How it Works
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TF5200
Users manual
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Beckhoff TF5200 Users manual

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Functional description
TF5200 | TC3 CNC
Real time status information of CNC
Version Date
1.0
29.01.2020

Notes on the documentation

Notes on the documentation
This description is only intended for the use of trained specialists in control and automation engineering who are familiar with the applicable national standards. It is essential that the documentation and the following notes and explanations are followed when installing and commissioning the components. It is the duty of the technical personnel to use the documentation published at the respective time of each installation and commissioning.
The responsible staff must ensure that the application or use of the products described satisfy all the requirements for safety, including all the relevant laws, regulations, guidelines and standards.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under development. We reserve the right to revise and change the documentation at any time and without prior announcement. No claims for the modification of products that have already been supplied may be made on the basis of the data, diagrams and descriptions in this documentation.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, EtherCAT G®, EtherCAT G10®, EtherCAT P®, Safety over EtherCAT®, TwinSAFE®, XFC®, XTS® and XPlanar® are registered trademarks of and licensed by Beckhoff Automation GmbH. Other designations used in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owners.
Patent Pending
The EtherCAT technology is patent protected, in particular by the following applications and patents: EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702 with corresponding applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany. The reproduction, distribution and utilisation of this document as well as the communication of its contents to others without express authorisation are prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.

General and safety instructions

General and safety instructions
Icons used and their meanings
This documentation uses the following icons next to the safety instruction and the associated text. Please read the (safety) instructions carefully and comply with them at all times.
Icons in explanatory text
Ø Indicates an action.
ð Indicates an action statement.
DANGER
Acute danger to life!
If you fail to comply with the safety instruction next to this icon, there is immediate danger to human life and health.
CAUTION
Personal injury and damage to machines!
If you fail to comply with the safety instruction next to this icon, it may result in personal injury or damage to machines.
NOTICE
Restriction or error
This icon describes restrictions or warns of errors.
Tips and other notes
This icon indicates information to assist in general understanding or to provide additional informa­tion.
General example
Example that clarifies the text.
NC programming example
Programming example (complete NC program or program sequence) of the described function or NC com­mand.
Specific version information
Optional or restricted function. The availability of this function depends on the configuration and the scope of the version.
TF5200 | TC3 CNC4 Version 1.0

Table of contents

Table of contents
Notes on the documentation .......................................................................................................................3
General and safety instructions..................................................................................................................4
1 Overview........................................................................................................................................................8
2 Status information........................................................................................................................................9
3 Description....................................................................................................................................................10
3.1 D_CoveredDistance .............................................................................................................................10
3.2 D_CommandFeed, D_ActiveFeed........................................................................................................10
3.3 D_StopConditions.................................................................................................................................11
3.4 X_ProgramEnd .....................................................................................................................................11
3.5 X_WaitErrorRemoval............................................................................................................................12
3.6 X_InterpolationActive, X_DwellTimeActive...........................................................................................12
3.7 HLIBahnCoordDispData_Coord ...........................................................................................................12
3.8 HLISAddProgInfo_Data ........................................................................................................................12
3.9 Extended status information .................................................................................................................13
3.9.1 X_SpeedLimitDetect, Look Ahead für Geschwindigkeitsgrenzwert...................................... 13
3.9.2 Description............................................................................................................................ 14
4 Example.........................................................................................................................................................19
5 Parameter ......................................................................................................................................................20
5.1 Overview...............................................................................................................................................20
5.2 Description............................................................................................................................................20
6 Support and Service.....................................................................................................................................22
Index ..............................................................................................................................................................23
Table of contents
TF5200 | TC3 CNC6 Version 1.0

List of figures

List of figures
Fig. 1 Path shape block position over time of D_CoveredDistance....................................................... 10
Fig. 2 Path velocity at D_ActiveFeed..................................................................................................... 10
Fig. 3 F Word and status signal “speed limit detected”.......................................................................... 14
Fig. 4 Timing diagram without override weighting (f_override_weight_v_limit = 0) ............................... 15
Fig. 5 Timing diagram with override weighting (f_override_weight_v_limit = 1) .................................... 15
Fig. 6 Missing PLC acknowledgement and "speed limit detected" status signal ................................... 16
Fig. 7 A restart after PLC acknowledgement resets the “speed limit detect” status signal.................... 17
Fig. 8 Inadequate block supply results in the activation of the "speed limit detected" signal. ............... 18
Fig. 9 F word and “speed limit detected” status signal .......................................................................... 19
Overview

1 Overview

Task
The CNC provides the user with 2 types of status information:
1. Status information and status signals of an informative nature provided to the user by means of dis­play data or by the HMI or the PLC.
2. Status information on improved techniques to master machining technologies.
Characteristics
Real-time status signals consist of information from the real-time area of the CNC. The status information provided by the path interpolator is described below.
This mainly consists of information regarding CNC operation modes such as:
• active manual mode,
• active path interpolation,
• program status and
• state information regarding CNC-internal sequences.
This information is useful for diagnosis purposes. The PLC can control or influence the internal status process by the logical linking of status signals.
The CNC also provides status information to improve mastery of specific machining technologies with the support of the PLC.
The information signals described are located in the HLI interface.
Programming
Status information on the HLI with the structure StateBahn is created and is invokable in the PLC programming language Structured Text on the path pMC[ChannelIdx]^.addr^.StateBahn_Data…
Links to other documents
For the sake of clarity, links to other documents and parameters are abbreviated, e.g. [PROG] for the Programming Manual or P-AXIS-00001 for an axis parameter.
For technical reasons, these links only function in the Online Help (HMTL5, CHM) but not in pdf files since pdfs do not support cross-linking.
TF5200 | TC3 CNC8 Version 1.0
Status information

2 Status information

This documentation only lists the most important status information that is valid at interpolator level.
A complete description of all available access or influencing options can be found in the documentation [HLI, section "Status information of a channel"].
The information listed below is saved on the HLI in the structure StateBahn and can be invoked in the PLC programming language structured text on the path.
pMC[ChannelIdx]^.addr^.StateBahn_Data…
..............
Status information Meaning
D_CoveredDistance Current block position or path distance
D_CommandFeed Programmed feedrate (F word)
D_ActiveFeed Current path feedrate
D_StopConditions Current stop condition (bit-encoded)
X_ProgramEnd Program end reached (M30)
X_WaitErrorRemoval Wait for error acknowledgement by user
X_InterpolationActive Interpolation is active
X_AxesInPosition Axis group is in position
X_WaitAxesInPosition Wait until axes are in position
X_WaitTechnoAcknowledge Wait for acknowledgement from PLC
X_WaitContinue Wait for user continuation request
X_DwellTimeActive Wait due to dwell time
X_BlockSearchActive Interpolator block search active
X_SpeedLimitDetect Speed limit undershot
HLIBahnCoordDispData_Coord CNC coordinates and coordinate system
HLISAddProgInfo_Data Additional program information
Description
t
0
s d (t1 )
Covered distance sd(t)
t1
1000
500

3 Description

3.1 D_CoveredDistance

Data type HLI_SGN32 ST path pMC[ChannelIdx]^.addr^.StateBahn_Data.D_CoveredDistance
This variable contains the current block position referred to the path distance in space in the motion block in per mil sd(t). The path distance in space results from the path components of the main axes and the path component of a single axis. Within a motion block, the value sd(t) always varies within the range of 0 < D_CoveredDistance < 1000.
Fig.1: Path shape block position over time of D_CoveredDistance

3.2 D_CommandFeed, D_ActiveFeed

Data type HLI_SGN32 ST-Path pMC[ChannelIdx]^.addr^.StateBahn_Data.D_CommandFeed
The D_CommandFeed variable contains the path velocity programmed via the F word. D_ActiveFeed is the current command path feedrate in the block.
Fig.2: Path velocity at D_ActiveFeed
pMC[ChannelIdx]^.addr^.StateBahn_Data.D_ActiveFeed
TF5200 | TC3 CNC10 Version 1.0
Description

3.3 D_StopConditions

Data type HLI_UNS32 ST-Path pMC[ChannelIdx]^.addr^.StateBahn_Data.D_StopConditions
In bit-encoded form, this contains the stop conditions which cause a motion stop or a program execution stop in the interpolator as a result of NC programming or a PLC command.
The table below shows the constants which are defined for these stop conditions in the PLC:
Stop condition Constant in PLC Status bit
Feedhold SC_BIT_FEEDHOLD 0x0000 0001
No axis-specific feed enable SC_BIT_VFG 0x0000 0002
Single step mode active SC_BIT_SINGLE_BLOCK 0x0000 0004
Wait due to M00, M01 SC_BIT_M00_OR_M01 0x0000 0010
Wait for PLC acknowledgement SC_BIT_PLC_ACKNOWLEDGE 0x0000 0020
Override = 0 SC_BIT_OVERRIDE_ZERO 0x0000 0040
Dwell time SC_BIT_DELAY_TIME 0x0000 0200
Channel synchronisation active SC_BIT_CHANNEL_SYNC 0x0000 0800
IPO input FIFO empty SC_BIT_IPO_INPUT_EMPTY 0x0000 1000
Read-in enable SC_BIT_IPO_INPUT_DISABLED 0x0000 2000
Wait for axes in case of axis exchange SC_BIT_WAIT_FOR_AXES 0x0000 8000
Channel in error state SC_BIT_CHANNEL_ERROR 0x0001 0000
Waiting for acknowledgement of M/H/ST technology functions
Wait to continue motion after a collision is detected
Block supply problem (HSC slope only) SC_BIT_SLOPE_SUPPLY_PROBLEM 0x0008 0000
Back-interpolation after tracking mode active
SC_BIT_STOP_WAIT_TECHNO_ACKN 0x0002 0000
SC_BIT_WAIT_CONT_AFTER_COLLISION 0x0004 0000
SC_BIT_BACK_INTERPOLATION 0x0010 0000

3.4 X_ProgramEnd

Data type HLI_BOOLEAN ST-Path pMC[ChannelIdx]^.addr^.StateBahn_Data.X_ProgramEnd
This status information indicates that the program end is reached or that no NC program is currently executed.
Description

3.5 X_WaitErrorRemoval

Data type HLI_BOOLEAN ST-Path pMC[ChannelIdx]^.addr^.StateBahn_Data.X_WaitErrorRemoval
This status is indicated in the event of a CNC error in the real-time area that can be removed by means of an NC reset (depending on the error reaction class).

3.6 X_InterpolationActive, X_DwellTimeActive

Data type HLI_BOOLEAN ST-Path pMC[ChannelIdx]^.addr^.StateBahn_Data.X_InterpolationActive
pMC[ChannelIdx]^.addr^.StateBahn_Data.X_DwellTimeActive
Block is in the process of being interpolated
The X_InterpolationActive status is indicated if a part program with path motions is in execution and if a path block is being currently interpolated in the real-time part.
N20 G01 X10 Y20 Z30 F2000 #Block is in the process of being interpolated
Block currently executed with dwell time
The X_DwellTimeActive status is indicated if a part program with dwell time is in execution and a block with a dwell time is currently being executed in the real-time part.
N20 G04 10 #Block currently executed with dwell time

3.7 HLIBahnCoordDispData_Coord

Data type HLIBahnCoordDispData ST-Path pMC[ChannelIdx]^.addr^.StateBahn_Data.HLIBahnCoordDispData_Coord[Ch
AxIdx]…
This consists of the coordinates of various coordinate systems that the CNC can provide to the outside world.

3.8 HLISAddProgInfo_Data

Data type HLISAddProgInfo ST-Path pMC[ChannelIdx]^.addr^.StateBahn_Data.HLISAddProgInfo_Data….
This consists of additional information that can be retrieved in relation to the NC program.
TF5200 | TC3 CNC12 Version 1.0
Description

3.9 Extended status information

3.9.1 X_SpeedLimitDetect, Look Ahead für Geschwindigkeitsgrenzwert

Data type HLISAddProgInfo ST-Path pMC[ChannelIdx]^.addr^.StateBahn_Data.X_SpeedLimitDetect
General
This function generates a CNC status signal depending on the motion blocks and the current path velocity. It is mainly used for plasma cutting technology to deactivate distance control of the cutting head via the PLC if the speed drops below a certain limit. This occurs, for example
• when decelerating ahead of and
• accelerating after a corner.
Therefore, the critical positions in the motion segment (corner) are defined by a speed limit.
"Speed limit detect” status flag
The “speed limit detect” status flag to the PLC is set if the current path velocity is below the specified limit. The drop in path velocity results from:
• Reduction in velocity at block transition due to a kink in the path contour.
• Reduction of velocity due to override setting.
• Expected M function acknowledgement from PLC at block transition.
• Look-ahead reduces velocity because of inadequate block supply.
Zone
In addition the signal can be set in advance or cleared with a delay at a specified distance (time/distance).
• Advance: The expected velocity at block end undershoots the speed limit, for example due to a geometrical corner. The status flag is set in advance at the specified distance to the expected limit undershoot.
• Delay: The expected velocity at block start already undershoots the speed limit. The status flag is again cleared with a delay at the specified distance to the actual speed overshoot.
Clear
I.e. the status flag is reset when both of the following conditions are met:
• The current path velocity rises above the speed limit.
• The path position is outside the specified time and distance delay.
Description
t
t
Statussignal "speed limit detected"
path velocity
N20 F5000 N30 F10000
velocity limit
block transition
distance to "corner"
end velocity of block
N40 F10000
block transition
distance from "corner"

3.9.2 Description

Activation
When the function is activated, a CNC status signal is generated according to the control flag P­CHAN-00017 and signals a speed limit undershoot or the detection of a future speed limit undershoot.
Limit value
The speed limit is defined via the percentage weighting (P-CHAN-00089) of the F word in the NC program.
Advance, delay
The expected drop in velocity at block end can be signalled in advance by the parameter P-CHAN-00013. Accordingly, the signal can also be cleared with a delay by the parameter P-CHAN-00012. The parameters P-CHAN-00012 / P-CHAN-00013 can therefore define a type of hysteresis.
Distance, time
The parameter P-CHAN-00018 defines the zone parameter unit as either a distance or time.
The CNC generates the “speed limit detect” status signal if the path position is inside this zone.
Fig.3: F Word and status signal “speed limit detected”
TF5200 | TC3 CNC14 Version 1.0
Description
t
t
State signal "speed limit detected"
Path velocity
N20 F5000
N30 F10000
Speed limit value
Block transition
Block end velocity
50% override
N40 F10000
Block transition
t
t
State signal "speed limit detected"
Path velocity
N20 F5000
N30 F10000
Speed limit value
Block transition
Block end velocity
50% override
N40 F10000
Block transition
Influence of override
The parameter P-CHAN-00155 controls the influence of the speed limit by means of the real-time feed override.
In the default setting (P-CHAN-00155 = 0) the real-time feed override does not influence the speed limit P-CHAN-00089. The “speed limit detect” status signal is also set if the path feedrate weighted by the override drops below the speed limit P-CHAN-00089.
Since override is a user-initiated online influence of speed, the delay/advance of the status signal cannot be evaluated in this case.
Fig.4: Timing diagram without override weighting (f_override_weight_v_limit = 0)
When P-CHAN-00155 is set, the parameterised speed limit P-CHAN-00089 is weighted by the override value. This is desirable e.g. for path start-up or run-in.
Note that, with a non-constant programmed feed, the "speed limit detect" signal is activated in each acceleration phase because the speed limit at the start of the block is set to the new value.
Fig.5: Timing diagram with override weighting (f_override_weight_v_limit = 1)
Description
block limit
t
t
Statussignal "speed limit detected"
path velocity
N10 F10000
velocity limit
distance from "corner"
distance to "corner"
deceleration
PLC acknowledge
N20 F10000
Influence of technology functions
The “speed limit detect” status signal is set if the CNC has to stop and wait due to certain types of technology functions or missing PLC synchronisation. In this case, the signal advance or delay related to the set time or distance is also evaluated.
Waiting for PLC acknowledgement
Fig.6: Missing PLC acknowledgement and "speed limit detected" status signal
With M functions of the MVS_SNS type, later synchronisation or M functions with look-ahead are only stopped if the PLC acknowledgement is missing. If the PLC acknowledgement arrives before the motion, a restart can be executed immediately.
However, the advance signal (advance, distance to “corner”) can still be executed correctly although an actual speed undershoot no longer arrives.
TF5200 | TC3 CNC16 Version 1.0
PLC acknowledgement during deceleration
block transition
t
t
Statussignal "speed limit detected"
path velocity
N20 F10000
velocity limit
deceleration
PLC acknowledge
N10 F10000
distance to "corner"
expected
undercut
Description
Fig.7: A restart after PLC acknowledgement resets the “speed limit detect” status signal.
Interruption of block supply
If the path velocity fluctuates due to short blocks and inadequate block supply, this may cause activation of the “speed limit detect” status signal. In the example below the advance/delay parameters (distance to corner and distance from corner) are disabled for the sake of simplification.
Each M or H function of the MVS_SVS or MNS_SNS type always results in a motion stop (see also [FCT-C1]).
Description
t
t
Statussignal "speed limit detected"
path velocity
block transition
N10 F10000 N20 N30
N40
Fig.8: Inadequate block supply results in the activation of the "speed limit detected" signal.
TF5200 | TC3 CNC18 Version 1.0
Example
t
t
Status signal "speed limit detected"
path velocity
N40 X200
velocity limit: 75% von F5000
distance to "corner"
block end velocity
N50 X250 Y-25
distance from "corner"
1 mm 1 mm
block limit

4 Example

The “speed limit detect” status signal is generated depending on the set parameters if the programmed paths cause deceleration along the path and the speed drops below the speed limit, e.g. due to a corner.
Parameter
Excerpt from the channel parameter list [CHAN]:
# Speed limit look ahead parameterisation # ====================================== speed_limit_look_ahead.f_enable1 speed_limit_look_ahead.v_limit750 speed_limit_look_ahead.f_time0 speed_limit_look_ahead.dist_to_corner10000 speed_limit_look_ahead.dist_from_corner10000 speed_limit_look_ahead.f_override_weight_v_limit 0
Parameters can also be changed in the NC program by appropriate variables (V.G.SPEED_LIMIT.*) [PROG].
"Speed limit detect” status signal
Speed drop at end of NC block
%main X0 Y0 N10 G01 X50 F5000 N20 X100 N30 X150 N40 X200 (speed drop at end of NC block) N50 X250 Y-25 N60 X300 Y-50 M30
The parameters listed above and the F word in the NC program result in:
Speed limit = 75% of the programmed velocity
→ v_limit = 3750mm/min (62500um/s)
In the NC program example the path velocity drops to 8.562um/s at block transition N40 -> N50 due to a path kink angle of 30 degrees. This means that the “speed limit detect” status signal is set 1 mm before limit speed undershoot at the block end of N40 and reset 1 mm after limit speed overshoot at the block start of N50.
Fig.9: F word and “speed limit detected” status signal
Parameter

5 Parameter

5.1 Overview

ID Parameter Description
P-CHAN-00012 dist_from_corner Distance to corner
P-CHAN-00013 dist_to_corner Distance from corner
P-CHAN-00017 enable Enabling/disabling the function
P-CHAN-00018 time Control flag (distance or time) for P-CHAN-00012/13
P-CHAN-00089 limit Weighting of the velocity limit
P-CHAN-00155 override_weight_v_limit Weighting of the velocity limit value by override

5.2 Description

P-CHAN-00012 Distance from corner for speed limit look ahead
Description The logical signal SLD 1 ->0 is generated depending on the parameters ‘distance
from corner’ or ‘time from corner’. Here, corner means the position in the block at which the speed rises again above the speed limit.
Parameter speed_limit_look_ahead.dist_from_corner
Data type UNS32
Data range 0 ... MAX(UNS32)
Dimension 0.1µm or µs
Default value 0
Remarks
P-CHAN-00013 Distance to corner for speed limit look ahead
Description The logical signal SLD 0 ->1 is generated in advance depending on the parameters
‘distance to corner’ or ‘time to corner’. Here, corner means the position in the block at which the speed drops below the speed limit.
Parameter speed_limit_look_ahead.dist_to_corner
Data type UNS32
Data range 0 ... MAX(UNS32)
Dimension 0.1µm or µs
Default value 0
Remarks
P-CHAN-00017 Enable / disable speed limit look ahead
Description Parameter to enable or disable the speed limit look ahead function.
Parameter speed_limit_look_ahead.enable
Data type BOOLEAN
Data range 0: Speed limit look ahead is disabled.
1: Speed limit look ahead is enabled.
Dimension ----
Default value 0
Remarks speed_limit_look_ahead.f_enable (old syntax up to V2.11.2022.13)
TF5200 | TC3 CNC20 Version 1.0
Parameter
P-CHAN-00018 Unit to interpret the SLD signal for speed limit look ahead
Description The logical signal SLD is generated depending on the parameter values for distance
or time.
Parameter speed_limit_look_ahead.time
Data type BOOLEAN
Data range 0: The parameter values P-CHAN-00012 and P-CHAN-00013 are interpreted as
path.
1: The parameter values P-CHAN-00012 and P-CHAN-00013 are interpreted as time.
Dimension ----
Default value 0
Remarks speed_limit_look_ahead.f_time (old syntax up to V2.11.2022.13)
P-CHAN-00089 Weighting of speed limit for speed limit look ahead
Description Speed limit value in 0.1 percent of programmed speed. If current speed falls below
the limit
v = v
*v_limit/1000,
prog
the logical signal SLD 0 ->1 is generated.
Parameter speed_limit_look_ahead.v_limit
Data type UNS32
Data range 0 ... MAX(UNS32)
Dimension 0.1%
Default value 0
Remarks
P-CHAN-00155 Weighting the speed limit via override for speed limit look ahead function
Description This parameter controls the influence of the speed limit via the real-time feed
override. In the default setting, the real-time feed override does not influence the speed limit P-CHAN-00089 (v_limit). However, if this is desirable e.g. to commission or engage contours, the parameter is set to 1. Then the parametrised speed limit value is weighted by the override value. Note that at a non-constant programmed feed, the SLD signal is activated in each acceleration phase because the speed limit at the start of the block is set to the new value.
Parameter speed_limit_look_ahead.override_weight_v_limit
Data type BOOLEAN
Data range 0: No weighting of P-CHAN-00089 (default).
1: Weighting of P-CHAN-00089 via override.
Dimension ----
Default value 0
Remarks f_override_weight_v_limit (old syntax up to V2.11.2022.13)
Support and Service

6 Support and Service

Beckhoff and their partners around the world offer comprehensive support and service, making available fast and competent assistance with all questions related to Beckhoff products and system solutions.
Beckhoff Support
Support offers you comprehensive technical assistance, helping you not only with the application of individual Beckhoff products, but also with other, wide-ranging services:
• Support
• design, programming and commissioning of complex automation systems
• and extensive training program for Beckhoff system components
Hotline: +49(0)5246/963-157 Fax: +49(0)5246/963-9157 E-mail: support@beckhoff.com
Beckhoff Service
The Beckhoff Service Center supports you in all matters of after-sales service:
• on-site service
• repair service
• spare parts service
• hotline service
Hotline: +49(0)5246/963-460 Fax: +49(0)5246/963-479 E-mail: service@beckhoff.com
Further Support and Service addresses can be found on our website at http://www.beckhoff.de.
Beckhoff headquarters
Beckhoff Automation GmbH & Co. KG
Hülshorstweg 20 33415 Verl Germany
Phone: +49(0)5246/963-0 Fax: +49(0)5246/963-198 E-mail: info@beckhoff.com
The addresses of Beckhoff’s branch offices and representatives round the world can be found on the internet pages:
http://www.beckhoff.de
You will also find further documentation for Beckhoff components there.
TF5200 | TC3 CNC22 Version 1.0

Index

P
P-CHAN-00012 20 P-CHAN-00013 20 P-CHAN-00017 20 P-CHAN-00018 21 P-CHAN-00089 21 P-CHAN-00155 21
Index
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