siemens 805SM-P User Manual

Preliminary Remarks

The documentation of the SINUMERIK 805SM-P is subdivided into 4 parts:

l

General Documentation

l

User Documentation

l

Manufacturer Documentation and

l

Service Documentation

The following manuals are part of the Manufacturer Documentation:

l

Instruction Manual

l

Interface Description Part

l

Interface Description Part 2: Connection Conditions

l

PLC Programming Guide

l

Standard Operating Guide

l

NC Programming Guide

l

Roll Feed Module, Planning Guide

l

Pressure Control Module, Planning Guide

l

Cycles, Planning Guide

1:

Signals

This documentation (Cycles, Planning Guide) is intended for the press manufacturer and describes the start-up of the standard cycles.

This manual is written for technically qualified personnel, especially those having knowledge of or being trained in automation and control technology.

The knowledge, understanding and correct observance of all the Safety Rules and Warnings are the necessary preconditions for the safe installation and commissioning as well as for the safe operation and maintenance of the product described in this manual. This manual describes the General Safety

Rules and Warnings. Only the qualified personnel has the necessary technical knowledge to

properly interpret and apply all the Safety Rules and Warnings in a particular case. The contents of this instruction manual shall not become part or modify any prior or existing

agreement, commitment or relationship. The Sales Contract between the parties is the sole warranty of Siemens. Any statements contained herein do not create new warranties or modify the existing

warranty. If you need further documentation for the SINUMERIK 805SM-P, please contact your local Siemens

representative.

-

0

General Remarks

Press Data

Central R Parameters

Channel-Specific R Parameters

Overview of the Data Exchange Within the Control

1

u

4 .

q

5

rl

.o

Fixed Cycles

Basic Press Functions

Tool Change

Messages of the Standard Cycles

6

cl

7

tl

9

I I

Annex

10

cl

1 General Remarks

General Remarks

Cycles are subroutines which can be stored either in the part program memory or (from software version 2.0 onwards) in the user memory submodule of the control. With these subroutines the technology modes of the press are implemented (continuous stroke, single stroke, etc.). Furthermore, a (TOOL CHANGE) cycle is necessary for carrying out a tool change.

A subroutine consists of the following program sections: . ENTRY SECTION

. LOOP SECTION . TERMINATING SECTION

In the ENTRY SECTION, the starting conditions are checked on start-up of an operating mode.

If a starting condition is not fulfilled, a corresponding “CYCLE MESSAGE” is issued and the cycle interrupted. These messages also provide hints for the user. Information on the causes and, if necessary, about a remedy may be found in the Technology Operating Guide and the Installation Instructions.

After the ENTRY SECTION the program jumps into the LOOP SECTION, which coordinates the press operating mode and provides press-specific functions (see the general overview of the data exchange within the control). Only after a cycle stop has been triggered is this loop section left and the TERMINATING SECTION processed, so that the operating mode and with it the subroutine are terminated in a defined state.

The flowcharts describe the program flow of the technology cycles in detail.

Apart from the technology cycles there are several further subroutines (L 900 - L 999), which

are mainly calculating programs.

The step cycles provide certain functions which are necessary for the tool change procedure. Thus the sequence of operations for the tool change may be adapted “individually”to the

press. Exchange of information with the PLC is carried out via:

Inputs (commands for reading and writing)

l

. outputs

l

Flags (flag interface of the standard cycles, overview in Chapter

l

R parameters (FE 61/62).

10,

Annex)

Exchange of information with the NC is carried out via:

l

Press data (via @ commands, see installation lists)

l

Central R parameters (R965-R999)

The selection of the press operating modes (corresponding menu + subroutine) is carried out via the operator interface. The subroutine number belonging to the operating mode is preselected automatically.

The I/O fields of the individual operating modes are only updated after the NC-start.

For almost every press operating mode a so-called cycle is necessary. A cycle is a background program of a loop.

l-l

1 General Remarks

06.93

Loading of standard cycles: The cycles are supplied on a floppy disk formatted in MS-DOS. The different language ver-

sions are stored in the following sub-directories:

805SMP-D... German 805SMP-E... English 805SMP-I . . . Italian 805SMP,S... Spanish 805SMP-F . . . French

The cycles on the floppy disks are available in CL 800 source code (extension: ZPQ) and in DIN code (extension: ZPL).

Information about the loading of the cycles can also be found in the README.TXT file available on the floppy disk.

For the transfer to the control there are the following possibilities: a) Selection of the batch file: “INSTALLBAT

Procedure:

1) Connect the transfer cable (Order No.: 6FC9 344-4Rn) to COMl.

2.) Preselect and initialize (FITS-Line, 9600 Bd) the correct interface at the control and start it for input.

3.) Call up the batch file from the corresponding floppy disk drive and state the desired language version.

Example:

AUNSTALL E and press Enter .

cl

+ The English language version is transferred from the floppy disk in disk drive A to COMl. At the same time, the programmer interface is initialized correctly.

b) Transfer of the standard cycles with the MS-DOS system command COPY (the batch file

described above uses the same command): Please make sure that the programmer interface is initialized correctly (7 data bits, 2 stop

bits, parity = even). Example:

COPY A:U05SMPJV.ZPL COMl

c) With the program PCIN, version 2.0, the transfer may be carried out comfortably in both

directions (PG-NC). It is a menu-driven program which offers the possibility to configure the interfaces

accordingly. All files with the extension “ZPL” have to be transferred from the sub-directory for the

desired language version (see above).

d) If a workstation (WSSOOA) is available, it can be used for the transfer. The standard cycles

have been created with this software package. Transfer the files from the floppy disk.

l-2

SINUMERIK 805S.WP (PJ)

12.91 2 Press Data

2

This data area can be accessed from the cycle via @-commands.

Press Data

e rndwdual data

INSTRUCTIONS.

and for the access

possibilities,

2-1

06.93

3 Central R Parameters

3.1 General remarks

3

Central R Parameters

3.1 General remarks

Central R parameters exist only once in the control. They can be accessed by all channels. If you use a workstation to generate your cycles, you have to define a list of the parameters used in your subroutines. The following two lists are used in standard cycles:

Lists/

File name

Contents

I

3.2 R parameter area R800 - R899

This area can be freely assigned by the user.

3.3 R parameter area R900 - R984

This area is used as an “interface” between cycles, i.e. it is accessed by all cycles. This parameter area may used only by the cycles.

Use: Parameters from this area are used for codes to identify operating states or arithmetic values

required by more than one subroutine. The parameters have a fixed significance (such as saving the “previous tool position”).

For the meaning of these parameters, see Chapter parameters, say to modify a subroutine, you can use a parameter from area R800 to R899.

3.4

The parameters from this area receive their assigned values from the system and are made available especially for the cycles. The cycles work with these parameters and respond to changes in their values.

Exception: R996 and R994 receive their values from the cycles and are actually part of the parameter

area described in section 3.3.

R parameter area R985 - R999

10

(Appendix). If you need additional

SINUMERIK 805SMaP (PJ)

6tB5 440.ONX02-OAAl

3-l

3 Central R Parameters

3.5 Work memory I R parameter area RlOOO - R1499

06.93

3.5 Work memory / R parameter area RlOOO - R1499

As soon as a tool is changed, the whole of this memory area is newly written and provides the data for the new tool. The work memory is accessed by both the cycle and the operator interface.

Distribution

The first 100 parameters have standard assignments. 6 parameters are earmarked for the first axis and 4 for each further axis. Axes can only be selected in ascending order. The user can define a maximum of 84 additional tool data (see section 3.56 in the Operating Instructions on installation of general texts 1 - 84). The data block for the pressure module needs a maximum of 11 parameters, if 4 sensors are selected.

Data block for roll feed 1 and 2: The number of parameters required depends on the maximum number of feeds, which is defined via machine data. The tool protection needs up to 32 parameters, depending on the number of monitorings defined via MO.

In order to make the best possible use of the memory available, the option-dependent data for pressure module, roll feed and tool protection can be shifted in blocks to any location in the work memory using a relative initial address.

(see also Chapter 10, Annex):

Note:

A system-supported distribution of the tool data is carried out in the basic display INSTALLATION via softkey DISTRIBN. OF TL. DATA.

3.6 Input buffer / R parameter area R1500 - R1999

After input, the tool data is stored in this area. The assignment corresponds to that of the work memory, i.e. R1500 is equivalent to RlOOO. Thanks to this separate buffer, it is possible to edit a tool during operation.

3.7

The data of all available tool is stored in the tool data memory. In the standard version, 8000 R parameters are available (R2000 - R9999). Optionally, the tool data memory can be expanded to 18000 R parameters (R2000 - R19999). The figure “Overview of the data exchange within the control” in Chapter 5 shows the access to this memory.

Tool data memory / R parameter area R2000 - R19999

3-2

SINUMERIK 805SM.P (PJ)

12.91

4 Channel-Specific R

4.1 Local parameters I350 - R99

Parameters

4 Channel-Specific R Parameters

4.1 Local parameters R50 - R99

Local R parameters are used as a “scratchpad” for calculations and are only valid for one

cycle. As soon as the program level is left by calling a subroutine, the local variables are saved

and preset to “zero” for the following program. Therefore, they can be used as independent parameters in the program called.

The following two data formats can be defined in the cycle for these parameters: Local Integer: In this format, the variables can only be integers.

Value range: *I- 99999999

Local Real: In this format, the variables are defined as floating-point numbers.

Value range: + I- 0.00000001 to + I- 99999999.

4.2 Transfer parameters RO - R49

These R parameters have the same significance in all cycles within one NC channel. I.e., the value of the variable is preserved on branching into a subroutine; the value is, in a way, transferred.

Definition in the cycle: Par Real: Transfer parameter as a floating-point number.

Value range: +/- 0.00000001 to +/- 99999999.

An overview of the parameters used in the standard cycles is given in Chapter 10, Annex.

0 Siemens AG 1991 All Rights Resewed 6285 440.ONX02-OAAl SINUMERIK 605SM-P (PJ)

4-l

12.91

5 Overview of the Data Exchange Within the Control

5 Overview of the Data Exchange Within the

Control

I I

l-----------

V

6ZB5 440.ONX02-OAAl

12.91 6 Fixed cycles

6.1 Continuous stroke

6

6.1 Continuous Stroke

6.1.1 Description

If this press operating mode is selected and the cycle is started, the press executes strokes “continuously” until the program is interrupted or finished.

The interruption may have been triggered in the following ways:

l l l l

The following functions are carried out by the cycle:

l l l

Fixed Cycles

cycle stop has been triggered manually the preset number (specified in counter 1 or 2) has been reached emergency stop has been triggered there is a malfunction which leads to an automatic standstill of the press (+ PLC alarm)

checking of the starting conditions (e.g.: safety stroke carried out, etc.) moving of tool change axes into working position (e.g.: sheet run-in height, etc.) variation of the number of cycles per minute between preselected cycle speed and operating cycle speed with the following keys

+

MANU+ : gradual increase of cycles per minute;

•l El

MANU- : gradual reduction of cycles per minute;

+

la la

AUTO+ : automatic increase till operating cycle speed is reached

or AUTO-STOP pressed;

AUTO- : automatic reduction till preselected cycle speed is

reached or AUTO-STOP is pressed:

AUTO-STOP: current cycle speed maintained

Ia

a

step-by-step position correction of all tool change axes

l

calculation of brake angle for TDC stop

l

TDC following

628.5 440.ONX02-OAA7

6-1

6 Fixed Cycles

6.1.2 Start-up checklist

The following items have to be observed:

1. Has a value been defined for all cycle-specific machine data?

2. Is there a PLC program for disengaging/engaging the clutch?

3. Has the tool change been carried out without fault?

4. Has the safety stroke been carried out without fault?

5. For selecting and starting procedure see OPERATING GUIDE STANDARD and OPERATING GUIDE TECHNOLOGY

Note:

If a starting condition is not fulfilled, a corresponding message is read out and the cycle is aborted.

Explanation of the check list items: Item 1:

l

Machine data bits

12.91

MD 5015 bit 0 = 0

1

MD 5051 bit 1 = 0

1

MD 5052 bit 2 = 0

1

MD 5052 bit 3 = 0

1

MD 5055 bit 4 = 0

1

MD 5055 bit 6 = 0

1

MD 5055 bit 7 = 0

1

l

Machine data values: MD 302 Brake angle as MD

3D-interpolation not possible

3D-interpolation selected Safety stroke necessary before start

No safety stroke necessary

Calculation of brake angle according to a parabola with the factors A, 6, and C

User-specific calculation of brake angle; this calculation has to be carried out by the manufacturer in a subroutine (L=MD 370) compiled by himself (see also chapter 6.4.3, Calculation of the brake angle L 998)

TDC following inactive TDC following active (see also chapter 6.4.1, TDC following L 994)

Brake cam from tool data for cam 17

Brake cam from machine data MD 302

Cycle stop enabled by counter 1

Cycle stop blocked by counter 1

Cycle stop enabled by counter 2

Cycle stop blocked by counter 2

MD 320 Factor A for calculation of the brake angle (X

10-E

in cycle) MD 321 Factor B for calculation of the brake angle ( X 10-e in cycle) MD 322 Factor C for calculation of the brake angle ( x 10-s in cycle)

(see also chapter 6.4.3, Calculation of the brake angle L 998)

MD 370 Subroutine no. for user-specific calculation of brake angle MD 372 Subroutine no. for “Move tool change axes to starting position”

(standard = L 31)

6-2

SINUMERIK 805SM-P (PJ)

12.91

6 Fixed Cycles

6.1.2 Start-up checklist

The following four machine data are only needed for axis correction if the corresponding axis is designed as a deceleration step control axis (MD 584*.4 = 1). (See chapter 6.4.2, correction of all tool change axes L995).

MD 378 “Move-away distance” for 1st axis (0.001 mm) MD 379 “Move-away distance” for 2nd axis (0.001 mm) MD 380 “Move-away distance” for 3rd axis (0.001 mm) MD 381 “Move-away distance” for 4th axis (0.001 mm)

The term “move-away distance” refers to the distance the axis must move back from its current position in order to be at a sufficient distance from the desired position to reach the range of the last switch-off steps. This allows to carry out very small axis corrections

(i.e. compensation of the trail after the last switch-off of the axis, see also chapter 6.4.2).

Item 2: “Clutch engaged” (e.g. with the two palm buttons) must be realized via a PLC program which

has to be programmed by the user. For this S5 program the cycle transfers the following codes (via setting of flags) to the PLC.

F 136.0 Code “CONTINUOUS STROKE” started;

is read out at the beginning of the cycle.

F 137.3 PLC enable:

is set by the cycle if all prerequisites for engaging the clutch are fulfilled.

F 137.4

Code “END OF CYCLE”: is set at the end of each cycle.

These flags are set by the cycle as static flags. That means that the resetting has to be carried out by the 5% program.

Cam output - TDC stop via brake cam (no. 17): After the prerequisites for the cycle have been fullfilled, the cam output is enabled. The brake

cam is blocked until a TDC stop has been triggered. When the deceleration point has been reached, the brake cam (cam no. 17) takes the value “0” for a moment. The disengaging of the clutch must be effected by this cam (see also chapter 6.4.3, Calculation of brake angle L

998). Item 3:

The cycle can only be started if a correct tool change has been carried out before. If a mistake

has been made during the tool change, the prerequisites for CONTINUOUS STROKE are not fulfilled. The code R996 is interrogated (see also chapter 8, TOOL CHANGE).

item 4: If it is determined via machine datum that a safety cycle is necessary, R parameter no. 946

code “safety cycle carried out”) is interrogated by the cycle. CONTINUOUS STROKE can

(= be started only if a safety cycle has been carried out correctly.

6285 440.ONX02-OAAl

6-3

6 Fixed Cycles

6.1.3 Flowchart

6.1.3 Flowchart ,-----. I

1

-_-_-_ J

iNTRY SECTION for operating mode CONTINUOUS STROKE (Ll)

I

I = Interfog.

06.93

.-_-_-_

CONTINUOUS STROKE code -

.,

‘: :,I

::.‘j;:: General section, <I, : .: ,.’

,.

:-

---------------

Check of input value

Lggg .!.‘!i

fixed cycles :,

Limit max. cycle speed dep. on

- max. brake angle

- roll feed

- tool protection

CONTINUOUS CYCLE

STARTED

TOOL-DEPENDENT BRAKE “)

ANGLE IS TOO SMALL

- MAX. SPEED IS TOO LOW BECAUSE OF ROLL FEED DATA

CARRY OUT TOOL CHANGE

---

JLF 136.0

---

*)

1

,

.------

aborts the cycle

3

6-4

Accelerate main preselected cycle speed

w------------m

--------------

Prevent TDC stop

PLC enable

CARRY OUT SAFETY STROKE

MAIN DRIVE ACCELERATING

drive to

-

BRAKING MAIN DRIVE

/

“1

---

1 F 137.3

L ---

6285 440-ONXOZ-OAAl

SINUMERIK 805SM-P (PJ)

1

,

12.91 6 Fixed Cydes

6.13 Flowchart

.oop section for operating mode CONTINUOUS STROKE (L 1)

from entry

section

0

I

, R991 I ?

---*---I

-mm----

l ,

R993 I 7

--m----1

no

1

CONTIN. ST*; ~~UNNINO 1

+ + Read out operating

Dl

EBI Dl

la IBI

cycle speed

3 Read out current

cycle speed

- 3 Read out pre-selected cycle speed

+ * Increment cycle

speed

+ Decrement cycle

speed

I

i Terminate

CONTIN. STROKE RUNNING/

SPEED LIMITATION

cycle

section i: Program

yes

t

Prevent TDC stop

6ZB5 440.ONX02-OAAl

6-5

6 Fixed Cycles

6.1.3 Flowchart

‘rogram section: TERMINATE CYCLE for operating mode CONTINUOUS STROKE

Enable TDC stop Read out pre-selected cycle speed

12.91

Final activities

we-------m--v-

END OF CYCLE code

r----

1 F 137.4

----a

1

,

6-6

6ZB5 440.ONX02-OAAl

SINUMERIK 805SM-P (PJ)

12.91

6.2 Single stroke

6.2.1 Description

If this operating mode has been selected and started, the press performs a forward motion as long as the two palm buttons are pressed. In other words, the clutch is disengaged at once when the two buttons are released.

The operating mode is terminated by:

l

manual triggering of cycle stop

l

reaching the preset batch size (counter 1 or 2)

l

triggering of emergency stop

l

a malfunction which leads to an automatic standstill of the press (+ PLC alarm)

The following functions are carried out by this cycle:

l

check of the starting conditions (e.g.: tool change carried out, etc.)

l

move of the tool change axes into working position (e.g.: sheet run-in height, etc.)

l

variation of the number of cycles per minute between minimum cycle speed and operating cycle speed with the following keys:

6 Fixed Cycles

6.2 Single stroke

+

MANU+ :

gradual increase of cycles per minute

Dl

MANU- :

gradual reduction of cycles per minute

Ial

+

Dl la

AUTO+ :

AUTO- :

AUTO-STOP:

automatic increase till operating cycle speed is reached or AUTO-STOP is pressed

automatic reduction till minimum cycle speed is reached or AUTO-STOP is pressed

current cycle speed maintained

la

l

step-by-step position correction of all tool change axes

l

calculation of brake angle for TDC stop

l

TDC following

6285 440.ONX02-OAAl

6-7

6 Fixed Cycles

6.2.2 Start-up checklist

6.2.2 Start-up check list

The following items should be observed:

1. Has a value been defined for all cycle-specific machine data?

2. Has a PLC program been compiled for disengaging/engaging the clutch?

3. Has the tool change been carried out faultlessly?

4. For selecting and starting procedure see OPERATING GUIDE STANDARD and OPERATING GUIDE TECHNOLOGY

Note:

If a starting condition is not fulfilled, a corresponding message is read out and the cycle is aborted.

Explanation of the check list items: Item 1:

l

Machine data bits:

12.91

MD 5015 bit 0 = 0

MD 5024 bit 6 = 0

3D-interpolation not possible

1

3D-interpolation selected Single stroke not available

Single stroke available

MD 5052 bit 2 = 0

Calculation of brake angle according to a parabola with the factors A, 6, and C

User-specific calculation of brake angle; this calculation has to be

carried out by the manufacturer in a subroutine (L = MD 370) com-

piled by himself (see also chapter 6.4.3, Calculation of the brake

angle L 998)

MD 5052 bit 3 = 0

MD 5055 bit 4 = 0

MD 5055 bit 6 = 0

MD 5055 bit 7 = 0

l

Machine data values:

TDC following inactive

1

TDC following active (see also chapter 6.4.1, TDC following L 994) Brake cam from tool data for cam 17

1

Brake cam from machine data MD 302 Cycle stop enabled by counter 1

1

Cycle stop blocked by counter 1 Cycle stop enabled by counter 2

1

Cycle stop blocked by counter 2

MD 302 Brake angle as MD [ms] MD 320 Factor A for calculation of brake angle

(X

10-s in cycle) MD 321 Factor B for calculation of brake angle ( X 10-s in cycle) MD 322 Factor C for calculation of brake angle (X 10-s in cycle)

(see also chapter 6.4.3, Calculation of the brake angle L 998)

MD 370 Subroutine no. for user-specific calculation of brake angle MD 372 Subroutine no. for “Move tool change axes to starting position”

(standard = L 31)

6-8

6285 440.ONX02-OAAl

SINUMERIK 805SM-P (PJ)

12.91

6 Fixed Cycles

6.2.2 Start-up checklist

The following four machine data are only needed for axis correction if the corresponding axis is designed as a deceleration step control axis (MD 584’.4 = 1). (See chapter 6.42, Correction of all tool change axes).

MD 378 “Move-away distance” for 1st axis (0.001 mm) MD 379

“Move-away distance” for 2nd axis (0.001 mm) MD 380 “Move-away distance” for 3rd axis (0.001 mm) MD 381 “Move-away distance” for 4th axis (0.001 mm)

The term “move-away distance” refers to the distance the axis must move back from its current position in order to be at a sufficient distance from the desired target position to reach the range of the last switch-off steps. This allows to carry out very small axis corrections (i.e. compensation of the trail after the last switch-off of the axis, see also chapter 6.4.2).

Item 2: “Clutch engaged” (e.g. with the two palm buttons) has to be realized via a PLC program,

which has to be programmed by the user. For this %-program the cycle transfers the following codes (via setting of flags) to the PLC.

F 136.1

Code “SINGLE STROKE” started: is read out at the beginning of the cycle.

F 137.3 PLC enable:

is set by the cycle if all prerequisites for engaging the clutch are fulfilled.

F 137.4 “END OF CYCLE” code;

is set at the end of each cycle.

These flags are set by the cycle as static flags. That means that the resetting has to be carried out by the 55 program.

Cam output - TDC stop via brake cam (no. 17): After the prerequisites for the cycle have been fullfilled, the cam output is enabled. The brake

cam is always enabled during this cycle, i.e. during every stroke the brake cam (no. 17) takes the value “0” for a moment when the deceleration point is reached. The disengaging of the clutch must be effected by this cam (see also chapter 6.4.3, Calculation of brake angle L 998).

Item 3:

The cycle can only then be started if a correct tool change has been carried out before. If a fault has ocurred during the tool change, the prerequisites for SET UP are not fulfilled. The code R996 is interrogated (see also chapter 8, TOOL CHANGE).

6-9

6 Fixed Cycles

6.2.3 Flowchart

6.2.3 Flowchart ,---w-e

I

-,-.-.A

ENTRY SECTION for operating’tnode SINGLE STROKE (L2)

I

I = Interrog.

1 = Cycle mess. i

NC

start

0

t

SINGLE STROKE code

i

- SINGLE STROKE STARTED

06.93

,----7

;=

PLC flag

-I--

I

, F 136.1

----

Check of input value

Limit max. cycle speed

depending on

- max. brake angle

- tool protection

Accelerate main drive to

minimum cycle speed

-m-v-------Enable TDC stop

~~e~~e~<g~get~h-

MAX. SPEED FOR SINGLE

STROKE IS TOO HIGH

ANGLE IS TOO LOW

CAM 0 TOO SHORT

MAIN DRIVE STARTING

BRAKING MAIN DRIVE

r----i 1 F 137.3

-----

i

3

6-10

= aborts

the cycle

0 Siemens

SINUMERIK 805SM-P (PJ)

12.91

OOP SECTION for operating mode SINGLE STROKE (L 2)

SINGLE CYCLE RUNNING/

SPEED LIMITATION

#

=$ Read out operating

*-*em-.

I

, I?991

------A la

cycle speed

~4 Read out current

cycle speed

* Read out minimum

cycle speed

* Increment cycle

speed

=+ Decrement cycle

speed

6 Fixed Cycles

6.2.3 Flowchart

SINGLE CYCLE RUNNING

------.

I

, MD 5052.2 I

------A

--.-mm*

I

,

R990

-.---.A

+

I

*

:;:::;.:

,:,q::

%$ Correction of ‘i.jr:i;

.,. :,.,j

,:>:::’

1

L 995

i fix;;

:‘,; >

axes iii’::

@ Slemens AG 1991 All Rights Resewed

SINUMERIK 805SM-P (PJ)

6285 440.ONX02-OAAl

6-11

6 Fixed Cycles

62.3 Flowchart

Program section: TERMINATE CYCLE for operating mode SINGLE STROKE (L 2)

Read out minimum

cycle speed

12.91

m-.-.-s

I

, R992 ,

-.-e---1

---e-w MD 5055.6 I

i

; MD 5055.7 1

----m-1

1

I

,

.‘:I :y:j ,::: :

‘;;,I; ,t;,9;;m ;jj.

..:,:j, ;j :)x;

wait

+

counter ::jj:,

1

-zivr = ;-FyLFj

-----------END OF CYCLE code

6-12

6285 440.ONX02-OAAl

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12.91

6.3 Set up - Main drive JOG-INC mode

6.3.1 Description

If this operating mode has been selected and started, the press performs a stroke in forward direction as long as the two palm buttons are pressed. When the buttons are released, the clutch is disengaged at once, The eccentric may thus be jogged into any position over the entire stroke length.

There are two different operating modes:

l

Set up without TDC stop

l

Set up with TDC stop; the clutch is disengaged at the TDC

The operating mode is terminated by:

l

manual triggering of the cycle stop

l

reaching the number of pieces of the preset batch size (counter 1 or 2)

l

triggering of emergency stop

l

a malfunction which leads to an automatic standstill of the press (3 PLC alarm)

The following functions are carried out by this cycle:

6 Fixed Cycles

l

check of the starting conditions (e.g.: tool change carried out, etc.)

l

move of tool change axes into working position (e.g.: sheet run-in height, etc.)

l

variation of the number of cycles per minute between minimum cycle speed and operating cycle speed with the following keys

+

MANU +

: gradual increase of cycles per minute;

tiol

MANU -

: gradual reduction of cycles per minute:

El

+

Dl la

AUTO +

AUTO -

AUTO-STOP: current cycle speed maintained.

: automatic increase till operating cycle speed is reached

or AUTO-STOP is pressed;

: automatic reduction till minimum cycle speed is reached

or AUTO-STOP is pressed:

•5l

0

step-by-step correction of the position of all tool change axes

l

calculation of brake angle for TDC stop

l

TDC following

6285 440.ONX02-OAAO

6-13

6 Fixed Cycles

6.3.2 Start-up checklist

6.3.2 Start-up check list

The following items should be observed:

1. Have all cycle-specifc machine data been assigned a value?

2. Has a PLC program been compiled for disengaging/engaging the clutch?

3. Has the tool change been carried out faultlessly?

4. For selection and start see the OPERATING GUIDE STANDARD and the OPERATING GUIDE TECHNOLOGY

Note:

If a starting condition is not fulfilled, a corresponding message is read out and the cycle is aborted.

Explanation of the check list items: Item 1:

l

Machine data bits:

12.91

MD5015bitO = 0

MD 5052 bit 0 = 0

MD 5052 bit 2 = 0

3D-interpolation not possible

1

3D-interpolation selected Set up without TDC stop

1

Set up with TDC stop Calculation of brake angle according to a parabola with the factors

A, B, and C

1

User-specific calculation of brake angle; this calculation must be

carried out by the manufacturer in a subroutine written by himself

(see also chapter 6.4.1, Calculation of the brake angle L 998)

MD 5052 bit 3 = 0

MD 5055 bit 4 = 0

MD 5055

bit 6 = 0

TDC following inactive

1

TDC following active (see also chapter 6.4.1, TDC following L 994) Brake cam from tool data for cam 17

1

Brake cam from machine data MD 302 Cycle stop enabled by counter 1

Cycle stop blocked by counter 2

MD 5055 bit 7 = 0

l

Machine data values:

MD 302

Brake angle as MD [ms]

MD 320 Factor A for calculation of brake angle ( X MD 321

Factor B for calculation of brake angle ( X 10-s in cycle)

Cycle stop enabled by counter 1

1

Cycle stop blocked by counter 2

10-6

MD 322 Factor C for calculation of brake angle (X 10-s in cycle)

(see also chapter 6.4.3, Calculation of the brake angle L 998)

in cycle)

MD 370 Subroutine no. for user-specific calculation of brake angle MD 372

Subroutine no. for “Move tool change axes to starting position” (standard = L 31)

SINUMERIK 805SM-P (PJ)

12.91 6 Fixed Cycles

6.3.2 Start-up checklist

The following four machine data are only needed for axis correction if the corresponding axis is designed as a deceleration step control axis (MD 584”.4 = 1). (See chapter 64.2, Correction of all tool change axes).

MD 378 “Move-away distance” for 1st axis (0.001 mm) MD 379 “Move-away distance” for 2nd axis (0.001 mm) MD 380 “Move-away distance” for 3rd axis (0.001 mm) MD 387 “Move-away distance” for 4th axis (0.001 mm)

The term “move-away distance” refers to the distance the axis must move back from its current position in order to be at a sufficient distance from the desired target position to reach the range of the last switch-off steps. This allows to carry out very small axis corrections (i.e. compensation of the trail after the last switch-off of the axis).

Item 2:

“Clutch engaged” (e.g. with the two palm buttons) has to be realized via a PLC program, which has to be programmed by the user. For this S5 program the cycle transfers the following codes (via setting of flags) to the PLC.

M 136.2 Code “SET UP jog main drive with TDC stop”;

is read out at the beginning of the cycle. M 136.3 M 137.3

Code “SET UP jog main drive without TDC stop”;

PLC enable;

is set by the cycle if all prerequisites for engaging the clutch are fulfilled. M 137.4 “END OF CYCLE” code:

is set at the end of each cycle.

These flags are set by the cycle as static flags. That means that the resetting has to be

carried out by the S5 program. Cam output - TDC stop via brake cam (no. 17):

After the prerequisites for the cycle have been fullfilled, the cam output is enabled. Set up without TDC stop: The brake cam for TDC stop is always blocked. Set up with TDC stop:

The brake cam is always enabled, i.e. the brake cam takes the value “0” each time the deceleration point is reached. The disengaging of the clutch must be effected by this cam (see also chapter 6.4.3, Calculation of the brake angle L 998).

Item 3:

The cycle can only be started if a correct tool change has been carried out. If a fault has occurred during the tool change, the prerequisites for SINGLE STROKE are not fulfilled. The code R996 is interrogated (see also chapter 8, TOOL CHANGE).

6-l 5

6 Fixed Cycles

6.3.3 Flowchart

6.3.3 Flowchart ,-m-.-e I

I

-e-m-,J

iNTRY SECTION for operating mode SET UP jog main drive (L 3)

I

, = Interrog.

looL CHANGE STARTED

06.93

s-.-w-.

m-w-e-e

MD 372 1

------d

Check of input values

Limit max. cycle speed

depending on

-

max. brake angle

- tool protection

l-i

I

l-l

MAX. SPEED FOR TOOL

CHANGE IS TOO LOW

I

TOOL-DEPENDENT BRAKE

ANGLE IS TOO SMALL

CARRY OUT TOOL CHANGE 3

*)

I

*)

I

/

*) aborts the cycle

6-16

PLC

enablehengage clutch

1

1-1 F 137.4 ,

r----

6ZB5 440-ONX02-OAAl

SINUMERIK 805SM-P (PJ)

1

12.91

,OOP SECTION for operating mode SET UP (L 3)

6 Fixed Cycles

6.3.3 Flowchart

e-m-m-m

I

, R991

------m.4

“-.--mm

I

, R993 ;-c

-------I

I ;-c

- t Terminate cycle

+ + Read out operating

Dl

ls3l IDI

I

la IDI

cycle speed

+ Read out current

cycle speed

+ Read out minimum

cycle speed

3 Increment cycle

+

speed

+ Decrement cycle

speed

j Program section

4

6285 440.ONX02-OAAl

6-l 7

6 Fixed Cycles

6.33 Flowchart

12.91

Program section

: TERMINATE CYCLE

Read out minimum

cycle speed

.--------m----s

END OF CYCLE code

for operating mode

SET UP (L 3)

r----

1 F 137.4

m--m-

1

,

6-l 8

6285 440-ONX02-OAAl

SINUMERIK 805SM-P (PJ)

12.91

6.4 Common subroutines

6 Fixed Cycles

6.4 Common subroutines

6.4.1

TDC following L 994

Condition: Calculation of brake angle with a polynomial of 2nd degree (MD 5052 bit 2 = 0). If an exact TDC stop position in the operating modes CONTINUOUS STROKE and SINGLE

STROKE is required, the calculation of the brake angle may be adapted to the non-constant mechanical conditions. The factor A is adjusted within the preset limits in case of a positioning error. The corrected value is transferred into MD

320.

The tolerance band to the right and to the left of the TDC position where a correction of factor A seems reasonable must be determined by the user via machine data. The following figure illustrates these facts.

If the main drive is not within this window, a code is transferred to the PLC, which the user has to evaluate.

MD 137.2 Main drive not within tolerance window

If a TDC following has to be carried out, the following MD must be loaded: MD 5052 Bit 3 = 0 TDC following deselected

1 TDC following selected

MD 300 right maximum tolerance limit MD 301 left maximum tolerance limit MD 330

right minimum tolerance limit

MD 331 left minimum tolerance limit

In these areas the TDC following is effective

1800;

I

“BDC”

“TDC following” for CONT/NUOUS STROKE and SlNGLE STROKE; the indicated degree values are meant as

examples!

6-19

6 Fixed Cycles

6.4.2 Correction of all tool change axes (L 995)

This subroutine is executed if the user has selected the axes correction and pressed step + or -.

Each time the softkey is actuated

l

R990 is loaded with the corresponding axis number

l

the corresponding axis-specific parameter

parameters in work memory) is decremented or incremented by one.

The program now calculates the correction values from this number of steps and from the defined step size, e.g. 1st axis = R1103 X R1104

The axis position of the corresponding tool change axis is corrected by this value during operation. Subsequently, R990 is deleted again by the cycle. Example of the corrected axis position of the 1st axis: =

R1102+(R1103xR1104).

for

the number of steps (see distribution of the

The following characteristics apply for deceleration step control axes:

Owing to the fact that these axes have an open-loop position control, a desired position can only be approached if it lies outside the mechanic trail beyond the last switch-off position.

12.91

In order to be able to carry out very small corrections, the axis is moved away from the actual position by the “move-away distance” determined in MD before the final desired position is approached. It is only a matter of leaving the switch-off stage. The following figure illustrates these facts. The user only has to determine a sufficiently large “move-away distance”. The cycle realizes automatically whether the corrected axis is a deceleration step control axis or not.

MD 378 “Move-away distance” for 1st axis (0.001 mm) MD 379 “Move-away distance” for 2nd axis (0.001 mm) MD 380 “Move-away distance” for 3rd axis (0.001 mm) MD 381 “Move-away distance” for 4th axis (0.001 mm)

Axis position before the correction

I

ve away distance

\I

\

=F2=F3 ----

I’

:s

l Trail after last

so I-

Sl=S2= S3 I

1 switch-off stage

Axis correction for deceleration step control axes with analog output and two switch-off stages

For this example applies: If corrections < SO are to be carried out, the axis has to be moved away from the actual

position by a move away distance > SO (1st step) before the corrected axis position can be approached (2nd step).

6-20

6285 440-ONX02-OAAl

SINUMERIK 805SM-P (PJ)

0

12.91 6 Fixed Cycles

6.4.3 Calculation of the brake angle L 998

In order to guarantee that the press stands in the top dead center when “TDC stop” has been

triggered, the brake angle must be calculated continuously during a cycle. Standard: Calculation of the brake angle with a polynomial of 2nd degree

(MD 5052 bit 2 = 0) The cycle calculates the brake angle according to the following formula: a = axHa+bXH+c

a: brake angle in relation to cycles per minute H: cycles per minute

The factors a, b and c have to be stored in machine data with the correct multiplier:

MD 320 factor A = a X 10s MD 321 factor B = b X 10s MD 322 factor C = c

For the calculation of these factors the program “Factor” is at your disposal, which is supplied

on a floppy disk together with the standard cycles and is thus executable in MS-DOS.

X 103

Call: “Factor”; You are prompted by the program to input 3 points of the characteristic brake curve

which you have established before via trial stops with minimum, maximum and medium cycle speed. It is likely that the shortest stroke length has to be selected so that the machine may be operated in the maximum cycle speed range. Please use the standard assignment for the machine data (MD 320 - 322 = l),‘because in this manner a brake angle of 0 degrees is calculated for each cycle speed and therefore the indicated angle after the stop corresponds to the brake angle for the set cycle speed. With the values established, the program calculates the machine data, which can then be entered by the user.

With this brake angle, the TDC offset and the stop position, the deceleration point is established. This angle is loaded into the press datum no. “0”. If the brake cam is enabled, it takes the value “0” for a moment each time this angle is passed. You determine in the tool data (cam parameters) or in the machine datum MD 302 how long the brake cam remains in “low” position.

The following applies:

MD 5055 bit 4 =

1

+ Brake cam from MD 302 [ms]

0 + Brake cam from cam parameter

User-specific calculation of the brake angle (MD 5052 bit 2 = 1) If the manufacturer wants to calculate the brake angle according to his own formula, this must

be done in a subroutine designed for that purpose, The number of this subroutine must be defined in MD 370.

SINUMERIK 805SM-P (PJ)

6285 440-ONX02-OAAl

6-21

12.91

7 Basic Press Functions

7.1 Safety stroke

7.1

Safety stroke

7.1 .l Description

In “Safety stroke”, the press executes a slow forward stroke at creep speed. This is to prevent

the destruction of incorrectly clamped tools. The clutch can only be engaged when the creep

speed has been reached, Now the two palm buttons must be pressed until the clutch has been automatically disengaged. If the press is stopped within the tolerance window, the message SAFETY CYCLE CARRIED OUT is displayed and the acknowledge code for “Safety stroke executed” (R946 = 946) is set.

After the clutch has been disengaged, the cycle terminates itself. The cycle is aborted in the following cases:

l

if the cycle stop key is pressed

l

if the tolerance window is not reached

l

if the two palm buttons are released too early

l

if the set creep speed is outside the permitted range (

+ Messages of the standard cycles,

Chapter 9)

7.1.2 Start-up check list

l

Correct values assigned to machine data?

- MD 304 = Creep speed

- MD 332 = Tolerance window for safety stroke

- MD 373 =

Subroutine No. for additional user program

l

Tool change correctly carried out?

7.1.3 Codes for the PLC:

M 136.5 Safety stroke started M 137.3 PLC enable for engaging clutch M 137.4

These flags are set as static flags in the PLC.

Cycle terminated

The engaging of the clutch must be implemented in an

6ZB5 440.ONX02.OAAl

7-l

7 Basic Press Functions

7.1.4 Flowchart

,---m-m

I

1

-,-,--J

PREPARE ENGAGING OF THE CLUTCH for basic function SAFETY STROKE (L 4)

I

I = Interrogation

I[ = Cycle mess. ~~~--~ = PLC Flags

12.91

*-.--mm

I

, MD 304 ,

------A

--.----

-------I

SAFETY STROKE code

I

Reset o.k. code:

Load MD

i

check input limits

( Accelerr;mfnd$fe to /

-------mm-----

Enable TDC stop

Start enable to PLC

k

CARRY OUT

TOOL CHANGE

/

3

r----

1 F 137.3

-----

1

I

*) aborts the cycle

6ZB5 440-ONX02-OAAl

SINUMERIK 805SM-P (PJ)

12.91

XECUTION SECTION for SAFETY STROKE (L 4)

wait

-6

7 Basic Press FunctionS

SAFETY CYCLE

RUNNING

7.1.4 Flowchart

-3-m

Entry

on ABORT

-----------m-m

Terminating

CYCLE END code

‘I

jobs

6285 440.ONX02-OAAl

l-----

1 F 137.4

--me-

1

,

7-3

7 Basic Press Functions

7.2 Reversing

12.91

7.2 Reversing

7.2.1 Description

In “Reversing”, the press executes a slow stroke backward. With this mode it is possible to move the press back to TDC if the forward motion is mechanically blocked.

The press moves back at creep speed as long as the two palm buttons are pressed. When the TDC is reached, the clutch is automatically disengaged.

After the clutch has been disengaged, the cycle terminates itself. The cycle is aborted in the following cases:

l

if the cycle stop key is pressed

l

if the set creep speed is outside the permitted range (+ Messages of the standard cycles, Chapter 9)

7.2.2 Start-up check list

l

Correct values assigned to machine data?

- MD 304 = Creep speed

- MD 332 = Tolerance window for reverse

- MD 373 = Subroutine No. for additional user program

l

Tool change correctly carried out?

7.2.3 Codes for the PLC:

F 136.4 Reversing started F 137.3 PLC enable for engaging clutch F 137.2 Main drive outside tolerance range F 137.4 Cycle terminated

These flags are set as static flags in the PLC.

The engaging of the clutch must be implemented in an

SS program written by the user!

7-4

SINUMERIK 805SM-P (PJ)

12.91

7.2.4 Flowchart

7 Basic Press Functions

7.2.4 Flowchart

,---m-m

I

-,-m--J

I

I = Interrogation

I1 = Cycle mess. I----; = PLC flags

= Assignment

PREPARE ENGAGING OF THE CLUTCH for basic function REVERSING (L 5)

--m-.-.,

! MD304

---e-*4

Gi-:;T,Y

REVERSE code

Disable counter

I

,

Load MD

Reset codes

check input limit

REVERSING

CREEP SPEED

TOO HIGH

I

3

m-a-m-m

I

, MD 5052.2 ,

---w--d

I

-1

z.:.:,>:

,g Brake .::;.:.:.

*~r-EGc;

.;. .:.

:.:,x;

,$g

L 998

angle

:3 ;:,.

ijj: ;j/

,:::,:‘;

f!, t::..:..

l

) abortsthecycle

@ Siemens AG SINUMERIK 805SM-P (PJ)

1991

6285 440-ONX02-OAAl

7-5

7 Basic Press Functions

7.2.4 Flowchart

EXECUTION SECTION for basic function REVERSING (L 5)

12.91

F-F--

/

-------------CYCLE END code

1

REVERSING

OVER

+

Terminating

jobs

REVERSING

RUNNING

---[,,,,(I

.

r---1 F 137.2

m---m

r----

‘I F 137.4 :

-----

-I ,

1

7-6

SINUMERIK 805SM-P (PJ)

12.91

7

Basic Press Functions

7.3

Open press

7.3

Open press

7.3.1 Description

In this mode, the stroke adjustment axis is moved to its upper position (RllOO). For this, the clutch must be disengaged.

The tool change axis is normally moved by step cycle L 46. As a prerequisite for this, the stroke adjustment axis must be the first axis.

If the user has written his own program for this purpose, its number must be entered in MD 375.

7.3.2

Codes for the PLC

F 136.6 “Open press” code F 137.3 PLC enable F 137.4 Cycle terminated

These flags are set as static flags in the PLC.

7.3.3 Flowchart .------

I

-m-m-m J

I

a = Interrogation

basic function OPEN PRESS (L 6)

NC start

0

Disable counter

-------------OPEN PRESS code

PLC enable

1

Terr$nnting

-------mm-----

CYCLE END code

r----

1 F 136.6

-----

MAIN DRIVE

OPENING

PRESS

-

PRESS

OPEN

r----

-j F 137.3

--m-c

r----

1 F 137.4

-----

1

,

1

,

1

,

6ZS5 440*ONX02-OAAl

7-7

7 Basic Press Functions

7.4 Close press

12.91

7.4

Close press

7.4.1 Description

In this mode, the stroke adjustment axis is moved to its working position clutch must be disengaged.

The tool change axis is normally moved by step cycle L 30. As a prerequisite for this, the

stroke adjustment axis must be the first axis. If the user has written his own program for this purpose, its number must be entered in

MD 376.

7.4.2

Codes for the PLC

F 136.7 “Close Press” code F 137.3 PLC enable F 137.4 Cycle terminated

These flags are set as static flags in the PLC.

(R1102).

For this, the

7.4.3 Flowchart

Basic function CLOSE PRESS (L 7)

7-8

PLC enable

---------- ----

CYCLE END code

MAIN DRIVE

RUNNING

r----

CLOSED

--I F 137.4

SINUMERIK 805SM-P (PJ)

r----

-----

6285 440.ONX02-OAAl

1

I

8 Tool

12.91

8.1

General remarks

Change

8 Tool Change

8.1 General remarks

8.1 .l Description

With the TOOL CHANGE cycle, the tool change in the press is executed. The TOOL CHANGE cycle has two different tasks: a) it provides the new data for the tool

b) it is the prerequisite for the mechanical tool change Item a):

Implemented in subroutines L 990, L 992 and L 993. The tool data is stored in the work memory, and the tool selection is checked (is the selected

tool number available in the memory?). After this, the data can be modified in the work memory, if desired. For this, a user-written subroutine must be used, whose number can be freely defined in machine datum MD 371 (application example: definition of permanent, pressspecific cams which are identical for all tools).

The new data is now transferred to the hardware (e g. cam-specific data to the cam controller RAM). In doing so, the system checks this data for plausibility. If it detects a fault, the tool change cannot be executed. The cycle is aborted, and a message is output for the user.

If the tool data is checked and found correct, the system loads into central R parameters machine data required for the operating cycles (example: copying the stroke length table from the MD). The cycle checks this data for correctness.

With the ROLL FEED (RF) option, the cycle additionally calculates the “maximum speed

because of roll feed data”, which is also needed by the operating cycles to set the speed limit.

The following start cams are assumed: cam 18 for RF1 and cam 20 for RF2.

In general, the cam output is disabled in this cycle. Machine data to be set for the cycle:

MD 303 Minimum speed MD 305

Maximum speed for SINGLE STROKE MD 320-322 Factors for calculation of the brake angle MD 371

No. of the user-defined subroutine Stroke length table

MD 5051 Bit 1 = 0 Carry out safety stroke

1 No safety stroke required

With roll feed option:

MD 728 1st R parameter for roll feed MD 811 Number of roll feed blocks

6tB5 440-ONX02-OAAl

8-l

8 Tool Change

8.1 .l Description

Item

b):

If all prerequisites described under a) are fulfilled, the mechanical tool change can be carried out. This can be done either by:

l

manual tool change or by

l

automatic tool change

8.1.2 Flowchart

12.91

,----me

I

-.--w-J

I

, = Interrogation

rJ= [---Il= PLC flags

II

Cycle messages

= Parameters receiving values

rooL CHANGE GENERAL (L 990) ‘ROVIDE TOOL DATA AND CHECK PLAUSIBILITY

Reset o.k. codes

_-_-_-_

CHECK TOOL SELECTION 2

n

) aborts the cycle

8-2

6285 440.ONX02-OAAl

SINUMERIK 805SM-P (PJ)

12.91

8 Tool Change

8.1.2 Flowchart

1 MD321 i ;. MD 322

v-.-,2

Reset safety stroke o.k. code

(R946 = 0)

A

r---1

--m-e

CHECK STROKE LENGTH “)

MIN. SPEED TOO HIGH 7

I3946

1

,

t

11 Return to 1’1

7 aborts the cycle

6265 440-ONX02-OAAl

r----

I F 137.3 j

-----

8-3

8 Tool Change

8.1.2 Flowchart

OPTION: TOOL CHANGE - ROLL FEED SECTION (L 992)

12.91

--m-e-

! MD 728 !

I

, MD811 r L--*-.-l

,---e-m 1 Option RF2 ‘W

‘---m-m

J

RF1

Calculate total program length

RF2 Calculate total

--w----------e

program length

Reset number of steps in

RF1 and RF2

+

Calculate max. speed

from roll feed data RF1 = Start cam RF2 = Start cam 20

+

18

r----

j R931

-----

r---1 A926

-----

r----

1 A924

-----

1

,

I

,

8-4

6285 440-ONXO2-OAAl

SINUMERIK 805SM-P (PJ)

12.91

rERMlNATE TOOL CHANGE (L 993)

Store the previous

- tool change position

-

stroke number

-

stroke referred to zero

-------------Reset loop flag

Automatic TOOL CHANGE

6 Tool Change

6.1.2 Flowchart

Read interface flags

(F24.6 and F24.7)

4

Reset data transfer

code

-

--

DATA TRANSFER

!STlLL RUNNING

TOOL CHANGE

----

I

+, F 139.3 I

--e-m

1

6285 440-ONX02-OAAl

8-5

8 Tool Change

8.2 Manual tool change - jog main drive (L 9)

12.91

8.2 Manual tool change - jog main drive (L 9)

8.2.1 Description

If the tool data of a new tool are not known, the tool can be mounted and dismounted by hand with this cycle.

For this purpose, the subroutine provides, in its basic version, the possibility to jog the main drive at creep speed via the two “palm buttons” and to move the axes by means of the direction keys (selection via softkeys). Any further functions required for the tool change can be executed as so-called step cycles in a step sequence (example: step cycle No. 43: “Start data transfer to an external device”).

For this step sequence, MD 335 - 339 are available to define the order of the subroutine functions to be called. In our example, it would suffice to enter the subroutine number 43 in MD 335 in order to trigger the data transfer during the tool change procedure. Furthermore, the notes on the individual step cycles must be borne in mind. The available step cycles can be found in the overview of standard cycles in Chapter 10.

Machine data to be set: MD 304

Creep speed

MD 335

Step sequence MANUAL TOOL CHANGE

: >

MD 339 Please pay attention to the machine data of the step cycles!

PLC codes F 137.0

F 137.3

MANUAL TOOL CHANGE code PLC enable

F 137.4 Cycle terminated Please pay attention to the codes of the step cycles used!

These flags are set as static flags in the PLC.

8-6

SINUMERIK 805&M-P (PJ)

12.91

8.2.2 Flowchart ,-m---m

I

-s---m J

MANUAL TOOL CHANGE - jog main drive (L 9)

I

a = Interrogation

8 Tool Change

8.2.2 Flowchart

--.-e-

! MD 335

I

a MD:339 r

L.---w-l

f

Enter subrout. no.

from MD

.

MANUAL TOOL

RUNNING

CHANGE

loop parameter (R913)

. . . . . .

,. :.:.:

1

:jj ;

,j$: L= MD(R913) ‘;$ ,\$i9: Step cycles $:i

..,.,_

:j :‘;:I

(I

@ Siemens AG 1991 All Flights ReSet’Ved 8285 440.ONX02-OAAl SINUMERIK 805SM-P (PJ)

r-e--

1 F 137.4

-----

1

a-7

8 Tool Change

8.3 Automatic tool change (L 8)

12.91

8.3 Automatic tool change (L 8)

8.3.1 Description

If the tool data of a new tool are known, it is also possible to carry out a manual operatorguided tool change.

The press-specific sequence of operations to mount and dismount a tool can be defined in this cyle via machine data. Just as in Manual tool change, a number of step cycles is available to the user which can be integrated in the tool change procedure as “function macros” (on this, see the overview of standard cycles in Chapter 10).

An example of the aforesaid is given below, along with a detailed description of how to implement an automatic stroke adjustment with the available step cycles.

Overview of the machine data

MD 5040.0 = 0: Re-entry at the interruption point

1:

Permit only MANUAL TOOL CHANGE after the interruption

Step sequence for AUTOMATIC TOOL CHANGE

to

be set:

PLC codes:

F 137.1 MANUAL TOOL CHANGE code F 137.3 F 137.4

Please pay attention to the codes of the step cycles used! These flags are set as static flags in the PLC.

8.3.2

This example describes the automatic removal of a tool using standard cycles for the tool change operations.

Pre-defined sequence of operations:

PLC enable Cycle terminated

Example for the implementation of an automatic tool change

Step 1: Move punch to TDC position L 24

Step 2: Acknowledge message ‘Remove residual strip” L 35

Step 3: Move to previous tool hange position Step 4: Move punch to LDC position Step 5: Step 6: Move punch to TDC position Step 7: Acknowledge message “Remove tool” L 35

Each of these steps is implemented by an individual subroutine (standard cycles for tool change operations). It suffices to enter the subroutines in the above order in the machine data (MD 340 - MD 369).

8-8

Release tool clamp

Q Siemens AG 1991 All Rtghts Reserved

L 29 L 25 L 36 L 24

6ZB5 440.ONX02-OAAl

SINUMERIK 805SM-P (PJ)

05.94 8 Tool Change

8.3.2 Example for the implementation of an automatic tool change

In this example, therefore, the following subroutine numbers would have to be entered: MD 340 = 24 MD 341 = 35 MD 342 = 29 MD343=25 MD344=36 MD345 = 24 MD 346 = 35 MD 347 = 50

Subroutine No. 50 marks the terminating cycle and must always be entered for the reset of

the loop flag in the main program and thus for the correct termination of the tool change cycle.

Before starting the actual tool change, it must now be checked whether the step cycles used require a PLC program supplement (see description of the individual step cycles in Section 8.4).

8.3.3

Automatic stroke adjustment during the tool change

Depending on the type of blocking mechanism used,’ two ways of positioning are possible:

1. Absolute positioning (MD 5051.4 = 0)

A shaft can only be blocked and released in an absolute way in the “stroke adjustment position”. For the stroke adjustment, the following sequence of subroutines must be called:

L 26: Move to the previous adjustment position (MD 420 - 439) L 40: Block shaft and release eccentric L 27: Move to the new adjustment position (MD 420 - 439) L 41: Release shaft and block eccentric

2 Relative positioning (MD 5051.4 = 1) The shaft can be blocked in any position (e.g. by a holding brake). The following sequence of

subroutines must be called: L 40: Block shaft and release eccentric

L 27: Move to the new adjustment position (MD 420 - 439) L 41: Release shaft and block eccentric

Depending on the hardware used, positioning in cycles L 26 and L27 can be implemented either with NC function Ml9 or with press function “Brake cam positioning”.

You make your choice by means of a machine data bit. MD 5051.3

= 0: Positioning with brake cam (cam 17)

1: Positioning with Ml9

8-9

8 Tool Change

8.3.3 Automatic stroke adjustment during the tool change

Overview of machine data to be set for the stroke adjustment: MD 5051.2

= 0: No correction of the anticipation angle

1: Automatic correction of the anticipation angle after the first positioning

attempt

MD 5051.3 = 0: Positioning with brake cam (cam 17)

1: Positioning with Ml9

MD 5051.4 = 0: Absolute positioning to the new adjustment position

1: Relative positioning, considering only the difference between the new

and the previous adjustment position MD 377.. Anticipation angle to calculate the deceleration point (l/l0 degree) MD 420

.

MD 439

>

Stroke adjustment position of the individual strokes

OS.94

9-10

8ZB5 440-ONX02-OAAl

SINUMERIK 805SWP (PJ)

12.91

8.3.4 Flowchart ,-m-e-.

I

4

-,-.,,J

Al JTOMATIC TOOL CHANGE (L 8)

I

I = Interrogation

8 Tool Change

8.3.4 Flowchart

--w-c--

------

1

AUTOMATIC TOOL CHANGE code

-----------a--

Disable cam

Enter subroutine no. from MD in - AUTOMAnC TOOL CHANGE

AUTOMATIC TOOL CHANGE

STARTED

ERROR’ DURING AUTOM. =3

MANUAL TOOL CHANGE

RUNNING

--we

-1

, F 137.1 ,

-----

1

a a

CYCLE

END code

SINUMERIK 805SM-P (PJ)

r----

1 F 137.4

--e-w

1

,

8-l 1

8 Tool Change

8.4 Description of the step cycles

12.91

8.4

L 20

L 21

L 22

Description of the step cycles

Decelerate main drive and wait for speed = 0

This cycle defines a setpoint of 0 for the main drive + The drive decelerates after the acceleration ramp (MD). The step cycle waits for the standstill of the main drive. No PLC program supplement required. No MD to be set. Hardware prerequisite: NC main drive

Decelerate main drive to crawl speed and wait for speed + 10

In this cycle, the creep speed is read from MD 304 and output. The tachometer voltage (0 to 10 V) is picked up via sensor input no. 3 of the pressure module. As soon as creep speed + 10 strokes is reached, the cycle is exited. No PLC program supplement required. MD 304 set creep speed. Hardware prerequisite: Pressure module for connecting the tacho voltage to sensor

3; NC main drive

Output crawl speed

In this cycle, the creep speed is output, The subroutine is exited again immediately

afterwards, without waiting until the creep speed is actually reached.

No PLC requirements. Hardware prerequisite: NC main drive

L 23

L 24

L 25

Activate (additional) motor for creep speed

If an additional motor is to be used for the creep speed of the eccentric, the command

to switch over to this motor can be given by this cycle. To do this, flag F 137.5 is set,

and the PLC must reset it to acknowledge the command.

Move to TDC position

The current TDC position is transferred to parameter R900 ( = punch stop position).

+ Prepares positioning in step cycle L 28.

Can be used without restrictions.

Move to LDC position

The current LDC position is transferred to parameter R900 ( = punch stop position).

-+ Prepares positioning in step cycle L 28. Can be used without restrictions.

8-12

6tB5 440-ONXOZ-OAAl

SINUMERIK 805SM-P (PJ)

12.91 8 Tool Change

8.4 Description of the step cycles

L 26 Move main drive to previous stroke adjustment position

This cycle is only required for the stroke adjustment if, due to the type of blocking mechanism used, the adjustment must be executed from the “absolute” position (MD 5051.4=0). To prepare L 28, the previous adjustment position is entered in parameter R900.

L 27 Move main drive to new stroke adjustment position

To prepare L 28, the new adjustment position is entered in parameter R900.

MD 5051.4 = 0: The adjustment position is taken from the stroke length table

(MD 420 - 439), according to the new stroke number (R949).

MD 5051.4 =

1:

The new absolute adjustment position is calculated from the actual position plus the difference between the previous and the new stroke adjustment position (MD 420 - 439).

L 28 Move the main drive to the preselected position

This cycle executes the positioning proper, either via Ml9 or, if there is no NC main drive, via the brake cam. The choice is made by MD bit 5051.3.

Positioning with the brake cam: For positioning with the brake cam, the “anticipation angle“ (= punch trail) must be

entered in machine datum MD 377. It is also possible to carry out an automatic correction of this angle if the previous positioning has been incorrect ( = punch outside the tolerance window MD 4430).

The maximum number of positioning attempts in this cycle is generally limited to 2

(+ R902 interrogated for <2).

This cycle is called by cycles L 24, L 25, L 26 and L 27. The number of possible

“brake angle positioning attempts” in these standard cycles is permanently set by presetting the R parameter R902.

L 24 and L 25: 1 attempt only (positioning not repeated) L 26 and L 27: 2 attempts (positioning repeated once)

L 29 Move to current tool change position

The punch adjustment axis is moved to the current tool change position (R910). R910 always contains the change position of the tool clamped in the press at this moment, i.e. either of the previous or the new tool. Hardware prerequisite: Punch adjustment = 1st axis.

L 30 Move to mounting height

The punch adjustment axis is moved to the new tool’s work position: corrections made are taken into account.

Hardware prerequisite: Punch adjustment = 1st axis.

8-l 3

8 Tool Change

8.4 Description of the step cycles

12.91

L 31

L 32

L

33

L 34

L 35

Move all tool change axes to work position

If possible, all tool change axes used (3D interpolation) are simultaneously moved to the position set in the tool data. Corrections are taken into account.

Manual tool removal

This cycle outputs a code to the PLC.

--f Flag F 138.0 is set. Furthermore, the function “Move axes via direction keys” (L 44) is enabled until the PLC acknowledges code F 138.0. The step is only exited after reset of this flag.

Manual tool installation

Function as above, but different PLC code in flag F 138.1. + Reset by user when the step is to be terminated (e.g. by the”tick-off” key

a).

Manual stroke adjustment

The cycle sets code F 138.2 and remains in a loop until the code has been acknowledged by the PLC program (e.g. by the “tick-off” key

q

).

General acknowledge message

If the operator is supposed to carry out a manual job, the prompt to do so can be

output by this cycle. The cycle outputs a code (flag F 138.3) and’ remains in a loop

until the code has been reset by the PLC program. The message text can be modified as desired via “Edit part program”. If several messages are required during one tool change procedure, the cycle can be copied any number of times under a new subroutine number. If the step is acknowledged every time by the same key (e.g. by the

“tick-off” key ml the same flag can be used throughout (F 138.3).

L

36

L 37

L36

L 39

Open tool clamp

The cycle sets code F 138.4 and outputs the message “OPEN TOOL CLAMP”.

The code must be acknowledged by the user himself in the PLC program.

Close tool clamp

Analogous to L 36.

Code: F 138.5

Message: “CLOSE TOOL CLAMP”.

Move tool out

Analogous to L 36.

Code: F 138.6

Message: “MOVE TOOL OUT”.

Move tool in

Analogous to L 36.

Code: F 138.7

Message: “MOVE TOOL IN”.

8-l 4

6ZBS 440-ONX02-OAAl

SINUMERIK 805SM-P (PJ)

12.91

L 40 Block shaft - Open eccentric

Used for stroke adjustment (see also the section on stroke adjustment during the tool change).

In this step are output: Code: F 139.0 Message: “UNLOCKING EXCENTER”. After the eccentric has been unlocked, the PLC has to reset flag F 139.0 + acknowledgement of the step.

L 41 Close eccentric - Release shaft

Analogous to L 40. Code: F 139.1 Message: “LOCKING EXCENTER”.

L 42 Check tool code

This step cycle is used with coded tools in order to ensure that the tool installed is identical with the tool selected by the controller. Code F 139.2 is transferred to the PLC. The S5 program must now load the coded number of the installed tool into R parameter R919. The cycle compares this number with the number selected during the tool change. If the numbers are not identical, the message “PROGRAMMED TOOL NUMBER DIFFERENT FROM TOOL CODE” is output and the tool change is aborted. The code is reset by the cycle.

8 Tool Change

8.4 Description of the step Cycles

L 43 Start data transfer

This step cycle is used for data transfer to an external device via the second V.24 interface. With this cycle, R parameters can be output via the second interface. If one interface is already active, the cycle waits for termination of the transfer and then outputs a code to the PLC (F 139.3). As all codes are reset at the end of the cycle, the PLC should treat this flag as a dynamic flag.

Prerequisites:

l

RO = initial address and

Rl

= final address are set.

l

The selected R parameters contain the data to be transferred.

l

The setting data for the second V.24 interface are correctly set.

L 44

Move axes via the direction keys By this cycle, it is possible to move the tool change axes as in JOG via the direction

keys with an operating mode (e.g. SET-UP) active. For this, a PLC program supplement is required which provides for the axis-specific interface signals.

6265 440-ONX02-OAAl

8-l 5

8 Tool Change

8.4 Description of the step cycles

Example:

Segment: TOOL CHANGE - MOVE AXES VIA KEYS

AN F 139.4 MOVE AXES code from cycle JC = MOO1 A I 69.7 AN I 69.6 - key

= F 139.5

12.91

+ direction key

1st positive axis to cycle

A I 69.6

AN I 69.7 + key

= F 139.6 1st negative axis to cycle

MOOl: A F 139.4

AN F 139.5 AN F 139.6 AN Q 87.3

= Q 87.3 Cancel residual path

L 45

Automatic drift compensation for main drive

This cycle calculates the drift of the main drive (mean value of 100 measurings) and automatically carries out the compensation via MD 4010. The clutch must be engaged by the user via code F 140.5. After the compensation, the cycle resets the code (+ disengaging the clutch).

L 46

Move punch axis to upper position The punch axis is moved to the upper position (RllOO).

Hardware prerequisite: Punch adjustment = 1st axis

L 50

Terminating cycle This cycle is always required at the end of the step sequence. In it, the loop flags are

reset.

- key

8-16

6265 440.ONX02-OAAl

SINUMERIK 805SM-P (PJ)

12.91

9

Messages

9.1

of

the Standard Cycles

CONTINUOUS STROKE cycle

9

Messages of the Standard Cycles

The messages of the standard cycles are stored as operation messages in the cycles. These cycle messages may be deleted by:

. POWER-ON

l

RESET key

. a

cl

key and QUIT softkey

+ or

0

or

This type of message does not have an error number and is not displayed in the DIAGNOSIS menu.

9.1

Cause:

Effect:

CONTINUOUS STROKE cycle

I

CONTINUOUS CYCLE STARTED

The CONTINUOUS CYCLE has been started. Code CONTINUOUS has been transferred to the PLC (F136.0).

Cause: Effect: Remedy:

Cause: Effect:

Remedy:

I

CARRY OUT TOOL CHANGE

The TOOL CHANGE cycle has not been carried out or was terminated incorrectly. The cycles CONTINUOUS STROKE, SINGLE STROKE, SET UP, safety stroke and reversing cannot be carried out. Carry out a TOOL CHANGE cycle for the selected tool.

I

CARRY OUT SAFETY STROKE

Safety condition MD 5051 Bit 1

= 0 has been selected and the SAFETY STROKE cycle has not been carried out (R946 f 946). The cycle is aborted.

Select safety stroke and start the cycle.

9-l

9 Messages of the Standard Cycles

9.1 CONTINUOUS STROKE cycle

06.93

Cause:

Effect: Remedy:

I

TOOL-DEPENDENT BRAKE ANGLE IS TOO SMALL

Due to the tool-dependent brake angle (R939 < R1095) the max. cycle speed is lower than the preselected speed. The cycle is terminated.

l

Check the tool-dependent brake angle and the preselected cycle speed for the selected tool.

l

Check the factors of the brake parabola.

MAX. SPEED IS TOO LOW BECAUSE OF ROLL FEED

DATA

The max. cycle speed which has been determined based on the roll

feed data is lower than the preselected speed (R924 C R1095), i.e.

the positioning time of the RF would not be sufficient even for the pre-

selected cycle speed.

The cycle is terminated.

Check the tool data.

I

Cause: Effect:

Remedy:

I

Cause: The main drive accelerates to the preselected cycle speed.

I I

I

Cause:

TOOL PROTECTION: CAM c] TOO SHORT

For a reliable recognition of the cam displayed, the press would have to run at less than the pre-selected cycle speed. The cycle is aborted.

l

Extend the cam angle

l

Enter the cam (type ~0)

MAIN DRIVE ACCELERATING

BRAKING MAIN DRIVE

I

1

The main drive is slowed down to the preselected cycle speed.

I

9-2

6ZB5 440-ONX02-OAAl

SINUMERIK 805SM-P (PJ)

06.93

9 Messages

9.1

of the

CONTINUOUS

Standard Cycles

STROKE cycle

I

Cause:

I

Cause:

Effect:

Remedy:

rr---

CONTINUOUS STROKE RUNNING

The main drive runs within the permissible range. The prerequisites

were fulfilled + ready for engaging the clutch.

CONTINUOUS STROKE RUNNING / SPEED

LIMITATION

The max. cycle speed is lower than the programmed operating speed due to

l

the maximum tool-dependent brake angle

l

the roll feed positioning time or the

l

the reaction time of the tool protection

The operating speed is never reached.

l

Decrease the preset operating speed (R1087).

l

Check the tool data.

PIECE COUNT OF COUNTER 1 REACHED

Cause: Effect:

Remedy:

COMMAND value and ACTUAL value of counter 1 are equal.

l

The ACTUAL value is set to zero.

l

The clutch is disengaged + the CONTINUOUS STROKE cycle is terminated.

l

If the same batch size is to be worked off again, press the NC-START key.

l

If the input of a batch size is not necessary, preset counter 1 and counter 2 to zero.

I

PIECE COUNT OF COUNTER 2 REACHED

COMMAND value and ACTUAL value of counter 1 are equal.

l

The ACTUAL value is set to zero.

l

The clutch is disengaged * the CONTINUOUS STROKE cycle is terminated.

l

If the same batch size is to be worked off again, press the NCSTART key.

l

If the input of a batch size is not necessary, preset counter 1 and

counter 2 to zero.

6ZB5 440-ONX02-OAAl

9-3

9 Messages of the Standard Cycles

9.2 SINGLE STROKE cycle

06.93

9.2

Cause: Effect:

Remedy:

Cause:

Effect: Remedy:

SINGLE STROKE cycle

SINGLE

The SINGLE STROKE cycle has been stat-ted. Code SINGLE STROKE (= F136.1) is output to the PLC.

I

CARRY OUT TOOL CHANGE

The TOOL CHANGE cycle has not been carried out or was terminated incorrectly. The cycle is terminated.

Carry out a TOOL CHANGE cycle for the selected tool.

MAX. SPEED FOR

The max. cycle speed for single stroke is higher than the stroke length-dependent max. cycle speed. The cycle is terminated. . MD 305 =

~ l Check the max. cycle speed for the selected stroke length.

STROKE STARTED

SINGLE

Check the limit cycle speed for single stroke.

STROKE

IS

TOO

HIGH

Cause: Effect:

Remedy:

I

MAX. SPEED FOR

SINGLE

STROKE

IS

TOO LOW

I

The maximum cycle speed for single stroke is lower than the minimum cycle speed (MD 303) The cycle is terminated.

l

Check the limit cycle speed for single stroke (MD 305).

l

Check the minimum cvcle speed (MD 303).

TOOL PROTECTION: CAM q TOO SHORT

For a reliable recognition of the cam displayed, the press would have to run at less than the preselected cycle speed. The cycle is aborted.

l

Extend the cam angle

l

Enter the cam (type f 0)

94

6285 440.ONX02-OAAl

SINUMERIK 805SM-P (PJ)

06.93

9 Messages of the Standard Cycles

9.2 SINGLE STROKE cycle

Cause: Effect:

Remedy:

Cause:

I

TOOL-DEPENDENT BRAKE ANGLE IS TOO SMALL

Due to the max. tool-dependent brake angle (R 939) the max. cycle speed is lower than the minimum cycle speed (MD 303). The cycle is terminated. Check the tool-dependent brake angle and the minimum cycle speed for selected tool. Check the factors of the brake parabola.

I

MAIN DRIVE STARTING

The main drive accelerates to the minimum cycle speed (MD 303).

I

BRAKING MAIN DRIVE

The main drive is slowed down to the minimum cycle speed (MD 303).

I I

I

Cause:

I

SINGLE CYCLE RUNNING

The main drive runs within the permissible range. Prerequisites have been fulfilled 3 ready for engaging the clutch.

SINGLE CYCLE RUNNING / SPEED LIMITATION

The max. cycle speed is lower than the limit cycle speed for SINGLE

STROKE (MD 305). This is due to

l

the max. tool-dependent brake angle or

l

the reaction time of the tool protection

The max. cycle speed for single stroke is not reached.

l

Reduce the preset limit cycle speed

l

Check the tool data.

6285 440.ONX02-OAAl

9-5

9 Messages of the Standard Cycles

9.2 SINGLE STROKE cycle

06.93

Cause: Effect:

Remedy:

Cause: Effect:

Remedy:

II

I

PIECE

COMMAND value and ACTUAL value of counter 1 are equal.

l l

l

COUNT OF COUNTER 1 REACHED

The ACTUAL value is set to zero. The clutch is disengaged + the CONTINUOUS STROKE cycle is terminated.

If the same batch size is to be worked off again, press the NC-

START key.

If the input of a batch size is not necessary, preset counter 1 and

counter 2 to zero.

PIECE COUNT OF COUNTER 2 REACHED

COMMAND value and ACTUAL value of counter 2 are equal.

l

The ACTUAL value is set to zero.

l

The clutch is disengaged + the CONTINUOUS STROKE cycle is terminated.

l

If the same batch size is to be worked off again, press the NCSTART key.

l

If the input of a batch size is not necessary, preset counter 1 and counter 2 to zero.

9.3

I

Cause:

I

Effect:

SET UP cycle

I

SET UP STARTED

The SINGLE STROKE cycle has been started.

Dependent on MD 5052 bit 0 the corresponding code is output to the

PLC. F136.2 = SET UP code with TDC stop F136.3 = SET UP code without TDC stop

9-6

Q Siemens AG 1991 All Rights Resewed 6ZB5 440-ONX02.OAAl

SINUMERIK 805SM-P (PJ)

06.93

1

9 Messages of the Standard Cycles

9.3 TOOL CHANGE cycle

CARRY OUT TOOL CHANGE

The TOOL CHANGE cycle has not been carried out or was terminated incorrectly. The cycle is terminated. Carry out a TOOL CHANGE cycle for the selected tool.

I I

I

MAX. SPEED FOR SET UP

The max. speed for SET UP (R1097) is higher than the tool-dependent

max. cycle speed. The cycle is terminated.

l

Check the maximum cycle speed for SET UP.

l

Check the maximum cycle speed for the selected stroke length.

MAX. SPEED FOR SET UP

The maximum cycle speed for SET UP (R1097) is lower than the

minimum cycle speed (MD 303)

The cycle is terminated.

l

Check the maximum cycle speed for SET UP.

l

Check the minimum cycle speed (MD 303).

TOOL PROTECTION: CAM

IS

TOO

IS

TOO LOW

q

TOO SHORT

HIGH

d

Cause:

F-

Effect: Remedy:

I

For a reliable recognition of the cam displayed, the press would have to run at less than the pre-selected cycle speed. The cycle is aborted.

l

Extend the cam angle

l

Enter the cam (type f 0)

6ZB5 440-ONX02-OAAl

9-7

9 Messages of the Standard Cycles

9.3 TOOL CHANGE cycle

TOOL-DEPENDENT BRAKE ANGLE IS TOO LOW

06.93

Cause: Effect:

Remedy:

Cause:

Effect:

Due to the tool-dependent brake angle (R939) the max. cycle speed is lower than the minimum cycle speed (MD 303).

The cycle is terminated.

l

Check the tool-dependent brake angle and the minimum cycle speed for the selected tool.

l

Check the factors of the brake parabola.

MAIN DRIVE STARTING

I

1 The main drive accelerates to the minimum cvcle soeed (MD 303).

I

BRAKING MAIN DRIVE

I

1 The main drive is slowed down to the minimum cycle speed (MD 303).

1

I

Cause:

Cause: Effect:

Remedy:

I

SET UP RUNNING

I

The main drive is running within the permissible range. The prerequisites have been fulfilled + ready for engaging the clutch.

SET UPRUNNING / SPEED LIMITATION

The max. cycle speed is lower than the limit cycle speed for SET UP

(R1097). This is due to

l

the max. tool-dependent brake angle or

l

the reaction time of the tool protection

The max. cycle speed for SET UP is not reached.

l

Reduce the max. cycle speed for SET UP.

l

Check the tool data.

9-8

6285 440-ONX02-OAAl

SINUMERIK 805SM-P (PJ)

12.91

9

Messages

9.3 TOOL CHANGE cycle

of the Standard Cycles

Cause: Effect:

Remedy:

I

PIECE

COUNT OF COUNTER 1 REACHED

COMMAND value and ACTUAL value of counter 1 are equal.

l

The ACTUAL value is set to zero.

l

The clutch is disengaged =# the SET UP cycle is terminated. If the same batch size is to be worked off again, press the NC-START key. If no batch size is necessary, preset counter 1 and counter 2 to zero.

PIECE

COUNT OF COUNTER 2 REACHED

COMMAND value and ACTUAL value of counter 2 are equal.

l

The ACTUAL value is set to zero.

l

The clutch is disengaged * the SET UP cycle is terminated. If the same batch size is to be worked off again, press the NC-START key. If no batch size is necessary,

preset counter 1 and counter 2 to zero.

9.4

Cause: Effect:

Remedv:

REVERSING cycle

I

I I

REVERSING STARTED

The REVERSING cycle has been started. The REVERSING code (F 136.4) is output to the PLC.

I

CARRY OUT TOOL CHANGE

The TOOL CHANGE cycle has not been carried out or was terminated

incorrectly. The REVERSING cycle is terminated. Carry out a TOOL CHANGE cycle for the selected tool.

6265 440.ONX02-OAAl

9-9

9 Messages of the Standard Cycles

9.4 REVERSING cycle

12.91

CREEP SPEED TOO

HIGH

Cause: The creep speed is higher than the minimum cycle speed (MD 303). Effect: The REVERSING cycle is terminated. Remedy: Check the cycle speed (MD 304) and the min. cycle speed (MD 303)

I

REVERSING RUNNING

Cause: 1 ClutcheEngagedp 3 the press carries out a slow reversing stroke. 1

REVERSING OVER

Cause: Effect:

The REVERSING cycle has been terminated correctly. Code “Reversing carried out” is set (R935 = 935).

9.5 SAFETY STROKE cycle

I

Cause: Effect:

I

Cause:

Effect: Remedy:

I

SAFETY CYCLE STARTED

The SAFETY STROKE cycle has been started. The SAFETY STROKE code (F 136.5) is output to the PLC.

CARRY

OUT TOOL CHANGE

The TOOL CHANGE cycle has not been carried out or was terminated incorrectly. The SAFETY STROKE cycle is terminated.

Carry out a TOOL CHANGE cvcle for the selected tool.

CREEP SPEED TOO

HIGH

Cause: Effect: Remedy:

1

9-l 0

The creep speed is higher than the minimum cycle speed (MD 303). The SAFETY STROKE cycle is terminated. Check the creep speed (MD 304) and the min. cycle speed (MD303).

6ZB5 4;0-ONX02.OAAl

SINUMERIK 805SM-P (PJ)

12.91

9 Messages of the Standard Cycles

9.5 SAFETY STROKE cycle

I

Cause:

I

Cause: Effect:

SAFETY CYCLE RUNNING

Clutch 4 Engaged D j the press carries out a slow forward stroke.

SAFETY CYCLE

The SAFETY STROKE cycle has been terminated correctly. Code “Safety stroke” has been set (I3946 = 946).

9.6 CLOSE PRESS cycle

I

Cause: Remedy:

MAIN DRIVE RUNNING

The eccentric is still running. Disengage the clutch.

CARRIED

OUT

I

CLOSING PRESS

Cause: The stroke adiustment axis is moved to the starting position.

I

Cause:

9.7

Cause: Remedv:

I

OPEN

I

PRESS CLOSED

The PRESS CLOSED cycle has been terminated.

PRESScycle

MAIN DRIVE RUNNING

The eccentric is still running.

Disenaaae the clutch.

I

9-l 1

9 Messages of the Standard Cycles

9.7 OPEN PRESS cycle

OPENING PRESS

I

The stroke adjustment axis is moved to the upper punch position.

12.91

I

Cause:

9.8 GENERAL TOOL CHANGE cycle

I

Cause:

Effect: Remedv:

I

Cause: Effect: Remedy:

PRESS OPEN

The OPEN PRESS cycle has been terminated.

CHECK TOOL

The selected tool is not identical with the one available in the work memory. The cycle is aborted.

Check whether the selected tool is available in the work memory.

CHECK TOOL DATA

Incorrect tool data input.

The cycle is aborted.

Check the tool data for the selected tool.

SELECTION

1

I

Cause: Effect: Remedy:

I

9-12

I

CHECK STROKE LENGTH

Stroke length of selected stroke number = 0. The cycle is aborted. Assign a value to MD 400 - 419.

6ZB5 440.ONX02-OAAl

SINUMERIK 805SM-P (PJ)

06.93 9 Messages of the Standard Cycles

9.8 GENERAL TOOL CHANGE cycle

I

Cause: Effect:

Remedy:

Cause:

Effect: Remedy:

t

I

MINIMAL

The minimum cycle speed (MD 303) is higher than the pre-selected

cycle speed (R1095). The cycle is aborted. Check the preselected cycle speed. Check the minimum cvcle speed.

OPERATING

The operating cycle speed (R1087) is higher than the stroke-lengthdependent maximum cycle speed (MD 460 - 479). The cycle is aborted.

l

Check the operating cycle speed for the tool.

l

Check the maximum cycle speed for the selected stroke length.

DATA TRANSFER

SPEED TOO

STILL RUNNING

HIGH

Cause:

Effect: Remedy:

I

Cause: Effect:

I

9.8.1 MANUAL TOOL CHANGE

I

Cause: The manual tool change has been started. Effect:

The data transfer to an external device (2.V24) is still running.

The cycle waits until this transfer is terminated. Press

and stop the 2nd interface.

I

TOOL CHANGE COMPLETED

I

l

The TOOL CHANGE cycle has been terminated.

l

Code “Tool chanae carried out” is set (R996 = 996).

MANUAL TOOL CHANGE STARTED

I

Code “Manual tool chanae” is output to the PLC (F137.0).

I

9-13

9 Messages of the standard cycles

9.8.1 MANUAL TOOL CHANGE

12.91

I

MANUAL TOOL CHANGE

RUNNING

I

Cause: The prerequisites have been fulfilled.

The step cycles are running. The creep cycle speed has been output.

9.8.2 AUTOMATIC TOOL CHANGE

I

Cause: Effect:

I

AUTOMATIC TOOL CHANGE STARTED

The automatic tool change has been started. Code “Automatic tool change” is output to the PLC (F137.1).

ERROR DURING

AUTOMATIC

I

Cause:

Remedy:

The previous automatic tool change has been aborted due to an error. Carry out a manual tool change.

*MANUAL TOOL CHANGE

9.9 Step cycles

L20:

I

Cause: The main drive is slowed down to cycle speed = 0.

L21:

Cause: The cycle waits until the creep cycle speed + 10 strokes has been

BRAKING MAIN DRIVE

WAITING

reached.

FOR CREEP SPEED

9-l 4

SINUMERIK 805SM-P (PJ)

12.91

L23:

9 Messages of the

Standard Cycles

9.9 Step cycles

I

Cause: The main drive is supposed to reach a low cycle speed. Acknowledgement:

L24:

I

Cause: The eccentric is set to the TDC position.

Cause:

I-=

SWITCH TO CREEP MODE

Please adhere to the manufacturer’s specifications.

APPROACHING TDC POSITION

APPROACHING LDC POSITION

The eccentric is set to the LDC position.

L26:

I

Cause:

I

L27:

I

Cause:

I

DRIVE RUNNING TO BLOCKED POSITION

The eccentric is set to the stroke adjustment position (MD 420 - 439) of the tool to be dismounted (R912 = old stroke adjustment position).

MAIN DRIVE RUNNING TO NEW ADJUSTMENT

POSITION

The eccentric is set to the stroke adjustment position (MD 420 - 439) of the tool to be mounted.

I

9-15

9

Messages

9.9 Step cycles

L28:

of the Standard Cycles

06.93

Cause

Effect:

Cause:

Effect: Remedy:

I

MAIN DRIVE POSITIONING

The eccentric is moved to the preselected position via the brake cam. . TDC (L24) . LDC (L25)

l

old stroke adjustment position (L26)

l

new stroke adjustment position (l-27) The cycle waits until the disengaging of the clutch is acknowlegded by the PLC + the flag (F137.6) is reset (&clutch check)

I

POSITION

NOT FOUND

After two attempts to position it to the stroke adjustment position, the main drive is not within the tolerance window (MD 4430). The message appears only if the main drive is positioned by means of the

brake cam.

The cycle is aborted.

l

Correct the anticipation angle (MD 377).

l

Check the tolerance window (MD 4430).

i l Check the mechanic svstem.

L29:

I

APPROACHING TOOL CHANGE POSITION

Cause: The tool change position (R910) of the current tool is approached with

1

L30:

I

rapid traverse speed.

APPROACHING PUNCH LENGTH

Cause: The stroke adjustment axis (1st axis) is moved to the punch length

R1102 of the new tool with rapid traverse speed. Corrections are taken into account.

9-l 6

6285 440-ONXOZ-OAAl

SINUMERIK 805SM-P (PJ)

12.91

L31:

9 Messages of the Standard Cycles

9.9 Step cycles

I

Cause: All tool change axes are moved simultaneously to their working

I

L32:

Acknowledgement:

L33:

I

TOOL CHANGE

AXIS

TRAVERSING TO

WORKING

POSITION

oosition with rapid traverse soeed. Corrections are taken into account. I

DISMOUNT

The tool is to be dismounted. The axes may be traversed via the direction keys. Adhere to the manufacturer’s specifications.

MOUNT TOOL

TOOL

I

Cause:

I

The same aoolies as for “Dismount tool”. 1

I

L34:

I

Cause: Remedy:

I

L36:

I

Cause: Acknowledgement:

I

SET

DISPLAYED

The displayed stroke length has to be set manually. Acknowledgement + adhere to manufacturer’s specifications.

OPEN TOOL CLAMP

Request to the operator to open the tool clamps. Adhere to the manufacturer’s scecifications.

STROKE LENGTH

6ZB5 440.ONX02-OAAl

9-l 7

9 Messages of the Standard Cycles

9.9 Step cycles

L37:

12.91

I

Cause:

CLOSE TOOL CLAMP

Request to the operator to clamp the tool.

Acknowledgement: Adhere to the manufacturer’s specifications.

L38:

-

MOVE TOOL OUT

Cause: Request to the operator to dismount the tool.

Acknowledgement: Adhere to manufacturer’s specifications.

L39:

m

MOVE TOOL IN

Cause: Request to the operator to mount the tool.

Acknowledgement: Adhere to manufacturer’s specifications.

L40:

UNLOCKING EXCENTER

Cause: For stroke length adjustment, the eccentric is unlocked or the shaft is

blocked.

L41:

I

Cause: Stroke length adjustment: Having been moved with respect to the

LOCKING EXCENTER

shaft, the eccentric is locked aaain.

9-l 8

6285 440.ONX02-OAAl

SINUMERIK 805SM-P (PJ)

12.91

L42:

9 Messages of the Standard Cycles

9.9 Step cycles

Cause: Effect:

Remedy:

Cause: Effect:

Remedy:

I

PROGRAMMED TOOL NUMBER DIFFERENT FROM TOOL

CODE

The selected tool number is different from the number of the mounted toot. The cycle is aborted.

l

Input the correct tool number when changing the tool.

l

Mount the correct tool.

I

DATA TRANSFER:

WAIT TILL INTERFACE IS

AVAILABLE

R parameters are to be output to an external device via the 2nd

interface. The interface is not available at the moment.

6ZB5 440.ONX02.OAAl

9-19

06.93

10 Annex

10.1 Overview of the standard cycles

10.1.1 Technology cycles

10 Annex

10.1 Overview of the standard C!Kle.S

10.1.2 Subroutines for the technology cycles

995 996 997 998 999

File name:

Correction of all tool change axes Prog. no. reserved Counter Calculate current deceleration point General fixed cycles

ELOSZAEH

EBREMSWI

EARALLE

The first sign stands for the language version (e.g. EUMALLE, E for English)

6ZB5 440.ONX02-OAAl

1 o-1

10 Annex

10.1.3 Step cycles

12.91

46 Move stroke adjustment axis to upper position 50 Termination cycle

1 o-2

EU46 EU50

SINUMERIK 805SM-P (PJ)

12.91

10 Annex

10.2 Overviewofthe work memory

10.2

Overview of the work memory

Cam parameters:

1 2 R1005 3 R1009 4 R1013 R1014 R1015

RlOOl R1002

R1006 RlOlO

R1003 R1007 RIO11

R1004 R1008 R1012 R1016

13 14

15 16 R1061 R1062 17 R1065 R1066

R1049 R1053

R1057 R1058 R1059

R1050 R1054 R1055

Start cams for roll feed 1:

18 R1069 R1070

19 R1073 R1074

R1051

R1063 R1067 R1068

R1071 R1075

R1052 R1056 R1060 R1064

R1072 R1076

10-3

10 Annex 06.93

10.2 Overview of the work memory

Start cams for roll feed 2:

20

Cam 18

R1082

General parameters:

R1081

I

R1089

I

1 R1086 1 Reserved for system 1 R1087 1 Operating speed

I I

I31077

Reserved for system Reserved for system

R1078

Cam 19

R1083

R1079 R1080

Cam 20

R1084

I I

1 R1088 1

R1092

I

R1093 R1094 R1095

I

R1096

I

R1097 R1098 R1099

I

Stroke length number

COMMAND tool inspection interval

I

I I

Maximum cycle speed for tool change

I

Reserved for system Reserved for system

Reserved for system

Pre-selected speed

Reserved for system

Stop position of punch

Maximum brake angle

I

1 o-4

SINUMERIK Ei05SM-P (PJ)

06.93

10.2

Overview of the work memory

The following parameters are assigned only if the corresponding axis has been selected.

Selection in ascending order only!

10 Annex

I31112 Fill13

I31114 R1115 R1116 R1117

Correction of number of steps

Correction of maximum number of steps

Position 4th axis

Correction of step size

Correction of number of steps

Correction of maximum number of steps

If further tool parameters are needed, they may be put in here (a maximum of 84 texts and parameters is possible, texts 1 - 84).

General text

R1201

General text

6285 440-ONXOZ-OAAl

10-5

10

Annex

10.2 Overview

of

the work memory

With pressure module option

06.93

RP [MD (850) + 0] RP [MD (850) + l]

RP [MD (850) +2] RP [MD (850) +3] 1) RP [MD (850) +4] 1) RP [MD (850) +5] 1) RP [MD (850) +6] 1)

RP [MD (850) +7] 1) RP [MD (850) +8] 1)

I

RP [MD (850)+9] 1)

RP [MD (850) + IO] 1)

With roll feed option

Selection of press force monitoring Measuring window start

Measuring window end Maximum force sensor 1 Minimum force sensor 1 Maximum force sensor 2 Minimum force sensor 2

Maximum force sensor 3 Minimum force sensor 3 Maximum force sensor 4 Minimum force sensor 4

RP [MD (728)+0] RP [MD (728) + l] RP [MD (728) +2]

RP [MD (728) +3] RP [MD (728)+4] RP [MD (728) + 51

RP [MD (728)+6]

RP [MD (728) + 71

RP [MD (728) + 81

1) if the sensor is selected

2) RF = roll feed axis

Permissible remaining time

Tolerance window

1+2 1+2

Speed

Acceleration

Brake deceleration Start acceleration in % of the tool-dependent axis 1

acceleration End deceleration in % of the tool-dependent axis

deceleration

Effective range of the start acceleration in % of the

tool-dependent axis speed

Effective range of the end deceleration in % of the

tool-dependent axis speed

1

1 O-6

Q Siemens AG 1991 Ail Rights Reserved 6ZB5 440-ONX02-OAAl

SINUMERIK 605SM-P (PJ)

06.93 10

10.2

Overview of the work memory

Annex

I

The following distribution applies only if two roll feeds have been selected.

RP [MD (728)+9] 1)

RP [MD (728) + 121 1) Repetition factor Block 2 1

RP [MD (728) + 151 1)

RP [MD (728)+3XMD(811)+9] 1

RP [MD (728) +3x MD(811) + 101 1 Command acceleration

Repetition factor Block 13 Feed length Feed length

Feed length Block 3 Feed length Block 3

Speed

Block 1 Block 1

J

1

2

1+2

I

1 2

I 2

I

RP [MD (728)+3xMD(811)+11] RP [MD (728)+3xMD(811)+12] Start acceleration in % of the tool-dependent axis

RP [MD (728) + 3 x MD(811) + 131 End deceleration in % of the tool-dependent axis

RP [MD (728) +3x MD(811) + 141 Effective range of the start acceleration in % of the 2

RP [MD (728) + 3 x MD(811) + 151 Effective range of end deceleration in % from the

RP [MD (728)+3XMD(811)+16] 1 RP [MD (728)+3XMD(811)+17] RP [MD (726) + 3 X MD(811) + 181 RP [MD (728) + 3 X MD(811) + 191 I

RP [MD (728) + 3 X MD(811) + 201 1 No. of steps Act. Feed length correction RP [MD (728)+3XMD(811)+211 1 No. of steps Max. Feed length correction

Command braking rate

acceleration

tool-dependent axis speed

Step size

No. of steps Act. Feed length correction No. of steps Max. Feed length correction

Step size

Act. Feed length correction

I

I 1

I I

I 2 I 2

2 2

2

1 1

7) if selected

2) RF

@ Siemens SINUMERIK

= Roll feed axis

1 o-7

805SM-P (PJ)

10 Annex

10.2 Overview of the work memory

If only

one

roll feed has been selected:

06.93

RP [MD (728) + 3 x MD(811) +9]

Step size Act. RP [MD (728)+3XMD(811)+10] No. of steps RP [MD (728)+3XMD(811)+11]

No. of steps Max. Roll feed correction

Act.

Roll feed correction Roll feed correction

With the option “Tool protection”

. . . . .

,:,:,

:,: ,:,:.,,,.,:

. . . . . . . .,.,.

““““.....:.:.:..:,: :.:. :.:.;.,; ,,,,: ~

:8:::;.: ..,‘,‘.:.,,,,:,:,:,:,::.,., :,:,I.:, ~~~~~~

::::::::::,:,:, ~ :,:,,,,:,:, ~ :,:,;: ,::::::::,

..,.,,,:,:,:,: ,:,:,::::::,:,:,:,:,:,:.:,:,,,,.,,

,,.,:,,,,.,,,,,,,,,,,.,,,,,,,:,,,,,:,:,

t,.,. . . . . .

. . .

” “’ ” ““‘:+‘~Y+: : ::,::::::.:.:. .:::::::::::::~,:.:.:.:.:.:.:.:.:.:.: ~~.~.~.~~,~~.,.,~,.~~,~,~,.~~,~,.,~,~,~,~,~,~,~,.,~,~,~, ,(, ,,, ,,, ,( ,,,,,(,,,,,,, (, . ,,,,, ,, .,(,,,,

“i’:‘.‘,..‘.....‘,‘,‘,.,.,.,.,.,.,.~.,.~~;~~.~.~.~.,.,~,.,.,.,.,. ,A., ‘,‘,‘,,.“.‘,:.‘.‘..~,..,.,.,,. . . ,,.,,,,,:,,,, ,,, ,,,,,,, ,,

““““““““““““““‘,‘,‘,‘,‘,‘.‘.‘,‘.’.’,~.’,’.’.”’.‘.‘.‘.‘.‘~’,~,~:~~,~,~.::,~,~,~.~~~:‘:~~~~~~:.:~:. I.. .,.,,,.,.,.,.,.,.,.,.,.,.,..,,.,.,.,.,.,.. ,.

~~~;;l~;i;~~~~~~~~~~~~~~~~~~ :~~~~~~~~~~~~~~~~~~~~~~~~ ~::~:ii::i:~~~:~:~:~~~

v .A\ ,A ,. . . . . . . . . ,.,

.A.::,.:::,::::: :::-

:‘:‘::“: ::‘::::i”:::‘.‘.~.:.:~:.:.:~:.~.:.’.:.:.::::::::,:.:.:.:,:.:.:.:.~:.:.: :.:,:(,:.:::):,:: ::: ::::: ::, ,, _,

“VA”’ “’ “’ “” ‘~9,~~‘~ . ‘.‘.‘.‘..........I.. . . . . . . . . . . . . . . . ,,,,,,/ ‘:“‘.“‘.‘.‘.‘.‘.‘.‘.‘.‘.‘.............,.,’.:... .,.,.. ‘:.:‘.‘.‘.‘:‘:“’ ‘..‘~‘.‘.‘.‘.O’..\/.. .,_.,.,.n.,.,,( ,,

:.:S:.:.:::.‘.:.:.:.:~:.:.:.:.:.,,...:.~:.?:,:...:,: .(...,.,i.,.,.,.,i.,.,.,.,..,.~,, :,: :;, ,:: :,.;,.:.;:.:::::: :. _, .~.,,,,,,,.

~~~~~~~:,....~....1....... .

,.:r;:yp:.:

.,,“““““““.‘.‘.‘.‘.‘.‘.‘,‘.‘.‘.‘.’ .~~...,.,~\.,.i,,,,__~~,,,,,,,,,,,,

::::::‘::::.‘,‘:”

‘~~~...c’.‘o.~A’ .

. . . . . ..C....,,,,,_,,,,,:,;

:::: ,.,~,.,:.~, :,~I+:.~,,,

:,:,,; y.- .‘.

,,, ,.,.,“f,~,.,~.:,.,.... ,.

. . . . . . . . . . . . . . . . . . . . . . . . .

,:::,....

. . . . ..y......:..: . . . . . :.:...,.

‘y:‘;”

. . . . . ‘.,.,.,.“,.‘,.‘,.,.,.,~,~,~,,,,

““““““‘.““‘.““““.

. . . . . . ..~............~.....~~.......,,,,,,,,,,,,,~

‘.“.“.““’

,,,,,,

_,.,,,...,. ,.,. ,.,.,..,,

RP [MD (991)+0]

:i:i:$ii:i:I:i:::B~:~::~:~:.:.:.: . . . . . . . . . . . . . . . .

..,.....,,_,,. ~ ,,,,,,,,_,,,,,,,,,/,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,

,.... ., ,..

.,.,,,_,.,.,..,.(,,,,.l,.,.C,.,.,.,.,.: .,.,.,.,.,.,.,.,.,.,.,.,.,.,., :,,: ,,.,.,. :,:,:.,1,.: ,,.,.,,,,,,., ,,,,,

,,,,,,,.,,.,‘,~,‘,‘,‘,.,.,.,‘,‘.’.’.’.’.’.:’; ,.;,::;,: ~~,‘,.,‘,‘,‘,‘~.,‘,‘,~,.,.,.,.,~,.,.,~,~,.,..,.,.,.,,,,,,

:‘:‘:‘.‘.‘:.~:‘.‘.‘:.‘.‘,‘.‘.‘.‘.’.’.’.’.’.”.’.“.‘,“‘.“.‘.’.’.’.‘.‘.‘.‘.“.‘.‘.“.‘.‘.‘.‘:.‘.’.’.’:‘i:““:‘::‘:‘~‘~:.:~:~:~‘~~:::.:.:.:::::::::::::::::::::~:::::::::::,(:::.: .,.(.,.,.,.,/..i,,,,_ :,:,:,

““““‘““““““““““““‘~““““““~““““““”~””’~’:’:’:’:’.‘.:.~~ ..,..i”.....“““.“..I...I.,.“..,.,~,~,~,~,:~ ,:,:,:::,:,

.“‘,. .‘.““.‘.‘.‘.‘.‘.‘.‘.‘.‘.‘.‘.‘.‘.’,’.’.’.’..,’.’.‘.‘.‘.:,:.:.:.::~::: ::::::: :::::::::::::,:::.:,::::.:.~:.:.:~.:,:.:.:.:,:.:.:.:,:.: .,.,:,: ,:,:f,:,:,:,:,:,:,:C, :.: ,:,::))):.,.,.,,,,,,~,,,,~;,,,,

“““”

., ,, .,.,.,.,.,,..,.,.,o.,~,.,.,.,.,~, ,., ,. .‘:.‘.‘,‘,‘.‘:.‘:.‘.‘.‘:.‘.‘.‘.“’ “’ ‘. ”

/,,,,,,

“.A .....,......... ,,,,. ~,.,.~.,,.,...,..,,.,...~..~.,.,.,~,..,...,,,,,,,,,,,,,.,.,,~,,,,,,,,,,,,,,,,,,,,,,,~,,,,,,,,,,,,,,,,,,,

‘.Z:.:.:.: . . . . . .

. . . .

. ,.,‘, ,(,I,

.~(~~~~~~~~~~~~,~,,,~,~~~‘.,~,....:.~....,:...:.:.:,:~: .,., :.:‘:,:,:::.:‘,: ,..:,: .,,,,_,,,,,,,,

““““‘..‘“.1’1”‘.‘..‘.‘,‘,1,...,:,:.:~:.:~:!~~,~:~~ .,.,,,..,.~\,,,,,\,,

. . . . . . . . . . . . . . . . . ..~.....~...!... ,,.

We

..i...~_~......................~..~...~..........~.....,..,,....:.~

:::::,::,,:::: ,,,,:,,.,,, :,: :,:,:, ~ ,,,,,,,,,,,,,,(,,,,,,,,,.,,,,,,,.,,,,

“::‘:‘:‘:““.‘..... . . . . . . .

,,,,.,:,:,:.:j::,...::.... . . . . . . . . .._.. ::::: . : : . . . . ..l. .:.:.,i:::::i:::iUir.:i:::::ii::::::j:::

“‘“‘.‘“““:::,;,:::,“‘.‘..‘.:.:.~~::.::: “,: ,.,., :,: .,: ,,,. :.: ..,.,..,....,., ,,

.I. . .,

.,.,.,., :.:

‘,‘.‘..‘,:,:,:,:,:,:.:,:,~.;

. . . . . . .

.,,, ,,,.,,,,,,,,/, ,,,/,,,,_,,, ~:i.&fifl$l~$$ ..11.1

RP [MD (991)+ l] Monitoring input RP [MD (991) +2] RP [MD (991) +3] Activate alarm RP [MD (991) +4] 1) RP [MD (991) + 51 1)

Cam

output

Type Monitoring input

1 1

1

1 1 1 1

2 2

1) if selected

2) RF = Roll feed axis

1 O-8

6285 &to-ONX02-OAAl

SINUMERIK 805SM-P

(PJ)

06.93

10 Annex

10.2 Overview of the work memory

RP [MD (991)+ 161’) RP [MD (991)+17] 1)

RP [MD (991)+18] 1) RP [MD (991)+ 191’) RP [MD (991) + 201’) RP [MD (991)+21] 1) RP [MD (991) +22] 1) RP [MD (991)+23] 1) RP [MD (991) + 241’) RP [MD (991) +25] 1) RP [MD (991) + 261’)

RP [MD (991)+27] 1) RP [MD (991) + 281’) RP [MD (991) +29] 1) RP [MD (991)+30] ‘1

Type

Monitoring input Cam

Activate alarm output We

Monitoring input 6 Cam Activate alarm output

Type Monitoring input

Cam Activate alarm output

TYPO Monitoring input

Cam 8

5 5 5

5 6

6 6

7 8

8

RP [MD (991)+31] 1)

Activate alarm output

I

10.3 Survey of the R parameters used

10.3.1 Local R parameters (RSO - R99)

CONTIN. STROKE SINGLE STROKE

TOOL CHANGE

SAFETY STROKE REVERSE R52 Subroutine No. for safety stroke/reverse

R50 R51 Scratchpad parameter for calculation R52 Subroutine No. for axes in starting position R53 R54 R55

>

R56 Local Real:

R56 Scratchpad parameter for tool protection Local Real:

Current command cycle speed (AUTO + , . ..) Local Real

Scratchpad parameter for calculation Scratchpad parameter for tool protection

R50 Current command cycle speed (AUTO + , . ..) R51 Scratchpad parameter for calculation R52 Subroutine No. for axes in starting position

R50 Creep speed

Scratchpad parameters for calculation

1 8 t

2) if selected

@ Siemens

SINUMERIK 805SM-P (PJ)

AG 1991 All

Rights Reserved

6ZB5 440-ONX02-OAAl

1 o-9

10

Annex

10.3.1 Local R

06.93

parameters (R50 - R99)

DPEN PRESS CLOSE PRESS

MANUAL TOOL CHANGE

AUTOMATIC TOOL CHANGE

Tool change general

L 990

Messages ??Werkzeugsicherun LJ?? L 991

Tool change RF L 992

Tool change END

TDC

following

L 994

Local Real: R50 Scratchpad parameter for calculation

R51

Subroutine No. for close Dress

Local Integer: R50 Subroutine No. for the step cycles

R51

Creep speed

Local Integer: R50 Subroutine No. for the step cycles

R51 Code “Entry at the point of interruption”

Local Integer: R50 Scratchpad parameter for calculation

R51

Subroutine No. for user-defined subroutine

Local Real:

R50 Scratchpad parameter for calculation R51 Not assigned

Local Real:

Scratchpad parameters for calculation

Local Integer: R50

Scratchpad parameters for calculation

Local Integer: R50 Interface signal “2. V24 running” F 24.7

R51 Interface signal “1. V24 running” F 24.6

Local Real: R60

Scratchpad parameters for calculation

i I

R64

J

Local Integer: R50

Scratchpad parameters for calculation

:>

R52

Con. axes L 995

Counter L 997

Current brake angle L 998 Gen. operat. modes L 999

Local Real: R50 Move-away distance

R51

Scratchpad parameters for calculation

:>

R53

Local Integer: R60

R63 R66 Input resolution

Local Integer: R50 Scratchpad parameter for calculation

Local Real: R50

Scratchpad parameters for calculation

9

R52 R53 Subroutine No. for user-specific brake angle calculation

10-10

Q Siemens AG 1991 All Rights Resewed

6fB5 440+ONX02-OAAl

SINUMERIK 805SM-P (PJ)

12.91

Local Integer: R50 Creep speed

R51 Current command

103.1 Local R parameters (R50 - R99)

value sensor

3

10

Annex

L22 L23, L27, L36 L28

1 Local Integer: R50 Creep speed

Local Integer: R50 Scratchpad parameter for calculation Local Integer: R50 Anticipation angle

R51

:

R58

L 31

L 32 - L 42 L 43

Local Real:

Local Integer: R50 Scratchpad parameter for calculation Local Integer: R50 Scratchpad parameter for calculation

R51 Scratchpad parameter for calculation

L44 Local Integer: R50

Local Real: R64 Safety distance from SW limit switch

R66 Input resolution

L45

Local Real:

R50 Virtual

),,,chpad parameters for calculation

Scratchpad parameters for calculation

drift value MD 4010

Scratchpad parameters for calculation

10.3.2 Transfer parameters (RO - R49)

Par Real: RO Start parameter

Rl End parameter

6ZB5 440-ONX02-OAAl

Data transfer

>

10-11

10 Annex

10.3.3 Central R parameters

06.93

I3900

Punch stop position during tool change R901 Error flag for positioning program R902 I3903

R910

O.K. code for steps of tool change

Repeat flag for positioning program

Current tool change position

R911 Old stroke number R912 Old stroke adjustment position R913

Loop flag for manual tool change

R914 Loop flag for automatic tool change R915

Current TDC offset

R916 Temporary storage of current stroke No.

lo-12

935: Code: Reversing not ii

SINUMERIK 805SM-P (PJ)

l

06.93

10.33 Central

10 Annex

R parameters

0

I

R942

R943 Constant “a” for brake parabola R944

R945 R946

R948

R949 R950 R951 R952 1 Reserved for stroke length table R953 R954 R9.55

R085 R986 R987

Maximum speed in SINGLE STROKE

Constant “b” for brake oarabola

1 Constant “c” for brake parabola

0:

Carry out safety stroke

946: Safety Stroke lenath Stroke adjustment position TDC offset Maximum speed

Reserved for stroke length table Reserved for stroke length table

Reserved for standard cycles

Reserved for system software Reserved for svstem software

stroke

carried out

(MD 305) (MD 320 *10-s) (MD 321 l 10-s) (MD 322

(MD 40’) (MD 42’)

(MD W (MD 46”)

(MD 48*) (MD 50’) (MD 52’)

-10-3)

I

R988 R989 R990

R991

R992

R993 R994 R996

R997 R998 0:

I3999

Reserved for system software Reserved for system software 1: Correction axis 1

2: 3: Correction axis 3 4: Correction axis 4

;; 3: Speed AUTO - STOP

;;

Increment for manual jog mode with jog keys Tool number in the TOOL CHANGE menu 0: Carry out tool change

996: Tool change finished

Copy/rename buffer for tool number

I

;i

998:

1999: Code for TDC STOP or NC STOP

Correction axis 2

Speed AUTO + Speed AUTO -

Message: Piece count reached (counter 1) Message: Piece count reached (counter 2)

Checking tool data Incorrect tool data Work memory loaded without error Tool data check finished

@ Siemens AG 1991 AI1 Rights Reserved 6285 440.ONX02-OAAl

SINUMERIK EOSSM-P (PJ)

10-13

10 Annex

10.4

Survey of

the

@ commands used in the standard cycles

12.91

10.4 Survey of the @ commands used in the standard cycles

All @ commands which are executable in the controller are described in the NC programming guide.

Write press data

Read press data

Read PLC input*)

Read PLC output?

Read PLC flags7

Write PLC input*)

Write PLC output?

Write PLC flags’)

Select V24 interface Output of R parameters*)

@3eO eVar> <Value>

@380 c Var > Kl c Value 1>

< Value 2 >

@381 CVar > Kl c Value 1>

@382 CVar > Kl <Value 1 >

c Value 2 >

@480 Kl <Value 1s <Value 2 >

c Value >

@481 Kl C Value 1 > C Value 2 >

< Value >

@482 Kl C Value 1 > C Value 2 >

@a20

C Value >

@a27 C Value 1 > c Value 2 >

< Value 3 >

Var:

Destin.: R parameter Value 1: Byte address 0 - 127 Value 2: Bit address 0 - 7

Var:

Destin.: R parameter

Value 1: Byte address 0 - 127 Value 2: Bit address 0 - 7

Var:

Destin.: R parameter

Value 1: Byte address 0 - 255 Value 2: Bit address 0 - 7

Value 1: Byte-address 0 - 127 Value 2: Bit address 0 - 7 Value: Source

Value 1: Byte address 0 - 127 Value 2: Bit address 0 - 7 Value: Source

Value 1: Byte address 0 - 255 Value 2: Bit address 0 - 7 Value: Source

Value: No. of interface Value 1: Channel no. 0 . . . 2

Value 2: Start address Value 3: End address

Input of R parameters”)

@a28 <Value 4 >

Value 4: Data type

0 = no check

10 = R parameter

‘) The writing of PLC signal bits may be disabled via PLC-MD 2002.6. *) The block change may be disabled by machine data bits during the simultaneous input and output of the R

parameters. MD 5147.1 = “1” means read-in disable for @a27. MD 5147.0 = “1” means fead-in disable for @a28.

10-14 .

6285 440-ONX02-OAAl

SINUMERIK 805SM-P

(PJ)

12.91

10.4 Survey of the @ commends

10

used in the standard

Annex

Cycles

Read current ramp command

value for the cycle speed

Read current speed (encoder) Read angle position of main

drive

@36e < Var > Kl Var: Destin.: R parameter

@364 C Var > Kl @363 cVar> Kl

Note:

<Var>:

< Value > :

- Symbol for a numeric variable (R parameter)

- Symbol for a pointer variable [ c Var > 1.

- Constant (e.g. K3)

- Symbol for a numeric variable (R parameter)

- Symbol for a pointer variable [ CVar >I.

10.5 Overview of all cycle-specific

General machine data:

MD 300 MD 301

1 MD 302 1 Brake cam as MD

MD 303

Upper tolerance limit for TDC stop Lower tolerance limit for TDC stop

Minimum cycle speed

Var: Var:

machine data

Weal fdegl

I fmsl I -

[strokes/min]

Destin.: R parameter Destin.: R parameter

I

L 990 MD 304 MD 305

1 MD 320 1 A factor for calculation of brake angle

MD 321 MD 322 MD 330 MD 331 MD 332 Tolerance limit

MD 335 MD:339

MD 340 MD!369

Creep speed Limit soeed SINGLE STROKE

B factor for calculation of brake angle C factor for calculation of brake angle Upper minimum limit for TDC following

Lower minimum limit for TDC followinn

SAFETY STROKE/REVERSING

Step sequence tool change MANU

Step sequence tool change AUTO

[strokeslmin] L 9, L 4, L 21, L 22, L 5 fstrokeslminl L 990

1 [10-G]

u O-61

[lo-31

[WI

[deal

k&t1

-

1 L 994, L 990, L 999 1

L 990, L 999 L 990, L 999

L 994

L4,L5

(L 9)

6 8)

10-15

10

Annex

10.5 Overview of all cycle-specific machine data

12.91

MD 370

MD 371 MD 372 MD 373 MD 374 MD 375 MD 376 MD 377 MD 378

MD 379

MD 380

MD 381

MD 440 MD1460

Subroutine No. for user-specific calculation of the brake angle

Subroutine No. for adjustment cycle

Subroutine No. move axis to starting position Subroutine No. for safety cycle

Subroutine No. for reversing

Subroutine No. for OPEN press Subroutine No. for CLOSE press

Anticipation angle for positioning with brake cams

1 st axis move-away distance for correction as

deceleration step control axis 2nd axis move-away distance for correction

deceleration step control axis 3rd axis move-away distance for correction as

deceleration step control axis 4th axis move-away distance for correction as

deceleration step control axis

Stroke length table

(L 998, L 999)

I-l I

s

-

- I

I

IO.1 degl

I [o*oo1 mm1l

(L 8, L 9)

(L 1, L 2, L 3)

(L 4) o- 5) 6 6) (L 7)

(L 28)

(L995)

I [o-oo1 mm1l

(L995)

* 7

I

-

I

see commissioning lists

3

lo-16

SINUMERIK 805SM-P (PJ)

06.93

Machine data bits:

I

10 Annex

10.5 Overview of all cycle-specific machine data

1

= Single stroke available

0 = Single stroke not available

= Continue automatic tool change at the point

1

of interruption

0 = Disable automatic tool change in case of

error, only enable MANUAL tool change

1

= Safety cycle need not be carried out after

tool change

0 = Safety cycle has to be carried out after tool

change

1 = Write corrected anticipation angle into

MD 377

0 = Do not transfer corrected anticipation angle

= Positioning of main drive via Ml9

1

0 = Positioning of main drive via brake cam

1

= Stroke adjustment: relative positioning

0 = Stroke adjustment: absolute positioning 1 = Counter 1 selected

0 = Counter 1 deselected

7

1

= Counter 2 selected

0 = Counter 2 deselected

(L

6 8)

1,

L990)

(L 28)

6 28)

6 27)

MD 5052 O

2

I-

MD 5055 4

6

t--

7

1 = Set up with TDC stop 0 = Set up without TDC stop

1

= User-specific calculation of brake angle via

L = MD 370

0 = Calculation according to quadratic equation

1

= Carry out TDC following

0 = No TDC following

1

= Counter (RF program)

0 = Counter (strokes)

1

= Set brake cam via MD 302

0 = Set brake cam via cam 17

1

= Counter 1 triggers “cycle stop”

0 = Counter 1 triggers no “cycle stop”

1

= Counter 2 triggers “cycle stop”

10 = Counter 2 triggers no “cycle stop”

(L 3)

L 999, L994

(L 1, l-2)

L 997

6ZB5 440-ONX02-OAAl

IO-17

10 Annex

10.6 Flag area assigned to standard cycles

12.91

10.6

1 F 136.0

I

1 F 136.3

I

I I

1 F 137.4

Flag area assigned to standard cycles

F 136.1 F 136.2

F 136.4

F 136.7 F 137.0 F 137.1

Code CONTINUOUS Code SINGLE STROKE Code SET UP withTDC stop Code SET UP without TDC stop Code REVERSING Code SAFETY STROKE

Code OPEN PRESS Code CLOSE PRESS

Code MANUAL

Code

AUTOMATIC

Main drive not within tolerance range PLC enable (ready for engaging the clutch) Code END OF CYCLE (for cancelling of static flag bits)

TOOL CHANGE

I

(L 4) (L 6)

(L 9) (L 8)

(L 994) (L 1 - L 9) (L 1 - L9)

l 0

I

The following flags are used by the step cycles for standard tool change. If a step cycle is not used, these flags are at the user’s own diposal.

lo-18

6tB5 440-ONX02-OAAl

SINUMERIK 805SM-P

0 0

(PJ)

12.91

10 Annex

10.6 Flag area assigned to standard CyCleS

F 140.4 4th axis of negative direction (only interrogation) F 140.5 Code drift cycle started + engage the clutch

(L w (L 45)

I

@ Siemens

SINUMERIK 805SM.P (PJ)

10-19

siemens 805SM-P User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preliminary Remarks

Contents

1 General Remarks

12.91 2 Press Data

3 Central R Parameters

3.1 General remarks

3.2 R parameter area R800 - R899

3.3 R parameter area R900 - R984

R parameter area R985 - R999

3.6 Input buffer / R parameter area R1500 - R1999

Tool data memory / R parameter area R2000 - R19999

4 Channel-Specific R Parameters

4.1 Local parameters R50 - R99

4.2 Transfer parameters RO - R49

5 Overview of the Data Exchange Within the Control

12.91 6 Fixed cycles

6.1 Continuous stroke

6.1.1 Description

6.1.2 Start-up checklist

6.1.3 Flowchart

6.2.1 Description

6.2 Single stroke

6.2.2 Start-up checklist

6.2.3 Flowchart

6.3 Set up - Main drive JOG-INC mode

6.3.1 Description

6.3.2 Start-up checklist

6.3.3 Flowchart

6.4 Common subroutines

TDC following L 994

6.4.2 Correction of all tool change axes (L 995)

6.4.3 Calculation of the brake angle L 998

7 Basic Press Functions

7.1 Safety stroke

7.1 .l Description

7.1.2 Start-up check list

7.1.3 Codes for the PLC:

7.1.4 Flowchart

7.2 Reversing

7.2.1 Description

7.2.2 Start-up check list

7.2.3 Codes for the PLC:

7.2.4 Flowchart

Open press

7.3.1 Description

Codes for the PLC

7.3.3 Flowchart .------

7.4 Close press

7.4.1 Description

Codes for the PLC

7.4.3 Flowchart

8 Tool Change

8.1 General remarks

8.1 .l Description

8.1.2 Flowchart

8.2 Manual tool change - jog main drive (L 9)

8.2.1 Description

8.2.2 Flowchart

8.3 Automatic tool change (L 8)

8.3.1 Description

Example for the implementation of an automatic tool change

Automatic stroke adjustment during the tool change

8.3.4 Flowchart

8.4 Description of the step cycles

CONTINUOUS STROKE cycle

Messages of the Standard Cycles

9.2 SINGLE STROKE cycle

SET UP cycle

REVERSING cycle

9.5 SAFETY STROKE cycle

9.6 CLOSE PRESS cycle

9.8 GENERAL TOOL CHANGE cycle

9.8.1 MANUAL TOOL CHANGE

9.8.2 AUTOMATIC TOOL CHANGE

9.9 Step cycles

10.1 Overview of the standard cycles