HEIDENHAIN SW 68894x-03 User Manual

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User’s Manual

CNC PILOT 640

NC Software 688946-03 688947-03

English (en) 1/2015

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Controls and displays of the CNC PILOT

DEL

ERR

CALC

Keys on visual display unit

Key Function

Switches the help graphics between outside and inside machining (only in the cycle programming)

No function

Soft keys for selecting functions on screen

Switches to the soft-key menu at left / right

Switches to the next menu in the PLC menu

Operating mode keys

Key Function

Machine operating modes:

 Manual Operation  Program Run

Programming modes

 smart.Turn  DINplus  DIN/ISO

Tables for tool data and technology data

Organization:

 Parameters  File organization  Transfer  Diagnosis

smart.Turn keys

Key Function

Go to the next form

Next/previous group

Navigation keys

Key Function

Up/Down arrow keys

Numeric keypad

Key Function block

Number keys 0-9:

 Numeric input keys  Menu operation

Decimal point

Switchover between positive and negative values

Escape key: Cancelation of dialogs and next higher menu level

Insert key: OK in dialogs and new NC blocks in the editor

Delete block: Deletes the selected area

Backspace: Deletes the character to the left of the cursor

CE key: Deletes the error messages in the machine operating mode

Next: Enables input fields for additional entries in dialog boxes

Enter: Confirms the input

Special keys

Key Function

Error key: Opens the error window

Starts the integrated calculator

Info key: Shows additional information in the parameter editor

Activates special functions, such as input options or input of characters as on an alphabetic keyboard

Machine operating panel

Key Function

Cycle start

Cycle stop

Feed rate stop

Spindle stop

Left/Right arrow keys

Screen page or dialog page up/down

Go to beginning of program/list or to end of program/list

Spindle on – M3/M4 direction

Spindle jog – M3/M4 direction. The spindle rotates as long as you press the key.

Manual direction keys +X/–X

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Operating panel of the CNC PILOT

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CNC PILOT 640, software and features

This manual describes functions that are available in the CNC PILOT with NC software number 688946-03 and 688947-03.

The programming of smart.Turn and DIN PLUS is not included in this manual. These functions are described in the User's Manual for smart.Turn and DIN PLUS Programming (ID 685556-xx). Please contact HEIDENHAIN if you require a copy of this manual.

The machine manufacturer adapts the features offered by the control to the capabilities of the specific machine tool 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 that are not available on every machine are:

 Positioning of spindle (M19) and driven tool  Operations with the C or Y axis

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. We recommend these courses as an effective way of improving your programming skill and sharing information and ideas with other CNC PILOT users.

HEIDENHAIN also offers the DataPilot MP 620 or DataPilot CP 640 software for personal computers, which is designed to simulate the functions of the MANUALplus 620 and CNC PILOT 640. The DataPilot is suitable for both shop-floor programming as well as offlocation program creation and testing. It is also ideal for training purposes. The DataPilot can be run on PCs with WINDOWS operating systems.

Intended place of operation

The CNC PILOT complies with the limits for Class A devices in accordance with the specifications in EN 55022, and is intended for use primarily in industrially-zoned areas.

Legal information

This product uses open source software. Further information is available on the control under

 Organization mode of operation  LICENSE INFO SOFT KEY

HEIDENHAIN CNC PILOT 640 5

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New functions of software 688945-02

 In the program simulation, the current contour description (of work-

piece blank and finished part) can be mirrored and saved. In smart.Turn, these contours can be reinserted (siehe Seite 498)

 On machines with opposing spindle, the workpiece spindle can now

be selected in the TSF menu (siehe Seite 98)

 On machines with opposing spindle, its zero point can be shifted

(see Seite 98)

 The user documentation is now also available in the context-sensi-

tive help system TURNguide (see Seite 66)

 You can make your own project folder in the project management,

so that you can centrally manage associated files (see Seite 129)

 With a manual tool change system it is possible to insert tools that

are not in the turret during a program run (see Seite 511)

 Engraving cycles are now available in the Teach-In mode of opera-

tion (see Seite 345)

 During tool data backup, you can now select in a dialog window the

data to be saved or restored (see Seite 596)

 The G30 function is now available for converting G functions, M

functions or spindle numbers, as well as for mirroring traverse paths and tool dimensions (see the smart.Turn and DIN Programming User’s Manual)

 The "traverse to a fixed stop" function (G916) is now available for

transferring the workpiece to the second traversable spindle or for pressing the tailstock against the workpiece (see the smart.Turn and DIN Programming User’s Manual)

 The G925 function makes it possible to define and monitor the max-

imum contact force for an axis. This function can be applied to use the opposing spindle as a mechatronic tailstock, for example (see the smart.Turn and DIN Programming User’s Manual)

 Controlled parting using servo-lag monitoring (G917) can now be

activated to prevent collisions caused by incomplete parting processes (see the smart.Turn and DIN Programming User’s Manual)

 The spindle synchronization option G720 synchronizes the shaft

speeds of two or more spindles so that they rotate synchronously with a gear ratio or a defined offset (see the smart.Turn and DIN Programming User’s Manual)

 In combination with the synchronization (G720) of main spindle and

tool spindle, the new "Hobbing" cycle (G808) is available for milling external teeth and profiles (see the smart.Turn and DIN Programming User’s Manual)

 With G924, a "fluctuating speed" can now be programmed to pre-

vent resonance (see the smart.Turn and DIN Programming User’s Manual)

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New functions of software 688945-03 and 68894x-01

 In the Organization mode of operation, you can grant or restrict

access to the control by using the EXTERNAL ACCESS soft key (siehe auch „Organization mode of operation” auf Seite 542)

 The pocket calculator can now be activated in each application and

also remains active after a change in operating modes. The Get current value and Load current value soft keys enable you to fetch

numerical values from an active input field or to transfer them to an active input field (siehe auch „Integrated calculator” auf Seite 58)

 Tool touch probes can now be calibrated in the Machine Setup

menu (siehe auch „Calibrating the tool touch probe” auf Seite 100)

 The workpiece zero point can now also be set in the direction of the

Z axis using a touch probe (siehe auch „Machine setup” auf Seite

92)

 In Teach-in mode, the oversizes RI and RK for the workpiece blank

were introduced for finishing in the recess-turning cycles (siehe auch „Recess turning, radial finishing—expanded” auf Seite 250)

 The oversizes RI and RK for the workpiece blank were introduced for

finishing in the recess-turning units and in Cycle G869 (see smart.Turn and DIN Programming User's Manual).

 On machines with a B axis it is now also possible to drill, bore, and

mill in oblique planes. In addition to this, the B axis enables you to use tools even more flexibly during turning (see smart.Turn and DIN Programming User's Manual).

 The control now provides numerous touch probe cycles for various

applications (see smart.Turn and DIN Programming User's Manual):

 Calibrating a touch trigger probe  Measuring circles, circle segments, angle and position of the C

axis

 Misalignment compensation  Single-point and double-point measurement  Finding a hole or stud  Zero point setting in the Z or C axis  Automatic tool measurement

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 The new TURN PLUS function automatically generates NC pro-

grams for turning and milling operations based on a fixed machining sequence (see smart.Turn and DIN Programming User's Manual).

 The G940 function now provides a way to calculate the tool lengths

in the basic (definition) position of the B axis (see smart.Turn and DIN Programming User's Manual).

 For machining operations that require rechucking, you can define a

separation point on the contour description with G44 (see smart.Turn and DIN Programming User's Manual).

 The G927 function enables you to convert tool lengths to the refer-

ence position of the tool (B axis = 0) (see smart.Turn and DIN Programming User's Manual).

 Recesses that were defined with G22 can now be machined with

the new Cycle 870 ICP Recessing (see smart.Turn and DIN Programming User's Manual).

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New functions of software 68894x-02

 The "Zero point shift" miscellaneous function was introduced in ICP

(siehe auch „Zero point shift” auf Seite 389)

 In ICP contours, fit dimensions and inside threads can now be cal-

culated using an input form (siehe auch „Fits and inside threads” auf Seite 384)

 The miscellaneous functions "Copy in linear/circular series, and by

mirroring" were introduced in ICP (siehe auch „Copying a contour section in linear series” auf Seite 389)

 The system time can now be set using an input form (siehe auch

„Displaying operating times” auf Seite 101)

 The parting cycle G859 was expanded by the parameters K, SD and

U (siehe auch „Parting” auf Seite 267)

 The angle of approach and departure can now be defined for ICP

recess turning (siehe auch „ICP recess turning, radial finishing” auf Seite 258)

 With TURN PLUS you can now create programs for machining with

an opposing spindle and for multipoint tools (see the smart.Turn and DIN Programming User’s Manual)

 In the G797 Area Milling function, milling contours can now be

selected (see the smart.Turn and DIN Programming User’s Manual)

 The G720 function was expanded by the Y parameter (see the

smart.Turn and DIN Programming User’s Manual)

 The G860 function was expanded by the O and U parameters (see

the smart.Turn and DIN Programming User’s Manual)

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New functions of software 68894x-03

 In the Teach-In submode, the parameter RB was added to the cycles

"Figure, axial", "Figure, radial", "ICP contour, axial" and "ICP contour, radial" (siehe „Milling cycles” auf Seite 317)

 In the Teach-In submode, the parameters SP and SI were added to

all tapping cycles (siehe „Drilling cycles” auf Seite 299)

 In the Simulation submode, the 3-D view provides additional fea-

tures (siehe „3-D view” auf Seite 491)

 Tool control graphics were introduced in the Tool Editor mode of

operation (siehe „Tool control graphics” auf Seite 505)

 An ID number can be entered directly in the turret list (siehe „Filling

the turret list” auf Seite 88)

 The tool list provides additional filter options (siehe „Sorting and fil-

tering the tool list” auf Seite 502)

 The Transfer submode provides enhanced tool backup functionality

(siehe „Transferring tool data” auf Seite 596)

 The Transfer submode provides enhanced tool import functionality

(siehe „Importing tool data of the CNC PILOT 4290” auf Seite 604)

 The Set Axis Values menu item now also enables you to define off-

set values for shifts using G53, G54 and G55 (siehe „Defining offsets” auf Seite 94)

 Load monitoring was introduced in the Program Run submode

(siehe „Load monitoring (option)” auf Seite 119)

 The definition of skip levels was introduced in the Program Run sub-

mode (siehe „Program execution” auf Seite 114)

 A function was introduced to query information on the tool status

(siehe „Tool life monitoring”, Seite 90), (siehe „Editing tool-life data” auf Seite 509)

 A user parameter was introduced to enable you to activate and deac-

tivate the software limit switches for the Simulation submode (siehe „List of user parameters” auf Seite 545)

 A user parameter was introduced to enable you to suppress the

error message for the software limit switches (siehe „List of user parameters” auf Seite 545)

 A user parameter was introduced to enable you to use NC Start for

executing a tool change programmed in the T,S,F dialog (siehe „List of user parameters” auf Seite 545)

 A user parameter was introduced to divide the T,S,F dialog into sep-

arate dialogs (siehe „List of user parameters” auf Seite 545)

 The parameter WE was added to G32 (see the smart.Turn and DIN

Programming User's Manual)

 The parameters U, V and W were added to G51, G56 and G59 (see

the smart.Turn and DIN Programming User's Manual)

 Parameters ensuring maximum compatibility with the ICP contour

description were added to G0, G1, G12/G13, G101, G102/G103, G110, G111, G112/G113, G170, G171, G172/G173, G180, G181 and G182/G183 (see the smart.Turn and DIN Programming User's Manual)

 The parameter C was added to G808 (see the smart.Turn and DIN

Programming User's Manual)

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 The parameter U was added to G810 and G820 (see the smart.Turn

and DIN Programming User's Manual)

 The parameter D was added to G4 and G860 (see the smart.Turn

and DIN Programming User's Manual)

 The parameter B was added to G890 (see the smart.Turn and DIN

Programming User's Manual)

 The parameter RB was added to the units G840 "Contour milling, fig-

ures" and G84X "Pocket milling, figures" (see the smart.Turn and DIN Programming User's Manual)

 The parameters SP and SI were added to all tapping units (see the

smart.Turn and DIN Programming User's Manual)

 G48 was introduced to allow limiting the rapid traverse rate for

rotary and linear axes (see the smart.Turn and DIN Programming User's Manual)

 G53, G54 and G55 were introduced for zero point shifts using offset

values (see the smart.Turn and DIN Programming User's Manual)

 The functions for superimposing axis movements G725 "Eccentric

turning", G726 "Transition to eccentric" and G727 "Eccentric X" were introduced (see the smart.Turn and DIN Programming User's Manual)

 The load monitoring functions G995 "Monitoring zone definition" and

G996 "Type of load monitoring" were introduced (see the smart.Turn and DIN Programming User's Manual)

 The AWG submode now also supports tools with quick-change

holders (see the smart.Turn and DIN Programming User's Manual)

 A tree view is available in the smart.Turn operating mode (see the

smart.Turn and DIN Programming User's Manual)

 Skip levels can be defined in the smart.Turn operating mode (see

the smart.Turn and DIN Programming User's Manual)

 A function was introduced to query information on the tool status

(see the smart.Turn and DIN Programming User's Manual)

HEIDENHAIN CNC PILOT 640 11

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About this manual

The symbols used in this manual are described below.

This symbol indicates that important information about the function described must be considered.

This symbol indicates that there is one or more of the following risks when using the described function:

 Danger to workpiece  Danger to fixtures  Danger to tool  Danger to machine  Danger to operator

This symbol indicates that the described function must be adapted by the machine tool builder. The function described may therefore vary depending on the machine.

This symbol indicates that you can find detailed information about a function in another manual.

About this manual

Would you like any changes, or have you found any errors?

We are continuously striving to improve our documentation for you. Please help us by sending your requests to the following e-mail address: tnc-userdoc@heidenhain.de.

HEIDENHAIN CNC PILOT 640 13

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About this manual

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Contents

Introduction and fundamentals

Basics of operation

Machine mode of operation

Teach-in mode

ICP programming

Graphic simulation

Tool and technology database

Organization mode of operation

Tables and overviews

Overview of cycles

HEIDENHAIN CNC PILOT 640 15

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1 Introduction and fundamentals ..... 35

1.1 The CNC PILOT ..... 36

1.2 Configuration ..... 37

Slide position ..... 37

Tool carrier systems ..... 37

The C axis ..... 37

The Y axis ..... 38

Full-surface machining ..... 39

1.3 Features ..... 40

Configuration ..... 40

Modes of operation ..... 40

1.4 Data backup ..... 42

1.5 Explanation of terms ..... 43

1.6 CNC PILOT design ..... 44

1.7 Fundamentals ..... 45

Position encoders and reference marks ..... 45

Axis designations ..... 45

Coordinate system ..... 46

Absolute coordinates ..... 46

Incremental coordinates ..... 47

Polar coordinates ..... 47

Machine zero point ..... 47

Workpiece zero point ..... 48

Units of measure ..... 48

1.8 Tool dimensions ..... 49

Tool length ..... 49

Tool compensation ..... 49

Tool-tip radius compensation (TRC) ..... 50

Milling cutter radius compensation (MCRC) ..... 50

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2 Basics of operation ..... 51

2.1 General information on operation ..... 52

Operation ..... 52

Setup ..... 52

Programming – Teach-in mode ..... 52

Programming – smart.Turn ..... 52

2.2 The CNC PILOT screen ..... 53

2.3 Operation and data input ..... 54

Operating modes ..... 54

Menu selection ..... 55

Soft keys ..... 55

Data input ..... 56

smart.Turn dialogs ..... 56

List operations ..... 57

Alphanumeric keyboard ..... 57

2.4 Integrated calculator ..... 58

Calculator functions ..... 58

Adjusting the position of the calculator ..... 60

2.5 Types of programs ..... 61

2.6 The error messages ..... 62

Display of errors ..... 62

Opening the error window ..... 62

Closing the error window ..... 62

Detailed error messages ..... 63

"Details" soft key ..... 63

Clearing errors ..... 64

Error log file ..... 64

Keystroke log file ..... 65

Saving service files ..... 65

2.7 TURNguide context-sensitive help system ..... 66

Application ..... 66

Working with the TURNguide ..... 67

Downloading current help files ..... 71

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3 Machine mode of operation ..... 73

3.1 Machine mode of operation ..... 74

3.2 Switch-on / Switch-off ..... 75

Switch-on ..... 75

Monitoring EnDat encoders ..... 75

Traversing the reference marks ..... 76

Switch-off ..... 77

3.3 Machine data ..... 78

Input of machine data ..... 78

Machine data display ..... 80

Cycle statuses ..... 84

Axis feed rate ..... 84

Spindle ..... 84

3.4 Setting up a tool list ..... 85

Machine with turret ..... 85

Machine with multifix ..... 85

Tools in different quadrants ..... 86

Filling the turret list from the database ..... 87

Filling the turret list ..... 88

Tool call ..... 89

Driven tools ..... 89

Tool life monitoring ..... 90

3.5 Machine setup ..... 92

Defining the workpiece zero point ..... 93

Defining offsets ..... 94

Homing the axes ..... 95

Setting the protection zone ..... 96

Defining the tool change position ..... 97

Setting C-axis values ..... 98

Setting up machine dimensions ..... 99

Calibrating the tool touch probe ..... 100

Displaying operating times ..... 101

Setting the system time ..... 102

3.6 Tool measurement ..... 103

Touch off ..... 104

Touch probe (tool touch probe) ..... 105

Optical gauge ..... 106

Tool compensation ..... 107

3.7 Manual mode ..... 108

Tool change ..... 108

Spindle ..... 108

Handwheel operation ..... 108

Manual direction keys ..... 109

Teach-in cycles in Manual mode ..... 109

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3.8 Teach-in mode ..... 110

Teach-in mode ..... 110

Programming Teach-in cycles ..... 110

3.9 Program Run mode ..... 111

Loading a program ..... 111

Comparing a tool list ..... 112

Before executing a program ..... 112

Finding a start block ..... 113

Program execution ..... 114

Entering compensation values during program run ..... 115

Program execution in "dry run" mode ..... 118

3.10 Load monitoring (option) ..... 119

Reference machining ..... 121

Checking the reference values ..... 122

Adapting the limit values ..... 124

Using load monitoring during production ..... 125

3.11 Graphic simulation ..... 126

3.12 Program management ..... 127

Program selection ..... 127

File manager ..... 128

Project management ..... 129

3.13 Conversion into DIN format ..... 130

Making a conversion ..... 130

3.14 Units of measure ..... 131

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4 Teach-in mode ..... 133

4.1 Working with cycles ..... 134

Cycle starting point ..... 134

Help graphics ..... 135

DIN macros ..... 135

Graphical test run (simulation) ..... 135

Contour follow-up in Teach-in mode ..... 136

Cycle keys ..... 136

Switching functions (M functions) ..... 137

Comments ..... 137

Cycle menu ..... 138

Addresses used in many cycles ..... 140

4.2 Workpiece blank cycles ..... 141

Bar/tube blank ..... 142

ICP workpiece blank contour ..... 143

4.3 Single cut cycles ..... 144

Rapid traverse positioning ..... 145

Move to the tool change position ..... 146

Linear machining, longitudinal ..... 147

Linear machining, transverse ..... 148

Linear machining at angle ..... 149

Circular machining ..... 151

Chamfer ..... 153

Rounding arc ..... 155

M functions ..... 157

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4.4 Turning cycles ..... 158

Tool position ..... 159

Cut longitudinal ..... 161

Cut transverse ..... 163

Roughing, longitudinal—expanded ..... 165

Roughing, transverse—expanded ..... 167

Finishing cut, longitudinal ..... 169

Finishing cut, transverse ..... 170

Finishing cut, longitudinal—expanded ..... 171

Finishing cut, transverse—expanded ..... 173

Cut, longitudinal plunge ..... 175

Cut, transverse plunge ..... 177

Cut, longitudinal plunging—expanded ..... 179

Cut, transverse plunging—expanded ..... 181

Cut, longitudinal finishing plunge ..... 183

Cut, transverse finishing plunge ..... 185

Cut, longitudinal finishing plunge—expanded ..... 187

Cut, transverse finishing plunge—expanded ..... 189

Cut, ICP contour-parallel, longitudinal ..... 191

Cut, ICP contour-parallel, transverse ..... 194

Cut, ICP contour-parallel, longitudinal finishing ..... 196

Cut, ICP contour-parallel, transverse finishing ..... 198

ICP cutting, longitudinal ..... 200

ICP cut transverse ..... 202

ICP longitudinal finishing cut ..... 204

ICP transverse finishing cut ..... 206

Examples of turning cycles ..... 208

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4.5 Recessing cycles ..... 212

Cutting and infeed directions for recessing cycles ..... 212

Undercut position ..... 213

Contour forms ..... 213

Recessing, radial ..... 214

Recessing, axial ..... 216

Recessing, radial—expanded ..... 218

Recessing, axial—expanded ..... 220

Recessing radial, finishing ..... 222

Recessing axial, finishing ..... 224

Recessing radial, finishing—expanded ..... 226

Recessing axial, finishing—expanded ..... 228

ICP recessing radial ..... 230

ICP recessing cycles, axial ..... 232

ICP recessing, radial finishing ..... 234

ICP recessing, axial finishing ..... 236

Recess turning ..... 238

Recess turning, radial ..... 239

Recess turning, axial ..... 240

Recess turning, radial—expanded ..... 242

Recess turning, axial—expanded ..... 244

Recess turning, radial finishing ..... 246

Recess turning, axial finishing ..... 248

Recess turning, radial finishing—expanded ..... 250

Recess turning, axial finishing—expanded ..... 252

ICP recess turning, radial ..... 254

ICP recess turning, axial ..... 256

ICP recess turning, radial finishing ..... 258

ICP recess turning, axial finishing ..... 260

Undercutting type H ..... 262

Undercutting type K ..... 264

Undercutting type U ..... 265

Parting ..... 267

Examples of recessing cycles ..... 269

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4.6 Thread and undercut cycles ..... 271

Thread position, undercut position ..... 271

Handwheel superimposition ..... 272

Feed angle, thread depth, proportioning of cuts ..... 273

Thread run-in / thread run-out ..... 273

Last cut ..... 274

Thread cycle (longitudinal) ..... 275

Thread cycle (longitudinal)—expanded ..... 277

Tapered thread ..... 279

API thread ..... 281

Recut (longitudinal) thread ..... 283

Recut (longitudinal) thread—expanded ..... 285

Recut tapered thread ..... 287

Recut API thread ..... 289

Undercut DIN 76 ..... 291

Undercut DIN 509 E ..... 293

Undercut DIN 509 F ..... 295

Examples of thread and undercut cycles ..... 297

4.7 Drilling cycles ..... 299

Drilling, axial ..... 300

Drilling, radial ..... 302

Deep-hole drilling, axial ..... 304

Deep-hole drilling, radial ..... 307

Tapping, axial ..... 309

Tapping, radial ..... 311

Thread milling, axial ..... 313

Examples of drilling cycles ..... 315

4.8 Milling cycles ..... 317

Rapid positioning milling ..... 318

Slot, axial ..... 319

Figure, axial ..... 321

ICP contour, axial ..... 325

Face milling ..... 328

Slot, radial ..... 331

Figure, radial ..... 333

ICP contour, radial ..... 337

Helical-slot milling, radial ..... 340

Milling direction for contour milling ..... 342

Milling direction for pocket milling ..... 343

Example of milling cycle ..... 344

Engraving, axial ..... 345

Engraving, radial ..... 347

Engraving, axial/radial ..... 349

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4.9 Drilling and milling patterns ..... 350

Drilling pattern linear, axial ..... 351

Milling pattern linear, axial ..... 353

Drilling pattern circular, axial ..... 355

Milling pattern circular, axial ..... 357

Drilling pattern linear, radial ..... 359

Milling pattern linear, radial ..... 361

Drilling pattern circular, radial ..... 363

Milling pattern circular, radial ..... 365

Examples of pattern machining ..... 367

4.10 DIN cycles ..... 370

DIN cycle ..... 370

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5 ICP programming ..... 373

5.1 ICP contours ..... 374

Loading contours ..... 374

Form elements ..... 375

Machining attributes ..... 375

Calculation of contour geometry ..... 376

5.2 ICP editor in cycle mode ..... 377

Editing contours for cycles ..... 377

File organization with the ICP editor ..... 378

5.3 ICP editor in smart.Turn ..... 379

Editing a contour in smart.Turn ..... 380

5.4 Creating an ICP contour ..... 382

Entering an ICP contour ..... 382

Absolute or incremental dimensioning ..... 383

Transitions between contour elements ..... 383

Fits and inside threads ..... 384

Polar coordinates ..... 385

Angular input ..... 385

Contour graphics ..... 386

Selection of solutions ..... 387

Colors in contour graphics ..... 387

Selection functions ..... 388

Zero point shift ..... 389

Copying a contour section in linear series ..... 389

Copying a contour section in circular series ..... 390

Copying a contour section by mirroring ..... 390

Inverting ..... 390

Contour direction (cycle programming) ..... 391

5.5 Editing ICP contours ..... 392

Superimposing form elements ..... 392

Adding contour elements ..... 392

Editing or deleting the last contour element ..... 393

Deleting a contour element ..... 393

Editing contour elements ..... 394

5.6 The zoom function in the ICP editor ..... 399

Changing the view ..... 399

5.7 Defining the workpiece blank ..... 400

"Bar" blank ..... 400

"Tube" blank ..... 400

"Cast part" blank ..... 400

5.8 Contour elements of a turning contour ..... 401

Basic elements of a turning contour ..... 401

Contour form elements ..... 405

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5.9 Contour elements on face ..... 412

Starting point of face contour ..... 412

Vertical lines on face ..... 413

Horizontal lines on face ..... 414

Line at angle on face ..... 415

Circular arc on face ..... 416

Chamfer/rounding arc on face ..... 417

5.10 Contour elements on lateral surface ..... 418

Starting point of lateral surface contour ..... 418

Vertical lines on lateral surface ..... 420

Horizontal lines on lateral surface ..... 420

Line at angle on lateral surface ..... 421

Circular arc on lateral surface ..... 422

Chamfer/rounding arc on lateral surface ..... 423

5.11 C and Y axis machining in smart.Turn ..... 424

Reference data, nested contours ..... 425

Representation of the ICP elements in the smart.Turn program ..... 426

5.12 Face contours in smart.Turn ..... 427

Reference data for complex face contours ..... 427

TURN PLUS attributes ..... 428

Circle on face ..... 428

Rectangle on face ..... 429

Polygon on face ..... 430

Linear slot on face ..... 431

Circular slot on face ..... 431

Hole on face ..... 432

Linear pattern on face ..... 433

Circular pattern on face ..... 434

5.13 Lateral surface contours in smart.Turn ..... 435

Reference data of lateral surface ..... 435

TURN PLUS attributes ..... 436

Circle on lateral surface ..... 437

Rectangle on lateral surface ..... 438

Polygon on lateral surface ..... 439

Linear slot on lateral surface ..... 440

Circular slot on lateral surface ..... 441

Hole on lateral surface ..... 442

Linear pattern on lateral surface ..... 443

Circular pattern on lateral surface ..... 444

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5.14 Contours in the XY plane ..... 446

Reference data in XY plane ..... 446

Starting point of contour in XY plane ..... 447

Vertical lines in XY plane ..... 447

Horizontal lines in XY plane ..... 448

Line at angle in XY plane ..... 449

Circular arc in XY plane ..... 450

Chamfer/rounding arc in XY plane ..... 451

Circle in XY plane ..... 452

Rectangle in XY plane ..... 453

Polygon in XY plane ..... 454

Linear slot in XY plane ..... 455

Circular slot in XY plane ..... 456

Hole in XY plane ..... 457

Linear pattern in XY plane ..... 458

Circular pattern in XY plane ..... 459

Single surface in XY plane ..... 460

Centric polygon in XY plane ..... 461

5.15 Contours in the YZ plane ..... 462

Reference data in YZ plane ..... 462

TURN PLUS attributes ..... 463

Starting point of contour in YZ plane ..... 464

Vertical lines in YZ plane ..... 464

Horizontal lines in YZ plane ..... 465

Line at angle in YZ plane ..... 466

Circular arc in YZ plane ..... 467

Chamfer/rounding arc in YZ plane ..... 468

Circle in YZ plane ..... 469

Rectangle in YZ plane ..... 470

Polygon in YZ plane ..... 471

Linear slot in YZ plane ..... 472

Circular slot in YZ plane ..... 473

Hole in YZ plane ..... 474

Linear pattern in YZ plane ..... 475

Circular pattern in YZ plane ..... 476

Single surface in YZ plane ..... 477

Centric polygons in YZ plane ..... 478

5.16 Loading existing contours ..... 479

Integrating cycle contours in smart.Turn ..... 479

DXF contours (option) ..... 480

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6 Graphic simulation ..... 483

6.1 Simulation mode of operation ..... 484

Using the graphic simulation ..... 485

The miscellaneous functions ..... 486

6.2 Simulation window ..... 487

Setting up the views ..... 487

Single-window view ..... 488

Multiple window view ..... 488

6.3 Views ..... 489

Traverse path display ..... 489

Tool depiction ..... 490

Material-removal graphic ..... 490

3-D view ..... 491

6.4 The zoom function ..... 493

Adjusting the visible section ..... 493

6.5 Simulation with mid-program startup ..... 495

Startup block with smart.Turn programs ..... 495

Mid-program startup in cycle programs ..... 496

6.6 Time calculation ..... 497

Showing the machining times ..... 497

6.7 Saving the contour ..... 498

Saving the generated contour in the simulation ..... 498

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7 Tool and technology database ..... 499

7.1 Tool database ..... 500

Tool types ..... 500

Multipoint tools ..... 501

Tool life management ..... 501

7.2 Tool editor ..... 502

Sorting and filtering the tool list ..... 502

Editing the tool data ..... 504

Tool control graphics ..... 505

Tool texts ..... 506

Editing multipoint tools ..... 507

Editing tool-life data ..... 509

Manual change systems ..... 511

7.3 Tool data ..... 516

General tool parameters ..... 516

Standard turning tools ..... 519

Recessing tools ..... 520

Thread-cutting tools ..... 521

Twist drills and indexable-insert drills ..... 522

NC center drill ..... 523

Centering tool ..... 524

Counterbore ..... 525

Countersink ..... 526

Tap ..... 527

Standard milling tools ..... 528

Thread milling tools ..... 529

Angle cutters ..... 530

Milling pins ..... 531

Knurling tool ..... 532

Touch probes ..... 533

Stopper tool ..... 534

Gripper ..... 535

7.4 Technology database ..... 536

Technology editor ..... 537

Editing a workpiece material or cutting material list ..... 538

Displaying/editing cutting data ..... 539

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8 Organization mode of operation ..... 541

8.1 Organization mode of operation ..... 542

8.2 Parameters ..... 543

Parameter editor ..... 543

List of user parameters ..... 545

Descriptions of the most important machining parameters (processing) ..... 561

General settings ..... 561

Thread cutting ..... 576

8.3 Transfer ..... 581

Data backup ..... 581

Data exchange with TNCremo ..... 581

External access ..... 581

Connections ..... 582

Ethernet interface CNC PILOT 620 ..... 583

Ethernet interface CNC PILOT 640 ..... 584

USB connection ..... 591

Data transfer options ..... 592

Transferring programs (files) ..... 593

Transferring parameters ..... 595

Transferring tool data ..... 596

Service files ..... 598

Creating a data backup file ..... 599

Importing NC programs from predecessor controls ..... 600

Importing tool data of the CNC PILOT 4290 ..... 604

8.4 Service pack ..... 605

Installing a service pack ..... 605

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9 Tables and overviews ..... 607

9.1 Thread pitch ..... 608

Thread parameters ..... 608

Thread pitch ..... 609

9.2 Undercut parameters ..... 615

DIN 76—undercut parameters ..... 615

DIN 509 E – undercut parameters ..... 617

DIN 509 F – undercut parameters ..... 617

9.3 Technical information ..... 618

9.4 Compatibility in DIN programs ..... 627

Syntax elements of the CNC PILOT 640 ..... 629

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10 Overview of cycles ..... 641

10.1 Workpiece blank cycles, single cut cycles ..... 642

10.2 Turning cycles ..... 643

10.3 Recessing and recess-turning cycles ..... 644

10.4 Thread cycles ..... 645

10.5 Drilling cycles ..... 646

10.6 Milling cycles ..... 647

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Introduction and fundamentals

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1.1 The CNC PILOT

The CNC PILOT was conceived for CNC lathes. It is suitable for horizontal and vertical lathes. The CNC PILOT supports lathes with tool turrets. The tool carrier of horizontal lathes can be located in front of or behind the workpiece.

The CNC PILOT supports lathes with spindle, one slide (X and Z axis), C axis or positionable spindle, driven tool and machines with a Y axis.

Regardless of whether you are turning simple parts or complex workpieces, the CNC PILOT provides you with the benefits of graphical contour input and convenient programming with smart.Turn.

1.1 The CNC PILOT

Programming with variables, controlling special machine components, or using externally created programs, etc. is no problem: Simply switch to DINplus. This programming mode helps you solve all your special tasks.

The CNC PILOT also offers the powerful Teach-in mode. It enables you to perform simple machining, rework or repair operations without writing NC programs.

The CNC PILOT supports operations with the C axis in cycle, smart.Turn and DIN programming. In the Y axis, the CNC PILOT supports operations with smart.Turn and DIN programming.

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1.2 Configuration

In the standard version, the control is equipped with the axes X and Z and a main spindle. Optionally, a C axis, a Y axis, and a driven tool can be configured.

Slide position

The machine tool builder configures the CNC PILOT. These are the available possibilities:

 Z axis horizontal with tool slide behind the workpiece  Z axis horizontal with tool slide in front of the workpiece  Z axis vertical with tool slide to the right of the workpiece

The menu symbols, help graphics and graphic representations during ICP and simulation consider the slide position.

The representations in this User’s Manual assume a lathe with tool carrier behind the workpiece.

Tool carrier systems

The CNC PILOT supports turrets with a number n of tool mounts as tool carriers.

The C axis

1.2 Configuration

With a C axis you can drill and mill a workpiece on its face and lateral surfaces.

When the C axis is used, 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:

 Teach-in mode  smart.Turn programming  DINplus programming

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The Y axis

With a Y axis you can drill and mill a workpiece on its face and lateral surfaces.

During use of the Y 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 program creation with the Y axis in:

 Teach-in mode

1.2 Configuration

 smart.Turn programs  DINplus programs

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Full-surface machining

Functions like angle-synchronous part transfer with rotating spindle, traversing to a stop, controlled parting, and coordinate transformation ensure efficient machining as well as simple programming of fullsurface machining.

The CNC PILOT supports full-surface machining for all common machine designs. Examples: Lathes with

 Rotating gripper  Movable opposing spindle  Several spindles and tool carriers

1.2 Configuration

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1.3 Features

Configuration

 Basic version: X and Z axis, spindle  Positionable spindle and driven tool  C axis and driven tool

1.3 Features

 Y axis and driven tool  B axis for machining a tilted plane  Digital current and speed control

Modes of operation

Manual operation

Manual slide movement through axis-direction keys or electronic handwheels.

Graphic support for entering and running Teach-in cycles without saving the machining steps in alternation with manual machine operation.

Thread reworking (thread repair in a second workpiece setup).

Teach-in mode

Sequential linking of Teach-in cycles, where each cycle is run immediately after input, or is graphically simulated and subsequently saved.

Program run

All are possible in single-block and full-sequence modes

 DINplus programs  smart.Turn programs  Teach-in programs

Setup functions

 Setting the workpiece zero point  Defining the tool-change point  Defining the protection zone  Tool measurement through touch-off, touch probe or optical gauge

Programming

 Teach-in programming  Interactive Contour Programming (ICP)  smart.Turn programming  Automatic program creation with TURN PLUS  DINplus programming

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Graphic simulation

 Graphic depiction of the sequence of smart.Turn or DINplus

programs and graphic depiction of a Teach-in cycle or Teach-in program

 Simulation of the tool paths as wire-frame or cutting-path graphics,

special identification of the rapid-traverse paths

 Machining simulation (2-D material-removal graphic)  Side or face view, or 2-D view of cylindrical surface  Display of programmed contours  Shifting and magnifying functions

Tool system

 Database for 250 tools, optionally 999 tools  Description can be entered for every tool  Optional support of multipoint tools (tools with multiple reference

points or multiple cutting edges)

 Turret or multifix system

Technology database

 Cutting data is entered in the cycle or in the UNIT as default values  9 workpiece-material/tool-material combinations (144 entries)  Optionally 62 workpiece-material/tool-material combinations (992

entries)

Interpolation

 Linear: In 2 principal axes (max. ± 100 m)  Circular: in 2 axes (radius max. 999 m)  C axis: Interpolation in the linear axes X and Z with the C axis  Y axis: Linear or circular interpolation of two axes in the given plane.

The respective third axis can simultaneously perform linear interpolation.

 G17: XY plane  G18: XZ plane  G19: YZ plane

 B axis: Drilling, boring and milling operations in oblique planes

1.3 Features

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1.4 Data backup

HEIDENHAIN recommends saving new programs and files created on a PC at regular intervals.

HEIDENHAIN provides a backup function for this purpose in the data transfer software TNCremoNT. Your machine tool builder can provide you with a copy.

You additionally need a data medium on which all machine-specific data, such as the PLC program, machine parameters, etc., are stored.

1.4 Data backup

Please contact your machine tool builder.

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1.5 Explanation of terms

 Cursor: In lists, or during data input, a list item, an input field or a

character is highlighted. This "highlight" is called a cursor. Entries and operations, like copying, deleting, inserting a new item, etc., refer to the current cursor position.

 Arrow keys: The cursor is moved with the horizontal and vertical

arrow keys and with the PG UP / PG DN keys.

 Page keys: The PG UP / PG DN keys are also called "Page keys."  Navigation: Within a list or an input box, you can move the cursor

to any position you would like to check, change, delete or add to. In other words, you "navigate" through the list.

 Active/ inactive windows, functions, menu items: Of all

windows that are displayed on the screen, only one is active. That means, any data you type on the keyboard or keypad are entered in the active window only. In the active window the title bar is shown in color. In the inactive windows, the title bar appears dimmed. Inactive function keys or menu keys also appear dimmed.

 Menu, menu key: The CNC PILOT arranges the available functions

and function groups in a 9-field box. This box is called a menu. Each symbol in the menu is a menu key.

 Editing: Editing is changing, deleting and adding to parameters,

commands, etc. within programs, tool data or parameters.

 Default value: If the parameters of cycles or DIN commands are

preassigned values, these values are referred to as default values. These values are used if you do not enter the parameters.

 Byte: The capacity of storage media is measured in bytes. Since the

CNC PILOT features an internal memory, the individual program lengths are expressed in bytes.

 Extension: File names consist of the actual name and the

extension. The name part and the extension part are separated by a dot ("."). The extension indicates the type of file. Examples:

 *.NC "DIN programs"  *.NCS "DIN subprograms (DIN macros)"

 Soft key: Soft keys are the unmarked keys along the side of the

screen. The meaning of each key is shown on the screen.

 Form: The individual pages of a dialog are shown as easy-to-fill

forms.

 UNITS: A UNIT is a group of functions united into a dialog in

smart.Turn.

1.5 Explanation of terms

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1.6 CNC PILOT design

The dialog between machinist and control takes place via:

 Screen  Soft keys  Data input keypad  Machine operating panel

The entered data can be displayed and checked on the screen. With the soft keys directly below the screen, you can select functions, capture position values, confirm entries, and a lot more.

With the ERR key you can call error and PLC information. The data input keyboard (operating panel) serves for the input of

1.6 CNC PILOT design

machine data, positioning data, etc. The CNC Pilot has an alphanumeric keyboard for easy input of tool descriptions, program descriptions or comments in an NC program. The machine operating panel contains all necessary controls for manual operation of the lathe.

Cycle programs, ICP contours and NC programs are stored in memory in the CNC PILOT.

For data exchange and data backup, you can use the Ethernet

interface and the USB interface.

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1.7 Fundamentals

Zref

Xref

Z

Z+

Y+

X

X+

Position encoders and reference marks

The machine axes are equipped with position encoders that register the positions of the slide or tool. When a machine axis moves, the corresponding position encoder generates an electrical signal. The control evaluates this signal and calculates the precise actual position of the machine axis.

If there is a power interruption, the calculated position will no longer correspond to the actual position of the machine slide. To recover this association, incremental position encoders are provided with reference marks. The scales of the position encoders contain one or more reference marks that transmit a signal to the control when they are crossed over. This enables the CNC PILOT to re-establish the assignment of the displayed position to the current machine position. For linear encoders with distance-coded reference marks, you only need to move each axis a maximum of 20 mm (0.8 in.) for these, and a maximum of 20° for angle encoders.

If incremental encoders are without reference marks, fixed reference positions have to be traversed after switch-on. The control knows the exact distance between these reference points and the machine datum (see figure).

With absolute encoders, an absolute position value is transmitted to the control immediately upon switch-on. In this way the assignment of the actual position to the machine slide position is re-established directly after switch-on.

X (Z,Y)

1.7 Fundamentals

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.

Lathes with Y axis: The Y 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.

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Coordinate system

The meanings of the coordinates X, Y, Z, and C are specified in DIN 66 217.

The coordinates entered for the principal axes X, Y and Z are referenced to the workpiece zero point. The angles entered for the rotary axis (C axis) are referenced to the datum of the C axis.

The axis designations X and Z describe positions in a two-dimensional coordinate system. As you can see from the figure to the center right, the position of the tool tip is clearly defined by its X and Z coordinates.

The CNC PILOT can connect points by linear and circular paths of

1.7 Fundamentals

traverse (interpolations). Workpiece machining is programmed by entering the coordinates for a succession of points and connecting the points by linear or circular paths of traverse.

Like the paths of traverse, you can also describe the complete contour of a workpiece by defining single points through their coordinates and connecting them by linear or circular paths of traverse.

Positions can be programmed to an accuracy of 1 µm (0.001 mm). This is also the accuracy with which they are displayed.

Absolute coordinates

If the coordinates of a position are referenced to the workpiece datum, they are referred to as absolute coordinates. Each position on a workpiece is clearly defined by its absolute coordinates (see figure).

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Incremental coordinates

Incremental coordinates are always given with respect to the last programmed position. They specify the distance from the last active position to the subsequent position. Each position on a workpiece is clearly defined by its incremental coordinates (see figure).

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 (see figure).

1.7 Fundamentals

Machine zero point

The point of intersection of the X and Z axes 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. It is designated with the letter "M" (see figure).

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Workpiece zero point

To machine a workpiece, it is easier to enter all input data with respect 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. It is designated with the letter "W" (see figure).

1.7 Fundamentals

Units of measure

You can program 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.

Dimensions Metric Inches

Coordinates mm inch

Lengths mm inch

Angle 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/s

48 Introduction and fundamentals

ft/s

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1.8 Tool 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 programmed and displayed position values are given with respect to the distance between the tool tip and workpiece zero point. Since the control only knows the absolute position of the tool carrier (slide), the CNC PILOT needs the dimensions XL and ZL (see figure) to calculate and display the position of the tool tip.

Tool compensation

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

1.8 Tool dimensions

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Tool-tip 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. With non-paraxial contours, this will lead to inaccuracies during machining.

The TRC function compensates for this error by calculating a new path of traverse, the equidistant line (see figure).

The CNC PILOT calculates the TRC for cycle programming. The smart.Turn and DIN programming feature also takes the TRC for clearance cycles into account. During DIN programming with single

1.8 Tool dimensions

paths, you can also enable/disable TRC.

Milling cutter radius compensation (MCRC)

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

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Basics of operation

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2.1 General information on operation

Operation

 Select the desired operating mode with the corresponding operating

mode key.

 Within the operating mode, you can change the mode through the

soft keys.

 With the numeric keypad you can select the function within the

menus.

 Dialogs can consist of multiple pages.  Besides with the soft keys, dialogs can be concluded positively with

"INS" or negatively with "ESC."

 Changes made in lists are effective immediately. They are also

saved if the list is closed with "ESC" or "Cancel."

Setup

 You will find all setup functions in the machine mode in "Manual

mode."

 All preparatory work can be performed through the "setup" menu

item and "Set S,F,T."

2.1 General information on operation

Programming – Teach-in mode

 Select Teach-in in the "machine" mode and use the Program list

soft key to open a new cycle program.

 Activate the cycle menu through the Add cycle soft key. Here you

select the operation and enter the details.

 Then press the Input finished soft key. Now you can start the

simulation and check the machining process.

 Start the operation in the machine with "Cycle on."  Save that cycle after the operation is completed.  Repeat the last steps for each new operation.

Programming – smart.Turn

 Convenient programming with UNITS in a structured NC program.  Combinable with DIN functions.  Contour definition is graphically possible.  Contour follow-up when used with a workpiece blank.  Conversion of cycle programs to smart.Turn programs with the

same functions.

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2.2 The CNC PILOT screen

The CNC PILOT shows the data to be displayed in windows. Some windows only appear when they are needed, for example, for typing in entries.

In addition, the control shows the type of operation, the soft-key display and the PLC soft-key display on the screen. Each function that appears in a field of the soft-key row is activated by pressing the soft key directly below it.

Operating mode line

The operating mode tabs (at the top of the screen) show the four operating modes as well as the submodes.

Machine display

The machine display field (beneath the operating mode tabs) is configurable. It shows all important information on axis positions, feed rates, rotational speeds, and tool.

Other windows used:

 List and program window

Display of program lists, tool lists, parameter lists, etc. To select specific elements from the list, simply move the highlight to the desired element with the arrow keys.

 Menu window

Display of menu symbols. This window only appears on the screen in the Teach-in and Manual modes.

 Input window/Dialog window

For entering the parameters of a cycle, ICP element, DIN command, etc. Look over the existing data, then delete or edit them in the dialog window.

 Graphic support window

Input data (such as cycle parameters, tool data, etc.) are explained with graphics. The switchover key (the key with three rotating arrows at the left edge of the screen) allows you to switch between the help graphics for internal and external machining (only for cycle programming).

 Simulation window

The simulation window shows a graphic representation of the contour elements and a simulation of the tool movements. This enables you to check cycles, entire cycle programs, and DIN programs.

 ICP contour graphics

Display of the contour during ICP programming.

 DIN editing window

Display of the DIN program during DIN programming.

 Error window

Display of occurred errors and warnings.

2.2 The CNC PILOT screen

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2.3 Operation and data input

Operating modes

The active mode of operation is highlighted in the operating-mode tab. The CNC PILOT differentiates between the following operating modes:

 Machine—with the submodes:

 Manual (display: "Machine")  Teach-in (Teach-in mode)  Program Run

 Programming—with the submodes:

 smart.Turn  Simulation  ICP  TURN PLUS: Automatic working plan generation (AWG)

2.3 Operation and data input

 Tool management—with the submodes:

 Tool editor  Technology editor

 Organization—with the submodes:

 User parameters  Transfer  User login

You can use the operating mode keys to switch between the modes. The selected submode and the current menu position remain during the mode change.

If you press the operating mode key in a submode, the CNC PILOT switches back to the main level of the mode.

At some places, a dialog has to be ended in order to switch modes (e.g. in the tool editor).

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Menu selection

The numerical keypad is used for activating a menu and for entering data. They are displayed differently depending on the operating mode.

 During setup, Teach-in mode etc., the functions are shown in a 9-

field box, the menu window. The meaning of the selected symbol / menu item is described in the footer.

 In other operating modes, the keypad symbol is shown with the

position of the function marked (see figure).

Press the corresponding numerical key, or move the highlight with the arrow keys to the symbol on the screen and press the ENT key.

Soft keys

 With some system functions, the available functions are arranged

on several soft-key levels.

 Some soft keys work like “toggle switches.” A function is active

when the associated field in the soft-key row is highlighted in color. The setting remains in effect until the function is switched off again.

 With functions like Take over position you do not have to enter

values manually. The data are automatically written into the appropriate input fields.

 Data entries are not concluded until the Save or Input finished soft

key has been pressed.

 The Back soft key takes you back to the previous operating level.

2.3 Operation and data input

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Data input

Input windows comprise several input fields. You can move the cursor to the desired input field with the vertical arrow keys. The CNC PILOT shows the function of the selected field in the footer of the window.

Place the highlight on the desired input field and enter the data. Existing data are overwritten. With the horizontal arrow keys, you can move the cursor within the input field and place it on the position where you want to delete, copy or add characters.

To confirm the data you entered in a field, press a vertical arrow key or the ENTER key.

If there are more input fields than a window can show, a second input window is used. You will recognize this through the symbol in the bottom line of the input window. To switch back and forth between the windows, press the PG UP/PG DN keys.

Data entry is concluded when you press the OK or Input

2.3 Operation and data input

finished or Save soft key. The Back or Cancel soft key discards input or changes.

smart.Turn dialogs

The unit dialog is divided into fillable forms and the forms are divided again into groups. The forms are identified by tabs and fine lines divide each tab into groups. You can navigate between the forms and groups with the smart keys.

smart keys

Go to the next form

Next/previous group

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List operations

Cycle programs, DIN programs, tool lists, etc. are displayed as lists. You can scroll through a list with the arrow keys to check data or to highlight elements for operations like deleting, copying, editing, etc.

Alphanumeric keyboard

You enter letters and special characters with the screen keypad or (if available) with a PC keyboard connected over the USB port.

Entering text with the screen keyboard

 Press the "Alphabetic keyboard" soft key or the GOTO key to enter

a text, for example a program name.

 The CNC PILOT opens the Text Input window.  Just as on a cell phone, you press the numerical keys a few times

to get the desired letters or special characters.

 Wait until the selected character is transferred to the entry field

before you enter the next character.

 Use the OK soft key to load the text into the open dialog field.  Use the abc/ABC soft key to select upper or lower case.  To delete individual characters, use the Backspace soft key.

2.3 Operation and data input

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2.4 Integrated calculator

Calculator functions

The calculator can be selected only from open dialogs in cycle programming or smart.Turn programming. You can use the calculator in the following three views (see figures at right):

 Scientific  Standard  Equation editor. Here you can type in multiple calculations in

immediate sequence (for example 17*3+5/9).

The calculator remains in effect even after a change in operating modes. Press the END soft key to close the

2.4 Integrated calculator

Using the calculator

 Use the arrow keys to select the input field.

calculator. The GET CURRENT VALUE soft key enables you to

transfer a numerical value from the active input field to the calculator. The CONFIRM VALUE soft key enables you to load the current value from the calculator to the active input field.

 Use the CALC key to activate and deactivate the

calculator.

 Shift the soft-key menu until the desired function

appears.

 Perform the calculation.

 Press the soft key. The CNC PILOT transfers the value

into the active input box and closes the calculator.

Switching the view of the calculator

 Shift the soft-key menu until the VIEW soft key appears.

 Press the View soft key until the desired view is set.

Mathematical function Shortcut (soft key)

Addition +

Subtraction -

Multiplication *

Division /

Calculations in parentheses ()

Arc cosine ARC

Sine SIN

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Mathematical function Shortcut (soft key)

Cosine COS

Tangent TAN

Powers of values X^Y

Square root SQRT

Inversion 1/x

pi (3.14159265359) PI

Add value to buffer memory M+

Save the value to buffer memory MS

Recall from buffer memory MR

Delete buffer memory contents MC

Natural logarithm LN

Logarithm LOG

Exponent function e^x

Check the algebraic sign SGN

Form the absolute value ABS

Truncate decimal places INT

Truncate places before the decimal point FRAC

Modulus operator MOD

Select view View

Delete value DEL

Unit of measure MM or INCH

Display mode for angle values DEG (degree) or

RAD (radian measure)

Display mode of the numerical value DEC (decimal) or

HEX (hexadecimal)

2.4 Integrated calculator

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Adjusting the position of the calculator

You can move the calculator as follows:

 Move the calculator with the arrow keys

 Move the calculator to the center

2.4 Integrated calculator

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2.5 Types of programs

The CNC PILOT supports the following programs/contours:

 Teach-in programs (cycle programs) are used in the "Teach in"

mode of operation.

 smart.Turn and DIN main programs are written in the smart.Turn

mode of operation.

 DIN subprograms are written in the smart.Turn operating mode

and are used in cycle programs and smart.Turn main programs.

 ICP contours are generated during Teach-in in the Teach-in or

Manual mode of operation. The extension depends on the contour described.

In smart.Turn the contours are saved directly in the main program.

Program type Folder Extension

Teach-in programs (cycle programs)

smart.Turn and DIN main programs

DIN subprograms "nc_prog\ncps" "*.ncs"

ICP contours "nc_prog\gti"

Turning contours "*.gmi"

Contours of workpiece blanks

Contours on face "*.gms"

Lateral surface contours

"nc_prog\gtz" "*.gmz"

"nc_prog\ncps" "*.nc"

"*.gmr"

"*.gmm"

2.5 Types of programs

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2.6 The error messages

Display of errors

The CNC PILOT generates error messages when it detects problems such as:

 Incorrect data input  Logical errors in the program  Contour elements that are impossible to machine

When an error occurs, it is displayed in red type in the header. Long and multi-line error messages are displayed in abbreviated form. If an error occurs in a background mode, the error symbol is shown in the operating mode tab. Complete information on all pending errors is shown in the error window.

2.6 The error messages

If a rare "processor check error" should occur, the CNC PILOT automatically opens the error window. You cannot remove such an error. Shut down the system and restart the CNC PILOT.

The error message is displayed in the header until it is cleared or replaced by a higher-priority error.

An error message that contains the block number of an NC program was caused by an error in the indicated block or in the preceding block.

Opening the error window

 Press the ERR key. The CNC PILOT opens the error

window and displays all accumulated error messages.

Closing the error window

 Press the END soft key—or

 Press the ERR key. The CNC PILOT closes the error

window.

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Detailed error messages

The CNC PILOT displays possible causes of the error and suggestions for solving the problem:

Information on error causes and remedies:

 Open the error window.

 Position the cursor on the error message and press

the soft key. The CNC PILOT opens the window with information on the error cause and corrective action.

 To exit the info, press the Info soft key again.

"Details" soft key

The DETAILS soft key supplies information on the error message. This information is only required if servicing is needed.

 Open the error window.

 Position the cursor on the error message and press

the soft key. The CNC PILOT opens the window with internal information about the error.

 To exit the details, press the Details soft key again.

2.6 The error messages

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Clearing errors

Clearing errors outside of the error window:

 Open the error window.

 To clear the error/message in the header: Press the

CE key.

In some operating modes (such as the Editing mode), the CE key cannot be used to clear the error, since the key is reserved for other functions.

Clearing more than one error:

 Open the error window.

2.6 The error messages

 To delete an individual error: Position the cursor on the

error message and press the soft key.

 To delete all errors: Press the Delete All soft key.

If the cause of the error has not been removed, the error message cannot be deleted. In this case, the error message remains in the window.

Error log file

The CNC PILOT stores errors and important events (e.g. system startup) in an error log file. The capacity of the error log file is limited. If the log file is full, it switches to the next one, etc. If the last log file is full, the first one is overwritten by a new one, etc. If necessary, switch the log file to see the history. 5 log files are available.

 Open the error window.

 Press the Log file soft key.

 Open the log file.

 Select previous log file, if needed.

 Select current log file, if needed.

The oldest entry is at the beginning of the log file, and the most recent entry is at the end.

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Keystroke log file

The CNC PILOT stores keystrokes and important events (e.g. system startup) in the keystroke log file. The capacity of the keystroke log file is limited. If the log file is full, it switches to the next one, etc. If the last log file is full, the first one is overwritten by a new one, etc. If necessary, switch the log file to see the history. 10 log files are available.

 Open the keystroke log file.

 Press the Log file soft key.

 Open the log file.

 Select previous log file, if needed.

 Select current log file, if needed.

The CNC PILOT saves each key pressed during operation in the keystroke log file. The oldest entry is at the beginning of the log file, and the most recent entry is at the end.

Saving service files

If necessary, you can save the "Current status of the CNC PILOT," and make it available to a service technician for evaluation. A group of service files is saved that contain information about the current status of the machine and the machining. See “Service files” auf Seite 598.

The information is summarized in a service files data record as a zip file.

TNC:\SERVICEx.zip The "x" designates a consecutive serial number. The CNC PILOT

always generates the service file with the number 1, and all existing files are renamed to the numbers 2 to 5. An existing file with the number 5 is deleted.

Saving service files

 Open the error window.

 Press the Log file soft key.

2.6 The error messages

 Press the Service files soft key.

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2.7 TURNguide context-sensitive help system

Application

Before you can use the TURNguide, you need to download the help files from the HEIDENHAIN home page (siehe „Downloading current help files” auf Seite

71).

The TURNguide context-sensitive help system includes the user documentation in HTML format. The TURNguide is called with the Info key, and the control often immediately displays the information specific to the condition from which the help was called (contextsensitive call). Even if you are editing in a cycle and press the Info key, you are usually brought to the exact place in the documentation that describes the corresponding function.

The control always tries to start the TURNguide in the language that you have selected as the conversational language on your control. If the files with this language are not yet available on your control, it automatically opens the English version.

The following user documentation is available in the TURNguide:

 User's Manual (BHBoperating.chm)  smart.Turn and DIN (ISO) programming (smartTurn.chm)  List of All Error Messages (errors.chm)

2.7 TURNguide context-sensitive help system

In addition, the main.chm "book" file is available, with the contents of all existing .chm files.

As an option, your machine tool builder can embed machine-specific documentation in the TURNguide. These documents then appear as a separate book in the

main.chm file.

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Working with the TURNguide

Calling the TURNguide

There are several ways to start the TURNguide:

 Press the Info key if the control is not already showing an error

message

 Click the help symbol at the lower right of the screen beforehand,

then click the appropriate soft keys

If one or more error messages are waiting for your attention, the control shows the help directly associated with the error messages. To start the TURNguide, you first have to acknowledge all error messages.

When the help system is called on the programming station, the control starts the internally defined standard browser (usually the Internet Explorer), or otherwise an adapted browser.

For many soft keys there is a context-sensitive call through which you can go directly to the description of the soft key's function. This functionality requires using a mouse. Proceed as follows:

 Select the soft-key row containing the desired soft key  Click with the mouse on the help symbol that the control displays

just above the soft-key row: The mouse pointer turns into a question mark.

 Move the question mark to the soft key for which you want an

explanation, and click: The TNC opens the TURNguide. If no specific part of the help is assigned to the selected soft key, the control opens the book file main.chm, in which you can use the search function or the navigation to find the desired explanation manually.

Even if you are editing a cycle, context-sensitive help is available:

 Select any cycle.  Press the Info key: The control start the help system and shows a

description for the active function (does not apply to miscellaneous functions or cycles that were integrated by your machine tool builder)

2.7 TURNguide context-sensitive help system

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Navigating in the TURNguide

It's easiest to use the mouse to navigate in the TURNguide. A table of contents appears on the left side of the screen. By clicking the rightward pointing triangle you open subordinate sections, and by clicking the respective entry you open the individual pages. It is operated in the same manner as the Windows Explorer.

Linked text positions (cross references) are shown underlined and in blue. Clicking the link opens the associated page.

Of course you can also operate the TURNguide through keys and soft keys. The following table contains an overview of the corresponding key functions.

The key functions described below are only available on the control hardware, and not on the programming station.

Function Soft key

 If the table of contents at left is active:

Select the entry above it or below it

 If the text window at right is active:

Move the page downward or upward if texts or graphics are not shown completely

 If the table of contents at left is active:

Open a branch of the table of contents. If the branch is at its end, jump into the window at right

 If the text window at right is active:

No function

 If the table of contents at left is active:

2.7 TURNguide context-sensitive help system

Close a branch of the table of contents

 If the text window at right is active:

No function

 If the table of contents at left is active:

Use the cursor key to show the selected page

 If the text window at right is active:

If the cursor is on a link, jump to the linked page

 If the table of contents at left is active:

Switch the tab between the display of the table of contents, display of the subject index, and the full-text search function and switching to the screen half at right

 If the text window at right is active:

Jump back to the window at left

 If the table of contents at left is active:

Select the entry above it or below it

 If the text window at right is active:

Jump to the next link

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Function Soft key

Select the page last shown

Page forward if you have used the "Select page last shown" function

Move up by one page

Move down by one page

Display or hide table of contents

Switch between full-screen display and reduced display. With the reduced display you can see some of the rest of the control window.

The focus is switched internally to the control application so that you can operate the control when the TURNguide is open. If the full screen is active, the control reduces the window size automatically before the change of focus.

Exit TURNguide

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Subject index

The most important subjects in the Manual are listed in the subject index (Index tab). You can select them directly by mouse or with the cursor keys.

The left side is active.

 Select the Index tab  Activate the Keyword input field  Enter the word for the desired subject and the control

synchronizes the index and creates a list in which you can find the subject more easily, or

 Use the arrow key to highlight the desired keyword  Use the ENT key to call the information on the

selected keyword

You can enter the search word only with a keyboard connected via USB.

Full-text search

In the Find tab you can search all of TURNguide for a specific word. The left side is active.

 Select the Find tab  Activate the Find: input field  Enter the desired word and confirm with the ENT key:

the control lists all sources containing the word

2.7 TURNguide context-sensitive help system

 Use the arrow key to highlight the desired source  Press the ENT key to go to the selected source

You can enter the search word only with a keyboard connected via USB.

The full-text search only works for single words. If you activate the Search only in titles function (by

mouse or by using the cursor and the space key), the control searches only through headings and ignores the body text.

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Downloading current help files

You’ll find the help files for your control software on the HEIDENHAIN homepage www.heidenhain.de. Help files for most conversational languages are at:

 Services and Documentation  Software  CNC PILOT help system  NC software number of your control, for example 34056x-02  Select the desired language, e.g. English: You will see a ZIP file with

the appropriate help files

 Download the ZIP file and unzip it  Move the unzipped CHM files to the control in the

TNC:\tncguide\en directory or into the respective language subdirectory (see also the following table)

If you want to use TNCremoNT to transfer the CHM files to the TNC, then in the

Extras>Configuration>Mode>Transfer in binary format menu item you have to enter the extension .CHM.

Language TNC directory

German TNC:\tncguide\de

English TNC:\tncguide\en

Czech TNC:\tncguide\cs

French TNC:\tncguide\fr

Italian TNC:\tncguide\it

Spanish TNC:\tncguide\es

Portuguese TNC:\tncguide\pt

Swedish TNC:\tncguide\sv

Danish TNC:\tncguide\da

Finnish TNC:\tncguide\fi

Dutch TNC:\tncguide\nl

Polish TNC:\tncguide\pl

Hungarian TNC:\tncguide\hu

Russian TNC:\tncguide\ru

Chinese (simplified) TNC:\tncguide\zh

Chinese (traditional) TNC:\tncguide\zh-tw

2.7 TURNguide context-sensitive help system

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Language TNC directory

Slovenian (software option) TNC:\tncguide\sl

Norwegian TNC:\tncguide\no

Slovak TNC:\tncguide\sk

Korean TNC:\tncguide\kr

Turkish TNC:\tncguide\tr

Romanian TNC:\tncguide\ro

2.7 TURNguide context-sensitive help system

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Machine mode of operation

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3.1 Machine mode of operation

The Machine mode of operation includes all functions for machine setup, workpiece machining, and Teach-in program definition.

 Machine setup: For preparations like setting axis values (defining

workpiece zero point), measuring tools or setting the protection zone.

 Manual mode: Machine a workpiece manually or semi-

automatically.

 Teach-in mode: "Teach-in" a new cycle program, change an existing

program, or graphically simulate cycles.

 Program run: Graphically simulate existing cycle programs or

smart.Turn programs and use them for the production of parts.

A Teach-in cycle is a machining step that has already been programmed for you. This can be any machining operation from a single cut through to a complex machining task like thread cutting. In any case, a cycle is always a complete machining step that is immediately executable once you have defined a few parameters that describe the workpiece to be machined.

In Manual mode, the cycles that you program are not stored. In

3.1 Machine mode of operation

Teach-in mode, each machining step is executed with a cycle and then stored and integrated into a complete Teach-in program. You can subsequently use this program in parts production by repeating it as often as desired in the Program Run mode.

In ICP programming, any contour can be defined using linear/circular elements and transition elements (chamfers, rounding arcs, undercuts). You include the contour description in ICP cycles (see “ICP contours” auf Seite 374).

You write smart.Turn and DIN programs in the smart.Turn mode of operation. The DIN programming feature provides you with commands for simple traversing movements, DIN cycles for complex machining tasks, switching functions, mathematical operations and programming with variables.

You can either create "independent" programs that already contain all necessary switching and traversing commands and are executed in the Program Run mode, or program DIN subprograms that are integrated in Teach-in cycles. The commands that you use in a DIN subprogram depend on the job at hand. DIN subprograms support the complete range of commands that is available for DIN programs.

You can also convert Teach-in programs to smart.Turn programs. This enables you to make use of straightforward Teach-in programming, and then convert the part program to DIN format for subsequent optimization or completion.

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3.2 Switch-on / Switch-off

Switch-on

The CNC PILOT displays the startup status. When the system has completed all tests and initializations, it switches to the Machine mode of operation. The tool display shows the tool that was last used.

If errors are encountered during system start, the control displays the error symbol on the screen. You can check these error messages as soon as the system is ready (see “The error messages” auf Seite 62).

After system start, the CNC PILOT assumes that the tool which was last used is still inserted in the tool holder. If this is not the case, you must inform the control of the tool change.

Monitoring EnDat encoders

If EnDat encoders are used, the control saves the axis positions during switch-off of the machine. During switch-on, the CNC PILOT compares for each axis the position during switch-on with the position saved during switch-off.

If there is a difference, one of the following messages appears:

 "S-RAM error: Saved position of the axis is invalid."

This message is correct if the control has been switched on for the first time, or if the encoder or other control components involved were exchanged.

 "Axis was moved after power-off. Position difference: xx mm or

degrees" Check the current position and confirm it if the axis was in fact moved.

 "HW parameter changed: Saved position of the axis is invalid."

This message is correct if configuration parameters were changed.

The cause for one of the above listed messages can also be a defect in the encoder or control. Please contact your machine supplier if the problem recurs.

3.2 Switch-on / Switch-off

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Traversing the reference marks

Whether a reference run is necessary depends on the encoders used:

 EnDat encoder: Reference run is not necessary.  Distance-coded encoders: The position of the axes is ascertained

after a short reference run.

 Standard encoder: The axes move to known, machine-based points.

As soon as a reference mark is traversed, a signal is transmitted to the control. The control knows the distance between the reference mark and the machine zero point and can now establish the precise position of the axis.

REFERENCE RUN

Press the Z reference soft key

3.2 Switch-on / Switch-off

Press the X reference soft key

Or press the All soft key

Press Cycle start for the control to traverse the reference marks

The CNC PILOT activates the position display and switches to the main menu.

In case you traverse the reference marks separately for the X and Z axes, you only traverse in either the X or the Z axis.

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Switch-off

Proper switch-off is recorded in the error log file.

SWITCH-OFF

Go to the main level of the Machine mode of operation

Activate the error window

Press the MORE FUNCTIONS soft key

Press the OFF soft key

The CNC PILOT displays a confirmation request.

Press the Enter key or the YES soft key. The software shuts down

3.2 Switch-on / Switch-off

Wait until the CNC PILOT requests you to switch off the machine.

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3.3 Machine data

Input of machine data

In Manual mode, you enter the information for tool, spindle speed and feed rate/cutting speed in the TSF dialog box (Set T, S, F input window). In Teach-in programs the tool information and technology data are included in the cycle parameters, and in smart.Turn programs they are part of the NC program.

3.3 Machine data

In the TSF dialog box you also define the "maximum speed", the "stopping angle" and the workpiece material.

You can save the cutting data (cutting speed, feed rate) in the technology database as a function of the workpiece material, the tool's cutting material and the type of operation. With the Proposed technology soft key the data are taken into the dialog.

The Tool list soft key opens the tool list. With the Turret list soft key you open a list of the current assignment of the tool carrier. There is a place in the table for every tool holder. During setup, each tool (ID number) is assigned to a tool holder.

If your machine is equipped with a driven tool, you use the spindlechange key to select the spindle for which the entries are to apply. The selected spindle is indicated in the display. For this reason there are two versions of the TSF dialog box:

 Without driven tool: The parameters S, D and A apply to the main

spindle

 With driven tool: The parameters S, D and A apply to the selected

spindle

Meaning of the parameters:

 S: Cutting speed / constant speed  D: Max. spindle speed  A: Stopping angle  BW: Angle in the B axis (machine-dependent function)  CW: Reverse tool position (No/Yes): For determining the tool's work

position for machining the front or rear face (machine-dependent function)

In the machine parameter Separate dialogs for tool change, speed and feed rate (604906) you can define how you would like the TSF dialog to be displayed:

 TSF dialog box with input of all cutting data  Separate dialogs for T, S and F

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TSF dialog box with input of all cutting data

ENTER THE TOOL DATA AND TECHNOLOGY DATA

Select Set T, S, F (only available in Manual mode)

Soft keys for "Set T, S, F"

Siehe „Tool compensation” auf Seite 107.

Siehe „Touch off” auf Seite 104.

Define the parameters

Conclude data input

Caution. Depending on the machine, this operation might cause the turret to turn.

TSF dialog box with separate dialogs

ENTER THE TOOL DATA OR TECHNOLOGY DATA

Select Set T, S, F (only available in Manual mode)

Select T for tool change

Select S for setting the spindle speed

Select F for setting the feed rate

Call the tool list. Transfer of T number from the tool list: Siehe „Setting up a tool list” auf Seite 85.

Transfer of cutting speed and feed rate from the technology data.

 On: Feed per minute (mm/min)  Off: Feed per revolution (mm/rev)

 On: Constant speed (rpm)  Off: Constant surface speed (m/min)

3.3 Machine data

Enter the parameters in the submenu

Conclude data input

Caution. Depending on the machine, the input of data in the T dialog might cause the turret to turn.

Selecting the workpiece spindle (machine-dependent)

If your machine is equipped with a workpiece spindle, the WP parameter is shown in the TSF form. The WP parameter allows you to select the workpiece spindle for machining in Teach-in mode and MDI.

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Select the workpiece spindle for machining with WP:

 Main drive  Opposing spindle for rear-face machining

The WP parameter setting is saved in the Teach-in and MDI cycles and displayed in the corresponding cycle form.

If you selected the opposing spindle for rear-face machining with the WP parameter, the cycle is mirrored (in the opposite Z direction). Use tools with suitable tool orientation.

In the TSF menu, the setting for the WP parameter is

3.3 Machine data

changed when you:

 run a cycle with another WP parameter setting  select a program during program run

Machine data display

Elements of machine data display Position display X, Y, Z, W: Distance between tool tip and workpiece zero point

 A black axis letter means the axis is enabled; white means it is not enabled.

Handwheel active Clamping active

Display of C position: Position of C axis

 Empty box: C-axis is not active  A black axis letter means the axis is enabled; white means it is not enabled.

Display settings of the position display: Can be set via the MP_axesDisplayMode user parameter. The setting is shown by a letter next to the position window.

 A: Actual value (setting: REF ACTL)  N: Nominal value (setting: REF NOML)  L: Following error (setting: LAG)  D: Distance to go (setting: DIST)

Display of the slide number and C-axis number: A numeral next to the position window of the axis shows the assigned slide or C-axis number. The numeral is only displayed if an axis was configured multiple times, e.g. a second C-axis as opposing spindle.

Distance-to-go display X, Y, Z, W: The distance remaining from the current position to the target position of the active traversing command.

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Elements of machine data display Distance-to-go and protection zone status: Distance-to-go display and display of

status of protection zone monitoring.

Protection zone monitoring active

Position display for four axes: Display of position values for up to four axes. The displayed axes depend on the machine configuration.

T number display

 T number of the inserted tool  Tool compensation values

For all of the T displays:

 T highlighted in color indicates a driven tool  T number or ID highlighted in color indicates a mirrored tool holder  T number with index: Multipoint tool  A letter X/Z of the compensation highlighted in color indicates that a special

compensation is active in the X/Z direction

T ID display

 ID of the inserted tool  Tool compensation values

T ID display without compensation values

 ID of the inserted tool

Protection zone monitoring not active

3.3 Machine data

Tool compensation

 Special compensation only for recessing tools or button tools  Special compensation value in gray means special compensation is not active  A letter X/Z of the compensation highlighted in color indicates that a special

compensation is active in the X/Z direction

Additive compensation

 Compensation values in gray means D compensation is not active  Compensation values in black means D compensation is active

Tool life information

 "T": Black=global tool life monitoring on; white=global tool life monitoring off  MT, RT active: Monitoring for tool life  MZ, RZ active: Monitoring for part quantity  All fields empty: Tool without tool-life monitoring

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Elements of machine data display Slide display and cycle status

 Upper field: Setting of the override control  Lower field with white background: Actual feed rate  Lower field with gray background: Programmed feed rate with stationary slide

Slide display and cycle status

 Upper field: Programmed feed rate  Lower field: Actual feed rate

3.3 Machine data

Slide display and cycle status

 Upper field: Setting of the override control  Middle field: Programmed feed rate  Lower field: Actual feed rate

Slide display with rear-face machining

 If rear-face machining is enabled, the slide number is highlighted in blue.

Spindle display with spindle number, gear range and spindle status

 Upper field: Setting of the override control  Lower field: Actual speed or spindle position

For all of the spindle displays:

 Spindle symbol: Black means the spindle is enabled; white means it is not.  Numeral in spindle symbol: Gear range  Numeral at right next to the spindle symbol: Spindle number  If a spindle key exists, the number of the selected spindle is highlighted in color.  Spindle status: Siehe “Spindle” auf Seite 84.  Display of the programmed speed in rpm or m/min  Display of the actual speed in rpm  If M19 is active and the machine tool builder has made the setting, when the

spindle is not turning, the display shows the spindle position instead of the spindle speed.

 If a spindle is in slave mode during synchronous operation, the value "0" is

displayed instead of the programmed speed.

 During synchronous operation, the spindle symbol is highlighted in color for both

the master spindle and the slave spindle

Spindle display with spindle number, gear range and spindle status

 Upper field: Programmed speed  Lower field: Actual speed or spindle position

Spindle display with spindle number, gear range and spindle status

 Upper field: Setting of the override control  Middle field: Programmed speed  Lower field: Actual speed or spindle position

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Elements of machine data display Override display of the active spindle

 F: Feed rate  R: Rapid traverse  S: Spindle

Utilization of the drives: Utilization of the drive relative to the rated torque.

 Digital axis and spindle motors  Analog axis and spindle motors, if set up by the machine tool builder

Display of unit quantities: The quantity is incremented after each M30, M99 or M18 programmed counter pulse.

 MP: Default unit quantity  P: Number of finished parts

Display of unit quantities and time per unit: The quantity is incremented after each M30, M99 or M18 programmed counter pulse.

 MP: Default unit quantity  P: Number of finished parts  t: Run time of the current program  Sum t: Total time

Display of skip levels and M01 conditional stop

 Defined skip levels (upper row) and set/activated skip levels (lower row)  Setting for M01: M01 is not executed in Continuous Run mode (yellow display)

3.3 Machine data

Display of rear-face machining: The RSM display (RSM: Rear Side Machining)

provides information about rear-face machining.

 RSM status  Active zero point shift of the configured RSM axis

B-axis display: The information displayed about the status of the tilted plane varies depending on the setting of the machine parameters.

 Programmed angular value of the B axis  Display of the current values I, K, U and W

 I: Plane reference in X  K: Plane reference in Z  U: Shift in X  W: Shift in Z

The machine data display is configurable by the machine tool builder. The machine data that appear on your screen may therefore deviate from the example shown.

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Cycle statuses

The CNC PILOT shows the current cycle status with the cycle symbol (see table at right).

Axis feed rate

3.3 Machine data

F is the identification letter for feed data. Depending on which mode

of the Feed rate soft key is active, data is entered in:

 Millimeters per spindle revolution (feed per revolution)  Millimeters per minute (feed per minute).

On the screen, you can tell the type of feed rate from the unit of measure in the input field.

You can change the feed value with the feed compensation

controller (feed override) (range: 0 % to 150 %).

Spindle

S is the identification letter for spindle data. Depending on which

mode of the Constant speed soft key is active, data is entered in:

 Revolutions per minute (constant speed)  Meters per minute (constant surface speed).

The input range is limited by the maximum spindle speed. You define the speed limitation in the Set T, S, F dialog box or in DIN programming with the G26 command. The speed limit remains in effect until a new speed limit value is programmed.

The speed compensation controller (speed override) allows you to change the spindle speed (range: 50% to 150 %).

 If you are machining with a constant cutting speed, the

CNC PILOT calculates the spindle speed from the position of the tool tip. The smaller the diameter of the tip, the higher the spindle speed. The maximum spindle speed, however, is never exceeded.

 The spindle symbols indicate the direction of spindle

rotation as seen from the point of view of the machinist.

 The spindle designation is fixed by the machine tool

builder (see table at right).

Cycle symbols Status "Cycle ON"

Cycle or program execution is active.

Status "Cycle OFF"

Cycle or program execution is not active.

Spindle symbols (S display) Direction of spindle rotation M3

Direction of spindle rotation M4

Spindle stopped

Spindle position-controlled (M19)

C axis on spindle motor is active

Spindle designations

Main spindle H0 1

Driven tool 112

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3.4 Setting up a tool list

Machine with turret

The tools used are listed in the turret list. The ID number of the mounted tool is assigned to every tool holder in the turret.

In the Teach-in cycle you program the turret position as T number. The tool ID number is automatically entered under "ID."

The turret list can be set up through the TSF menu or directly from the cycle dialogs in the Teach-in mode.

 T turret pocket number  Tool ID (name) is entered automatically.

 Open the Turret list. If the cursor is on the ID input

field, the CNC PILOT also automatically opens the

tool list with the entries in the tool database.

Machine with multifix

Machines with multifix tool holders have one tool pocket in which the tools are changed manually.

 T turret pocket number: Always T1  Tool ID (name): Select the ID number from the tool list

 Open the Tool list.

3.4 Setting up a tool list

The turret and multifix tool systems can be used together on one machine. The machine tool builder defines the number of the multifix pocket.

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Tools in different quadrants

Example: The principal tool carrier of your lathe is in front of the workpiece (standard quadrant). An additional tool holder is behind the workpiece.

When CNC PILOT is configured, it is defined for each tool holder whether the X dimensions and the direction of rotation of circular arcs are mirrored. In the above-mentioned example the additional tool holder is assigned the attribute "mirrored."

If this method is used, all machining operations are programmed as usual—regardless of which tool holder executes the operation. The simulation also shows all machining operations in the standard quadrant.

The tools are also described and dimensioned for the standard quadrant—even if they are inserted in the additional tool holder.

3.4 Setting up a tool list

Mirroring does not become effective until the machining of the workpiece, i.e. when the additional tool holder is executing the machining operation.

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Filling the turret list from the database

The turret list indicates the current assignment of the tool carrier. The turret list can be set up through the TSF menu or directly from the cycle dialogs in the Teach-in mode.

Look at the entries in the tool database in order to move entries from the database into the turret assignment list. The CNC PILOT displays the database entries in the lower area of the screen. The cursor keys are active in this list. You can move the cursor directly to a tool ID number by entering the first few letters or digits of the ID number.

OPEN THE TURRET LIST

Select Set T, S, F (only available in Manual mode)

Initiate the cycle dialog

Press the Tool list soft key to activate the turret assignment list and the tool list.

Adapt the turret assignment

TRANSFERRING TOOLS FROM THE DATABASE

Select the position in the turret assignment list.

Select and sort the entries in the tool database (see soft-key table at right)

3.4 Setting up a tool list

Selecting and sorting entries in the tool database

The CNC PILOT opens the soft-key menu to select the desired tool type.

The CNC PILOT opens the soft-key menu containing additional filter options.

The CNC PILOT opens the soft-key menu containing various sorting options.

Sorts the tools in the displayed list as desired according to:

 Tool type  Tool ID  Tool orientation

Each time the soft key is pressed it changes to the next sorting mode.

Switches between ascending and descending sorting.

Use the cursor keys to select the entry in the tool database.

Load the selected tool into the turret assignment list.

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Not active here

Closes the tool list.

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Filling the turret list

The turret assignment indicates the current assignment of the tool carrier. When you set up a turret list, you enter the ID numbers of the tools.

The turret list can be set up through the TSF menu or directly from the cycle dialogs in the Teach-in mode. The desired turret pocket is selected through the cursor keys.

You can also set up manual changing systems in the turret assignment (siehe „Setting up the holder for manual change systems” auf Seite

515).

SET UP THE TURRET LIST

Select Set T, S, F (only available in Manual mode)

3.4 Setting up a tool list

Initiate the cycle dialog

Press the Turret list soft key to activate the turret assignment list

Use the arrow keys to select a turret pocket

Adapt the turret assignment with the soft keys (see soft-key table at right).

Enter the tool ID number directly

ENTER THE TOOL ID NUMBER DIRECTLY

Press the ENT key to activate direct input.

Enter the tool ID number

Press the INS key to conclude input.

Soft keys in turret list

Delete entry

Paste entry from clipboard

Cut out entry and save it in the clipboard

Show entries in the tool database

Switch to next menu

Delete the complete turret list

Reset tool life

Back by one menu level

Load the T number and the tool ID number into the TSF or cycle dialog

Close the turret list without loading the T

Press the ESC key to cancel input.

88 Machine mode of operation

number and tool ID into the dialog box. Changes in the turret list remain effective.

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Tool call

T is the identification letter for the tool holder. ID designates the tool

ID number. The tool is called by "T" (turret pocket number). The ID number ID is shown and automatically filled in the dialogs. A turret list is kept.

In the turret list, multipoint tools are displayed with all cutting edges. In manual operation, you enter the T number in the TSF dialog box. In

Teach-in mode, “T” and “ID” are cycle parameters.

If a T number is entered in the TSF dialog box with an ID number that is not defined in the turret list, then the turret list will be changed accordingly. The existing turret list will be overwritten.

Driven tools

 Driven tools are defined in the tool description.  The driven tool can be operated with feed per revolution if the tool

spindle drive is equipped with a rotary encoder.

 If driven tools are used with constant cutting speed, the spindle

speed is calculated from the tool diameter.

3.4 Setting up a tool list

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Tool life monitoring

If desired, you can have the CNC PILOT monitor tool life or the number of parts that are produced with a specific tool.

The tool life monitoring function adds the time a tool is used at feed rate. The quantity monitoring counts the number of finished parts. The count is compared with the entry in the tool data.

As soon as the tool life expires or the programmed quantity is reached, the CNC PILOT sets the diagnostic bit 1. This causes an error message to be issued the next time the tool is called. If no replacement tool is available, the program will be stopped.

 For Teach-in programs, the simple tool life monitoring is available.

Here the CNC PILOT informs you when a tool is worn out.

 In smart.Turn and DIN PLUS programs, you have the choice

between the simple tool life monitoring and the tool life monitoring with replacement tools option. If you use

3.4 Setting up a tool list

replacement tools, the CNC PILOT automatically inserts the "sister tool" as soon as the tool is worn-out. The CNC PILOT does not stop the program run until the last tool of the tool sequence of exchange is worn out.

You activate/deactivate the tool life management in the parameter "System/General settings for automatic operation/user parameter tool life."

The CNC PILOT manages the type of monitoring, the "tool life/ remaining tool life" and the "maximum number of pieces/remaining number of pieces" in the diagnostic bits of the tool data. You can edit and display the diagnostic bits and the tool life in the tool editor (see “Editing tool-life data” auf Seite 509).

You can define replacement tools when setting up the turret in smart.Turn. The "interchange chain" can contain more than one replacement tool. The interchange chain is part of the NC program (see chapter titled "Tool Programming" in the "smart.Turn and DIN Programming" User's Manual).

You must update the data on tool life and number of pieces in the "tool management" mode when you replace the insert of a tool.

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Resetting the tool life in the turret list

RESET TOOL LIFE

Select Set T, S, F (only available in Manual mode)

Open the turret list

Press the Special Functions soft key

Press the Set new cutting edge soft key

Answer Yes to the confirmation prompt

Press the Back soft key

3.4 Setting up a tool list

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3.5 Machine setup

The machine always requires a few preparations, regardless of whether you are machining a workpiece manually or automatically. In Manual mode the following functions are subitems of the Setup menu item:

 Setting the axis values (defining workpiece zero point)

 Machine reference (axis reference run)

 Setting the protection zone  Defining the tool change position

3.5 Machine setup

 Setting C-axis values  Defining machine dimensions  Display operating times  Probing

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Defining the workpiece zero point

In the dialog, the distance between the machine zero point and the workpiece zero point (also know as offset) is shown as XN and ZN. If the workpiece zero point is changed, the display values will be changed accordingly.

The workpiece zero point can also be set in the Z axis using a touch probe. When setting the zero point, the control checks which type of tool is currently active. If you select the Workpiece zero point setup function and a touch probe is inserted, the control automatically adjusts the input form. Press NC Start to start the measuring process.

SETTING THE WORKPIECE ZERO POINT

Select Setting up

Select Set axis values

Touch the workpiece zero point (end face)

Define this point as the "workpiece zero point Z"

3.5 Machine setup

Enter the distance between the tool and the workpiece zero point as "measuring point coordinate Z"

The CNC PILOT calculates the workpiece zero point Z

Machine zero point Z = workpiece zero point Z (offset = 0)

This makes it possible to enter the zero point shift directly in ZN

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Defining offsets

Before using zero point shifts with G53, G54 and G55, you need to define the offset values in setup mode.

SET OFFSET

Select Setting up

Select Set axis values

3.5 Machine setup

Press the Shift soft key

Enter the offset value

Press the G53 soft key

Press the G54 soft key

Press the G55 soft key

Press the Save soft key.

The CNC PILOT saves the values to a table. In this way, you can activate the offsets in the program by entering the respective G codes.

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Homing the axes

It is possible to home axes that have already been homed. Here you can select individual axes or all axes simultaneously.

REFERENCE RUN

Select Setting up

Select Set axis values

Press the Machine reference soft key

Press the Z reference soft key

Press the X reference soft key

Or press the All soft key

3.5 Machine setup

Press Cycle start for the control to traverse the reference marks

The CNC PILOT refreshes the position display.

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Setting the protection zone

With active protection zone monitoring, the CNC PILOT checks for every movement whether the protection zone in –Z direction would be violated. If it detects such a violation, it stops the axis movement and generates an error message.

The "Setting the protection zone" setup dialog shows the distance between the machine zero point and the protection zone in –ZS.

The status of the protection zone monitoring is shown in the machine display if it has been configured by the machine manufacturer (see table).

3.5 Machine setup

SETTING THE PROTECTION ZONE/SWITCHING OFF THE MONITORING FUNCTION

Select Setting up

Select Set protection zone

Move the tool with the jog keys or handwheel until it reaches the protection zone

Use the Take over position soft key to load this position as protection zone

Protection zone status Protection zone monitoring active

Protection zone monitoring not active

Enter the position of the protection zone relative to the workpiece zero point (field: "Meas. pt. coordin.–Z")

Use the Save soft key to load the entered position as protection zone

Switch off protection zone monitoring

 Protection zone monitoring is not active if the Set

protection zone dialog box is open.

 In DIN programming, you deactivate protection zone

monitoring with G60 Q1 and reactivate it with G60.

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Defining the tool change position

With the cycle Move to tool change position or the DIN command G14, the slide moves to the tool change point. Program the tool

change point far enough away from the workpiece so that the turret can rotate without collision and the tools do not damage the workpiece during tool change.

DEFINING THE TOOL CHANGE POSITION

Select Setting up

Select the tool change point

Move to the tool change position

Move to the tool change point using the jog keys or the handwheel and load this position as tool change point

Enter the tool change position directly

Enter the desired tool change position in the X and Z input fields in machine coordinates (X = radius dimension).

3.5 Machine setup

The coordinates of the tool change position are entered and displayed as the distance between machine zero point and tool carrier zero point. It is recommended to move to the tool change point and load the position with the Take over position soft key.

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Setting C-axis values

The "Set C-axis values" function enables you to define a zero point shift for the workpiece spindle:

 CN: Position value of the workpiece spindle (display)  C: Zero point shift of the C axis

DEFINING THE ZERO POINT OF THE C AXIS

Select Setting up

3.5 Machine setup

Select Set C axis values

Position the C axis

Define the position as the C axis zero point

Enter the zero point shift of the C axis:

Confirm entry for CNC PILOT to calculate the C axis

zero point

Delete the zero point shift of the C axis

Expanded form view for machines with opposing spindle

If your machine is equipped with an opposing spindle, the CA parameter is shown. The CA parameter enables you to specify for which workpiece spindle (main spindle or opposing spindle) entries for the "Set C-axis value" function are effective.

The active angle offset is shown in the CV parameter. An angle offset is activated with G905 to match the position of main and opposing spindle to each other. This may be necessary if both spindles need to be synchronized for a part transfer. The "Delete CV offset" soft key enables you to reset an active angle offset.

Additional parameters for machines with opposing spindle:

 CV: Display of active angle offset  CA: Selection of C axis (main spindle or opposing spindle)

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Setting up machine dimensions

The "Set up machine dimensions" function allows you to save any positions to use these in NC programs.

SETTING UP MACHINE DIMENSIONS

Select Setting up

Select Set up machine dimensions

Enter the number for the machine dimensions

Assume position of a single axis as machine dimensions

Assume position of all axes as machine dimensions

3.5 Machine setup

Save machine dimensions

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Calibrating the tool touch probe

The "Calibrate the tool touch probe" function enables you to determine the exact position values of the tool touch probe.

MEASURING THE TOUCH PROBE POSITION

Insert an exactly measured tool or reference tool

Select Setting up

3.5 Machine setup

Select touch probe

Select tool touch probe

Pre-position the tool for the first direction of measurement

Set the positive or negative traverse direction

Press the soft key for this direction (e.g. –Z direction)

Press Cycle START. The tool moves in the direction of measurement. The position of the touch probe is measured and saved when the tool touch probe releases a trigger signal. The tool returns to the starting point.

Press the "Back" soft key to terminate the calibration process. The calibration values measured are saved, or

Pre-position the tool for the next measuring direction and repeat the procedure (max. 4 measuring directions)

100 Machine mode of operation

HEIDENHAIN SW 68894x-03 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Controls and displays of the CNC PILOT

Keys on visual display unit

Operating mode keys

smart.Turn keys

Navigation keys

Numeric keypad

Special keys

Machine operating panel

Operating panel of the CNC PILOT

CNC PILOT 640, software and features

Intended place of operation

Legal information

New functions of software 688945-02

New functions of software 688945-03 and 68894x-01

New functions of software 68894x-02

New functions of software 68894x-03

About this manual

Would you like any changes, or have you found any errors?

1 Introduction and fundamentals ..... 35

2 Basics of operation ..... 51

3 Machine mode of operation ..... 73

4 Teach-in mode ..... 133

5 ICP programming ..... 373

6 Graphic simulation ..... 483

7 Tool and technology database ..... 499

8 Organization mode of operation ..... 541

9 Tables and overviews ..... 607

10 Overview of cycles ..... 641

Introduction and fundamentals

1.1 The CNC PILOT

Slide position

Tool carrier systems

The C axis

1.2 Configuration

The Y axis

Full-surface machining

Configuration

1.3 Features

Modes of operation

1.4 Data backup

1.5 Explanation of terms

1.6 CNC PILOT design

Position encoders and reference marks

1.7 Fundamentals

Axis designations

Coordinate system

Absolute coordinates

Incremental coordinates

Polar coordinates

Machine zero point

Workpiece zero point

Units of measure

Tool length

Tool compensation

1.8 Tool dimensions

Tool-tip radius compensation (TRC)

Milling cutter radius compensation (MCRC)

Basics of operation

Operation

Setup

2.1 General information on operation

Programming – Teach-in mode

Programming – smart.Turn

2.2 The CNC PILOT screen

Operating modes

2.3 Operation and data input

Menu selection

Soft keys

Data input

smart.Turn dialogs

List operations

Alphanumeric keyboard

Calculator functions

2.4 Integrated calculator

Adjusting the position of the calculator

2.5 Types of programs