siemens 805SM-P User Manual

Preliminary Remarks

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

General Documentation

User Documentation

Manufacturer Documentation and

Service Documentation

The following manuals are part of the Manufacturer Documentation:

Instruction Manual

Interface Description Part

Interface Description Part 2: Connection Conditions

PLC Programming Guide

Standard Operating Guide

NC Programming Guide

Roll Feed Module, Planning Guide

Pressure Control Module, Planning Guide

Cycles, Planning Guide

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.

General Remarks

Press Data

Central R Parameters

Channel-Specific R Parameters

Overview of the Data Exchange Within the Control

4 .

Fixed Cycles

Basic Press Functions

Tool Change

Messages of the Standard Cycles

I I

Annex

Page

1 General Remarks . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Central R Parameters . . . . . . . . . . . , . . , . . . . , . . . . . . . . . . . . . . .

3.1 General remarks

3.2 R parameter range R800 - R899

3.3 R parameter range R900 - R984

3.4 R parameter range R985 - R999

3.5 Work memory / R parameter range RlOOO - R1499

3.6 Input buffer / R parameter range R1500

3.7 Tool data memory / R parameter range R2000 - Rl9999

4 Channel-Specific R Parameters

4.1

4.2

5 Overview of the Data Exchange Within the Control . . . . . . . s . . . .

Press Data ..,................,..,....................

....................................... 3-l

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

............................ 3-l

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

Local parameters R50 - R99 Transfer parameters RO - R49

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

.............................. 4-l

. R1999

............... 3-2

................. 3-2

...........

l-l

2-l

3-l

3-2

4-l 4-l

5-1

6 Fixed Cycles . . . . . . . . . . . . . . . . . , . . . . . . , . . . . . . . . . . . . . . . .

6.1 Continuous stroke

6.1 .l Description

6.1.2 Start-up checklist

6.1.3 Flowchart

6.2 Single stroke

6.2.1 Description

6.2.2 Start-up checklist

6.2.3 Flowchart

6.3 Set up - Main drive JOG-INC mode

6.3.1

6.3.2

6.3.3 Flowchart

6.4 Common subroutines

6.4.1 TDC following L994

6.4.2 Correction of all tool change axes L995

6.4.3 Calculation of the brake angle L 998

Description Start-up checklist

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

6-1

6-l 6-l 6-2 6-4 6-7 6-7

6-8 6-l 0 6-l 3 6-l 3 6-14 6-l 6 6-l 9 6-l 9 6-20 6-21

Basic Press Functions

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

7-l

7.1

7.1.1

7.1.2

7.1.3

7.1.4

7.2

7.2.1

7.2.2

7.2.3

7.2.4

7.3

7.3.1

7.3.2

7.3.3

7.4

7.4.1

7.4.2

7.4.3

8.1

8.1.1

8.1.2

8.2

8.2.1

8.2.2

8.3

8.3.1

8.3.2

8.3.3

8.3.4

8.4

Safety stroke Description Start-up checklist CodesforthePLC Flowchart

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

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

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

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

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

Reversing ............................................

Description Start-up checklist CodesforthePLC

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

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

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

Flowchart .............................................

Open press

Description

CodesforthePLC

Flowchart

Close press

Description

Codesforthe PLC

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

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

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

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

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

Flowchart .............................................

Tool Change ..,.....,.....,...........................

General remarks

Description

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

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

Flowchart .............................................

Manual tool change - jog main drive (L9) Description Flowchart

Automatic tool change (L8)

Description

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

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

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

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

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

Example for the implementation of an automatic tool change Automatic stroke adjustment during the tool change

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

Flowchart .............................................

Description of the step cycles

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

........

7-l 7-l 7-l 7-l 7-2 7-4

7-4 7-4 7-4 7-5 7-7 7-7 7-7 7-7 7-8

7-8 7-8 7-8

8-l

8-l 8-l 8-2 8-6 8-6 8-7 8-8 8-8

8-8

8-9 8-11 8-12

9.1

9.2

9.3

9.4

9.5

9.6

9.7

9.8

9.8.1

9.8.2

9.9

Messages of the Standard Cycles CONTINUOUS STROKE cycle

SINGLE STROKE cycle TOOL CHANGE cycle REVERSING cycle

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

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

SAFETY STROKE cycle CLOSE PRESScycle OPEN PRESScycle

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

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

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

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

GENERAL TOOL CHANGE cycle MANUAL TOOL CHANGE

AUTOMATIC TOOL CHANGE

Step cycles

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

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

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

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

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

9-l

9-l 9-4 9-6 9-9

9-l 0 9-11 9-11

9-12 9-13 9-14 9-14

10 Annex .,....,........................................

lo-l

10.1

10.1.1

10.1.2

10.1.3

10.2

10.3

10.3.1

10.3.2

10.3.3

10.4

10.5

10.6

Overview of the standard cycles Technology cycles

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

Subroutines for the technology cycles Step cycles

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

Overview of the work memory Survey of the R parameters used Local R parameters Transfer parameters

Central R parameters

(MO

- R99)

(RO - R49)

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

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

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

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

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

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

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

Survey of the @ commands used in the standard cycles Overview of all cycle-specific machine data Flag area assigned to standard cycles

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

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

...........

10-l 10-l 10-l 10-2

103 10-9 1 o-9

10-11

10-12 10-14 10-15 lo-18

06.93

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)

. outputs

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

R parameters (FE 61/62).

10,

Annex)

Exchange of information with the NC is carried out via:

Press data (via @ commands, see installation lists)

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 .

+ 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

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

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

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

(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-----------

6ZB5 440.ONX02-OAAl

12.91 6 Fixed cycles

6.1 Continuous stroke

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

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

calculation of brake angle for TDC stop

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:

Machine data bits

12.91

MD 5015 bit 0 = 0

MD 5051 bit 1 = 0

MD 5052 bit 2 = 0

MD 5052 bit 3 = 0

MD 5055 bit 4 = 0

MD 5055 bit 6 = 0

MD 5055 bit 7 = 0

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

-_-_-_ J

iNTRY SECTION for operating mode CONTINUOUS STROKE (Ll)

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

---

.------

aborts the cycle

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)

12.91 6 Fixed Cydes

6.13 Flowchart

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

from entry

section

, R991 I ?

---*---I

-mm----

l ,

R993 I 7

--m----1

CONTIN. ST*; ~~UNNINO 1

+ + Read out operating

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 Terminate

CONTIN. STROKE RUNNING/

SPEED LIMITATION

cycle

section i: Program

yes

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

6-6

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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:

manual triggering of cycle stop

reaching the preset batch size (counter 1 or 2)

triggering of emergency stop

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

The following functions are carried out by this cycle:

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

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

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

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

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

calculation of brake angle for TDC stop

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:

Machine data bits:

12.91

MD 5015 bit 0 = 0

MD 5024 bit 6 = 0

3D-interpolation not possible

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

Machine data values:

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

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

-,-.-.A

ENTRY SECTION for operating’tnode SINGLE STROKE (L2)

I = Interrog.

1 = Cycle mess. i

start

SINGLE STROKE code

- SINGLE STROKE STARTED

06.93

,----7

PLC flag

-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

-----

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?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

------.

, MD 5052.2 I

------A

--.-mm*

R990

-.---.A

:;:::;.:

,:,q::

%$ Correction of ‘i.jr:i;

.,. :,.,j

,:>:::’

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

, R992 ,

-.-e---1

---e-w MD 5055.6 I

; MD 5055.7 1

----m-1

.‘:I :y:j ,::: :

‘;;,I; ,t;,9;;m ;jj.

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

wait

counter ::jj:,

-zivr = ;-FyLFj

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

6-12

6285 440.ONX02-OAAl

SINUMERIK 805SM-P (PJ)

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:

Set up without TDC stop

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

The operating mode is terminated by:

manual triggering of the cycle stop

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

triggering of emergency stop

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

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

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

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:

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

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

calculation of brake angle for TDC stop

TDC following

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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:

Machine data bits:

12.91

MD5015bitO = 0

MD 5052 bit 0 = 0

MD 5052 bit 2 = 0

3D-interpolation not possible

3D-interpolation selected Set up without TDC stop

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

A, B, and C

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

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 2

MD 5055 bit 7 = 0

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

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)

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