Motion Control Systems Postfach 3180 D 91050 Erlangen Bundesrepublik Deutschland www ad siemens de Siemens AG 2003 Anderungen vorbehalten Bestell Nr 6FC5597 3AA10 OBP3 Gedruckt in der Bundesrepublik Deutschland
220. lt 45 degrees the thread of the longitudinal axis is machined otherwise the transversal thread Angle lt 45 Angle gt 45 Longitudinal thread Transversal thread Fig 9 67 Programming example Thread cutting Using this program you can produce a metric external thread M42x2 with flank infeed Infeed is carried out with constant cutting cross section 5 roughing cuts are carried out at a thread depth of 1 23 mm without finishing allowance At completion of this operation 2 idle passes will be carried out SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 313 Cycles 9 5 Turning cycles M42x2 Z Fig 9 68 N10 GO G90 Z100 X60 Selection of the starting position N20 G95 D1 T1 S1000 M4 Specification of the technological values N30 CYCLE97 42 0 35 42 42 10 3 1 23 0 30 Cycle call 0 5 2 3 1 N40 G90 GO X100 Z100 Approach next position N50 M2 End of program 9 5 7 Chaining of threads CYCLE98 Note This standard cycle is not available with the 802D bl Programming CYCLE98 PO1 DM1 PO2 DM2 PO3 DM3 PO4 DM4 APP ROP TDEP FAL IANG NSP NRC NID PP1 PP2 PP3 VARI NUMT Parameter Table 9 20 Parameter CYCLE98 First intermediate point in the longitudinal axis Diameter at the first intermediate point SINUMERIK 802D 802D base line 9 314 6FC5 698 2AA00 O0BP3 11 03 OP T Cycles 9 5 Turning cycles Table 9 20 Parameter CYC
221. luding the main program level are provided in total 1st level 2nd level 3rd level me 8th level Main program Subroutine Subroutine Subroutine Fig 8 54 Sequence with 8 program levels SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 215 Programming 8 11 Subroutine Technique Information In a subroutine modally effective G functions can be changed e g G90 gt G91 When retur ning to the calling program make sure that all modally effective functions are set such as you need them The same applies to the arithmetic parameters R Make sure that the values of the arithmetic parameters used for the upper program levels are not inadvertently changed in lower program levels SIEMENS cycles will require up to 4 program levels 8 11 2 Calling Machining Cycles Functionality Cycles are technology subroutines that realize a certain technology such as drilling or thread cutting in a generally applicable form The adaptation to the particular problem is carried out using the defining parameters values directly at the moment when the related cycle is called Programming example N10 CYCLE83 110 90 call cycle 83 transfer values directly separate block N40 RTP 100 RFP 95 5 set transfer parameters for cycle 82 N50 CYCLE82 RTP RFP call cycle 82 separate block SINUMERIK 802D 802D base line 8 216 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 12 Timer and Workpiece Coun
222. m is divided into clearly structured pro gram parts and current paths called networks Generally programs written in LADs represent the electrical current flow using various logical operations Network 1 Initialization SCAN_1 few N k 2 Emergency control etwor Absolute MG_STP address 20 p I Zoom S l A 5 T_52 ASe Zoom Network 3 Transfer 8802D MCP signals to interface area V1000 z ONE Find a 2 Column 3 Symbol SSS al PLC Status Fete Window Tal Cross info status list 0B1 SBR33 refs Fig 7 33 Window 1 In this menu you can switch between symbolic and absolute representation of the operand Furt hermore it is possible here to view a desired program section in different resolutions and to search for a certain operand This softkey can be used to display the list of the PLC program blocks Use the Cursor Up Cursor Down or Page Up Page Down keys to select the PLC program block you want to open The current program block is displayed in the Info line of the list box SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T System 7 1 PLC diagnosis using the ladder diagram representation Network 2 6 UW4 V45001 i E Back PLC Status MET Gnas u Window Z Cross status list SBR32 SBR33 refs Fig 7 34 PLC block selection te Pressing this softkey displays the description of the selected program block which was stored when the PLC project was created Properties Na
223. m variables with read and write access either from the program or by operation pay attention to the protection level for writing It is possible to control the counter activation the time of resetting to zero and the counting algorithm via machine data e Number of parts required required parts AC_REQUIRED_PARTS This counter can be used to define the number of workpieces at which when reached the number of current workpieces A4C_ACTUAL_PARTS is set to zero The generation of the display alarm 21800 Number of required parts reached can be acti vated via machine data e Number of parts produced in total total parts AC_TOTAL_PARTS The counter specifies the number of all parts produced from the moment of starting The timer is automatically reset to zero when the control system boots e Number of current parts actual parts AC_ACTUAL_PARTS This counter counts the number of all parts produced from the moment of starting The counter is automatically reset to zero when the number of required parts is reached AC_REQUIRED_PARTS value greater than zero e Number of parts specified by the user AC_SPECIAL_PARTS This counter permits the user to carry out part counting using his own definition It is possi ble to define an alarm output if the AC_REQUIRED_PARTS required number of parts is reached It is the user s job to reset the counter to zero SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T
224. me Author Date of creation 61 61 1906 13 66 68 Last changed 61 61 2668 14 66 06 Comment 61 83 Back Al i PLC PLC Status MET Ggs Window Z Cross info status list 0B1 SBR33 refs Fig 7 35 Properties of the selected PLC program block ee Pressing this softkey displays the table of local variables of the selected program block There are two types of program blocks e OB1 only temporary local variable e SBRxx _ in in out out and temporary local variable A table of variables exists for each program block SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 7 125 System 7 1 Program stat ON Program stat OFF 7 126 PLC diagnosis using the ladder diagram representation Local variables buffered handwheel 1 information Nane Yar type Data type Comment HWi TEMP BYE uffered handwheel 1 inforn Al Back PLC PLC Status MET Gnas u Window Z Cros info status list SBR37 SBR33 refs Fig 7 36 Table of local variables for the selected program block s Texts which are longer than the column width are cut in all tables and the character is attached For such a case a higher level text field exists in such tables in which the text of the current cursor position is displayed If the text is cut with a it is displayed in the same color as that of the cursor in the higher level text field With longer texts it is possible to display the whole text
225. med is output and the cycle is aborted SDAC direction of rotation Because the cycle can also be called modally see Section 9 3 it requires a direction of rota tion for tapping further threaded holes This is programmed in parameter SDAC and corres ponds to the direction of rotation programmed before the first call in the higher level program If SDR 0 the value assigned to SDAC has no meaning in the cycle and can be omitted in the parameterization ENC tapping 9 254 If tapping is to be performed without encoder although an encoder exists parameter ENC must be assigned value 1 If however no encoder is installed and the parameter is assigned the value O it is ignored in the cycle SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Cycles 9 4 Drilling cycles MPIT and PIT as a thread size and as a value The parameter for the spindle pitch is only relevant if tapping is performed with encoder The cycle calculates the feedrate from the spindle speed and the pitch The value for the thread pitch can be defined either as the thread size for metric threads bet ween M3 and M48 only or as a value distance from one thread turn to the next as a numeri cal value The parameter not required in each case is omitted in the call or is assigned the value zero If the two thread pitch parameters have conflicting values alarm 61001 Thread pitch wrong is generated by the cycle and cycle execution is
226. ments this sequence is repeated for each relief cut p Roughing without relief cut Roughing of the first relief cut Roughing of the second relief cut Fig 9 47 SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 293 Cycles 9 5 Turning cycles Finishing The cycle starting point is approached axis by axis with GO The contour starting point is approached with GO in both axes at the same time Finishing along the contour with G1 G2 G3 and FF3 Retraction to the starting point with both axes and GO Explanation of the parameters NPP name 9 294 This parameter is used to specify the name of the contour 1 The contour can be defined as a subroutine NPP name of subroutine The name of the contour subroutine is subject to all name conventions described in the Programming Guide Input The subroutine already exists gt enter name continue The subroutine does not yet exist gt enter name and press softkey new file A pro gram main program with the entered name is created and the program will jump to the contour editor To quit your input press the softkey Technol mask the program returns to the cycle support screenform The contour can also be a section of the calling program NPP name of starting label name of end label Input Contour is already described gt name of starting label Enter name of end label Contour is not yet described gt enter
227. message is executed or until the end of the program is reached Max 65 Zeichen characters of a message text can be displayed A message without message text will delete a previous message MSG THIS IS THE MESSAGE TEXT Programming example 8 1 5 N10 Company G amp S Order No 12A71 N20 Pump part 17 Dwg No 123 677 N30 Program created by H Adam Dept TV 4 N40 MSG BLANK ROUGHING 50 G54 F4 7 S220 D2 M3 Main block N60 GO G90 X100 Z200 N70 G1 2185 6 N80 X112 N90 X118 Z180 Block can be skipped N100 X118 Z120 N110 GO G90 X200 N120 M2 End of program Character Set The following characters are used for programming they are interpreted in accordance with the relevant definitions Letters digits A B C D E F G H l J K L M N O P Q R S T U V W X Y Z 0 1 2 3 4 5 6 7 8 9 No distinction is made between lowercase and uppercase letters Printable special characters 8 134 left round bracket i inverted commas right round bracket es underscore belonging to a letter eft bracket decimal point eright bracket comma separator lt less than l begin of a comment gt greater than reserved do not use main block completion of label amp reserved do not use SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 1 Fundamentals of NC Programming assignment part of equality reserved do not use division block skip system spe
228. mory is prepared which can accommodate a maximum number of contour elements Much is dependent on the contour If a contour contains to many contour elements the cycle is aborted with alarm 10934 Contour table overflow In this case the contour must be divided into several contour sections and the cycle has to be called for each section separately If the maximum diameter is not at the programmed end or starting point of the contour at the end of machining the cycle will automatically add a paraxial straight line up to the maximum of the contour and this part of the contour will be removed as the relief cut i Added straight line End point Starting point Fig 9 53 The programming of the tool radius compensation with G41 G42 in the contour subroutine will result in abortion of the cycle with output of alarm 10931 Invalid stock removal contour Contour direction The direction in which the stock removal contour is programmed can be freely selected In the cycle the machining direction is defined automatically In complete machining the con tour is finished in the same direction as machining was carried out when roughing When deciding on the machining direction the first and the last programmed contour points are taken into account Therefore both coordinates must always be programmed in the first block of the contour subroutine SINUMERIK 802D 802D base line 9 300 6FC5 698 2AA00 0BP3 11 0
229. n Change of tool offset number D The offset number D can be changed in compensation mode In this case a changed tool ra dius starts to come into effect already in the beginning of the block that contains the new D number Its full change is only achieved at the end of the block This means that the change is traversed continuously over the entire block this also applies to circular interpolation Cancellation of compensation by M2 If compensation mode is canceled by M2 end of program without programming the com mand G40 the last block will end with the coordinates in normal position of the compensation vector No compensatory movement is carried out The program will end at this tool position Critical machining cases When programming pay special attention to cases where the contour path of internal corners is less than the tool radius or in case of two internal corners following each other where the contour path is less than the diameter Such cases should be avoided Also check over several blocks that no bottle necks are contained in the contour To carry out a test dry run use the largest tool radius offered to choose from Acute contour angles If very acute rearward elbows occur in the contour with intersection point G451 active the control system will automatically switch to transition circle This will avoid long lost idle mo tions SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 199
230. n this alarm always occurs in conjunction with an NCK alarm 10930 10934 15800 or 15810 Starting point program CYCLE95 The starting point reached prior to the cycle call is not med incorrectly outside the rectangle described by the contour subrou 61604 61607 tine 61608 Invalid tool point direction CYCLE94 A tool point direction 1 4 matching to the relief cut programmed form must be programmed 61609 Form defined incorrectly CYCLE94 Check the parameters for the relief cut form 61611 No intersection point CYCLE95 No intersection point with the contour could be calcula found ted Check the contour programming or change the infeed depth SINUMERIK 802D 802D base line 9 322 6FC5 698 2AA00 0BP3 11 03 OP T 9 6 4 Cycles 9 6 Error Messages and Error Handling Messages in the cycles The cycles display their messages in the message line of the control system These message will not interrupt the program execution Messages provide information with regard to a certain behavior of the cycles and with regard to the progress of machining and are usually kept beyond a machining step or until the end of the cycle The following messages are possible Table 9 23 Depth according to the value for the relative depth CYCLE82 CYCLE88 CYCLE840 4st drilling depth according to the value for the rela CYCLE83 tive depth Thread turn lt no gt machining as a longitudi
231. n as with M4 Note A complete tapping cycle with thread interpolation is provided with the standard cycle CYCLE84 Velocity of the axes 8 168 With G331 G332 the velocity of the axis for the thread length results from the spindle speed and the thread lead The feedrate F is not relevant but it remains stored The maximum axis velocity rapid traverse rate however which is defined in the machine data cannot be excee ded In this case an alarm is issued SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 3 Axis Movements Programming example 8 3 9 Metric thread 5 lead as per table 0 8 mm rev drill hole already prepared N5 G54 GO G90 X10 Z5 approach starting point N10 SPOS 0 Spindle in position control N20 G331 Z 25 K0 8 S600 tapping K positive CW rotation of spindle end point 25 mm N40 G332 Z5 K0 8 retraction N50 GO X Z Fixed Point Approach G75 Functionality G75 can be used to approach a fixed point on the machine e g the tool change point The position is fixed in the machine data for all axes No offset is effective The velocity of each axis is its rapid traverse G74 requires a separate block and is effective block by block The machine axis identifier must be programmed In the block following G74 the previous G command of the interpolation type group GO G1 G2 is active again Programming example 8 3 10 N10 G75 X1 0 Z1 0
232. n at rapid traverse 1 Motion commands GO X Z G1 Linear interpolation at feedrate interpolation type G1 X Z F G2 Circular interpolation in CW direction G2 X Z K F center and end points G2 X Z CR F jradius and end point G2 AR K F japerture angle and center point G2 AR X Z F japerture angle and end point G3 Circular interpolation in CCW direction G3 otherwise as with G2 CIP Circular interpolation via intermediate point CIP X Z 11 K1 F 511 K1 is intermediate point CT Circular interpolation tangential transition N10 N20 CT Z X F jcircle tangential transition to previous path piece N10 G33 Thread cutting with constant lead modal G33 Z K SF cylindrical thread G33 X I SF transversal thread G33 Z X K SF jtaper thread in Z axis travel greater than in X axis G33 Z X 1 SF taper angle in X axis travel greater than in Z axis buluwelsbold L dO 0 LL da0 00VVe 869 S049 aul seq AZ08 AZ08 MIYAWNNIS LEL 8 G34 Thread cutting increasing lead G33 Z K SF cylinder thread constant lead G34 Z K F17 123 increasing lead with 517 123 mm ey 2 G35 Thread cutting decreasing lead G33 ZeKa SF cylinder thread G35 Z K F7 321 decreasing lead with 7 321 MM ey 2
233. n of rota tion of spindle M3 N60 M2 End of program 9 4 11 Drilling with stop CYCLE88 Programming CYCLE88 RTP RFP SDIS DP DPR DTB SDIR Parameters Table 9 9 Parameters of CYCLE88 a tt tela daniel aseeina SDIS Safety clearance enter without sign DP real Final drilling depth absolute real Final drilling depth relative to the reference plane enter wi thout sign DTB real Dwell time at final drilling depth chip breaking SDIR int Direction of rotation Values 3 for M3 4 for M4 Function The tool drills at the programmed spindle speed and feedrate to the entered final drilling depth During boring pass 4 a dwell time a spindle stop without orientation M5 and a pro grammed stop MO are generated when the final drilling depth is reached Pressing the NC START key continues the retraction movement at rapid traverse until the retraction plane is reached Operational sequence Position reached prior to cycle start The drilling position is the position in the two axes of the selected plane SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 265 Cycles 9 4 Drilling cycles The cycle creates the following sequence of motions e Approach of the reference plane brought forward by the safety clearance by using GO e Traversing to final drilling depth with G1 and the feedrate programmed prior to the cycle Call e Dwell time at final drilling depth e Spindle and program stop wi
234. nal CYCLE97 thread Thread turn lt no gt machining as a transversal CYCLE97 thread no gt in the message text always stands for the number of the figure currently machined SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 323 Cycles 9 6 Error Messages and Error Handling notice SINUMERIK 802D 802D base line 9 324 6FC5 698 2AA00 O0BP3 11 03 OP T Index A absolute drilling depth 9 241 Address 8 132 B Block search 5 66 _ Block structure 8 133 Boring 9 238 boring 1 9 256 Boring 2 9 259 Call conditions 9 234 9 238 Center drilling Centering 9 240 Chaining of threads CYCLE98 9 314 Character set Circle of holes Configuring input screenforms 9 237 Contour definition Contour monitoring 9 277 9 301 Cycle call 9 234 Cycle support in the program editor 9 236 Data transfer 6 97 Deep hole drilling 9 245 SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Deep hole drilling with chip breaking 9 246 Deep hole drilling with swarf removal 9 246 Determining tool offsets 3 33 _ Drilling 9 240 Drilling cycles 9 233 9 238 Drilling with stop 9 265 E Entering tools and tool offsets 3 30 F Fundamentals of NC Programming 8 131 G Geometrical parameters 9 238 Grooving CYCLE93 9 279 H Handwheel 4 53 HOLES1j 9 269 HOLES2 Interface parameters 7 118 J JOG 4
235. nation You can insert the elements chamfer or rounding into any contour corner The corresponding statement CHR or RND is programmed in the block containing the axis movements leading to the corner Programming of the contour definition can be used in blocks with GO or G1 Theoretically you can link as many straight line blocks as you want and insert a rounding or a chamfer between them When doing so each straight line must be unambiguously defined by point and or angle specifications Programming ANG angle specification for defining a straight line CHRe insert chamfer value side length of chamfer RND insert rounding value radius of rounding SINUMERIK 802D 802D base line 8 188 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 5 Special Turning Functions Angle ANG If for a straight line only one end position coordinate of the plane is known or in case of con tours over several blocks the entire end point an angle specification can be used to define the straight path section unambiguously The angle is always referred to the Z axis normal case G18 active Positive angles are oriented in the counter clockwise direction End point in N20 not fully known N10 G1 X1 Z1 N20 X2 ANG N10 G1 X1 Z1 N20 Z2 ANG The values are only symbolically Fig 8 30 Angle specification to define a straight line Rounding RND Another circle contour element is inserted in the corner between two lin
236. nce plane absolute SDIS Safety clearance enter without sign DP freal Final drilling depth absolute real Final drilling depth relative to the reference plane enter wi thout sign DTB Dwell time at final drilling depth chip breaking Function The tool drills at the programmed spindle speed and feedrate to the entered final drilling depth If the final drilling depth is reached a dwell time may be programmed Operational sequence Position reached prior to cycle start The drilling position is the position in the two axes of the selected plane SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 267 Cycles 9 4 Drilling cycles The cycle creates the following sequence of motions e Approach of the reference plane brought forward by the safety clearance by using GO e Traversing to final drilling depth with G1 and the feedrate programmed prior to the cycle Call e Dwell time to final drilling depth e Retraction up to the reference plane brought forward by the safety clearance using G1 and the same feedrate value e Retraction to the retraction plane with GO Explanation of the parameters Parameter RTP RFP SDIS DP DPR see CYCLE81 0 gt GO gt G1 gt G4 RTP REP SDIS RFP ponon Fig 9 18 DTB dwell time The dwell time to the final drilling depth chip breaking is programmed under DTB in se conds Programming example Fifth boring At X80 Y90 in the XY plane the
237. ne 6FC5 698 2AA00 0BP3 11 03 OP T Introduction 1 3 Accessibility Options This function is used to select the given coordinate of the end point The ordinate value or the abscissa value is given The second straight line is rotated in CW direction or in counterclockwise direction by 90 degrees relative to the first straight line Se IE S The missing end point is calculated The value of the abscissa is copied into the input box from which the calculator function has been called and the value of the ordinate is copied into the next following input box If the function has been called from the part program editor the coordinates are saved with the axis names of the selected basic plane Example Fig 1 9 Add the drawing above by the value of the center circle in order to be able to calculate then the intersection point between the circle sector of the straight line The missing coordinate of the center point is calculated using the calculator function since the radius in the tangential transition stands vertically on the straight line Fig 1 10 Calculating M1 in section 1 The radius stands at an angle of 90 turned CW on the straight line defined by the angle Use the softkey to select the appropriate direction of rotation Use the softkey to define the given end point SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 1 21 Introduction 1 3 1 3 2 1 3 3 1 22 Accessi
238. ned vertically to the infeed direction in one or several steps whereby each step in turn is divided according to the infeed depth From the second cut along the groove width onwards the tool will retract by 1 mm each before retraction ee eee aN a Ped a iii ii iii r l Fig 9 32 SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 280 Cycles 9 5 Turning cycles 3rd step Stock removal of the flanks in one step if angles are programmed under ANG1 or ANG2 in feed along the groove width is carried out in several steps if the flank width is larger Fig 9 33 4th step Stock removal of the finishing allowance parallel to the contour from the edge to the groove center During this operation the tool radius compensation is selected and deselected by the cycle automatically Fig 9 34 SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 281 Cycles 9 5 Turning cycles Explanation of the parameters SPD and SPL starting point These coordinates can be used to define the starting point of a groove starting from which the form is calculated in the cycle The cycle starting point approached at the beginning is deter mined by the cycle itself In the case of an external groove first the tool will traverse in the direction of the longitudinal axis and in the case of an internal groove first in the direction of the transverse a
239. nel is inactive In the lower half of the screen the parameters measuring time and trigger type can be set for channel 1 The remaining channels will accept this setting e Determining the measuring time The measuring time is entered in ms directly in the input box Measuring time SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Marker V OFF Marker T OFF FIX V Mark FIX T Mark Show trace Time scale Time scale Vertical scale vertical scale Marker steps System e Selecting the trigger condition Position the cursor on the field Trigger condition and select the appropriate condition using the toggle key No trigger i e the measurement starts immediately after pressing the Start softkey Positive edge Negative edge Exact stop fine reached Exact stop coarse reached You can hide unhide the auxiliary lines using the softkeys Marker on Marker off The markers can be used to determine the difference in the horizontal and vertical direction To do So position the marker on the start point and press the softkey Fix H Mark or Fix T Mark The difference between the start point and the current marker position is now displayed in the status bar The softkey designation will change to Free H Mark or Free T Mark P
240. ng in the cycles Alarms with numbers between 61000 and 62999 generated in the cycles This range of num bers in turn is divided again with regard to alarm responses and cancel criteria The error text that is displayed together with the alarm number gives you more detailed infor mation on the error cause Table 9 21 AlarmNumber Number Clear Criterion Alarm Alarm Response _ 61999 NC_RESET Block preparation in the ee is aborted 62000 62999 Clear key The block preparation is inter rupted the cycle can be conti nued with NC START after the alarm has been cleared 9 6 3 Overview of cycle alarms The error numbers are classified as follows ele ie e X 0 General cycle alarms e X 1 Alarms generated by the drilling drilling pattern and milling cycles e X 6 Alarms generated by the drilling cycles The Table below includes a list of all errors occurring in the cycles with their location of occur rence and appropriate instructions for fault correction SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T 9 321 Cycles 9 6 Error Messages and Error Handling Table 9 22 Alarm Alarm Text Explanation Remedy Number 61000 No tool compensation ac CYCLE93 D offset must be programmed prior to cycle call tive to CYCLE95 61001 Illegal thread pitch CYCLE84 Check parameters for thread size or pitch specification CYCLE840 are contradicting CYCLE97 61002 Machining type defined C
241. ng is displayed in the window SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 4 53 Manually Controlled Operation 4 2 Operating Mode MDA Manual Input 4 2 Operating Mode MDA Manual Input Functionality In MDA mode you can create and run a part program Caution In manual mode the same safety locks are applicable as in fully automatic mode Furthermore the same prerequisites are required as in fully automatic mode Operating sequence 5 Use the MDA key on the machine control panel to select MDA mode SKP DRY ROY MO1 PRT SBL function DEHMO1 MPF Position Dist to go ALE Auxiliary G ABB E D 1 function 8 008 mm 8 aaa 8 6 088 nines 6 666 mm min 6 6 8 Delete MDA Block MDA prog ion Prog se 5j Toe ca ae naa Face Es Fig 4 6 The MDA main screen Enter one or several blocks using the keyboard lt p Press NC START to start machining During the machining the blocks cannot be edited After execution the contents of the input field remain stored so that NC Start can be activated again to continue SINUMERIK 802D 802D base line 4 54 6FC5 698 2AA00 OBP3 11 03 OP T Parameters Manually Controlled Operation 4 2 Operating Mode MDA Manual Input Table 4 2 Description of the parameters displayed in the MDA working window Parameters Explanation MCS Display of existing axes in MCS or WCS X Z X
242. nt Contour section circle straight line circle with tangential transitions Contour section circle circle circle with tangential transitions Contour section straight line circle straight line circle with tangential transitions More Fig 6 6 The coordinates can be input either as an absolute incremental or polar value Input is swit ched using the Toggle key SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 6 77 Part Programming 6 3 Blueprint programming Softkeys 6 78 Use these softkey functions to branch into the individual contour elements When opening a contour screenform for the first time or after a cursor motion the control sy stem must be advised of the starting point of the relevant contour section All subsequent mo tions will refer to this point PROGRAH Program editor TEST1 MPF 36 Not selected G2 X96 66066 Y56 66006 I35 74616 J 17 96232 amp 1 G9 X54 25998 Y107 96232 r zy al TRACYL Enter confirm start point absolute Approach z 6 BABA start pt x 6 66068 JO Z Abort Starting point axis 1 E A E A A Ep amp amp amp ip ml E E E E E E E E Fig 6 7 Setting the starting point Use this interactive screenform to define whether the following contour sections are to be pro grammed using radius or diameter programming or whether the transformation axes are to be used for TRANSMIT or for TRACYL Note The
243. o achieve higher velocities than without LookA head i continuous path control mode with LookAhead G60 exact stop N2 N3 N4 N5 N6 N7 N8 N9 N10 N11 N12 Block travel Fig 8 24 Comparison of velocity behavior using G60 and G64 resp with short block travels 8 3 14 Acceleration Behavior BRISK SOFT BRISK The axes of the machine are traversed as a path at maximum acceleration until they have achieved the required feedrate BRISK provides time optimized working The set speed is achieved within a short time However jerks in the acceleration characteristic are to be noti ced SOFT The machine axes are traversed along a non linear steady characteristic until they have re ached the required final velocity This jerk free acceleration allows SOFT to provide for a lo wer burden on the machine the same behavior will also apply to braking processes Velocity path BRISK SOFT time optimized saving to the mechanical system Set value Fig 8 25 Diagram of tool path feedrate characteristic with BRISK SOFT SINUMERIK 802D 802D base line 8 174 6FC5 698 2AA00 0BP3 11 03 OP T Programming 8 3 Axis Movements Programming BRISK abrupt path acceleration SOFT jerk limited path acceleration Programming example N10 SOFT G1 X30 284 F6 5 jerk limited path acceleration N90 BRISK X87 Z104 further with abrupt path acceleration 8 3 15 Percentage Acceleration Compensation ACC Functional
244. oduced with Interleaf V 7 The reproduction transmission or use of this document or its contents is not permitted without express written authority Offenders will be liable for demages All rights including rights created by patent grant or registration of utility model or design are reserved Siemens AG 2003 All rights reserved Bestell Nr 6FC5 698 2AA00 OBP3 Printed in the Federal Republic of Germany 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 We have checked that the contents of this document correspond to the hardware and software described Nonetheless differences might exist and therefore we cannot guarantee that they are completely identical The information contained in this document is however reviewed regularly and any necessary changes will be included in the next edition We welcome suggestions for improvement Subject to change without prior notice Siemens Aktiengesellschaft Safety notices ZN aX This Manual contains notices intended to ensure your personal safety and to avoid material damage The notices are highlighted by a warning triangle and depending on the degree of hazard represented as shown below Danger indicates that loss of life severe personal injury or substantial material damage will result if the appropriate pre cautions are n
245. of cycles Programs with cycle calls can be tested first in simulation During simulation the traversing movements of the cycle are visualized on the screen SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 235 Cycles 9 3 Graphical cycle support in the program editor 9 3 Graphical cycle support in the program editor The program editor in the control system provides you with programming support to add cycle calls to the program and to enter parameters Function The cycle support consists of three components 1 2 Cycle selection Input screenforms for parameter assignment 3 Help display per cycle Overview of required files The following files constitute the basis for cycle support sc comMm cov com Note These files are loaded during the start up of the control system and must always remain loa ded Operating the cycle selection To add a cycle call to the program carry out the following steps one after the other 9 236 In the horizontal softkey bar you can branch to the individual cycles using the appropriate softkeys Drilling or Turning The cycle selection is carried out using the vertical softkey bar until the appropriate input screenform with the help display appears on the screen Then enter the values for the parameters The values can be entered either directly numerical values or indirectly R parameters e g R27 or expressions consisting of R parame
246. of straight line 1 The angle is specified in the counterclockwise direction Angle of straight line 2 The angle is specified in the counterclockwise direction SINUMERIK 802D 802D base line 6 94 6FC5 698 2AA00 OBP3 11 03 OP T Part Programming 6 3 Blueprint programming End and center points can be specified either absolute incremental or polar coordinates The screenform generates one circle and two straight line blocks from the data you have entered Use this softkey to switch the direction of rotation from G2 to G3 G3 will appear on the display G2 G3 Pressing this softkey again will switch back the display to G2 The display changes to G2 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 6 95 Part Programming 6 4 Simulation 6 4 Simulation Note With the 802D bl this function is only available with the color dislay option Functionality The programmed tool path can be traced using a broken line graphics Operating sequence You are in the Automatic mode and have selected a program you want to run cf Section 5 1 Simulation The main screen appears Program simulation To origin Show Zoon oon aa Cursor co arsefiine Fig 6 36 The Simulation main screen KO Press NC Start to start the simulation of the selected part program Softkeys Zoom Use this softkey if you wish the recorded tool path to be scaled automatic
247. of the flank angle of the tool WAY Infeed along a Infeed with flank alternating flanks Fig 9 64 The execution of the infeed is defined by the sign of this parameter With a positive value infeed is always carried out at the same flank and with a negative value at both flanks alter nating The infeed type with alternating flanks is only possible for cylindrical threads If the value of IANG for tapered threads is nonetheless negative the cycle will carry out a flank in feed along a flank NSP starting point offset and NUMT number Using this parameter you can program the angle value defining the point of the first cut of the thread turn at the circumference of the turned part This is a starting point offset The parame ter can assume values between 0 and 359 9999 degrees If no starting point offset is speci fied or the parameter is omitted from the parameter list the first thread turn automatically starts at the zero degree mark SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 311 Cycles 9 5 Turning cycles O degree mark Start Start 1 Thread turn 4 Thread turn Start 2 Thread turn Start 3 Thread turn NUMT 4 Fig 9 65 Use the parameter NUMT to define the number of thread turns with a multiple turn thread For a single turn thread the parameter must be assigned zero or can be dropped completely in the parameter list The thread tu
248. oftkey to select the next higher cutting edge number Use this softkey to select the next lower cutting edge number Use this softkey to create a new edge Use this softkey to reset all offset values of the cutting edge to zero Use this function to change the tool type Use the relevant softkey to select the appropriate tool type Type the number of the tool you are looking for and start the search using the OK softkey If the tool you are looking for exists the cursor is positioned on the relevant line Use this softkey to create tool offset data for a new tool A maximum of 48 tools can be created with the 802D and 18 tools with the 802D bl Milling tools are not offered for the 802D bl SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 3 31 Setting Up 3 1 Entering Tools and Tool Offsets 3 1 1 Creating a New Tool Operating sequence New tool OK 3 32 This function offers another two softkey functions to select the tool type After selecting the tool type type the desired tool number max 3 digits in the input field 1 Cut edge Active tool no Length1 Length2 Radius n z Length1 Length2 Radius 11 9 6008 6 680 6 600 6 000 8 0060 6 000 3 ri 6 060 6 668 6 606 6 606 6 6000 6 000 3 22 6 6008 8 888 6 606 6 606 6 000 8 888 6 600 6 666 6 606 6 606 6 000 46 000 S Turning tool C edge pos ee ae ee ee eee eee ee Tool No lar lke Ie R B 1A Is VA C edge
249. ompensa tion axis In addition it is necessary to enable tool radius compensation using G41 G42 Programming example 8 192 Tool change N10 T1 tool 1 is activated with the related D1 N11 GO X Z the length offset compensation is superimposed N50 T4 D2 change tool 4 D2 of T4 is active N70 GO Z D1 D1 for tool 4 is active only cutting edge changed SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 6 Tool and Tool Compensation Contents of tool offset memory e Geometric quantities Length radius These consist of various components geometry wear The control system uses these components and calculates a resulting quantity e g total length 1 total radius The ap propriate total dimension comes into effect when activating the offset memory How these values are taken into account in the axes is determined by the tool type and by the commands G17 G18 G19 see the following illustrations e Tool type The tool type determines which geometry specifications are required and how these are taken into account drill or turning tool or milling tool e Tool point direction With the tool type Turning tool the tool tip position must additionally be specified The illustrations below show which tool parameters have to be used for which tool type Turning tool F Tool holder refe rence point Length 1 X Tool tip P G18 Length 1 in X cutting Length 2 in Z edge
250. on N30 T1 N40 GO X70 Z150 N50 WALIMON working area limitation ON ioe only inside working area N90 WALIMOF working area limitation OFF SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 157 Programming 8 3 Axis Movements 8 3 Axis Movements 8 3 1 Linear Interpolation at Rapid Traverse GO Functionality The rapid traverse movement GO is used for quick positioning of the tool not for direct work piece machining All axes can be traversed at the same time resulting in a straight path The maximum speed rapid traverse for each axis is defined in machine data If only one axis traverses it will traverse at its rapid traverse If two axes simultaneously traverse the tool path feedrate e g resulting speed at the tool tip will be selected such that the maximum possible tool path feedrate results with consideration of all axes involved A programmed feed F word is not relevant for GO GO is effective until it is canceled by another statement from this G group G1 G2 G3 Fig 8 9 Linear interpolation at rapid traverse from point P1 to P2 Programming example N10 GO X100 Z65 Note Another possible way to program a straight line is to use the angle specification ANG see Section Contour Definition Programming Information To approach a position another group of G functions see Section 8 3 13 Exact Stop Conti nuous Path Control Mode G60 G64 is provided With G60 Exact
251. on distance is calculated internally in the cycle as follows e If the drilling depth is 30 mm the value of the anticipation distance is always 0 6 mm e For larger drilling depths the formula drilling depth 50 is used maximum value 7 mm Programming example deep hole drilling This program executes the cycle CYCLE83 at the position XO The first drill hole is drilled with a dwell time zero and machining type chip breaking The final drilling depth and the first dril ling depth are entered as absolute values The tapping axis is the Z axis N10 GO G54 G90 F5 500 M4 Specification of the technological values N20 D1 T6 Z50 Approaching the retraction plane N30 G17 X0 Approaching the drill position N40 CYCLE83 3 3 0 0 80 0 10 0 0 0 0 1 0 Call of cycle depth parameters with absolute values N50 M2 End of program SINUMERIK 802D 802D base line 9 248 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 4 Drilling cycles 9 4 6 Rigid tapping CYCLE84 Programming CYCLE84 RTP RFP SDIS DP DPR DTB SDAC MPIT PIT POSS SST SST1 Parameters Table 9 4 Parameters of CYCLE84 SDIS Safety clearance enter without sign DP real Final drilling depth absolute a Final drilling depth relative to the reference plane enter wi thout sign DTB frea Dwell time at thread depth chip breaking SDAC int Direction of rotation after end of cycle Values 3 4 or 5 for M3 M4 or M5 MPIT real Pitch as thread size signed
252. ontrol system automatically Interrelation TDEP FAL NRC and NID thread depth finishing allowance number of cuts The programmed finishing allowance acts paraxially and is subtracted from the specified thread depth TDEP the remainder is divided into roughing cuts The cycle will calculate the individual infeed depth automatically depending on the parameter VARI SINUMERIK 802D 802D base line 9 310 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 5 Turning cycles When the thread depth is divided into infeeds with constant cutting cross section the cutting force will remain constant over all roughing cuts In this case the infeed will be performed using different values for the infeed depth A second variant is the distribution of the whole thread depth to constant infeed depths When doing so the cutting cross section becomes larger from cut to cut but with smaller values for the thread depth this technology can result in better cutting conditions The finishing allowance FAL is removed after roughing in one step Then the idle passes pro grammed under parameter NID are executed IANG infeed angle Using parameter IANG the angle is defined under which the infeed is carried out in the thread If you wish to infeed at a right angle to the cutting direction in the thread the value of this parameter must be set to zero If you wish to infeed along the flanks the absolute value of this parameter may amount maximally to the half
253. op modally effective G64 continuous path control mode G9 exact stop effective block by block G601 exact stop window fine G602 exact stop window coarse Exact stop G60 G9 If the Exact Stop function G60 or G9 is enabled the speed is decelerated to zero at the end of the block in order to be able to achieve the exact target position Another modally effective G group is provided to set when the traversing movement of the block concerned is considered completed and switching to the next block is carried out e 601 exact stop window fine Block relaying is only carried out if all axes have achieved the exact stop window fine va lue in machine data e 602 exact stop window coarse Block relaying is only carried out if all axes have achieved the exact stop window coarse value in machine data The selection of the exact stop window substantially influences the total time if many positio ning processes are carried out Fine adjustments require more time SINUMERIK 802D 802D base line 8 172 6FC5 698 2AA00 0BP3 11 03 OP T Programming 8 3 Axis Movements Block relaying for coarse for fine G602 coarse Fig 8 23 Exact stop windows coarse and fine effective with G60 G9 enlarged representation of the windows Programming example N5 G602 exact stop window coarse N10 GO G60 Z exact stop modal N20 X Z G60 remains active N50 G1 G601 exact stop window fine N80 G64 Z
254. or circular inter 0 010 99 999 999 a possibility to define a circle with G2 G3 see G2 G3 polation negative sign for circle selection greater than semicircle CYCLE Machining cycle only given values The machining cycle call requires a separate block the intended transfer parameters must be assigned values see also Section Cycles CYCLE82 Center drilling N10 RTP 110 RFP 100 assign values N10 CYCLE82 RTP RFT separate block DulwweIboId L dO 0 LL da0 00VVe 869 S049 aul seq AZ08 AZ08 MIYAWNNIS Gt L 8 Address Meaning Value Assignment Explanation Programming CYCLE83 Deep hole drilling N10 CCYCLE83 110 100 or transfer values directly separate block CYCLE84 Rigid tapping N10 CYCLE84 separate block CYCLE840 Tapping with compensating chuck N10 CYCLE840 separate block CYCLE85 Reaming N10 CYCLE85 separate block CYCLE86 Boring N10 CYCLE86 separate block CYCLE88 Drilling with stop N10 CYCLE98 separate block CYCLE93 Grooving N10 CYCLE93 separate block CYCLE94 Undercut forms E and F N10 CYCLE9A separate block CYCLE95 Stock removal N10 CYCLE95 separate block CYCLE97 Thread cutting N10 CALL CYCLE9 7 separate block DC Absolute coordinate di For a rotary axis the unit for the end point with DC N10 A DC 45 3 approach position of A rect position approach can be sp
255. or the transverse axis Programming example N10 DIAMON X44 Z30 for X axis diameter input N20 X48 Z25 DIAMON is still active N30 210 N110 DIAMOF X22 Z30 _ switchover to radius data input for X axis from here N120 X24 225 N130 210 Note A programmable offset with TRANS X or ATRANS X is always interpreted as a radius di mension input Description of this function see next following Section SINUMERIK 802D 802D base line 8 152 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 2 Positional Data 8 2 4 Programmable Zero Offset TRANS ATRANS Functionality The programmable zero offset is used in case of recurring geometries arrangements in different positions on a workpiece or simply when selecting a new reference point for the dimensional notation or as the allowance for roughing this results in the current workpiece coordinate system The newly programmed dimensions will refer to this coordinate system The offset is possible in all axes Note In the X axis the workpiece zero should be in the rotation center because of the functions Diameter programming DIAMON and Constant cutting speed G96 In this case none or only a minor offset e g as the allowance along the axis Original workpiece Workpiece X current Z current Z Workpiece Offset X Z Workpiece shifted Fig 8 5 Effects of the programmable offset Programming TRANS Z
256. ordinates i e the X coordinate with reference to zero The end point remains open PROGRAM Program editor DEHMO1 HPF Not selected Input form circle line circle G21G3 G98 POT tang ESE x Mi Z 159 00000 ABS x 69 00008 Ri 56 0000A H2 Z 316 00000 x 42 00000 R2 100 000900 AO O OO O RND Fig 6 18 After you have filled out the interactive screenform click on OK to quit the screenform The points of intersection are calculated and the two blocks are generated ANF G1 G94 X78 F3666 T1i 1 Di 1 amp DIAMON s G2 G96 2 262 54467 X88 85279 K 56 66060 6 666605 G1 Z 228 91667 X182 29441 iO Vn FI Fa Fig 6 19 Result of step 1 Since the end point has been left open the point of intersection of the straight line with the circle sector 2 will be used as the starting point for the next contour definition Now call the interactive screenform for calculating the contour section _ amp again The end point of the contour section are the coordinates Z 413 0 and X 212 Program editor DEHMO1 MPF Not selected Input form circle line Z circle G31G2 G98 POI tang C G2 G3 413 99088 J addit 212 69008 i Functions 316 BBA l 42 90008 413 0008A 146 00A Fig 6 20 Calling the screenform SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T Part Programming 6 3 Blueprint programming PROGRAH Program editor DEMO1 MPF 7 Not selected
257. ot taken Warning indicates that loss of life severe personal injury or substantial material damage may result if the appropriate pre cautions are not taken Caution indicates that minor personal injury or material damage may result if the appropriate precautions are not taken Caution eithout a warning triangle means that material damage can occur if the appropriate precautions are not taken Attention means that an undesired event or status can occur if the appropriate note is not observed Note is used to draw your special attention to an important information on the product the handling of the product or the corresponding part of the documentation Qualified personnel Start up and operation of a device may only be carried out by qualified personnel Qualified personnel as refer red to in the safety notices provided in this Manual are persons who are authorized to start up ground and tag devices systems and circuits according to the relevant safety standards Usage as per intended purpose ZN Please observe the following Warning The device may only be used for the cases of application as intended by the Catalog and only in conjunction with third party devices and components recommended or approved by Siemens The proper and safe operation of the product requires transport storage and installation according to the relevant instructions and qualified operation and maintenance at the prescribed intervals
258. piled The simulation is described in Section 6 4 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Part Programming 6 3 Blueprint programming 6 3 Blueprint programming Functionality The control system offers various contour screenforms for the fast and reliable creation of part programs The interactive screenforms must be filled with the required parameters Using the contour screenforms you can program the following contour elements or contour sections HERP BPRS MITEL Fee Straight line section with specification of end point or angle Circle sector with specification of center point end point radius Contour section straight line straight line with specification of angle and end point Contour section straight line circle with tangential transition calculated on the basis of angle radius and end point Contour section straight line circle with any transition calculated on the basis of angle center point and end point Contour section circle straight line with tangential transition calculated on the basis of angle radius and end point Contour section circle straight line circle with any transition calculated on the basis of angle center point and end point Contour section circle circle with tangential transition calculated on the basis of center point radius and end point Contour section circle circle with any transition calculated on the basis of center point and end poi
259. pointlabsolute Approach z 72 66668 start za x 196 66066 C x Abort wv ok ee d ee ee Starting point axis Z Fig 6 28 Setting the starting point SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 6 91 Part Programming 6 3 Blueprint programming PROGRAX Program editor DEHMO1 MPF Not selected Input form circle Z circle circle G21G31G2 G98 POI tang z x Z 111 00000 ABS X 98 0800 R z X 1 39 00000 233 68688 130 00000 RZ 39 0888A R3 69 0088A F RND 0 Feedrate Fig 6 29 Input of step 1 PROGRAH Program editor DEMO1 MPF 5 Not selected ANF Gi G94 X78 F3086 Ti 1 Di 1 amp TAMONS l G2 G96 Z2 141 66648 X146 36623 K 39 66666 I6 66060 G3 Z 219 66492 X187 19512 K 53 18392 I 43 95988 amp uO Vn FIC Fa Fig 6 30 Result of step 1 The function provides the point of intersection between circle sector 2 and circle sector 3 as the end point In the second step use the screenform to calculate the contour section 63 For calculation select the direction of rotation G2 G3 G2 Starting point is the end point of the first calculation PROGRAH Program editor DEHO1 HPF Not selected Input form circle circle circle G21G31G2 G98 POI tang 233 09000 ABS 130 9808 39 08008 399 20008 81 08898 39 00980A 49 00980A 0 Feedrate Fig 6 31 Input of step 2 SINUMERIK 802D 802D base l
260. pos 3 1o Fig 3 4 The New Tool window Input of tool number For milling and drilling tools the operator must select the machining direction Geometry Lengthi Length2 Radius Lengthi Length2 Radius 11 A 8 8008 8 000 8 000 8 000 94 000 3 2 2 8 008 8 9008 8 008 8 000 0 000 28 000 Fig 3 5 Selection of the machining direction for a milling tool Use OK to confirm your input A data record loaded with zero by default will be accepted into the tool list SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Setting Up 3 1 Entering Tools and Tool Offsets 3 1 2 Determining Tool Offsets manually Functionality This function can be used to determine the unknown geometry of a tool T Prerequisite The respective tool is changed In JOG mode use the cutting edge of the tool to approach a point on the machine with known machine coordinate values This can be a workpiece with a known position Procedure Enter the reference point in the appropriate field or ZO Please observe The assignment of length 1 or 2 to the axis depends on the tool type turning tool drill With a turning tool the reference point for the X axis is a diameter dimension Using the actual position of the point F machine coordinate and the reference point the con trol system can calculate the compensation value assigned to length 1 or length 2 for the axis preselected Note You can also use a zero offset already determined e g val
261. position coordinate an equality sign must be written The value must be put in round brackets Absolute dimensions can also be specified for circle centers using AC Otherwise the reference point for the circle center will be the circle start point Programming example N10 G90 X20 Z90 absolute data input N20 X75 Z IC 32 X dimensions still remain absolute Z incremental dimen sion N180 G91 X40 Z20 Switch to incremental data input N190 X 12 Z AC 17 X still incremental data input Z absolute 8 2 2 Metric and Inch Dimensions G71 G70 G710 G700 Functionality lf the workpiece dimensions are other than set in the basic system of the control system inch or mm you can enter the dimensions directly into the program The required conversions into the basic system are carried out by the control system Programming G70 inch dimensions G71 metric dimensions G700 inch dimensions also for feed F G710 metric dimensions also for feed F Programming example N10 G70 X10 Z30 inch dimensions N20 X40 Z50 G70 sill active N80 G71 X19 217 3 metric dimensions from here Information Depending on the basic scaling settings the control system interprets all geometrical values as metric or inch dimensions Tool offsets and settable zero offsets including the correspon ding displayed values are also to be understood as geometrical values this also applies to the feed F specified in mm min or inch min
262. proach start position N25 SETMS 2 Master spindle is now the milling spindle N30 TRANSMIT Activate TRANSMIT function N35 G55 G17 Zero offset activate X Y plane N40 ROT RPL 45 Programmable rotation in the X Y plane N50 ATRANS X 2 Y3 Programmable offset N55 S600 M3 Turn on milling spindle N60 G1 X12 Y 10 G41 Enable tool radius compensation N65 Z 5 Infeed cutter N70 X 10 N80 Y10 N90 X10 N100 Y 12 N110 GO 240 gt Retract cutter N120 X15 Y 15 G40 Disable tool radius compensation N130 TRANS Disable programmable offset and rotation N140 M5 Turn off milling spindle N150 TRAFOOF Deactivate TRANSMIT N160 SETMS Master spindle is now main spindle again N170 G54 G18 GO X50 Z60 SPOS 0 Approach start position N200 M2 The turning center with X0 Y0O is referred to as the pole It is therefore not recommended to machine a workpiece in the vicinity of the pole since in some cases substantial feedrate reductions are requi red to avoid that the rotary axis is not overloaded Avoid to select TRANSMIT if the tool stands ex actly in the pole You should also avoid passing of the pole X0 YO with the tool center point SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 14 Milling on turning machines References Description of Functions Section Kinematic Transformations 8 14 2 Milling of peripheral surfaces TRACYL With SINUMERIK 802D this function is an option and available wi
263. program by choice from six possible groups G54 to G59 For the operation see Section Entering Modifying Zero Offset Programming G54 1st settable zero offset G55 ond settable zero offset G56 3rd settable zero offset G57 Ath settable zero offset G58 5th settable zero offset G59 6th settable zero offset G500 settable zero offset OFF modal G53 settable zero offset OFF non modal also suppresses the programmable offset G153 as with G53 also suppresses basic frame SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 155 Programming 8 2 Positional Data X1 Machine Workpiece X workpiece Z Workpiece Specify offset only along the Z axis Fig 8 7 Settable zero offset Programming example N10 G54 calling the first settable zero offset N20 X Z machining of workpiece N90 G500 GO X disabling of settable zero offset 8 2 7 Programmable Working Area Limitation G25 G26 WALIMON WALIMOF Functionality G25 G26 can be used to define a working range for all axes within which traversing is permit ted and outside of which traversing is not permitted With tool length compensation active the tool tip can be inside this range otherwise the tool carrier reference point The coordinates are specified with reference to the machine The validity of the working area limitation can be defined for each axis and direction separa tely in the setting da
264. programmable offset deletes all statements of offset rotation scaling factor mirroring ATRANS Z programmable offset additive to the existing statements TRANS without values deletes all statements of offset rotation scaling factor mirroring The statement with TRANS ATRANS always requires a separate block Programming example N10 N20 TRANS Z5 programmable offset 5mm along the Z axis N30 L10 Subroutine call contains the geometry to be shifted N70 TRANS offset deleted Subroutine call see Section 8 11 Subroutine Technique SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 153 Programming 8 2 8 2 5 Positional Data Programmable Scaling Factor SCALE ASCALE Functionality SCALE ASCALE can be used to program a scaling factor for all axes by which an increase or a reduction is carried out along the specified axis The currently set coordinate system serves as the reference for the scale modification Programming Notes SCALE X Z ASCALE X Z SCALE programmable scaling factor deletes all statements of offset rotation scaling factor mirroring programmable scaling factor additive to the existing statements without values deletes all statements of offset rotation scaling factor mirroring The statements with SCALE ASCALE require a separate block e For circles the same factor should be used for both axes e f ATRANS is progr
265. r on time Setting User data data Fig 3 21 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 3 45 Setting Up 3 4 Programming Setting Data Operating Area Parameters Meaning e Parts required Number of workpieces required required workpieces e Parts total Number of workpieces manufactured in total actual total e Part count This counter logs the number of all workpieces produced beginning from the starting time e Run time Total runtime of NC programs in the AUTOMATIC mode in seconds The AUTOMATIC mode counts the runtimes of all programs executed between NC START and end of program RESET The timer is reset to zero with every power up of the control system runtime of the selected NC program in seconds e Cycle time Tool action time in seconds In the NC program selected the runtime between NC START and end of program RE SET is measured Starting a new NC program will clear the timer e Cutting time The runtime of the path axes is measured in all NC programs between NC START and end of program without rapid traverse active and the tool active With the dwell time active the measurement is additionally interrupted If the control system is booted with the default values the timer is reset to zero automatically Misc Use this softkey to display a complete list of all setting data of the control system The data are divided into e general e axis specific and e
266. r the character In the first co lumn the PLC reference number must be specified and in the second column the file name 1 Welle mpf 2 Kegel mpf Example This function can be used to insert or modify PLC user alarm texts Select the desired alarm number using the cursor At the same time the text currently valid is displayed in the input line User alarm 1 User alarn 2 User alarm 3 User alarm 4 User alarm 5 User alarm 6 User alarm 7 User alarn 8 User alarn User alarm 10 User alarm 11 User alarm 12 User alarm 13 User alarm 14 User alarm 15 User alarm 16 User alarm 17 User alarm 18 User alarm 1 E STEP 7 PLC Status PLC Program connect status list program list Fig 7 24 Editing the PLC alarm text Enter the new text in the input line Press the Input key to complete your input and select Save to save it For the notation of the texts please refer to the Start Up Guide The window is divided into two columns The left column is used to select the data group and the right hand column is used to select individual data for transfer If the cursor is positioned in the left hand column the whole data group is output when Read out is selected If it is positioned in the right hand column only the selected file is transferred You can use the TAB key to switch between the two columns SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T System Data types Main Sub part p
267. rammed in the calling program for chip breaking Traversing to the next drilling depth with G1 and the programmed feedrate Sequence of motions is continued until the final drilling depth is reached Retraction to the retraction plane with GO SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Cycles 9 4 Drilling cycles RFP RTP RFP SDIS RFP DPR FDEP G4 Go Q G1 DP Fig 9 7 Deep hole drilling with chip breaking Explanation of the parameters For the parameters RTP RFP SDIS DP DPR see CYCLE82 Interrelation of the parameters DP or DPR FDEP or FDPR and DMA The intermediate drilling depth are calculated in the cycle on the basis of final drilling depth first drilling depth and amount of degression as follows In the first step the depth parameterized with the first drilling depth is traversed as long as it does not exceed the total drilling depth From the second drilling depth on the drilling stroke is obtained by subtracting the amount of degression from the stroke of the last drilling depth provided that the latter is greater than the programmed amount of degression The next drilling strokes correspond to the amount of degression as long as the remai ning depth is greater than twice the amount of degression The last two drilling strokes are divided and traversed equally and are therefore always greater than half of the amount of degression If the value
268. rate The screenform generates one straight line and two circle blocks from the data you have ent ered Use this softkey to define the direction of rotation of the two circle sectors You can choose between G3 G2 G3 The end point and the center point coordinates can be entered either in absolute dimensions incre mental dimensions or polar coordinates The current settings are displayed in the interactive screen form SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Part Programming 6 3 Blueprint programming Example DIAMON Fig 6 16 Given R1 50 mm R2 100 mm R3 40mm M1 Z 159 X 138 M2 Z 316 X84 M3 Z 413 X 292 Starting point The point X 138 and Z 109 mm 159 R50 is supposed as the starting point PROGRAH Program editor TEST HPF Not selected scuf EJ Enter confirm start point absolute Approach Z 109 00800 start pt X 138 AC Abort Starting point axis 2 vV A E E ee E eee Fig 6 17 Setting the starting point After you have confirmed the starting point use the screenform to calculate the contour section t ed Use softkey 1 to set the direction of rotation G2 G3 of the two circle sectors and to fill out the parameter list SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 6 85 Part Programming 6 3 6 86 Blueprint programming The center point coordinates must be entered as absolute co
269. rere quisites G34 or G35 are effective until they are canceled by another statement of this G group GO G1 G2 G3 G33 Thread lead e lorKk Starting thread lead in mm rev belonging to axis X or Z Lead change In the block that contains G34 or G35 the address F is given the meaning of the lead change The lead mm per revolution changes per revolution e F lead change in MM rey 2 Note Beyond G34 G35 the address F has additionally the meaning of the feedrate or of the dwell time when using G4 The values programmed there remain stored Determining F If the starting and final leads of a thread are known the thread lead change F to be program med can be calculated using the following equation IK2 K2g1 F mm y 2 2 Le The meanings of the variables above are Ke Thread lead of the axis target coordinate mm rev Ka Thread starting lead programmed under K mm rev Le Thread length in mm Programming G34 Z K F cylinder thread with increasing lead G35 X L F face thread with decreasing lead G35 Z X K F taper thread with decreasing lead SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 167 Programming 8 3 Axis Movements Programming example 8 3 8 cylinder thread then with decreasing lead N10 M3 S40 turn on spindle N20 GO G54 G90 G64 Z10 X60 approach starting point N30 G33 Z 100 K5 SF 15 thread constant lead
270. ressing this softkey will open another menu level providing softkeys to hide unhide the diagrams If a softkey has a black background the diagrams will be displayed for the trace channel selected Use this function to zoom in zoom out the time basis Use this function to increase reduce the resolution amplitude Use this function to define the step sizes of the markers T 6 500008 V 6 500080 Fig 7 10 SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 7 105 System The markers are moved using the cursor keys at a step size of one increment Larger step sizes can be set using the input boxes The value specifies by how many grid units the marker must be moved using the cursor If a marker reaches the margin of the diagram the grid au tomatically appears in the horizontal or vertical direction File This function is used to save or load trace data service File service File nave iT Fig 7 11 Enter the desired file name without extension in the File Name box The Save softkey is used to save the data with the specified name in the part program direc tory The file can then be read out via the RS232 interface and the data can be edited using MS Excel The Load softkey loads the specified file and displays the data graphically TE This window contains the version numbers and the date of creation of the individual CNC compo nents HMI The HMI details
271. rical and tapered external and internal threads with constant pitch in longitudinal and face machining The threads can be both sin gle start and multiple threads With multiple threads the individual thread starts are machi ned one after the other The infeed is performed automatically you can choose between the variants constant infeed per cut or constant cutting cross section Right hand or left hand thread is determined by the direction of rotation of the spindle which must be programmed prior to the cycle start SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Cycles 9 5 Turning cycles Both feed and spindle override are ineffective in the traversing blocks with thread Fig 9 62 Important To be able to use this cycle a soeed controlled spindle with position measuring system is required Operational sequence Position reached prior to cycle start Starting position is any position from which the programmed thread starting point run in path can be approached without collision The cycle creates the following sequence of motions Approach of the starting point determined in the cycle at the beginning of the run in path for the first thread turn with GO Infeed for roughing according to the infeed type defined under VARI Thread cutting is repeated according to the programmed number of roughing cuts The finishing allowance is removed in the following step with G33 This step is repea
272. rns are distributed equally over the circumference of the turned part the first thread turn is determined by the parameter NSP To produce a multiple turn thread with an asymmetrical arrangement of the thread turns on the circumference the cycle for each thread turn must be called when programming the ap propriate starting point offset VARI machining type 9 312 Using the parameter VARI it is defined whether external or internal machining will be carried out and which technology will be used with regard to the infeed when roughing The parame ter VARI can assume values between 1 and 4 with the following meaning 4 Infeed with constant infeed depth e Infeed with constant cutting cross section Fig 9 66 SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 5 Turning cycles Table 9 19 Type of machining Ext int Const infeed const cutting cross section Constant infeed 1 A Constant cutting cross section A a Constant cutting cross section If a different value is programmed for the parameter VARI the cycle is aborted after output of alarm 61002 Machining type defined incorrectly Further notes Differentiation between longitudinal and transversal thread The decision whether a longitudinal or transversal thread is to be machined is made by the cycle itself This depends on the angle of the taper at which the threads are cut If the angle at the taper is
273. rograms You have selected the operating area Programs and are in the overview of the programs already created in the NC New lf you press the New softkey a dialog box appears where you can type the new name of the main program or subroutine The extension MPF for main programs is entered automatically The exten sion SPF for subroutines has to be entered with the program name Type Length MPF 71 HPF 163 HPF 163 MPF 163 MPF 163 MPF 71 MPF 71 New program WELLE1 Please specify name NC memory assignment in bytes 246540 Press Open softkey to edit program Fig 6 3 Input screen form New Program Enter the name of the new program OK Press the OK softkey to complete your input The new part program file is generated and the editor window opens automatically Abort Use Abort to cancel the creation of the program the window will be closed 6 74 SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T Part Programming 6 2 Editing a Part Program Operating Mode Program 6 2 Editing a Part Program Operating Mode Program Functionality A part program or sections of a part program can only be edited if the program is not being executed All changes in the part program are stored immediately i DEHO1 MPF Picasa NF Gi G94 X78 F38000 Ti 1 D1 1 a ANA X70 Z75 N51 Z M3 51000 Mark G1 G98 X28
274. rograms E LOAD1 MPF Standard cycles Ei LOAD2 MPF Data Bi LOAD3 MPF Start up data PC i LOAD4 MPF PLC Application PC EA TEST1 MPF Display machine data PC Ei DEMO1 MPF PLC Sel alarm texts PC El TEST2 PF Start up data NC Card PLC Application NC Card Display mach data NC Card PLC Sel alarm texts NC Card Part programs NC gt NC_CARD Part programs NC_CARD gt NC Start up data HMI NC Card Read in a ee Fig 7 25 In the NC Card selection area the set interface parameters are ineffective When reading in data from NC Card first the desired area must be selected If PLC Sel or Alarm texts PC is selected when reading in Start up data PC PLC Application PC or Display machine data PC the settings of the column special functions are internally switched to Binary format Note If you select the menu option Part programs to the NC card or Part programs from the NC card to the NC existing files are overwritten without any confirmation warning Note These functionalities are not implemented in the 802D bl _ e Part programs NC gt NC_CARD e Part programs NC_CARD gt NC Data Select the data to be transferred To start the transfer of the data to an external device use the selection Read out softkey function To read in data from an external device use the Read in function For reading in it is not necessary to select the data group s
275. rresponding axis with zero e Setting individual axes to zero If you select either of the softkeys X 0 Y 0 or Z 0 the current position will be overwritten with zero Pressing the Set Rel softkey switches the display to the relative coordinate system The follo wing inputs will modify the reference point in this coordinate system Note A modified basic zero offset will act regardless of any other zero offsets Determining the zero offset see Chapter 3 Use this softkey to determine the tool compensation values see Chapter 3 In MDA mode this screen form is used to set the retraction level the safety distance and the direc tion of rotation for part programs generated automatically In addition this screen form can be used to set the values for JOG feed and for the variable incremental dimension Position Repos offset Q 0AA 6 668 mm A l HAG 6 668 mm Switch Settings mm gt inch Retract plane Ei s 5 5 mm Safety distance gg nn JOG Feedrate PONE mm min Variable increment 8 8088 Dir of rot M3 O Back Measure workpiece tool Fig 4 4 Retraction plane The Face function will retract the tool to the specified position Z position after execution Safety distance Clearance to the workpiece surface defines the minimum distance between workpiece surface and workpiece It is used by the functions Face and Automatic tool gauging SINUMERIK 802D 802D base line 6FC5 698 2AA0
276. s and Tool Offsets Functionality The tool offsets consist of several data describing the geometry the wear and the tool type Depending on the tool type each tool is assigned a defined number of parameters Tools are identified by a number T number See also Section 8 6 Tool and Tool Offset Operating sequence Offset Use this softkey to open the Tool Offset Data window that contains a list of the tools created Use Param the cursor keys and the Page Up PageDown keys to navigate in this list Tool List Lengthi Pem Radius Lengthi Length2 Radius Ik n n s n n measure aE mooo maoa a AE ar New e Tool f k i A Epa Berea ee zaa Pae Fig 3 2 Tool list Use the following operating sequence to enter the compensation values e Position the cursor bar on the input box you want to modify e enter the desired value s gt and confirm your input by pressing Input or by a cursor movement Extend For special tools the softkey function Extend is provided which offers a complete parameter list which can be filled in Softkeys Tol Use this softkey to determine the tool offset data measure Measure Use this softkey to determine the tool offset data manually see section 3 1 2 manual Measure Use this softkey to determine the tool offset data semi automatically see Section 3 1 3 auto Calibrate Use this softkey to calibrate th
277. section Fig 6 25 Pressing OK accepts the point of intersection of the displayed contour into the part program This function will insert a circle sector between two adjacent circle sectors The circle sectors are described by their center points and circle radii and the inserted sector is described only be its ra dius The operator is offered a screenform where he will enter the parameters center point radius for circle sector 1 and the parameters end point center point and radius for the circle sector 2 Furthermore the radius for the inserted circle sector 3 must be entered and the direction of rotation be defined A help screen is provided to display the selected settings Pressing OK calculates three blocks from the entered values and inserts them into the part program Program editor TEST MPF Not selected Input form circle Z circle circle G21G31G2 G98 POI tang C G2 G3 ABS addition f ti Mi Z 111 00000 ABS Ea masii x 98 68808 R1 39 00000 M2 Z 233 00000 ABS x 136 60688 R2 39 66668 R3 69 0000 F 0 oe Radius R3 circle 3 v REJ ok Fig 6 26 Screenform for calculating the contour section circle circle circle SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 6 89 Part Programming 6 3 Blueprint programming End point E 1st and 2nd geometry axes of the plane If no coordinates are entered this function provides the point of intersection between the circl
278. sector must be described by the parameters starting point and radius and the straight line must be described by the parameters end point and angle SINUMERIK 802D 802D base line 6 82 6FC5 698 2AA00 OBP3 11 03 OP T G2 G3 POI Part Programming 6 3 Blueprint programming Program editor DEHMO1 MPF Not selected Input form circle line G2 G3 Addit Functions Fig 6 14 Tangential transition Table 6 3 Input in the interactive screenform End point of straight E Enter the end point of the straight line in absolute incremental or line polar coordinates Center point M Enter the center point of the circle in absolute incremental or po lar coordinates Radius of the circle R Input field for the circle radius Angle of straight line 1 A The angle is specified in the counterclockwise direction from O to 360 degrees and with reference to the point of intersection Feedrate F Input field for the interpolation feedrate Use this softkey to switch the direction of rotation from G2 to G3 G3 will appear on the display Pressing this softkey again will switch back the display to G2 The display changes to G2 You can choose between tangential or any transition The screenform generates a straight line and a circle block from the data you have entered If several points of intersection exist the desired point of intersection must be selected from a dialog box This
279. sed for error detection These are added to the coded character to convert the number of digits set to 1 into an odd or even number Input No parity default setting Parity even Parity odd 7 118 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Special functions System Table 7 3 Special functions Function active inactive Start with XON The transmission is started if an XON The transmission is started indepen character has been received in the dently of whether or not an XON cha data stream issued by the sender racter was issued Overwriting When reading in it is checked whether The files are overwritten without confir with confirma tion the file already exists in the NC mation warning End of block with CR LF With output in the punched tape for mat CR characters hexadecimal OD are inserted No additional characters are inserted Stop at the end of transmission The end of transmission character is active The character is not evaluated Evaluating the If the DSR signal is missing the trans DSR signal without effect DSR signal mission is interrupted Leader and The leader is skipped when data are Leader and trailer are also read in trailer received With the data output no leader is out With the data output a leader 120 0 h is created put Punched tape format Reading in of part programs Reading in of archives
280. sition Before tapping the spindle is stopped with orientation in the cycle by using the command SPOS and switched to position control The spindle position for this spindle stop is programmed under POSS SST speed Parameter SST contains the spindle speed for the tapping block SST1 retraction speed The speed for retraction from the tapped hole is programmed under SST1 with G332 If this parameter is assigned the value zero retraction is carried out at the speed programmed un der SST Note The direction of rotation when tapping in the cycle is always reversed automatically Programming example Rigid tapping Rigid tapping is carried out at position XO the drilling axis is the Z axis No dwell time is pro grammed the depth is programmed as a relative value The parameters for the direction of rotation and for the pitch must be assigned values A metric thread M5 is tapped N10 GO G90 G54 T6 D1 Specification of the technological values N20 G17 X0 240 Approaching the drill position N30 CYCLE84 4 0 2 30 3 5 90 200 500 Cycle call parameter PIT has been omitted no value is entered for the absolute depth or the dwell time spindle stop at 90 degrees speed for tapping is 200 speed for retraction is 500 N40 M2 End of program SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 251 Cycles 9 4 Drilling cycles 9 4 7 Tapping with compensation chuck CYCLE840 Programming CYCLE84
281. t signal off off V Mark T Mark trace trace Fig 7 7 The Servo Trace main screen The title bar of the diagram contains the current scaling of the abscissa and the difference va lue of the marker SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 7 103 System Select signal 7 104 The diagram shown above can be moved within the visible display area using the cursor keys 4 500 ms DT 6 000 ms Zeitbasis Zeit der Zeitdifferenz zwischen Markerposition Marker 1 und aktueller Markerposition Fig 7 8 Meaning of the individual fields This menu is intended to parameterize the measuring channel Signal selection Axis Signal Type Status Trace1 PS Progranmed Speed O on Q Trace X Q PS Programned Speed on Q Trace3 X PS Progranmed Speed O off Traced X Q PS Programned Speed O off O Parameter Set parameter for Trace Fig 7 9 e Selecting the axis The selection of the axis is carried out in the toggle field Axis e Signal type Following error Servo difference Contour deviation Actual position value Velocity actual value Velocity setpoint Compensation value Parameter record Position setpoint at controller input Velocity setpoint at controller input Acceleration setpoint at controller input Velocity feedforward control value Exact stop fine signal Exact stop coarse signal e Status On The recording is carried out in this channel Off The chan
282. t different values are assigned SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 9 Arithmetic parameters R LUD and PLC variables Value assignment for the field that contains a REP statement N20 PVAR7 4 REP 2 From field element 4 all are assigned the same value 2 in this case Number of LUDs With the SINUMERIK 802D max 200 LUDs may be defined Please note The SIEMENS standard cycles also use LUDs and share this number with the user Always keep a sufficient reserve when working with these cycles Note with regard to this display There is no special display for LUDs They would anyway only be visible during the runtime of the program For testing purposes when creating the program the LUDs may be assigned to the arithmetic parameters R and are thus visible via the arithmetic parameter display but are converted into the REAL type Another possibility of displaying is offered in the STOP condition of the program via a mes sage output MSG value VAR1 lt lt PVAR1 lt lt value VAR2 lt lt PVAR2 value of PVAR1 PVAR2 Mo 8 9 3 Reading and writing PLC variables Functionality To provide fast data exchange between NC and PLLC there is a special data area in the PLC user interface which has a length of 512 bytes In this area PLC data are agreed with a data type and a position offset These agreed PLC variables can be written or read in the NC pro gram To
283. t on Connect off Modem settings 7 110 Use this softkey to activate the link between the PC and the control system The softkey designation changes to Connect off The Enabled or Disabled status remains stored also after Power On except booting with de fault data Use RECALL to quit the menu In this area the modem settings are made Possible modem types are Analog Modem ISDN Box Mobile Phone The types of both communication partners must match with each other SYSTEH Modem configuration Moden settings Active modem parameters Moden type Esc sequence e Defaults Hang up ATHA AT Befehle AT amp FSE 1 OK OK CONNECT CONNECT NO CARRIER NO CARRIER Auto answer Hardware Fig 7 18 Settings for an analog modem When specifying several AT strings AT must merely be written once the remaining com mands can simply be attached e g AT amp FSO 1E1X0 amp W How the individual commands and their parameters must look exactly is to be seen in the manufacturer manuals since these are partially very different between the devices of one and the same manufacturer The default values of the control system are therefore only a real minimum and should be verified very exactly in any case before they are used for the first time To be on the safe side you can also first connect the devices to a PC and try and optimize the connection establishment via a ter minal program SINUMERIK 80
284. t and which technology will be used with regard to the infeed when roughing The parame ter VARI can assume values between 1 and 4 with the following meaning Infeed with constant infeed depth Infeed with constant cutting cross section Fig 9 72 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Value Ext int il external 2 internal 3 external 4 internal Cycles 9 5 Turning cycles Const infeed const cutting cross section Constant infeed Constant infeed Constant cutting cross section Constant cutting cross section If a different value is programmed for the parameter VARI the cycle is aborted after output of alarm 61002 Machining type defined incorrectly NUMT number of thread starts Use the parameter NUMT to define the number of thread turns with a multiple turn thread For a single turn thread the parameter must be assigned zero or can be dropped completely in the parameter list The thread turns are distributed equally over the circumference of the turned part the first thread turn is determined by the parameter NSP To produce a multiple turn thread with an asymmetrical arrangement of the thread turns on the circumference the cycle for each thread turn must be called when programming the ap propriate starting point offset 0 degree mark Start 1 Thread turn Start 2 Thread turn Start 4 Thread turn Start 3 Thread turn NU
285. t be inside the program Conditional jump instructions require a separate block Several conditional jump instructions per block are possible If you use conditional program jumps you may achieve a considerable program reduction Programming IF condition GOTOF Label jump forward IF condition GOTOB Label jump backwards GOTOF jump direction forward in the direction of the last block of the program GOTOB jump direction backwards in the direction of the first block of the program Label selected character sequence for the label or block number IF initiation of jump condition Condition arithmetic parameter arithmetic term required to formulate the condition SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 211 Programming 8 10 Program Jumps Comparison operations Operands Meaning O O ss fewe The comparison operations are used to assist the formulation of a jump condition It is also possible to compare arithmetic terms The result of comparing operations is either fulfilled or not fulfilled Not fulfilled is to be considered as zero Programming example for comparison operands R1 gt 1 R1 greater than 1 1 lt R1 1 less than R1 R1 lt R2 R3 R1 less than R2 plus R3 R6 gt SIN R7 R7 R6 greater than or equal to SIN R7 2 Programming example N10 IF R1 GOTOF LABEL1 if R1 is not zero go to block with LABEL1 N90 LABEL1 N100 IF R1 gt 1 GOTOF LABEL2 if R1 is gr
286. ta In addition to programming the values using G25 G26 it is also possi ble to input these values in the setting data via operation For enabling disabling the limitation for all enabled axes directions another programmable instruction group with WALIMON WALIMOF is provided Programming GO X Z lower working area limitation G26 X Z working area limitation WALIMON working area limitation ON WALIMOF working area limitation OFF SINUMERIK 802D 802D base line 8 156 6FC5 698 2AA00 0BP3 11 03 OP T Programming 8 2 Positional Data X1 Machine F toolholder reference point Z1 Machine et Mo 2626 Fig 8 8 Programmable work area limiting Notes e When working with G25 G26 the channel axis identifier from machine data 20080 AXCONF_CHANAX_NAME_TAB must be written With SW 2 0 and higher kinematic transformations are possible for the SINUMERIK 802D In this case different axis identifiers are configured for MD 20080 and for the geometry axis identifiers MD 20060 AXCONF_GEOAX_NAME_TAB e G25 G26 is also used in conjunction with address S for the spindle speed limitation see also Section Spindle Speed Limiting e Aworking area limitation can only be activated if the reference point has been approached for the relevant axes Programming example N10 G25 X0 Z40 values for the lower working area limitation N20 G26 X80 Z160 values for the upper working area limitati
287. ted according to the number of idle passes The whole sequence of motions is repeated for each further thread turn SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 309 Cycles 9 5 Turning cycles Explanation of the parameters Fig 9 63 PIT and MPIT value and thread size The thread pitch is an axis parallel value and is specified without sign To produce metric cylindrical threads it is also possible to specify the thread start as a thread size via the para meter MPIT M3 to M60 Only one of the two parameters should be used by option If they contain contradicting values the cycle generates the alarm 61001 Invalid thread pitch and is aborted DM1 and DM2 diameter Use this parameter to define the thread diameter of starting and end point of the thread In the case of internal threads this is the tap hole diameter Interrelation SPL FPL APP and ROP starting end point run in and run out path The programmed starting point SPL or end point FPL constitutes the original starting point of the thread The starting point used in the cycle however is the starting point brought for ward by the run in path APP and correspondingly the end point is the programmed end point brought back by the run out path ROP In the transversal axis the starting point defined by the cycle is always by 1 mm above the programmed thread diameter This retraction plane is generated in the internally c
288. ter 8 12 Timer and Workpiece Counter 8 12 1 Runtime Timer Functionality Timers that can be used for monitoring technological processes either in the program or only in the display are provided as system variables A These timers are read only timers Certain timers are always active Other timers are activa ted using machine data Timers that are always active e Time since the last booting of the CNC with default values in minutes AN_SETUP_TIME read only When the control system boots with the default values the timer is automatically reset to zero e Time since the last booting of the CNC in minutes SAN _POWERON_TIME read only When the control system boots the timer is automatically reset to zero Timers that can be disabled The timers listed below are activated using machine data default setting The start is timer specific Every active runtime measurement is interrupted automatically either by a program state other than Program running or if the feed override is equal to zero The response of the activated time measurements with dry run feed and program test active can be defined using machine data e Total runtime of NC programs in AUTOMATIC mode in seconds AC_OPERATING_TIME The runtimes of all programs between NC start and program end reset are added The timer is set to zero with each booting of the control system e Runtime of the selected NC program in seconds AC_CYCLE_
289. ter you have selected the OK softkey the password is set Use ABORT to return without any action to the System main screen SINUMERIK 802D 802D base line 7 116 6FC5 698 2AA00 OBP3 11 03 OP T Change password Delete password Change language Save data System Changing the password SYSTEH Hachine configuration No Axis number Name Type x Linear axis Zz Linear axis Please enter new password Expert Manu facturer Fig 7 28 Changing the password Depending on the access right various possibilities are offered in the softkey bar to change the password Select the password level using the appropriate softkeys Enter the new password and press OK to complete your input You will be prompted to enter the new password once more for confirmation Press OK to complete the password change Use ABORT to return without any action to the main screen Resetting the access right Switching the language Use this softkey to switch between foreground and background language Save data This function will save the contents of the volatile memory into a nonvolatile memory area Prerequisite There is no program currently executed Do not carry out any operator actions while the data backup is running SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 7 117 System Interface parameters Table 7 2 Interface parameters Parameter
290. ters e g R27 10 If numerical values are entered a check is carried out to see whether the value is within the admissible range Some parameters that may have only a few values are selected using the toggle key With drilling cycles it is also possible to use the vertical softkey Modal Call for calling a cycle modally To deselect the modal call choose Deselect modal from the list box for the drilling cycles Press OK to confirm or Abort in case of error SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Cycles 9 3 Graphical cycle support in the program editor Recompiling Recompiling of program codes serves to make modifications to an existing program using the cycle support Position the cursor on the line to be modified and press the softkey Recompile This will reopen the input screenform from which the program piece has been created and you can modify the values SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 9 237 Cycles 9 4 9 4 9 4 1 9 4 2 Drilling cycles Drilling cycles General Drilling cycles are motional sequences defined to DIN 66025 for drilling boring tapping etc They are called in the form of a subroutine with a defined name and a parameter list They all follow a different technological procedure and are therefore parameterized differently The drilling cycles can be modal i e they are executed at the end of each
291. th M5 MO After program stop press the NC START key e Retraction to the retraction plane with GO Explanation of the parameters For the parameters RTP RFP SDIS DP DPR see CYCLE81 gt GO gt G1 gt G4 M5 Mo PIT IMIOIU00 0 Fig 9 17 DTB dwell time The dwell time to the final drilling depth chip breaking is programmed under DTB in se conds SDIR direction of rotation The programmed direction of rotation is active for the distance to be traversed to the final drilling depth If values other than 3 or 4 M3 M4 are generated alarm 61102 No spindle direction pro grammed is generated and the cycle is aborted Programming example Drilling with stop CYCLE88 is called at XO The tapping axis is the Z axis The safety clearance is programmed with 3 mm the final drilling depth is specified relative to the reference plane M4 is active in the cycle SINUMERIK 802D 802D base line 9 266 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 4 Drilling cycles N10 T1 S300 M3 N20 G17 G54 G90 F1 S450 Specification of the technological values N30 GO XO Z10 Approach drilling position N40 CYCLE88 5 2 3 72 3 4 Cycle call with programmed direction of rota tion of spindle M4 N50 M2 End of program 9 4 12 Reaming 2 boring 5 CYCLE89 Programming CYCLE89 RTP RFP SDIS DP DPR DTB Parameter Table 9 10 Parameter CYCLE89 RTP Retraction plane absolute RFP Refere
292. th software release 2 0 and hig her Functionality e The kinematic transformation function TRACYL is used for the milling of peripheral surfaces of cylindrical bodies allowing the manufacture of any shape and running in any direction e The course of the grooves is programmed in the plane peripheral surface which was wound off in the mind at a certain machining cylinder diameter GDS Fig 8 57 Cartesian coordinate system X Y Z when programming TRACYL e The control system transforms the programmed traversing motions in the Cartesian coordinate system X Y Z into motions of the real machine axes In this case the main spindle works as a machine rotary axis e TRACYL must be configured via special machine data It is also defined at which position of the rotary axis the value Y 0 is to be found e If the machine possesses a real Y machine axis YM an extended TRACYL variant may be configured Thus it is possible to produce grooves using the groove side correction groove side and groove bottom stand vertically to one another even if the cutter diameter is less than the groove width Otherwise this is only possible with an exactly matching cutter SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 227 Programming 8 14 Milling on turning machines Fig 8 58 Special machine kinematics with additional machine Y axis YM Langsnut Quernut parallel begrenzte L ngsnut mit Nutwand korrektur
293. the axis path in the whole con tour path The feed F is active for the interpolation types G1 G2 G3 CIP CT and remains stored until a new F word is programmed Programming F Note For integer values the decimal point may be omitted e g F300 Unit for F G94 G95 The unit of the F word is determined by G functions e G94 Fas feed in mm min e G95 Fas feed in mm rev of the spindle only makes sense if the spindle rotates Note This unit applies to metric dimension input As mentioned in Section Metric and Inch Dimen sion Input a setting using inch dimensions is also possible Programming example N10 G94 F310 Feed in mm min N110 S200 M3 Spindle rotation N120 G95 F15 5 Feed in mm rev Note Write a new F word if you change G94 G95 Information The G group with G94 and G95 also contains the functions G96 and G97 for constant cutting speed These functions additionally affect the S word see Section 8 5 1 Constant Cutting Speed SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 171 Programming 8 3 Axis Movements 8 3 13 Exact Stop Continuous Path Control Mode G9 G60 G64 Functionality To set the traversing behavior at the block borders and for block relaying G functions are pro vided for optimum adaptation to various demands Example You want to use the axes for quick positioning or you want to machine path contours over several blocks Programming G60 exact st
294. the unit for the end point with N10 A ACN 45 3 absolute position proach position in the po ACP can be specified other than for G90 G91 also approaching A axis in the sitive direction for rotary applicable to spindle positioning negative direction axis spindle SPOS ACN 33 1 positioning the spindle ANG Angle for specification of 0 0001 359 99999 Specification in degrees a possibility to specify a N10 G1 X Z a straight line with contour straight line with GO or G1 only one end point coordi N11 X ANG definition nate of the plane is known or the entire end point is or contour over several blocks known in case of contours over several blocks N10 G1 X Z N11 ANGe N12 X Z ANG AR Aperture angle for circular 0 00001 359 99999 Specification in degrees one possibility to define a see G2 G3 interpolation circle with G2 G3 CALL Indirect cycle call Special form of cycle call no parameter transfer name N10 CALL VARNAME variable name of cycle stored in variables intended for cycle internal use only CHF Chamfer general use 0 001 99 999 999 inserts a chamfer of specified chamfer length bet N10 X Z CHF ween two contour blocks N11 X Z CHR Radius for circular inter 0 001 99 999 999 inserts a chamfer of specified leg length between two N10 X Z CHF polation negative sign for circle contour blocks N11 X Z selection greater than semicircle CR Radius f
295. ther words the parameter may also be omitted from the parameter list since in this case it is automatically loaded with zero by default If you wish to infeed along the flanks the absolute value of this parameter may amount maximally to the half of the flank angle of the tool The execution of the infeed is defined by the sign of this parameter With a positive value infeed is always carried out at the same flank and with a negative value at both flanks alter nating The infeed type with alternating flanks is only possible for cylindrical threads If the value of IANG for tapered threads is nonetheless negative the cycle will carry out a flank in feed along a flank NSP starting point offset Using this parameter you can program the angle value defining the point of the first cut of the thread turn at the circumference of the turned part This is a starting point offset The parame ter can assume values between 0 0001 and 359 9999 degrees If no starting point offset is specified or the parameter is omitted from the parameter list the first thread turn automati cally starts at the zero degree mark PP1 PP2 and PP3 thread pitch Using these parameters you will define the thread pitch from the three sections of the thread chain The pitch value must be entered as a paraxial value without sign VARI machining technology 9 318 Using the parameter VARI it is defined whether external or internal machining will be carried ou
296. this end special system variables are provided A_DBBJn Data byte 8 bit value A_DBW n Data word 16 bit value A_DBDj n Data double word 32 bit value A_DBRin REAL data 32 bit value n stands for the position offset from the beginning of the data area to the beginning of the variable in bytes Example R1 A_DBR 5 Reading of a REAL value offset 5 starting at byte 5 of the area Notes e When reading variables a preprocessing stop is generated internal STOPRE e A maximum of 3 variables may be programmed at the same time in one block SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 8 209 Programming 8 10 Program Jumps 8 10 Program Jumps 8 10 1 Jump Destination for Program Jumps Functionality A label or block number is used to mark blocks as a jump destination for program jumps Program jumps provide branching of the program sequence Labels can be freely defined but include a minimum of 2 max of 8 letters or digits whereby the first two characters must be letters or underscores Labels are completed by a colon in the block used as the jump destination They always stand at the beginning of the block If in addition to the label a block number is provided the label follows the block number Labels must be programmed unambiguously Programming example N10 LABEL1 G1 X20 LABEL1 is the label jump destination TR789 GO X10 220 TR789 is the label jump destination
297. ti block thread it is recom mended to specify a start point offset only in the first thread block because the information is used only in this block Multi block threads will automatically be linked using G64 continuous path control mode see Section 8 3 13 Exact Stop Continuous Path Control Mode G60 G64 N10 G33 Z K SF N20 Z X K 3rd block with G33 NSO Z X K 2nd block with G33 4 block with G33 Fig 8 22 Example of multi block thread thread chaining Velocity of the axes 8 166 For G33 threads the velocity of the axes for the thread length results from the set spindle speed and the programmed thread lead The feed F will not apply here However it remains stored The maximum axis velocity rapid traverse however which is defined in machine data cannot be exceeded In this case an alarm will be output SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Programming 8 3 Axis Movements Information Important e Make sure that the spindle speed override switch is not changed when machining the thread e The feed override switch is not relevant in this block 8 3 7 Thread cutting with variable lead G34 G35 Functionality G34 G35 can be used to manufacture threads with variable lead in one block e G34 thread with increasing lead e G35 thread with decreasing lead Both functions provide the same functionality as contained in G33 and require the same p
298. tifiers If no symbol exists for an identifier the description is automatically absolute The type of representation of identifiers is displayed in the status bar The absolute representation of identifiers is set by default The operand selected from the list of cross references is opened in the appropriate window Example You want to view the logic interrelation of the absolute operand M251 0 in network 1 in program block OB1 Select the relevant operand from the list of cross references and press the Open in window 1 soft key the display will appear in window 1 Symbolic address Open in window 1 Open in 3 l anna ra PLC PLC Status Window 1 Window 2 all PLC Status Wa Ganis Window 2 Cross info status list 0B1 SBR33 info status list A SBR37 P refs Fig 7 42 Cursor M251 0 in OB1 network 2 M251 0 in OB1 network 2 in window 1 is used to search for operands in the list of cross references You can search for the operands as whole words identifiers When searching uppercase and lo wercase letters are ignored Search options e Search for absolute and symbolic operands e Gotoline Search criteria e Down from the current cursor position e Whole program block from the beginning SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 7 129 System 7 1 7 130 PLC diagnosis using the ladder diagram representation Elenent kd ar P a ar s
299. ting sequence to traverse settable A increments The set increment is displayed in the display area To cancel simply press Jog once more The Jog main screen displays position feed and spindle values as well as the current tool JIG 16666 INC RESET SKP DRY ROY HO1 PRT SBL G DEHO1 MPF function HCS Position Repos offset Ug ieee X 0 00g em T1 gt nate Z ee see S wno A eee A MCS 7 A REL Hand wheel Measure Measure Settings workpiece _ tool Fig 4 3 The Jog main screen SINUMERIK 802D 802D base line 4 50 6FC5 698 2AA00 OBP3 11 03 OP T Parameters Softkeys Set base Manually Controlled Operation 4 1 Jog Mode Operating Area Position Table 4 1 Description of the parameters displayed in the Jog main screen Parameters Explanation MCS Display of addresses of existing axes in the machine coordinate system MCS X Z X If you traverse an axis in the positive or negative direction a plus or minus sign is dis 7 played in the corresponding field If the axis is already in the desired position no sign will be displayed Position These fields display the current position of the axes in the MCS or WCS mm Repos offset If the axes are traversed in the state Program interrupted in Jog mode this column displays the distance traversed by each axis with reference to the break point G function Display of important G functions Spindle S Display of actu
300. tion Y Z plane N60 S800 M3 Turn on milling spindle N70 GO Y70 Z10 Start position Y Z N80 G1 X17 5 Infeed cutter to groove bottom N70 OFFN 12 4 Groove side distance 12 4 mm to the groove center line N90 G1 Y70 Z1 G42 Enable TRC approach groove side N100 Z 30 Groove section parallel to cylinder axis N110 Y20 Groove section parallel to circumference N120 G42 G1 Y20 Z 30 Restart TRC approach other groove side groove distance to the groove center line remains 12 4 mm N130 Y70 F600 Groove section parallel to the circumference N140 Z1 Groove section parallel to the cylinder axis N150 Y70 Z10 G40 Disable TRC N160 GO X25 Retract cutter N170 M5 OFFN 0 Turn off milling spindle delete groove side distance N180 TRAFOOF Turn off TRACYL N190 SETMS Master spindle is now main spindle again N200 G54 G18 GO X25 Z50 SPOS 200 Approach start position N210 M2 SINUMERIK 802D 802D base line 6FC5 698 2AA00 0BP3 11 03 OP T 8 231 Programming 8 15 Equivalent G Functions with SINUMERIK 802S Turning 8 15 Equivalent G Functions with SINUMERIK 802S Turning SINUMERIK 802S SINUMERIK 802D G158 TRANS G22 DIAMOF G23 DIAMON The remaining G functions are identical for 802S and 802D as far as provided SINUMERIK 802D 802D base line 8 232 6FC5 698 2AA00 OBP3 11 03 OP T Cycles 9 1 Overview of cycles Cycles are generally applicable technology subroutines that can be used to carry out a speci fic machin
301. tool of the NC loaded via a part program or e a tool loaded via the PLC If the tool has been loaded by the PLC the tool number in the interactive screen form can dif fer from the tool number in the window T F S If you change the tool number no automatic tool change is carried out The measurement re sults however are assigned to the entered tool Measuring process Approach the probe using either the traversing keys or the handwheel SINUMERIK 802D 802D base line 3 36 6FC5 698 2AA00 0BP3 11 03 OP T Setting Up 3 1 Entering Tools and Tool Offsets pote s After the symbol Probe triggered has appeared release the traversing key and wait e until the end of the measuring process During the automatic measurement a gauge 2 is displayed symbolizing that the measuring process is in progress Note To create the measuring program the parameters safety clearance from the Settings screen form and feedrate from the Probe Data screen form are needed If several axes are moved simultaneously no calculation of the compensation data is carried out 3 1 4 Determining the tool compensations values using an optical measuring system Note This function is only available with the 802D DEMO1 MPF Position Repos offset Welt G l AAA 6 666 mm T 1 Tool Liae 2 l AAA 0 80800 mm F Aaa aX 6 688 8 988 6 666 mm min a Reset SKP DRY ROY M61 PRT SBL i a 8 66 120 Messen Werkzeug optisc
302. tool on the external device PC to set active the program intended for data out put The program will be loaded into the buffer memory and automatically selected and displayed in the program selection It is advantageous for the program execution to wait until the buffer memory has been filled The program execution starts with NC START The program is reloaded continuously The program is automatically removed from the control system either at the end of the pro gram or in the event of RESET Note Any errors during the program transfer are displayed in the Services Data I O area if you press the Error log softkey Block search is not possible for programs read in from external SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 5 69 Automatic Mode 5 6 Program Execution from External RS232 Interface For your notes SINUMERIK 802D 802D base line 5 70 6FC5 698 2AA00 OBP3 11 03 OP T Part Programming Operating sequence eae Open the Program Manager It displays the part program or cycle directory in the form of a list MANAGER Execute Copy Open Press Open softkey to edit program ee eee fH Pro User es Cycles grans cycles data Free NC memory O Byte Fig 6 1 The Program Manager main screen You can use to cursor key for navigating in the program directory To find programs quickly type the initial letter of the program name The control
303. tudinal axis Range of values 0 lt STA1 lt 180 degrees ANG1 real Flank angle 1 on the groove side determined by the starting point enter without sign Range of values 0 lt ANG1 lt 89 999 degrees ANG2 real Flank angle 2 on the other side enter without sign Range of values 0 lt ANG2 lt 89 999 RCO1 real Radius chamfer 1 externally on the side determined by the starting point IDEP Infeed depth enter without sign VARI int Machining type Range of values 1 8 and 11 18 The grooving cycle can be used to carry out symmetrical and asymmetrical recesses for lon gitudinal and face machining at any straight contour elements You can carry out both exter nal and internal grooves Operational sequence The infeed in the depth towards the groove base and in the width from groove to groove are calculated in the cycle internally and distributed equally with the maximum possible value SINUMERIK 802D 802D base line 6FC5 698 2AA00 O0BP3 11 03 OP T 9 279 Cycles 9 5 Turning cycles When grooving at oblique faces the tool will traverse from one groove to the next on the shortest path i e parallel to the cone at which the groove is machined During this process a safety clearance to the contour is calculated internally in the cycle 1st step Paraxial roughing in individual infeed steps up to the base The tool will retract for chip breaking after each infeed Fig 9 31 2nd step The groove is machi
304. u want to edit and select Open to open the program Program editor Pressing this key will execute the selected file Use this softkey to select a text block up to the current cursor position Use this softkey to copy a selected block into the clipboard Use this function to paste a text from the clipboard to the current cursor position Use this softkey to delete a selected text block Use the softkeys Find and Find Next to search for a string in the displayed program file In the input box type the term you are looking for and press OK to start the search If the string you are looking for is not found in the program file an error message appears Use Back to close the dialog box without starting the search This function replaces the block numbers from the current cursor position to the program end For programming the contour blueprint programming see Section 6 3 see Manual Cycles see Manual Cycles with the options Transmit and Tracyl see Manual Cycles For recompilation position the cursor on the cycle calling line in the program The function decodes the cycle name and prepares the screen form with the appropriate parameters If there are any pa rameters across the valid range the function will automatically load default values If the screen form has been quitted the original parameter block is replaced by the corrected block Please note Only blocks generated automatically can be recom
305. ue of G54 as the known machine coordinate In this case use the edge of the tool to approach the workpiece zero point If the edge is positioned directly at workpiece zero the reference point is zero F tool carrier reference point M machine zero W workpiece zero The offset value in the X axis is a diameter value Workpiece X Machine Machine Length 2 Fig 3 6 Determination of length compensation values using the example of a cutting tool SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 3 33 Setting Up 3 1 Entering Tools and Tool Offsets F tool carrier reference point M machine zero W workpiece zero X Machine Workpiece Actual position Z Machine Length 1 Fig 3 7 Determining the length compensation using the example of a drill Length 1 Z axis Note The diagram 3 7 is only applicable if the variables 42950 TOOL_LENGTH_TYPE and TOOL_LENGHT_CONST 0 otherwise length tool will apply for the milling and drilling tools Operating sequence Mezire Use this softkey to open the selection window for manual or semi automatic measurement tool Heasure manual Position Repos offset B a8 8 808 mn mee A l HAG 6 606 mm 8 008 aX 6 666 mm min i E a Calibrate probe Back Hassua Heasure EE workpiece Baal Fig 3 8 Selection of manual or semi automatic measurement Measure Use this softkey to open the Measure tool win
306. uisite The desired program has already been selected see Section 5 1 and the con trol system is in the reset condition Progr The block search function provides program advance to the desired part program position The control search destination is set by directly positioning the cursor bar on the desired block of the part pro gram L e Reset SKP DRY ROY M 1 PRT SBL To a ee Se DEHO1 HPF contour Block search Plane 1 DEMO1 MPF 1 NF Gi G94 X78 F3000 T1 1 D1 1 amp To ANA X780 Z75 amp end point N51 Z M3 510900 amp N66 X100 296 F1000 amp Without N75 F856 ZO amp calculat N76 X 2160 amp N86 GOTOB ANA amp Interr N96 H2 point eof Find pf DEMO1 MPF Back Progran Block Real time Correct control search simulat program Lia EEY Fig 5 5 Block search To Block search up to start of block contour To Block search up to end of block endpoint Without Block search without calculation calculate Interr The interruption point is loaded point Find If you press this softkey a dialog box will open which will prompt you to enter the terms you are looking for SINUMERIK 802D 802D base line 5 66 6FC5 698 2AA00 0BP3 11 03 OP T 5 3 SKP DRY ROY H 1 PRT SBL DEHO1 MPF Block Search Level 1 DEHO1 MPF AJF G1 G94 X78 F3666 T1 1 D1 1 ANA X70 275 N51 26 M3 1660 G1 G96 X26 666 Y86 606 F656 668 CYCLE82 R12 1 666
307. ume values between 0 and 180 degrees and always refers to the longitudinal axis ANG1 and ANG2 flank angle Asymmetric grooves can be described by flank angles specified separately The angles can assume values between 0 and 89 999 degrees RCO1 RCO2 and RCI1 RCI2 radius chamfer The form of the groove can be modified by entering radii chamfers at the edge or base Note that radii are entered with positive sign and chamfers with negative sign How the programmed chamfers are taken into account is specified in dependence of the tens digit of parameter VARI e If VARI lt 10 tens digit 0 Chamfers with CHF e If VARI gt 10 Chamfers with CHR programming CHF CHR see Section 8 1 6 FAL1 and FAL2 finishing allowance It is possible to program separate finishing allowances for groove base and flanks During roughing stock removal is carried out up to these finishing allowances Then a cut is carried out parallel to the contour with the same tool along the final contour SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 283 Cycles 9 5 Turning cycles Finish allow of the flanks FAL2 Finish allow at the base FAL1 Serer Fig 9 37 IDEP infeed depth You can divide the paraxial grooving into several depth infeeds by programming an infeed depth After each infeed the tool is retracted by 1 mm for chip breaking The parameter IDEP must be programmed in all cases
308. unction has been called and the value of the ordinate is copied into the next following input box If the function has been called from the part program editor the coordinates are saved with the axis names of the selected basic plane This function converts the given polar coordinates into Cartesian coordinates PP abscissa PP ordinate vector length D angle A E radius programming Fig 1 7 Enter reference point vector length and slope angle When you press this softkey the Cartesian coordinates are calculated which are then copied into two input fields following another to one The value of the abscissa is copied into the input box from which the calculator function has been called and the value of the ordinate is copied into the next following input box If the function has been called from the part program editor the coordinates are saved with the axis names of the selected basic plane This function is used to calculate the missing end point of the straight line straight line contour sec tion whereby the second straight line stands vertically on the first straight line The following values of the straight line are known Straight line 1 Start point and slope angle Straight line 2 Length and one end point in the Cartesian coordinate system M m f a jei s ma Q PP abscissa PP ordinate EP abscissa L length x aE PP angle A EE E diameter programming SINUMERIK 802D 802D base li
309. xis Grooves at bent contour elements can be realized differently Depending on the form and radius of the bend either a paraxial straight line can be laid over the maximum of the bend or a tangential oblique line can be created in a point of the edge points of the groove Radii and chamfers at the groove edge make sense with bent contours only if the appropriate edge point is on the straight line specified for the cycle Fig 9 35 WIDG and DIAG groove width and groove depth The parameters groove width WIDG and groove depth DIAG are used to define the form of the groove In its calculation the cycle always assumes the point programmed under SPD and SPL If the groove width is larger than that of the active tool the width is removed in several steps When doing so the whole width is distributed by the cycle equally The maximum infeed is 95 of the tool width after deduction of the cutting edge radii This provides a cutting overlap If the programmed groove width is smaller than the real tool width the error message 61602 Tool width defined incorrectly and machining is aborted The alarm will also appear if a cut ting edge width equal to zero is detected in the cycle SINUMERIK 802D 802D base line 9 282 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 5 Turning cycles Fig 9 36 STA1 angle Use the parameter STA1 to program the angle of the oblique line at which the groove is to be machined The angle can ass
310. xis names of the selected basic plane Example Calculate the intersection point between circle sector and straight line 2 in plane G78 Given Radius 10 Circle center Z 147 X103 Connection angle of the straight line 45 CC abscissa CC ordinate angle A radius R dianeter progranning Result Z 154 071 X 110 071 This function calculates the Cartesian coordinates of a point in the plane which is to be linked with a point PP on a straight line For calculation the distance between the points and the slope angle A2 of the new straight line to be created with reference to the slope A1 of the given straight line must be known i shift a point PP abscissa PP ordinate Az PP angle A1 line shift LA ay PP rotation AZ radius programming Fig 1 6 Enter the following coordinates or angles e the coordinates of the given point PP e the rise angle of the straight line A1 e the distance of the new point with reference to PP e the rise angle of the connecting straight line A2 with reference to A1 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 1 19 Introduction 1 3 Accessibility Options w4 Accept w4 Accept 1 20 When you press this softkey the Cartesian coordinates are calculated which are then copied into two input fields following another to one The value of the abscissa is copied into the input box from which the calculator f
311. y Use this softkey to activate the data groups selected After you have quitted the window you will only see the selected data on the machine data display The Select all softkey Pressing this softkey will display all data groups The Deselect all softkey Pressing this softkey will deselect all data groups SYSTEH elect group E Expert mode E Filter active Filter active Configuration scaling Menory configuration JPLC machine data Drive control Select 1l Status data diagnostics Expert Monitoring functions limits Deselect Auxiliary func all Offsets compensations Technology functions i 0 configuration Standard machine abore Fig 7 6 Display filter Other machine data Open the Channel Specific Machine Data window Use the PageUp PageDown keys to leaf up and down Drive machine data Open the Drive Specific Machine Data window Use the PageUp PageDown keys to leaf up and down Display machine data Open the Display Machine Data window Use the PageUp PageDown keys to leaf up and down Lesehinweis For a description of the machine data please refer to the manufacturer documentation SINUMERIK 802D Start Up SINUMERIK 802D Description of Functions The Service Axes window appears The window displays information on the axis drive SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T Service drive Service Profibus
312. y It is thus possible e g to determine the workpiece diameter The saved value of the axis position will then be used for calculating the length compensation The behavior of the softkey is determined by the display machine data 373 MEAS_SAVE_POS_LENGTH2 see also Manufacturer Documentation SINUMERIK 802D Start Up SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 3 35 Setting Up 3 1 Entering Tools and Tool Offsets 3 1 3 Determining the Tool Compensations Using a Probe Note This function is only available with the 802D Operating sequence Measure Select this softkey and then tool Measure the Measure Tool window appears auto n Repos offset Position Repos offset 6 668 mn Tool lie 2 2 8 000 mn Tool iz D 1 D 1 8 008 mm 0 008 190 Length2 0 BAG e 8 088 100 Lengthi 6 666 mm min f 6 666 mm min 8 8 160 8 100 B B I I A Length1i os i a a 4 P Length1 6 606 mn 6 8066 mn SS T Back fl Back Settings par perais Toni Settings base vworkpiece i tig Fig 3 10 The Measure Tool window This interactive screen form can be used to enter tool and edge number In addition the tool point direction is displayed after the fa symbol After the screen form has been opened the boxes of the interactive screen form are filled with the tool currently being in mesh The tool can be either e the active
313. y be selected in the RESET state If you press this softkey the feed override switch will also be active for rapid traverse Use this softkey to quit the screen form you are currently working in Use the Block Search key to go to the desired position in the program Block search forward with calculation During block search the same calculations are carried out as in normal program mode only the axes do not move Block search forward with calculation to the end of block position During block search the same calculations are carried out as in normal program mode only the axes do not move SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 5 63 Automatic Mode Without calculate Interr point Find Real time simulat Correct progr funct Auxiliary function Axis feedrate Program sequence MCS WCS REL External programs 5 64 Block search forward without calculation During block search no calculations are carried out The cursor is positioned on the main program block of the interruption point Setting of the search destination in the subroutine levels is carried out automatically The Find softkey provides the functions Find line and Find text The programmed tool path can be tracked using a broken line graphics see also Section 6 4 Us
314. y clearance by using GO e Traversing to final drilling depth with G1 and the feedrate programmed prior to the cycle Call e Spindle stop with M5 e Press NC START e Retraction to the retraction plane with GO Explanation of the parameters Parameter RTP RFP SDIS DP DPR see CYCLE81 SINUMERIK 802D 802D base line 6FC5 698 2AA00 OBP3 11 03 OP T 9 263 Cycles 9 4 Drilling cycles gt GO gt G1 e M5 MO LILIOUOUOII DI TT UU SDIS RFP DPR Fig 9 15 SDIR direction of rotation This parameter determines the direction of rotation with which the drilling operation is carried out in the cycle If values other than 3 or 4 M3 M4 are generated alarm 61102 No spindle direction pro grammed is generated and the cycle is aborted Programming example Third boring CYCLE87 is called at position X70 Y50 in the XY plane The drilling axis is the Z axis The final drilling depth is specified as an absolute value The safety clearance is 2 mm Fig 9 16 SINUMERIK 802D 802D base line 9 264 6FC5 698 2AA00 0BP3 11 03 OP T Cycles 9 4 Drilling cycles DEF REAL DP SDIS Definition of the parameters N10 DP 77 SDIS 2 Value assignments N20 GO G17 G90 F200 S300 Specification of the technological values N30 D3 T3 Z113 Approaching the retraction plane N40 X70 Y50 Approaching the drill position N50 CYCLE87 113 110 SDIS DP 3 Cycle call with programmed directio
315. ys be programmed in a separate block Basic instructions with regard to the assignment of standard cycle parameters The Programming Guide describes the parameter list of every cycle with the e order and the e type It is imperative to observe the order of the defining parameters Each defining parameter of a cycle has a certain data type The parameter being used must be specified when the cycle is called In the parameter list you can transfer e R parameters only numerical values e constants If R parameters are used in the parameter list they must first be assigned values in the cal ling program Cycles can be called e with an incomplete parameter list or e by leaving out parameters If you want to exclude the last transfer parameters that have to be written in a call you can prematurely terminate the parameter list with If you wish to leave out parameters in bet ween a comma is used as a place holder No plausibility checks are made for parameter values with a limited range of values unless an error response has been specifically described for a cycle If when calling the cycle the parameter list contains more entries than parameters are defined in the cycle the general NC alarm 12340 Too many parameters is displayed and the cycle is not executed Cycle call The individual methods for writing a cycle are shown in the programming examples provided for the individual cycles Simulation
316. ys display only the data of one spindle The control system displays the spindle data taking into account the following aspects The master spindle is displayed inthe idle condition at spindle start if both spindles are active The workspindle is displayed at spindle start of the workspindle In all cases the power bar applies to the spindle currently active When you press this softkey the softkeys for selecting the program control options e g Skipped Block Program Test are displayed Pressing Program Test will disable the setpoint output to the axes and spindles In this case the setpoint display will simulate the traversing movement Traversing movements are carried out with the feed setpoint specified using the Dry Run Feed set ting data The dry run feed is active instead of the programmed motion commands If this function is active the program execution always stops at the blocks in which the miscella neous function M01 is programmed Program blocks that are marked with a slash ahead of the block no will be ignored during the pro gram execution e g N100 If this function is active the part program blocks will be executed separately as follows Each block will be decoded separately and the program will stop at each block an exception are only thread blocks without dry run feed With these blocks the program stops only at the end of the current thread block Single Block fine can onl

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