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

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

Select programs and files

Delete programs and files (only TNC 406) Activate external data transfer (only TNC 406) Pocket calculator

Moving the highlight, going directly to blocks, cycles and parameter functions

Move highlight

Go directly to blocks, cycles and parameter functions

Override control knobs for feed rate/C axis

	100		100
50	150	50	150
	F %		S %
	0		0

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

Define and call cycles

Enter and call labels for subprogramming and program section repeats

Program stop in a program

Enter touch probe functions in a program

Coordinate axes and numbers:Entering and editing

Select coordinate axes or

. . . enter them into the program

. . . Numbers

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

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
	280 621-12
	280 622-12
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.

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		1
				2
		Manual Operation, Setup and Probing
		Functions		3
		Positioning with manual data input
		(MDI)
		Programming: Fundamentals, Files,		4
		Program Entry, Spark Erosion, Erosion
		Tables
		Programming: Tools		5
		Programming: Programming Contours		6
				7
		Programming: Miscellaneous Functions
				8
		Programming: Cycles
				9
		Programming: Subprograms and
		Program Section Repeats		10
		Programming: Q Parameters
				11
		Test Run and Program Run
				12
		MOD Functions
				13
		Tables and Overviews

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

1

Introduction

1.1 The TNC 406, the TNC 416

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

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

1.2Visual 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.

1Header

When the TNC is on, the selected operating modes are shown in the screen header.

2Soft 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.

3Soft key selector keys

4Switching the soft-key rows

5Setting the screen layout

6Shift key for switchover between machining and programming modes

Keys on BC 120 only

7Screen demagnetization; Exit main menu for screen settings

8Select 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

9In the main menu: Move highlight upward

In the submenu: Increase value or move picture to the right or upward

10In the main menu: Select submenu

In the submenu: Exit submenu

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

1

	2
4													4
			31
5					7		8		9				61
											10

1

			2
51		41				3		4		6
								1

1.2 Visual Display Unit and Keyboard

HEIDENHAIN TNC 406, TNC 416

3

1.2 Visual Display Unit and Keyboard

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 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

1

The figure at right shows the keys of the keyboard grouped according to their functions:

1Alphabetic keyboard for entering text and file names

2File management

MOD functions	5
3 Programming modes	21

4Machine operating modes

5Initiation of programming dialog

6	Arrow keys and GOTO jump command
		41				5
				3
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.

7

6

1.2 Visual Display Unit and Keyboard

HEIDENHAIN TNC 406, TNC 416

5

1.3 Modes of Operation

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)

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

1.3 Modes of Operation

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

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:

Additional status display

Soft keys

Information on the current electrode

General program information

Information on the current OEM cycle

Positions and coordinates

Active coordinate transformations

Tilting the working plane

1.4 Status Display

HEIDENHAIN TNC 406, TNC 416

9