HEIDENHAIN TNC 122 User Manual

User's Manual

TNC 122

December 1994

Display
X
Y					X	7	8	9
Z					Y	4	5	6
					Z	1	2	3
				NO
				ENT
			DEL	CL	–	0		ENT
MOD	PGM	LBL
	STOP	SPEC	F	TOOL	R+/–
		FCT		DEF
						HEIDENHAIN

Position displays for the coordinate axes

Program run	Block number
indicator

X

Y

Z

	X	7	8	9
Input line
	Y	4	5	6
NO	Z	1	2	3
ENT

Operating modes, Programming

X
Y					X	7	8	9
Z					Y	4	5	6
					Z	1	2	3
				NO
				ENT
			DEL	CL	–	0		ENT
MOD	PGM	LBL
	STOP	SPEC	F	TOOL	R+/–
		FCT		DEF
						HEIDENHAIN

POSITIONING Program MANUAL WITH MDI management

OPERATION

User parameters	PGM	LBL	DEL
MOD
PROGRAM RUN	STOP	SPEC	F
		FCT
SINGLE BLOCK
PROGRAM RUN
FULL SEQUENCE	PROGRAMMING	Stop
	& EDITING

Input in all modes of operation

X
Y					X	7	8	9
Z					Y	4	5	6
					Z	1	2	3
				NO
				ENT
			DEL	CL	–	0		ENT
MOD	PGM	LBL
	STOP	SPEC	F	TOOL	R+/–
		FCT		DEF
						HEIDENHAIN

	Coordinate axes
Incremental dimensions		X	7	8	9
Actual position capture		Y	4	5	6
Clear entry	ENT	Z	1	2	3
	NO
Reset entry	CL	–	0		ENT
Change sign
Tool length and radius	DEF	R+/–
	TOOL

Labels for subprograms and program section repeats

Delete block; abort function

Feed rate

Special functions

Numerical input

Confirm entry

Decimal point

Change program block

Tool radius Program block selection compensation

The TNC Guideline

From the workpiece drawing to program-controlled machining

Step	Task	TNC mode	Starting
		of operation	on page
	Preparation
1	Select tools	——	——
2	Set workpiece datum
	for coordinate system	——	——
3	Determine spindle speeds
	and feed rates	——	——
4	Switch on TNC and machine	——	15
5	Cross over reference marks		15
6	Clamp workpiece	——	——
7	Set datum/
	set position displays		21
	Entering and testing part programs
8	Enter part program or
	download over external
	data interface		from 31
9	Test run: Run program block
	by block without tool		51
10	If necessary:
	Optimize the part program		from 31
	Machining the workpiece
12	Insert tool and
	run part program		51

TNC Accessory

Floppy disk unit

With the HEIDENHAIN FE 401 B floppy disk unit you can store programs from the TNC on diskette.

It is also a means of transferring programs created on a personal computer to the TNC.

The FE 401 B Floppy Disk Unit

Contents
	Scope of this Manual .........................................................................................	7
	TNC 122 .............................................................................................................	7
	How to Use This Manual ....................................................................................	8
	Dialog Flowcharts ...............................................................................................	8
	Special Notes in This Manual .............................................................................	9
1	Fundamentals of Positioning ...................................................	11
	Reference system and coordinate axes ...........................................................	11
	Datums and positions ......................................................................................	12
	Machine axis movements and position feedback ............................................	14
2	Working with the TNC 122 – First Steps .................................	15
	Before you begin ..............................................................................................	15
	Switch on the TNC ...........................................................................................	15
	Operating modes .............................................................................................	16
	Error messages ................................................................................................	16
	Selecting the position display mode .................................................................	17
3	Manual Operation and Setup ...................................................	19
	Moving the machine axes with the axis direction buttons ...............................	19
	Entering tool length and radius .........................................................................	20
	Setting the datum ............................................................................................	21
4	Positioning with Manual Data Input (MDI) .............................	23
	Before you machine the part ............................................................................	23
	Taking the tool radius into account ...................................................................	23
	Entering the miscellaneous function M ............................................................	24
	Entering and changing the feed rate F .............................................................	24
	Entering and moving to positions .....................................................................	25
	Hole patterns ...................................................................................................	27
	Input for a bolt hole circle .................................................................................	27
	Input for linear hole patterns ............................................................................	27
	Drilling the hole pattern ....................................................................................	27
5	Programming .............................................................................	31
	Entering the program number ..........................................................................	32
	Deleting programs ............................................................................................	32
	Selecting program blocks .................................................................................	33
	Changing program blocks .................................................................................	33
	Deleting program blocks ..................................................................................	34
	Feed rate F and miscellaneous function M ......................................................	35
	Entering a program interruption .......................................................................	36
	Entering workpiece positions ...........................................................................	37
	Actual-position capture: Teach-In programming ...............................................	38
	Hole patterns in programs ................................................................................	39
	Bolt hole circle ..................................................................................................	39
	Linear hole patterns .........................................................................................	41
	Subprograms and Program Section Repeats ...................................................	43
	Subprograms ....................................................................................................	44
	Program section repeats ..................................................................................	46

Contents

6	Transferring Programs over the Data Interface ......................	49
	Transferring a program to the TNC ...................................................................	49
	Transferring programs out of the TNC .............................................................	50
7	Executing Programs ..................................................................	51
	Interrupting program run ..................................................................................	52
	Single block ......................................................................................................	52
	Automatic .........................................................................................................	52
8	User Parameters ........................................................................	53
9	Tables and Overviews ...............................................................	55
	Miscellaneous functions (M functions) ............................................................	55
	Pin layout and connecting cable for the data interface .....................................	57
	TNC Messages .................................................................................................	58
	Specifications ...................................................................................................	60
	Accessory ........................................................................................................	60
	Subject Index .............................................................................	61

Scope of this Manual

This manual describes the operation of the TNC 122 from the software version

Progr. 246 xxx 01.

The three x's represent any numbers.

For detailed technical information, refer to the Technical

Manual for the TNC 122.

TNC 122

TNC-Familie

What is NC?

NC stands for Numerical Control, that is, control of a machine tool by means of numbers. Modern controls such as the TNC have a built-in computer for this purpose and are therefore called CNC (Computerized Numerical Control).

From the very beginning, the TNCs from HEIDENHAIN were developed specifically for shop-floor programming by the machinist. This is why they are called TNC, for “Touch Numerical Controls.”

The TNC 122 is a straight cut control for milling, drilling, and boring machines with up to three axes.

Differences from the TNC 121

The TNC 122 features the following improvements over the TNC 121:

•Larger program memory

•Tool compensation

•Programmable feed rate

•RS-232-C/V.24 data interface

Programming

Workpiece machining is defined in a part program. It contains a complete list of instructions for machining a part, for example the target position coordinates or the feed rate

TNC 122

7

How to Use This Manual

As a TNC beginner, you can use the operating instructions as a step-by-step workbook. This part begins with a short introduction to some important basics concepts, and provides an overview of the available features. Then each feature is explained in detail, using a practical example that you can immediately try out on the machine — so you can't get lost in the theory. As a beginner you should work through all the examples presented.

The examples are intentionally brief; it generally won't take you longer than 10 minutes to enter the example data.

As a TNC expert, you can use this manual as a comprehensive review and reference guide. The clear layout and the subject index make it easy to find the desired topics.

Dialog Flowcharts

Dialog flowcharts are used for each example in this manual.

They are laid out as follows:

The operating mode is indicated above the first dialog flowchart.

This area shows the	This area explains the function of the key or the work step.
keys to press.	If necessary, supplementary information will also be included.

P r o m p t

This area shows the	This area explains the function of the key or the work step.
keys to press.	If necessary, supplementary information will also be included.

If there is an arrow at the end of the flowchart, this means that it continues on the next page.

A prompt appears with some actions (not always) above the input keypad.

Abbreviated flowcharts

Abbreviated flowcharts supplement the examples and explanations. An arrow ( ) indicates a new input or a work step.

8

TNC 122

Special Notes in This Manual

Especially important information is shown as a separate note in a gray box. Pay special attention to these notes. Ignoring them would prevent effective use of the control, or even result in damage to the tool or workpiece.

Symbols in the gray boxes

The symbols in the left of the gray boxes indicate the nature of the provided information.

General information

for example on the machine tool.function

Information for the machine tool builder

for example that he must implement a certain function

Essential information

for example that a certain tool is needed for the described function

TNC 122

9

NOTES

10

TNC 122

1 Fundamentals of Positioning

1

Fundamentals of Positioning

Reference system and coordinate axes

Reference system

In order to define positions on a surface one needs a reference system. For example, positions on the earth's surface can be defined “absolutely” by their geographic coordinates of longitude and latitude. The term “coordinate” comes from the Latin word for “that which is arranged.” The network of horizontal and vertical lines on the globe constitute an absolute reference system in contrast to the “relative” definition of a position that is referenced to some other known location.

The illustration at right shows the 0° longitude at the Greenwich observatory and the 0° latitude at the equator.

Cartesian coordinate system

On a milling or boring machine, workpieces are normally machined according to a workpiece-based Cartesian coordinate system (a rectangular coordinate system named after the French mathematician and philosopher Renatus Cartesius, who lived from 1596 to 1650). The Cartesian coordinate system is based on three coordinate axes designated X, Y and Z which are parallel to the machine guideways.

The figure at right illustrates the “right-hand rule” for remembering the three axis directions: the middle finger is pointing in the positive direction of the tool axis from the workpiece toward the tool (the Z axis), the thumb is pointing in the positive X direction, and the index finger in the positive Y direction. X, Y and Z are the main axes of the Cartesian coordinate system.

60°

Greenwich

30°

0°

30°

60°

90° 0° 90°

Fig. 1.1: The geographic coordinate system is an absolute reference system

+Y	+Z
	+X
	+Z
	+X
	+Y

Fig. 1.2: Designations and directions of the axes on a milling machine

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11

1 Fundamentals of Positioning

Datums and positions

Setting the datum

The workpiece drawing identifies a certain point on the workpiece (usually a corner) as the “absolute datum” and perhaps one or more other points as relative datums. The datum setting procedure establishes these points as the origin of the absolute or relative coordinate systems: The workpiece, which is aligned with the machine axes, is moved to a certain position relative to the tool and the display is set either to zero or to another appropriate value (e.g., to compensate the tool radius).

Example: Coordinates of hole 1 :

X =	10	mm
Y =	5	mm
Z =	0	mm (hole depth: Z = – 5 mm)

The datum of the Cartesian coordinate system is located 10 mm from hole 1 on the X axis and 5 mm from it in the Y axis (in negative direction).

Z

Y

X

Fig. 1.3: The workpiece datum represents the origin of the Cartesian coordinate system

	Z
Y
		X
		1
5
		10
Fig. 1.4:	Hole	defines the coordinate system

12

TNC 122

1Fundamentals of Positioning Datums and positions

Absolute workpiece positions

Each position on the workpiece is uniquely identified by its absolute coordinates.

Example: Absolute coordinates of the position 1 :

X	=	20	mm
Y	=	10	mm
Z	=	15	mm

If you are drilling or milling a workpiece according to a workpiece drawing with absolute coordinates, you are moving the tool to the value of the coordinates.

Incremental workpiece positions

A position can also be referenced to the preceding nominal position. In this case the relative datum is always the last programmed position. Such coordinates are referred to as incremental coordinates (increment = increase). They are also called incremental or chain dimensions (since the positions are defined as a chain of dimensions). Incremental coordinates are designated with the prefix I.

Example: Incremental coordinates of position 3 referenced to position 2

Absolute coordinates of position 2 :

X	=	10	mm
Y	=	5	mm
Z	=	20	mm

Incremental coordinates of position 3 :

IX=	10	mm
IY=	10	mm
IZ	=	–15 mm

	Z
			1
Y
15		Z=15mm
			Y=10mm	X
	X=20mm
10
				20

Fig. 1.5: Position definition through absolute coordinates

		3
Y			I
		15mm–Z=I	Y
	2		=
			1
			0
			m
			m
20			IX=10mm
10	15		X
5	5		10
0			10
	0

Fig. 1.6: Position definition through incremental coordinates

If you are drilling or milling a workpiece according to a drawing with incremental coordinates, you are moving the tool by the value of the coordinates.

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13

1 Fundamentals of Positioning

Machine axis movements and position feedback

Programming tool movements

During workpiece machining, an axis position is changed either by moving the tool or by moving the machine table on which the

workpiece is fixed. +Y

When entering tool movements in a part program you always program as if the tool is moving and the workpiece is stationary.

+Z

+X

Position feedback

The position feedback encoders convert the movement of the machine axes into electrical signals. The control evaluates these signals and constantly calculates the actual position of the machine axes.

If there is an interruption in power, the calculated position will no longer correspond to the actual position. When power is restored, the TNC can re-establish this relationship with the aid of the encoders' reference marks.

Reference marks

Fig. 1.7: On this machine the tool moves in the Y and Z axes; the workpiece moves in the X axis.

Z

Y

X

Fig. 1.8: Linear position encoder, here for the X axis

The scales of the position encoders have one or more reference marks. When a reference mark is passed over, it generates a signal which identifies that position as the reference point (scale reference point = machine reference point). With the aid of this reference mark the TNC can re-establish the assignment of displayed values to machine axis positions.

If the position encoders feature distance-coded reference marks, each axis need only move a maximum of 20 mm (0.8 in.) for linear encoders, and 20° for angle encoders.

Fig. 1.9: Linear scales: above with distancecoded reference marks, below with one reference mark

14

TNC 122

2 Working with the TNC 122 – First Steps

2

Working with the TNC 122 – First Steps

Before you begin

You must cross over the reference marks after every switch-on. From the positions of the reference marks, the TNC automatically re-establishes the relationship between axis slide positions and display values that you last defined by setting the datum.

When you set a new datum point, the control automatically stores the new relationship between axis positions and display values.

Switch on the TNC

0 1

Switch on the TNC and the machine tool.

M E M O R Y T E S T

Please wait...	The TNC automatically checks its internal memory.

P O W E R I N T E R R U P T E D

CL	Clear the TNC message indicating that the power was interrupted.

N O C O N T R O L V O L T G

I		Switch on the control voltage.
		The TNC automatically checks the function of the EMERGENCY STOP button.
	R E F T R A V E N T / N O E

ENT	Select reference mark evaluation.

R E F	M A R K	X Y Z
Press and hold:
X	Cross the reference marks in any direction:
Y	Press and hold the machine axis direction button until the moving
	axis disappears from the screen.
	Sequence in this example: X axis, Y axis, Z axis

Z

The TNC 122 is now ready for operation in the

MANUAL OPERATION mode.

If you do not wish to cross over the reference marks:

Answer the REF TRAV ENT/NOE dialog prompt with NO ENT (this feature must be implemented by the machine tool builder).

TNC 122

15

2 Working with the TNC 122 – First Steps

Operating modes

Selecting an operating mode makes a specific group of functions available.

Usable functions		Operating mode Key
Moving the machine axes;		MANUAL
Setting the datum		OPERATION
Entering positioning blocks		POSITIONING
and executing them block		WITH MANUAL
by block;		DATA INPUT
Changing feed rate and
miscellaneous functions;
Entering tool data
Storing working steps for		PROGRAMMING
small-lot production by		AND EDITING
•	Keyboard entry
•	Teach-In
Transferring programs
through the data interface
Running programs		SINGLE BLOCK
blockwise
Running programs		AUTOMATIC
continuously

You can switch to another operating mode at any time by pressing key for the desired mode.

Error messages

If an error occurs while you are operating the TNC, a message will appear in plain language. You will find an overview of error message in Chapter 9.

To clear an error message:Press the CL key.

Blinking error messages

W A R N I N G !

A blinking error messages means that the operational reliability of the TNC has been impaired.

If the TNC shows a blinking error message:

Write down the message.

Switch off the TNC and the machine tool.

Try to correct the error with the power off.

If the error cannot be corrected or if a blinking error message persists, call your service representative.

16

TNC 122

2 Working with the TNC 122 – First Steps

Selecting the position display mode

The TNC can show different types of position values for a tool position.

Fig 2.1 shows the following positions

•Starting position A of the tool

•Target position Z of the tool

•Workpiece datum W

•Scale reference point M

The TNC position display can be set to show the following types of information:

•Actual position 2

The position at which the tool is presently located as referenced to the workpiece datum.

•Servo lag 3

The difference between nominal 1 and actual 2 positions

•Actual position referenced to the scale reference point 4

	1
2	3
A	Z
W	4
M

Fig 2.1: Tool and workpiece positions

To change position display modes:

Set another position display mode in the user parameter MP 7322 (see Chapter 8).

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17

2 Working with the TNC 122 – First Steps

NOTES

18

TNC 122

3 Manual Operation and Setup

3

Manual Operation and Setup

The TNC 122 provides two methods for manually moving the machine axes:

•Axis direction buttons

•Positioning with Manual Data Input (see Chapter 4)

Changing the feed rate F

Some machines are equipped with a potentiometer to enable you to vary the feed rate.

Moving the machine axes with the axis direction buttons

In the MANUAL OPERATION mode you can move a machine axis by pressing the appropriate axis direction button on the machine control panel. As soon as you release the button the axis stops.

Continuing machine axis movement

With the user parameter MP7680 (see Chapter 8) you can set the TNC for continuing machine axis movement. The machine then continues to move the axis after you have released the axis direction button. To stop the machine axis you must press a button again (see example 2 below).

Example: Moving the machine axis with the machine axis direction
button in the Z+ direction (retracting the tool)	Z

Y

X

Example 1: Moving the machine axis

Mode of operation: MANUAL OPERATION

Press and hold:

Z

Press the direction button, e.g. Z, and hold it as long as you wish the machine axis to move.

Example 2: Moving the machine axis (continuing movement)

Mode of operation: MANUAL OPERATION

	Together:	Z	I	To start the axis, press an axis direction button, such as Z, and the NC start
				button at the same time.
		0		Stop the axis with the NC stop button.

TNC 122

19