bosch CC 220 User Manual

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Typ1 osa / CC 220

Diagnosis Operation, Application

Version

101

Typ1 osa / CC 220

Diagnosis Operation, Application

1070 073 306-101 (91.10) GB (V25)

E 1991

by Robert Bosch GmbH,

Reproduction or handing over to third parties are subject to our written permission.

Discretionary charge 10.– DM

Flexible Automation

Contents

1. General 1 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Safety instructions − 1 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Calling the diagnostic programs 1 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Description of the diagnostic programs

D1 Logbook − D1 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D5 Internal reference point offset D5 – 1. . . . . . . . . . . . . . . . . . . . . . .

D6 Interface data D6 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D7 Communication store display D7 – 1. . . . . . . . . . . . . . . . . . . . . . .

D9 EEPROM management − D9 – 1. . . . . . . . . . . . . . . . . . . . . . . . .

D21 Logic analyzer − D21 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D22 Axis oscilloscope − D22 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D23 Contour display − D23 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D24 Axis optimization D24 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D25 Lead screw error compensation − D25 – 1. . . . . . . . . . . . . . . . .

D26 CNC remote diagnosis (information) D26 – 1. . . . . . . . . . . . . . . .

D27 Putting into operation for circular compensation ‘ D27 – 1. . .

D28 Tapping ‘ D28 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CC 220 / 320

Diagnosis

Notes: Diagnostic programs which are not available in the CC 200/300 are identified by

an ‘ in front of the page number. If a diagnostic program contains new or modified functions – compared with the controls of the Type CC 200/300 –, this is indicated by a − in front of the page num- ber.

The following diagnostic programs are intended exclusively for BOSCH service personnel and are not described in this manual: D2 Reloading the operating program D3 Cancelling all memory

Separate manuals are available for the diagnostic programs D4 and D26: D4 Machine parameter program CC 220 M/T: P. No.: 4201

CC 320 M: P. No.: 4180

D26 CNC remote diagnosis P. No.: 4184 The diagnostic programs

D8 Change language D10 Library management implemented in the CC 220/320 are no longer present as special diagnostic programs in controls of the type CC 220/320, but can now be called directly by way of softkey. Please refer to the appropriate operating manual for operating instructions.

C – 1

Flexible Automation

Contents

CC 220 / 320

Diagnosis

C – 2

Flexible Automation

1. General

This manual refers to the software version V25 for the controls CC 220/320. The diagnostic programs D21 to D28 are options which are subject to charge.

2. Safety instructions

Diagnostic programs permit critical changes to be made in the interaction of CNC, machine and drives right up to complete deletion of the CNC memory. If they are used by insufficiently trained or untrained personnel, this may thus result in serious damage to the machine and drives, loss of software or even injury!

For this reason, diagnostic programs must be started and operated only by correspondingly trained expert personnel.

In this context, please note our extensive range of training courses. You will find an overview of the available seminars on the inner cover of this manual. Our training center will gladly provide you with further information.

General

CC 220 / 320

Diagnosis

MOVE

In some diagnostic programs, axes have to be traversed in order to optimize CNC servo loops and drives.

For this reason, make sure that no one enters the machine’s danger area during execution of such diagnostic programs.

The following symbols are used in this manual in order to point out certain things which are relevant to safety:

Axis movement possible! For this reason, make sure that there are no persons or objects in the machine’s danger area. Make sure that no collisions are possible in the axis traversing range.

Machine parameter record is modified! This is followed by a CNC restart. The modified machine parameters are active after this. Is there a backup of the original machine parameters? BOSCH will not be liable for damaging resulting from incorrectly calculated, programmed or optimized machine parameters or non–observance of limit data!

Active axis processor data is modified! This effects the axis response.

SERVO

Data loss possible! Data in the user RAM (part programs, tables etc.) may possibly be deleted or over-

DATA

written. Do you possess a backup of this data?

3. Calling the diagnostic programs

1 – 1

Flexible Automation

General

The following monitor display appears after selection of group operating mode

(DIAGNOSTIC):

Diagnosis

CC 220 / 320

No CP0

ERROR CONDITION ON STATUS

AT LAST PROGR.

F 0.0 M 0T 0

DIAGNOSTIC

CONTROL

ACT

DIAGNOSTIC

MACHINE

NC0 STOP

153

146

994

FUNCTION

G G G G G G

130

253 G G G

115

RESET

66 40

62 68

DIAGNOSTIC

12. 5 16:53PROGRAM

140 G G

167

DRIVE ON

SERVICE

FUNCTION

The control displays all available diagnostic programs after operation of the softkey SERVICE FUNCTION (possibly only after input of a code number; refer to the section ”Notes”):

No CP0

NUMBER PROGRAM NAME LENGTH

D D D D D D D D D D D D D D

MEMORY USED BY DIAG.: MEMORY A V AILABLE:

SERVICE FUNCTION

21 22 23 24 25 27

1 2 3 4 5 6 7 9

ACT

LOGBOOK MONITOR RELOAD OPERATING PROGRAM CANCEL ALL MEMORY MACHINE PARAMETER PROGRAM INTERNAL REF. POINT OFFSET INTERFACE DATA COMMUNICATION STORE DISPLAY MANAGE EEPROM LOGIC–ANALYZER AXIS OSCILLOSCOPE CONTOUR DISPLAY AXIS OPTIMIZATION LEAD SCREW ERROR COMPENSATION PUTTING INTO OPERATION FOR CIRCULAR COMPENSATION

DATA IN DATA OUT START DELETE

NC0 WAIT

DIAGNOSTIC

14.10 8:28PROGRAM ACCESS

E E E E E E E E E E E E E E

44384 OTHERS: 2658

2574398

The system asks for the number of the desired program when the softkey START is pressed. Input of the program number is acknowledged with the ENTER key. The CNC then starts the corresponding diagnostic program.

1 – 2

Flexible Automation

General

Notes:

‘ If the softkey RESET FUNCTION and then softkey CLEAR ALL LOGIC are

pressed in group operating mode DIAGNOSTIC, it is possible to enter the softkey level SERVICE FUNCTION only by input of a code number as from this point in time. When a correct code number has been entered, the softkey level SERVICE FUNCTION is accessible without input of the code number until renewed operation of the softkey sequence DIAGNOSTIC, RESET FUNCTION, CLEAR ALL LOGIC.

‘ Some diagnostic programs create files with the group identifier ”L” or ”D” for

recording data. This reduces the memory space which is available for part programs.

‘ Data recordings can be repeated any number of times within diagnostic pro-

grams, since the previous recording is overwritten by each new recording. All other operating modes of the control can be used during recording of data by a diagnostic program. Exception: CONTROL RESET and selection of a different diagnostic program cancel the currently active diagnostic program (except for D21).

Diagnosis

CC 220 / 320

1 – 3

Flexible Automation

General

CC 220 / 320

Diagnosis

1 – 4

Flexible Automation

D1 Logbook

4. Description of the diagnostic programs D1 – Logbook

General

The diagnostic program D1 is used for management of one or more ”logbooks”. A logbook is a file with the identifier ”D” which contains various data for reconstruction of operating sequences, error messages or warnings etc. This file is divided into 5 ring memories which store warnings, errors, system errors, other messages and operating steps in the order of their occurrence.

Activating/deactivating a logbook

There are two possibilities for activation of a logbook:

CC 220 / 320

Diagnosis

‘ Input of a logbook file number in machine parameter P 9914. Then ACTI-

V ATE the machine parameters. The logbook is automatically initialized with the specified file number after control start–up and is active as from this point in time. The ring memories are created with the following sizes: R1 to R4:

512 bytes, R5: 0 byte. ‘ Operation of softkey INIT in diagnostic program D1. An already active logbook can be deactivated in diagnostic program D1 by pressing

softkey INIT, input of ”0” and acknowledgement with the ENTER key or by selection of a different logbook (also refer to softkey LOGBOOK SELECTION). A logbook cannot be activated again once it has been deactivated. Only deactivated logbooks can be deleted.

User interface/softkey assignments

The following display appears if no logbook is yet active when D1 is selected:

No CP0

ACT

LOGBOOK NOT INITIALIZED!

NC0 STOP

DIAGNOSTIC

12. 5 16:59

12. 5 16:59PROGRAM

DISPLAY

RING STORE

D1 – 5

INIT

LOGBOOK

SELECTION

LOGBOOK

PUNCHOUT

Flexible Automation

D1 Logbook

CC 220 / 320

The following monitor display is shown if a logbook is already active:

Diagnosis

No CP0 PROGRAM

LOGBOOK D 11000 ACTIVE

RING STORE FOR WARNING RING STORE 2 FOR ERRORS RING STORE 3 FOR SYSTEM ERRORS RING STORE 4 FOR OTHER MESSAGES RING STORE 5 FOR OPERATING STEPS

TEST POINT 1 ADDRESS 0000064 TEST POINT 2 ADDRESS 00000000

TOTAL LOGBOOK SIZE: 605 BYTES

DISPLAY

RING STORE

INIT

ACT

NC0 STOP

INIT

DIAGNOSTIC

12. 5 16:59

SIZE = 100 BYTES SIZE = 100 BYTES SIZE = 100 BYTES SIZE = 100 BYTES SIZE = 100 BYTES

LOGBOOK

SELECTION

LOGBOOK

PUNCHOUT

Initialization of a logbook (creation of a new logbook file). When the softkey INIT is pressed, the CNC expects input of a logbook file number (value range 0.3000–999999999). Input of ”0” deactivates a currently active logbook (”active” means that recordings take place in this logbook). A logbook cannot be activated again once it has been deactivated. Only deactivated logbooks can be deleted. Two test points are interrogated after input of the file number. However, these are of importance only for service purposes. Skip test point input by pressing the ENTER key twice. The system then asks for the memory size for the individual ring stores. Reservation of approx. 500 bytes per ring store will already permit a sensible recording to be made. After this, the logbook is initialized and automatically activated. Any events which occur are recorded from this point in time onwards.

The number of logbooks which can be created is limited by the available memory space. Only one logbook can be active at any time.

In order to use the file number of a deactivated logbook again for an active logbook, it is first necessary to delete the deactivated logbook in the softkey level SERVICE FUNCTION and to then create a logbook again in D1 under softkey INIT.

LOGBOOK

SELECTION

Selection of any existing deactivated logbooks for display on the monitor.

D1 – 6

Flexible Automation

D1 Logbook

CC 220 / 320

Diagnosis

LOGBOOK

PUNCHOUT

The currently displayed logbook is output on an external data medium. The current setting in group operating mode DATA I/O, softkey DATA OUT, determines via which interface output takes place. A change in operating mode aborts active output. Output via the DNC interface is not possible.

DISPLAY

RING STORE

This softkey results in display of the contents of the individual ring stores. The store contents are displayed in plain text with data, time and message.

Example: Ring store 1 (warnings):

No CP0 PROGRAM

LOG 11 23.05 09:31 WARNING: DATA PROTECTED

KEYING: DATA SK1+ SK1− 0 ENTR TEST POINT: 1=00000000 2=00000000 MODE: DATA

LOG 7 16.05 11:34 WARNING: AXIS MOVING

KEYING: SK5+ TEST POINT: 1=00000000 2=00000000 MODE: DIAGNOSTIC

DISPLAY END

PAG E

FORWARDS

ACT

NC0 STOP

SK5− DIAG SK3+ SK3− SK3+

PAG E BACK

LAST

KEY

Example: Ring store 5 (operating steps):

No CP0

SK4− ERET SK4− DIAG SK4+ SK3+ SK4+ SK5− SK5+ 2 SK3+ ENTR SK2+ SK4−

SK4+ ERET SK4+ SK4− 2 SK4− SK3− SK5+ ERET SK1− DATA 5 SK1− SK4+

ERET SK4− SK4+ 5 SK4+ SK3+ ENTR SK4− SK1+ SK2− SK1− SK1+ ENTR

ACT

ERET SK4+ ENTR 2 SK4− DIAG 0 SK4+ SK3− SK2+ SK1+ ENTR 2

NC0 STOP

RESET ENTR

6 SK4− SK4+ ERET 2 SK3− SK3+ SK1− ERET 1 SK4−

SK3+ 6

5 SK4+ DIAG SK5− SK1− SK3+ SK5− SK1+ SK2− SK1− SK4+

ENTR SK3− 5 RESET 2 DIAG DATA SK5+ SK1+ SK5− SK5+ SK1− SK2+ SK1+ ERET

SOFTKEY

MASK

1 SK3+ 2 SK3+ 7 SK3− RESET ENTR SK1− SK5+ SK1− SK1+ SK1− ENTR SK4−

DIAGNOSTIC

12. 5 17: 5PROGRAM

SK4− DIAG 7 SK3− 2 SK3+ SK5+ 0 SK1+ ENTR SK1+ SK1− SK1+ 3 SK4+

SK4+ ERET 2 SK3+ SK4− SK3− SK4− 1 SK5− 0 SK3− SK1+ SK2− 3 SK4−

PAG E

FORWARDS

PAG E BACK

The last–pressed key is shown at the top left in the uppermost data line of the monitor (”ENTR” here in the example).

D1 – 7

Flexible Automation

D1 Logbook

The following abbreviations are used for display of the keys: ABAR, MDI, MASC, DATA, DIAG, KORR Group operating modes

CUP+, CDN+, CRI+, CLE+ Cursor keys pressed CUP–, CDN–, CRI–, CLE– Cursor keys released LPE+ Magnifier pressed LPE– Magnifier released SK1+, SK2+, SK3+, SK4+, SK5+ Softkey pressed SK1–, SK2–, SK3–, SK4–, SK5– Softkey released ERET Level return DEL Delete key ENTR Enter key 1 ... 0 Numeric keys : * – + = Arithmetic operation keys +/– Sign change . Decimal point RESET Stands for Control Reset,

CAL = System error 1 NC reset, switching on/off, Logbook Init

?? Unknown key code

CC 220 / 320

Diagnosis

SOFTKEY

MASK

The softkey mask present at the time of the entry is displayed. If the key assignment is displayed by a number, this indicates variable softkey designations, such as occur, for example, for wool sub–tables.

D1 – 8

Flexible Automation

D5 – Internal reference point offset

D5 Internal reference point offset

CC 220 / 320

Diagnosis

The currently active axis offset values are displayed after selection of the program D5. These may have been generated by G92 or by ZERO SET. Zero offsets by way of G54 – G59, G154 – G159, G254 – G259, G60 or G160 are not taken into account here.

No CP0

AXIS

ACT

OFFSET VALUE

767.766 MM

− 715.692

124.423

NC0 WAIT

DIAGNOSTIC

14.10 8:32PROGRAM

D5 – 9

Flexible Automation

D5 Internal reference point offset

CC 220 / 320

Diagnosis

D5 – 10

Flexible Automation

D6 – Interface data

General

User interface/softkey assignments

D6 Interface data

CC 220 / 320

Diagnosis

Data arriving at the standard interfaces can be displayed with D6. The data is not stored during this operation.

No check is made of the data (e.g. with respect to correct file header, program end, ECODE etc.). Reading–in is not subject to any time monitoring function. No mes- sage is issued if data transfer is faulty.

The following functions are offered after program selection:

DEVICE

SELECT

DEVICE

SELECT

STATUS

DFS

DFS–NO.

START

Selection of the data interface and definition of the connected peripheral device.

STATUS

The following softkey bar appears when STATUS is pressed:

CONTROL

HEX CHAR/HEX CHAR/SYMB

Activation/deactivation of the XON/XOFF protocol. Softkey is shown inverted: software handshake active (Xon/Xoff). Softkey is displayed normally: hardware handshake active (DTR/DSR).

HEX

Display of the incoming data in HEX format.

CHAR/HEX

Incoming data is displayed as ASCII characters. Exception: display of control characters occurs in HEX format.

CHAR/SYMB

Incoming data is shown as ASCII characters. Exception: control characters are displayed symbolically (e.g. <SP> = Space, <LF> = Line Feed).

D6 – 11

Flexible Automation

D6 Interface data

CC 220 / 320

Diagnosis

START

Start of the reading–in operation. This operation continues until the screen is full. Half of the screen is filled again in each case by repeated operation of this key.

DFS

Reading–in is started by pressing the softkeys DFS SEARCH and START and is then continued until a correct DFS identifier is found. After this, a maximum of 17 lines of the program/table are displayed. The rest of the incoming program/table data of this file is skipped after renewed operation of DFS SEARCH and then START. The control displays the first 17 lines of the program/table again only after the next DFS identifier has been found. Note: ”DFS search” is active as long as the softkey is shown inverted. The function is executed only if the DFS identifier is correctly received.

DFS–NO.

The system asks for the file number for which a search is to be made after operation of this softkey. After input of this number and subsequent operation of the softkey START, reading–in takes place until the specified file number (DFS identifier) is found. The incoming data is displayed only after this has occurred.

Note: ”DFS search” is active as long as the softkey is displayed inverted. The

function is executed only if the DFS identifier is received correctly.

Example: Display of read–in data in the format CHAR/HEX:

No CP0

<13><12><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00 <00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00 <00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00

<00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><14><12 <00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00 <00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00 <00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00><00 <00><00><02><0D><0A> <14><12>(DFS,P 55555,TEACH IN 18.08,RWED)< D><0A> <14><12>1 A%=3:REM NUMBER OF AXES <0D><0A> 1 A1$="X":REM AXIS ADDRESS<0D><0A> 1 A2$="Y"<0D><0A> 1 A3$="Z"<0D><0A> 1 A4$="B"<0D><0A> 1 A5$="B"<0D><0A> 1 <14><12>B%=250:REM INTERFACE OUTPUT FOR SETTING MODE ACTIVATION <0D><0A>

INTERFACE DATA

DEVICE

SELECT.

ACT

STATUS

NC0 WAIT

DFS−

DFS−No.

DIAGNOSTIC

14.10 8:40PROGRAM

START

D6 – 12

Flexible Automation

D7 – Communication store display

General

D7 Communication store display

CC 220 / 320

Diagnosis

The content of the communication store from the point of view of the PLC can be displayed on the monitor of the CNC in hexadecimal format using the diagnostic program D7. D7 is offered only if word coupling exists between the CNC and PLC.

The communication store is a 128 KByte dual port RAM area on the NC–PLC–word module (WK3). Both the CNC and the PLC (PC 600) have read and write access to this area.

Start address Page 0

End address Page 0

Start address Page 1

End address Page 1

User interface/softkey assignments

After D7 is started, the control always displays the communication store content from address C000 H to C07F H (address information as hexadecimal numbers from the point of view of the PLC):

No CP0

C00 C01 C02 C03 C04 C05 C06 C07

0002 E752 E852 E010 E73E E746 E952 F000 EA26 F006 F026 F0BA E000 0000 F092 BB00

C000 COMMUNICATION STORE DISPLAY

C400 F212 F24C F04E E95E 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

*000 0*00 00*0

ACT

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

NC0 WAIT

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

BC34 BC34 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

8000 H

FFFF H

8000 H

FFFF H

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

. . . . .

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Page 0

Page 1

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

BACKUP PAG E 1

DIAGNOSTIC

17.10 14: 0PROGRAM

0 1 2 3 4 5 6 7 8 9 A B C D E F

PAG E 0*ADVANCE

128 data words (256 bytes) can be displayed on one screen page. The data is displayed in a table form (8 columns of 16 lines each). It is possible to see the assign-

D7 – 13

Flexible Automation

D7 Communication store display

CC 220 / 320

Diagnosis

ment between the displayed data words and their addresses in the communication store by way of the inversely displayed bars above and on the right of the table.

The three most significant positions of an address (e.g. ”C02” of address ”C02F”) are shown in the top, highlighted bar, while the least significant position is shown in the bar on the right of the table (e.g. ”F” of the address ”C02F”).

The address of the top left data word is displayed in the prompt line (here in the example: ”C000 COMMUNICATION STORE DISPLAY”).

Example:

No CP0

C00 C01 C02 C03 C04 C05 C06 C07

0002 E752 E852 E010 E73E E746 E952 F000 EA26 F006 F026 F0BA E000 0000 F092 BB00

C000 COMMUNICATION STORE DISPLAY

C400 F212 F24C F04E E95E 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

*000 0*00 00*0

ACP

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Address C025 H Address C046 H

NC0 WAIT

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

BC34 BC34 0000 0000 0000

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

BACKUP PAG E 1

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

DIAGNOSTIC

17.10 14: 0PROGRAM

0 1 2 3 4 5 6 7 8 9 A B C D E F

PAG E 0*ADVANCE

Search for an arbitrary address

Select the required memory area by means of the softkey PAGE 0/PAGE1. The currently displayed memory area is shown inverted on the softkey. The individual digits of the address displayed in the prompt line can be incremented or decremented by means of the three softkeys *000,0*00 and 00*0. The asterisk on the softkey indicates the position which is changed. The least significant address need not be specified, since all 16 possible addresses are displayed underneath each other in one column.

It is possible to switch between incrementation and decrementation of the corresponding position by means of the softkey ADVANCE/BACKUP. The active condition is shown inverted.

D7 – 14

Flexible Automation

D7 Communication store display

Example:

You are on Page 0. The prompt line shows the address C000 H. You are looking for the content of the address D123 H on Page 0. Switch to ”Increment” (the field ADVANCE on the softkey ADVANCE/BACKUP is then shown inverted). Press the softkey *000 once. Press the softkey 0*00 once. Press the softkey 00*0 twice. The 4th data value (from the top) in the left column now shows the content of address D123 H.

CC 220 / 320

Diagnosis

D7 – 15

Flexible Automation

D7 Communication store display

CC 220 / 320

Diagnosis

D7 – 16

Flexible Automation

D9 – EEPROM management General

D9 EEPROM management

CC 220 / 320

Diagnosis

The MEM5 memory module (or CP/MEM4 in the case of CC220) contains a 32 KByte EEPROM area as standard (optionally 64 KBytes). Important data should be saved in the EEPROM since the content of the EEPROM area is not lost – in contrast to the RAM area – after a total power failure on the MEM module or after forced backup loading.

The following files can be written into the EEPROM area and read out again using the diagnostic program D9: Part programs LSEC tables W tables Zero offset tables Compensation tables Machine parameters.

For example, it is then possible to choose whether machine parameters and tables are to be copied back from the EEPROM to the RAM when the control is put into operation again.

User interface/softkey assignment

After D9 has been started, the monitor displays a list of all files stored in the EEPROM area. Each entry in the list additionally contains information as to whether a file with the same name already exists in the RAM area (column ”IN RAM”) and whether this file also contains the same data (column ”EQUAL”).

No CP0

LIST OF PROGRAMS TO BE SPECIFIED

No PROGRAM NAME IN RAM EQUAL

0 1

ACT

3000 3001 3002 1131

NC0 WAIT

MACHINE PARAMETER MAIN PROGRAM MOD. DIA 18.08 SR SELECT MODULE SR TEST DIAGNOSTIC CHANNEL SR CP

22.06

02.07

22.01

DIAGNOSTIC

14.10 8:45PROGRAM

YES YES YES YES YES

NO NO NO NO NO

MEMORY USED BY PROGRAM: MEMORY AVAILABLE: :

MANAGE EEPROM

MACHINE

PARAMETER

PROGRAM

SELECTION

5409

22239

DELETE COPY

OTHERS: 3224

EEPROM

PROGR.

This list can now be extended by new entries or be shortened by deleting entries.

The functions PROGRAM EEPROM and COPY (from EEPROM to RAM) refer to the files displayed here!

If it is wished to store files in addition to the files which are already contained in the EEPROM, it is not necessary for files which are already stored in the EEPROM to also be present in the RAM for programming of the EEPROM.

D9 – 17

Flexible Automation

D9 EEPROM management

CC 220 / 320

Diagnosis

The following functions can be initiated by means of the softkeys:

MACHINE

PARAMETER

The currently active machine parameter record (not file L444!) is incorporated in the list under number ”0”. A machine parameter record stored in the EEPROM can be copied into the RAM area again only if the softkey FROM EEPROM is selected when reloading the complete operating system (diagnostic program D2). File L444 must be stored in the EEPROM (by means of the softkey PROGRAM SELECTION) if it i s w i shed to permit restoration of machine parameters without reloading the complete operating system.

PROGRAM

SELECTION

PROGRAM

ALL

PROGRAMS

GROUP

Files can be entered in the list from the groups P, L, V, K, W after pressing PROGRAM SELECTION. To do this, first select the desired file group with the softkeys NEXT GROUP or PREVIOUS GROUP. The control then shows you all existing files of the selected group. All files of this group can be included in the list by pressing the softkey ALL PROGRAMS. The softkey PROGRAM permits selection of a single file.

Notes:

‘ When programs are entered in the list, the CNC checks whether the size of

the EEPROM area is sufficient for later programming. If not, the error mes-

sage ”MEMORY FULL” appears in the prompt line.

‘ Link files cannot be included in the list. ‘ The K1 table must not be stored in the EEPROM.

DELETE

DELETE LIST ENTRIES

PROGRAM

ALL

PROGRAMS

D9 – 18

Flexible Automation

DATA

D9 EEPROM management

CC 220 / 320

Diagnosis

It is possible to delete either individual entries or all entries in the list. This function relates only to modification of the displayed list! If it is wished to delete a file

in the EEPROM, it is first necessary to delete the corresponding file in this list. The EEPROM must then be reprogrammed with the thus modified list. Files existing in the EEPROM are then possibly overwritten by newer file versions (which are contained in the RAM).

If an individual list entry is deleted (by means of the softkey PROGRAM), it is necessary to enter not the file number but the list number of the corresponding file (column ”NO”) and confirm this with the ENTER key.

COPY

COPY FILES FROM EEPROM

PROGRAM

ALL

PROGRAMS

Files can be copied from the EEPROM area to the RAM area of the control by means of the function COPY. All files entered in the list are copied into the RAM after operation of the softkey ALL PROGRAMS. If you wish to copy an individual file (by means of the softkey PROGRAM), you must enter the list number of the corresponding file (column ”NO”) after operation of the softkey PROGRAM and then confirm this with the ENTER key.

Notes:

‘ Copying of the machine parameter record (list entry ”0”) to the RAM area

is not possible using this function. A machine parameter record stored in the

EEPROM can be copied into the RAM area again only if the softkey FROM

EEPROM was selected when reloading the operating system. ‘ The function COPY is protected by a code.

EEPROM

PROGR.

Programming the EEPROM area with the files entered in the list. The system first asks for input of a code in order to prevent unintentional programming. After this, the operator can enter an identifier consisting of a maximum of 50 ASCII characters. This identifier is of no significance in the current software version. If it is wished to start programming, skip input of the identifier by pressing the ENTER key. However, if it is wished to abort the function EEPROM PROGRAMMING at this point, simply press the level return key.

D9 – 19

Flexible Automation

DATA

D9 EEPROM management

The softkey EEPROM PROGR. is displayed inversely during programming. CNC operation is not possible during this time. The message ”PROGRAMMING IS AC- TIVE!” flashes in the prompt line. The number of programmed bytes is displayed continuously. An asterisk appears in front of the list number of a file as soon as this file has been completely programmed.

The list is moved up on the screen if not all previously programmed files can be displayed on one screen page.

CC 220 / 320

Diagnosis

D9 – 20

Flexible Automation

D21 – Logic analyzer

General

D21 Logic analyzer

CC 220 / 320

Diagnosis

The logic analyzer permits recording of a maximum of 16 signals of the CNC–PLC interface.

During a recording, 500 sampling operations of all selected signals (refer to softkey CHANNEL SELECTION) are always stored. The interval between two sampling steps is adjustable. File D121 is used to record the data. If this file does not yet exist, the system creates it automatically before a recording (file size: approx. 2 – 2.5 KByte part program memory). An existing file D121 is overwritten by each new recording. In addition, recorded data (including the current logic analyzer settings at the time of recording) or arbitrary logic analyzer settings can also be stored in separate files for possible subsequent use (refer to softkey FILE SELECTION).

Functional principle of the logic analyzer:

0 ...................500 (Sampling steps)

Trigger

position

Memory

Trigger condition Comparator Clock

Delay

Data stream

Clock

D21 – 21

Flexible Automation

User interface/softkey assignments

D21 Logic analyzer

The following display appears after selection of D21:

CC 220 / 320

Diagnosis

No CP0

LOGIC−ANALYZER

WAITING

STARTING VALUES

CHANNELS 8 STORE CLOCK TRIGGER−POS.

DISPLAY

STARTING

VALUES

STARTING VALUES CHANNELS

8 OR 16

POSITION

ACT

LOGIC−ANALYZER STATUS

500 CLOCKS

1 PLC−CY

250 CLOCKS

CHANNEL

SELECTION

TRIGGER

NC0 WAIT

No TYPE ADDR. BIT TRIGGER COND.

0 I 40.7 1 1 O 2 O 3 O 4 O 5 O 6 O 7 O

STARTING

VALUES

CHANNELS

36.0

36.1

36.2

36.3

36.4

36.5

36.6

FILE

SELECTION

* * * * * * *

CLOCK

DIAGNOSTIC

13. 5 8:57PROGRAM

START

RECORDING

The functions of the logic analyzer can be adapted to the respective task by means of these softkeys:

CHANNELS

8 OR 16

It is possible to record 8 or 16 channels simultaneously. The number of channels can be set to 8 or 16 by means of this softkey.

TRIGGER POSITION

You define here how many sampling steps are to be stored before occurrence of the trigger event. 500 sampling steps are always stored in total in the recording file.

Examples:

Trigger position = 250: The sampling step executed when the trigger event occurs is assigned the ”num- ber” 250. A further 250 sampling steps (500 – 250) are then stored additionally as from this point.

Trigger position = 10: The sampling step executed when the trigger event occurs is assigned the ”num- ber” 10. A further 490 sampling steps (500 – 10) are then stored additionally as from this point.

D21 – 22

Flexible Automation

D21 Logic analyzer

CLOCK

CC 220 / 320

Diagnosis

Specification of the time interval between two sampling steps. It is possible to set three different types of time interval here. In addition, it is necessary to enter the size of an individual time interval. The following table provides an overview of the possible inputs:

Interval type Size Meaning

1 (MS) 1 ms – 50 ms Channels can be sampled at ms inter-

vals. Possible interval size: 1 ms to 50 ms, depending on set size.

2 (TASKS) 1 – 9999 The channels can be sampled on the

basis of task changes. This type of interval is relevant only for users who possess extremely good system knowledge of the control.

3 (PLC CYCLES) 1 – 9999 The channels can be sampled each

time the PLC performs a ”PE”. (Possible interval size: time from PE to PE.) (Possible only for PIC 250 or word– coupled PC 600).

CHANNEL

SELECTION

INPUT OF CHANNEL AND TRIGGER CONDITION PLC INPUTIPLC OUTPUTOPLC MARKER

STORE

TRIGGER

CONDITION

Select the channel number to be changed (0 – 7 or 0 – 15) with the cursor keys

after operation of CHANNEL SELECTION. It is then possible to assign an input, output, marker or memory address to the selected channel number by means of softkey and numeric input. The input must be acknowledged with the ENTER key.

Setting the trigger condition:



Selection of the channel number with the cursor keys

. The active channel

is shown inverted.



Input of 0 results in low–level triggering,

1 results in high–level triggering, * (multiplication symbol) No trigger.



An input, output, marker or memory bit is assigned to the active channel by pressing the corresponding softkey (1 – 4) and subsequently making a numeric input. The following input values are permitted:

Input/output: bits 0.0 to 255.7 Marker: markers 0.0 to 511.7

D21 – 23

Flexible Automation

MOVE

D21 Logic analyzer

START

RECORDING

The logic analyzer records. The message ”RECORDING” appears underneath the line ”LOGIC ANALYZER”. The condition ”WAITING” is displayed here when the re- cording has been completed.

Notes:

‘ The recording is aborted by selection of a different diagnostic program. ‘ CONTROL RESET does not normally interrupt recording. However , if active

remote diagnosis is aborted by selection of D21 and a restart then performed by CONTROL RESET, this operating sequence results in termination of the recording and of diagnostic program D21.

CC 220 / 320

Diagnosis

D21 – 24

Flexible Automation

D21 Logic analyzer

FILE

SELECTION

LOGIC ANALYZER DIAGRAM/PARAMETER FILES

SAVE LOAD

MODIFY

HEADER FILE

PARAMETER

ONLY

CC 220 / 320

Diagnosis

COMPLETE

DIAGRAM

The softkey FILE SELECTION permits access to a number of functions which are used for storage or loading of current logic analyzer settings or complete logic analyzer recordings (time diagrams). The control displays all logic analyzer recording or setting files which exist in the system on this softkey level.

SAVE

Using the softkey SAVE, it is possible to store current settings or the current recording (including settings) in a file of the group ”D”, depending on which softkey (PA- RAMETER ON LY or COMPLETE DIAGRAM) is shown inverted. File numbers from 3101 to 3300 are permitted. A recording (time diagram) can be stored only after completion of storage in one of these files.

LOAD

Loading of a stored setting or stored recording. Only the files which contain recordings are displayed on the monitor after operation of LOAD if the softkey COMPLETE DIAGRAM is shown inverted.

MODIFY

HEADER FILE

The file header (text) can be modified after input of the file number. The text ”LOGIC DIAGRAM” is entered as standard in the file header for recording files and the text ”LOGIC PARAMETER” for setting files.

PARAMETER

ONLY

Only current settings of the logic analyzer are taken into account for LOAD or SAVE if this softkey is inverted. Settings should be understood as all parameters which can be influenced on the softkey levels INITIAL VALUES and CHANNEL SELECTION.

COMPLETE

DIAGRAM

If this softkey is shown inverted, recordings (time diagrams) are also taken into account in addition to settings (refer to SK PARAMETER only) for LOAD or SAVE.

D21 – 25

Flexible Automation

D21 Logic analyzer

DISPLAY

The current recording (time diagram) appears on the monitor:

CC 220 / 320

Diagnosis

No CP0 PROGRAM

5.4

0.0

0.1

2.0

0.2

0.3

2.1

36.6

0 250 500

CUR:

0 REF: 500 REF−CUR: 500 ( 5.0005)

*1 CURSOR

ACT

NC0 STOP

*10 REFERENCE

DIAGNOSTIC

START

RECORDING

The recording contains three markings in the form of vertical lines. These are identified by C (cursor), T (trigger position) and R (reference mark).

The cursor is located at the cursor position ”0” (1st sampling step) in the initial display condition. The mark T indicates the defined trigger position. The mark T is moved to the respective sampling step if fewer sampling steps are performed than defined under softkey TRIGGER POSITION after the start of recording before the trigger condition occurs. The mark R is initially located at the cursor position 500.

The marks C and R can be moved – after corresponding softkey selection (CURSOR or REFERENCE) – with the cursor keys

or by input of a sampling step

number. The positions of the marks C and R and the distance of the reference mark from

the cursor mark (in sampling steps and seconds) are displayed in the message line under CUR, REF and REF–CUR. The current level (0 or 1) at the markings C and R is displayed at the right edge of the screen (under C and R) for each channel. The current signal assignment (input, output, marker, store) is shown for each channel at the left edge of the screen.

The time axis can be expanded by a factor of ten (*10) by softkey.

D21 – 26

Flexible Automation

D22 – Axis oscilloscope

General

D22 Axis oscilloscope

The diagnostic program allows the user to assess the dynamic response of the axes. It is thus possible to establish sluggish movement, jamming or overshoot of the axes or excessively slow axis circling.

For this purpose, D22 offers the possibility of simultaneously recording axis movements and 2 logical signals and displaying these as diagrams on the CNC monitor .

The file D122 is used for data recording. If this file does not yet exist, the system creates it automatically before a recording (file size approx. 5 KByte part program memory). An existing file D122 is overwritten by each new recording. In addition, recorded data (including the axis oscilloscope settings valid at the time of recording) or arbitrary axis oscilloscope settings can also be stored in separate files for possible subsequent use (refer to softkey FILE SELECTION).

Diagnosis

CC 220 / 320

480 actual axis position values are always stored during a recording at the time interval defined in machine parameter P9901 (interpolation time in ms). From these values, the control calculates the following:

‘ Setpoint/actual speed ‘ Setpoint/actual acceleration ‘ Setpoint speed/lag

This data can then be displayed on the monitor as diagrams.

User interface/softkey assignments

The following display appears after selection of D22:

No CP0

AXIS−OSCIL.

WAITING

ADJUSTMENTS

AXIS: 1 PC1 PC2

Y1: Y2:

X: X−EXP.START = TRIGGER−POS.

JOG BUT TON 1st AXIS

A E

TRIGGER ACTIVATION

ACT

0.0

1.000000

240.00

NC0 STOP

OSCILLOSCOPE STATUS

M/S 2 PER SCALE DIVISION

M/S 2 PER SCALE DIVISION MS PER SCALE DIVISION

SCALE DIVISIONS

2670

DIAGNOSTIC

10. 4 16:12PROGRAM

DISPLAY

SELECT DISPLAY

D22 – 27

DISPLAY

SPLITTING

OTHER

COMMANDS

START

RECORDING

Flexible Automation

D22 Axis oscilloscope

SELECT

DISPLAY

CC 220 / 320

Diagnosis

CMD. SPEED

ACT. SPEED

CMD. ACCEL.

ACT. ACCEL.

CMD. SPEED

LAG

Select the diagram which is desired after operation of the softkey DISPLAY here. It is possible to choose between setpoint and actual speed (CMD. SPEED/ACT. SPEED), setpoint and actual acceleration (CMD. ACCEL. ACT. ACCEL.) or setpoint speed and lag (CMD. SPEED/LAG). The inverted softkey indicates the currently active setting. The settings can also still be changed after recording.

DISPLAY

SPLITTING

X–DISPLAY

START

EXPAND X

*10

SCALE

1.Y–AXIS

SCALE

2.Y–AXIS

The diagram representation can be influenced by means of these functions:

X–DISPLAY

START

The time axis of a diagram is divided into 20 scale divisions. Complete representation of the diagram is not possible if the time axis is expanded by a factor of 10. Using the softkey X–DISPLAY START, it is thus possible to specify as from which scale division the diagram is displayed on the monitor with an expanded time axis (inputs: 0–18) (also refer to softkey EXPAND X*10). The scale division specified here is marked on the non–expanded representation of the diagram with the character ”D” (also refer to softkey DISPLAY).

EXPAND X

*10

This softkey allows the diagram to be expanded by a factor 10 in the X–axis (time axis). The softkey is shown inverted if axis expansion is active. It is possible to switch back to the non–expanded diagram by pressing the softkey once more. The time axis of a diagram is subdivided into 20 scale divisions. Two scale divisions are shown on the screen in the expanded diagram. One scale division of the time axis corresponds here to the time t = 2.4 x P9901.

SCALE

1.Y–AXIS

SCALE

2.Y–AXIS

The scale of the two Y–axes is set here. SCALE 1.Y–AXIS acts on the Y–AXIS of the top diagram, while SCALE 2.Y–AXIS acts on the Y–AXIS of the bottom diagram (refer to softkey DISPLAY for diagram structure). Input range: 0.0000001–9999999 m/min.

D22 – 28

Flexible Automation

D22 Axis oscilloscope

Examples:

Input: 1 Setpoint speed of 1 m/min. corresponds to a Y–value of 1 scale divi-

sion.

Input: 2 Setpoint speed of 1 m/min. corresponds to a Y–value of 1/2 scale

division.

Input: 0.25 Setpoint speed of 1 m/min. corresponds to a Y–value of 4 scale divi-

sions.

OTHER

COMMANDS

Diagnosis

CC 220 / 320

RECORDING

SELECTION

RECORDING

SELECTION

AXIS

NUMBER

TRIGGER

CONDITION

PLC INPUTIPLC OUTPUT

TRIGGER

POSITION

FILE

SELECTION

STORE

The axis for which recording is desired is defined on this softkey level (softkey AXIS NUMBER).

In addition, it is possible to use the cursor keys

to select channels to which an interface signal or, in the case of word coupling between CNC and PC 600, also a memory bit can be assigned with the softkeys PLC INPUT I, PLC OUTPUT O and STORE S (maximum of 2 channels can be selected). These 2 channels are then recorded during recording and later displayed on the DISPLAY between the top and bottom diagrams. The bits 0.0 to 255.7 are permitted as input values for an input or output.

D22 – 29

Flexible Automation

D22 Axis oscilloscope

TRIGGER

CONDITION

CC 220 / 320

Diagnosis

JOG

BUTTON

PROG.–NO.

BLOCK NO.

PLC INPUTIPLC OUTPUT

STORE

Setting the trigger condition. When the softkey START RECORDING is pressed, the start of recording is delayed until the trigger event set here occurs. The active trigger condition is identified by inverse display of the corresponding softkey . I f t h e trigger event does not occur , the axis oscilloscope must be reset by means of a control reset.

Note:

If JOG BUTTON is selected as the trigger condition, jog mode must have been activated in group operating mode MACHINE. If not, triggering is initiated by the jog button, but no axis movement takes place.

TRIGGER POSITION

You define here how many actual axis position values are to be stored before the trigger event occurs. 480 actual axis position values are always stored in total. The input must be made in the unit ”Scale divisions” (see example). The permitted value range for inputs lies within the limits 0.0 to 20.0. The time interval from scale division to scale division is calculated as follows: nt = Machine parameter P9901 * 24.

Example: It is wished to store 252 actual axis position values before the trigger event occurs:

252 : 24 = 10.5 ! Input: 10.5

The recording thus consists of 252 values before the trigger event occurs plus 228 values after this trigger event (always making up a total of 480 actual axis position values).

D22 – 30

Flexible Automation

DATA

D22 Axis oscilloscope

FILE

SELECTION

AXIS OSCILLOSCOPE DIAGRAM/PARAMETER FILES

SAVE LOAD

MODIFY

HEADER FILE

The softkey FILE SELECTION allows access to a number of functions which can be used to store or load current axis oscilloscope settings or complete axis oscilloscope recordings (time diagrams). The control displays all axis oscilloscope recording or setting files which exist in the system on this softkey level.

SAVE

The softkey SAVE allows current settings or the current recording (including settings) to be stored in a file of the group ”D”, depending on which softkey (PARAMETER ON LY or COMPLETE DIAGRAM) is shown inverted. File numbers from 3301 to 3500 are permitted. A recording (time diagram) can be stored only after inclusion in one of these files. Memory requirement of a recording: approx. 5 KByte. Memory requirement of a setting: approx. 100 Byte.

PARAMETER

ONLY

Diagnosis

COMPLETE

DIAGRAM

CC 220 / 320

LOAD

Loading of a stored setting or stored recording. If the softkey COMPLETE DIAGRAM is shown inverted, only the files which contain recordings are displayed on the monitor after operation of LOAD.

MODIFY

HEADER FILE

The header of a file (text) can be changed after input of the file number. The text

”OSCIL–DIAGRAM” is entered in the file header as standard for recording files and ”OSCIL–PARAMETER” for setting files.

PARAMETER

ONLY

If this softkey is shown inverted, only current settings of the axis oscilloscope are taken into account for LOAD or SAVE.

COMPLETE

DIAGRAM

Recordings, (time diagrams) are taken into account as well as settings (refer to SK PARAMETER ONLY) for LOAD or SAVE if this softkey is shown inverted.

D22 – 31

Flexible Automation

D22 Axis oscilloscope

START RE-

CORDING

The axis oscilloscope records. The message ”RECORDING” appears under the line ”AXIS OSCILLOSC.”. The status ”WAITING” is displayed here when the recording has been completed.

Notes:

‘ An ongoing recording is aborted by selection of a different diagnostic pro-

gram or by CONTROL RESET.

‘ If the trigger event does not occur, the axis oscilloscope must be reset by

means of a control reset.

‘ If JOG BUTTON was activated as the trigger condition, jog mode must have

been activated in group operating mode MACHINE. Otherwise, no traversing movement occurs.

Diagnosis

CC 220 / 320

DISPLAY

The axis oscilloscope recording appears on the monitor. Once scale division of the time axis corresponds to the time t = 24 x P9901 in non–expanded form and t = 2.4 x P9901 in expanded form.

The recording contains the marks D (for the expansion function) and T (trigger position). The mark D can be moved with the cursor keys

COMMAND SPEED

ACTUAL SPEED

The display is expanded by a factor of 10 in the X–axis (time axis) by pressing the MAGNIFIER key. The starting point for the expanded display is the position of the mark D in this case (refer to following monitor screen for an example of an expanded display). The display switches back to non–expanded form if ”MAG- NIFIER” is pressed again (same function as softkeys EXPAND X *10 and X–DIS- PLAY START).

D22 – 32

Flexible Automation

D22 Axis oscilloscope

CC 220 / 320

Diagnosis

The display can be quit by pressing the level return key.

D22 – 33

Flexible Automation

D22 Axis oscilloscope

CC 220 / 320

Diagnosis

D22 – 34

Flexible Automation

D23 – Contour display

General

User interface/softkey assignments

D23 Contour display

The contour display permits comparison of a programmed contour with the con- tour generated by the machine tool. Evaluation is performed by means of the measuring system feedback function with the resolution set in the machine parameters (P 9901). The actual values are recorded exactly to 1 increment for each sampling step.

If D23 is selected, the control first checks whether file D123 exists. This file is required by D23 to store a recording. If D123 does not exist, it is necessary to enter the number of desired sampling steps. Approx. 16 KByte of part program memory is required for D123 for every 1000 sampling steps. The maximum number of sampling steps is restricted only by the available free part program memory. The recording duration depends on the number of defined sampling steps and on machine parameter P9901:

T [ms] = number of sampling steps * P9901

Diagnosis

CC 220 / 320

Example: Number of sampling steps = 2000; P9901 = 10

. Duration of recording = 20 s;

required part program memory: approx. 32 KByte

Note:

D123 must be deleted if it is wished to change the number of sampling steps. Only after this can the number of desired sampling steps be entered again when starting D23.

The following display appears when the number of sampling steps has been entered:

No CP0

CONTOUR DISPLAY

WAITING

DISPLAY AXIS: X:

ACT

ADJUSTMENTS

NC0 STOP

CONTOUR DISPLAY STATUS

DIAGNOSTIC

14.10 8:48PROGRAM

TRIGGER: JOG BUT TON

SCALING FACTOR

DISPLAY

1st AXIS

STARTING

VALUE

D23 – 35

TRIGGER

START

RECORDING

Flexible Automation

STARTING

VALUES

D23 Contour display

CC 220 / 320

Diagnosis

DISPLAY

X–AXIS

DISPLAY

Y–AXIS

EXPANSION

X–AXIS

EXPANSION

The softkeys DISPLAY X–AXIS and DISPLAY Y–AXIS are used to assign an arbitrary machine axis (axis number) to the abscissa (DISPLAY X–AXIS) and to the ordinate (DISPLAY Y–AXIS) of the contour diagram.

The softkeys Y–AXIS EXP ANSION and X–AXIS EXPANSION should be used only in conjunction with D27 (circular compensation). In order to optimize parameters set with D27, it is necessary to expand the representation of one axis involved in circular interpolation more than the other (e.g. X and Y). This makes it possible to see the contour errors at quadrant transitions of a circle more easily. The expansion factor can be entered separately for each axis (value range: 1 –

1000). In order to avoid a situation where the contour can no longer be completely dis-

played on the monitor as a result of axis expansion, reduction of the non–expanded axis by the specified factor occurs instead of an increase in the expanded axis. The displayed proportions are thus correct.

Example:

No expansion Y−axis expanded by

a factor of 2

X−axis expanded by a factor of 2

Note:

If the function EXPANSION is active for an axis, the text ”AXIS” with the corresponding expansion factor appears on the display under the column ”MAGNIFI. FACTOR” (refer to softkey DISPLAY) in addition to ”DISPLAY” and ”MAGNIF.”.

D23 – 36

Flexible Automation

TRIGGER

D23 Contour display

CC 220 / 320

Diagnosis

MOVE

JOG BUTTON

PROGR. NO.

BLOCK NO.

Definition of trigger condition. When the softkey START RECORDING is pressed, recording is delayed until the trigger event defined here occurs. The active trigger condition is indicated by inverted display of the corresponding softkey.

START

RECORDING

After operation of START RECORDING, recording is started when the trigger condition occurs. The message ”RECORDING” appears under the line ”CONTOUR DISPLAY”. The status ”WAITING” is displayed here when recording has been completed.

DISPLAY

The contour diagram can be called after the end of a recording by pressing the softkey DISPLAY. The set and actual contours are shown (set contour: green; actual contour: red).

Two cross–hairs can be moved simultaneously along the contour with the cursor keys tion and

. results in cross–hair movement opposite to the machining direc-

in movement in machining direction. The values for axis position and axis speed (referred to the contour locations marked by the cross–hairs) are displayed on the left of the monitor.

The ”movement speed” of the cross–hairs can be preselected with the softkey

(see next monitor display). The active mode is shown inverted on the softkey:

<< Fast movement (step distance = 10 sampling steps) < Slow movement (step distance = 1 sampling step).

D23 – 37

Flexible Automation

D23 Contour display

CC 220 / 320

Diagnosis

MAGNIFI. FACTOR

DISPLAY MAGNIF.

CURSOR VALUE

COMMAND−POS.

X 47.883

47.883Y

ACTUAL−POS.

X 48.618

49.110Y

COMMAND−SPEED

X −0.708

−0.708Y

ACTUAL−SPEED

X −0.243

−0.531Y

1.00

The whole display or part of it can be magnified with the MAGNIFIER key in order to examine certain contour locations.

A frame appears on the screen after operation of the MAGNIFIER key . In addition, the following softkey bar is offered:

MAGNIFI. FACTOR

DISPLAY MAGNIF.

CURSOR VALUE

COMMAND−POS.

X 47.883

47.883Y

ACTUAL−POS.

X 48.618

49.110Y

COMMAND−SPEED

X −0.708

−0.708Y

ACTUAL−SPEED

X −0.243

−0.531Y

1.00

10.00

ON OFF + −

Magnification of the displayed frame content to the complete display area of the monitor. The cross–hairs stay in their current position and may thus not be visible initially after magnification.

OFF

Deactivation of the magnifier function. The graphic display is built up again without magnification. The cross–hairs stay in their current positions.

D23 – 38

Flexible Automation

D23 Contour display

+ –

Magnification or reduction in size of the displayed magnifier frame. The step distance by which the frame is magnified or reduced each time the soft-

keys ”+” or ”–” are pressed can be set by means of the softkey <<< .

The frame can be moved arbitrarily with the cursor keys while the magnifier frame is displayed on the monitor. The step width by which the frame is moved can be adjusted by way of softkey

Example: Magnified display of the previously marked screen section.

MAGNIFI. FACTOR

DISPLAY MAGNIF.

CURSOR VALUE

COMMAND−POS.

X 47.883

47.883Y

ACTUAL−POS.

X 48.618

49.110Y

COMMAND−SPEED

X −0.708

−0.708Y

ACTUAL−SPEED

X −0.243

−0.531Y

10.00

Diagnosis

CC 220 / 320

ON OFF + −

Note:

‘ It is possible to perform magnification several times successively. However,

when the displayed values under the column ”MAGNIFI. FACTOR” are re- placed by an asterisk, magnification should be stopped.

D23 – 39

Flexible Automation

D23 Contour display

CC 220 / 320

Diagnosis

D23 – 40

Flexible Automation

D24 – Axis optimization

General

D24 Axis optimization

The servo loops of the control must be adapted to the drives used. The diagnostic program D24 offers the following functions for this purpose:

‘ Definition of a step function (speed) for each applied axis. ‘ Graphic representation of the axis reaction to the step function (as speed

characteristic) and numeric display of the determined servo loop parameters.

‘ Display of position, lag, offset and required lag of all axes. ‘ Modification of the active required closed–loop gain. ‘ Offset adjustment of one axis. ‘ Acceptance of the optimized closed–loop gain and offset values in the ma-

chine parameters.

Diagnosis

CC 220 / 320

The axis reaction is always measured by recording of 160 actual axis position values. The time between 2 sampling operations corresponds to the value entered in machine parameter P9901. The recording time is thus 1.6 s if P9901 = 10 ms.

User interface/softkey assignment

The following monitor display appears after selection of D24:

No CP0

AXIS OPTIMIZATION

WAITING

DISPLAY AXIS: TIME SCALE (SEC): TRAVEL RANGE (MM): TARGET VALUE (M/MIN): SERVO LOOP WITH SLOPE ACCELERATE

DISPLAY

ACT

ADJUSTMENTS

STARTING

VALUES

NC0 WAIT

AXIS OPTIMIZATION STATUS

0.50 100

1.00

MACHINE

PARAMETER

SELECTION

AXIS

DIAGNOSTIC

20.2 17:2PROGRAM

START

RECORDING

AXIS

SELECTION

Selection of the machine axis which it is wished to optimize by input of the axis number.

D24 – 41

Flexible Automation

D24 Axis optimization

STARTING

VALUES

CC 220 / 320

Diagnosis

SERVO O/P

SERVO LOOP

SERVO O/P

SERVO LOOP

DECELERATE/

ACCELERATE

TARGET

VALUE

TRAVEL

RANGE

Selection of the following operating modes is possible by repeated operation of this softkey:

‘ SERVO LOOP WITH SLOPE: The axis accelerates to the speed en-

tered on the softkey TARGET VALUE with a slope. The servo loop is closed during this operation (refer to machine parameter P1002 for details of slope).

‘ SERVO LOOP WITHOUT SLOPE: The axis accelerates without slope to

the speed entered under the softkey TARGET VALUE. The servo loop is closed during this operation (refer to machine parameter P1002 for details of slope).

‘ SERVO OUTPUT: The servo loop is open. The axis tra-

verses at the speed which was entered under the softkey TARGET VALUE. The measuring system is used only for speed measurement.

DECELERATE ACCELERATE

Selection of acceleration or deceleration.

TARGET

VALUE

It is possible to define the desired axis speed in m/min. here. 10 % of the maximum speed (refer to machine parameter P501) is stored as a default value for the modes SERVO LOOP with/without SLOPE. The entered value is interpreted in V in SERVO OUTPUT mode (default value:

1.5 V).

TRAVEL

RANGE

Input of the maximum distance which may be traversed for a single measurement (corresponds to an incremental value as from the starting position!). If the limit value entered here should be exceeded during the measurement, the axis will stop and a corresponding message is displayed.

Please note the maximum traversing range of your machine if you perform several successive measurements!

D24 – 42

Flexible Automation

D24 Axis optimization

MACHINE

PARAMETER

The following display appears:

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Diagnosis

No CP0 PROGRAM

POSITION LAG OFFSET REQIRED LAG

0.000

OFFSET−ADJ

AUTO

ACT

OFFSET−ADJ

MANUAL

0.000

NC0 STOP

REQUIRED

0.002

0.000

LAG

DIAGNOSTIC

2000.000

10000.000

ACTIVATE

Offset and required lag values of all axes can be changed on this operating level. Select the axis where you wish to change the values with the cursor keys

SERVO

OFFSET–ADJ

AUTO

OFFSET–ADJ

MANUAL

Automatic or manual offset adjustment. The lag should set itself to zero when the offset has been entered or automatically adjusted. The changed offset value is transferred directly to the axis processor and is thus active. The machine parameter record is not yet changed at this point in time. Active offset values remain active until they are overwritten by other offset values or until the control is reset.

REQUIRED

LAG

Input of a new required lag value. This input must be made with care in order to exclude incorrect drive response. The required lag is calculated as follows: Required lag = max. axis speed (P501)/required closed loop gain (P1001). If the required lag is changed by means of this softkey, the new value becomes active for the corresponding axis when the ENTER key is pressed. For this purpose, the CNC adapts the currently active required closed loop gain in accordance with the above relationship (the maximum axis speed remains constant). The entered value remains active until the control is reset or until a different value is entered. The CNC modifies machine parameter P1001 correspondingly if the required lag is changed by means of the softkey REQUIRED LAG and this value then transferred to the machine parameter record (by softkey ACTIVATE). P501 remains constant. The new values are then active after each control run–up.

D24 – 43

Flexible Automation

D24 Axis optimization

ACTIVATE

All currently active closed loop gain and offset values are immediately transferred to the machine parameter record when the softkey ACTIVATE is pressed. The READY 2 signal is cancelled and a new control run–up takes place.

Caution: The new values are not transferred to the file L444, if this file should exist. If you wish the file L444 to contain the modified values, you must first delete L444 after transfer and then regenerate it (with/without texts).

Diagnosis

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D24 – 44

Flexible Automation

MOVE

D24 Axis optimization

START

RECORDING

When this softkey is pressed, the text under AXIS OPTIMIZATION changes from ”WAITING” to ”RECORDING”. The instruction ”ACTIVATE JOG BUTTON” ap- pears in the message line.

The traversing movement starts after operation of the jog button (also without approached reference point or active jog mode!)

DISPLAY

The step response of the corresponding axis can be displayed as a graph after completion of a recording by pressing the softkey DISPLAY:

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ABSOLUTE VALUE

(M/MIN)

1.00

CHARACTERISTIC

DELAY TIME

0.000 S

TU REACTION TIME

TA 0.136

OVERSHOOT UE 44.600

CHAR.FREQ. WO 68.837

DAMPING DA 0.320

I.S.E.

3.7

8.867

1/S

One scale division of the time axis (T) always corresponds to 50 sampling steps. Consequently, the corresponding time interval of a scale division is nt = 50*P9901 (the time interval of a scale divisions is also displayed numerically in the start screen of D24 under the column ADJUSTMENTS as ”TIME SCALE (SEC):”). One scale division of the absicissa (XI) always corresponds to 10 % of the currently set target value.

In addition to the graph, the CNC also displays the internally calculated characteristic servo loop values on the left side of the screen:

XI: Currently active target value TU: Delay time TA: Reaction time UE: Overshoot (in % of XI) WO: Characteristic frequency (characterized by envelope curve A

in following figure) DA: Damping (characterized by n1/n2 in the following figure) I.S.E.: Quadratic control area KV

: Actual closed loop gain factor

act

= measured speed/measured lag (at last sampling step).

act

D24 – 45

Flexible Automation

D24 Axis optimization

Notes:

‘ If the CNC cannot calculate characteristic values which are sufficiently accu-

rate, question marks are displayed instead of the numbers.

‘ Range transgression of a calculated number (numeric value is greater than

the display range) is indicated by the CNC by ”*****”.

Interrelationships of the servo loop characteristics:

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TU TA

D1 Magnitude of the 1st overshoot D2 Magnitude of the 2nd overshoot

WP Reversing point A Envelope curve

Setpoint speed

Set

TU Delay time TA Reaction time

5%− limit

Optimization instructions

While the setpoint speed should be reached as quickly as possible for pure positioning operations (thus accepting overshoot), a compromise must be reached between fast attainment of the setpoint speed and the minimum possible overshoot (contour violation by overshoot) in the case of machining operations (tool engaged).

D24 – 46

Flexible Automation

D25 – Lead screw error compensation

General

D25 Lead screw error compensation

The lead screw error compensation function permits compensation of the mechanical inaccuracies of drive spindles or rack drives. It is possible to determine and compensate both linearity errors as well as reversing backlash. In order to permit compensation, an error curve is recorded for each axis traversing direction for each machine axis to be compensated. The actual axis position is measured exactly with an external device for this purpose. The established compensation data is entered in the files L101–L108 using this diagnostic program. After activation of the function (refer to the section ”General information” at the end of this chapter), the control corrects the corresponding machine positions automatically.

Note:

Diagnosis

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The machine parameter P1509 (reversing backlash) is no longer active if the lead screw error compensation is active.

User interface/softkey assignment

The following display is an example of the display which will appear on the screen after selection of D25:

No CP0

AXIS LEAD SCREW ERROR POSITION

ACT

NC0 WAIT

0 INCREMENTS

INCREMENTS

DIAGNOSTIC

14.10 8:49PROGRAM

INCREMENTS

−

INCREMENTS

EDIT DATA IN PRERUN DATA OUT MANAGE

DATA IN DATA OUT

These keys are used to read the compensation files (L101–L108) in or out via the standard interfaces of the CNC. Please refer to the operating manual for further information on reading data in/out.

D25 – 47

Flexible Automation

D25 Lead screw error compensation

MANAGE

Deletion of the displayed L files. All compensation files (L101–L108) are deleted (if present) by the softkey DELETE

ALL. Other files are not deleted by this softkey.

Diagnosis

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DATA

It is possible to selectively delete individual files by means of the softkey DELETE and specification of a file number. It is thus possible to delete all displayed files individually.

EDIT

A compensation file can be created or modified by means of EDIT. After pressing the key EDIT , enter the file number (101–108) and confirm this with the ENTER key. An L file is permanently assigned to each axis (X, Y, Z etc.). The following applies in accordance with machine parameter P102: Axis 1: L101; Axis 2: L102...Axis 8: L108.

After selection of the required file, the control switches to the LSEC editor . All ASCII characters required for programming of the compensation values are displayed in the softkey bar:

EDIT L101

LF X S R P N

OTHER

COMMANDS

The ASCII character is inserted at the current cursor position by operation of the 1st or 2nd softkey (from the left). In the case of softkeys which possess 2 characters, first select the character which it is wished to insert by repeatedly pressing this key (the selected character is shown inverted in the softkey). This character is then inserted at the current cursor position after operation of the ENTER key.

Notes:

‘ The 2nd softkey is always assigned the axis address valid for this com-

pensation file.

‘ Refer to the section ”Programming compensation values” for the meaning

of the ASCII characters.

‘ All required characters (except for the character LF!) can also be entered on

the ASCII keyboard.

OTHER

COMMANDS

Selection of further editor functions (refer to manual ”Operating instructions”.

D25 – 48

Flexible Automation

D25 Lead screw error compensation

PRERUN

When the corresponding L–files have been created for all axes which are to be compensated, a test run can be started by way of the PRERUN function which checks the created L–files for errors.

Error–free files are provided with the identifier ”LSEC” instead of the date in the directory display after the test run. The lead screw error compensation function can be activated by CLEAR ALL LOGIC only when all compensation files are error–free. The following error messages can occur during the test run:

LSEC–SYNTAX: Syntax error in the file. LSEC–LOGIC: The file is not unambiguous. LSEC–GRID: Entered compensation positions are not on the grid defined by

the step distance.

Diagnosis

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LSEC–OVER: Values outside the display range. The following rules apply:

Positions: max. 8 positions Error values: max. +/– 32 767 A maximum of 4000 compensation values are possible per traversing direction for all axes. This includes grid points which are not programmed with a compensation value.

Refer to the handbook ”Error messages”, P. No. 3914 for detailed error descrip- tions.

D25 – 49

Flexible Automation

Determination of the error curve

D25 Lead screw error compensation

The position errors must be determined for both the positive and negative traversing directions for each desired axis.

The unit of length for position and compensation values depends on the resolution used. Normally, the resolution is 1 lm for linear and 1/100 of a degree for circular axes.

First subdivide the traversing range of an axis into a number of equally large sections (guide value, approx. 10–20 mm). This grid defines the positions in the tra- versing range at which position compensation values may be programmed later on (refer to the section ”General information” for maximum number of position com- pensation values).

Travel the axis to the start of the traversing range (normally position 0) after reference point travel.

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MOVE

Now define the actual axis position using an external measuring device. The difference between the actual and setpoint positions (P compensation value which must be specified later on for this position.

First perform this measurement in positive traversing direction for arbitrary setpoint positions located on the grid. When you reach the end of the traversing range, perform measurement in negative traversing direction for arbitrary setpoint positions on the grid. A maximum of 4000 compensation values can be entered in the control per traversing direction for all axes together.

Pos. traversing direction

Complete traversing range

Measuring positions; the measuring position distribution may be

non−uniform over the complete traversing range. The measuring positions themselves must, however, all be located on the grid.

– P

act

Neg. traversing direction

) corresponds to the

set

Note:

It is not necessary to measure all positions defined by the grid in one traversing direction. If several grid points which are not measured lie between 2 positions in a traversing direction, the compensation value of the last–measured point applies to these grid points (also refer to the section ”General information” at the end of this chapter). In this way, it is possible to perform compensation only in specific, particularly critical areas of the traversing path of an axis.

D25 – 50

Flexible Automation

Programming the compensation values

D25 Lead screw error compensation

Several characters are used as well as numbers for programming a compensation file. By means of these characters, the control recognizes the meaning of any numeric value which has been programmed after them.

Note:

All characters required are offered on the softkey level EDIT, but can also be entered on the ASCII keyboard. Exception: The character LF must be entered by way of the softkey LF on the softkey level EDIT.

All numeric values must be programmed as integers in the unit of the positioning resolution (minimum traversable distance). The positioning resolution depends on machine parameter P103:

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Positioning resolution: (increment length)

Examples: Axis type P103 Positioning resolution

Linear 3 1 m

Linear 2 10 m

Circular 3 1/1000th degree

Circular 2 1/100th degree Characters used for programming: <LF>: (LINE FEED). Each programmed line of a compensation file

S: Step distance of the grid. The step distance must be pro-

P103

110

must be terminated with <LF>.

grammed in the first line of the compensation file. The reference point and all axis position values programmed later on must lie on this grid. However, it is not necessary to assign a compensation value to each grid point.

Examples: Linear axes: ”S20000” means: compensation values may be programmed every 20 mm (with 1 m positioning resolution). Circular axes: ”S1000” means: compensation values may be programmed every 10 degrees (with 1/100th degree positioning resolution).

<AXIS ADDRESS>: (e.g. ”X”, ”Y”, ”Z”). The position of the compensation value

is programmed by the axis address with subsequent numeric value. The compensation value itself (refer to character ”P or N”) must be programmed in the same line as the position value.

D25 – 51

Flexible Automation

D25 Lead screw error compensation

R: This identifies the following number as the position of the

reference point. The compensation value itself (refer to characters ”P, N”) must be programmed in the same line as the reference point position.

Examples: Linear axis: ”R100000” means: reference point position at 100 mm (with 1 m positioning resolution). Circular axis: ”R35000” means: reference point position at 350 degrees (with 1/100th degree positioning resolution).

P, N: ”P” identifies the following number as a compensation value

in positive traversing direction. ”N” identifies the following number as a compensation value in negative traversing direction. The compensation value to be entered corresponds to the difference between the actually measured position and setpoint position in the unit of positioning resolution.

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Examples: Setpoint position Actual position Compensation value 10000 10002 2 10000 9998 –2 10000 10000 0

Programming for circular axes

Only compensation values for the position range 0° x X t 360° need be pro- grammed for circular or infinite axes. If a circular axis moves out of this range, a modulo calculation is performed with respect to the axis position for access to the compensation values so that the compensation values for the position range 0° x X t 360° are active.

Examples: An initial position of 300° and an end position of 400° are defined, for example, when programming a circular axis in the part program. The compensation values programmed for the traversing range from 300° to < 360° are used for this range, while the compensation values programmed for the range 0° to 40° are used for the traversing range from 360° to 400°. The same is true analogously, for example, for a traversing distance from +40° to –40°. The compensation values programmed for the range from < 360° to 320° are active for the path from –0° to –40°.

D25 – 52

Flexible Automation

D25 Lead screw error compensation

Diagnosis

Programming example:

The traversing range of the X–axis (0–100 mm) has been subdivided into a grid with a step distance of 10 mm. Let the reference point position of the X–axis in this example be X = 100 [mm].

Error

[m]

8 6 4

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−2

−4

−6

−8

10 20 30 40 50

Compensation characteristic of the X−axis

90 100 110

Setpoint position

103]

: Measuring points

: Compensation char.

in positive direction

: Compensation char.

in negative position

Programming:

The file L101 must be programmed for the compensation values of the X–axis. S10000<LF> Step distance 10000 l; compensation value input

possible every 10 mm.

X0P0<LF> No compensation in pos. travel direction at X0 X10000P2<LF> Compensation by +2 l in pos. travel direction at X10 X30000P2<LF> Compensation by +2 l in pos. travel direction at X30 X40000P4<LF> Compensation by +4 l in pos. travel direction at X40 X60000P1<LF> Compensation by +1 l in pos. travel direction at X60 X70000P–4<LF> Compensation by –4 l in pos. travel direction at X70 X80000P–2<LF> Compensation by –2 l in pos. travel direction at X80 X90000P0<LF> No compensation in pos. travel direction at X90 R100000P0<LF> No compensation in pos. travel direction at X100

(reference point)

R100000N0<LF> No compensation in neg. travel direction (reversal point)

at X100 (reference point)

X90000N0<LF> No compensation in neg. travel direction at X90 X80000N–2<LF> Compensation by –2 l in neg. travel direction at X80 X50000N6<LF> Compensation by +6 l in neg. travel direction at X50 X20000N3<LF> Compensation by +3 l in neg. travel direction at X20 X10000N2<LF> Compensation by +2 l in neg. travel direction at X10 X0N0<LF> No compensation in neg. travel direction at X0 M30 File end

D25 – 53

Flexible Automation

General information

D25 Lead screw error compensation

‘ If there are several grid points which have not been programmed between

two programmed grid points in a traversing direction, the compensation value of the last–programmed grid point applies to these grid points which have not been programmed. Compensation values for machine positions between two successive group points are calculated by the control by way of linear interpolation.

‘ Error compensation starts to act at the first programmed position in a com-

pensation file. Error compensation ends at the last programmed position in a compensation file.

‘ A maximum of 4000 compensation values are possible per traversing direc-

tion for all axes. The grid points which have not been ”filled out” are included in this total.

‘ The position values for the positive traversing direction must be pro-

grammed in ascending order and those for the negative traversing direction in descending order.

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‘ Position information for circular axis compensation values must lie in the

range 0° x X t 360°.

‘ The reference point must lie on the compensation grid; a compensation

value can be entered here as well.

D25 – 54

Flexible Automation

D26 – Remote diagnosis (information)

D26 CNC remote diagnosis (information)

Fast and extensive information about failed installations is essential in order to satisfy the availability demands placed nowadays on modern machine concepts. For this purpose, BOSCH offers the user the ”remote diagnosis” option, which allows the service center to be informed by telephone about the type and scope of the problems which have occurred at short notice.

For this purpose, the service or maintenance center possesses a remote diagnosis computer, a fully–configured CNC control equipped with special software. The option ”remote diagnosis” must be applied to the machine (at the machine tool manufacturer or end customer) for the CNC to be diagnosed and REMOTE DIAGNOSIS (softkey) activated. D26 is activated directly by the remote diagnosis computer only for certain diagnostic functions such as local analyzer, axis oscilloscope, MSD etc. D26 automatically deactivates itself after completion of these functions.

Information is exchanged between the CNC and service center on a telephone line using an acoustic coupler or modem. The signalling rate can be set to 300, 1200, 2400 or 4800 baud by means of machine parameter 5509.

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Diagnosis

When a connection has been established between the two controls, the service center is in a p o s i tion to inform itself about the following data of the connected CNC:

Error messages

All pending error messages (from control and machine) are transmitted to the service center immediately after they occur and are displayed on the CNC.

DIAGNOSTIC mode, softkey CONTROL

The service center can receive information about the software version on this operating level.

DIAGNOSTIC mode, softkey MACHINE

Transmission of the current MSD data (machine status display) and the input and output states present at the PLC at the time of transmission.

Messages

The service center can output any message in plain text on the monitor of the connected CNC if it is wished to exchange all information (e.g. ”Please remove receiver from acoustic coupler”).

DIAGNOSTIC mode, softkey SERVICE FUNCTION

‘ Axis oscilloscope: Recording of axis data with subsequent transmission of

the values to the service center for evaluation.

‘ Logic analyzer: Signal and trigger settings; after the end of recording, the re-

corded data can be transmitted to the service center.

File transfer

The following files can be transferred: Part programs (file group P), diagnostic programs (file group D), graphic programs (file group G), system data (file group L), offset tables (file group V), compensation tables (file group K) and W–tables (file group W).

D26 – 55

Flexible Automation

D26 CNC remote diagnosis (information)

Directory display

The service center can have displayed all or specially selected directories of the individual file groups.

File transfer CNC ––> remote diagnosis computer

After a certain file has been selected, this can be transmitted by the control to the remote diagnosis computer and evaluated there.

File transfer remote diagnosis computer ––> CNC

Any files can be transmitted to the user by the remote diagnosis computer (e.g. after correction of a part program at the service center).

File deletion

Individual files can be deleted from the service center.

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Diagnosis

D26 – 56

Flexible Automation

D27 – Putting into operation for circular compensation

General

D27 Putting into operation

for circular compensation

The diagnostic program acts as an aid for putting into operation the option CIRCULAR COMPENSATION. Other required commissioning aids: – D23 Contour display.

You will find further information on the option CIRCULAR COMPENSATION in the section ”Circular compensation”. Please refer to the sections ”Preparations for optimization” and ”Optimizing the circular compensation parameters” for preparations and procedure for optimization.

Notes:

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Diagnosis

‘ The option requires the servo loop board SERVO–i and the option CS–

TABLES.

‘ Circular compensation is possible only for synchronous linear axes and is

sensible only in conjunction with a direct measuring system.

‘ If the option PILOT CONTROL is activated in the system, the pilot control

weighting factors (machine parameters P1016 and P1017) must have been optimized to minimize lag before circular compensation is activated and optimized.

Circular compensation

The option CIRCULAR COMPENSATION allows contour errors to be minimized during circular interpolation in the area of the quadrant transitions (at the reversal point of an axis). These contour errors occur with different degrees of severity on individual machines owing to the respective mechanical design (static friction, torsion etc.).

D27 – 57

Flexible Automation

D27 Putting into operation

for circular compensation

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Diagnosis

Circle contour display in diagnostic program D23 and assignment of the reversal points to the axes

Uy1

Ux1Ux2

Uy2

1 = 1st reversal point X−axis

2 = 2nd reversal point X−axis

1 = 1st reversal point Y−axis

Uy2 = 2nd reversal point Y−axis

Speed characteristic of both axes involved in circular interpolation

Ux1

Ux2

Uy1

Uy2

Uy1

Magnified representation of the point U

In order to avoid contour errors, a compensation pulse is generated at the reversal point of the respective axis in addition to the setpoint input. This ensures continuous movement of this axis through the standstill point (breakaway from static friction at the right time).

The ideal pulse height is related non–linearly to the path velocity. When the option is put into operation, this non–linear function must first be determined and graphically plotted for the reversal points of all axes involved in circular interpolation on the basis of measurements (with D27 and D23). This function is then approximated by a maximum of three adjacent straight lines, thus providing a maximum of four reference points (SP1–SP4) with the parameter pairs of pulse height (PH) and path velocity (VB) (refer to following figure).

SP1

Measured values=

SP = Reference points

SP2

SP3

SP4

V1 V2 V3 V4

Measured curve and its approximation by 3 straight lines

D27 – 58

Flexible Automation

D27 Putting into operation

for circular compensation

The W–table W999999003 is used for recording all parameters necessary for circular compensation (refer to the section ”Preparations for optimization” for the W– table definition program). The content of this table is read during every control run–up and is then active until a renewed run–up operation. On the basis of these values, the CNC calculates the required pulse height by linear interpolation for arbitrary speeds. The pulse height is decreased linearly down to P first programmed reference point (SP1) down to the speed V remains constant for path velocities above the last programmed reference point (SP4).

= 0 for path velocities below the

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Diagnosis

= 0. The pulse height

D27 – 59

Flexible Automation

User interface/softkey assignments

D27 Putting into operation

for circular compensation

The following monitor display appears after D27 has been started:

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Diagnosis

No CP0

AXIS: COMPENSATION PULSE 1.Q: COMPENSATION PULSE 2.Q: COMPENSATION TIME: 20

AXIS

NUMBER

AXIS

NUMBER

ACT

ADJUSTMENTS

COMPENSATION

PULSE 1.Q

NC0 STOP

CIRCULAR COMPENSATION

1 0 0

COMPENSATION

PULSE 2.Q

COMPENSATION

TIME

Selection of the axis to be optimized (value range: 0–8).

COMPENSATION PULSE

1.Q

COMPENSATION PULSE

2.Q

DIAGNOSTIC

30.11. 14: 8PROGRAM

ACTIVATE

SERVO

Input of the compensation pulse height at the 1st and 2nd reversal points respectively of the selected axis in the unit lm (value range: 0 – 9999).

COMPENSA-

TION TIME

Input of the compensation pulse duration in interpolation steps (value range: 0 –

9999). The actual pulse duration is calculated as follows: T = input value *P9901. The parameter ”Compensation time” is preassigned the value 20 and should not normally be changed.

ACTIVATE

The values displayed under ”ADJUSTMENTS” are transferred directly to the interpolation processor for optimization when this softkey is pressed. Transfer o f the values to the W–table does not take place automatically.

Caution: ‘ The optimized circular compensation parameters have to be manually en-

tered in the W–table W 999999003 (refer to the section ”Preparations for optimization” for definition and structure of the W–table). This W–table is evaluated during every control run–up (if the option CIR- CULAR COMPENSATION is applied).

D27 – 60

Flexible Automation

Preparations for optimization

D27 Putting into operation

for circular compensation

‘ The values become active only if all parameters of the corresponding axis

have been preassigned the value ”0” in the W–table before the last control run–up or if W 999999003 does not exist.

Several preparations have to be made before optimization:

‘ Test program generation

Example: P110 N10 G0 X50 Y60 Z0

N20 G17 G2 X60 Y50 R40 N30 G0 X50 Y60 M30

Since circular compensation is active only during circular interpolation and not at its start/end, the start and end points must not be programmed at a quadrant transition in this test program.

‘ Generation of a definition program for W–table W999999003

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Diagnosis

(DFS, W999999003,COMPENSATION–TAB) $[8] $[A,W,40,0,COMPENSATION TIME] $[B,W,40,0,U1:.1.F–VALUE.] $[C,W,40,0,U1:.1.P–HEIGHT] $[D,W,40,0,U1:.2.F–VALUE.] $[E,W,40,0,U1:.2.P–HEIGHT] $[F,W,40,0,U1:.3.F–VALUE.] $[G,W,40,0,U1:.3.P–HEIGHT] $[H,W,40,0,U1:.4.F–VALUE.] $[I,W,40,0,U1:.4.P–HEIGHT] $[J,W,40,0,U2:.1.F–VALUE.] $[K,W,40,0,U2:.1.P–HEIGHT] $[L,W,40,0,U2:.2.F–VALUE.] $[M,W,40,0,U2:.2.P–HEIGHT] $[N,W,40,0,U2:.3.F–VALUE.] $[O,W,40,0,U2:.3.P–HEIGHT] $[P,W,40,0,U2:.4.F–VALUE.] $[Q,W,40,0,U2:.4.P–HEIGHT] $[@1,8,AXIS NUMBER] #* M30

Store the definition program on a data medium (Important: read out without DFS identifier!).

The W–table is generated later on by reading this definition program into the con- trol.

The table contains 8 columns (axis number 1–8) of 17 lines each (circle parameters). The compensation time required for the respective axis will be entered later under address ”A”. A maximum of 4 parameter pairs (pulse height and path velocity) can be specified under addresses B to I for the first reversal point (U1). The parameter pairs for the second reversal point (U2) should be entered in addresses J to Q. The addresses of the parameter pairs valid for a reversal point need not be com-

D27 – 61

Flexible Automation

Optimizing the circular compensation parameters

D27 Putting into operation

for circular compensation

pletely allocated in the W–table. It is thus also permitted, for example, to specify only two parameter pairs.

D27 allows you to preallocate corresponding compensation values for the two reversal points of each axis. Please note that the entered values are active only if the W–table values of the corresponding axis have been preallocated the value ”0” and are active or if W999999003 does not exist (also refer to the section ”User interface/software as- signments” under softkey ACTIVATE). Diagnostic program D23 can be used to check the contour after execution of a circle. For this purpose, setpoint and actual contours are displayed in D23. In order to permit the quadrant transition to be seen more easily, the respective axis can be expanded on the display (for instructions on operation of D23, refer to chapter ”D23 Contour display”, softkey EXPANSION.

1. Define the radius which is to be used for optimization. Define the speed

range within which optimization is to take place. 9999 mm/min. is the maximum permitted path feedrate.

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Diagnosis

MOVE

SERVO

MOVE

2. Adapt the test program P110 (feedrate, radius) and then perform program

selection.

3. Select D23 and set the trigger condition (e.g. program number = 110, block

number = 20).

4. Start D23 recording. Start test program.

5. Check quadrant transitions with contour display.

6. Select D27. Enter the corresponding axis number and compensation values

(compensation pulse 1.Q/2.Q). Then press softkey ACTIVATE.

7. Select D23. Start recording. Start test program.

8. Check the quadrant positions. Optimize the compensation values if the com-

pensation is too large or too small (repeat steps 6–8).

9. Determine the optimum compensation values for various speeds by adapt-

ing the test program (feedrate). Note the found compensation values in a table (feedrate value, compensation path). Plot noted values graphically for each reversal point. Perform further measurements if necessary at critical points.

10. Approximate measured curves by maximum of 3 straight lines (refer to sec-

tion ”Circular compensation”).

11. Generate W–table and plot parameter pairs of the reference points.

12. Transfer the W–table values by pressing the softkeys RESET FUNCTION

and CLEAR ALL LOGIC in group operating mode DIAGNOSTIC.

D27 – 62

Flexible Automation

D28 – Tapping without compensation chuck

General

User interface/softkey assignments

D28 Tapping

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Diagnosis

The diagnostic program D28 acts as a commissioning aid for the option ”TAPPING WITHOUT COMPENSATION CHUCK” for correct adjustment of the pilot control weighting factors for speed and acceleration (machine parameters P7203 and P7204).

Note:

The option requires the servo loop board SERVO i.

The following display appears after D28 is started:

No CP0

RECORDING

WAITING

AXIS: V−WEIGHTING: A−WEIGHTING: Y1 :

Y2 : X−EXPANSION:

X−EXP. START:

JOG BUT TON 1. AXIS

DISPLAY

ACT

ADJUSTMENTS

1000 1000

100

TRIGGER SETTING

NC0 STOP

1 0 0

MM/MIN MM/MIN MS

0 SCALE DIVISION

AXIS

DATA

PER SCALE DIVISION PER SCALE DIVISION

PER SCALE DIVISION

DISPLAY

SPLITTING

TAPPING

OTHER

COMMANDS

DIAGNOSTIC

30.11. 14: 8PROGRAM

START

RECORDING

DISPLAY

After the end of a recording (refer to softkey START RECORDING), you can have recorded feedrate and lag values displayed as diagrams on the monitor by pressing this softkey . The graphic display parameters are influenced by means of the functions offered by the softkey DISPLAY SPLITTING.

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Flexible Automation

AXIS

DATA

D28 Tapping

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Diagnosis

SERVO

AXIS

NUMBER

FEED

WEIGHTING

ACCELERA-

TION

WEIGHTING

ACTIVATE

On this softkey level, the axis to be optimized and the setpoints of the pilot control values for feedrate and acceleration can be defined for an optimization step (refer to the section ”Optimizing the pilot control weighting factors” for the optimization procedure).

In addition, it is possible to transfer the pilot control values to the machine parameters 7203 and 7204 after optimization by means of the softkey ACTIV ATE, without the option ”PILOT SPEED CONTROL” having to be activated in the system. A CNC reset automatically takes place after operation of the softkey ACTIVATE.

Caution: The values are entered only in the machine parameter record by operation of the softkey ACTIVATE. The file L444 is not modified. In order to keep L444 up to date, L444 must first be deleted after transfer and then regenerated (with/without text) if necessary. Possibly save the machine parameter record in the EEPROM!

Note:

If it is wished to optimize several axes, it is not necessary to press the softkey ACTIVATE after adjustment of an individual axis. First optimize all desired axes successively and then press the softkey ACTIVATE.

SOFTKEY

DISPLAY

SPLITTING

X–DISPLAY

START

EXPAND X

* 10

SCALE

Y1–AXIS

SCALE

Y2–AXIS

It is possible to manipulate the display parameters of the graphic display here (refer to softkey DISPLAY). Both the right start point of the X–axis and expansion of the X–axis by a factor 10 as well as scale factors for the Y–axes of the feedrate (Y1) and lag diagram (Y2) can be defined separately.

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Flexible Automation

OTHER

COMMANDS

D28 Tapping

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Diagnosis

MOVE

TRIGGER JOG

BUTTON

TRIGGER

PROG./BLOCK

After activation of recording (refer to softkey START RECORDING), the start of data recording is delayed until a specific trigger event occurs. Both operation of a jog button and the start of execution of a specific program block can be defined as a trigger event. The set trigger condition is identified by inverse display of the corresponding softkey.

START

RECORDING

Data recording is activated after operation of this softkey. At this point in time, the pilot control values entered on softkey level AXIS DATA are valid and not the machine parameter values.

Recording starts when the trigger event occurs in accordance with the set trigger condition. During recording, the text ”RUNNING” is displayed on the monitor instead of the text ”WAITING” (under the line ”RECORDING”). 480 feedrate and lag values are always recorded. The recording time is calculated as follows: T[ms] = 480 * P9901. The generated diagram can be called by means of the softkey DISPLAY only after the end of recording.

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Flexible Automation

Preparations for optimization

D28 Tapping

Several preparations must be made before optimization:

‘ Adaption of the PLC program

The CNC output signal 16.5 is output for the duration of tapping. Feed enable is permitted by means of this signal although no M3, M4 is output.

‘ Adjustment of machine parameters

P7201 (gear speed–dependent spindle closed–loop gain): First take over the closed–loop gain value for the spindle axis from machine parameter P7014. The closed–loop gain must be set for each gear speed so that no spindle oscillations occur at the maximum speed which is to be used for tapping.

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Diagnosis

P7202 Gear speed–dependent spindle acceleration: Take over the value from machine parameter P7015.

P7203 and P7204 (axis–specific pilot control weighting factors): First leave these values unchanged. The values determined later on during optimization can be transferred here directly from D28 by means of the softkey ACTIVATE.

If the option ”PILOT CONTROL” is applied, it is additionally necessary to take into account the settings of P1014 and P1015 for optimization. Both pa rameters define the maximum possible limit values for speed and acceleration pilot control weighting factors.

‘ Test program generation

Example:P111 N10 G1 X0 Y0 Z0 M19 S0

N20 G32 F1000 M3 S1000 Z30 N30 G32 F1000 M4 S1000 Z0 M30

Before the start of tapping, the position servo loop of the spindle must be closed. This is achieved, for example, by way of the function SPINDLE ORIENTATION or SPINDLE STOP (M5).

If drilling is to take place several times in a hole, the spindle must be positioned with M19 before G32 (e.g. subsequent cutting after tool breakage).

D28 – 66

Flexible Automation

Optimizing the pilot control weighting factors

D28 Tapping

Aim of optimization: The lag of the drilling axis should be ”0” if possible during tapping. Realistic values here are a lag of less than 10 lm during constant speed phases and lag values of less than 20 lm during acceleration phases. The procedure for setting the pilot control parameters is described below.

Since the magnitude of the remaining lag significantly effects the accuracy of the thread, careful adjustment of the pilot control parameters is essential.

1. Select D28.

2. Set the trigger condition (e.g. program number = 11, block number = 20).

3. Set the axis number (e.g. axis number = 3; Z–axis).

4. Start recording by means of the softkey ST ART RECORDING then start test

program (P111).

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Diagnosis

MOVE

SERVO

MOVE

SERVO

5. Evaluate recording. Calculate the active closed–loop gain from the recorded

feedrate and lag values.

6. Compare the active closed–loop gain (CLG

chine parameter P1001. Depending on the result, you can now enter the rough value of the feedrate weighting factor in D28 under softkey level AXIS DATA:

Result of comparison Feedrate weighting factor to be entered

CLGact ~ P1001 approx. 10000 ( 300) CLGact > P1001 significantly less than 10000 CLGact < P1001 greater than 10000

7. Start recording by means of the softkey START RECORDING. Then start

test program (P111).

8. Evaluate recording. The lag which occurred during unaccelerated travel is

now relevant (stationary lag).

Lag Entered feedrate weighting factor

) with the value entered in ma-

act

became less increase; repeat as from step 7. has changed sign reduce; repeat as from step 7. (over–compensation) no reduction OK; continue with step 9. possible without sign change

Note:

It is possible to increase the resolution of the lag diagram in Y–direction by scale switchover on the softkey level DISPLAY SPLITTING in order to permit easy recognition of small lag values.

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Flexible Automation

SERVO

MOVE

D28 Tapping

9. Increase the value of the acceleration weighting factor in D28 on the softkey

level AXIS DA TA in order to now minimize the lag during acceleration/deceleration (recommendation: step distance 100).

10. Start recording by means of the softkey START RECORDING. Then start

test program (P111).

11. Evaluate recording.

The lag which occurred during accelerated travel is now relevant.

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Diagnosis

SERVO

Lag Entered acceleration weighting factor

became less increase; repeat as from step 10. changed sign reduce; repeat as from step 10. no reduction OK; continue with step 12. possible without sign change

Notes:

It is possible to increase the resolution of the lag diagram in Y–direction by switch- ing the scale on softkey level DISPLAY SPLITTING in order to permit easy recognition of small lag values. The lag during an accelerated travel must not change.

12. Select the next axis to be optimized on softkey level AXIS DA TA and adapt

test program (P111). Then continue with step 4.

When the weighting factors have been set for all drilling axes, press the softkey ACTIVATE on softkey level AXIS DATA. This transfers all optimized pilot control weighting factors to the machine parameter record. The file L444 is not changed as a result. A CNC reset automatically takes place after this. In order to keep L444 up to date, you must first delete L444 after transfer and then regenerate it (with/without text) again if necessary.

13. Check the optimized settings using the diagnostic program D23 CONTOUR

DISPLAY: The offset between spindle and drilling axis at the reversal point can be determined with D23. To do this, plot the spindle axis and drilling axis against each other (by means of the softkeys DISPLAY X/Y AXIS on the softkey level STARTING VALUES). In the ideal case, the ”ACTUAL CONTOUR” pro- duces a straight line for drilling in and out.

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1070 073 306-101 (91.10) GB · HB NC · AT/VSP · Printed in Germany

bosch CC 220 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual