HEIDENHAIN TNC 406 User Manual
NC Software
280 620-xx
280 621-xx
286 180-xx
User’s Manual
Conversational
Programming
English (en)
4/2001
1
50
0
50
100
F %
Controls on the visual display unit
Split screen layout
Switch between machining or
programming modes
Soft keys for selecting functions in screen
Switching the soft-key rows
Changing the screen settings
(only BC 120)
Typewriter keyboard for entering letters and symbols
File names
Comments
ISO
programs
Machine operating modes
MANUAL OPERATION
INCREMENTAL JOG
POSITIONING WITH MDI
PROGRAM RUN, SINGLE BLOCK
PROGRAM RUN, FULL SEQUENCE
Programming modes
PROGRAMMING AND EDITING
TEST RUN
Program/file management, TNC functions
Delete programs and files (only TNC 406)
Activate external data transfer (only TNC 406)
Pocket calculator
Select programs and files
Moving the highlight, going directly to blocks, cycles
and parameter functions
Go directly to blocks, cycles and parameter
Move highlight
functions
Override control knobs for feed rate/C axis
100
0
1
S %
50
50
Programming path movements
Straight line
Circle center/pole for polar coordinates
Circle with center
Circle with radius
Circular arc with tangential connection
Corner rounding
Electrode data
Enter and call electrode length and radius
Activate electrode radius compensation
Cycles, subprograms and program section
repeats
Program stop in a program
Enter touch probe functions in a program
Define and call cycles
Enter and call labels for subprogramming and
program section repeats
Coordinate axes and numbers:Entering and editing
. . .
. . .
Decimal point
Change arithmetic sign
Polar coordinates
Incremental dimensions
Q parameters
Capture actual position
Skip dialog questions, delete words
Confirm entry and resume dialog
End block
Clear numerical entry or TNC error
message
Abort dialog, delete program section
Select coordinate axes or
enter them into the program
Numbers
TNC Models, Software and Features
This manual describes functions and features provided by the TNCs as
of the following NC software numbers.
TNC Model NC Software No.
TNC 406 280 620-12
TNC 416 286 180-06
Location of use
The TNC complies with the limits for a Class A device in accordance
with the specifications in EN 55022, and is intended for use primarily
in industrially-zoned areas.
280 621-12
280 622-12
New features of the NC software 280 62x-xx and 280 180-xx
Cycle 14 CONTOUR GEOMETRY (see also ”Cycle 14 CONTOUR
GEOMETRY” on page 137)
Q parameters for the roughness (see also ”Data from the erosion
table” on page 203)
Q parameters for the gap size (see also ”Gap size LS max when
machining which Cycle 1 GENERATOR: Q164” on page 206)
After manual traverse, the incremental coordinates always refer to
the actual position (see also ”Resuming program run with the
GOTO key” on page 226)
Expansion of the tool table with tool pocket number, tool undersize
and radius (see also ”Entering electrode data in tables” on page 74)
Probed values can be written to a datum table as well as to a tool
table (see also ”Writing probed values to tables” on page 28)
Enhancement of functions FN14 and FN15 (see also ”Output of Q
Parameters and Messages” on page 197)
M108/M109 (see Overview of Miscellaneous Functions on the
inside rear cover of this manual)
HEIDENHAIN TNC 406, TNC 416 I
Contents
Introduction
Manual Operation, Setup and Probing
Functions
Positioning with manual data input
(MDI)
Programming: Fundamentals, Files,
Program Entry, Spark Erosion, Erosion
Ta b l e s
1
2
3
4
Programming: Tools
Programming: Programming Contours
Programming: Miscellaneous Functions
Programming: Cycles
Programming: Subprograms and
Program Section Repeats
Programming: Q Parameters
Test Run and Program Run
MOD Functions
Tables and Overviews
5
6
7
8
9
10
11
12
13
HEIDENHAIN TNC 406, TNC 416 III
1 Introduction ..... 1
1.1 The TNC 406, the TNC 416 ..... 2
Controls ..... 2
Visual display unit and keyboard ..... 2
Programming ..... 2
Graphics ..... 2
Compatibility ..... 2
1.2 Visual Display Unit and Keyboard ..... 3
Visual display unit ..... 3
Screen layout ..... 4
Keyboard ..... 5
1.3 Modes of Operation ..... 6
Manual Operation, Incremental Jog, and Positioning with Manual Data Input ..... 6
Programming and Editing ..... 7
Test Run ..... 7
Program Run, Full Sequence and Program Run, Single Block ..... 8
1.4 Status Display ..... 9
General status display ..... 9
Additional status displays ..... 9
1.5 Accessory: Electronic Handwheels from HEIDENHAIN ..... 13
HR electronic handwheels ..... 13
HEIDENHAIN TNC 406, TNC 416 I
2 Manual Operation, Setup and Probing Functions ..... 15
2.1 Switch-on ..... 16
Switch-on ..... 16
2.2 Moving the Machine Axes ..... 18
Note ..... 18
To traverse with the machine axis direction buttons: ..... 18
Traversing with the HR 410 electronic handwheel ..... 19
Incremental jog positioning ..... 20
Positioning with manual data input (MDI) ..... 20
Eroding a workpiece manually ..... 21
2.3 Datum Setting ..... 22
Example ..... 22
2.4 Calibration and Setup ..... 23
Using an electrode ..... 23
Select the touch probe function ..... 24
Calibrating the probing electrode ..... 25
Compensating workpiece misalignment ..... 27
2.5 Datum Setting with a Probing Electrode ..... 28
Functions for setting the datum ..... 28
Writing probed values to tables ..... 28
Datum setting in any axis ..... 29
Manual probing ..... 29
Workpiece center as datum ..... 30
Corner as datum ..... 31
Circle center as datum ..... 32
2.6 Measuring with a Probing Electrode ..... 33
Introduction ..... 33
To find the coordinate of a position on an aligned workpiece ..... 33
Finding the coordinates of a corner in the working plane ..... 33
Measuring workpiece dimensions ..... 34
Measuring angles ..... 35
2.7 Entering and Starting Miscellaneous Functions M ..... 36
Entering values ..... 36
3 Positioning with Manual Data Input (MDI) ..... 37
3.1 Positioning with Manual Data Input (MDI) ..... 38
Positioning with manual data input (MDI) ..... 38
Protecting and erasing programs in $MDI ..... 39
II
4 Programming: Fundamentals, Files,
Program Entry, Spark Erosion, Erosion Tables ..... 41
4.1 Fundamentals of Positioning ..... 42
Introduction ..... 42
What is NC? ..... 42
The part program ..... 42
Programming ..... 42
Position encoders and reference marks ..... 43
Reference system ..... 43
Reference system with EDMs ..... 44
Programming electrode movement ..... 44
Polar coordinates ..... 45
Absolute and incremental workpiece positions ..... 46
Setting the datum ..... 47
4.2 Files ..... 48
File directory ..... 48
Selecting, copying, deleting and protecting files ..... 50
4.3 Creating and Writing Programs ..... 51
Organization of an NC program in HEIDENHAIN conversational format. ..... 51
Defining the blank form–BLK FORM ..... 51
Creating a new part program ..... 52
Programming tool movements in conversational format ..... 54
Editing a program ..... 55
4.4 Automatic Workpiece Change with WP-Call ..... 57
Programming a workpiece change ..... 57
4.5 Fundamentals of Spark Erosion ..... 58
4.6 Erosion Tables ..... 61
Using erosion tables in a program ..... 61
Working without an erosion table ..... 61
Ready-to-use erosion tables ..... 61
HEIDENHAIN TNC 406, TNC 416 III
4.7 Parameters in the Erosion Table ..... 62
To enter erosion parameters in the erosion table ..... 63
Power stage (NR) ..... 64
Low voltage current (LV) ..... 64
High voltage current (HV) ..... 64
Gap voltage (GV) ..... 64
Pulse-on duration and pulse-off duration ..... 65
Servo sensitivity SV ..... 65
Erosion time ET, Auto jump distance AJD ..... 65
Arc sensitivity (AR) ..... 66
Electrode polarity (P) ..... 66
High voltage selector HS ..... 66
Wear rate WR ..... 67
Surface finish RA ..... 67
Stock removal SR ..... 68
Two-times gap (2G) ..... 68
Minimum undersize (UNS) ..... 69
Auxiliary parameters AUX 1, AUX 2, ... AUX 6 ..... 69
5 Programming: Tools ..... 71
5.1 Electrodes ..... 72
Electrode axis C ..... 72
Determining the electrode data ..... 72
Entering electrode data into a program ..... 73
Entering electrode data in tables ..... 74
Calling electrode data ..... 76
Following electrode ..... 77
Changing the electrode ..... 77
Electrode compensation ..... 78
5.2 Electrode Compensation Values ..... 79
Electrode length compensation ..... 79
Electrode radius compensation ..... 80
Radius compensation: Machining corners ..... 82
5.3 Entering Electrode-Related Data ..... 83
Introduction ..... 83
Feed rate F ..... 83
5.4 Actual Position Capture ..... 84
Function ..... 84
IV
6 Programming: Programming Contours ..... 85
6.1 General Information on Programming Electrode Movements ..... 86
Path functions ..... 86
Machines with 5 axes ..... 86
Subprograms and program section repeats ..... 86
Cycles ..... 87
Parametric programming ..... 87
6.2 Contour Approach and Departure ..... 88
Starting point and end point of machining ..... 88
Tangential contour approach and departure ..... 91
6.3 Path functions ..... 92
General ..... 92
Programmed machine axis movement ..... 92
6.4 Path Contours — Cartesian Coordinates ..... 93
Overview of path functions ..... 93
Straight line L ..... 94
Inserting a chamfer CHF between two straight lines ..... 96
Corner rounding RND ..... 97
Circles and circular arcs ..... 97
Circle center CC ..... 98
Circular path C around circle center CC ..... 100
Circular path CR with defined radius ..... 101
Circular path CT with tangential connection ..... 103
6.5 Path Contours — Polar Coordinates ..... 109
Overview ..... 109
Polar coordinate origin: Pole CC ..... 109
Straight line LP ..... 110
Circular path CP around pole CC ..... 111
Circular path CTP with tangential connection ..... 112
Helical interpolation ..... 113
HEIDENHAIN TNC 406, TNC 416 V
7 Programming: Miscellaneous functions ..... 119
7.1 Entering Miscellaneous Functions M and STOP ..... 120
Fundamentals ..... 120
7.2 Miscellaneous Functions for Program Run Control, Electrode and Flushing ..... 122
Overview ..... 122
7.3 Miscellaneous Functions for Contouring Behavior and Coordinate Data ..... 123
Introduction ..... 123
Machining small contour steps: M97 ..... 123
Machining open contours: M98 ..... 124
Programming machine-referenced coordinates: M91/M92 ..... 124
Retracting electrode to block starting point at end of block: M93 ..... 125
7.4 Vacant miscellaneous functions ..... 126
VI
8 Programming: Cycles ..... 129
8.1 General Overview of Cycles ..... 130
Prerequisites ..... 130
Start of effect ..... 130
Dimensions in the electrode axis ..... 130
OEM cycles ..... 130
Programming a cycle ..... 131
8.2 Cycle 1 GENERATOR ..... 133
Working with an erosion table ..... 133
Working without an erosion table ..... 133
To enter Cycle 1.0 GENERATOR ..... 133
Changing the power stage ..... 134
8.3 Electrode Definition ..... 135
Cycle 3 TOOL DEF ..... 135
Example NC blocks ..... 136
8.4 Erosion Cycles ..... 137
Overview ..... 137
Cycle 14 CONTOUR GEOMETRY ..... 137
Cycle 16 ORBIT ..... 139
Cycle 17 DISK ..... 142
Cycle 2 ERO.TIME LIM. ..... 145
Cycle 4 SPARK-OUT TIME ..... 146
8.5 Coordinate Transformation Cycles ..... 155
Cycles for electrode definition ..... 155
Coordinate transformation cycles ..... 155
DATUM SHIFT (Cycle 7) ..... 156
Working with datum tables ..... 157
MIRROR IMAGE (Cycle 8) ..... 158
ROTATION (Cycle 10) ..... 159
SCALING FACTOR (Cycle 11) ..... 160
WORKING PLANE (Cycle 19) ..... 161
8.6 Other Cycles ..... 171
DWELL TIME (Cycle 9) ..... 171
PGM-CALL (Cycle 12) ..... 171
HEIDENHAIN TNC 406, TNC 416 VII
9 Programming: Subprograms and Program Section Repeats ..... 173
9.1 Labeling Subprograms and Program Section Repeats ..... 174
Labels ..... 174
9.2 Subprograms ..... 175
Operating sequence ..... 175
Programming notes ..... 175
Programming a subprogram ..... 175
Calling a subprogram ..... 175
9.3 Program Section Repeats ..... 176
Label LBL ..... 176
Operating sequence ..... 176
Programming notes ..... 176
Resetting the program repeat counters after an interruption ..... 176
Programming a program section repeat ..... 176
Calling a program section repeat ..... 177
9.4 Separate Program as Subprogram ..... 178
Operating sequence ..... 178
Programming notes ..... 178
Calling any program as a subprogram ..... 178
9.5 Nesting ..... 179
Types of nesting ..... 179
Nesting depth ..... 179
Subprogram within a subprogram ..... 179
Repeating program section repeats ..... 180
Repeating a subprogram ..... 181
VIII
10 Programming: Q Parameters ..... 185
10.1 Principle and Overview ..... 186
Automatic deletion of Q parameters ..... 186
10.2 Part Families – Q Parameters in Place of Numerical Values ..... 187
Example NC blocks ..... 187
Example ..... 187
To assign numerical values to Q parameters ..... 188
10.3 Describing Contours through Mathematical Operations ..... 189
Function ..... 189
Overview ..... 189
Programming example for basic mathematical operations ..... 190
10.4 Trigonometric Functions ..... 192
Definitions ..... 192
Overview of functions ..... 193
10.5 If-Then Decisions with Q Parameters ..... 194
Function ..... 194
Unconditional jumps ..... 194
Programming If-Then decisions ..... 194
Abbreviations used: ..... 195
10.6 Checking and Changing Q Parameters ..... 196
Procedure ..... 196
10.7 Output of Q Parameters and Messages ..... 197
Output of error messages ..... 197
Output through an external data interface ..... 197
Indexed assignment ..... 198
Transferring values to/from the PLC ..... 198
10.8 Measuring with a probing electrode during program run ..... 199
Introduction ..... 199
To program the use of a probing electrode ..... 200
10.9 Q Parameters with Special Functions ..... 202
Vacant Q parameters ..... 202
Preassigned Q parameters ..... 202
Q parameters with special functions ..... 202
Preassigned Q parameters ..... 202
Q parameters with special functions ..... 206
HEIDENHAIN TNC 406, TNC 416 IX
11 Test run and Program Run ..... 215
11.1 Graphics ..... 216
Function ..... 216
Overview of display modes ..... 216
Plan view ..... 217
Projection in 3 planes ..... 217
3-D view ..... 217
Magnifying details ..... 218
Repeating graphic simulation ..... 219
11.2 Test run ..... 220
Function ..... 220
Running a program test ..... 220
Running a program test up to a certain block ..... 221
Operating time ..... 221
11.3 Program run ..... 222
Application ..... 222
Background programming ..... 222
Operating time ..... 222
Changing the erosion parameters during program run ..... 222
Running a part program ..... 223
Interrupting machining ..... 223
Mid-program startup (block scan) ..... 224
Resuming program run after an interruption ..... 225
Returning to the interruption spot ..... 226
Resuming program run with the GOTO key ..... 226
Resetting the counters ..... 227
Time capture table TIME.W ..... 227
X
12 MOD Functions ..... 229
12.1 MOD functions ..... 230
Selecting, Changing and Exiting the MOD Functions ..... 230
Overview of MOD functions ..... 230
Position Display Types ..... 231
Unit of measurement ..... 231
System Information ..... 232
Setting the external data interfaces ..... 232
BAUD RATE ..... 232
RS-232-C interface ..... 232
12.2 External Data Transfer ..... 233
Application examples ..... 233
LSV-2 protocol ..... 233
Protecting files ..... 233
12.3 Menu for External Data Transfer ..... 233
To select external data transfer ..... 233
Windows for external data transfer ..... 234
12.4 Selecting and Transferring Files ..... 235
Selecting the transfer function ..... 235
Selecting a file ..... 235
Transferring files ..... 235
Formatting disks ..... 236
Deleting files ..... 236
12.5 Software for Data Transfer ..... 237
Software for data transfer ..... 237
12.6 Enter Axis Traverse Limits ..... 240
Introduction ..... 240
12.7 Machine-Specific User Parameters ..... 242
Function ..... 242
12.8 Code Number ..... 243
Function ..... 243
12.9 Q Parameter Status Display ..... 244
Function ..... 244
HEIDENHAIN TNC 406, TNC 416 XI
13 Tables and Overviews ..... 245
13.1 General User Parameters ..... 246
Entering machine parameters ..... 246
Selecting the General User Parameters ..... 246
13.2 Pin Layout and Connecting Cable for the Data Interfaces ..... 254
RS-232-C/V.24 Interface HEIDENHAIN devices ..... 254
RS-422/V.11 Interface ..... 255
13.3 Preparing the Devices for Data Transfer ..... 256
HEIDENHAIN devices ..... 256
Non-HEIDENHAIN devices ..... 256
13.4 Technical Information ..... 257
13.5 TNC Error Messages ..... 259
TNC error messages during programming ..... 259
TNC error messages during test run and program run ..... 259
XII
Introduction
1
1.1 The TNC 406, the TNC 416
Controls
The TNC 406 and the TNC 416 are shop-floor programmable
contouring controls for EDM machines with up to five axes.
Visual display unit and keyboard
The 14-inch color monitor (TNC 406) and 15-inch color monitor
(TNC 416) display all information necessary for effective use of the
TNC’s capabilities.
Program entry is supported by soft keys on the monitor.
The keys on the operating panel are grouped according to function.
This makes it easier to create programs and use the TNC’s functions.
Programming
1.1 The TNC 406, the TNC 416
The user programs the TNC 406/TNC 416 right at the machine with
interactive conversational-type guidance.
Graphics
Workpiece machining can be graphically simulated. Various display
modes are available.
Compatibility
The TNC 406/TNC 416 can execute all programs whose commands
belong to the command set of the TNC 406/TNC 416.
2 1 Introduction
1.2 Visual Display Unit and
Keyboard
Visual display unit
The TNC 406 is delivered with the BC 110 color monitor (CRT); the
TNC 416 can be delivered with the BC 120 color monitor (CRT) or the
BF 120 flat-screen color monitor (TFT). The figure at top right shows
the keys and controls on the BC 120, and the figure at bottom right
shows those of the BF 120.
1 Header
When the TNC is on, the selected operating modes are shown in
the screen header.
2 Soft keys
In the footer the TNC indicates additional functions in a soft-key
row. You can select these functions by pressing the keys
immediately below them. The lines immediately above the softkey row indicate the number of soft-key rows that can be called
with the black arrow keys to the right and left. The line
representing the active soft-key row is highlighted.
3 Soft key selector keys
4 Switching the soft-key rows
5 Setting the screen layout
6 Shift key for switchover between machining and programming
modes
1
1
2
4
3
1
5
7
9
8
10
4
6
1
1.2 Visual Display Unit and Keyboard
Keys on BC 120 only
7 Screen demagnetization; Exit main menu for screen settings
8 Select main menu for screen settings:
In the main menu: Move highlight downward
In the submenu: Reduce value or move picture to the left or
downward
9 In the main menu: Move highlight upward
In the submenu: Increase value or move picture to the right or
upward
10 In the main menu: Select submenu
In the submenu: Exit submenu
5
1
Main menu dialog Function
BRIGHTNESS Adjust brightness
CONTRAST Adjust contrast
H-POSITION Adjust horizontal position
V-POSITION Adjust vertical position
V-SIZE Adjust picture height
HEIDENHAIN TNC 406, TNC 416 3
1
2
4
6
4
11
3
1
Main menu dialog Function
SIDE-PIN Correct barrel-shaped distortion
TRAPEZOID Correct trapezoidal distortion
ROTATION Correct tilting
COLOR TEMP Adjust color temperature
R-GAIN Adjust strength of red color
B-GAIN Adjust strength of blue color
RECALL No function
The BC 110 and BC 120 are sensitive to magnetic and electromagnetic
noise, which can distort the position and geometry of the picture.
Alternating fields can cause the picture to shift periodically or to
become distorted.
Screen layout
You select the screen layout yourself: In the TEST RUN mode of
operation, for example, you can have the TNC show program blocks in
the left window while the right window displays programming
graphics. You could also display the tool status in the right window
1.2 Visual Display Unit and Keyboard
instead, or display only program blocks in one large window. The
available screen windows depend on the selected operating mode.
To change the screen layout:
Press the SPLIT SCREEN key: The soft-key row
shows the available layout options (see ”Modes of
Operation” on page 6).
Select the desired screen layout.
4 1 Introduction
Keyboard
The figure at right shows the keys of the keyboard grouped according
to their functions:
1 Alphabetic keyboard for entering text and file names
2 File management
MOD functions
3 Programming modes
4 Machine operating modes
5 Initiation of programming dialog
6 Arrow keys and GOTO jump command
7 Numerical input and axis selection
The functions of the individual keys are described on the inside front
cover. Machine panel buttons, e.g. NC START, are described in the
manual for your machine tool.
1
5
2
1
4
1
5
3
7
6
1.2 Visual Display Unit and Keyboard
HEIDENHAIN TNC 406, TNC 416 5
1.3 Modes of Operation
Manual Operation, Incremental Jog, and Positioning with Manual Data Input
The Manual Operation mode is required for setting up the machine
tool. In this mode of operation, you can position the machine axes
manually or by increments, set the datums, and tilt the working plane.
The Incremental Jog mode of operation allows you to move the
machine axes manually with the HR electronic handwheel.
Simple traverse movements can be programmed in the Positioning
with Manual Data Input (MDI) mode of operation.
Soft keys for selecting the screen layout (see ”Screen layout” on
page 4)
1.3 Modes of Operation
Screen windows Soft key
Positions
Left: positions. Right: status display.
6 1 Introduction
Programming and Editing
In this mode of operation you can write your part programs. The
various cycles and Q parameter functions help you with programming
and add necessary information.
Soft keys for selecting the screen layout
Screen windows Soft key
Top: program. Bottom: positions
Top left: program. Top right: status
Bottom: positions
Test Run
In the Test Run mode of operation, the TNC checks programs and
program sections for errors, such as geometrical incompatibilities, or
missing or incorrect data within the program. This simulation is
supported graphically in different display modes.
Soft keys for selecting the screen layout
Screen windows Soft key
Top: program. Bottom: positions
Top left: program. Top right: status
Bottom: positions
Left: program. Right: status
Left: program. Right: graphics
Top left: program. Top right: graphics
Bottom: positions
Graphics
1.3 Modes of Operation
HEIDENHAIN TNC 406, TNC 416 7
Program Run, Full Sequence and Program Run, Single Block
In the Program Run, Full Sequence mode of operation the TNC
executes a part program continuously to its end or to a manual or
programmed stop. You can resume program run after an interruption.
In the Program Run, Single Block mode of operation you execute each
block separately by pressing the machine START button.
Soft keys for selecting the screen layout
Screen windows Soft key
Top: program. Bottom: positions
Top left: program. Top right: status
1.3 Modes of Operation
Bottom: positions
Top left: program. Top right: graphics
Bottom: positions
8 1 Introduction
1.4 Status Display
General status display
Besides the coordinates, the status display also contains the following
information:
Type of position display (ACTL, NOML, etc.)
Axis is locked ( on the axis)
Number of the current electrode T
Electrode axis
Feed rate F
Active miscellaneous functions M
TNC is in operation (indicated by )
Name of the selected erosion table
Permissible power stages (GENERATOR cycle)
Current power stage
Additional status displays
In all modes of operation (except PROGRAMMING AND EDITING),
you can split the screen layout to display additional status information
in the right screen window:
1.4 Status Display
Additional status display
Information on the current electrode
General program information
Information on the current OEM cycle
Positions and coordinates
Active coordinate transformations
Tilting the working plane
HEIDENHAIN TNC 406, TNC 416 9
Soft
keys
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