siemens 802D Programming Manual
Introduction 1
Turning On,
SINUMERIK 802D
Operation and Programming
Milling
Reference−Point Approach
Setting Up 3
Manually Controlled Mode 4
Automatic Mode 5
Part Programming 6
System 7
Programming 8
2
Valid for
Control system Software version
SINUMERIK 802D 2
Cycles 9
08/05 Edition
Safety information
This Manual contains information which you should carefully observe to ensure your own personal safety
and the prevention of material damage. The notices are highlighted by a warning triangle and, depending on
the degree of hazard, represented as shown below:
Danger
!
indicates that death or severe personal injury will result if proper precautions are not taken.
Warning
!
indicates that death or severe personal injury can result if proper precautions are not taken.
Caution
!
with a warning triangle indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a warning triangle means that material damage can occur if the appropriate precautions are not
taken.
Attention
indicates that an undesired event or status can occur if the appropriate note is not observed.
If several hazards of different degrees occur, the hazard with the highest degree must always be given preference. If a warning note with a warning triangle warns of personal injury, the same warning note can also
contain a warning of material damage.
Qualified personnel
Start−up and operation of the device/equipment/system in question must only be performed using this documentation. The start−up and operation of a device/system must only be performed by qualified personnel.
Qualified personnel as referred to in the safety guidelines in this documentation are those who are authorized to start up, earth and label units, systems and circuits in accordance with the relevant safety standards.
Proper use
Please note the following:
Warning
!
The device may only be used for the applications described in the Catalog and only in combination with the
equipment, components and devices of other manufacturers as far as this is recommended or permitted by
Siemens. It is assumed that this product be transported, stored and installed as intended and maintained
and operated with care to ensure that the product functions correctly and properly.
Trademarks
All designations marked with the copyright notice ® are registered trademarks of Siemens AG. Other names
in this publication might be trademarks whose use by a third party for its own purposes may violate the rights
of the registered holder.
Disclaimer of liability
Although we have checked the contents of this publication for agreement with the hardware and software
described, since differences cannot be totally ruled out. Nonetheless, differences might exist and therefore
we cannot guarantee that they are completely identical. The information given in this publication is reviewed
at regular intervals and any corrections that might be necessary are made in the subsequent editions.
Siemens AG
Automation and Drives
Postfach 4848
90437 NÜRNBERG
GERMANY
Copyright (E) Siemens AG 2005.
6FC5698−2AA10−1BP5
Siemens AG 2005
Subject to change without prior notice.
Preface
SINUMERIK Documentation
The SINUMERIK Documentation is organized in 3 levels:
S General Documentation:
S User Documentation
S Manufacturer/Service Documentation:
For detailed information regarding further publications about SINUMERIK 802D, as well as
for publications that apply for all SINUMERIK control systems (e.g. Universal Interface, Measuring Cycles...), please contact your Siemens branch office.
A monthly overview of publications with specification of the available languages can be found
on the Internet at:
http://www.siemens.com/motioncontrol
Follow the menu items ”Support”/”Technical Documentation”/”Overview of Publications”.
The Internet edition of DOConCD − DOConWEB − can be found at:
http://www.automation.siemens.com/doconweb
Addressees of the documentation
The present documentation is aimed at the machine tool manufacturer. This publication provides detailed information required for the machine tool manufacturer to start up the SINUMERIK 802D control system.
Standard scope
The present Instruction Manual describes the functionality of the standard scope. Any
amendments made by the machine manufacturer are documented by the machine manufacturer.
Other functions not described in this documentation can possibly also be performed on the
control system. However, the customer is not entitled to demand these functions when the
new equipment is supplied or servicing is carried out.
Hotline
If you have any questions, do not hesitate to call our hotline:
If you have any questions (suggestions, corrections) regarding the Documentation, please
send a fax to the following number or an e−mail to the following address:
Fax form: see return fax form at the end of this publication
A&D Technical Support
Tel.: +49 (0) 180 / 5050 − 222
Fax: +49 (0) 180 / 5050 − 223
Internet: http://www.siemens.de/automation/support−request
Fax: +49 (0) 9131 / 98 − 63315
E−mail: motioncontrol.docu@siemens.com
SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition
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Preface
Internet address
http://www.siemens.com/motioncontrol
iv
SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition
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Contents
Contents
1 Introduction 1-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Screen layout 1-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Operating areas 1-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Accessibility options 1-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.1 Calculator 1-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.2 Editing Chinese characters 1-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.3 Hotkeys 1-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 The help system 1-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Coordinate systems 1-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Turning On and Reference Point Approach 2-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Setting Up 3-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Entering tools and tool offsets 3-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Use this softkey to create a new tool. 3-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 Determining the tool offsets (manually) 3-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.3 Determining tool compensations using a probe 3-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.4 Probe settings 3-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Tool monitoring 3-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Entering/modifying a work offset 3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 Determining the work offset 3-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Programming setting data - ”Parameter” operating area 3-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 R parameters − ”Offset/Parameter”operating area 3-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Manually Controlled Mode 4-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 JOG mode - ”Position” operating area 4-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1 Assigning handwheels 4-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 MDA mode (Manual input) - ”Machine” operating area 4-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Face milling 4-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Automatic Mode 5-59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Selecting / starting a part program - ”Machine” operating
area 5-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Block search - ”Machine” operating area 5-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Stopping / canceling a part program 5-66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Reapproach after cancellation 5-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Repositioning after interruption 5-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Program execution from external 5-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Part Programming 6-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Entering a new program - ”Program” operating area 6-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Editing part programs - ”Program” operating area 6-73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Blueprint programming 6-75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Simulation 6-91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Data transfer via the RS232 interface 6-92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition
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Contents
7 System 7-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 PLC diagnosis represented as a ladder diagram 7-116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 Screen layout 7-116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.2 Operating options 7-117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Alarm display 7-127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Programming 8-129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Fundamentals of NC programming 8-129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.1 Program names 8-129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.2 Program structure 8-129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.3 Word structure and address 8-130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.4 Block structure 8-131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.5 Character set 8-132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.6 Overview of the instructions 8-134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Positional data 8-148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.1 Plane selection: G17 to G19 8-148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.2 Absolute / incremental dimensioning: G90, G91, AC, IC 8-149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.3 Dimensions in metric units and inches: G71, G70, G710, G700 8-150 . . . . . . . . . . . . . . . . . . . . . .
8.2.4 Polar coordinates, pole definition: G110, G111, G112 8-151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.5 Programmable work offset: TRANS, ATRANS 8-153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.6 Programmable rotation: ROT, AROT 8-153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.7 Programmable scaling factor: SCALE, ASCALE 8-155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.8 Programmable mirroring: MIRROR, AMIRROR 8-156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.9 Workpiece clamping − settable work offset:
G54 to G59, G500, G53, G153 8-157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.10 Programmable working area limitation:
G25, G26, WALIMON, WALIMOF 8-159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Axis movements 8-161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.1 Linear interpolation with rapid traverse: G0 8-161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.2 Linear interpolation with feedrate: G1 8-162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.3 Circular interpolation: G2, G3 8-163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.4 Circular interpolation via intermediate point: CIP 8-168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.5 Circle with tangential transition: CT 8-168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.6 Helix interpolation: G2/G3, TURN 8-169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.7 Thread cutting with constant lead: G33 8-170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.8 Tapping with compensating chuck: G63 8-171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.9 Thread Interpolation: G331, G332 8-172 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.10 Fixed point approach: G75 8-174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.11 Reference point approach: G74 8-174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.12 Measuring with touch−trigger probe: MEAS, MEAW 8-174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.13 Feedrate F 8-175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.14 Feedrate override for circles: CFTCP, CFC 8-176 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.15 Exact stop / continuous−path control mode: G9, G60, G64 8-177 . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.16 Acceleration pattern: BRISK, SOFT 8-180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.17 Percentage acceleration override: ACC 8-181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.18 Traversing with feedforward control: FFWON, FFWOF 8-182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.19 4th axis 8-183 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.20 Dwell Time: G4 8-183 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.21 Travel to fixed stop 8-184
8.4 Spindle movements 8-188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.1 Spindle speed S, directions of rotation 8-188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.2 Spindle speed limitation: G25, G26 8-188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.3 Spindle positioning: SPOS 8-189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.4 Gear stages 8-190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5 Contour programming support 8-191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5.1 Rounding, chamfer 8-191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5.2 Blueprint programming 8-192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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8.6 Tool and tool offset 8-195 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.1 General notes 8-195 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.2 Tool T 8-196 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.3 Tool offset number D 8-196 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.4 Selecting the tool radius compensation: G41, G42 8-200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.5 Corner behavior: G450, G451 8-202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.6 Tool radius compensation OFF: G40 8-203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.7 Special cases of the tool radius compensation 8-204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.8 Example of tool radius compensation 8-206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7 Miscellaneous function (M) 8-207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8 H function 8-208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9 Arithmetic parameters R, LUD and PLC variables 8-209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9.1 Arithmetic parameters R 8-209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9.2 Local User Data (LUD) 8-210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9.3 Reading and writing PLC variables 8-212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10 Program jumps 8-213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.1 Jump destination for program jumps 8-213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.2 Unconditional program jumps 8-213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.3 Conditional program jumps 8-214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.4 Program example for jumps 8-216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11 Subroutine technique 8-218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.1 General 8-218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.2 Calling machining cycles 8-221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.3 Modal subroutine call 8-221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12 Timers and workpiece counters 8-222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.1 Runtime timer 8-222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.2 Workpiece counter 8-223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.13 Language commands for tool monitoring 8-225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.13.1 Tool monitoring overview 8-225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.13.2 Tool life monitoring 8-226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.13.3 Workpiece count monitoring 8-227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.14 Smooth approach and retraction 8-230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.15 Milling of the peripheral surface − TRACYL 8-235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.16 G functions equivalent to the SINUMERIK 802S/C − Milling 8-240 . . . . . . . . . . . . . . . . . . . . . . . . .
9 Cycles 9-241 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 Overview of cycles 9-241 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Programming cycles 9-242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 Graphical cycle support in the program editor 9-244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4 Drilling cycles 9-246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.1 General 9-246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.2 Preconditions 9-247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.3 Drilling, centering – CYCLE81 9-248 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.4 Drilling, counterboring – CYCLE82 9-251 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.5 Deep hole drilling – CYCLE83 9-254 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.6 Rigid tapping – CYCLE84 9-258 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.7 Tapping with compensating chuck – CYCLE840 9-261 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.8 Reaming 1 (boring 1) – CYCLE85 9-266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.9 Boring (boring 2) – CYCLE86 9-270 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.10 Boring with Stop 1 (boring 3) – CYCLE87 9-273 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.11 Drilling with stop 2 (boring 4) – CYCLE88 9-275 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.12 Reaming 2 (boring 5) – CYCLE89 9-278 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5 Drilling pattern cycles 9-281 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents
9.5.1 Preconditions 9-281 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.2 Row of holes – HOLES1 9-282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.3 Circle of holes – HOLES2 9-286 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6 Milling cycles 9-289 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.1 Preconditions 9-289 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.2 Face milling − CYCLE71 9-290 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.3 Contour milling − CYCLE72 9-296 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.4 Rectangular spigot milling − CYCLE76 9-305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.5 Circular spigot milling − CYCLE77 9-310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.6 Slots on a circle − LONGHOLE 9-314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.7 Slots on a circle − SLOT1 9-319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.8 Circumferential slot − SLOT2 9-326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.9 Milling a rectangular pocket − POCKET3 9-332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.10 Milling a circular pocket − POCKET4 9-341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.11 Thread milling − CYCLE90 9-345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7 Error messages and error handling 9-352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7.1 General notes 9-352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7.2 Error handling in the cycles 9-352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7.3 Overview of cycle alarms 9-352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7.4 Messages in the cycles 9-354 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
viii
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SINUMERIK 802D Key Definition
”Recall” key
ETC key
”Acknowledge alarm” key
without function
Info key
Shift key
Controlkey
Altkey
SPACE
Backspace
Clear key
INSERT key
”Position” operating area key
”Program” operating area key
”Parameter” operating area
”Program Manager” operating area
”Alarm” / ”System” operating areas
(Shift+key)
not assigned
PageUp / PageDown keys
Cursor keys
Selection key / toggle key
Tabulator
ENTER / Input key
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Alphanumeric keys
Double assignment on the Shift level
ix
Numeric keys
Double assignment on the Shift level
External Machine Control Panel
%
Spindle override (option)
User−defined key with LED
User−defined key without LED
INCREMENT
80
70
60
90
100
110
120
JOG
REFERENCE POINT
AUTOMATIC
60
70
40
20
10
6
2
0
80
90
100
110
120
SINGLE BLOCK
MANUAL DATA
SPINDLE START LEFT
SPINDLE STOP
SPINDLE START RIGHT
RESET
NC STOP
NC START
EMERGENCY STOP
x
SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition
X axis
Z axis
%
RAPID TRAVERSE OVERRIDE
Feedrate override
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Introduction
1.1 Screen layout
1
Status area
Applicationarea
Tip
and softkey area
Fig. 1-1 Screen layout
The screen is divided into the following main areas:
S Status area
S Applicationarea
S Tip and softkey area
G
function
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Introduction
MDA
y
System
1. Alarm number with alarm text, or
1.1 Screen layout
Status area
Fig. 1-2 Status area
Table 1-1 Explanation of the display elements in the status area
Screen Con-
trol
1
2
3
4
Display Meaning
Active operating area, active mode
Position
JOG; 1 INC, 10 INC, 100 INC, 1000 INC, VAR INC (evaluation by increments in
the JOG mode)
MDA
AUTOMATIC
Offset
Program
Program Manager
stem
S
Alarm
Marked as an ”external language” using G291
Alarm and message line
In addition, the following is displayed:
1. Alarm number with alarm text, or
2. Message text
Program status
RESET Program canceled / default status
RUN Program running
STOP Program stopped
Program controls in the AUTOMATIC mode
1-12
5
6
7
Path N: − NC internal ”drive”
D: − CF card
NC messages
Selected part program (main program)
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Tip and softkey area
Fig. 1-3 Tip and softkey area
Introduction
1.1 Screen layout
Table 1-2 Explanation of the screen elements in the tip and softkey area
Screen Con-
trol
1
2
3
4
Display Meaning
Recall symbol
Pressing the Recall key lets you return to the next higher menu level.
Tip line
Displays tips for the operator
MMC status information
ETC is possible (Pressing this key displays the horizontal softkey bar
providing further functions.)
Mixed notation active (uppercase/lowercase letters)
Data transfer running
Connection to the PLC programming tool active
Softkey bar vertical and horizontal
Standard softkeys
Use this softkey to quit the screenform.
Use this softkey to cancel the input; the window is closed.
Selecting this softkey will complete your input and start the calculation.
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Introduction
1.2 Operating areas
Selecting this softkey will complete your input and accept the values you have entered.
1.2 Operating areas
The functions of the control system can be carried out in the following operating areas:
Position Machine operation
Offset/Parameters Input of offset values and setting data
Program Creation of part programs
Program Manager Part program directory
System Diagnosis, start−up
Alarm Alarm and message lists
To switch the operating area, use the relevant key (hard key).
Protection levels
The input and modification of vital data in the control system is protected by passwords.
In the menus listed below the input and modification of data depends on the protection level
set:
S Tool offsets
S Work offsets
S Setting data
S RS232 settings
S Program creation / program correction
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1.3 Accessibility options
1.3.1 Calculator
The calculator function can be activated from any operating area using ”SHIFT” and ”=”.
To calculate terms, the four basic arithmetic operations can be used, as well as the functions
”sine”, ”cosine”, ”squaring” and ”square root”. A bracket function is provided to calculate
nested terms. The bracket depth is unlimited.
If the input field is already occupied by a value, the function will accept this value into the input
line of the calculator.
When you press the Input key, the result is calculated and displayed in the calculator.
Selecting the Accept softkey enters the result in the input field at the current cursor position of
the part program editor and closes the calculator automatically.
Note
Introduction
1.3 Accessibility options
If an input field is in the editing mode, it is possible to restore the original status using the
”Toggle” key.
Fig. 1-4 Calculator
Characters permitted for input
+, − Basic arithmetic operations
*, /
S Sine function
The X value (in degrees) in front of the input cursor is replaced by the sin(X) value.
O Cosine function
The X value (in degrees) in front of the input cursor is replaced by the cos(X) value.
Q Square function
The X value in front of the input cursor is replaced by the X
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2
value.
1-15
Introduction
1.3 Accessibility options
R Square root function
The X value in front of the input cursor is replaced by the √⎮ value.
( ) Bracket function (X+Y)*Z
Calculation examples
100 + (67*3) 100+67*3 −> 301
sin(45_) 45 S −> 0.707107
cos(45_) 45 O −> 0.707107
2
4
√4 4 R −> 2
(34+3*2)*10 (34+3*2)*10 −> 400
To calculate auxiliary points on a contour, the calculator offers the following functions:
Task Input −> Result
4 Q −> 16
Softkeys
S Calculating the tangential transition between a circle sector and a straight line
S Moving a point in the plane
S Converting polar coordinates to Cartesian coordinates
S Adding the second end point of a straight line/straight line contour section given from an
angular relation
This function is used to calculate a point on a circle. The point results from the angle of the tangent
created, as well as from the radius and the direction of rotation of the circle.
1-16
Fig. 1-5
Enter the circle center, the angle of the tangent and the circle radius.
Use the G2 / G3 softkey to define the direction of rotation of the circle.
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Introduction
1.3 Accessibility options
Use this softkey to calculate the abscissa and ordinate values. The abscissa is the first axis of the
plane, and the ordinate is the second axis of the plane. The abscissa value is copied into the input
field from which the calculator function has been called, and the value of the ordinate is copied into
the next following input field. If the function has been called from the part program editor, the coordinates are saved with the axis names of the selected basic plane.
Example: If the G18 plane is active, the abscissa is the Z axis and the ordinate the X axis.
Example: Calculate the intersection point between the circle sector
.
Given: Radius: 10
Circle center: Z 20 X 20
Connection angle of the straight line: 45
°
Direction of rotation: G2
Result: X = 12.928
Y = 27.071
and the straight line
This function calculates the Cartesian coordinates of a point in the plane, which is to be connected
to a point in the plane (PP) on a straight line. For calculation, the distance between the points and
the slope angle (A2) of the new straight line to be created with reference to the slope (A1) of the
given straight line must be known.
Fig. 1-6
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Introduction
1.3 Accessibility options
Enter the following coordinates or angles:
S the coordinates of the given point (PP)
S the slope angle of the straight line (A1)
S the distance of the new point with reference to PP(offset)
S the slope angle of the connecting straight line (A2) with reference to A1
Use this softkey to calculate the Cartesian coordinates which are subsequently copied into two input
fields following one after another. The abscissa value is copied into the input field from which the
calculator function has been called, and the value of the ordinate is copied into the next following
input field.
If the function has been called from the part program editor, the coordinates are saved with the axis
names of the selected basic plane.
Example
Calculating the end point of the straight line . The straight line stands vertically on the end
point of the straight line
(Coordinates: X = 51.981, Y = 43.081) (see example: ”Converting
polar coordinates into Cartesian coordinates”). The length of the straight lines is also given.
Result: X = 68.668
Y = 26.393
This function converts the given polar coordinates into Cartesian coordinates.
1-18
Fig. 1-7
Enter the reference point, the vector length and the slope angle.
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Introduction
1.3 Accessibility options
Use this softkey to calculate the Cartesian coordinates which are subsequently copied into two input
fields following one after another. The abscissa value is copied into the input field from which the
calculator function has been called, and the value of the ordinate is copied into the next following
input field.
If the function has been called from the part program editor, the coordinates are saved with the axis
names of the selected basic plane.
Example
Calculating the end point of the straight line . The straight line is determined by the angle
° and its length.
A=45
Result: X = 51.981
Y = 43.081
Use this function to calculate the missing end point of the straight line/straight line contour section
whereby the second straight line stands vertically on the first straight line.
The following values of the straight line are known:
Straight line 1:
Starting point and slope angle
Straight line 2:
Length and one end point in the Cartesian coordinate system
Fig. 1-8
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1-19
Introduction
1.3 Accessibility options
This function is used to select the given coordinate of the end point.
The ordinate value or the abscissa value is given.
The second straight line is rotated in the CW direction or in the CCW direction by 90 degrees relative to the first straight line.
This function will select the relevant end position.
The missing end point is calculated. The abscissa value is copied into the input field from which the
calculator function has been called, and the value of the ordinate is copied into the next following
input field.
If the function has been called from the part program editor, the coordinates are saved with
the axis names of the selected basic plane.
Example
Add the present drawing by the values of the center circle to be able to calculate the points of
intersection between the circle sectors. The missing coordinates of the center points are cal-
culated using the calculator function,
since the radius in the tangential transition
stands vertically on the straight line.
Calculating M1 in section 1:
In this section, the radius stands in the counterclockwise direction turned on the straight
line section.
Use the softkeys
and to select the given configuration.
Enter the coordinates of the pole (PP) P1, the slope angle of the straight line, the given
ordinate value and the circle radius as the length.
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Introduction
1.3 Accessibility options
Result: X = −19.449
Y = 30
Calculating M2 in section 2:
In this section, the radius stands in the clockwise direction turned on the straight line sec-
tion. Use the softkeys
to select the given configuration.
Enter the parameters in the screenform.
1.3.2 Editing Chinese characters
This function is only available in the Chinese language version.
The control system provides a function for editing Chinese characters in the program editor
and in the PLC alarm text editor. After activation, type the phonetic alphabet of the searched
character in the input field. The editor will then offer various characters for this sound, from
which you can choose the desired one by entering either of the digits 0 to 9.
Result: X = 21.399
Y = 30
Fig. 1-9 Chinese editor
Alt S Is used to turn on / turn off the editor
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Introduction
1.3 Accessibility options
1.3.3 Hotkeys
This operator control can be used to select, copy, cut and delete texts using special key commands. These functions are available both for the part program editor and for input fields.
CTRL C Copy
CTRL B Select
CTRL X Cut
CTRL V Paste
Alt L Switches between uppercase and lowercase letters
Alt H Help system
or Info key
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1.4 The help system
To activate the help system, use the Info key. It offers a brief description for all important operating functions.
In addition, the help offers the following topics:
S Overview of the NC commands with a brief description
S Cycle programming
S Explanation of the drive alarms
Introduction
1.4 The help system
Show
Go to
topic
Back to
topic
Fig. 1-10 Table of contents of the help system
This function opens the selected topic.
Fig. 1-11 Description for a help topic
Use this function to select cross references. A cross reference is marked by the characters
”>>....<<”. This softkey is only unhidden if a cross reference is displayed in the application area.
If you select a cross reference, in addition, the Back to topic softkey is displayed.
This function lets you return to the previous screenform.
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Introduction
1.4 The help system
Find
Use this function to search for a term in the table of contents. Type the term you are looking for and
start the search process.
Help in the ”Program editor” area
The system offers an explanation for each NC instruction. To display the help text directly,
position the cursor after the appropriate instruction and press the Info key. This possibility will
only function if the NC instruction is written using uppercase letters.
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1.5 Coordinate systems
For machine tools, right−handed, right−angled coordinate systems are used.
The movements on the machine are described as a relative movement between tool and
workpiece.
+Z
+Y
+X
Fig. 1-12 Definition of the directions of the axes one to another; right−angled
coordinate system
+Z
90°
90°
Introduction
1.5 Coordinate systems
+Y
90°
+X
Machine coordinate system (MCS)
How the coordinate system is located with reference to the machine, depends on the machine
type concerned. It can be rotated in different positions.
+Z
+Y
+X
Fig. 1-13 Machine coordinates/machine axes using the example of a milling
machine
The origin of the coordinate system is the machine zero.
All axes have zero position. This point only represents a reference point defined by the machine manufacturer. It need not be approachable.
The traversing range of the machine axes can by in the negative range.
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Introduction
1.5 Coordinate systems
Workpiece coordinate system (WCS)
The coordinate system described above (see Fig. 1-12) is also used to describe the geometry
of a workpiece in the workpiece program.
The workpiece zero can be freely selected by the programmer. The programmer need not to
know the real motion relations on the machine, i.e. he need not to know whether the workpiece or the tool moves. Furthermore, it can be different from axis to axis. The directions are
always defined such if the workpiece would be resting and the tool would move.
Z
Y
W
W - workpiece zero
Fig. 1-14 Workpiece coordinate system
Relative coordinate system
In addition to the machine and workpiece coordinate systems, the control system provides a
relative coordinate system. This coordinate system is used for setting freely selected reference points which have no influence on the active workpiece coordinate system. All axis
movements are displayed relative to these reference points.
Clamping the workpiece
For machining, the workpiece is clamped on the machine. The workpiece must be aligned
such that the axes of the workpiece coordinate system run in parallel with those of the machine. Any resulting offset of the machine zero with reference to the workpiece zero is determined for each axis individually and entered in the relevant data areas intended for the set-
table work offset. In the NC program, this offset is activated, e.g. using a programmed G54
(see also Section ”Workpiece clamping − settable work offset, ...”).
X
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Z
Machine
Z
Workpiece
W - workpiece zero
M − machine zero
Y
e.g.
W
G54
M
Fig. 1-15 Workpiece on the machine
X
Y
Machine
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Current workpiece coordinate system
The programmed work offset TRANS can be used to generate an offset with reference to the
workpiece coordinate system resulting in the current workpiece coordinate system (see Section ”Programmable work offset: TRANS”).
Programmable offset
Z
Y
TRANS
Introduction
1.5 Coordinate systems
Z
current
Y
X
W
W - workpiece zero
Fig. 1-16 Coordinates on the workpiece; current workpiece coordinate sy-
stem
X
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Introduction
1.5 Coordinate systems
This sheet has been left empty for your notes
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Turning On and Reference Point Approach
Note
When you turn on the SINUMERIK 802D and the machine, please also observe the Machine Documentation, since turning on and reference point approach are machine−dependent functions.
This documentation assumes an 802D standard machine control panel (MCP). Should you use a
different MCP, the operation may be other than described herein.
Operating sequence
First, turn on the power supply of CNC and machine. After the control system has booted, you
are in the ”Position” operating area, in the Jog mode.
The ”Reference point approach” window is active.
2
Fig. 2-1 The ”Jog−Ref” start screen
Use the Ref key on the machine control panel to activate ”reference point approach”.
The ”Reference point approach” window (Fig. 2-1) displays whether or not the axes have a
reference point.
Axis must be referenced
Axis has reached its reference point
+X
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Press a direction key.
...
-Z
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Turning On and Reference Point Approach
If you select the wrong approach direction, no motion will be carried out.
Approach the reference points for each axis one after the other.
Quit the function by switching the mode (MDA, AUTOMATIC or Jog).
Note
”Reference point approach” is only possible in the Jog mode.
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