840D

siemens 840D Users Guide

User's Guide 11/2002 Edition

Measuring Cycles SINUMERIK 840D/840Di/810D

Part 1: User's Guide

SINUMERIK 840D/840Di/810D

Measuring Cycles

User's Guide

Introduction

Description of Parameters

Measuring Cycle Auxiliary

Programs

Measuring in JOG

Measuring Cycles for

Milling and Machining

Centers

Valid for

Control Software version

SINUMERIK 840D 6 SINUMERIK 840DE (export version) 6 SINUMERIK 840D powerline 6 SINUMERIK 840DE powerline 6 SINUMERIK 840Di 2 SINUMERIK 840DiE (export version) 2 SINUMERIK 810D 3 SINUMERIK 810DE (export version) 3 SINUMERIK 810D powerline 6 SINUMERIK 810DE powerline 6

Measuring Cycles for

Turning Machines

Miscellaneous Functions

Part 2: Description of

Functions

Hardware, Software and

Installation

Supplementary

Conditions

Data Description

Examples

11.02 Edition

Data Fields, Lists

Appendix

Contents 11.02

SINUMERIK® Documentation

Printing history

Brief details of this edition and previous editions are listed below.

The status of each edition is shown by the code in the "Remarks" column.

Status code in the "Remarks" column:

A .... New documentation.

B .... Unrevised edition with new Order No.

C .... Revised edition with new status.

If factual changes have been made on the page since the last edition, this is indicated by a new edition coding in the header on that page.

Edition Order No. Remarks

09.95

03.96

6FC5298-3AA01-0BP0 6FC5298-3AA70-0BP1

A C

12.97 6FC5298-4AA70-0BP0 C

12.98 6FC5298-5AA70-0BP0 C

08.99 6FC5298-5AA70-0BP1 C

06.00 6FC5298-5AA70-0BP2 C

10.00 6FC5298-6AA70-0BP0 C

09.01 6FC5298-6AA70-0BP1 C

11.02 6FC5298-6AA70-0BP2 C

This manual is included in the documentation available on CD ROM (DOCONCD) Edition Order No. Remarks

11.02 6FC5 298-6CA00-0BG3 C

Trademarks

SIMATIC POSMO be trademarks which, if used by third parties, could infringe the rights of their owners.

Further information is available on the Internet under: http:/www.ad.siemens.de/sinumeri k

This publications was produced with WinW ord V 8.0 and Designer V 7.0. The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved.

, SIMATIC HMI®, SIMATIC NET®, SIROTEC®, SINUMERIK®, SIMODRIVE® and SIMODRIVE

are registered trademarks of Siemens AG. Other product names used in this documentation may

Other functions not described in this documentation might be executable in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing.

We have checked that the contents of this document correspond to the hardware and software described. Nonetheless, differences might exist and therefore we cannot guarantee that they are completely identical. The information contained in this document is, however, reviewed regularly and any necessary changes will be included in the next edition. We welcome suggestions for improvement.

Subject to change without prior notice

Order No. 6FC5298-6AA70-0BP2 Printed in Germany

Siemens Aktiengesellschaft

11.02 Contents

Contents

Part 1: User's Guide

Introduction 1-15

1.1 Basics.............................................................................................................................. 1-16

1.2 General preconditions ..................................................................................................... 1-17

1.3 Plane definition................................................................................................................ 1-19

1.4 Suitable probes ............................................................................................................... 1-20

1.5 Workpiece probe, calibration tool in TO memory............................................................ 1-22

1.5.1 Workpiece probe in TO memory for milling machines and machining centers ........ 1-22

1.5.2 Workpiece probe, calibration tool in TO memory on turning machines .................... 1-23

1.6 Measuring principle ......................................................................................................... 1-25

1.7 Measuring strategy and compensation value calculation for tools with automatic

tool offset......................................................................................................................... 1-28

1.8 Parameters for checking the dimension deviation and compensation............................ 1-31

1.9 Effect of empirical value, mean value and tolerance parameters ................................... 1-37

1.10 Reference points on the machine and workpiece ........................................................... 1-38

1.11 Measurement variants for milling machines & machining centers .................................. 1-39

1.11.1 Workpiece measurement for milling machines......................................................... 1-39

1.11.2 Measurement variants for fast measurement at a single point ................................. 1-40

1.11.3 Measurement variants for workpiece measurement paraxial ................................... 1-40

1.11.4 Measurement variants for workpiece measurement at random angles .................... 1-42

1.11.5 Measuring a surface at a random angle ................................................................... 1-43

1.12 Measurement variants for lathes.................................................................................... 1-44

1.12.1 Tool measurement for lathes .................................................................................... 1-44

1.12.2 Workpiece measurement for turning machines: Single-point measurement............ 1-45

1.12.3 Workpiece measurement for turning machines: Two-point measurement ............... 1-47

1.13 Measuring cycles interface............................................................................................. 1-48

1.13.1 Displaying measuring result screens ........................................................................ 1-48

1.13.2 Setting parameters.................................................................................................... 1-50

Description of Parameters 2-53

2.1. Parameter concept for measuring cycles........................................................................ 2-54

2.2 Parameter overview ........................................................................................................2-56

2.2.1 Input parameters ....................................................................................................... 2-56

2.2.2 Result parameters..................................................................................................... 2-57

Contents 11.02

2.3 Description of the most important defining parameters...................................................2-58

2.3.1 Measurement variant: _MVAR ..................................................................................2-58

2.3.2 Number of measuring axis: _MA............................................................................... 2-61

2.3.3 Tool number and tool name: _TNUM and _TNAME .................................................2-62

2.3.4 Offset number _KNUM.............................................................................................. 2-63

2.3.5 Offset number _KNUM with flat D number structure................................................. 2-65

2.3.6 Variable measuring speed: _VMS............................................................................. 2-66

2.3.7 Compensation angle position for monodirectional probe: _CORA............................ 2-66

2.3.8 Tolerance parameters: _TZL, _TMV, _TUL, _TLL, _TDIF and _TSA....................... 2-67

2.3.9 Multiplication factor for measurement path 2a: _FA..................................................2-68

2.3.10 Probe type/Probe number: _PRNUM ........................................................................2-69

2.3.11 Empirical value/mean value: _EVNUM ..................................................................... 2-70

2.3.12 Multiple measurement at the same location: _NMSP ...............................................2-71

2.3.13 Weighting factor k for averaging: _K .........................................................................2-71

2.4. Description of output parameters ...................................................................................2-72

2.4.1 Measuring cycle results in _OVR ..............................................................................2-72

2.4.2 Measuring cycle results in _OVI ................................................................................2-73

Measuring Cycle Auxiliary Programs 3-75

3.1 Package structure of measuring cycles.......................................................................... 3-76

3.2 Measuring cycle subroutines ..........................................................................................3-77

3.2.1 CYCLE103: Parameter definition for measuring cycles ............................................3-78

3.2.2 CYCLE116: Calculation of center point and radius of a circle................................... 3-79

3.3 Measuring cycle user programs .....................................................................................3-81

3.3.1 CYCLE198: User program prior to calling measuring cycle ......................................3-81

3.3.2 CYCLE199: User program at the end of a measuring cycle .....................................3-82

3.4 Subpackages..................................................................................................................3-83

Measuring in JOG 4-85

4.1 General preconditions .................................................................................................... 4-86

4.2 Workpiece measurement ............................................................................................... 4-89

4.2.1 Operation and function sequence of workpiece measurement .................................4-90

4.2.2 Measuring an edge.................................................................................................... 4-91

4.2.3 Measuring a corner ................................................................................................... 4-92

4.2.4 Measuring a hole .......................................................................................................4-94

4.2.5 Measuring a spigot .................................................................................................... 4-95

4.2.6 Calibrating the measuring probe ...............................................................................4-96

4.3 Tool measurement .........................................................................................................4-99

4.3.1 Operation and function sequence of tool measurement ...........................................4-99

4.3.2 Tool measurement ..................................................................................................4-100

4.3.3 Calibrating the tool measuring probe ...................................................................... 4-101

0-6 SINUMERIK 840D/840Di/810D User's Guide Measuring Cycles (BNM) – 11.02 Edition

11.02 Contents

Measuring Cycles for Milling and Machining Centers 5-103

5.1 General preconditions ................................................................................................... 5-104

5.2 CYCLE971 Tool measuring for milling tools ................................................................. 5-106

5.2.1 CYCLE971 Measuring strategy............................................................................... 5-108

5.2.2 CYCLE971 Calibrate tool probe .............................................................................. 5-110

5.2.3 CYCLE971 Measure tool......................................................................................... 5-114

5.3 CYCLE976 Calibrate workpiece probe.......................................................................... 5-119

5.3.1 CYCLE976 Calibrate workpiece probe in any hole (plane) with known

hole center .............................................................................................................. 5-122

5.3.2 CYCLE976 Calibrate workpiece probe in any hole (plane) with unknown hole

center (measuring cycles SW 4.4 and higher) ........................................................ 5-124

5.3.3 CYCLE976 Calibrate workpiece probe on a random surface ................................. 5-126

5.3.4 Calibrate workpiece probe in applicate with calculation of probe length

(measuring cycles SW 4.4. and higher) .................................................................. 5-128

5.4 CYCLE977 Workpiece measurement: Hole/shaft/groove/web/rectangle (paraxial) ..... 5-130

5.4.1 CYCLE977 Measure hole, shaft, groove, web, rectangle ....................................... 5-134

5.4.2 CYCLE977 ZO calculation in hole, shaft, groove, web, rectangle .......................... 5-140

5.5 CYCLE978 Workpiece measurement: Surface ............................................................ 5-146

5.5.1 CYCLE978 ZO calculation on a surface (single point measuring cycle)................. 5-149

5.5.2 CYCLE978 Single-point measurement ................................................................... 5-152

5.6 CYCLE979 Workpiece measurement: Hole/shaft/groove/web (at a random angle)..... 5-156

5.6.1 CYCLE979 Measure hole, shaft, groove, web ........................................................ 5-159

5.6.2 CYCLE979 ZO calculation in hole, shaft, groove, web ........................................... 5-164

5.7 CYCLE998 Angular measurement (ZO calculation) ..................................................... 5-169

5.8 CYCLE961 Automatic setup of inside and outside corner ............................................ 5-180

5.8.1 Automatic setup of corner with distances and angles specified.............................. 5-180

5.8.2 Automatic setup of corner by defining 4 points (measuring cycles ≥ SW 4.5) ........ 5-185

Measuring Cycles for Turning Machines 6-189

6.1 General preconditions .................................................................................................. 6-190

6.2 CYCLE972 Tool measurement ....................................................................................6-192

6.2.1 CYCLE972 Calibrating the tool probe ..................................................................... 6-194

6.2.2 CYCLE972 Determine dimensions of calibration tools ........................................... 6-197

6.2.3 CYCLE972 Measure tool......................................................................................... 6-198

6.3 CYCLE982 Tool measurement (SW 5.3 and higher)................................................... 6-203

6.3.1 CYCLE982 Calibrate tool measuring probe ............................................................ 6-208

6.3.2 CYCLE982 Measure tool......................................................................................... 6-210

6.3.3 CYCLE982 Automatic tool measurement ............................................................... 6-221

6.3.4 Incremental calibration (SW 6.2 and higher)........................................................... 6-228

Contents 11.02

6.3.5 Incremental measurement (SW 6.2 and higher) .....................................................6-231

6.3.6 Milling tool: suppression of starting angle positioning with _STA1 (≥ SW 6.2)........6-237

6.4 CYCLE973 Calibrate workpiece probe .........................................................................6-238

6.4.1 CYCLE973 Calibrate in the reference groove (plane) .............................................6-240

6.4.2 CYCLE973 Calibrate on a random surface .............................................................6-242

6.5 CYCLE974 Workpiece measurement ..........................................................................6-244

6.5.1 CYCLE974 Single-point measurement ZO calculation ...........................................6-246

6.5.2 CYCLE974 Single-point measurement ...................................................................6-249

6.5.3 CYCLE974 Single-point measurement with reversal ..............................................6-253

6.6 CYCLE994 Two-point measurement............................................................................ 6-257

6.7 Complex example for workpiece measurement ...........................................................6-262

Miscellaneous Functions 7-265

7.1 Logging of measuring results .......................................................................................7-266

7.1.1 Storing the log .........................................................................................................7-266

7.1.2 Handling of log cycles.............................................................................................. 7-267

7.1.3 Selecting the log contents .......................................................................................7-269

7.1.4 Log format ...............................................................................................................7-271

7.1.5 Log header ..............................................................................................................7-272

7.1.6 Variable for logging.................................................................................................. 7-273

7.1.7 Example of measuring result log .............................................................................7-274

7.2 Cycle support for measuring cycles..............................................................................7-276

7.2.1 Files for cycle support.............................................................................................. 7-277

7.2.2 Loading the cycle support........................................................................................ 7-277

7.2.3 Assignment of calls and measuring cycles.............................................................. 7-278

7.2.4 Description of parameterization cycles.................................................................... 7-279

7.3 Measuring cycle support in the program editor (≥ SW 6.2) ..........................................7-290

7.3.1 Menus, cycle explanation ........................................................................................ 7-290

7.3.2 New functions of the input forms .............................................................................7-291

7.3.3 GUD variables for adaptation of measuring cycle support ......................................7-297

Part 2: Description of Functions

Hardware, Software and Installation 8-301

8.1 Overview....................................................................................................................... 8-302

8.2 Hardware requirements ................................................................................................8-303

8.2.1 General hardware requirements.............................................................................. 8-303

8.2.2 Probe connection..................................................................................................... 8-303

8.2.3 Measuring in JOG ................................................................................................... 8-303

8.3 Software requirements .................................................................................................8-308

8.3.1 General measuring cycles.......................................................................................8-308

0-8 SINUMERIK 840D/840Di/810D User's Guide Measuring Cycles (BNM) – 11.02 Edition

11.02 Contents

8.3.2 Measuring in JOG ................................................................................................... 8-309

8.4 Function check .............................................................................................................8-310

8.5 Start-up sequences ......................................................................................................8-312

8.5.1 Start-up flowchart for measuring cycles and probe circuit ...................................... 8-312

8.5.2 Starting up the measuring cycle interface for the MMC 102 ...................................8-315

Supplementary Conditions 9-317

Data Description 10-319

10.1 Machine data for machine cycle runs......................................................................... 10-320

10.2 Cycle data................................................................................................................... 10-323

10.2.1 Data concept for measuring cycles ....................................................................... 10-323

10.2.2 Data blocks for measuring cycles: GUD5.DEF and GUD6.DEF........................... 10-324

10.2.3 Central values .......................................................................................................10-328

10.2.4 Central bits ............................................................................................................ 10-333

10.2.5 Central strings ....................................................................................................... 10-336

10.2.6 Channel-oriented values ....................................................................................... 10-337

10.2.7 Channel-oriented bits ............................................................................................ 10-339

10.3 Data for measuring in JOG ........................................................................................ 10-344

10.3.1 Machine data for ensuring ability to function ......................................................... 10-344

10.3.2 Modifying the GUD7 data block ............................................................................ 10-346

10.3.3 Settings in data block GUD6 ................................................................................. 10-349

10.3.4 Loading files for measuring in JOG....................................................................... 10-351

Examples 11-353

11.1 Determining the repeat accuracy ............................................................................... 11-354

11.2 Adapting the data for a particular machine ................................................................ 11-355

Data Fields, Lists 12-359

12.1 Machine data.............................................................................................................. 12-360

12.2 Measuring cycle data ................................................................................................. 12-360

12.3 Alarms ........................................................................................................................ 12-361

Appendix A-369

A Overview of measuring cycle parameters ....................................................................A-371

B Abbreviations................................................................................................................A-405

C Terms ...........................................................................................................................A-407

D References...................................................................................................................A-415

E Index.............................................................................................................................A-429

F Identifiers......................................................................................................................A-434

Preface 11.02

Structure of the manual

840 D NCU 571

840 D NCU 572 NCU 573

810 D 840 Di

Preface

Organization of documentation

The SINUMERIK documentation is organized on 3 different levels:

• General Documentation

• User Documentation

• Manufacturer/Service Documentation

Target group

This manual is aimed at machine tool users. It provides detailed information for operating the SINUMERIK 840D, 810D.

Standard scope

This Operator's Guide describes only the functionality of the standard scope. A description of add-on features or modifications made by the machine builder are not included in this guide.

For more detailed information on SINUMERIK 840D, 810D publications and other publications covering all SINUMERIK controls (e.g. universal interface, measuring cycles...), please contact your local Siemens office.

Other functions not described in this documentation might be executable in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing.

Validity

This User's Guide is valid for the following controls: SINUMERIK 810D, 840D, 840Di, MMC 100 and MMC 102/103. Software versions stated in the User's Guide refer to the 840D and their 810D equivalent, e.g. SW 6 (840D) corresponds to SW 3 (810D).

SINUMERIK 840D powerline From 09.2001

• SINUMERIK 840D powerline and

• SINUMERIK 840DE powerline

are available, with improved performance. A list of the available powerline modules can be found in the hardware description /PHD/ in Section 1.1

SINUMERIK 810D powerline From 12.2001

• SINUMERIK 810D powerline and

• SINUMERIK 810DE powerline

are available, with improved performance. A list of the available powerline modules can be found in the hardware description /PHC/ in Section 1.1

0-10 SINUMERIK 840D/840Di/810D User's Guide Measuring Cycles (BNM) – 11.02 Edition

11.02 Preface

Structure of the manual

840 D NCU 571

Hotline

Internet address

840 D NCU 572 NCU 573

810 D 840 Di

Explanation of symbols

Procedure

Please address any questions to the following hotline: A&D Technical Support Phone: ++49-(0)180-5050-222

Fax: ++49-(0)180-5050-223 Email: adsupport@siemens.com

If you have any questions (suggestions, corrections) concerning the documentation, please fax or e-mail them to the following address:

Fax: ++49-(0)0131-98-2176 Email: motioncontrol.docu@erlf.siemens.de

Fax form: See answer form at the end of the document.

http://www.ad.siemens.de/sinumerik

Ordering option

Explanation

Function

Parameters

Programming example

Programming

Further notes

Cross-reference to other documentation, chapters, sections, or subsections

Notes and indication of danger

Additional notes or background information

Preface 11.02

Use as intended

840 D NCU 571

Warnings

The following warnings are used with graded severity.

840 D NCU 572 NCU 573

810 D 840 Di

Danger

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury or in substantial property damage.

Warning

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury or in substantial property damage.

Caution

Used with the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or in property damage.

Caution

Used without safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Notice

Used without the safety alert symbol indicates a potential situation which, if not avoided, may result in an undesirable result or state.

0-12 SINUMERIK 840D/840Di/810D User's Guide Measuring Cycles (BNM) – 11.02 Edition

11.02 Preface

Use as intended

840 D NCU 571

Basis

Your SIEMENS SINUMERIK 840D, 804Di, 810D is state of the art and is manufactured in accordance with recognized safety regulations, standards and specifications.

Add-on equipment

Using special add-on equipment and expanded configurations from SIEMENS, SIEMENS controls can be adapted to suit your specific application.

Personnel Only authorized and reliable personnel with the relevant training must be allowed to handle the

control. Nobody without the necessary training must be allowed to work on the control, not even for a short time.

840 D NCU 572 NCU 573

810 D 840 Di

The responsibilities of the personnel employed for setting, operating and maintenance must be clearly

defined and supervised.

Behavior Before the control is started up, it must be ensured

that the Operator's Guide has been read and understood by the personnel responsible. The operating company is also responsible for constantly monitoring the overall technical state of the control (faults and damage apparent from the outside and changes in response).

Preface 11.02

Use as intended

840 D NCU 571

Service

Repairs must only be carried out in accordance with the information given in the Service and Maintenance Guide by personnel trained and qualified in the relevant field. The relevant safety regulations must be observed.

Note The following is contrary to the intended purpose and exonerates the manufacturer from any liability:

Any use whatsoever beyond or deviating from the

application stated in the above points.

If the control is not in perfect technical condition, or is operated without awareness for safety or the dangers involved or without observing the instructions given in the instruction manual.

840 D NCU 572 NCU 573

810 D 840 Di

If faults that can reduce safety are not remedied before the control is started up.

Any modification, overriding or deactivation of equipment on the control used for the perfect functioning, unrestricted use or active and passive safety.

This can result in unforeseen dangers for:

• the health and life of people,

• the control, machine and other property of the

operating company and user.

0-14 SINUMERIK 840D/840Di/810D User's Guide Measuring Cycles (BNM) – 11.02 Edition

12.97 Introduction

09.01

Introduction

1.1 Basics.............................................................................................................................. 1-16

1.2 General preconditions ..................................................................................................... 1-17

1.3 Plane definition................................................................................................................ 1-19

1.4 Suitable probes ............................................................................................................... 1-20

1.5 Workpiece probe, calibration tool in TO memory............................................................ 1-22

1.5.1 Workpiece probe in TO memory for milling machines and machining centers ....... 1-22

1.5.2 Workpiece probe, calibration tool in TO memory on turning machines ................... 1-23

1.6 Measuring principle ......................................................................................................... 1-25

1.7 Measuring strategy and compensation value calculation for tools with automatic

tool offset......................................................................................................................... 1-28

1.8 Parameters for checking the dimension deviation and compensation............................ 1-31

1.9 Effect of empirical value, mean value and tolerance parameters ................................... 1-37

1.10 Reference points on the machine and workpiece ........................................................... 1-38

1.11 Measurement variants for milling machines & machining centers .................................. 1-39

1.11.1 Workpiece measurement for milling machines........................................................ 1-39

1.11.2 Measurement variants for fast measurement at a single point................................ 1-40

1.11.3 Measurement variants for workpiece measurement paraxial .................................. 1-40

1.11.4 Measurement variants for workpiece measurement at random angles................... 1-42

1.11.5 Measuring a surface at a random angle .................................................................. 1-43

1.12 Measurement variants for lathes ..................................................................................... 1-44

1.12.1 Tool measurement for lathes ................................................................................... 1-44

1.12.2 Workpiece measurement for turning machines: Single-point measurement........... 1-45

1.12.3 Workpiece measurement for turning machines: Two-point measurement.............. 1-47

1.13 Measuring cycles interface.............................................................................................. 1-48

1.13.1 Displaying measuring result screens ....................................................................... 1-48

1.13.2 Setting parameters................................................................................................... 1-50

Introduction 12.97

1.1 Basics

08.99

840 D

NCU 571

1.1 Basics

Measuring cycles are general subroutines designed to solve specific measurement tasks. They can be suitably adapted to the problem at hand by means of parameter settings.

With regard to measurement applications, a distinction

must generally be made between tool measurement

and workpiece measurement.

Workpiece measurement

For workpiece measurement, a measuring probe is moved up to the clamped workpiece in the same way as a tool. The flexibility of the measuring cycles makes it possible to perform nearly all measurements which may need to be taken on a milling machine. An automatic tool offset or an additive ZO can be applied to the result of the tool measurement. The measurement variants which can be implemented with the measuring cycles available in this configuration are described on the following pages.

840 D

NCU 572

NCU 573

810 D 840Di

Tool measurement

To perform tool measurement, the changed tool, which in the case of a lathe is usually located in the turret, is moved up to the probe which is either permanently fixed or swiveled into the working range. The automatically derived tool geometry is entered in the relevant tool offset data record.

1-16 SINUMERIK 840D/840Di/810D User's Guide Measuring Cycles (BNM) – 11.02 Edition

12.97 Introduction

11.02

1.2 General preconditions

840 D

NCU 571

840 D

NCU 572

NCU 573

1.2 General preconditions

Certain preconditions need to be fulfilled before measuring cycles can be used.

These conditions are described in greater detail in Part 2 Description of Functions (from Chapter 8 onwards).

The following checklist is useful in determining whether all such preconditions are fulfilled:

Machine

• All machine axes are designed in accordance with

DIN 66217

Availability of cycles

• The data blocks:

GUD5.DEF and

GUD6.DEF have been loaded into the control ("Definitions" directory in file system) and

• the measuring cycles have been loaded into the

standard cycle directory of the control followed by a power ON operation.

Initial position

• The reference points have been approached.

• All axes are positioned prior to the cycle call in such

a way that the setpoint position can be approached without a change in direction.

• The start position can be reached without collisions

by means of linear interpolation.

Displaying measuring result screens

It is only possible to display measurement result screens with an MMC/PCU.

810 D 840Di

Introduction 12.97

1.2 General preconditions

09.01

840 D

NCU 571

Programming

• The inch/metric units system selected in the

• The milling radius compensation and the

• All parameters for the cycle call have been defined

• The cycle is called no later than at the 5th program

• Neither of the operating modes "Block search" or

• The specified default setting of the supplied data

• With measuring cycles SW 4.4 and higher,

840 D

NCU 572

NCU 573

machine data for the basic setting is active.

programmable frame are deselected prior to the cycle call.

beforehand.

level.

"Dry run" is active since these are automatically skipped by the measuring cycles.

blocks is required to ensure that all example programs run correctly.

measurement in a programmed measurement system that differs from the basic system is possible, i.e. in a metric basic system with active G70 and in an inch basic system with active G71.

measurement in a programmed measurement system that differs from the basic system is possible with technology data switched over. This means in a metric basic system with active G700 and in an inch basic system with active G710.

810 D 840Di

Software status ID

In the delivery status of the measuring cycles, the current software status of the control is entered in parameter _SI[1] in the GUD6 block, i. e. 5 for SW 5. This parameter must be changed to match the measuring cycles to older software releases. Example: When using measuring cycles status 5.x.x on a control with SW 4, à_SI[1] = 4 Precondition: In order to use the measuring cycles, the software

status of the control must be ≥ 3.

1-18 SINUMERIK 840D/840Di/810D User's Guide Measuring Cycles (BNM) – 11.02 Edition

12.97 Introduction

1.3 Plane definition

840 D

NCU 571

1.3 Plane definition

Tool radius compensation planes G17, G18 or G19 can

be selected. Lengths 1, 2 and 3 are assigned as follows to the axes depending on the tool type used:

G17 plane

Tool type 100 Length 1 applies to Z Length 2 applies to Y Length 3 applies to X

840 D

NCU 572

NCU 573

810 D 840Di

Y Ordinate

Abscissa X

Z Applicate

G18 plane

Tool type 100 Length 1 applies to Y Length 2 applies to X Length 3 applies to Z

G19 plane

Tool type 100 Length 1 applies to X Length 2 applies to Z Length 3 applies to Y

X Ordinate

Abscissa Z

Y Applicate

Z Ordinate

Abscissa Y

X Applicate

Introduction 12.97

1.4 Suitable probes

840 D

NCU 571

1.4 Suitable probes

Function

In order to measure tool and workpiece dimensions, a touch-trigger probe is required that supplies a constant signal (rather than a pulse) when deflected.

The probe must be capable of virtually bounce-free switching. This is normally achieved by adjusting the probe mechanically.

The probe type is defined in the measuring cycles in a parameter.

Various types of probes made by different manufacturers are available on the market. Probes are classified in three groups according to the number of directions in which they can be deflected.

Classification of probe types

Probe type Turning machines Milling mach. and mach. centers

Multidirectional

Bidirectional

Monodirectional

While a bidirectional probe can be used for turning machines, with milling machines and machining centers it is also possible to use a mono probe for workpiece measuring.

The probe is defined in the measuring cycles in a parameter.

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Tool measurement Workpiece measurement Workpiece measurement

X X X

- X X

- - X

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12.97 Introduction

1.4 Suitable probes

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Multidirectional probe (3D)

With this type, measuring cycles for workpiece measurement can be used without limitation.

Bidirectional probe

This probe type is used for workpiece measurement on milling machines and machining centers.

This probe type is treated in the same way as a monodirectional probe for workpiece measurement on milling machines and machining centers.

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Monodirectional probe

This probe type can only be used for workpiece measurement on milling machines and machining centers with slight limitations; reference is made to this in the cycles concerned. In order to be able to use this type of probe on milling machines and machining centers, it must be possible to position the spindle with the NC function SPOS and to transmit the switching signal of the probe through 360° to the receiving station (at the machine column).

Introduction 12.97

1.5 Workpiece probe, calibration tool in TO memor

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The probe must be mechanically aligned in the spindle in

such a way that measurements can be taken in the following directions at the 0 degree position of the spindle.

X-Y plane G17 positive X direction

Z-X plane G18 positive Z direction

Y-Z plane G19 positive Y direction

The measurement will take longer when using a

1.5 Workpiece probe, calibration tool in TO memory

1.5.1 Workpiece probe in TO memory for milling machines and machining centers

monodirectional probe since the spindle must be positioned in the cycle several times by means of SPOS.

Workpiece probe

On milling machines and machining centers, the probe is classified as tool type 1x0 and must therefore be entered as such in the TO memory. In SW 4 and higher, tool type 710 (3D probe) can also be used.

Entry in TO memory

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P1 710 Tool type P3 L1 Geometr P6 r Geometry P21 L1 Tool base dimension

_CBIT[14]=1

_CBIT[14]=0

1-22 SINUMERIK 840D/840Di/810D User's Guide Measuring Cycles (BNM) – 11.02 Edition

12.97 Introduction

11.02

1.5 Workpiece probe, calibration tool in TO memor

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1.5.2 Workpiece probe, calibration tool in TO memory on turning machines

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On turning machines, the probes are treated as tool

type 500 with the permissible tool edge positions 5 to 8 and must therefore be entered like this in the TO memory. Measuring cycle SW 6.2 and higher also allows you to enter probe type 580 with tool edge positions 5 to 8. Due to their spatial positions, the probes are divided into the following types:

Workpiece probe SL 5

Entry in TO memory

P1 500 Tool type P2 5 Tool edge position P3 L1 Geometry

P4 L2 Geometry P6 r Geometry P12 L1 Wear P13 L2 Wear

P15 r Wear P21 L1 Tool base dimension P22 L2 Tool base dimension

Workpiece probe SL 6 (8)

(data in brackets is in front of turning center) Entry in TO memory

P1 500 Tool type P2 6 (8) Tool edge position P3 L1 Geometry P4 L2 Geometry P6 r Geometry

P12 L1 Wear P13 L2 Wear P15 r Wear P21 L1 Tool base dimension P22 L2 Tool base dimension

Introduction 12.97

1.5 Workpiece probe, calibration tool in TO memor

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Workpiece probe SL 7

Entry in TO memory

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P1 500 Tool type P2 7 Tool edge position P3 L1 Geometry

P4 L2 Geometry P6 r Geometry P12 L1 Wear

P13 L2 Wear P15 r Wear P21 L1 Tool base dimension P22 L2 Tool base dimension

Workpiece probe SL 8 (6)

(data in brackets is in front of turning center) Entry in TO memory

P1 500 Tool type P2 8 (6) Tool edge position P3 L1 Geometry

P4 L2 Geometry P6 r Geometry

P12 L1 Wear P13 L2 Wear P15 r Wear P21 L1 Tool base dimension P22 L2 Tool base dimension

Calibration tool

On turning machines, the calibration tool is classified as a tool with tool edge position 3 and must therefore be entered as such in the TO memory. Entry in TO memory

P1 500 Tool type P2 3 Tool edge position

P3 L1 Geometry P4 L2 Geometry P6 r Geometry

P12 L1 Wear P13 L2 Wear P15 r Wear P21 L1 Tool base dimension P22 L2 Tool base dimension

1-24 SINUMERIK 840D/840Di/810D User's Guide Measuring Cycles (BNM) – 11.02 Edition

12.97 Introduction

1.6 Measuring principle

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1.6 Measuring principle

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Two inputs for the connection of touch trigger probes

are provided on the I/O device interface of the SINUMERIK 840D and the FM-NC control systems.

Function

Evaluation of the measuring probe signal If a measuring point is to be approached, a traverse command is transmitted to the position control loop and the probe is moved towards the measuring point. A point behind the expected measuring point is defined as setpoint position. As soon as the probe makes contact, the actual axis value at the time the switching position is reached is measured and the drive is stopped. The remaining "distance-to-go" is deleted.

Meas. cycle

Delete distanceto-go

Act. val. acquis.

Position control

Actual value

"On-the-fly" measurement

The principle of "on-the-fly" measurement is implemented in the control. The advantage of this method is that the probe signal is processed directly in the NC.

Set position

Meas. dist. a

Delete dist.-to-go

-V

=Traversing path by signal processing

=Following error

1) Actual value loaded with probe signal

Meas. dist. a

Act. position

Probe switching point

Start position = End position

Introduction 12.97

1.6 Measuring principle

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Start position/setpoint position

In the measuring procedure used, a position is specified as setpoint value for the cycle at which the signal of the touch-trigger probe is expected.

Since it is unlikely that the probe will respond at precisely this point, the start position is approached by the control in rapid traverse mode or at a defined positioning velocity. The set position is then approached at the feedrate specified in the parameter for measurement speed. The switching signal is then anticipated over a distance of a maximum length of 2a from the start position.

Load actual value/delete distance-to-go

At the instant the switching signal is output by the probe, the current position is stored internally "on-thefly" as the actual value followed by execution of the "Delete distance-to-go" function.

Measuring path a/measuring speed

The path increment a is normally 1 mm, but can be increased with a parameter when measuring cycles are called.

The approach speed automatically increases from 150 mm/min to 300 mm/min if the value for a is defined as greater than 1.

The maximum approach speed (measurement speed) is thus dependent upon

• the permissible deflection path of the probe used

• the delay until "delete distance to go" is executed

• the deceleration behavior of the axis.

and

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11.02

1.6 Measuring principle

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Calculation of the deceleration path

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Since an optimal measurement speed can be set for measuring cycles via a parameter, it must be ensured that safe deceleration can take place within the deflection path of the probe. The required deceleration path can be calculated as follows:

sb = v t +

Deceleration path in m

∆

+ ∆s

∆

v Approach speed in m/s t Delay in s b Deceleration in m/s

s Following error in m

Measuring accuracy

The repeat accuracy of the 840D and FM-NC controls for "on-the-fly measurement" is ±1 µm.

The measuring accuracy which can be obtained is thus dependent on the following factors:

• Repeat accuracy of the machine

• Repeat accuracy of the probe

• Resolution of the measuring system

Example: Path-time diagram

s [mm]

Deceleration

b = 1m/s

(11 mm)

(1.66 mm)

The deflection of the probe up to zero spee d of the axis is approximately 12.6 mm with an approach speed of 6 m/min and a delay of 1 m/s

Kv-Factor

1m/min

min

Zero speed

1 m/min

(16 ms) Delay until distance-to-go is deleted

6 m/min Approach speed v

4 m/min

10 10

Axis zero speed

Zero speed

t [ms]

Introduction 12.97

1.7 Measuring strategy and compensation value calculation for tools

08.99

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1.7 Measuring strategy and compensation value calculation for tools with automatic tool

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offset

The actual workpiece dimensions must be measured

exactly in order to be able to determine and compensate the actual dimensional deviations on the workpiece.

Function

When taking measurements on the machine, the actual dimensions are derived from the path measuring systems of the position-controlled feed axes. For each dimensional deviation determined from the set and actual workpiece dimensions there are many causes which essentially can be classified in 3 categories:

• Dimensional deviations with causes that are

n o t subject to a particular trend,

scatter of the feedforward axes or differences in measurement between the internal measurement (measuring probe) and the external measuring device (micrometer, measuring equipment, etc.).

In this case, it is possible to apply so-called

empirical values, which are stored in separate

memories. The set/actual difference determined is automatically compensated by the empirical value.

• Dimensional deviations with causes that a r e

subject to a particular trend

thermal expansion of the leadscrew.

These deviations are compensated by specifying fixed threshold values.

• Accidental dimensional deviations, e.g. due to

temperature fluctuations, coolant or slightly soiled measuring points.

, e.g. tool wear or

e.g. positioning

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12.97 Introduction

1.7 Measuring strategy and compensation value calculation for tools

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Assuming the ideal case, only those dimensional

deviations which are subject to a trend can be taken into account for compensation value calculation. Since, however, it is hardly ever known to what extent and in which direction accidental dimensional deviations influence the measurement result, a strategy (floating average value generation) is needed which derives a compensation value from the actual/set difference measured.

Mean value calculation

Mean value calculation in combination with a higherorder measurement weighting has proved a suitable means to do this.

The formula of the mean value generation chosen is:

Mv D

−

Mv Mv

=−

new old

old i

Mv Mv

Mean value new = amount of compensation

new

Mean value prior to last measurement

old

k Weighting factor for average value calculation D

Actual/set difference measured

(minus empirical value, if any)

The mean value calculation takes account of the trend

of the dimensional deviations of a machining series,

weighting factor k from which the mean value is

where derived is selectable.

A new measurement result affected by accidental dimensional deviations only influences the new tool offset to some extent, depending on the weighting factor.

Introduction 12.97

1.7 Measuring strategy and compensation value calculation for tools

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Computational characteristic of the mean value

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with different weightings k (effects)

• The greater the value of k, the slower the formula

will respond when major deviations occur in computation or counter compensation. At the same time, however, accidental scatter will be reduced as k increases.

• The lower the value of k, the faster the formula will

react when major deviations occur in computation or counter compensation. However, the effect of accidental variations will be that much greater.

• The mean value Mv is calculated starting at 0 over

the number of workpieces i, until the calculated average value exceeds the range of "zero compensation". From this limit on, the calculated average value is applied for compensation.

Example of mean value generation

Lower limit = 40 µm

[µm]

Mean value

k=3

[µm]

Mean value

k=2

[µm]

1st measurement 30 10 15

2nd measurement 50 23.3 32.5

3rd measurement 60 35.5 46.2



4th measurement 20 30.3 10 5th measurement 40 32.6 25 6th measurement 50 38.4 37.5 7th measurement 50 42.3



43.75



8th measurement 30 10 15 9th measurement 70 30 42.5

10th measurement 70 43.3





Set/actual difference

Mean value calculated

Setpoint

1234 560

Characteristic of mean values with two different weighting factors k

12345678910

k=2

k=3

Lower limit = "Zero offset"

k=1

k=2

k=3

Number of averaging operations (workpieces)

Mean value calculated

k=10

Set/actual difference

Zero compensation

1-30 SINUMERIK 840D/840Di/810D User's Guide Measuring Cycles (BNM) – 11.02 Edition

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