Siemens SINUMERIK 840Di sl/840D sl,SINUMERIK 840Di/840D Function Manual

Preface

SINUMERIK 840Di sl/840D sl SINUMERIK 840Di/840D

ePS Network Services

Function Manual

Introduction

Machine information

Setting up functions

Organizational tasks

Statistics/export

Management

1

2

3

4

5

6

Applies to:

Software Version ePS Network Services 4.6

Establishing a connection and diagnostics

Appendix

7

A

Release 08/2008

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 codes in the "Remarks" columns:

A .... New documentation.

B .... Unrevised reprint with new Order No.

C .... Revised edition with new status.

Release Order no. Remark

08/2008 -- C

11/2007 -- C

04/2007 -- C

11/2006 -- C

08/2006 -- C

04/2006 -- C

11/2005 -- C

Registered Trademarks

All designations with the trademark symbol ® are registered trademarks of Siemens AG. Other designations in this documentation may be trademarks whose use by third parties for their own purposes can violate the rights of the owner.

Exclusion of Liability

We have checked that the contents of this document correspond to 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 Industry Sector P.O. Box 3180 91050 Erlangen

GERMANY

08/2008 Preface

Preface

SINUMERIK documentation

The SINUMERIK documentation is available in three versions:

• General documentation

• User documentation

• Manufacturer/service documentation

A monthly overview of publications with the available languages is available on the Internet at:

http://www.siemens.com/motioncontrol

Follow menu items "Support"  "Technical Documentation"  "Ordering Documentation"  "Printed Documentation".

The Internet version of the DOConCD (DOConWEB) is available at:

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

Information about training courses and FAQs (frequently asked questions) are available on the Internet under:

http://www.siemens.com/motioncontrol

Target group

This publication is intended for project engineers, programmers, technologists (of machine manufacturers), and system startup engineers (of systems/machines).

Use

The Function Manual describes the functions so that the target group is familiar with and can select them. It provides the target group with the information required to implement the functions.

Utilization phase: Planning and configuration phase, implementation phase, setup and commissioning phase

, under the menu item "Support".

Standard scope

This documentation only describes the functionality of the standard version. Additions or revisions made by the machine tool manufacturer are documented by the machine tool manufacturer.

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.

iii

Preface 08/2008

Further, for the sake of simplicity, this documentation does not contain all detailed information about all types of the product and cannot cover every conceivable case of installation, operation, or maintenance.

Questions about this document

If you have any queries (suggestions, corrections) in relation to this documentation, please fax or e-mail us:

Fax +49 9131 98 2176 E-mail docu.motioncontrol@siemens.com

A fax form is available at the end of this document.

SINUMERIK Internet address

http://www.siemens.com/sinumerik

Technical Support

If you have any technical questions, please contact our hotline:

Europe/Africa

Phone

Fax

Internet

America

Phone

Fax

E-mail

Asia/Pacific

Phone

Fax

E-mail

Note

Country-specific telephone numbers for technical support are provided under the following Internet address: http://www.siemens.com/automation/service&support

+49 180 5050 222 +49 180 5050 223

http://www.siemens.com/automation/support-request

+1 423 262 2522 +1 423 262 2200

techsupport.sea@siemens.com

+86 1064 719 990 +86 1064 747 474

techsupport.asia@siemens.com

Calls are subject to charge, e.g. 0.14 €/min. on the German landline network. Tariffs of other phone providers may differ.

iv ePS Network Services, Function Manual (FH) - Release 08/2008

08/2008 Preface

EC declaration of conformity

The EC Declaration of Conformity for the EMC Directive can be found on the Internet at: http://support.automation.siemens.com

or under the Order No. 15257461 or at the relevant branch office of the A&D MC Division of Siemens AG.

Safety information

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. Notices referring to your personal safety are highlighted in the manual by a safety alert symbol; notices referring to property damage only have no safety alert symbol. Depending on the hazard level, warnings are indicated in a descending order as follows:

!

Danger

Indicates that death or serious injury will result if proper precautions are not taken.

Warning

Indicates that death or serious injury may result if proper precautions are not taken.

Caution

(With warning triangle) indicates that slight personal injury may result if proper precautions are not taken.

Caution

(Without warning triangle) indicates that property damage may result if proper precautions are not taken.

Notice

Indicates that an unwanted result or situation may result if the appropriate advice is not taken into account.

In the event of a number of levels of danger prevailing simultaneously, the warning corresponding to the highest level of danger is always used. A notice warning of injury to persons with a warning symbol may also include a warning relating to property damage.

v

Preface 08/2008

Qualified persons

The associated device/system must only be set up and operated using this documentation. Commissioning and operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards.

Intended purpose

Please observe the following:

!

Warning

Siemens products must only be used for the applications specified in the catalog and in the technical documentation. If third-party products and components are used, they must be recommended or approved by Siemens.

To ensure trouble-free and safe operation of the products, they must be appropriately transported, stored, assembled, installed, commissioned, operated and maintained. The permissible ambient conditions must be adhered to. The notes in the associated documentation must be complied with.



vi ePS Network Services, Function Manual (FH) - Release 08/2008

08/2008 Contents

1 Introduction

1.1 Overview of functions

What are ePS Network Services?

The ePS Network Services support machine tool manufacturers and manufacturing companies with maintenance and services. This is carried out using software services that are available on a CNC control, S7 control, IPC or standard PC.

This requires both a control on the machine that complies with the specifications, and Internet access.

The ePS Network Services include:

Remote access

Remote access to the control via a secure Internet infrastructure. This service permits remote access to the control.

• Desktop control

• File transfer

• Chat

• Video ...

Control monitor services

Recording of events in a history and documentation of the current status of the control at this point. This allows the status of the device to be analyzed and compared with earlier states should a fault occur.

The current status of the machine is documented using the following events and data:

• Alarms, PLC events, time intervals, combinations of machine signals

• Limit value violation and time delay violation from condition monitoring

• Series of measurements/tests and operating performance monitors

• Manual help request by the machine operator in the event of faults

• HMI action log, machine data, NC status data

• PLC trace, PLC data blocks

• Certain files (e.g. log files) of the control

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1.1 Overview of functions

Condition monitoring services

Measurement and documentation of the current machine status on the basis of predefined, standardized tests and continuous recording of status characteristics (traverse path, traverse time and traverse operations for one axis). The test parameters can be defined centrally and configured with appropriate warning limits. Using series of measurements, it is also possible to identify trends and apply them as a basis for optimizing maintenance and service activities.

The machine operator can then carry out these predefined tests quickly and easily and without additional test equipment.

The following tests and monitors are available:

• Circularity test

• Synchronous operation axis test

• Universal axis test

• NC monitor

• Variable monitor

Data services

Save the current control archives (NCK and PLC archives) on the ePS Server. In the event of faults, they can be reimported into the controller in a controlled manner and used as reference for comparisons of control monitors.

Workflow services

Triggering of service and maintenance processes by notification via media that are internal and external to the system (SMS, e-mail, service cases). Planning, monitoring, and documentation of maintenance activities on the machine.

Maintenance schedules support you in the following tasks:

• "Look Ahead" maintenance relating to load and usage (see: Control monitors with machine and service triggers)

• Automated triggering of operating sequences when faults are detected (see: Maintenance schedules, maintenance jobs, fault help requests, and service cases).

• Planning condition monitors in terms of dates and content, and monitoring their processing (see: Maintenance schedules, maintenance jobs and control monitors)

The Workflow Services can respond to all event sources of the Control Monitor Services and Condition Monitor Services.

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08/2008 1 Introduction

1.2 Operating concept

Administration services

Functions for the administration of the system:

• Creation and administration of machines

• Creation and administration of users

• Assignment of access rights for external organizations

• Access to use data/invoices

1.2 Operating concept

Overview

The functions of the ePS Network Services are divided into five main categories which can be reached via tabs. The "Machine information" and "Set up functions" tabs always apply to the selected machine.

Fig. 1-1: Basic principle of operation

Note

The availability of each function to the machine operator in each of the various roles is described in the Appendix.

Please see the descriptions in each section for details of the functions.

Tab/Section Description

Machine information The "Machine information" tab contains impor-

Setting up functions The "Set up functions" tab allows you to make

tant information on a particular selected ma- chine.

It is divided into the following areas:

• Machine overview

• Maintenance

• Fault services

• Remote access

all the settings that apply to a particular selected machine.

It is divided into the following areas:

• Maintenance

• Fault services

• Global settings

• Copying function settings

• Client/server communication

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1.2 Operating concept

Tab/Section Description

Organizational tasks The "Organizational tasks" tab contains func-

tions and services that apply to all machines of an organization.

It is divided into the following areas:

• Maintenance jobs

• Service cases

Statistics/export The "Import/Export" tab contains functions and

services that apply to all machines of an organization.

It is divided into the following areas:

• Multi-machine views

• Import

• Export

• Overviews

Management The "Administration" tab contains functions and

services that apply to the settings of an organi- zation.

It is divided into the following areas:

• Organization management

• Personal settings



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08/2008 2 Machine information

2.1 Machine overview

2

2 Machine information

2.1 Machine overview

Overview

Machine events in the machine information:

The machine events of an individual machine can be viewed in the same way as the multi-machine events (see Section 5.1.1 "Multi-machine views") and always refer to the selected machine only.

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2.1 Machine overview

2.1.1 Current control software

Description of functions

In the Machine information area under Current Control Software, you can view all versions of the software packages currently installed on the control

Fig. 2-1: Control software

Function Description

Current control software

Displays the installed software version: The display depends on the device class. For device class SINUMERIK these are the NCU and

HMI version.

2.1.2 Machine events - List view

Description of functions

Under Machine events in the machine information area you can view the following events for the selected machine as a list:

• Events from Control Monitor Services

- Alarm or PLC events

- Fault processing request

- Cyclic events (time trigger)

Events that have been configured by control monitors with the identification "Without entry in the machine events" do not generate an entry, and their details cannot be viewed either.

• Events from condition monitor services

- Exceeded interval limits of variable monitors or NC operating performance

monitors

- Limit value violation for measurement series/test series

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08/2008 2 Machine information

2.1 Machine overview

• System events

- NC/PLC archives created

- Service sessions performed

For each event, you can view additional diagnostic information or triggered workflow services and evaluate them (in some cases graphically):

• Workflow services elements

- Transmitted notifications (SMS/e-mail)

- Generated maintenance jobs

- Service cases

• Diagnostics data

- Files

- HMI action log

- Machine data or NC status data

- PLC traces or PLC data blocks

- Variable monitors

To ascertain differences between machine data, NC status data, and data of the HMI action log, you can compare this data with data of the same type for several events on the same machine.

Fig. 2-2: Machine events - List view

Function Description

Filter events You can filter events according to their properties.

Various filter criteria are available:

• Filter according to type of event (alarm, PLC, time trigger, trigger from performance monitors, etc.)

• Filter according to type of diagnostics data (e.g. files, PLC Traces)

• Filter according to type of triggered Workflow Services Elements (e.g. maintenance jobs)

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2.1 Machine overview

Function Description

• Filter according to event priority

• Filter according to time periods (e.g. today, this

week, from/to)

Note:

The filter can be hidden to make it easier to evaluate the event history at lower screen resolutions. However, the filter settings still remain active.

Find events You can browse events using a free text search. The

search is applied to the "Designation" and "Details" fields.

Note:

Localized alarm texts of the machine loaded into the ePS server are also found, even if another language is currently set on your workstation (browser).

Open event You can open the detail view of events, for example, to

view and compare diagnostics data.

Sort events You can sort events according to time stamp (date),

designation or priority.

Delete event

Delete several events

Note:

If the list of events has already been reduced by filtering and/or a search, the reduced list is sorted.

You can delete individual events.

You can delete several events simultaneously:

• Click the check box in the "Select all" header,

followed by the "Delete" button.

• Select individual entries using the check boxes in

the line and then click the "Delete" button.

Note:

You can select events in the control monitor services to be "not deletable" (e.g. for verification purpose). You cannot remove these from the list!

Notice:

Diagnostics data generated with an event are also deleted; however, triggered Workflow Services Elements (e.g. maintenance jobs) are not deleted!

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08/2008 2 Machine information

2.1 Machine overview

2.1.3 Machine events - Detailed view

Description of functions

In the detailed view of an event you can view detailed information about a trigger event and the diagnostics data and triggered workflow service elements it generates.

The detailed view of an event is divided into three areas:

• Trigger

• Workflow actions: Opening displayed actions

(maintenance job, notification)

• Diagnostics data: Opening displayed actions

The visualization is performed analogous to the configuration of a control monitor except for the restricted editing functions.

Fig. 2-3: Machine events - Detailed view

Note

The detailed information displayed for a particular event depends on the event type. The timestamp is displayed for all event types.

The time stamp is based on the time set on the machine, in order to achieve a true-to-life time-based payment for the event.

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2.1 Machine overview

2.1.4 Evaluation of workflow actions

Description of functions

To view notifications, you can jump directly from the evaluation of one diagnostics data item to another, if it belongs to the same event.

Fig. 2-4: Display of completed workflow actions

Function Description

View workflow element You can view workflow elements in detail. The work-

flow element will open, but it will not be possible to edit it (e.g. maintenance job).

Note:

Notifications and maintenance jobs cannot be edited.

Delete workflow element You cannot delete workflow elements retroactively

from events that have already occurred, since these show the documentation history.

Note:

Notifications, maintenance jobs and service cases cannot be deleted.

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08/2008 2 Machine information

2.1 Machine overview

2.1.5 Evaluation of diagnostics data

Description of functions

ePS Network Services offers evaluation tools for data acquired from the actions. These are either a text viewer (e.g. for machine data) or contain graphic views (e.g. PLC trace). A comparison tool is available for the machine data, NC status data, and HMI action log data types of diagnostics data. You can switch directly between different diagnostics data records of an event.

The following evaluation tools are available for the various diagnostics data:

• Viewing file lists

• Viewing HMI action log

• Viewing machine data

• Viewing NC status data

• Viewing PLC trace (the view can be configured and offers evaluation -

functions.)

• Viewing PLC data block/list

• Visualize variable monitors

Fig. 2-5: Display of recorded diagnostics data

Function Description

Diagnostics data You can switch directly from viewing data for one

action to viewing data for another, provided that it belongs to the same machine event.

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2.1 Machine overview

File list

The files uploaded from the control with a particular event can be displayed in the Browser or in another application, or stored on a data carrier.

Fig. 2-6: List of uploaded files

Function Description

Display/save file You can open a file in either a separate browser

window or another application. Alternatively, you can save the file to a data carrier.

Note: The type of display depends on the data type and the applications installed on your system. Pure text or HTML documents are displayed in a separate browser window. Applications registered in the operating system are usually opened directly. You must save any files with unregistered data types and open them manually with your application.

Delete file You cannot delete individual files from machine

events; it is only possible to delete the entire event entry.

Note: Deleting individual details from an event constitutes illegal manipulation of the archived document.

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08/2008 2 Machine information

2.1 Machine overview

HMI action log

An HMI action log uploaded with an event can be displayed in the browser and compared with other HMI action logs.

Fig. 2-7: HMI action log display

Function Description

Display the HMI action log

Compare HMI action logs

Delete HMI action log You cannot delete individual HMI action log files from

You can display and evaluate the content of an HMI action log in a text window.

Note: The content of the HMI action log is defined via local settings on the control (see Section 3.4 "Global settings"). The time stamp of the recorded information is generated from the PLC clock at the time of its occurrence.

You can compare the HMI action log currently selected with another. For this purpose, the system provides a list of all the HMI action logs available for the currently selected machine.

The HMI action logs are displayed in two horizontally adjacent windows and can be compared with each other. The event is displayed for each HMI action log, together with the event details and time stamp.

machine events; it is only possible to delete the entire event entry.

Note: Deleting individual details from an event constitutes illegal manipulation of the archived document.

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2.1 Machine overview

Machine data

Machine data uploaded with an event can be displayed in the browser and compared with other machine data.

Fig. 2-8: Machine data display

Function Description

Display machine data You can display and evaluate the content of the ma-

chine data in a table. You can select which channel you want to view machine data for.

Note: Machine data without a channel reference is displayed in the first channel. The machine data generated with control monitor services does not include any drive machine data.

Compare machine data You can compare the machine data record currently

selected with another. The system offers you a list of all available machine data records of the currently selected machine. The machine data values are displayed side by side for each machine data item. Any machine data items with different values in the original data record and the data record you are comparing with is highlighted. The event is displayed for each machine data record, together with the event details and time stamp.

It is only possible to display differences. The system then hides all machine data with identical values in the original data record and data record being compared.

Note: Drive machine data is not compared.

Delete machine data You cannot delete individual machine data record files

from machine events; it is only possible to delete the entire event entry.

Note: Deleting individual details from an event constitutes illegal manipulation of the archived document.

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08/2008 2 Machine information

2.1 Machine overview

NC status data

NC status data uploaded with an event can be displayed in the browser and compared with other NC status data.

Fig. 2-9: NC status data display

Function Description

Display NC status data You can display and evaluate the content of the NC

status data in a table and evaluate it.

Notice:

The NC status data reproduces the status of the relevant NC variables after an event occurs. For some events (e.g. RESET alarms) there is a danger of misinterpretation as the event itself influences the variable value (example: pointer to current block is reset by alarm).

Compare NC status data You can compare the NC status data record currently

selected with another data record. The system offers you a list of all available NC status data records of the currently selected machine. The values of the NC status data records are listed next to each other by variable for comparison purposes. Any variable with different values in the original data record and the data record you are comparing is highlighted. The event is displayed for each NC status data record, together with the event details and time stamp.

It is only possible to display differences. The system then hides all variables with identical values in the original data record and data record being compared.

Delete NC status data You cannot delete individual NC status data items

from machine events; it is only possible to delete the entire event entry.

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2.1 Machine overview

Function Description

Note:

Deleting individual details from an event constitutes illegal manipulation of the archived document.

PLC trace

PLC trace data created with an event can be displayed in the browser and evaluated with graphical tools. Signal curves can be checked by displaying variable values in the graphical display, setting markers, and zooming.

Fig. 2-10: PLC trace display as diagram

Function Description

Change to As this menu is a detail of the machine events,

Display The PLC trace is displayed for all configured

and several details may exist for the event, you can quickly change to other existing diagnostics data of the event via a menu.

variables in the specified format. The signal triggering the recording is displayed

and selected as 0 cycle/0 time. Display updates the display with the predefined

details for the PLC trace.

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08/2008 2 Machine information

2.1 Machine overview

Function Description

+ /− Opening and closing of the details for:

• Recordings

• Display options

• Variables

PLC trace: Showing/hiding variables

Showing/hiding the graph of the variable in the display: For a clearer view, variables can be hidden in the display in order that individual variable configurations can be viewed.

Type Format of the variables.

Unit Dimension of evaluated variable values

(e.g. ° C).

Conversion of display scaling

Evaluation of variable values for the dimension adjustment, linearly through two defined value assignments.

The variables can be scaled linearly via two defined points for the display (e.g. byte value 16 corresponds to 20° C, byte value 128 corresponds to 90° C).

Bits Display of a variable in byte format; not as a

value, but individually as a binary signal for each selected bit. Variables configured as byte can also be displayed as individual bits (BOOL). If not all of the individual bits are required in the view, they can be specifically selected for the display.

Variable display: Changing the sequence

The sequence of the variables can be changed so that they can be compared directly next to each other.

PLC trace: Time/cycles display The horizontal axis is always displayed with a

millisecond specification for each cycle. This can be changed to the cycle number, each calculated with the starting point 0 from the trigger.

Display options PLC trace diagrams can be displayed in a de-

fault setting that can be evaluated on every monitor.

A complete recording can be displayed in a compressed format, by means of a zoom setting in a single view. However, this may result in a loss of information. Every detail is displayed in an optimized compressed display, but in the smallest possible view. The minimum level of precision that can be set for the graph view is the pixel level, but marking should allow a cycle level of precision to be set dynamically.

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2.1 Machine overview

Function Description

Diagram/table A graphical or tabular display of the variable

values can be selected.

PLC trace: Data display Horizontal/vertical

The display of the data table can be changed from a horizontal (time/cycle axis) to a vertical (variable axis) view.

PLC trace: Markings Markings can be set in the PLC trace display

that are used for the difference calculation and display of the current values.

The markings are retained when using the zoom function. Depending on the resolution, they can be positioned on a cycle-specific basis; the minimum level of precision that can be set is the pixel level, where all cycles appear between the markings.

PLC trace: Data export

PLC trace: Printing data

PLC trace: representation

The PLC trace data can be exported as a file for further processing.

The PLC trace data can be printed on an installed printer.

The window for the PLC trace display can be maximized/minimized.

Fig. 2-11: PLC trace values displayed vertically

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08/2008 2 Machine information

2.1 Machine overview

Fig. 2-12: PLC trace values displayed horizontally

PLC traces uploaded with an event can be displayed in the browser and evaluated with graphical tools. Incorrect signal curves can easily be found by displaying variable values in the graphical display, setting markers, and zooming.

PLC data blocks/list

PLC data blocks uploaded from the control on an event can be saved to a data carrier.

Fig. 2-13: PLC data block display

Function Description

Save PLC data block You can save a PLC data block to an external

Delete PLC data block You cannot delete individual PLC data blocks

data carrier.

from machine events; it is only possible to delete the entire event entry.

Note: Deleting individual details from an event constitutes illegal manipulation of the archived document.

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2.1 Machine overview

Variable monitors

The data of a variable monitor saved with a machine event can be displayed.

Fig. 2-14: Variable monitor data

Function Description

Open variable monitor You can open the variable monitor and display

the variations with time of all the recorded

monitor data. Delete variable monitor data from the event

You cannot delete individual variable monitor

data from machine events; it is only possible to

delete the entire event entry.

2.1.6 NC monitors

Function description

The life-cycle loads of machine axes (linear, rotary, and main spindle) can be collected and analyzed using the monitors. NC variables (counters) related to maintenance, such as the traverse path, traverse time, or number of traverses are summated over the life cycle or time intervals and can be viewed by the machine operator in the form of time charts.

Maintenance can be performed based on this load data, in connection with warning limits and critical limits.

Note:

Deleting individual details from an event

constitutes illegal manipulation of the archived

document.

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2.1 Machine overview

Fig. 2-15: Time chart NC monitor

This information provides support with specifying new machine designs because the real load data is available for machine dimensioning.

Availability and privileges

The time charts of the NC monitors can only be displayed on the PC. The current counter states of an NC monitor can also be viewed on the operator panel. The authorization required to use the NC monitors is described in detail in Appendix A.2.

Fig. 2-16: Counter states of an NC monitor on the operator panel

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2.2 Measurements and measurement series

2.2.1 Analyzing on the PC

Description of functions

The performance and status of a machine and its modules can be analyzed with measurements and measurement series that have been performed on the machine. This includes measurement curves generated from the measurements and characteristics, as well as additional information about the measurement result. Trend curves can be generated from characteristics in measurement series. The machine operator can use the measurement results to make an analysis at a later point, while away from the machine. Status changes can be derived from the trend curves. Limit values will show whether any maintenance work is necessary at an early stage.

Selection and filter area

Fig. 2-17: Overview of the time series for the machine selected

Function Description

Select the time series The measurement series can be selected from

the machine axes in the selection tree. It is possible to select several measurement series.

Select individual measurements This function displays a table for the axis

concerned containing all the measurements that do not belong to a measurement series. Several measurements for the display can be selected in the table.

Advertisements The "Display" function shows the selected

measurement series in diagrams.

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08/2008 2 Machine information

2.2 Measurements and measurement series

Function Description

Filter time series

Test types:  Synchronous operation

axis test

This function opens the menu for the purpose of filtering the measurement series displayed in the selection. Measurement series can be filtered according to the type of measurement series.

 Circularity test  Universal axis test

Filtering The "Filtering" function causes the selected

filter setting to take effect.

Show/hide filter areas This function shows or hides the entire filter

area.

Displaying diagrams of the selected time series

If the user clicks the "Display" text button under the time series selection tree, the graphs for the selected time series are displayed.

Displaying the measurement results

You can view measurement results both on the machine operator panel and on the PC. Trend curves produced by measurement series can only be viewed on the PC.

The warning and critical limits of the characteristics can give the machine operator evaluation information about how far the qualitative state of the machine is from the limit criterion.

Fig. 2-18: Examples of time series

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2.2 Measurements and measurement series

The trend curve can be generated from the measuring type-specific characteristics (characteristic over time) by cyclic repetition of individual measurements. This is used in particular as a basis for condition-oriented maintenance. For this, measurement series can be generated based on existing individual measurements. This ensures that the measurement series is based on the same measurement.

Measurement series are used as the basis for condition-oriented maintenance because the trend curve and the limit values provide a basis for planning maintenance activities.

How each test is conducted is described in Section 2.3 Test series on the machine.

The machine operator can view the measurement results on the operator panel of the machine and on the PC. Trend curves derived from measurement series can only be viewed by the operator on the PC.

Individual measurements for an axis

Measurements that are not generated by the measurement series are displayed in a table. The measurements to be displayed can be selected in this table. Several measurements can be selected.

Fig. 2-19: Table of individual measurements

Displaying individual measurements

The "Display table of individual measurements" function opens each of the individual measurements selected in a separate diagram.

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2.2.2 Operating diagrams

General control elements

Function Description

Minimize diagram Reduces the diagram so that only the header line

is visible.

Restore diagram Restores the minimized diagram to its standard

size.

Maximize diagram Magnifies the diagram so that it fills the entire

diagram space. Close diagram Closes the diagram Setting and displaying

markings

Display in new diagram If the user clicks the "Display in new diagram"

The regenerated diagram assumes all of the dis-

Export diagram The data points represented in the diagram are

A pair of markings can be set in the diagram. Left-

click to set the first marking. Move the cursor

without pressing any buttons to position the sec-

ond marking, and then left-click. The markings

can be reset if you wish.

The markings are deleted by means of the "Delete

markings" function in the "Display" menu.

button on the right-hand side next to the drop-

down list box, a new diagram of the same type will

be displayed below the diagram that is already

shown.

play properties of the original diagram (character-

istic selected, markings, display, selection and

sequence of time series, etc.), with the exception

of its scale. In a new diagram, the scale is always

set to Auto/Auto.

saved in a CSV file.

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Changing the characteristic

Fig. 2-20: Drop-down list box for circularity test characteristics

The drop-down list box contains the list of characteristics for each test type. If the user selects a characteristic, the diagram that has been displayed up to this point will be replaced by the time series diagram for the characteristic selected.

"Actions" menu

Entries menu

Warm boot Regenerates the diagram. All parameters A table containing the parameters for all of the

Fig. 2-21: Parameters for all measurement series

measurement series shown in the diagram is displayed.

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"Display" menu

The display settings of the diagram may be controlled using this menu.

Entries menu

Display all data Displays the complete progression over time of

the time series

Between the markings Displays the time domain between the two mark-

ings Last month | | | Last year Back to previous zoom Generates the diagram with the previous zoom

Time-based distribution The horizontal axis represents the time. The

Equal distribution The measured values are distributed equally

Delete markings Removes the markings from the diagram.

These options are used to select the zoom fac-

tor. When the zoom level is changed, the dia-

gram is regenerated to reflect this; however, all

of the other settings (in particular, the markings)

remain the same.

setting

measuring points are plotted along this accord-

ing to their date.

across the X axis; it is not possible to draw any

further conclusions about the time of the meas-

urement from the points on the X axis.

List of machines and time series with control elements

Fig. 2-22: Displaying/hiding individual measurement series

Function Description

Hide measurement series This function removes the measurement series

graph from the diagram. The diagram is redrawn, which involves recalculating the scale.

Display limit values This function plots the limit values of the selected

measurement series in a line in the diagram. If the limit values are outside the range of values displayed, an icon indicating this will appear.

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Context menu of the time series diagram

If the user points the cursor to an individual measuring point within the time series in the diagram and right-clicks, a context menu containing actions relating to that measuring point appears. The functions executed via the context menu relate to either the entire measurement range to which the measuring point belongs (i.e. the measurement range and the measurement), or simply the measurement represented by the data point.

Entries menu

Measurement series comment Displays the measurement series comment. This

can be changed and saved. Save graphic

Measurement/measurement series parameters

Supplementary conditions for measurement

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Entries menu

Characteristic/limit values measurement

Measurement comment

Display measurement Displays a diagram with the individual meas-

urement selected below the time series diagram

shown.

2.2.3 Control elements of the diagrams for individual measurements

Fig. 2-23: Header line for individual measurement diagram

Changing the diagram type

The drop-down list box contains the list of diagram types that are available for each type of test. If the user clicks a name of a type of diagram, it replaces the type that has been displayed up until this point.

New type of diagram in a separate diagram

If the user clicks the "Display in new diagram" button on the right-hand side next to the drop-down list box of diagram types, a new diagram of the same type will be displayed below the diagram that is already shown.

The new diagram adopts all of the display characteristics of the original diagram (markings, zoom, etc.), with the exception of the scale. The scale of a cloned diagram is always Auto/Auto.

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Where individual measurement diagrams are concerned, the "Actions" menu and context menu have the same options:

Entries menu

Parameters Shows the pop-up window with the list of measurement

parameters. The same pop-up window can be opened from the context of the time series.

Limit conditions Shows the pop-up window with the list of measurement

parameters. Comment Pop-up with measurement comment Scaling Setting for the diagram scale (for the synchronous op-

eration axis test only). In the case of the diagrams for

the circularity test and universal axis test, the "Actions"

menu does not contain "Scaling".

Scaling for the synchronous operation axis test

Fig. 2-24: Scaling for the synchronous operation axis test

"Display" menu

This menu is only available for the individual measurement diagram of the synchronous operation axis test.

Entries menu

All without ramps Displays the entire measuring range, but without

All with ramps Displays the entire measuring range, including

Between the markings Adjusts the zoom factor of the diagram at the

the acceleration ramps

area between the markings. This function assumes that both of the markings have been set.

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Navigating to previous/next measurement

The two buttons for this function can be used to navigate to the previous or next measurement of the measurement series in question.

Displaying the characteristics and limit values

Fig. 2-25: Table of characteristics and limit values

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2.2.4 Circularity test

Description of functions

The circularity test produces a polar plot of the circular path and circularity-specific characteristics:

Characteristic Meaning

Circular deviation The circular deviation is measured on the basis of

ISO 230-4 as difference between the maximum and minimum radius at movement of a circle in one direction. A value is calculated for each direction of movement.

Circular hysteresis As defined in ISO 230-4 the circular hysteresis is de-

termined by establishing the maximum difference of measured radii on an angular position between the two directions of movement.

The measurement type-relevant parameters are also specified. The goal is to test the drive dynamics and accuracy of the two axes involved.

Fig. 2-26: Measuring result of a circularity test

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2.2.5 Synchronous operation axis test

Description of functions

The synchronous operation axis test result returns the torque/force measurement curve over the axis position and various torque characteristics. The characteristics are determined for each direction of movement separately. If nothing else is described for the characteristics, the characteristics refer to the position range without the acceleration and braking ramps.

Characteristic Meaning

Maximum torque The maximum returns the maximum torque in the

measured position range. With torque characteristics with linear trend, the proportion the trend is computed for determining the maximum torque.

Minimum torque The minimum returns the minimum torque in the

measured position range. With torque characteristics with linear trend, the proportion of the trend is computed for determining the minimum torque.

Average torque The characteristic returns the mean torque in the

measured position range with the configured speed. Independently of the direction, a larger value always corresponds to a larger torque in the direction of movement.

Standard deviation The characteristic represents the standard deviation of

the torque characteristic in the measured position range at the configured speed. With torque characteristics with a linear trend, the proportion of the trend is eliminated from the standard deviation.

Increase in the linear trend of torque characteristic

Maximum torque of the acceleration ramp

For axes that also have a direct measuring system the overall rigidity curve over the axis position is also displayed. The rigidity is determined independently of the direction. The following rigidity characteristics are calculated:

The characteristic indicates the increase in the change to the torque at position changes.

The characteristic indicates the maximum torque which is run in the acceleration ramp.

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Characteristic Meaning

Maximum rigidity The characteristic returns the maximum rigidity

value via the rigidity characteristic in the measured position range at the configured speed.

Minimum rigidity The characteristic returns the minimum rigidity value

via the rigidity characteristic in the measured position range at the configured speed.

Average rigidity For calculating the characteristic, the mean rigidity

value is determined in the measured position range at the configured speed.

Standard deviation of the rigidity

For calculating the characteristic, the standard deviation of the rigidity is determined in the measured position range at the configured speed.

The synchronous operation axis test notifies the machine operator of faults and interference resistances from feed axis elements. The curve of the recorded values indicates at which axis position the disturbance is located. A trend analysis of the characteristics will indicate any change in the status of the drive train.

Fig. 2-27: Measurement results of a synchronous operation axis test

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2.2.6 Universal axis test

Description of functions

With the universal axis test different characteristics are calculated which describe the mechanical properties of an axis.

Characteristic Meaning

Residual torque (Res) This characteristic is not supported. Coulomb friction (Coul) The Coulomb friction describes the proportion of the

friction which is independent of the speed. Mixed friction (Mix) This characteristic is not supported. Viscous friction (Visc) This characteristic describes the proportion of the

friction which increases linear to the speed Moment of inertia (Inr) The characteristic describes the entire moment of

inertia that needs to be moved by the electrical

drive. This includes the moment of inertia of the

motor. Torque offset (Const) With axes which are pretensioned in one direction

(e.g. vertical axes) the characteristic indicates the

torque required for compensating for this pretension. Coherence (K) The coherence indicates how much a model param-

eterized with the calculated characteristics can

simulate the measured torque characteristics. Circular deviation (G) The characteristic describes the maximum position

deviation with axis movement on the basis of a ve-

locity profile. The calculation of the characteristic is

based on ISO 230-4 as is the case with the circular-

ity test.

The measurement type-relevant parameters are also specified.

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Fig. 2-28: Time series for a universal axis test

2.2.7 Variable monitors

Description of functions

Variable monitors enable the recording in the control of changes over time of any status data. The variable monitors are essentially for long-term recording in slow data recording cycles (as opposed to the PLC trace).

Up to 32 variables can be recorded in a common cycle in a variable monitor. The PLC variables recorded can be from the PLC environment: inputs, outputs, counters, flags, and any data addresses in PLC blocks. From the NC environment, they can be machine data, setting data, system variables and others.

The variables recorded can be scaled and assigned freely definable units. Individual variables of a variable monitor can be identified as counting variables (e.g. workpiece counters). These variables can be used in the configuration of interval triggers to trigger recurring actions after a certain number of counting units have elapsed. Counting variables are counted up monotonically. Resetting of the variables in the control is compensated for by the system because the count is resumed on the basis of the last value before reset.

Limit values can be configured for each variable for automatic monitoring of the state. Actions can be triggered when limit values are violated. This is the same as described for the control monitors.

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Selection and filter area

Fig. 2-29: Select variable monitors

Displaying diagrams of the selected variables

To display variables in a diagram, select them in the selection area. Activate the "Display" field to display all selected variables in one common diagram in graphs. Any variables from different variable monitors can be displayed together in one diagram. If you select additional variables and activate the "Display" button, a new diagramm is created which displays the newly selected variables. Any number of diagrams can be generated.

Operating diagrams

The diagrams for displaying variable monitors are operated in the same way as the diagrams for displaying measurement series. Some of the available functions may differ slightly due to the differences between measurement series and variable monitors. These differences are described in more detail in the following sections.

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List of displayed variable monitors and variables with control elements

Fig. 2-30: List of displayed variables

Function Description

Hide variable monitor This function removes all variable monitor graphs

from the diagram. The diagram is redrawn, which involves recalculating the scale.

Hide variable This function removes the variable graph from the

diagram. The diagram is redrawn, which involves recalculating the scale.

Display limit values This function plots the limit values of the selected

variable in a line in the diagram. If the limit values are outside the range of values displayed, an icon indicating this will appear.

"Actions" menu

Entries menu

Warm boot Regenerates the diagram. Variable details A table is displayed showing detail information

about the displayed variables.

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2.3.1 Performing measurement series

Perform measurement

The following alternatives are available for performing measurements on the machine:

• Performing a single measurement with manual entry of parameters before per-

forming the actual test

• Performance of a single measurement as the repetition of an existing meas-

urement without changing the parameters

• Performance of a further measurement as part of a series of measurements,

based on the parameters predefined in the measurement series

• Performance of a measurement of a measurement series prescribed by a

maintenance job

• Performance of measurements configured in a test series

• Performance of measurements in a test series by means of a maintenance job

• Performance of measurements in a test series without a machine operator, by

means of a maintenance job under the control of the PLC.

Availability and privileges

Measurements, measurement series, and test series can only be performed on the operator panel. The authorization required to perform measurements, measurement series, and test series is described in detail in the Appendix.

Measurement sequence

The sequence is performed as follows independently of the different types of execution and type of test:

• Machine operator selects measurement, measurement series, or test series

• Confirmation of the parameters of the measurement and display of the meas-

urement series contained in the test series

• A contour test to check collision can be performed before the actual measure-

ment

• Check release by the PLC

• Machine operator sets AUTO mode and feedrate override to 100% on the con-

trol

• Machine operator presses NC START on the control

• Perform machine-specific prolog of the measurement movement

• Perform the measurement movement with data recording

• Perform machine-specific epilog of the measurement movement

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• Result display

• Save the result

Notice

Please observe the information on the operator panel!

2.3.2 Requirements for performing the test

Requirements on the control

When making measurements, the machine axes must be moved with precisely the motion profile that is defined in the NC program. In addition, it must also be guaranteed that the motion is also executed in the machine coordinates. The following functions in the NCK could be problematical when carrying out measurements (sample selection):

• Asynchronous subprograms

• Static synchronized actions

• Coupled axes

• Kinematic transformations

• Superimposed (overlaid) motion, such as DRF, external work offset

• Tool length compensation

• Functions, that influence the velocity, such as G95

• Functions that change the position, such as DIAMON

• Axis replacement/geometry axis replacement

• Axis is passed over to the PLC (PLC axis)

The NC program for performing the measurement does not affect the functions listed above. Only the zero offsets are disabled and the offset produced by DRF and external zero point offset is compensated statically, i.e. the value is corrected by the value that applies at the beginning of the measurement.

Orientation transformations are a special case. It is possible to execute measurements with the geometry axes when transformation is active. However, the offset of the geometry axis coordinates produced by the orientation axes is not compensated for. It is therefore advisable to deactivate transformation.

Couplings between axes should be separated before the measurement movement (e.g. in the prolog program). The NC program of the ePS system does not separate couplings. The ePS system assumes that it is possible to load, select, and start an NC program (with subroutines) downloaded from the ePS system on the machine in a particular channel. For machines where the PLC prevents the machine operator from selecting or starting any NC program, the PLC can communicate with the ePS system via DB10.DBB90 or DBB91.

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Machine data must be set in the control to acquire data for the condition monitoring measurements. Not only Trace Server machine data but also MD 36730: DRIVE_SIGNAL_TRACKING must be set.

Drives that are linked via Profibus must be handled differently. Here the Profibus configuration must be changed so that the torque values can be transmitted to the control cyclically.

Prerequisites of the machine

The measurements for condition monitoring assume that the machine axes can be traversed separately with precisely the motion profile that is defined by the NC program for performing the measurements.

Machine designs with parallel kinematics, for example, that do not allow this are not suitable for condition monitoring by ePS Network Services.

Note

Axes that can only be programmed as positioning axes can only undergo the synchronized axis test. The circularity test or universal axis test cannot be performed on these axes.

NC programs are downloaded to the control to carry out the axis tests. There must be approximately 100 KB free NC program memory available.

A variable $AC_MARKER is used for executing the NC programs. You can configure the variable index. The default setting for the index is value 5. You must ensure that the $AC_MARKER variable of the configured index is not used by other control functions.

Note

The ePS system does not check whether the configured $AC_MARKER variable is also used by other control functions.

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2.3.3 Prolog and epilog program for a measurement

Description of functions

To prepare the control making it suitable for the test, an NC program that has been specially adapted to the machine by the machine manufacturer or end user is executed at the beginning of the test. This means that machine settings can be specifically changed so that the test can be performed (example: Disabling transformations and couplings, resetting pre-set G codes).

Suitable programming of the prolog and epilog program can influence how the test is performed. When a test series is carried out, individual measurement series can only be hidden under the tested conditions (e.g. due to a risk of collision).

The prolog and epilog program is reloaded into the control with name "N_EPS_PROLOGEPILOG_SPF" every time a test is run. The NC program editor of the operator panel (=HMI-Advanced) can be used to modify this program.

After the test has been performed, the ePS system automatically checks whether the prolog/epilog program has been changed and, if required by the machine operator, stores it permanently.

Fig. 2-31: Prompt for NC-START

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Fig. 2-32: Saving the prolog/epilog program permanently

Call sequence of the NC programs

The prolog and epilog program is executed before and after each measurement movement. The program is also called at the start of a test series and at the end of a test series.

Example of a call sequence:

Prolog for test series (testType == "FRAME")

Prolog for measurement series1 (testType == "CIRCULARITY") Checking the return parameters Measurement1 Epilog for measurement series1 (testType == "CIRCULARITY")

Prolog for measurement series2 (testType == "EQUABILITY") Checking the return parameters Measurement2 Epilog for measurement series2 (testType == "EQUABILITY")

Prolog for measurement series3 (testType == "UNIVERSAL") Checking the return parameters Measurement3 Epilog for measurement series3 (testType == "UNIVERSAL")

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Prolog for measurement series4 (testType == "CIRCULARITY") Checking the return parameters Measurement4 Epilog for measurement series4 (testType == "CIRCULARITY")

...

Epilog for test series (testType == "FRAME")

testType == "FRAME" marks the call to start and end of the test series. The other parameters with this call are irrelevant. testType == "CIRCULARITY" identifies a circularity test measurement. "EQUABILITY" stands for the synchronous operation axis test and "UNIVERSAL" for the universal axis test.

In the calls placed before and after a measurement, the further call parameters of the program contain the specific information about the measurement in accordance with the table.

Description of the call parameters

All position values refer to the machine coordinate system (MCS).

Synchronous

operation axis test

ePS_error ePS_errMsg

doProlog

Return parameters (see below)

TRUE = Call as prolog FALSE = Call as epilog

testType

FRAME = Prolog/epilog of the test series (The following parameters are irrelevant.)

testType

measSeriesName

intParam1

EQUABILITY CIRCULARITY UNIVERSAL Name of the measurement series (in UPPER CASE) Channel axis number

of the traverse axis

intParam2

Channel axis number of the measurement axis

intParam3

intParam4

intParam5

intParam6

realParam1

realParam2

realParam3

realParam4

realParam5

realParam6

Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Start position 1st center point coor-

End position 2nd center point co-

Reserved Circle diameter Reserved Feed Feed Reserved Reserved Reserved Reserved Reserved Reserved Reserved

Circularity test Universal axis test

Plane selection (1 = G17, 2 = G18,

Channel axis number

of the traverse axis 3 = G19) Reserved Reserved

Start position dinate of the circle

Maximum position ordinate of the circle

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Synchronous

operation axis test

axParam1

Channel axis (traverse axis)

axParam2

Machine axis (measurement axis)

axParam3

Machine axis (traverse axis)

axParam4

axParam5

axParam6

Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved

Description of the return parameters

You can influence the measurement via the return parameters. The return values are always queried after call with doProlog = True and testType = "", i.e. after the prolog is called for each measurement series. The process then continues according to the returned values.

Synchronous

operation axis test

ePS_error

ePS_errMsg

0 = (default setting) execute measurement 1 = Suppress execution of measurement, continue with the next

measurement series. Errors are not displayed. Reserved for future expansions

Circularity test Universal axis test

Channel axis 1 (traverse axis)

Channel axis 2

Channel axis

(traverse axis)

Reserved (traverse axis)

Reserved Reserved

Circularity test Universal axis test

2.3.4 Program example

Description

Here is a commented example program to illustrate how the prolog and epilog program can be used to prepare the machine specifically for a certain test. The structure of the program is as follows:

Prolog for the test series:

This section of the program is only executed once at the beginning of a test series and also on each single measurement outside a test series. This block contains everything that has to be executed irrespective of the type of test or the axis that is to be measured. For example, in this case G codes that are preset on the machine via machine data (G95, DIAMON, etc.) could be deactivated, the tool could be unloaded, the workpiece removed, and all axes moved to a safe initial position.

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Prolog for each measurement:

This section of the program is executed before each measurement, irrespective of whether the measurement is part of a test series or is performed individually. This block can be used with call parameters to check which axis is to be tested, which test type is to be conducted, and with which parameters the measurement will be performed. For example, when testing certain axes, it may be necessary to move other axes to another position than the basic position, or the starting point for the measurement cannot be approached directly (circularity test). Certain actions could also be performed depending on the position range in which the measurement is performed.

When programming axis movements, it is important to ensure that the parameters of a measurement always refer to the machine coordinate system if they represent positions. The example program shows how the axis movement can be offset into the machine coordinate system using the command SUPA.

It is possible to test the name of the measurement series in the program and to execute special functions for a certain measurement series. However, that should be limited to special cases because the parameters of a measurement series can be changed at any time without its name having to be changed.

Epilog for the test series:

This section of the program is only executed once at the end of a test series and also after each single measurement made outside a test series. The actions that are necessary for minimizing the work the machine operator must do in order to resume the machining process after performing measurements should be executed in this block.

Epilog for each measurement:

This section of the program is executed after each measurement, irrespective of whether the measurement is part of a test series or has been performed individually. It is useful for undoing actions performed before the measurement. It may be necessary to move all axes back to their safe initial position.

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PROC EPS_PROLOGEPILOG(BOOL doProlog, ePS_error,

; user DEF area

ePS_errMsg, STRING[32] testType, STRING[32] measSeriesName, INT intParam1, INT intParam2, INT intParam3, INT intParam4, INT intParam5, INT intParam6, REAL realParam1, REAL realParam2, REAL realParam3, REAL realParam4, REAL realParam5, REAL realParam6, AXIS axParam1, AXIS axParam2, AXIS axParam3, AXIS axParam4, AXIS axParam5, AXIS axParam6)

IF (doProlog == TRUE)

MSG("Start of Prolog ... ")

IF ( testType == "FRAME")

MSG("Frame Prolog ...")

; start of Prolog - user section start

; Frame prolog user section actions at the start of a test series

T0 M6

BASIC POSITION

TRAFOOF

G94

DIAMOF

G90

ELSE

MSG(testType << " Prolog ...")

; Unload tool ; all axes to safe position ; Deactivate transformation ; for lathes, G95 is often placed in front

; prolog for a specific series of measurements

; handling irrespective of type of measurement

; procedure when measuring specific axes:

IF (axParam1 == C) OR (axParam1 == A)

IF ($AA_IW[Q]!=0)

ENDIF

ENDIF IF (axParam1 == U) OR

(axParam1 == W)

IF ($AA_IW[Q]!=180)

ENDIF

IF (testType == "CIRCULARITY")

; if axis A or C are to be measured, Q must be set to 0

; M code for rotation of Q

; if axis U or W are to be measured, Q must be set to 180

; M code for rotation of Q

; specific procedure for circularity test ; actions for all circularity tests: to avoid

collision, the two axes are moved to the circle center one after the other. A particular sequence may be required.

G1 F1000 SUPA AX[axParam1]=realParam1

; SUPA, therefore target position in the machine coordinates

G1 F1000 SUPA AX[axParam2]=realParam2

IF (measSeriesName == "KFT_FFWON")

FFWON

; specifically this series of measurements should be performed using the pre-control FFWON

ENDIF

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IF (testType == "EQUABILITY")

; actions for all synchronous operation axis tests, e.g. approaching the start position

IF ( axParam1 == C ) AND

( realParam1 > 300 )

ePS_error = 1

ENDIF

IF (measSeriesName == "")

ENDIF

IF (testType == "UNIVERSAL")

IF (measSeriesName == "")

ENDIF

MSG(" ... finished Prolog.")

GOTOF PROG_END

ELSE

MSG("Start of Epilog ... ")

IF ( testType == "FRAME")

MSG("Frame Epilog ...")

ELSE

MSG(testType << " Epilog ...")

G90

BASIC POSITION

MSG(" ... finished Epilog.")

ENDIF

PROG_END:

G4 F1

M17

; example of using the return parameter ePS_error

; skip the synchronous operation axis test with the C axis

; specific actions for single series of measurements

; actions for all universal axis tests, e.g. approaching the start position

; specific actions for single series of measurements

; end of Prolog - user section end

; start of Epilog - user section start ; epilog of test series ; frame epilog user section

; Epilog specifically for the last meas. series conducted

; all axes back to safe position after measurement

; end of epilog - user section end

; is required for synchronization

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2.3.5 Commissioning measurements

Description of functions

The prolog and epilog program must be edited in order to perform measurements. If measurements are performed on a machine for the first time, or if the prolog and epilog program has been deleted, then a preconfigured prolog and epilog program takes effect, which prevents the further execution of the NC programs as the NC program code runs in an endless loop. This part of the preconfigured prolog and epilog program must be deleted. A program code adapted to the requirements of the machine must be used for the prolog or epilog.

Fig. 2-33: Prolog and epilog program

2.3.6 Release protocol between PLC and ePS system

Function description

Communication is performed between the ePS system and the PLC for the execution of a test. The ePS system signals that a test will be executed with axis movements. The PLC can then put the machine in a suitable state and signals to the ePS system that the test can begin.

The protocol allows test series that are to be carried out with a maintenance schedule to be executed in a fully automatic manner while being monitored by the PLC.

More details are given in /R1/.

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2.3.7 Contour test

Function description

A dry run is possible to ensure measurements can safely be performed on the machine. The machine operator has the option of executing a dry run with reduced velocity before beginning the test run configured to a specific type. This allows the operator to test for safety path motions (contour monitoring) of the machine axes to avoid collisions, etc.

Fig. 2-34: Selecting the contour test

Field Description Type

Contour test A contour test can be run to check that the

ACTION measurement part program is collision-free before actual measurement. The contour test can also be carried out with the function "single block execution" active.

Measurement Selection of the "Measurement type" tab. The

ACTION measurement can be performed once the notes have been read and understood.

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Fig. 2-35: Measurement series of a test series

2.4 Maintenance

Function description

Entering via "Machine information"  "Maintenance jobs" provides an overview of the jobs that are pending or complete for the single machine that is currently selected.

The overview of the maintenance jobs on the PC (see Section 4.1.1) is used for the following purposes:

• Obtaining an overview:

• Editing jobs:

Of the jobs that are pending and already complete; progress monitoring, planning service applications.

Automatic editing of controlled maintenance jobs on an individual basis, via control monitors and maintenance schedules

Changes made to the job here are on a oneoff basis and do not affect the original maintenance schedules.

Editing maintenance jobs is only possible for new jobs that are not due, open or closed.

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• Changing work instructions:

• Changing execution time:

• Editing comments:

If other tasks that were not known at the time of planning must be completed along with those specified in the maintenance schedule

If you change the work instruction, please note that this is only valid for the selected maintenance job. Any necessary modifications to the underlying maintenance schedule must be made via the "Set up function" menu  "Maintenance schedules".

Editing maintenance jobs is only possible for new jobs that are not due, open or closed.

E.g. scheduling tasks that can or should be performed together for the same day

Editing maintenance jobs is only possible for new jobs that are not due, open or closed.

Adding comments for the tasks that have been performed or have not been performed; attaching detailed service report files to the job.

Editing comments is only possible for new jobs that are not due, open or closed.

• Acknowledging jobs:

• Deleting jobs:

The maintenance procedures carried out are acknowledged as OK or Not OK and then closed.

Jobs can be deleted in their entirety.

This does not affect the underlying maintenance schedules and control mechanisms.

Deleting maintenance jobs is only possible for new jobs that are not due, open or closed.

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2.5.1 Remote access functions

Overview

Remote access is an efficient and low-cost way of providing support for machine tools and production equipment via the Internet.

In the event of a fault, the service organization of the machine manufacturer has fast access to important control data and diagnostic functions. In that way, the machine manufacturer or maintenance department of the end user can immediately analyze the current condition of the machine in which a fault occurred.

Remote access avoids time-consuming in-situ service assignments or at least helps prepare for them better. Machine manufacturers can therefore reduce their warranty costs while providing more efficient servicing support for their end users.

Summary of the most important functions

The following functions are available during a link with the machine control. These functions enable diagnostics and fault rectification via the machine control. It is usually up to the service technician to execute the function. The technician can work on all problems via remote access on a PC with a mouse and keyboard.

Function Property Chat

Permits the exchange of text messages with a participant in the service session.

Desktop sharing

Permits the display and remote control of machine control. For security reasons, however, it is not possible to initiate machine movements or to start NC programs. Within the function, areas of the screen can be marked with the Annotate function, which is similar to text marker.

Transfer file

Permits the transfer of single or multiple files or directories. Transfer can be from the service PC to the machine control or vice versa. This enables the import of patches to correct errors, for example. The machine control can also be updated quickly. Even complex NC programs can be transferred to the service employee for offline testing or to the service technician for modification via file transfer.

Video

Permits the transmission of video images of a webcam to the machine control

Recording and playback

Enable storage of the entire service session or parts of the service session for training or archiving purposes.

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Function Property Remote printing

Permits the printing on a local printer of the service PC of documents or graphics that are displayed on the control. This also installs the printer driver "Active Touch Document Loader" on the machine control.

2.5.2 Functions of a service session

Function description

The following functions are available during a link with the machine control. These functions enable diagnostics and fault rectification via the machine control. It is usually up to the service technician to execute the function. The technician can work on all problems via remote access on a PC with a mouse and keyboard. Several service employees and specialists can work together in a service session to solve a problem. The service technician who establishes the service session first keeps control of all functions throughout the service session. All other service technicians can only observe what is going on. If necessary, the first service technician can pass on and take back control to or from another service technician within a desktop control session. The entire session can also be passed on to a second service employee.

Function Property

Dialog via text window (Chat)

Remote display of the operator interface HMI (Desktop view)

Remote control of all operating functions (Desktop control)

Data transfer (Transfer file)

You can exchange text messages with the machine operator online via a chat window. The "Chat" function can be started without the need to obtain the machine operator's agreement. The "Desktop view" function is used to observe all operating steps at the operator interface of the machine HMI. That enables you to detect remotely on the service PC which functions are triggered on the control. You can provide the machine operator with instructions using the annotation function. You can use the "Desktop control" function to execute all operating functions of the machine control via remote access. For safety reasons, however, it is not possible to initiate machine movements or to start NC programs. You can use the "Transfer file" function to transfer data between the machine control and your service PC. Data transfer is possible in both directions. Which functions and views of drives are used within data transfer depends on the type of session set.

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Function Property

Conference link (Transfer session)

You can use the "Assist online support" function to invite other specialists to join the teleservice session. The person you invite to join a teleservice session that is currently underway has the option of either providing active support or simply

participating in the teleservice as an observer. Remarks (Annotate)

The "Annotate" function provides a kind of marker

pen function. You can use this marker pen to give

the machine operator instructions within the

following functions:

• Remote display - application view and desktop view

• Remote control - application control and desktop control

Video transmission from the PC of the service engineer (video session)

You can use the "Show video" function to transfer a video image from your workstation to the machine operator. This can be used to show a draw-

ing, for example. Remote printing (Remote print)

A special printer can be activated on the control.

If data is output to this printer, it is redirected to

your service PC during an online link. This en-

ables a printout of important information to be

forwarded to you. The printout is then output on

the printer of the service PC.

2.5.3 Starting a service session

Overview

To open a teleservice session, select main menu item "Machine information" and then menu item "Run teleservice". Go to the "Remote access" section and click on the "Run teleservice" link.

The session ID shown is transferred to the machine operator:

Fig. 2-36: Transfer session ID

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Function description

Fig. 2-37: Main menu of a support center session

Registers Content

Tools Selection of functions: chat, video, or file transfer Desktop Selection of functions: desktop control or desktop view Application No longer used starting with ePS Network Services V4.0 Session Selection of functions: transfer session, session options, or end

session

Functions on "Tools"

Function Description

Video This permits the transmission of video images of a webcam

from the service PC to the machine control.

Transfer file Permits the transfer of single or multiple files or directories.

Transfer can be from the service PC to the machine control or vice versa. This enables the import of patches to correct errors, for example. The machine control can also be updated quickly. Even complex NC programs can be transferred to the service employee for offline testing or for modification via file transfer. Which functions (advance or basis file transfer) and views of drives are used within data transfer depends on the type of session set for an organization.

Chat Once initiated, the chat function allows each participant to

send text messages. The participant can choose another participant to whom he/she wishes to send a message; alternatively, he/she can broadcast the message to all service employees who are logged on.

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Function Description

The chat function can be started within the menu at any time. For communication with the machine operator, it is advisable to start the chat function before executing the "Desktop control" function or transferring a file.

Note

It is not easy for the machine operator to operate the chat window without a mouse. The machine operator can place the chat window in the background or foreground via softkeys during a desktop control session. The chat window on the machine control is automatically placed in the foreground if a text message is received.

If the machine operator wants to send a text message on his or her own initiative and the chat window is minimized, the operator can place the chat window in the foreground via a softkey.

Functions under the "Desktop" tab

Function Description

Request View Permits display of a machine control:

Within the function, areas of the screen can be selected with the Annotate function, which is similar to a text marker. For safety reasons, however, it is not possible to initiate machine movements or to start NC programs.

Request Control Permits control of a machine control:

Within the function, areas of the screen can be selected with the Annotate function, which is similar to a text marker. For safety reasons, however, it is not possible to initiate machine movements or to start NC programs.

Functions under the "Session" tab

Function Description

Transfer session Transfer session control to another service technician Session options Optimize display of complex graphics End session Ending a service session

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2.5.4 Example of a session via remote access

Prerequisite

The service session has already been established. You want to open a chat session with the machine operator, then control the machine control via the desktop control, transfer data, and record the entire service session.

Starting a chat session

The chat function allows each participant to send text messages once it has been started. The participant can choose the participant to which he or she wants to send a message or broadcast the message to all service technicians who are logged onto the system. The chat function can be started within the menu at any time. For communication with the machine operator, it is advisable to start the chat function before executing the desktop control function or a file transfer.

Procedure

1. To start chatting, click the "Chat" button.

2. Select the recipient. The default setting is "All Participants".

3. Click the "Send" button to send the text message to the participant. You can

optionally use the enter key.

Fig. 2-38: Select recipient

Click the "−" button at the top right of the chat window to close the chat. If a participant closes the chat window, the initiator receives a message. The person who closed the Chat window cannot open it again. The initiator must end the chat and restart it to give all participants a chat window again.

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Note

It is not easy for the machine operator to operate the chat window without a mouse. The service technician should therefore minimize the chat window during a desktop control session. The chat window on the machine control is automatically placed in the foreground if a text message is received.

If the machine operator wants to send a text message on his or her own initiative and the chat window is minimized, the operator can place the chat window in the foreground via a softkey.

2.5.5 Granting permission to execute functions

Prerequisite

If you want to take control of the machine control, the machine operator has to grant you permission. The machine operator can grant you permission for the requested "Desktop control" function alone, or for all functions that you may still want to use during the service session. Indicate to the machine operator that it is simpler for both to grant permission for the entire session.

Desktop control

1. Go to the "Desktop" tab and click "Request Desktop Control ..." The following display appears for your information. You can acknowledge it with "OK".

Fig. 2-39: Requesting permission

2. As soon as permission has been granted at the machine end, the window is acknowledged automatically. In this dialog box, the machine operator permits monitoring of the machine control, as well as general execution of all functions without prior confirmation by the machine operator via "Grant Permissions for all actions …".

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The following dialog box is displayed to the machine operator:

Fig. 2-40: Granting permission

Data transfer/"Advanced" transfer file:

3. Go to the "Tools" tab and click "Transfer files" in the menu. The machine operator must agree to this file transfer. Unless the machine operator has granted general permission to execute all functions, he or she must agree to each individual transfer.

This transfer may contain one or more files or a whole directory. Alternatively, you can select the file transfer within the desktop control by clicking on the "Sharing" button top right, upon which the following dialog box opens.

Fig. 2-41: Starting file transfer

Note

It is advisable to perform data transfer at the ePS Network Services display level because there are no HMI headers that reduce the screen content at this point. In the case of file transfer within a desktop control session, both parties can view and operate the file transfer window. If this is not desired or is not permitted, the file transfer should only be started from the menu of the service technician. In this "stand-alone" file transfer, only the service employee has control of the files to be transferred.

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Fig. 2-42: Directory structure

4. Open a directory with a double-click. Click the back arrow to go to the next level up. To select several files, hold the <CTRL> key down during selection.

5. Data transfer is started by clicking the arrow buttons. When data transfer has been started, the progress of transfer is indicated, allowing you to estimate the remaining transfer time.

6. You can end the file transfer with the "X" button.

Fig. 2-43: End file transfer

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Recording a service session

7. Select the "Record Session" button. The "Record Session" dialog box opens. Select the storage location and a file name for the Record File and confirm this name with "Save".

Fig. 2-44: Recorder panel

8. The recorder panel is used to you select the various options and execute actions.

Start recording by clicking the "Record" button.

You can pause recording at any time and then resume it by clicking "Pause".

To end recording, click the "Stop" button.

Ending desktop sharing

9. To cancel or end desktop sharing, click the "Sharing" button at the top righthand side of the desktop sharing window and select "Stop Desktop Sharing".

Fig. 2-45: "Stop Desktop Sharing"

Selecting screen contents during desktop control

1. To apply annotations or markings to the desktop, click the Sharing button at the top right-hand corner of the Desktop Sharing window and select "Annotation".

Fig. 2-46: "Annotation" toolbar

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On the "Annotation" toolbar, the cursor changes shape to a marker pen with which you can select areas of the machine control.

2. To end the "Annotation" function, click the "−" button at the top right-hand corner of the toolbar.

3. You must then click on the desktop of the machine control with the mouse to get back mouse control.

Ending a service session

4. To end the service session, click the "Leave session" button. Confirm the end of the session by clicking Yes.

Fig. 2-47: Leave session

2.5.6 Setting up a service conference call

Description of functions

Several service employees and specialists can work together in a service session to solve a problem. The service technician who establishes the service session first keeps control of all functions throughout the service session. All other service technicians can only observe what is going on. If necessary, the first service technician can pass on and take back control to or from another service technician within a desktop control session.

The entire session can also be passed on to a second service employee. After that, all functions must be confirmed again by the machine operator.

Example

Participants:

• "Service technician 1" "Service technician 1" opens a "desktop control session" and can execute all

functions of the control.

• "Service technician 2" "Service technician 2" is logged on with the name "Support Assist". "Service technicians 2" sees the same content, but cannot execute functions.

(Exception: participating in the chat)

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Transferring desktop control to "service technician 2" (Support Assist)

To transfer control, click the "Sharing" button in the top right-hand corner of the Desktop Sharing window and select "Allow to Control Remotely". Click on the participant "Support Assist" (example):

Fig. 2-48:

Control is transferred to "Service employee 2" for the current desktop control function. He or she can now take over control by clicking on the desktop of the machine control with the mouse. "Service employee 2" can execute the following functions:

• Operate the machine control

• End desktop control

• Exit a service session

Transferring desktop control back from "service technician 2" (Support Assist)

"Service technician 1" can regain control. To transfer control, click the "Sharing" button in the top right-hand corner of the Desktop Sharing window and select "Allow to Control Remotely". Click on the "Support Assist" participant and control is passed back to you.

Fig. 2-49:

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Transfer of the entire service session

If "service employee 1" transfers the entire service session to "service employee 2", "service employee 1" can continue to observe the session or leave the session without closing the entire service session. "Service employee 1" clicks the "Transfer Session" button.

Fig. 2-50:

A selection menu with the name of the other service technicians who are logged onto this session is displayed. "Service technician 1" selects "service technician 2" (example: Support Assist) and acknowledges with OK. From this point on, "service employee 1" can only participate as an observer. All functions are deactivated in his/her menu. "Service employee 2" has taken over the service session completely and can now let "service employees 3, 4, 5", etc., take part in the session. The service session can be transferred any number of times.

Note

Transferring the service session within the desktop view or desktop control terminates the desktop view or desktop control function.

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2.5.7 Remote control via the keyboard

Function description

In a service session the special function keys on the operator keyboard can also be operated using the keyboard of the service PC via remote access. The following table shows the keys on the PC to which the horizontal and vertical softkeys and the special keys for the SINUMERIK keyboard are mapped.

Fig. 2-51: Special keys

Key Meaning

Area switchover key You can call the main menu from any operating area by pressing this key. Pressing the key twice in succession changes from the current operating area to the previous one and back again. Etc. key Expansion of the horizontal softkey bar in the same menu.

<Recall> key The <Recall> key goes to the next highest menu. It also closes a window. Machine area key Direct jump to the "Machine" operating area.



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3.1 Maintenance

3

3 Setting up functions

Displaying overview

The functions below are set up, defined and executed in the "Set up functions" area for a selected machine and its corresponding maintenance and monitoring:

• Service/Maintenance

• Monitoring PLC and NC sizes

• General function settings for user configurations

• Function settings for communication

• Copying user configurations

Setting up functions

Service/Maintenance

►

Maintenance schedules

►

NC monitors

►

Variable monitors

►

Measuring series

►

Test series

►

Prolog and epilog for measurement

Fault services

►

Control monitors

Global settings

►

PLC settings

►

Notification limitation

Copying function settings

►

Copying function settings

Client-server communication

►

Synchronization times

►

Offline synchronization

►

Monitoring ePS services

[ Display overview ]

Display an overview of all functions set up

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As soon as a machine is selected, the function for displaying a group-based overview of all the configurations that the user has created for the machine becomes available. If required, the selection for display can be set up in the main functions menu.

All functions and user configurations set up

In the overview of configurations, the first column displays the type of configuration; the "Name" column displays the configuration names (arranged alphabetically); the "Required for" column displays other configurations where this subconfiguration is used; and the "Dependent on" column shows which other configurations are used as subconfigurations in this configuration.

A gradual fading is used for configuration names that cannot be displayed in full. The overview can be completely printed out for documentation purposes (printer icon

c).

The overview can be exported for the purpose of comparing the configurations and names, and can be compared with overview exports of other machines in a spreadsheet program, for example (d icon).

d c

Fig. 3-1: Displaying overview

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3.1.1 Creating maintenance schedules

Function description

The maintenance schedules contain the maintenance-related tasks to be performed on the machine (maintenance, inspection, and servicing).

Maintenance procedures may be logged in the schedule in a purely text-based format; alternatively, "intelligent" maintenance procedures, which automatically determine data via axis tests in order to performing purposeful status-oriented maintenance, may also be logged.

• The schedules are activated in a control monitor either on a timer- or event- triggered basis or as a combination of both. The maintenance schedule then becomes a maintenance order and is due for the responsible organization. A schedule always applies to just one machine.

• The maintenance jobs are produced on a time-controlled basis, in time inter- vals, on an event-triggered basis, or in event-triggered intervals. This is executed via the universal trigger of a control monitor.

• A maintenance job via a control monitor only becomes pending when the con- trol monitor is initiated, and is then due immediately.

• Maintenance schedules can be updated at any time: This only affects mainte- nance schedules that will be output after the changes have been made, and not those that have already been output. This also applies if a schedule is deleted.

Note

If users are logged on to the control as machine operator, they can process the pending jobs. For machines with version V3, they do not have to be a member of the target organization; for machines of version V4, they require authorization to act as machine operator (MO) for this machine.

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Fig. 3-2: Editing a maintenance schedule

Field Content Type

Name Short name for the maintenance proce-

dure. This is also located in the overview of maintenance jobs on the ePS Network Services PC and the machine HMI.

DISPLAY INPUT (Max. 40 char-

acters; any character permissible)

Responsible org. Organization allocated to carry out the

job in this schedule.

DISPLAY SELECTION

Note:

This information is added to the jobs from this schedule. However, any organization with access to this machine can change or delete the jobs in this schedule.

Work instruction Explanatory description of the mainte-

nance task

Link test series Selection of a test series to be carried

out in the framework of the maintenance job.

Automatically executing a test series

Link measurement series

Time when the maintenance job is to be performed

Selection of the "series of measurements" condition monitor in which the result of the measurement is updated as part of a maintenance job.

Note:

Only one series of measurements can be selected from the series of measurements available on the machine.

Add file To provide more details about the task,

documents with more information can be appended.

DISPLAY INPUT SELECTION

SELECTION

DISPLAY ACTION

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Field Content Type

Note:

The machine operator at the operator panel can only view documents in PDF format.

Security note on displaying PDF documents

Notice

PDF documents to be displayed on the control operator panel must not contain any active contents (Java script, e-mail fields, etc.) nor have any HTML Links!

Otherwise there is a danger that it may be possible to navigate from the ePS system to other Web pages.

ePS Network Services can display PDF documents compatible with Acrobat 1.3 (Reader Version 4.x) on the control operator panel.

For optimum display, please create your PDF documents with the option "Initial View: Page Only/Magnification Fit Width".

3.1.2 Configuring variable monitors

Overview

You configure a variable monitor in the following steps:

1. Select the variable monitor or create a new variable monitor.

2. Name the variable monitor; comments and icons can be added as an option.

3. Define the PLC variables.

4. Use a control monitor to execute the variable monitor.

Selecting or creating variable monitors

Since it is possible for each machine to have several variable monitors, there is the option of sorting them in the overview display either by their names or by the two classification fields. In addition, it is possible to filter them by searching for specific parts of text that appear in the Name and Variables columns using the "Search text" box.

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Fig. 3-3: Select the variable monitor

Fig. 3-4: Configure the variable monitor

Make the following entries to configure a variable monitor:

Field

Content

Name Name of the variable monitor DISPLAY

Triggered by control monitor

Selection of a control monitor that is to trigger the variable monitor.

New creation of a control monitor that is to trigger the variable monitor.

Icon and text Selection of an icon stored in the

system and naming the icon selected.

Type

INPUT (Max. 40

characters; any character permissible)

DISPLAY SELECTION MENU

DISPLAY SELECTION INPUT

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Field

Content

Notice:

Type

The text entered applies to the entire machine and overwrites any existing text.

Comment Individual text for the variable monitor DISPLAY

INPUT (Max. 2000

characters; any character permissible)

Last

Time stamp of last data capture DISPLAY

measurement Variables Table of variables configured in the

DISPLAY

variable monitor

Time series Display the time series for the

DISPLAY

selected variable Name Name of the variable DISPLAY Warning limit Display the configured values for the

DISPLAY

warning limits Critical limit Display the configured values for the

DISPLAY

critical limit

Edit Remove variables from or add vari-

Activate limit value of type upper limit ACTION

Activate limit value of type lower limit ACTION

Display the variable as diagram ACTION

Remove variable from the

ACTION

configuration of the variable monitor

ACTION able to the configuration of the variable monitor

Save Save the changes to the configuration

ACTION and return to the calling page.

Cancel Discard the changes to the configura-

ACTION tion and return to the calling page.

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Configuring variable

The system provides a selection of predefined variables which can be added to the variable monitor configuration simply by selecting them.

Fig. 3-5: Variable monitor – configure variables

Field Content Type

Open the form to configure a new variable

Edit the configuration of a freely defined

variable Name Name of the variable DISPLAY Axis With variables that refer to an axis, the

name of the machine axis is displayed

here.

The reference to an axis can be

changed as long as no data was cap-

tured for this variable. [ ] The unit for the variable is displayed in

this column.

This function is used to create a copy of

the variable.

Remove the variable from the configu-

ration and delete the data for this vari-

able

ACTION

DISPLAY SELECTION

DISPLAY

ACTION

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Add variables by selecting them from predefined variables:

Field

Content

Axis The variables that can be selected refer to

one axis each. This axis is defined with this selection field.

Select all All variables that are available are se-

lected.

Add The selected variables are added to the

Type

DISPLAY SELECTION MENU SELECTION

ACTION

configuration of the variable monitor.

As an alternative a form can be used to configure any variables.

Fig. 3-6: Variable monitor - select variable

Field Content Type

Address Absolute address in the syntax match-

ing the data source

Name Name of the variable DISPLAY

Counter type No counter:

the variable is always processed with

the current variable value.

Up counter:

the variable is used by the system as an

endless difference totalizer.

Notice:

Only the up counter is intended for

evaluating intervals.

DISPLAY INPUT

INPUT (Max. 40 charac-

ters; any character permissible)

DISPLAY SELECTION

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Field Content Type

Note:

The type can only be assigned once

when the variables are created and

cannot be changed at any point (can

only be assigned again if variables are

deleted in their entirety and created

again). Data source PLC: The address is interpreted in S7

syntax.

DISPLAY

SELECTION NC: Address in the syntax of the NC interface.

Data type Interpretation of the variable value in

permissible S7 syntax.

DISPLAY

SELECTION Note:

The type can only be assigned once when the variables are created and cannot be changed at any point (can only be assigned again if variables are deleted in their entirety and created again).

Unit Unit of variables to be recorded DISPLAY

INPUT

Value Display of the current variable value

and converted variable value. Input and display of the dimension in a

unit for the converted value.

DISPLAY

INPUT

(Max. 5 charac-

ters; any charac-

ter permissible)

Conversion Output:

Input of 2 values for the real variable value.

Converted:

DISPLAY

INPUT

(Max. 32 digits)

Specification for the associated dimensioned values.

Changes to the configuration are not effective until the machine is synchronized.

Using (a) control monitor(s) to execute the variable monitor

The "Trigger variable monitor(s)" diagnostic action is used to detect the PLC variable values promptly and store them on the ePS server. It is only possible to access the data manually via the machine events or variable monitor data series. Limit value triggers can be used to react automatically to the variable values via control monitors.

3.1.3 Configuring NC monitors

Configuration at the PC

Make the following entries to configure an NC monitor:

Fig. 3-7: Configuring an NC monitor on the PC

Field Content Type

Name Name of the monitor for easy identification INPUT Axis Axis identifier, machine SELECTION Upload data Cycles in which the data is acquired and

stored Comment Detailed description of the monitor INPUT Select counter The selected counter variables are acquired

with the NC monitor Warning limit Entry of the value for the warning limit INPUT Critical limit Entry of the value for the critical limit INPUT

Availability and privileges

The NC monitors can be configured on the PC and on the operator panel. The authorization required for configuring the NC monitors is described in detail in the Appendix.

SELECTION

ACTION

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3.2 Configuring measurements and measurement series

Description of functions

Configuration of measurements and measurement series it when you define the parameters required for measurement. The configurations created are always stored with the measurements and can be used again to repeat the measurements. That especially applies to measurement series. The configuration of a measurement series ensures that measurements are made with the same settings every time. This permits evaluation of the progression of characteristics over time.

In addition to parameters for performing a measurement, the limit values of the characteristics are also configured. Limit values can be configured for measurement series. The configuration is only possible on the PC. Individual measurements that do not belong to a measurement series cannot have limit values.

Availability and privileges

On the operator panel, a measurement is configured or a measurement series configuration changed only during the measurement procedure. On the operator panel, it is only possible to create a measurement series based on a measurement being performed.

On the PC, it is possible to configure measurement series. The authorization required to configure measurements and measurement series is described in detail in the Appendix.

3.2.1 Circularity test

Parameter description

Parameters for conducting a circularity test:

Field Content Type

Name Name of the measurement series (meas-

Channel Selection of the required channel:

Axes Selection of possible pairs of geometric

Center point 1st axis

Center point 2nd axis

Diameter Diameter of circle INPUT Feed Path velocity of the circular movement INPUT

urements do not have a name).

The channel defines the possible axis pairs in the "Axes" selection list.

axes Specification of the center coordinates of

the circle for the first axis Specification of the center coordinates of

the circle for the second axis

INPUT

SELECTION

INPUT

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Fig. 3-8: Circularity test on the operator panel

Fig. 3-9: Measurement series of a circularity test on the PC

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3.2.2 Synchronous operation axis test

Parameter description

Parameters for conducting a synchronous operation axis test:

Field Content Type

Name Name of the measurement series (measure-

ments do not have a name).

Channel Selection of the required channel. The chan-

nel defines the possible machine axes in the "Axis" selection list.

Axis Selection of the possible machine axes that

can be programmed in the selected channel.

Start point The axis position at which the first partial

movement of the measurement begins.

End point The axis position at which the first partial

movement of the measurement ends.

Feed Velocity at which the axis is moved. INPUT

INPUT

SELECTION

INPUT

Fig. 3-10: Synchronous operation axis test on the operator panel

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Configuring the limit values

With synchronous operation axis test one movement is carried out each forwards and backwards. The characteristics are calculated separately for each direction. As standard limit values are defined for the characteristics and are the same for both directions of movement.

Optionally limit values can be entered which can have different values for both directions for each characteristic.

Fig. 3-11: Measurement series of a synchronous operation axis test on the PC

3.2.3 Universal axis test

Parameter description

Parameters for conducting a universal axis test:

Field Content Type

Name Name of the measurement series (meas-

urements do not have a name)

Channel Selection of the required channel: The chan-

nel defines the possible machine axes in the "Axis" selection list.

Axis Selection from the possible machine axes

that can be programmed in the selected channel

Start point The axis position at which the various

movements of the measurement begin. The position value is never lower than this

value during measurement.

INPUT

SELECTION

INPUT

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Fig. 3-12: Universal axis test on the operator panel

Fig. 3-13: Measurement series for a universal axis test at the PC

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3.2.4 Performing test series

Overview

Test series are used to automate measurements for condition monitoring to a great extent. A test series can contain any number of measurement series. These measurement series are performed one after the other in the defined order when a test series is run. An machine operator is only required at the machine for the purpose of starting the test series.

The measurements are made and measurement results stored without any further operator actions.

Function description

The following entries have to be made to configure a test series:

Field Content Type

Name Name of the test series. The system sug-

gests an automatically generated name, which you can change. The names of test series must be unique within the context of the machine. The system adds another element to the name automatically if the name entered by the machine operator has already been assigned to another test se-

ries. Channel Selects the required channel. SELECTION Comment Any text entered to provide a detailed de-

scription of the test series

To add, remove, or change the sequence of measurement series, these are selected in the overview displayed and moved by dragging and dropping or using the arrow buttons on the form.

A test series can only contain measurement series in one channel. It is not possible to change the channel of a test series.

INPUT

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Availability and privileges

Test series can only be configured on the PC. The authorization required for configuring the test series is described in detail in the Appendix.

Fig. 3-14: Changing the configuration of a test series

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3.3 Fault services

3.3.1 Control monitors - List view

Description of functions

Events occurring directly in the control, or even as a result of evaluations of control values or a machine operator's activities, can be evaluated by control monitors.

As a result, machine statuses can be acquired in order to draw general conclusions about errors (e.g. alarms), current machine states (e.g. about accuracy determined by circularity test), or use of resources; to collect production data (e.g. workpiece counters); to obtain statistical data; and to analyze individual events on a temporary basis.

The machine operator can use a control monitor to determine which signals he/she is interested in and, therefore, which automatic tasks he/she wishes to trigger. When the ePS system detects such an event, it can automatically trigger actions which, in turn, trigger specific operating sequences or provide diagnostics data for further analysis.

Note

By creating one or more control monitors, the machine operator defines the signal or combination of signals from a machine, and predefined states on the ePS server, that cause particular data to be generated or actions to be triggered.

Fig. 3-15: Control monitors - List view

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Field Content Type

Control monitors Tree for selecting the control monitor

TREE to be processed. It can be expanded to show the triggers defined in it, which can be jumped to directly.

Status (overall) Switches the control monitors currently

active on or off on the next synchroni-

DISPLAY

SELECTION zation.

Note:

Does not change the activation state of each monitor.

Common starting date The common start date defines the

point at which all triggers will begin to

DISPLAY

SELECTION execute the control monitor. Each

trigger can be set so that it responds to the starting date. If a starting date has not been specified, all of the triggers react to the common start date with the reaction identification.

Specifying dates in the past is not permitted. Dates that are no more than 2 years in the future can be specified.

New triggers participation

Default setting for the function setting for triggers: If an individual trigger

DISPLAY

SELECTION setting has not been made for partici-

pation at the starting date, the triggers will respond at the starting date.

PLC remaining memory and performance index

Overview of the remaining memory of the individual PLC blocks and overview of the PLC performance index cur-

DISPLAY

rently in use and maximum PLC performance index:

• PLC trigger configurations

• PLC trace configurations

• PLC data

Exchanging addresses in notifications

An address that is configured in one or more notifications of a control monitor

ACTION

can be replaced by another address from the organization's address book.

Next synchronization in

Shows the time remaining until the next synchronization: If synchroniza-

DISPLAY

tion is overdue, negative values are displayed.

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Field Content Type

Name Names of the control monitors DISPLAY Memory requirements (single monitor)

Performance (single monitor) Clock icon (single monitor)

Single monitor status (activation state)

Synchronization status (single monitor)

Used memory requirement of monitor for:

• PLC trigger configurations

• PLC trace configurations

• PLC data

Currently used PLC performance. DISPLAY

Display indicating whether the control monitor has triggers that are independent of the common start date:

No display: No Faded display: Yes, at least one Normal display: Yes, all Monitor runs on the machine or is

inactive. An exclamation point indicates that the

configuration currently stored is not yet effective on the machine.

DISPLAY

Fig. 3-16: Exchanging addresses in notifications

Note

The PLC performance index allows you to define how much performance may be used for the ePS PLC trigger. Each ePS PLC trigger uses a certain number of performance points. In this way you can control to what extent the PLC may be occupied by the ePS PLC trigger.

The PLC performance index can be defined on an individual basis, since the amount of memory and the cycle time guaranteed for ePS Network Services may vary depending on the performance of the control and the processes executed on it.

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Field Content Type

Person previously notified

Opens the list of all addresses configured in notifications of the control

SELECTION DISPLAY

monitors for this machine

• E-mail

Displays the e-mail address corre-

DISPLAY sponding to the address selected, if one exists

• SMS

Displays the telephone number cor-

DISPLAY responding to the address selected, if one exists

Replace with Opens the organization's address

book so that a replacement address

SELECTION

DISPLAY can be selected

• E-mail

Displays the e-mail address corre-

DISPLAY sponding to the address selected, if one exists

• SMS

Displays the telephone number cor-

DISPLAY responding to the address selected, if one exists

Edit selected address Corrections to the replacement ad-

ACTION dress can be made, or it can be edited for completeness. The menu described in the section dealing with creating addresses is used for this purpose.

It should be noted that any changes

made to a name affect all configurations within the entire organization, and that changes are accepted automatically in all configurations without a request being made to do so.

Create address If the replacement address does not

ACTION yet exist in the address book, a new entry for it can be created.

The menu described in the section dealing with creating addresses is used for this purpose.

OK The address is replaced. ACTION Cancel The address is not replaced. ACTION

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3.3.2 Control monitors - Detailed view

Function description

Control monitors are divided into three modules:

1. Trigger module

2. Action module

3. Workflow module

Generally speaking, function settings are made on a control monitor.

• The triggers are used to configure the logic which links information queries from the NC, PLC or database; in order to initiate actions and/or workflows.

• Workflows are notifications via e-mail or SMS and maintenance schedules.

• Diagnostic actions are data acquired from the control (NCK, PLC, PC).

Actions

After you have created a new control monitor or opened a control monitor for editing, you can perform the following actions:

• Select or change the trigger signals that will cause the monitor to run.

• Define or change the actions to be executed when a trigger is detected.

Fig. 3-17: Control monitor - Detailed view

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Fields in the

Content Type

function settings

Details Displays function settings on the

control monitor, which can be edited.

TAB SELECTION

Comment Displays an editable comments field DISPLAY

INPUT (Max. 2000

characters; any character permissible)

Name Name of the control monitor: Names

of control monitors must be unique. If a name has not been entered, the system will generate it automatically (control monitor (n), where n is the automatic serialization).

Priority Definition of a class used to enter

events in the machine event list, so that they can be specifically filtered.

DISPLAY INPUT (Max. 40

characters; any character permissible)

SELECTION DISPLAY (Digits from

1 to 5)

Must not be deleted If this option is selected, events can-

not be deleted from the event history.

Generate event entry An entry in the machine events is not

required for every control monitor.

For notifications, maintenance or

SELECTION DISPLAY SELECTION DISPLAY

acquisition of value series from the NC or PLC, there is no need for an entry in the history, since these actions are events in and of themselves.

Delete Deletes the selected control monitor

ACTION

following a query

Save Saves the changes made on the

ACTION

monitor.

Reject Any changes that have been made

ACTION will not be applied. The control monitor in place prior to opening remains unchanged.

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Siemens SINUMERIK 840Di sl/840D sl,SINUMERIK 840Di/840D Function Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ePS Network Services

Preface

Contents

1 Introduction

1.1 Overview of functions

1.2 Operating concept

2 Machine information

2.1 Machine overview

2.1.1 Current control software

2.1.2 Machine events - List view

2.1.3 Machine events - Detailed view

2.1.4 Evaluation of workflow actions

2.1.5 Evaluation of diagnostics data

2.1.6 NC monitors

2.2 Measurements and measurement series

2.2.1 Analyzing on the PC

2.2.2 Operating diagrams

2.2.3 Control elements of the diagrams for individual measurements

2.2.4 Circularity test

2.2.5 Synchronous operation axis test

2.2.6 Universal axis test

2.2.7 Variable monitors

2.3 Test series on the machine

2.3.1 Performing measurement series

2.3.2 Requirements for performing the test

2.3.3 Prolog and epilog program for a measurement

2.3.4 Program example

2.3.5 Commissioning measurements

2.3.6 Release protocol between PLC and ePS system

2.3.7 Contour test

2.4 Maintenance

2.5 Remote access

2.5.1 Remote access functions

2.5.2 Functions of a service session

2.5.3 Starting a service session

2.5.4 Example of a session via remote access

2.5.5 Granting permission to execute functions

2.5.6 Setting up a service conference call

2.5.7 Remote control via the keyboard

3 Setting up functions

3.1 Maintenance

3.1.1 Creating maintenance schedules

3.1.2 Configuring variable monitors

3.1.3 Configuring NC monitors

3.2 Configuring measurements and measurement series

3.2.1 Circularity test

3.2.2 Synchronous operation axis test

3.2.3 Universal axis test

3.2.4 Performing test series

3.3 Fault services

3.3.1 Control monitors - List view

3.3.2 Control monitors - Detailed view