siemens 828D User Manual

SINUMERIK 828D

Turning

Control system overview

for machine tools' sales people

09/2009

Preface

	Introduction	1
	System overview	2
	CNC operation in manual
		3
	mode (JOG)
	Tool Management	4
	User memory	5
	Data transfer	6
	Graphical support functions	7
	CNC operation in automatic
		8
	mode (AUTO)
	CNC performance capability
		9
	and optimization functions
	CNC programming methods	10
	Simulation	11
	CNC technology cycles	12
	Complete machining	13
	PC software	14
	Option list for the
		15
	SINUMERIK package
	Summary of the highlights	16

Legal information

Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION

with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.

CAUTION

without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

NOTICE

indicates that an unintended result or situation can occur if the corresponding information is not taken into account.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel

The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation for the specific task, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens products

Note the following:

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be adhered to. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG		Copyright © Siemens AG 2009.
Industry Sector	09/2009	Technical data subject to change

Postfach 48 48 90026 NÜRNBERG GERMANY

Preface

Scope of validity

This document provides you with an overview of the range of functions included in the SINUMERIK 828D Version 2.6 operator panel controller for turning machines.

The document is focusing on vendors and dealers of machine tools.

Organization of the information

●Of the varied functional features of the SINUMERIK products, only those are listed which are of direct value to the machine user.

●All functions contained in the machine's basic configuration will be identified as follows:

Basic configuration

●All functions not contained in the machine's basic configuration will be identified as follows:

Option: ...

●You can find a summary of the most important unique selling points of the SINUMERIK 828D in the chapter "Summary of highlights".

●For information on marketing options through the machine manufacturer, please see the technical description of each machine.

Subject to change without prior notice

Contact person at machine manufacturer

Marketing & Sales
Phone:	+49 xxx xxx
Fax:	+49 xxx xxx
Email:	[e-mail]
Service
Phone:	+49 xxx xxx
Fax:	+49 xxx xxx
Email:	[e-mail]
Homepage:
http://www.machinemanufacturer.com

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Preface

Contact person at Siemens

Country	Name	e-mail	Phone
Argentina	Santiago Fernandez Veron	[e-mail]	+54	(11) 4738-3348
Belgium	Pieter Vanderhaeghen	[e-mail]	+32	253-69697
Bosnia and Herzegovina	Helmut Stralz	[e-mail]	+43	51 707 29115
Brazil	Gustavo Marino	[e-mail]	+ 55 (11) 3908-1752
Bulgaria	Helmut Stralz	[e-mail]	+43	51 707 29115
China	Yang Yifei	[e-mail]	+86	10 64765236
Denmark	Stefan Karlstrand	[e-mail]	+46	500 774-148
Germany (Headquarters)	Gerhard Micka	[e-mail]	+49	9131 98 3314
Finland	Juha Meriaho	[e-mail]	+358		50 59 26181
France	François Chevalier	[e-mail]	+33	(0)1 49 22 35 19
Great Britain	Tony Bennison	[e-mail]	+44	780 882 2054
India	Narayanan Shankar	[e-mail]	+91	99451 88837
Indonesia	Andy Lesmono	[e-mail]	+62	21 7918 6001
Italy	Nicodemo Megna	[e-mail]	+39	335 6328927
Canada	Sagar Arora	[e-mail]	[phone]
Korea	Kim Sung Hyun	[e-mail]	+ 82 55 268 1906
Croatia	Matjaz Mlinsek	[e-mail]	+386		1 47 46 152
Lithuania	Juha Meriaho	[e-mail]	+358		50 59 26181
Malaysia	Ridwan Aziz	[e-mail]	+603		5621 6126
Mexico	Marco Lopez	[e-mail]	+52	(55) 5328-2000
Netherlands	Frank de Korte	[e-mail]	+31	70 333 1568
Norway	Stefan Karlstrand	[e-mail]	+46	500 774-148
Austria	Helmut Stralz	[e-mail]	+43	51 707 29115
Portugal	Molaguero Godoy	[e-mail]	+34	670929001
Romania	Matjaz Mlinsek	[e-mail]	+386		1 47 46 152
Russia	Alexander Kudinov	[e-mail]	[phone]
Sweden	Stefan Karlstrand	[e-mail]	+46	500 774-148
Switzerland	Hans-Peter Kueng	[e-mail]	+41	585 581 524
Serbia Montenegro	Helmut Stralz	[e-mail]	+43	51 707 29115
Slovakia	Matjaz Mlinsek	[e-mail]	+386		1 47 46 152
Slovenia	Matjaz Mlinsek	[e-mail]	+386		1 47 46 152
Spain	Molaguero Godoy	[e-mail]	+34	670929001
Taiwan	Jerry Lin	[e-mail]	+886		4 2261 9225
Thailand	Rajeev Madhyastha	[e-mail]	[phone]
Czech	Eva Klocova	[e-mail]	+420		605726829
Turkey	Taner Okayi	[e-mail]	+90	216 459 3906
Hungary	Istvan Joo	[e-mail]	+36	1 471 1598
USA	Jon Cruthers	[e-mail]	[phone]
Vietnam	Pham-Vu Trung	[e-mail]	+84	908 346 534

Homepage:

For further information please visit ...

http://www.siemens.de/cnc4you

http://www.automation.siemens.de/doconweb

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Table of contents

	Preface	......................................................................................................................................................	3
1	Introduction................................................................................................................................................		9
	1.1	Application ......................................................................................................................................	9
	1.2 ..........................................................................................................................	Machine spectrum	9
2	System ......................................................................................................................................overview		11
	2.1 .......................................................................................................................	SINUMERIK 828D	11
	2.2 .............................................................................................	SINUMERIK 828D operator panels	12
	2.3 ..................................................................................................................	Performance versions	13
	2.4 .........................................................................................................	Maintenance - free operation	13
	2.5 ................................................................................................	Languages of operating software	14
3	CNC operation ....................................................................................................in manual mode (JOG)		15
	3.1 .....................................................................................................................	TSM universal cycle	15
	3.2 ..............................................................................................................................	Stock removal	16
	3.3 ................................................................................................................................	Measure tool	17
	3.4 ......................................................................................................................	Measure workpiece	18
	3.5 .................................................................................................................................	Work offsets	19
4	Tool Management....................................................................................................................................		21
	4.1 .....................................................................................................................................	Tool table	21
	4.2 ........................................................................	Monitoring of tool life and quantity of workpieces	22
	4.3 .......................................................................................................................	Replacement tools	22
5	User memory...........................................................................................................................................		23
	5.1 ........................................................................................................	Buffered CNC work memory	23
	5.2 ..................................................................................	Memory expansion by compact flash card	23
6	Data transfer............................................................................................................................................		25
	6.1 .....................................................................................................................................	Interfaces	25
	6.2 ........................................................................................................................	Program manager	26
	6.3 ...................................................................................................	Data transfer by serial interface	27
	6.4 .................................................	Data transfer using a USB memory stick or compact flash card	27
	6.5 .........................................................................................................................	RCS Commander	28
	6.6 .....................................................................................................................	Ethernet networking	29
	6.7 ..............................................................................................................................	Easy Message	29

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Table of contents

7	Graphical support functions.....................................................................................................................		31
	7.1	Animated Elements.....................................................................................................................	31
	7.2	Onboard documentation..............................................................................................................	32
8	CNC operation in automatic mode (AUTO)..............................................................................................		33
	8.1	Block search................................................................................................................................	33
	8.2	Program control...........................................................................................................................	34
	8.3	Simultaneous recording ..............................................................................................................	35
9	CNC performance capability and optimization functions..........................................................................		37
	9.1	80bit NANO FP accuracy..............................................................................................................	37
	9.2	Jerk limitation..............................................................................................................................	38
	9.3	Dynamic feedforward control......................................................................................................	38
10	CNC programming methods....................................................................................................................		39
	10.1	Overview of programming methods............................................................................................	39
	10.2	programGUIDE and SINUMERIK CNC programming................................................................	40
	10.2.1	Introduction .................................................................................................................................	40
	10.2.2	Program editor ............................................................................................................................	40
	10.2.3	Languages ..................................................................................................................................	41
	10.2.4	programGUIDE input support......................................................................................................	42
	10.3	ShopTurn.....................................................................................................................................	43
	10.3.1	Introduction .................................................................................................................................	43
	10.3.2	Sequence editor..........................................................................................................................	43
	10.3.3	Interlinking of sequences ............................................................................................................	44
	10.3.4	Broken-line graphics ...................................................................................................................	45
	10.4	Online ISO dialect interpreter......................................................................................................	46
11	Simulation................................................................................................................................................		47
	11.1	2D simulation ..............................................................................................................................	47
	11.2	3D simulation ..............................................................................................................................	48
12	CNC technology cycles............................................................................................................................		49
	12.1	CNC technology cycles for programGuide and ShopTurn..........................................................	49
	12.2	Highlights of machining cycles....................................................................................................	50
	12.2.1	Stock removal along contour with blank contour........................................................................	50
	12.2.2	Engraving cycle...........................................................................................................................	51
	12.2.3	Counterspindle cycle...................................................................................................................	52
	12.2.4	Residual material detection during turning..................................................................................	53
	12.2.5	Detection of residual material when milling.................................................................................	54
	12.2.6	Process measurements for workpieces and tools......................................................................	55
13	Complete machining................................................................................................................................		57
	13.1	End face machining (TRANSMIT)...............................................................................................	57
	13.2	Peripheral surface machining (TRACYL)....................................................................................	58

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			Table of contents
14	PC software.............................................................................................................................................		59
	14.1	CAD reader for PC.......................................................................................................................	59
	14.2	SinuTrain......................................................................................................................................	60
	14.3	Computer-based training .............................................................................................................	60
15	Option list for the SINUMERIK package ..................................................................................................		61
16	Summary of the highlights.......................................................................................................................		63
	Index	........................................................................................................................................................	65

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Introduction

1

1.1Application

With the SINUMERIK 828D you get a CNC system which is customized for the application in turning and milling machines. CNC, PLC, user interface and axis control for six CNC measuring circuits are all combined within a single compact unit. The controller provides comprehensive CNC functions such as support of counterspindle machining and a powerful tool management capability. The SINUMERIK 828D offers comprehensive turning capabilities specially for turning machines as well as drilling and milling operations for face machining and peripheral surface machining of workpieces. The performance of the controller and the new motion control allow you to achieve mirror finish surfaces with a minimum machining time.

The SINUMERIK 828D has eliminated all unnecessary functionalities; this is particularly noticeable in the graphical user interface. This means it is optimally suitable for use in the workshop. Operation, programming and maintenance can quickly be mastered without any heavy training requirement.

●Optimum operator guidance thanks to CNC input screens with animated elements

●Easy data exchange thanks to USB, CF and Ethernet interfaces on the panel front

●Integral mobile radio modem for optimum process monitoring via mobile phone

1.2Machine spectrum

The SINUMERIK 828D is perfectly tailored for equipping horizontal and vertical turning centers with one machining channel and up to eight CNC measuring circuits,

Apart from the main spindle and the geometry axes (X axis and Z axis), further machine units can also be operated:

●CNC controlled turret

●Tailstock axis (with travel to fixed stop)

●Driven tools and C axis mode for end face and peripheral surface machining

●Y axis (orthogonal or oblique)

●Counterspindle with synchronous spindle function for complete machining of workpieces

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Introduction

1.2 Machine spectrum

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System overview

2

2.1SINUMERIK 828D

The SINUMERIK 828D is a complete unit comprising screen, CNC keyboard and CNC electronics.

The motors can be easily connected to the digital drives via DRIVE-CLiQ. In combination with the modular structure of the SINAMICS S120 drive system, this design is conceived to ensure very simple and rugged installation with minimum wiring overhead.

The performance range of the controller has been selected to meet the requirements of standardized turning and milling machines - from one-off production runs to industrial scale manufacture.

●Digital drive controller

●Modular design for drive controller and power unit

●Up to 6 axes/spindles for milling applications

●Intelligent control functions meeting the highest standards of machining technology

Highlights

●Maximum reliability due to compact design with few interfaces

●The same hardware for milling and for turning, leading to optimum spare parts management.

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System overview

2.2 SINUMERIK 828D operator panels

2.2SINUMERIK 828D operator panels

The operator panel consists of a hard-wearing die-cast magnesium alloy and is available in two versions, for horizontal and vertical mounting.

●10.4" TFT color display

●Integrated QWERTY full CNC keyboard with short-stroke keys

●USB, CF card and Ethernet interfaces on the operator panel front

Highlights

●All relevant functions at a glance, thanks to horizontal and vertical softkeys

●Simple data handling using easily accessible sockets for USB and compact flash card storage media on the front panel

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System overview 2.3 Performance versions

2.3Performance versions

The 828D is available in two performance versions: the PPU 260/261 and the PPU 280/281. These allow optimum matching to the demands of the machine.

Scope of performance	PPU 260 / 261		PPU 280 / 281
Minimum block cycle time	~6 ms		~6 ms
CNC work memory	3 MB		5 MB
Maximum number of
tools/cutting edges	128/256	256/512
Maximum number of	6	8
axes/spindles

Highlights

●Outstanding performance even with the standard package

●Complete machining with counterspindle with expansion stage PPU 280/281

2.4Maintenance-free operation

The SINUMERIK 828D offers maintenance-free operation:

●High reliability, as the SINUMERIK 828D does not have a hard disk, battery or fan

●Storage of part programs on a NVRAM, so no loss of data even during an extended loss of power

Highlight

● Highest machine availability thanks to reliable hardware

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System overview

2.5 Languages of operating software

2.5Languages of operating software

Basic configuration

The following languages are available on the operator interfaces of the SINUMERIK 828D. Pressing the CTRL + L keys or by softkey switching you can toggle between between languages.

●Chinese Simplified

●Chinese traditional

●German

●English

●French

●Italian

●Korean

●Portuguese

●Spanish

on request

Language extensions for the HMI sl operating software are available on request for the following languages:

●Danish

●Finnish

●Japanese

●Dutch

●Polish

●Romanian

●Russian

●Swedish

●Slovakian

●Czech

●Turkish

●Hungarian

Highlights

●Operator interface in your language so that the CNC is easy to learn and safe to operate

●All languages are available on the control and can online be changed

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CNC operation in manual mode (JOG)

3

3.1TSM universal cycle

Basic configuration

A universal cycle is available in the setup for the most commonly used machine functions:

●Tool change with direct access via the tool table (T)

●Spindle speed and direction (S)

●M functions (M)

●Activation of work offsets

Highlight

● Take-over and change-in tools directly from the tool table

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CNC operation in manual mode (JOG) 3.2 Stock removal

3.2Stock removal

Basic configuration

Stock removal is conveniently available in the set-up. Soft collet chucks can, for example, be turned with this cycle.

The following parameters can be specified:

●Roughing or finishing

●Undercut for soft collet chucks

Highlight

● Preparation of workpiece or collet chuck without having to create a part program

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CNC operation in manual mode (JOG) 3.3 Measure tool

3.3Measure tool

Basic configuration

The tool compensation value can be directly determined in the machine set-up.

The following variants are supported:

●Touch chuck

●Determine lengths via reference diameter

●Tool measuring probe (tooleye) or magnifier

Highlight

● User-friendly functions for determining the tool dimensions directly in the machine

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CNC operation in manual mode (JOG) 3.4 Measure workpiece

3.4Measure workpiece

Basic configuration

The workpieces can be measured as follows: ● Reference tool

Highlight

● Fast zero point definition by dialog

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CNC operation in manual mode (JOG) 3.5 Work offsets

3.5Work offsets

Basic configuration

The following adjustable work offsets are available to you:

●A basic offset

●Maximum of 99 work offsets (G54, G55 ...)

●Each work offset with axis rotation and fine offset

Highlights

●Flexible machining due to great number of adjustable work offsets

●Unlimited possibilities of programmable work offsets

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CNC operation in manual mode (JOG) 3.5 Work offsets

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