HEIDENHAIN CNC Pilot 4290 User Manual

CNC PILOT 4290

NC Software 368 650-xx V7

User’s Manual

English (en)

10/2004

Data input keypad

Manual operating mode

Automatic mode

Programming modes (DIN PLUS, simulation,TURN PLUS)

Organization modes (parameter, service, transfer)

Display error status

Call the info system

ESC (escape)

■Go back by one menu level

■Close dialog box, do not save

INS (insert)

■ Insert list element

■ Close dialog box, save data

ALT (alter)

■ Change the list element

DEL (delete)

■Deletes the list element

■deletes the selected character or the character to the left of the cursor.

. . . Numbers for value input and soft-key selection

Decimal point

Minus as algebraic sign

”Continue key” for special functions (e.g. marking)

Arrow keys

Page forward, page backward

■ Change to previous/next screen page

■Change to previous/next dialog box

■Switch between input windows

Machine operating panel

Cycle Start

Cycle Stop

Feed Stop

Spindle Stop

Spindle on – M3/M4 direction

Spindle jog – M3/M4 direction (The spindle turns until you press the key.

Manual direction keys +X/–X

Manual direction keys +Z/–Z

Manual direction keys +Y/–Y

Rapid traverse key

Slide change key

Spindle change key

Spindle speed at the programmed value

Increase/decrease spindle speed by 5%

Override dial for feed rate

Touch pad with right and left mouse key

Enter – Confirmation of input

CNC PILOT 4290, Software and

Functions

This manual describes functions that are available in the CNC PILOT 4290 with NC software number 368 650-xx (Release 7.0). For programming theY-axis, please refer to the User's Manual ”CNC PILOT 4290 withY-Axis”. It is not described in this manual.

The machine manufacturer adapts the features offered by the control to the capabilities of the specific lathe by setting machine parameters. Therefore, some of the functions described in this manual may not be among the features provided by the CNC PILOT on your machine tool.

Some of the CNC PILOT functions which are not available on every machine are:

■Machining with the C axis

■Machining with theY-axis

■Full-surface machining

■Tool monitoring

■Graphically supported interactive contour definition

■Automatic or graphically supported interactive DIN PLUS program generation

Please contact your machine manufacturer for detailed information on the features that are supported by your machine tool.

Many machine manufacturers and HEIDENHAIN offer programming courses for the CNC PILOT controls. We recommend these courses as an effective way of improving your programming skills and sharing information and ideas with other CNC PILOT users.

HEIDENHAIN also offers the PC software DataPilot 4290, which is designed for use with the CNC PILOT 4290.The DataPilot is suitable for both shop-floor programming as well as off-location program creation and testing. It is also ideal for training purposes. DataPilot can be run on WINDOWS 95, WINDOWS 98, WINDOWS ME, WINDOWS NT 4.0 or WINDOWS 2000.

Intended place of operation

The CNC PILOT 4290 complies with EN 55022, Class A, and is intended primarily for operation in industrially zoned areas.

Contents

Introduction and Fundamentals

Basics of operation

Manual Control and Automatic Modes

DIN PLUS

Graphic Simulation

TURN PLUS

Parameter

Operating Resources

Service and Diagnosis

Transfer

Tables and overviews

Contents1

2

3

4

5

6

7

8

9

10

11

HEIDENHAIN CNC PILOT 4290	I

Contents

1 Introduction and Fundamentals				..... 1
1.1	The CNC PILOT.....	2
1.2	The Operating Modes.....		5
1.3	Expansion Stages (Options).....			6
1.4	Fundamentals.....	7
1.5	Tool Dimensions.....	10

.....2 Basics of Operation				11
2.1	User Interface.....			12
	2.1.1	Screen Displays.....			12
	2.1.2	Controls and Displays.....				13
	2.1.3	Selection of Operating Modes.....					14
	2.1.4	Selection of Functions, Data Input					..... 14
2.2	The Info System.....			16
2.3	The Error System			..... 17
	2.3.1	Direct Error Messages.....				17
	2.3.2	Error Display, PLC Display.....				17
2.4	Data Backup.....		19
2.5	Explanation of Terms.....				19

.....3 Manual Control and Automatic mode							21
3.1 Switch-On, Switch-Off, Reference Run.....							22
	3.1.1	Switch-On and Traversing the Reference Marks.....							22
	3.1.2	Switch-Off.....	23
3.2	Manual Operating Mode.....			24
	3.2.1	Entering machine data.....			25
	3.2.2	M Commands.....		25
	3.2.3	Manual Turning Operations.....				26
	3.2.4	Handwheel.....	26
	3.2.5	Spindle and Axis Direction Keys.....					27
	3.2.6	Slide/Spindle change key.....				27
3.3	Tool Lists, Tool Life Management.....					28
	3.3.1	Setting Up a Tool List.....			29
	3.3.2	Comparing a Tool List with an NC Program.....							31
	3.3.3	Transferring the Tool List from an NC Program.....							32
	3.3.4	Tool Life Management.....			33
3.4	Setup Functions.....		34
	3.4.1	Defining the Tool Change Position.....					34
	3.4.2	Shifting the Workpiece Datum.....					35
	3.4.3	Defining the protection zone.....				36
	3.4.4	Setting up the Chucking Table.....					37
	3.4.5	Setting up Machine Dimensions.....					38
	3.4.6	Measuring Tools.....		39

II

Contents

3.5 Automatic Mode of Operation.....							41
	3.5.1	Program Selection.....				41
	3.5.2	Defining a Start Block.....					42
	3.5.3	Program Sequence Modification.....							43
	3.5.4	Compensation.....				44
	3.5.5	Tool Life Management.....					45
	3.5.6	Inspection Mode.....				46
	3.5.7	Block Display.....			48
	3.5.8	Graphic Display.....				49
	3.5.9	Post-Process Measuring Status Display.....								51
3.6	Machine Display.....			52
3.7	Load Monitoring.....			54
	3.7.1	Reference Machining.....					54
	3.7.2	Production Using Load Monitoring.....							55
	3.7.3	Editing Limit Values.....					56
	3.7.4	Analyzing Reference Machining.....							57
	3.7.5	Machining Using Load Monitoring.....							57
	3.7.6	Load Monitoring Parameters.....						58
4 DIN PLUS.....		59
4.1	DIN Programming.....			60
	4.1.1	Introduction.....		60
	4.1.2	DIN PLUS Screen.....				61
	4.1.3	Linear and Rotary Axes.....					62
	4.1.4	Units of Measurement.....					63
	4.1.5	Elements of the DIN Program.....						63
4.2	Programming Notes.....				65
	4.2.1	Parallel Editing.....				65
	4.2.2	Address Parameters.....					65
	4.2.3	Contour Programming.....					66
	4.2.4	Tool Programming.....				68
	4.2.5	Fixed cycles.....		69
	4.2.6	NC Subprograms.....				70
	4.2.7	Template Control.....				70
	4.2.8	NC Program Interpretation.....						70
4.3 The DIN PLUS Editor.....					71
	4.3.1	Main Menu.....		72
	4.3.2	Geometry Menu.....				75
	4.3.3	Machining Menu.....				76
	4.3.4	Block Menu.....		77

Contents

HEIDENHAIN CNC PILOT 4290	III

Contents

4.4	Program Section Codes			.....	79
	4.4.1	PROGRAMMKOPF [PROGRAM HEAD].....							79
	4.4.2	TURRET.....	80
	4.4.3	CHUCKING EQUIPMENT.....				82
	4.4.4	Contour Definition.....			82
	4.4.5	BEARBEITUNG [MACHINING].....					83
	4.4.6	UNTERPROGRAMM [SUBPROGRAM].....							83
4.5	Geometry Commands.....				84
	4.5.1	Definition of Blank.....			84
	4.5.2	Basic Contour Elements.....				84
	4.5.3	Contour Form Elements.....				86
	4.5.4	Help Commands for Contour Definition.....								92
	4.5.5	Contour Position.....			95
	4.5.6	Front and Rear Face Contours.....					96
	4.5.7	Lateral Surface Contours.....				102
	4.5.8	Circular Pattern with Circular Slots.....						108
4.6	Machining Commands.....				110
	4.6.1	Assigning the Contour to the Operation							.....	110
	4.6.2	Tool Positioning without Machining.....							110
	4.6.3	Simple Linear and Circular Movements.....							111
	4.6.4	Feed Rate and Spindle Speed.....					113
	4.6.5	Cutter Radius Compensation (TRC/MCRC).....								115
	4.6.6	Zero Point Shift.....			116
	4.6.7	Oversizes, Safety Clearances.....					118
	4.6.8	Tools, Types of Compensation.....					120
4.7	Turning Cycles.....		122
	4.7.1	Contour-Based Turning Cycles.....					122
	4.7.2	Simple Turning Cycles.....				134
4.8	Thread Cycles.....		140
4.9	Drilling cycles.....		143
4.10	C-Axis Machining.....		148
	4.10.1 General C-Axis Functions.....					148
	4.10.2 Front/Rear Face Machining.....						149
	4.10.3 Lateral Surface Machining.....						150
4.11	Milling Cycle Group.....			152
4.12	Special functions.....		159
	4.12.1 Chucking		Equipment in Simulation.....						159
	4.12.2 Slide Synchronization.....					160
	4.12.3 Spindle Synchronization, Workpiece Transfer.....									161
	4.12.4 Contour Follow-Up.....				164
	4.12.5 In-Process Measuring.....					165

IV

Contents

	4.12.6 Post-Process Measuring.....					166
	4.12.7 Load Monitoring.....			167
4.13	Other G Functions.....		168
4.14	Data Input and Data Output.....				173
	4.14.1 Input/Output of # Variables.....					173
	4.14.2 Input/Output of V Variables.....					174
4.15	Programming Variables.....			175
	4.15.1 # Variables.....		175
	4.15.2 V Variables.....		177
	4.15.3 Program Branches, Program Repeats, Conditional Block Execution.....						179
4.16	Subprograms.....	182
4.17	M Functions.....	183

4.18 Programming Notes and Examples.....										184
	4.18.1 Programming Machining Cycles									.....	184
	4.18.2 Contour Repetitions.....							184
	4.18.3 Full-Surface Machining.....							187
5 Graphic Simulation.....					195
5.1	Simulation Mode of Operation.....							196
	5.1.1	Graphic Elements, Displays.....								197
	5.1.2	Basics of Operation.....						200
5.2	Main Menu		..... 201
5.3	Contour Simulation.....					203
	5.3.1	Contour-Simulation Functions.....								203
	5.3.2	Dimensioning.....					204
5.4	Machining Simulation.....						205
5.5	Motion Simulation.....					207
5.6	Zoom Function.....				208
5.7	3-D View.....		209
5.8	Checking the
5.9	Time Calculation.....				212
5.10	Synchronous Point Analysis.....							213
6 TURN PLUS		.....	215
6.1	TURN PLUS Mode of Operation.....								216
6.2	Program Management.....						217
	6.2.1	TURN PLUS Files.....					217
	6.2.2	Program Head.....					218
6.3	Workpiece Description.....						219
	6.3.1	Entering the Contour of a Blank Part.....									219
	6.3.2	Input of the Finished Part Contour.....									220
	6.3.3	Superimposing form elements.....								221
	6.3.4	Integrating a Contour Train.....							222

Contents

HEIDENHAIN CNC PILOT 4290	V

Contents

	6.3.5	Entering Contours Machined with the C Axis.....						223
	6.3.6	Basics of Operation		..... 225
	6.3.7	Help Functions for Element Definition.....					226
6.4	Contours of Workpiece Blanks.....				228
6.5	Contour of Finished Part.....			229
	6.5.1	Basic Contour Elements.....			229
	6.5.2	Form elements.....		232
	6.5.3	Overlay Elements.....		239
6.6	C-Axis Contours.....		242
	6.6.1	Contours on the Front and Rear Face.....					242
	6.6.2	Contours of the Lateral Surface.....				249
6.7	Manipulating Contours.....			256
	6.7.1	Editing the Contours of a Blank Part				.....	256

6.7.2Trimming..... 256

6.7.3Change..... 258

6.7.4Deleting..... 259

6.7.5Inserting..... 260

6.7.6Transformations..... 261

6.7.7Connect..... 262

	6.7.8	Resolve.....		262
6.8	Importing DXF Contours.....						263
	6.8.1	Fundamentals.....				263
	6.8.2	Configuring the DXF Import.....						264
	6.8.3	DXF-Import		.....	266
	6.8.4	Transferring and Organizing DXF Files.....							266
6.9	Assigning attributes.....				267
	6.9.1	Attributes for Workpiece Blanks						..... 267
	6.9.2	Oversize.....			267
	6.9.3	Feed rate/peak-to-valley height.....						267
	6.9.4	Precision stop.....				268
	6.9.5	Separation Points.....					268
	6.9.6	Machining Attributes.....					269
6.10	User Aids.....		273

6.10.1Calculator..... 273

6.10.2Digitizing..... 274

6.10.3	Inspector – Checking Contour Elements.....				274
6.10.4	Unresolved Contour Elements.....			275
6.10.5 Error Messages.....		276
6.11 Preparing a Machining Process			..... 277
6.11.1	Chucking a Workpiece.....		277
6.11.2	Setting Up a Tool List.....		284

VI

Contents

6.12	Interactive Working Plan Generation (IWG).....							286
	6.12.1 Tool call.....			287
	6.12.2 Cutting Data.....				288
	6.12.3 Cycle specification.....					288
	6.12.4 Roughing.....			289
	6.12.5 Recessing			..... 294
	6.12.6 Drilling.....			299
	6.12.7 Finishing.....			301
	6.12.8 Thread Machining(G31)					..... 306
	6.12.9 Milling.....			307
	6.12.10 Special Machining Tasks (SM).....						309
6.13	Automatic Working Plan Generation (AWG).....							310
	6.13.1 Generating a Machining Plan.....						310
	6.13.2 Machining Sequence.....					311
6.14	Control Graphics.....			321
6.15	Configuration.....			322
6.16	Machining Information.....				324
	6.16.1 Tool Selection, Turret Assignment.....							324
	6.16.2 Cutting Parameters.....					325
	6.16.3 Coolant.....			325
	6.16.4 Hollowing.....			326
	6.16.5 Inside Contours.....				326
	6.16.6 Drilling.....			328
	6.16.7 Full-Surface Machining.....					328
	6.16.9 Shaft Machining.....				330
6.17	Example.....	332
7 Parameters.....		337
7.1	Parameter Mode of Operation.....					338

7.1.1Parameters..... 338

	7.1.2 Editing Parameters.....		339
7.2	Machine Parameters.....	341
7.3	Control Parameters.....	348
7.4	Set-Up Parameters.....	355
7.5	Machining Parameters.....	357

Contents

HEIDENHAIN CNC PILOT 4290	VII

Contents

.....8 Operating Resources			371
8.1	Tool Database.....		372
	8.1.1	Tool Editor.....	372
	8.1.2	Tool Types (Overview).....				375
	8.1.3	Tool Parameters.....		377
	8.1.4	Multipoint Tools, Tool Life Monitoring.....						384
	8.1.5	Explanation of Tool Data.....				385
	8.1.6	Tool Holder, Mounting Position					..... 387
8.2	Chucking Equipment Database.....					390
	8.2.1	Chucking Equipment Editor.....					390
	8.2.2 Chucking Equipment Data.....					392
8.3	Technology Database (Cutting Values).....						399

.....9 Service and Diagnosis					401
9.1	Service Mode of Operation.....						402
9.2	Service Functions.....			402
	9.2.1	Access Authorization.....					402
	9.2.2	System Service.....			403
	9.2.3	Fixed-Word Lists.....			404
9.3	Maintenance System.....				405
9.4	Diagnosis.....		408

.....10Transfer		411
10.1	The Transfer Mode of Operation.....					412
10.2	Transfer Systems			..... 413
	10.2.1 General Information.....				413
	10.2.2 Configuring for Data Transfer.....						414
10.3	Data Transfer.....			417
	10.3.1 Enabling, Data Types.....				417
	10.3.2 Transmitting and Receiving Files.....						418
10.4	Parameters and Operating Resources.....						420
	10.4.1 Converting Parameters and Operating Resources							..... 420
	10.4.2 Saving Parameters and Operating Resources.....							422
10.5	File Organization.....			423

.....11 Tables and overviews			425
11.1	Undercut and Thread Parameters.....					426
	11.1.1	Undercut DIN 76, Parameters				.....	426
	11.1.2	Undercut DIN 509 E, Parameters					..... 427
	11.1.3	Undercut DIN 509 F, Parameters.....					427
	11.1.4	Thread Parameters.....			428
	11.1.5	Thread Pitch.....	429
11.2	Technical Information.....		433
11.3	Peripheral Interfaces.....		437

VIII

Contents

1

Introduction and Fundamentals

1.1The CNC PILOT

1.1The CNC PILOT

The CNC PILOT is a contouring control designed for lathes and turning centers. In addition to turning operations, you can perform milling and drilling operations with the C-axis or theY-axis.The CNC PILOT supports parallel machining of up to 4 workpieces in programming, testing and production. Full-surface machining is supported on lathes with:

■Rotating gripper

■Movable opposing spindle

■Multiple spindles, slides and tool carriers

The CNC PILOT controls up to 6 slides, 4 spindles and 2 C axes.

Programming

Depending on the type and complexity of the parts to be machined and your organization, you can choose the type of programming best suited to your tasks.

In TURN PLUS you describe the contour of the blank and finished part with interactive graphics.Then you call the automatic working plan generation (AWG), and the NC program will be generated fully automatically at a keystroke. Alternately, you can choose the interactive working plan generation (IWG). When using the IWG, you determine the sequence of machining and other technical details.

Every working step is shown in the control graphics and can be corrected immediately. The result of program creation with TURN PLUS is a structured DIN PLUS program.

TURN PLUS minimizes the number of entries required, but it requires that the the tool data and cutting data has already been entered.

If TURN PLUS fails to create the optimal NC program for technologically sophisticated machining operations, or if you primarily want to reduce the machining time, program the NC program in DIN PLUS.

DIN PLUS supports the separation of the geometric description from the machining of the workpiece. Powerful cycles are available for programming in DIN PLUS.The ”simple geometry programming” function calculates coordinates if the dimensions used in the drawing are not suitable for NC programs.

Alternately, you can machine your workpiece in DIN PLUS with linear and circular movements and simple turning cycles, as you are accustomed to in conventional DIN programming.

BothTURN PLUS and DIN PLUS support machining with the C-axis or Y-axis and full-surface machining.

The Graphic Simulation feature enables you to subject your NC programs to a realistic test. The CNC PILOT displays the machining of up to 4 workpieces in the working space. Workpiece blanks and finished parts, chucking equipment and tools are shown to scale.

You can program your NC programs and test them -even during machining operationsdirectly on the machine.

Regardless of whether you are machining a simple or complex part, producing a single part or a series of parts, or a whole batch on a turning center, the CNC PILOT always gives you optimum support.

2	1 Introduction and Fundamentals

The C-axis

With a C-axis you can drill and mill a workpiece on its front, back and lateral surfaces.

During use of the C-axis, one axis interpolates linearly or circularly with the spindle in the given working plane, while the third axis interpolates linearly.

The CNC PILOT supports part program creation with the C-axis in:

■DIN PLUS

■TURN PLUS contour definition

■TURN PLUS working plan generation

TheY-axis

With aY-axis you can drill and mill a workpiece on its front, back and lateral surfaces.

During use of theY-axis, two axes interpolate linearly or circularly in the given working plane, while the third axis interpolates linearly. This enables you to machine slots or pockets, for example, with plane floors and perpendicular edges. By defining the spindle angle, you can determine the position of the milling contour on the workpiece.

The CNC PILOT supports part program creation with theY-axis in:

■DIN PLUS

■TURN PLUS contour definition

■TURN PLUS working plan generation

1.1The CNC PILOT

HEIDENHAIN CNC PILOT 4290

3

1.1The CNC PILOT

Full-surface machining

The CNC PILOT supports full-surface machining for all common machine designs.The features include anglesynchronous part transfer with rotating spindle, traversing to a stop, controlled parting, and coordinate transformation.This ensures efficient full-surface machining and simple programming.

The CNC PILOT supports full surface machining in:

■DIN PLUS

■TURN PLUS contour definition

■TURN PLUS working plan generation

4	1 Introduction and Fundamentals

1.2The Operating Modes

The functions of the CNC PILOT are grouped into the following operating modes:

Manual operating mode

In the Manual mode you set up the machine and move the axes manually.

Automatic mode

The NC programs are run in Automatic mode.You control and monitor the machining of the workpiece.

DIN PLUS programming mode

In ”DIN PLUS,” you can create structured NC programs. You first define the geometry of the blank and finished part, and then program the individual operations.

Simulation programming mode

The Simulation mode shows a graphic representation of programmed contours, the paths of traverse and cutting operations.The working space, tools and chucking equipment are shown true to scale.

During simulation, the CNC PILOT calculates the machining and idle-machine times for every tool. For lathes with several slides, the Synchronous point analysis enables you to optimize your NC program.

TURN PLUS programming mode

In ”TURN PLUS” you describe the contour of the workpiece using interactive graphics. For Automatic Working plan Generation (AWG), you select the material and chucking equipment. The CNC PILOT will generate the NC program automatically at a keystroke. As an alternative, you can create the working plan with the aid of interactive graphics (IAG).

Parameter organization mode

The system behavior of the CNC PILOT is controlled with parameters. In this mode, you set the parameters to adapt the control to your situation.

In addition, in this mode you describe the operating resources (tools and chucking equipment) and the cutting values.

Service organization mode

In ”Service” mode, you log on for password-protected functions, select the conversational language and make the system settings.This operating mode also provides diagnostic functions for commissioning and checking the system.

Transfer organization mode

In ”Transfer” you exchange the files with other systems, organize your programs and make data backups.

The actual control is not accessible to the machinist. You should know, however, that your CNC PILOT has an integrated hard disk on which allTURN PLUS and DIN PLUS programs that you enter are stored. This allows you to save a vast number of programs.

For data exchange and data backup, you can use the Ethernet interface. Data exchange is also possible over the serial interface. (RS232).

1.2 Modes of Operation

HEIDENHAIN CNC PILOT 4290

5

Expansion Stages (Options)

1.3Expansion Stages (Options)

The machine manufacturer configures the CNC PILOT according to the capabilities of the specific lathe.The following upgrades (options) are available, which enable you to adapt the control to your specific requirements:

■TURN PLUS

Graphically supported interactive contour definition

■Graphic description of the workpiece for blank and finished part

■Geometry-programming function for calculating and displaying missing contour data

■Simple input of standard form elements like chamfers, rounding arcs, recesses, undercuts, threads, fits, etc.

■Easy-to-use transformations like shifting, rotating, mirroring or multiplying

DIN PLUS program generation with interactive graphics

■Selection of the appropriate machining method

■Selection of the tools and definition of the cutting data

■Direct graphic control of machining process

■Immediate compensation possibility

Automatic DIN PLUS program generation

■Automatic selection of tools

■Automatic generation of working plan

■TURN PLUS – extension by C-axis orY-axis

■C-axis: representation of programmed contour in the following views: XC plane (front/rear end) and ZC plane (unrolled surface)

■Y-axis: representation of programmed contour in the following views: XY plane (front/rear end)YZ plane (side view)

■Hole and figure patterns

■Fixed cycles

■Interactive or automatic working plan generation – also for machining with the C-axis orY-axis

■TURN PLUS – extension by opposing spindle

■Rechucking with expert program

■Interactive or automatic generation of working plan – also for rechucking and 2nd setup

■In-process measuring

■With triggering probe

■For measuring tools

■For measuring workpieces

■Post-process measuring

■Connection of measuring system via RS-232 interface

■Evaluation of measuring results in Automatic mode

Options can usually be retrofitted.Your machine manufacturer can give you more information on retrofitting.

This operating manual describes all options.The operating sequences described in this manual may therefore deviate from those on your machine whenever a certain option is not supported by your system.

6	1 Introduction and Fundamentals

1.4Fundamentals

Axis designations

The cross slide is referred to as the X-axis and the saddle as the Z- axis.

All X-axis values that are displayed or entered are regarded as diameters. In TURN PLUS you can define whether the X-axis values are to be interpreted as diameters or radii.

Lathes with Y-axis: TheY-axis is perpendicular to the X-axis and Z-axis (Cartesian system).

When programming paths of traverse, remember to:

■Program a positive value to depart the workpiece.

■Program a negative value to approach the workpiece.

1.4 Fundamentals

Coordinate system

The coordinates entered for the principal axes X,Y and Z are referenced to the workpiece zero point – exceptions to this rule will be indicated.

Angles entered for the C-axis are referenced to the ”zero point of the C-axis” (precondition: the C-axis has been configured as a principal axis).

Absolute coordinates

If the coordinates of a position are referenced to the workpiece zero point, they are referred to as absolute coordinates. Each position on a workpiece is clearly defined by its absolute coordinates.

HEIDENHAIN CNC PILOT 4290

7

1.4 Fundamentals

Incremental coordinates

Incremental coordinates are always referenced to the last programmed position.They specify the distance from the last active position and the subsequent position. Each position on a workpiece is clearly defined by its incremental coordinates.

Polar coordinates

Positions located on the face or lateral surface can either be entered in Cartesian coordinates or polar coordinates.

When programming with polar coordinates, a position on the workpiece is clearly defined by the entries for diameter and angle.

You can enter polar coordinates as absolute or incremental values.

Units of measurement

You can program and operate the CNC PILOT either in the metric or inch system.The units of measurement listed in the table below apply to all inputs and displays.

Measure	Metric	inch
Coordinates	mm	inch
Lengths	mm	inch
Angles	Degrees	Degrees
Spindle speed	rpm	rpm
Cutting speed	m/min	ft/min
Feed per revolution	mm/rev	inch/rev
Feed per minute	mm/min	inch/min
Acceleration	m/s2	ft/s2

8	1 Introduction and Fundamentals

Machine reference points

Machine zero point

The point of intersection of the X-axis with the Z-axis is called the machine zero point. On a lathe, the machine zero point is usually the point of intersection of the spindle axis and the spindle surface.The machine zero point is designated with the letter M.

Workpiece zero point

For machining a workpiece, it is easier to reference all input data to a zero point located on the workpiece. By programming the zero point used in the workpiece drawing, you can take the dimensions directly from the drawing, without further calculation.This point is the ”workpiece zero point.” The workpiece zero point is designated with the letterW.

Reference marks

Whether the control ”forgets” the positions of the machine axes when it is switched off depends on the position encoders used. If the positions are lost, you must pass over the fixed reference points after switching on the CNC PILOT. The system knows the distances of the reference points to the machine datum.

1.4 Fundamentals

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1.5Tool Dimensions

1.5Tool Dimensions

The CNC PILOT requires information on the specific tools for a variety of tasks, such as calculating the cutting radius compensation or the proportioning of cuts.

Tool length

All position values that are programmed and displayed are referenced to the distance between the tool tip and workpiece zero point. Since the control only knows the absolute position of the tool carrier (slide), it needs the dimensions XE and ZE to calculate and display the position of the tool tip. For milling and drilling tools operating with theYaxis, the CNC PILOT additionally needs the dimension inY.

Tool compensation

The tool tip is subjected to wear during machining processes.To compensate for this wear, the CNC PILOT uses compensation values. The system automatically adds the compensation values to the values for length.

Tooth and cutter radius compensation (TRC)

The tip of a lathe tool has a certain radius. When machining tapers, chamfers and radii, this results in inaccuracies which the CNC PILOT compensates with its cutting radius compensation function.

Programmed paths of traverse are referenced to the theoretical tool tip S. The TRC function compensates for this error by calculating a new path of traverse, the equidistant line.

Milling cutter radius compensation (MRC)

In milling operations, the outside diameter of the milling cutter determines the contour. When the MRC function is not active, the system defines the center of the cutter as reference point for the paths of traverse. The MRC function compensates for this error by calculating a new path of traverse, the equidistant line.

10	1 Introduction and Fundamentals

2

Basics of Operation

2.1 User Interface

2.1User Interface

2.1.1 Screen Displays

1Operating mode line

Show the status of the operating modes.

■The active mode of operation is shown with a dark-gray background.

■Programming and organization modes:

–The selected mode is shown at the right of the symbol

–Additional information such as the selected program, submode, etc. are shown below the operating mode symbol.

2Menu bar and pull-down menus

For function selection

3Working window

Size and content depend on the operating mode. Some programming and organization modes overlap the machine display.

4Machine display

Current status of the machine (tool position, the cycle and spindle situation, active tool, etc.).The machine display is configurable.

5Status line

■Simulation,TURN PLUS: display of current settings or information on the next operating steps

■Other operating modes: display of the last error message

6Calendar date and service ”traffic light”

■Display of date and time

■A color background signals a error or a PLC message

■The ”service traffic light” shows the servicing state of the machine (see ”9.3 Maintenance system”)

7Soft-key row

Shows the current meaning of the soft keys.

8Vertical soft-key row

Shows the current meaning of the soft keys. For more information: see the machine manual

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3

8

4

5		6

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12	2 Basics of Operation

2.1.2 Controls and Displays

Screen with

■Horizontal and vertical soft keys: The meaning is shown above or next to the soft keys

Additional keys (same function as on the operating panel):

■ESC

■INS

Operating panel with

■Alphanumeric keyboard with integrated numeric keypad

■Keys for Operating mode selection

■Touch pad: For cursor positioning (menu or soft key selection, selection from lists, selecting edit boxes, etc.)

Machine operating panel with

■Operating elements for the manual and automatic operation of the lathe (cycle keys, manual direction keys, etc.)

■Handwheel for exact positioning in manual operation

■Override button for feed-rate override

Operation of the touch pad

Normally, you can use the touch pad as an alternative to the cursor keys. In the following, the keys below the touch pad are referred to as the left and right mouse keys.

The functions and operation of the touch pad are similar to the mouse operation of theWindows operating systems.

■Single click of the left mouse key or single touch on the touch pad:

■The cursor is positioned in lists or input windows.

■Menu items, soft keys or buttons are activated

■Double-click of the left mouse key or double touch on the touch pad: In lists, the selected element is activated (the input window is activated)

■Single-click with the right mouse key:

■Same function as the ESC key – prerequisite: the ESC key is allowed in this situation (for example to go back by one menu level)

■Same function as the left mouse key when selection soft keys or buttons

2.1 User Interface

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2.1 User Interface

2.1.3 Selection of Operating Modes

You can switch the operating mode at any time. After the change, the new mode starts in the function in which it was last exited.

In the programming and organization modes a difference is made between the following situations:

■No operating mode is selected (no entry next to the operating mode symbol): Select the desired mode from the menu.

■Operating mode selected (indicated next to the operating mode symbol):The functions of this operating mode are available. Within the programming or organization modes, you can switch the modes by soft key or by repeatedly pressing the corresponding mode key.

2.1.4 Selection of Functions, Data Input

Menu bar and pull-down menu

The individual menu items are preceded by a 9-field symbol with one field highlighted.This field represents the field on the numeric keypad. Press the key whose position corresponds to the position of the highlighted field.

The function selection begins in the menu row, then goes to the pulldown menus. In the pull-down menu, press again the numeric key assigned to the menu item – or alternatively, select the menu item with touch pad or with the ”page up/page down” keys and press Enter.

Soft-key row

The meaning of the soft keys is dependent on the current operating situation.

Some soft keys work like ”toggle switches”. A function is active when the associated field in the function-key row is highlighted in color. The setting remains in effect until the function is switched off.

List Operations

DIN PLUS programs, tool lists, parameter lists, etc. are displayed as lists. You can scroll through a list with the touch pad or arrow keys to check data, to select the position where you wish to enter data, or to highlight items for operations like deleting, copying, editing, etc.

After having selected the desired list position or a list item, press the ENTER, INS, ALT or DEL key to execute the operation.

Keys for operating mode selection:

Manual operating mode

Automatic operating mode

Programming modes

Organization modes

Continued

14	2 Basics of Operation

Data Input

Data are entered and edited in input windows. An input window consists of several input fields.You position the cursor with the touch pad or with the page up/page down keys to the input box.

Once the cursor is located in the box, you can enter your data. Existing data are overwritten. With the right/left arrow keys you can place the cursor on a position within the input box in order to delete or add characters. The up/down arrow keys or Enter confirm and terminate the entry.

Some dialogs have more input fields than a window can show. In these cases, more than one input window appears on the screen, one superimposed on the other.You will recognize this through the window number in the top line.To toggle between input windows, use the Page Up/Page Dn keys.

By pressing the ”OK” button, you confirm the data entered or edited. Independent of the position of the cursor, you can press the INS key as an alternative. If you leave the input window by pressing the ”Cancel” button or the ESC key, entries or changes will be lost.

If the dialog consists of more than one input window, you already confirm the data when pressing the PageUp/PageDn key.

Buttons

The CNC PILOT allows you to choose various options via different buttons such as the ”OK” and ”Cancel” buttons for terminating a dialog box or the buttons contained in the ”Extended inputs” window.

Select the required button and press ENTER.

Note: Instead of selecting the ”OK” or ”Cancel” button, you can press the INS or ESC key.

2.1 User Interface

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2.2 The Info System

	2.2	The Info System
	The info system calls excerpts from the User's Ma-
	nual to the screen. The system is structured in info
	topics comparable to the chapters of a book. In the
	top line of the information window, the topic you
	selected and the page number are shown.
	The info system gives you information on the current
	operating situation (context-sensitive help). Also, you
	can select the info topics through the table of
	contents or the subject index. Simply select the
	desired topic or word and click ”Topic select” (or
	Enter).
	Cross references in the text are highlighted. Place
	the cursor on the desired cross reference and call the
	topic with ”Topic select.” ”Topic return” switches
	back to the previous topic.
	Error display
	When an error message occurs, press the info key, or
	place the cursor on the error message in the ”display
	of errors” and then press the info key, to get further
			Soft keys
	information on the respective error.
			Calls the
		Call the info system
			■ Selected cross reference
			■ Topic from the table of contents
		End the info system	■ Topic from the subject index
			Returns to the most recent info topic
			Calls the table of contents with the overview of info
			topics. The table of contents is arranged in several
			levels.
			Calls the subject index
			Switches to the previous topic.
			Switches to the next topic.
			(or page up key) previous info page
			(or page down key) next info page

16	2 Basics of Operation

2.3The Error System

2.3.1 Direct Error Messages

Direct error messages appear whenever immediate error correction is possible. Confirm the message by pressing ENTER and correct the error. Example:The input value of the parameter is out of range.

Information of the error message:

■Error description: Explains the error

■Error number: For service inquiries

■Time of day When the error occurred (for your information).

Symbols

Warning

The program run/operation continues.The CNC PILOT indicates the problem.

Error

The program run/operation is stopped.You must correct the error before you can continue the current job.

2.3.2 Error Display, PLC Display

Error Display

If during the system start or during program run or other operation an error occurs, it is indicated in the date box, displayed in the status line, and saved in the error display.

The date and time remain highlighted in red until all of the errors have been canceled.

Notes on using TURN PLUS:

Opens the ”error display”

Further information on the error marked with the cursor

Exits the error display

Deletes the error message marked with the cursor

Deletes all error messages.

Continued

2.3The Error System

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2.3The Error System

Information of the error message:

■Error description: Explains the error

■Error number: For service inquiries

■Channel number: Slide for which the error occurred.

■Time of day When the error occurred (for your information).

■Error class (only with errors):

■Background: The message serves for information only, or it is a minor error.

■Cancel: The running process (cycle run, traverse command, etc.) was aborted.You can resume operation once the error has been cleared.

■Emergency stop: Traverse and the execution of the DIN program were stopped.You can resume operation once the error has been cleared.

■Reset: Traverse and the execution of the DIN program were stopped. Switch off the control for a moment, then restart. Contact your machine manufacturer if the error occurs again.

System Error, Internal Error

If a system error or internal error occurs, write down all information on the displayed message and inform your machine manufacturer. You cannot correct an internal error. Switch off the control and restart.

Warnings during Simulation

In the event of problems during simulation of an NC program, the CNC PILOT displays a warning in the status line (see ”5.1.2 Notes on Operation”).

PLC display

The PLC window is used for PLC messages and the PLC diagnosis.Your machine manual provides more detailed information on the PLC window.

To call the PLC window, open the error window with the Error status key and then press ”PLC Diagnosis” soft key.

To exit the PLC status display, press the ESC key; to switch to the error window, use the ”CNC Diagnosis” soft key.

Soft keys

Switch to PLC display

Deletes all error messages

Return to error display

18	2 Basics of Operation