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The axis/spindle concerned is stopped with rapid stop with open position feedback loop via a speed setpoint ramp.. The axis/spindle concverned is stopped with rapid stop with open positi

Description of Functions

Description of Functions 11.2003 Edition

sinumerik

Preface, Table of Contents

Velocities, Setpoint/Actual - Value Systems, Closed - Loop Control

Reference Point Approach (R1) 8

Manual Traversing and Hand

Description of Functions

SINUMERIK Documentation

Printing history

Brief details of this edition and previous edition are listed below.

The status of each edition is shown by the code in the “Remarks” column.

Status code in the “Remarks” column:

A New documentation.

B Unrevised reprint with new Order No.

C Revised edition with new status

If actual changes have been made on the page since the last edition, this is indicated by

a new edition coding in the header on that page.

This publication was produced with Interleaf V 7.

The reproduction, transmission or use of this document or its

contents is not permitted without express written authority.Offenders

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,

Notes for the reader

The descriptions of functions are only valid for or up to the specified software release When new software releases are issued, the relevant descriptions of functions must be requested Old descriptions of functions can only partially be used for new software releases.

Note

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.

Technical notes

Notations

The following notations and abbreviations are used in this Documentation:

 PLC interface signals -> IS ”Signal name” (signal data)

The variable byte is in the range “at axis“, “x” stands for the axis: 0 axis 1

1 aixs 2

n axis n+1.

 Machine data -> MD MD_NR: MD_NAME

 Setting data -> SD SD_NR: SD_NAME

 The headlines of the individual chapters/sections are added by a code designation in kets (e.g Chapter 1: EMERGENCY STOP (N2)) This code designation is used in referen- ces to individual Chapters/Sections.

brak-Explanation of the code designations

In the chapters/sections of each Description of Functions, the data and/or signals are ned which are important for the function discussed Within these explanations provided in the form of tables, some terms and abbreviations are used, which are explained here.

explai-Default value:

This is the default value of the machine/setting data when loading the standard machine data.

Range of values (minimum/maximum values):

specifies the input limits If no range of values is specified, the data type defines the input mits, and the field is marked with ”***”.

li-Activation of changes:

Changes in machine data, setting data or the like come not immediately into effect in the trol system The conditions for activation are therefore always specified The possibilities used are listed below by their priority:

con- POWER ON (po) Turning off/turning on the power supply

or softkey “StartUp/Normal” on HMI

 NEW_CONF (cf) ”RESET” key on the control unit

 immediately (im) after input of a value

Protection level:

There are the protection levels 0 to 7 whereby the interlock for protection levels 1 to 3 can be canceled by setting a password and the interlock for protection levels 4 to 7 via the IS “Protec- tion level” (e.g.: keyswitch position) Protection level 0 cannot be accessed (see Chapter “Va- rious Interface Signals”).

The operator has only access to information that corresponds to this particular protection level and the lower protection levels The machine data are assigned different protection levels by default and are marked by a Write/Read value (e.g 4/7).

Note: In this document, the machine and setting data of protection levels 2 to 7 are ted Notes on machine data of protection level 1 are only provided in special cases (expert mode).

Floating point value (64 -bit value )

Input limits from +/ -4.19*10- 307 to +/ -1.67*10308

 DWORD

Integer values (32 -bit value)

Input limits from -2 147 483 648 to +2 147 483 648 (decimal),

as a hexadecimal value: 0000 to FFFF

 BYTE

Integer values (8 -bit value)

Input limits from -128 to +127 (decimal), as a hexadecimal value: 00 to FF

Example machine data

Meaning:

Alarms

For detailed explanations on occurring alarms, please refer to:

References: ”Diagnostics Guide“.

1 EMERGENCY STOP (N2) 1-17

1.1 Brief description 1-171.2 EMERGENCY STOP sequence 1-181.3 EMERGENCY STOP acknowlededgement 1-191.4 Data descriptions (MD, SD) 1-201.5 Signal descriptions 1-211.6 Data fields, lists 1-221.6.1 Interface signals 1-221.6.2 Machine data 1-22

2 Axis Monitoring (A3) 2-23

2.1 Overview of monitoring functions 2-232.2 Motion monitoring functions 2-242.2.1 Contour monitoring 2-242.2.2 Positioning monitoring 2-252.2.3 Zero speed monitoring 2-272.2.4 Clamping monitoring 2-272.2.5 Speed setpoint monitoring 2-282.2.6 Actual velocity monitoring 2-302.3 Encoder monitoring functions 2-312.3.1 Encoder limit frequency monitoring 2-312.3.2 Zero mark monitoring 2-322.4 Monitoring of static limitations 2-332.4.1 Limit switch monitoring 2-332.4.2 Working area limitation 2-352.5 Boundary conditions 2-372.6 Data descriptions (MD, SD) 2-382.6.1 Channel - specific machine data 2-382.6.2 Axis/spindle - specific machine data 2-382.6.3 Axis/spindle - specific setting data 2-442.7 Signal description 2-452.7.1 Axis/spindle - specific signals 2-452.8 Data fields, lists 2-472.8.1 Axis/spindle - specific interface signals 2-472.8.2 Axis/spindle - specific machine data 2-472.8.3 Channel - specific machine data 2-482.8.4 Axis/spindle - specific setting data 2-48

3.1 Velocities, traversing ranges, accuracies 3-493.1.1 Velocities 3-493.1.2 Traversing ranges 3-503.1.3 Input/display resolution, computational resolution 3-513.1.4 Standardization of physical quantities of machine and setting data 3-523.2 Metric/inch scaling system 3-533.2.1 Conversion of the scaling system using the part program 3-533.2.2 Switching over the scaling system manually 3-553.3 Setpoint/actual- value system 3-57

3.3.2 Drives connected to Profibus DP 3-583.3.3 Speed setpoint and actual - value assignment 3-593.3.4 Speed setpoint output 3-623.3.5 Actual - value processing 3-633.4 Closed - loop control 3-653.5 Data description (MD, SD) 3-683.5.1 General machine data 3-683.5.2 Channel - specific machine data 3-703.5.3 Axis - specific machine data 3-713.6 Signal descriptions 3-763.7 Data fields, data lists 3-773.7.1 Interface signals 3-773.7.2 Machine data 3-77

4 Acceleration (B2) 4-79

4.1 Acceleration profiles 4-794.2 Jerk limitation on interpolator level 4-804.3 Jerk limitation in JOG mode 4-814.4 Percentage acceleration correction, ACC 4-824.5 Data descriptions (MD, SD) 4-834.6 Data fields, lists 4-84

5 Spindle (S1) 5-85

5.1 Brief description 5-855.2 Spindle modes 5-865.2.1 Spindle mode: Control mode 5-875.2.2 Spindle mode: Oscillation mode 5-885.2.3 Spindle mode: Positioning mode 5-905.2.4 Spindle mode: Axis mode 5-945.3 Synchronizing 5-955.4 Gear stage change 5-965.5 Programming 5-1015.6 Spindle monitoring functions 5-1025.6.1 Axis/spindle stopped 5-1025.6.2 Spindle in set range 5-1035.6.3 Max spindle speed 5-1035.6.4 Min./max speed of the gear stage 5-1035.6.5 Max encoder limit frequency 5-1045.6.6 Target position monitoring 5-1055.7 2nd spindle / master spindle 5-1065.8 Analog spindle 5-1075.9 Data descriptions (MD, SD) 5-1085.9.1 Channel - specific machine data 5-1085.9.2 Axis/spindle - specific machine data 5-1085.9.3 Spindle - specific setting data 5-1165.10 Signal descriptions 5-1185.10.1 Axis/spindle - specific signals 5-1185.11 Data fields, lists 5-1275.11.1 Interface signals 5-1275.11.2 Machine data 5-128

5.11.3 Setting data 5-129

6 Rotary Axes (R2) 6-131

6.1 General 6-1316.2 Modulo 360 degrees 6-1336.3 Programming rotary axes 6-1346.3.1 Rotary axis with active modulo conversion 6-1346.3.2 Rotary axis without modulo conversion 6-1356.4 Data descriptions (MD, SD) 6-1366.4.1 Axis/spindle - specific machine data 6-1366.5 Data fields, lists 6-1386.5.1 Machine data 6-1386.5.2 Setting data 6-138

7 Transverse Axes (P1) 7-139

7.1 Defining a transverse axis 7-1397.2 Diameter programming 7-1397.3 Constant cutting rate: G96 7-140

8 Reference Point Approach (R1) 8-141

8.1 Fundamentals 8-1418.2 Referencing using incremental measuring systems 8-1438.3 Referencing using absolute encoders 8-1468.3.1 General 8-1468.3.2 Operator- sssisted adjustment 8-1468.4 Supplementary conditions for absolute encoders 8-1488.4.1 Adjusting the absolute encoder 8-1488.5 Data descriptions (MD, SD) 8-1498.5.1 Channel - specific machine data 8-1498.5.2 Axis/spindle - specific machine data 8-1498.6 Signal descriptions 8-1578.6.1 Channel - specific signals 8-1578.6.2 Axis/spindle - specific signals 8-1588.7 Data fields, lists 8-1598.7.1 Interface signals 8-1598.7.2 Machine data 8-159

9 Manual Traversing and Handwheel Traversing (H1) 9-161

9.1 General features when traversing in JOG mode 9-1619.2 Continuous traversing 9-1659.3 Incremental traversing (INC) 9-1669.4 Handwheel traversing in JOG mode 9-1679.5 Data descriptions (MD, SD) 9-1709.5.1 General machine data 9-1709.5.2 Axis/spindle - specific machine data 9-1719.5.3 General setting data 9-1729.6 Signal descriptions 9-1749.6.1 Signals from HMI to PLC 9-1749.6.2 NCK signals and signals in the operating mode area 9-1759.6.3 Channel - specific signals 9-176

9.6.4 Axis/spindle - specific signals 9-1809.7 Data fields, lists 9-1839.7.1 Interface signals 9-1839.7.2 Machine data 9-1849.7.3 Setting data 9-184

10 Operating Modes, Program Mode (K1) 10-185

10.1 Brief description 10-18510.2 Operating modes 10-18610.2.1 Mode change 10-18710.2.2 Possible functions in the individual operating modes 10-18810.2.3 Monitoring functions in the individual operating modes 10-18910.2.4 Interlocks in the individual operating modes 10-19010.3 Execution of a part program 10-19110.3.1 Program mode and part program selection 10-19110.3.2 Starting the part program or part program block 10-19110.3.3 Part program interruption 10-19210.3.4 RESET command 10-19310.3.5 Program control 10-19410.3.6 Program status 10-19410.3.7 Channel status 10-19510.3.8 Reactions to operator or program actions 10-19610.3.9 Example of time diagram for a program sequence 10-19710.4 Program test 10-19810.4.1 General remarks on program test 10-19810.4.2 Program execution without axis movements (PRT) 10-19810.4.3 Program execution in single block mode 10-19910.4.4 Program execution with Dry Run Feed (DRY) 10-20010.4.5 Block search: Execution of certain program sections 10-20110.4.6 Skipping part program blocks (SKP) 10-20310.4.7 Graphical simulation 10-20410.5 Timer for program runtime 10-20510.6 Workpiece counter 10-20610.7 Data descriptions (MD, SD) 10-20810.7.1 Display machine data 10-20810.7.2 Channel - specific machine data 10-21110.7.3 Channel - specific setting data 10-21310.8 Signal descriptions 10-21510.8.1 Mode signals 10-21510.8.2 Channel - specific signals 10-21710.9 Data fields, lists 10-22810.9.1 Channel machine data 10-22810.9.2 Channel - specific setting data 10-22910.9.3 Interface signals 10-229

11 Feed (V1) 11-233

11.1 Feedrate F 11-23311.1.1 Feed with G33 (thread cutting) 11-23411.1.2 Feed with G63 (tapping with compensating chuck) 11-23511.1.3 Feed with G331, G332 (rigid tapping = tapping without compensating chuck) 11-23511.2 Rapid traverse G0 11-23611.3 Feed override 11-23711.3.1 Overview 11-23711.3.2 Feed disable and feed/spindle stop 11-237

11.3.3 Feed override from the machine control panel 11-23811.4 Data descriptions (MD, SD) 11-24011.5 Signal descriptions 11-24111.5.1 Channel - specific signals 11-24111.5.2 Axis/spindle - specific signals 11-24511.6 Data fields, lists 11-24811.6.1 Interface signals 11-24811.6.2 Machine data/setting data 11-248

12 Continuous - Path Mode, Exact Stop and LookAhead (B1) 12-249

12.1 Brief description 12-24912.2 General 12-25012.3 Exact Stop 12-25112.4 Continuous path mode 12-25212.4.1 General 12-25212.4.2 Velocity reduction according to the overload factor 12-25312.4.3 Velocity reduction for jerk limitation on the path 12-25412.4.4 Machine axis - specific jerk limitation 12-25512.5 LookAhead 12-25612.6 Data descriptions (MD, SD) 12-25812.6.1 Channel - specific machine data 12-25812.6.2 Axis - specific machine data 12-25812.7 Signal descriptions 12-25912.7.1 Channel - specific signals 12-25912.7.2 Axis - specific signals 12-25912.8 Data fields, lists 12-26012.8.1 Interface signals 12-26012.8.2 Machine data 12-260

13 Output of Auxiliary Functions to the PLC (H2) 13-261

13.1 Brief description 13-26113.2 Programming of auxiliary functions 13-26213.3 Transfer of values and signals to the PLC interface 13-26313.4 Division of auxiliary functions into groups 13-26413.5 Behavior on block search 13-26513.6 Description of the auxiliary functions 13-26613.6.1 M function 13-26613.6.2 T function 13-26613.6.3 D function 13-26613.6.4 H function 13-26713.6.5 S function 13-26713.7 Data descriptions (MD, SD) 13-26813.7.1 General machine data 13-26813.7.2 Channel - specific machine data 13-26813.8 Signal descriptions 13-27013.9 Data fields, lists 13-27213.9.1 Interface signals 13-27213.9.2 Machine data 13-273

14 Tool: Compensation and Monitoring (W1) 14-275

14.1 Overview: Tool and tool compensation 14-27514.2 Tool 14-27614.3 Tool compensation 14-27714.4 Tool monitoring 14-27814.4.1 Overview: Tool monitoring 14-27814.4.2 Tool life monitoring 14-28014.4.3 Workpiece count monitoring 14-28114.4.4 Examples for tool life monitoring 14-28214.5 Special cases of tool compensations 14-28414.6 Data descriptions (MD, SD) 14-28714.7 Signal descriptions 14-28914.8 Data fields, lists 14-29014.8.1 Interface signals 14-29014.8.2 Machine data 14-290

15 Measuring (M5) 15-291

15.1 Brief description 15-29115.2 Hardware requirements 15-29215.2.1 Probes that can be used 15-29215.2.2 Connecting the probe 15-29315.3 Channel - specific measuring 15-29515.3.1 Measuring mode 15-29515.3.2 Measurement results 15-29515.4 Measuring accuracy and testing 15-29615.4.1 Measuring accuracy 15-29615.4.2 Sensing probe function test 15-29615.5 Tool gauging in JOG 15-29815.6 Supplementary conditions 15-30115.7 Data descriptions (MD, SD) 15-30215.8 Signal descriptions 15-30315.9 Data fields, lists 15-30515.9.1 Interface signals 15-30515.9.2 Machine data 15-305

16 Compensation (K3) 16-307

16.1 Brief description 16-30716.2 Backlash compensation 16-30816.3 Interpolatory compensation 16-30916.3.1 General 16-30916.3.2 Leadscrew error compensation (LEC) 16-31016.3.3 Special features of interpolatory compensation 16-31316.4 Following error compensation (feedforward control) 16-31416.4.1 General 16-31416.4.2 Speed feedforward control 16-31516.5 Data descriptions (MD, SD) 16-31616.6 Data fields, lists 16-31816.6.1 Interface signals 16-31816.6.2 Machine data 16-318

17 Traversing to Fixed Stop (F1) 17-319

17.1 Brief description 17-31917.2 Functionality 17-32017.3 Behavior in case of RESET and cancellation of the function 17-32617.4 Behavior in the case of block search 17-32717.5 Miscellaneous 17-32817.6 Data descriptions (MD, SD) 17-33017.7 Signal descriptions 17-33417.8 Data fields, lists 17-33617.8.1 Interface signals 17-33617.8.2 Machine data/setting data 17-336

18 Kinematic Transformations (M1) 18-337

18.1 Brief description 18-33718.2 TRANSMIT 18-33818.2.1 Overview 18-33818.2.2 Configuring TRANSMIT 18-33918.3 TRACYL 18-34318.3.1 Overview 18-34318.3.2 Configuring TRACYL 18-34618.3.3 Programming example for TRACYL 18-34918.4 Special features with TRANSMIT and TRACYL 18-35218.5 Data descriptions (MD, SD) 18-35318.6 Signal descriptions 18-35718.7 Data fields, lists 18-35818.7.1 Interface signals 18-35818.7.2 Machine data/setting data 18-358

19 Various Interface Signals (A2) 19-359

19.1 Brief description 19-35919.2 Signals from PLC to NCK 19-36019.3 Signals from NCK to PLC 19-36419.4 Signals from PLC to HMI 19-36819.5 Signals from HMI to PLC 19-370

20 PLC User Interface 20-371

20.1 Address ranges 20-37120.2 User data 20-37320.2.1 User data 1 20-37320.2.2 User Data 2 20-37320.2.3 Retentive data area 20-37320.3 User alarm 20-37420.3.1 User alarm: Enabling 20-37420.3.2 Variable for alarm 20-37420.3.3 Active alarm reaction 20-37520.4 Signals from/to HMI 20-37520.4.1 Program control signals from HMI (retentive area) 20-37520.4.2 General selection/status signals from MMC (retentive area) 20-377

20.4.3 General selection/status signals to MMC (retentive area) 20-37720.5 Auxiliary function transfer from NC channel 20-37820.5.1 Decoded M signals (M0 - M99) 20-37820.5.2 T functions transferred 20-37920.5.3 M functions transferred 20-37920.5.4 S functions transferred 20-38020.5.5 D functions transferred 20-38020.5.6 H functions transferred 20-38020.6 NCK signals 20-38120.7 Channel signals 20-38320.7.1 Signals to NC channel 20-38320.7.2 Signals from NC channel 20-38520.8 Axis/spindle signals 20-38720.8.1 Transferred M/S functions, axis - specific 20-38720.8.2 Signals to axis/spindle 20-38720.8.3 Signals from axis/spindle 20-38920.9 PLC machine data 20-39120.9.1 INT values (MD 14510 USER_DATA_INT) 20-39120.9.2 HEX values (MD 14512 USER_DATA_HEX) 20-39120.9.3 FLOAT values (MD 14514 USER_DATA_FLOAT) 20-39120.9.4 User alarm: Configuration (MD 14516 USER_DATA_PLC_ALARM) 20-39220.10 Reading and writing of PLC variables 20-39220.11 Tool management functions provided by the NC channel 20-39320.12 Axis actual values and distances to go 20-394

21 Various Machine Data 21-395

21.1 Display machine data 21-39521.2 General machine data 21-39621.3 Channel - specific machine data 21-39821.4 Axis - specific machine data 21-401

notice

The VDE 0113 Part 1 is only valid for a transition period and is replaced by EN 60204.

EMERGENCY STOP in the control system

The following arrangements are provided in the control system to support the machine facturer in implementing the EMERGENCY STOP function:

manu- Initiation of the EMERGENCY STOP sequence in the NC via the PLC input.

 The EMERGENCY STOP sequence in the NC will decelerate all axes and spindles in the

EMERGENCY STOP button

A mushroom button (with one normally closed and normally open contact each), further red to as EMERGENCY STOP button, is installed in the Siemens machine control panel (MCP) for the 802D.

refer-1

1.2 EMERGENCY STOP sequence

1.2 EMERGENCY STOP sequence

Prerequisite

The actuation of the EMERGENCY STOP button or a signal directly derived from it must be carried to the control (PLC) as a PLC input In the PLC user program, this PLC input must be passed on to the NC to the IS ”EMERGENCY STOP“ (V2600 0000.1).

Resetting of the EMERGENCY STOP button or a signal directly derived from it must be ried to the control (PLC) as a PLC input In the PLC user program, this PLC input must be passed on the NC to the IS “Acknowledge EMERGENCY STOP” (V2600 0000.2).

2 The IS ”802 -READY” (V3100 0000.3) is reset.

3 The IS ”EMERGENCY STOP active” (V2700 0000.1) is set.

4 Alarm 3000 is set.

5 The servo enable is disabled after an axis/spindle -specific time that can be set in MD 36620: SERVO_DISABLE_DELAY_TIME (servo enable cutout delay) has been elapsed.

In this context, make sure that 36620: SERVO_DISABLE_DELAY_TIME must be specified

at least as large as MD 36610: AX_EMERGENCY_STOP_TIME.

Sequence on the machine

The EMERGENCY STOP sequence on the machine is exclusively defined by the machine manufacturer The following must be observed in conjunction with the sequence in the NC:

 The sequence in the NC is started using the IS ”EMERGENCY STOP“ (V2600 0000.1) After the axes and spindles have been stopped, the power supply must be interrupted acc.

to EN418.

 The sequence in the NC has no influence on the PLC I/Os (digital outputs) If you wish individual outputs to have a certain status in case of EMERGENCY STOP, the machine manufacturer must implement the appropriate functions in the PLC program.

Important

To interrupt the power supply, is the sole and only responsibility of the machine manufacturer.

If you wish the sequence in the NC in case of EMERGENCY STOP not to be carried out as defined, the IS “EMERGENCY STOP” (V2600 0000.1) may not be set until an EMERGENCY STOP status defined by the machine manufacturer in the PLC user program is reached Until the IS “EMERGENCY STOP” is not yet set and no other alarm is pending, all IS are active in the NC Thus, any manufacturer -specific EMERGENCY STOP status is possible.

EMERGENCY STOP (N2)

1.3 EMERGENCY STOP acknowlededgement

Acknowledging EMERGENCY STOP

The EMERGENCY STOP status will only be reset if first the IS “Acknowledge EMERGENCY STOP” (V2600 0000.2) and then the IS “Reset” (V3000 0000.7) is set When doing so, make sure that the IS ”Acknowledge EMERGENCY STOP” and the IS ”Reset” must be set together

at least as long as the IS “EMERGENCY STOP active” (V2700 0000.1) has been reset (see Fig 1-1).

IS ”EMERGENCY STOP”

V2600 0000.1

IS ”AcknoweledgeEMERGENCY STOP“

V2600 0000.2

IS ”EMERGENCY STOPactive“

V2700 0000.1

IS ”RESET”

V3000 0000.7The IS ”Acknowledge EMERGENCY STOP” has no effect

1

2

12The IS ”Acknowledge EMERGENCY STOP” and ”RESET” will reset ”EMERGENCY STOP active

The IS ”RESET” has no effect

3

3

Fig 1-1 Resetting EMERGENCY STOP

Resetting the EMERGENCY STOP status:

 resets the IS ”EMERGENCY STOP active”;

 connect servo enable;

 set the IS ”Position control active“;

 set the IS ”802-READY”;

The speed enable (servo enable) of the drive is canceled internally in the control system at thelatest after a set delay time if the axis / spindle is moving.

The entered delay time acts due to the following events:

 in case of errors resulting in immediate axis stop

 if the IS “Servo enable” is canceled from the PLC.

Once the actual speed reaches the zero speed range (MD 36060: STANDSTILL_VELO_ TOL),

“Servo enable” is disabled for the drive

The time should be set as large as the axis / spindle needs to come to a standstill from maximumtraversing velocity or speed

If the axis / spindle is already at a standstill, “Servo enable” is disabled for the drive immediately

can come to a standstill from maximum traversing velocity or speed For this time, the cancellation

of “Servo enable” should be delayed for an axis/spindle moving

even if the axis/spindle is still traversing In this case, it is suddenly stopped with setpoint 0.The time set in this MD should therefore be greater than the time of the braking ramp in case oferror statuses (MD 36610: AX_EMERGENCY_STOP_TIME)

MD 36610: AX_EMERGENCY_STOP_TIME (time of braking ramp in case of error statuses)

Signal state 1 or edge

 The NC is not in the EMERGENCY STOP status

 The EMERGENCY STOP status is (still) active, but can be reset using the IS ”AcknowledgeEMERGENCY STOP” and IS ”Reset”

IS ”EMERGENCY STOP active” (V2700 0000.1)

Signal state 1 or edge

change 0 - ->1

The EMERGENCY STOP status will only be reset if first the IS ”Acknowledge EMERGENCYSTOP“ and then the IS ”Reset” (V3000 0000.7) are set When doing so, make sure that the IS

“Acknowledge EMERGENCY STOP” and the IS ”Reset” must be set together at least as long

as the IS ”EMERGENCY STOP active” (V2600 0000.1) has been reset

Resetting the EMERGENCY STOP status:

 resets the IS ”EMERGENCY STOP active”;

 connects “Servo enable”;

 sets the IS ”Position control”;

 sets the IS ”802-Ready”;

 lcears alarm 3000;

 aborts the part program execution

IS ”EMERGENCY STOP active” (V2700 0000.1)

IS ”Reset” (V3000 0000.7)

Signal state 1 or edge

change 0 - ->1

The NC is in the EMERGENCY STOP status

IS ”Acknowledge EMERGENCY STOP” (V2600 0000.2)

1.6 Data fields, lists

1.6 Data fields, lists

1.6.1 Interface signals

General

Mode signal range

1.6.2 Machine data

Axis-specific

Axis Monitoring (A3)

2.1 Overview of monitoring functions

 Motion monitoring functions

- Contour monitoring

- Positioning monitoring

- Zero speed monitoring

- Clamping position monitoring

- Speed setpoint monitoring

- Actual velocity monitoring

- Encoder monitoring functions

 Monitoring of static limitations

- Limit switch monitoring

- Work area monitoring

2

2.2 Motion monitoring functions

2.2 Motion monitoring functions

2.2.1 Contour monitoring

Function

The principle of functioning of the contour monitoring is based on the permanent comparison

of measured actual position value and the actual position value calculated from the NC tion setpoint To calculate the following error in advance, a model is used which simulates the dynamic properties of the position control including feedforward control.

posi-To make sure that the monitoring system does not respond already in the case of slight speed variations (caused by load changes), a tolerance band is permitted for the maximum contour deviation.

If the permissible actual value deviation entered in MD 36400: CONTOUR_TOL (contour nitoring tolerance band) is exceeded, an alarm is output, and the axes are stopped.

mo-Activation

The contour monitoring is active for axes and a position - controlled spindle.

Effect

If the contour error is too large, the following will occur:

 Alarm 25050 ”Contour monitoring” is output.

 The axis/spindle concerned is stopped with rapid stop (with open position feedback loop) via a speed setpoint ramp.

The duration of the braking ramp is defined in the MD 36610: GENCY_STOP_TIME (duration of braking ramp in case of error statuses).

AX_EMER- If the axis/spindle interpolates with other axes/spindles, these are stopped by rapid stop with reduction of the following error (position setpoint = constant).

Remedy

 Increase tolerance band of monitoring function in MD 36400.

 The real servo gain factor must correspond to the desired servo gain factor set in

MD 32200: POSCTRL_GAIN (servo gain factor).

With an analog spindle, check

MD 32260: RATED_VELO (rated motor speed) and

MD 32250: RATED_OUTVAL (rated output voltage).

 Check optimization of speed controller.

 Check smooth running of axes.

 Check machine data for traversing movements (feedoverride, acceleration, max ties, )

veloci-Axis Monitoring (A3)

2.2.2 Positioning monitoring

Function

To make sure that an axis is positioned within a specified time, the time configured in MD 36020: POSITIONING_TIME (exact stop fine time delay) is started after a motion block has been ended (set point has reached the target), and after this time has elapsed, it is checked whether the axis has reached its set position within the tolerance of MD 36010: STOP_LI- MIT_FINE (exact stop fine).

”Exact stop coarse and fine“ see:

References: Chapter ”Continuous - Path Mode, Exact Stop and LookAhead”

MD:

STANDSTILL_POS_TOL

MD: STOP_LIMIT_COARSEMD: STOP_LIMIT_FINE

“Exact stop fine” - interface signal

“Exact stop coarse“ - interface signal

re-2.2 Motion monitoring functions

Effect

If the limit value for “Exact stop fine” has not yet been reached after the positioning ring time has elapsed, the following action is carried out:

monito- Alarm 25080 ”Positioning monitoring” is output.

 The axis/spindle concverned is stopped with rapid stop (with open position control loop) via a speed setpoint ramp.

The duration of the braking ramp is defined in MD 36610: GENCY_STOP_TIME (duration of braking ramp in case of error statuses).

AX_EMER- If the axis/spindle interpolates with other axes/spindles, these will be stopped by rapid stop with reduction of the following error (specification of partial position setpoint = 0).

Error cause/error elimination

 Too small position controller gain - -> change machine data for position control gain

MD 32200: POSCTRL_GAIN(servo gain factor)

 Positioning window (exact stop fine), positioning monitoring time and position control gain are not matched another to one - - > change machine data:

MD 36010: STOP_LIMIT_FINE (exact stop fine),

MD 36020: POSITIONING_TIME (exact stop fine delay time),

MD 32200: POSCTRL_GAIN (servo gain factor)

toleran-Axis Monitoring (A3)

2.2.3 Zero speed monitoring

Function

After a motion block has been completed (position setpoint has reached target), it is red whether the axis is no more away from its setpoint position than specified in MD 36060: STANDSTILL_POS_TOL (standstill tolerance) after the delay time that can be parameterized

monito-in MD 36040: STANDSTILL_DELAY_TIME (standstill monitormonito-ing delay time) has elapsed Otherwise, an alarm is generated.

The response of the monitoring function has the following effect:

 Alarm 25040 ”Standstill monitoring” is output.

 The axis/spindle concerned is stopped with rapid stop (with open position control loop) via

a speed setpoint ramp The duration of the braking ramp is defined in MD 36610: AX_EMERGENCY_STOP_TIME (duration of braking ramp in case of error statu- ses).

 If the axis interpolates with other axes/spindles, these will be stopped by rapid stop with reduction of the following error (specification of partial position setpoint = 0).

Error cause/error elimination

 Position control gain too large (vibrations of servo loop) - ->change machine data for troller gain MD 32200: POSCTRL_GAIN (servo gain factor)

con- Standstill window too small - -> change machine data

MD 36030: STANDSTILL_POS_TOL (standstill tolerance)

 Axis is mechanically pushed off position - -> eliminate cause

2.2.4 Clamping monitoring

Function

If you wish the axis to be clamped at the end of the positioning process, the clamping ring can be activated using the IS “Clamping monitoring running” (V380x 0002.3).

monito-2.2 Motion monitoring functions

This can be necessary because it is possible that during the clamping process the axis has been pushed off its setpoint position farther than permitted by the standstill tolerance The amount by which the setpoint position can be left is specified in MD 36050:

CLAMP_POS_TOL (clamping position tolerance at interface signal “Clamping running“) See Fig 2-1

 Alarm 26000 ”Clamping position monitoring” is output.

 The axis/spindle concerned is stopped with rapid stop (with open position control loop) via

a speed setpoint ramp The duration of the braking ramp is defined in

MD 36610: AX_EMERGENCY_STOP_TIME (duration of braking ramp in case of error statuses).

 If the axis/spindle interpolates with other axes/spindles, these will also be stopped by pid stop with reduction of the following error (specification of partial position setpoint = 0).

ra-2.2.5 Speed setpoint monitoring

Function

The speed setpoint monitoring checks whether the setpoint specification does not exceed the maximum permissible speed for the drives specified in MD 36210: CTRLOUT_LIMIT (maxi- mum speed setpoint) If necessary, it is limited to this value, and the axis/spindle is stopped and an alarm is output.

For the axes, the maximum speed setpoint (as a percentage) is above the speed at which the velocity defined in MD 3200: MAX_AX_VELO is reached (100%) This also defines the con- trol margin.

With an analog spindle, the maximum output speed cannot be greater than the speed ached at a maximum setpoint output voltage of 10V (100%).

re-The speed setpoint consists of the speed setpoint of the position controller and the ward control value (if feedforward control is active).

feedfor-Axis Monitoring (A3)

Feedforward control value

to speed controller

Speed setpointmonitoringPosition controller

Following error

Fig 2-2 Speed setpoint monitoring

Activation

The speed setpoint monitoring is always active for axes and for a spindle.

Effect

The following will occur if the maximum speed setpoint is exceeded:

 Alarm 25060 ”Speed setpoint limitation” is output.

 The axis/spindle concerned is stopped with rapid stop (with open position control loop) via

a speed setpoint ramp.

The duration of the braking ramp is defined in MD 36610: GENCY_STOP_TIME (duration of braking ramp in case of error statuses).

AX_EMER- If the axis interpolates with other axes/spindles, these will be stopped by rapid stop with reduction of the following error (specification of partial position setpoint = 0).

Note: At the access level “Expert mode” (protection level 1), a delay time can be set in

MD 36220: CTRLOUT_LIMIT_TIME, after which the alarm is generated, stopping the axes This time is zero by default.

The beginning limitation of the speed setpoint makes this servo loop non - linear Generally, this results in path deviations when an axis dwells in a speed setpoint limitation Therefore, a control margin must be set (see Section 3.3.4 “Speed setpoint output”).

Error causes

 A measuring error circuit or a drive error exists in the measuring circuit.

 Too high setpoints specified (accelerations, velocities, reduction factors)

 Obstacle in working area (e.g coming into contact with the work table)

 Tachogenerator adjustment with analog spindle has not been carried out correctly or a measuring circuit or drive error exists.

2.2 Motion monitoring functions

2.2.6 Actual velocity monitoring

is still below the imit frequency.

The actual velocity momnitoring is active for axes and for a spindle.

Effect

The following will occur if the “Threshold value for velocity monitoring” is exceeded:

 Alarm 25030 ”Actual velocity alarm limit”

 The axis/spindle concerned is stopped with rapid stop (with open position control loop) via

a speed setpoint ramp.

The duration of the brake ramp is defined in MD 36610: AX_EMERGENCY_STOP_TIME (duration of braking ramp in case of error statuses).

 If the axis/spindle interpolates with other axes/spindles, these will also be stopped by pid stop with reduction of the following error (specification of partial setpoint = 0).

ra-Notes for fault finding

 Check actual values.

 Check position control direction.

 Check MD 36200: AX_VELO_LIMIT (threshold value for velocity monitoring).

 In the case of an analog spindle, check speed setpoint cable.

Axis Monitoring (A3)

2.3 Encoder monitoring functions

2.3.1 Encoder limit frequency monitoring

Function

If the limit frequency of a measuring system, which is entered in MD 36300: MIT(encoder limit frequency), is exceeded, the position synchronization (reference point) bet- ween machine and control system will be lost A correct position control is no longer possible

ENC_FREQ_LI-in this cases This status is signaled to the PLC.

Activation

The encoder limit frequency monitoring is always active if the encoder is turned on and is active for axes and for a spindle.

Effect

The following will occur if the limit frequency of an encoder is exceeded:

 The IS “Encoder limit frequency exceeded 1” (V390x 0000.2) is set.

 Spindle continues running withspeed control

If the spindle speed is reduced such that the encoder frequency falls below the value cified in MD 36302: ENC_FREQ_LIMIT_LOW (% value of MD 36300: ENC_FREQ_LI- MIT), the spindle will automatically resynchronize with the reference system of the enco- der.

spe- If with an active measuring system of a position-controlled axis/spindle, the limit quency is exceeded, alarm 21610 ”Frequency exceeded” is output.

fre- The axis/spindle concerned is stopped with rapid stop (with open position control loop) via

a speed setpoint ramp.

The duration of the brake ramp is defined in MD 36610: AX_EMERGENCY_STOP_TIME (duration of braking ramp in case of error statuses).

 If the axis/spindle interpolates with other axes/spindles, these will also be stopped by pid stop with reduction of the following error (specification of partial setpoint = 0).

2.3 Encoder monitoring functions

2.3.2 Zero mark monitoring

Function

The zero mark monitoring checks whether pulses have been lost between two zero mark passages of the position actual - value encoder The number of detected zero mark errors at which the monitoring function is to respond is entered in MD 36310: ENC_ZERO_MONITO- RING (zero mark monitoring).

Activation

The monitoring is activated using MD 36310: ENC_ZERO_MONITORING.

The counting of the zero mark errors starts from zero after the encoder has been turned on.

 MD 36300: ENC_FREQ_LIMIT (encoder limit frequency) set too high.

 Encoder cable damaged.

 Encoder or encoder electronics defective.

Note

In case of an error, the IS “Referenced/synchronized 2” (V390x 0000.4) is canceled, i.e the axismust be rereferenced

Axis Monitoring (A3) 2.4 Monitoring of static limitations

2.4 Monitoring of static limitations

2.4.1 Limit switch monitoring

2nd SW limit switch(activated via PLC)

1st SW limit switch

traversing stopEMERGENCY STOPFig 2-3 Overview of limit stops of a linear axis

Hardware limit switches

”Hard-Activation

The hardware limit switch monitoring is active in all operating modes after the control system has powered up.

Effect

 When a hardware limit switch is overtraveled, depending on the direction, alarm 21614

”Hardware limit switch + or - ” is output.

 Depending on MD 36600: BRAKE_MODE_CHOICE (braking behavior with hardware limit switch), the axis is stopped.

 If the axis/spindle interpolates with other axes/spindles, these will also be stopped, ding on MD 36600: BRAKE_MODE_CHOICE (braking behavior with hardware limit switch).

depen- The direction keys in the direction of approach are disabled.

2.4 Monitoring of static limitations

Remedy

 Initiate Reset.

 Retract in the opposite direction (in JOG mode).

 Correct the program.

Software limit switches

ma-MD 36100: POS_LIMIT_MINUS (1st software limit switch minus)

MD 36110: POS_LIMIT_PLUS (1st software limit switch plus)

MD 36120: POS_LIMIT_MINUS2 (2nd software limit switch minus)

MD 36130: POS_LIMIT_PLUS2 (2nd software limit switch plus)

Activation

 The software limit switch monitoring is active in all operating modes after reference point approach.

 The position of the software limit switches can be approached.

 The 2nd software limit switch can be activated from the PLC via the interface signal ”2nd software limit switch plus/minus” (V380x 1000.3 or 2) The change will come into effect immediately The 1st software limit switch plus/minus is thus inactive.

 The SW limit switch monitoring is not active with endlessly rotating rotary axes, i.e if

MD 30310: ROT_IS_MODULO = 1 (modulo conversion for rotary axis and spindle)

- The program execution is canceled.

- Alarm 10720 ”Software limit switch + or - ” is output.

JOG:

- The axis is stopped at the software limit switch position.

- Alarm 10621 ”Axis has stopped on software limit switch + or - ”.

- The direction keys in the direction of approach are disabled.

Axis Monitoring (A3) 2.4 Monitoring of static limitations

Special features:

- Switching over the software limit switch:

If the current position after switching over lies after the new software limit switch, the axis is decelerated at the maximum permissible acceleration If the axis interpolates with other axes, these will also be decelerated A contour violation may result.

Remedy

 Initiate Reset.

 Retract in the opposite direction (in JOG mode).

 Correct the program.

2.4.2 Working area limitation

Function

Working area limitations describe the range in which a machining can be carried out In tion to the limit switches, the working area limitation is another means for the user to limit the traversing range of the axes.

addi-References: ”Operation and Programming“.

It is monitored whether the tool tip P is within the protected working area The value entered

in the working area limitation is the last permissible position for the axis.

Using MD 21020: WORKAREA_WITH_TOOL_RADIUS (taking into account the tool radius in the case of working area limitation), it can be determined whether the tool radius is taken into account in the monitoring.

One pair of values (minus/plus) can be specified per axis to describe the protected working area.

Specifying the working area limitation

The working area limitation can be specified and modified in two different ways:

 via the operator panel in the “Parameters” operating area using the following setting data:

SD 43430: WORKAREA_LIMIT_MINUS (working area limitation minus)

SD 43420: WORKAREA_LIMIT_PLUS (working area limitation plus) Any changes in Automatic mode are only possible in the Reset status and will then come into effect immediately.

In Jog mode, changes are always possible, but come only into effect when a new ment starts.

move- in the program with G25/G26 Any changes come into effect immediately.

A programmed limitation has first priority; it will overwrite the value entered in the setting data and is kept after RESET and program end.

2.4 Monitoring of static limitations

 Using SD 43410: WORKAREA_MINUS_ENABLE, SD 43400:

WORKA-REA_PLUS_ENABLE (working area limitation in the negative or positive direction active),

it is possible to activate the working area limitation; it comes into effect after reference point approach.

 During the program execution, the working area limitation can be activated using the dal G codes ”WALIMON” and deactivated using ”WALIMOF”.

mo- The working area limitation is not active with endlessly rotating rotary axes, i.e if MD 30310: ROT_IS_MODULO = 1 (modulo conversion for rotary axis and spindle).

- The program execution is aborted.

- Alarm 10730 ”Working area limitation + or - ” is set.

JOG:

- The axis stops at the position of the working area limitation.

- Alarm 10631 ”Axis stopped at working area limitation + or - ” is set.

- The direction keys in the direction of approach are disabled.

Axis Monitoring (A3)

Remedy

 Initiate Reset.

 Check the working area limitation in the part program (G25/G26) or in the setting data.

 Move away in the opposite direction (in JOG mode).

2.5 Boundary conditions

To make sure that the monitoring functions respond correctly, make especially sure that the machine data are correct:

 MD 31030: LEADSCREW_PITCH (leadscrew pitch)

 Gear transmission ratio (load gear):

MD 31050: DRIVE_AX_RATIO_DENOM(load gear denominator)

MD 31060: DRIVE_AX_RATIO_NUMERA(load gear numerator) Gear transmission ratio (encoder), also for spindle if any:

MD 31070: DRIVE_ENC_RATIO_DENOM (resolver gearbox denominator)

MD 31080: DRIVE_ENC_RATIO_NUMERA (resolver gearbox denominator)

 MD 32810: EQUIV_SPEEDCTRL_TIME

(speed control loop equivalent time constant for feedforward control)

 Ratio output voltage / output speed

(only applicable to analog spindle):

MD 32260: RATED_VELO (rated motor speed)

MD 32250: RATED_OUTVAL (rated output voltage)

 Encoder resolution

The corresponding machine data are described in

References: Chapter ”Velocities, Setpoint/Actual - Value Systems, Closed - Loop Control”

2.6 Data descriptions (MD, SD)

2.6 Data descriptions (MD, SD)

2.6.1 Channel - specific machine data

1: The tool radius is taken into account in the working area limitation.

2.6.2 Axis/spindle - specific machine data

setpoint position by the value of the entered exact stop limit If the actual position of a path axis

is not within this limit, the NC block is not considered completed and the part program cannot becontinued The time when the next block is processed depends on the size of the value entered.The larger the value is, the earlier is the block change initiated If the specified exact stop limit isnot reached,

MD 36020: POSITIONING_TIME (exact stop fine monitoring time) has elapsed;

window is also evaluated for spindles in the position - controlled mode

same block change behavior as with the exact stop fine criterion, the exact stop coarse windowmay be identical to the exact stop fine window

This MD may not be equal to or greater than MD 36030: STANDSTILL_POS_TOL (standstillposition tolerance)

This MD may not be equal to or greater than MD 36030: STANDSTILL_POS_TOL (standstillposition tolerance)

Axis Monitoring (A3)

value for exact stop fine after the time for approaching the position has elapsed (partial positionset value=0 at the end of the movement) If this is not the case, the alarm 25080 ”Positioningmonitoring” is set and the axis concerned is decelerated

The MD should be selected so generously that the monitoring does not respond in normal mode,since the entire traversing process (acceleration, constant traversing, braking) is monitored byother functions continuously

whe-ther the axis is no farwhe-ther away from its set position than specified in

MD 36060: STANDSTILL_POS_TOL (standstill tolerance) after the parameterizable delay timedefined in MD 36040 STANDSTILL_DELAY_TIME (standstill monitoring delay time) has elapsed

If the standstill position tolerance exceeds or falls below the set position, alarm 25040 ”Standstillmonitoring” is output and the axis is stopped

the monitored axis is pushed off the set position (exact stop limit) more than specified in theclamping tolerance, alarm 26000 ”Clamping monitoring” is generated and the axis stopped