Monday, November 23, 2009

Knowledge of Siemens 840D

SIEMENS PLC system Siemens SIMATIC MAGAGER used for PLC programming to carry out state control machine tool components, it mainly consists of power supply module, CPU module, input and output module, its interface with, RS232 interface, PROFIBUS Interface , MPI cable interfaces. Through the X122, MPI jack, so that the computer with the NCU connected PLC.
Hardware Configuration
Hardware configuration: tell the PLC hardware structure of the process of
Baud Rate: MPI 187.5kbps
OPI 1.5Mbps
Process: to build the project - → Jianzhan - → Configuration Hardware
? Auto Configuration: The Cable Construction PLC and 840D connected to an automatic configuration automatic identification (upload station) will be transmitted PLC computer:
PLC-→ UPLOAD-→ select MPI Address = 2, if the Address = 3, will include the PLC and the NCU
If the backup PLC, then the process is:
New Project-→ plc-→ upload station, so the hardware will be backed up.
End station building, there even folders: hardware and cpu.CPU folder under the S7 program.
S7 program there are three directories:
(1) symbols such as I40.1 symbol table for the first 40 bytes of the first one
(2) BLOCKS function block
? Manual Configuration:
Process: Open the S7-→ New File - → INSERT-→ STATION-→ SIMATIC 300 - → double-HARDWARE-→ appear Box - → INSERT-→ HARDWARE COMPONENT-→ PROFILE-→ STANDARD-→ S300-→ RACK300
Select the appropriate position (to be set bits in the table), then the corresponding module on the right side double-click on modules will be chosen, selected and then download the
Programming
PLC programming course, the can use the following three forms:
Ladder Logic (LAD):
Statement List (STL):
Function Block Diagram (FBD):
Statement List programming instructions commonly used:
And instruction: A normally open AN NC
Or to order: O Normally open ON NC
Output instructions: =
Call instruction: CALL FCXX
FP: rising edge detection instruction
FN: falling edge detection instruction
After the FP must register with the middle of
CLR operation results, Clear
SET set a
S Set 1
R Clear
Block
? STEP7 There are several commonly used BLOCK Main: OB tissue mass, FC function blocks, FB function blocks, DB data blocks, etc.
OB: function blocks, equivalent to the main program, often are OB1 and OB100;
FC, FB: Function Block, which is equivalent subroutine
Subroutine in the compilation finished, you must call the subroutine in the main program in the PLC after power-OB100 is the first execution, is executed only once; OB1 is the PLC CPU cycles implementation process. After the first implementation of the power-OB100, and then the implementation of OB1 (repeated implementation; OB100 call FB1 (Siemens compiled good)
FB1 is the system bus connection PCU with OPI and MCP, the control panel Definition:
(1) control panel starting address of the input address
(2) the number of control panel
(3) The control panel's output addresses starting address
Control Panel MPI Address: MCPIBUSADR = 6
? OB1 block
FC2: Basic NCK and PLC communications NCK ← → PLC
FC2 must be OB1 the beginning of FC2 ---- "gp_hp"
FC10: dealing with alarm information FC10 ---- "AL-MSG"
PLC generated alarm, passed NCK, NC to take measures, while MMC displays alarm text called FC10, there are two parameters must be set
TouserIF = TRUE (equivalent to 1) and FALSE (equivalent to 0)
Quit: = I3.7 (warning text). Alarm Reset button (RESET) addresses I3.7
FC19: Machine control panel main program FC19 ---- "MCP-IFM"
BAGNO (mode group number) = B # 16 # 1 (B - B hex 16-16 hex)
CHANNO (channel number) = B # 16 # 1
SPINDLEIFNO: = B # 16 # 4 (spindle number)
FEEDHOLD = M100.0 (feed suspended)
SPINDLEHOLD = M100.1 (spindle stop)
? DB block
1. DB module types are:
DBB - Data Module Type
DBW - block word (16 bit)
DBD - block double word (32 bit)
2. Data Type:
DOUBLE: real or integer number, input range ± 4.19 × 10-307 ----± 1.67 × 10308
DWORD: integer number, ranging from -2.147 × 109 ---- 2.147 × 109
BOOLEAN: 0 be a
BYTE: integer, range digital -128 ---- 127
STRING: a maximum of 16-bit string
3. Common data block feature
DB2: alarm interface signals. The signal from the PLC to the NCK, in the PLC set the corresponding bit in the MMC will be able to generate a corresponding alarm number (seven at the beginning of the alarm is set by machine field assumption)
DB10: Show NCU state, used to exchange NCK fast I / O interface to the state, there are a number of the state of the signal NCK
DB11: mode group signal interface
DB19: Operation panel signal interface
DB21-DB30: channel signal interface
DB31-DB61: shaft / spindle interface signals
4. Debugging a common data block mainly by:
DBX6.0: feed to be able to prohibit
DBX6.1: read to be able to prohibit
DBX7.0: Start to be able to prohibit PLC → NC
DBX7.7: Channel reset
DBX194.0 --- DBX206.3 NC → PLC
DBX1.5: entry into force of a measurement system
DBX1.6: force measurement system 2
DBX2.1: Control enabled
DBX21.7: Pulse enable (if not, compared to the free end)
DBX4.3: Axis Stop PLC → NC
DBX12.0: the hard-axis negative limit
DBX12.1: the hard-axis positive limit
DBX12.7: back to zero deceleration
DBX61.7: current loop effective
DBX61.6: speed loop effective
DBX61.5: Position Loop Effective
DBX61.4: axial static
DBX83.5: spindle speed setting within the framework of



SIEMENS PLC system Siemens SIMATIC MAGAGER used for PLC programming to carry out state control machine tool components, it mainly consists of power supply module, CPU module, input and output module, its interface with, RS232 excuse, PROFIBUS excuse , MPI cable interfaces. Through the X122, MPI jack, so that the computer with the NCU connected PLC.

Hardware Configuration

Hardware configuration: tell the PLC hardware structure of the process of

Baud Rate: MPI 187.5kbps

OPI 1.5Mbps

Process: to build the project - → Jianzhan - → Configuration Hardware

* Auto-configuration: The construction of PLC and 840D cable connected to an automatic configuration of automatic identification (upload station) will be transmitted PLC computer:

PLC-→ UPLOAD-→ select MPI Address = 2, if the Address = 3, will include the PLC and the NCU

If the backup PLC, then the process is:

New Project-→ plc-→ upload station, so the hardware will be backed up.

End station building, there even folders: hardware and cpu.CPU folder under the S7 program.

S7 program there are three directories:

(1) symbols such as I40.1 symbol table for the first 40 bytes of the first one

BLOCKS function block

* Manual configuration:

Process: Open the S7-→ New File - → INSERT-→ STATION-→ SIMATIC 300 - → double-HARDWARE-→ appear Box - → INSERT-→ HARDWARE COMPONENT-→ PROFILE-→ STANDARD-→ S300-→ RACK300

Select the appropriate position (to be set bits in the table), then the corresponding module on the right side double-click on modules will be chosen, selected and then download the

Programming

PLC programming course, the can use the following three forms:

Ladder Logic (LAD):

Statement List (STL):

Function Block Diagram (FBD):

Statement List programming instructions commonly used:

And instruction: A normally open AN NC

Or to order: O Normally open ON NC

Output instructions: =

Call instruction: CALL FCXX

FP: rising edge detection instruction

FN: falling edge detection instruction

After the FP must register with the middle of

CLR operation results, Clear

SET set a

S Set 1

R Clear

Block

BLOCK main · STEP7 There are several commonly used: OB tissue mass, FC function blocks, FB function blocks, DB data blocks, etc.

OB: function blocks, equivalent to the main program, often are OB1 and OB100;

FC, FB: Function Block, which is equivalent subroutine

Subroutine in the compilation finished, you must call the subroutine in the main program

OB100 is a PLC after power-first execution, is executed only once; OB1 is the PLC CPU cycles implementation process. After the first implementation of the power-OB100, and then the implementation of OB1 (repeated implementation; OB100 call FB1 (Siemens compiled good)

FB1 is the system bus connection PCU with OPI and MCP, the control panel Definition:

(1) control panel starting address of the input address

(2) the number of control panel

(3) The control panel's output addresses starting address

Control Panel MPI Address: MCPIBUSADR = 6

· OB1 block

FC2: Basic NCK and PLC communications NCK ← → PLC

FC2 must be OB1 the beginning of FC2 ---- "gp_hp"

FC10: dealing with alarm information FC10 ---- "AL-MSG"

PLC generated alarm, passed NCK, NC to take measures, while MMC displays alarm text

Call FC10, there are two parameters must be set

TouserIF = TRUE (equivalent to 1) and FALSE (equivalent to 0)

Quit: = I3.7 (warning text). Alarm Reset button (RESET) addresses I3.7

FC19: Machine control panel main program FC19 ---- "MCP-IFM"

BAGNO (mode group number) = B # 16 # 1 (B - B hex 16-16 hex)

CHANNO (channel number) = B # 16 # 1

SPINDLEIFNO: = B # 16 # 4 (spindle number)

FEEDHOLD = M100.0 (feed suspended)

SPINDLEHOLD = M100.1 (spindle stop)

· DB block

1. DB module types are:

DBB - Data Module Type

DBW - block word (16 bit)

DBD - block double word (32 bit)

2. Data Type:

DOUBLE: real or integer number, input range ± 4.19 × 10-307 ----± 1.67 × 10308

DWORD: integer number, ranging from -2.147 × 109 ---- 2.147 × 109

BOOLEAN: 0 be a

BYTE: integer, range digital -128 ---- 127

STRING: a maximum of 16-bit string

3. Common data block feature

DB2: alarm interface signals. The signal from the PLC to the NCK, in the PLC set the corresponding bit in the MMC will be able to generate a corresponding alarm number (seven at the beginning of the alarm is set by machine field assumption)

DB10: Show NCU state, used to exchange NCK fast I / O interface to the state, there are a number of the state of the signal NCK

DB11: mode group signal interface

DB19: Operation panel signal interface

DB21-DB30: channel signal interface

DB31-DB61: shaft / spindle interface signals

4. Debugging a common data block mainly by:

DBX6.0: feed to be able to prohibit

DBX6.1: read to be able to prohibit

DBX7.0: Start to be able to prohibit PLC → NC

DBX7.7: Channel reset

DBX194.0 --- DBX206.3 NC → PLC

DBX1.5: entry into force of a measurement system

DBX1.6: force measurement system 2

DBX2.1: Control enabled

DBX21.7: Pulse enable (if not, compared to the free end)

DBX4.3: Axis Stop PLC → NC

DBX12.0: the hard-axis negative limit

DBX12.1: the hard-axis positive limit

DBX12.7: back to zero deceleration

DBX61.7: current loop effective

DBX61.6: speed loop effective

DBX61.5: Position Loop Effective

DBX61.4: axial static

DBX83.5: spindle speed setting within the framework of

Common Maintenance Failure Analysis



1. Machine operating mode and channel of choice:

As the NCK function continuously strengthened, a NCK can complete multiple systems to complete the original work, which can have multiple channels, a channel rather with an independent NC, 840D can have up to 10 channels, each channel has its own zero over the set, tool compensation and R parameters, but the program area is shared, each channel has its own working methods, if the work of several channels have been the same, then this constitutes a method group. the 840D on the , mode is way switch to select, access is key to W1 ... n to choose.

2. Tools and zero-bias

Because different tools have different geometric shapes and geometry, while the program is subject to the workpiece size and therefore require compensation tool, each with its own knife, there is a corresponding geometric shape of the tool types, such as drills, milling cutters. Each of the knife can have more than a knife fill size to D, to mark the

Like with the tool, processing of different parts require different zero, so there is zero bias, in the 840D using G54 to G57 to select, if necessary, the number of zero-bias can also be used to expand the machine parameters.

3.840D system maintenance

* Maintenance of liquid crystal displays

LCD display life of 30,000 hours. While the backlight tube life is time 10000 - 20,000 hours.

Replacement backlight tube methods: a. Open the protective cover b. monitor the installation of loose screws, disconnect the power supply and display backlight control signal cable, remove the display c. replace the backlight tube d. above steps to install the opposite

* Replacement of the battery

A total of 840 system, two batteries, one in MMC above, the main information to save CMOS, and its lifetime is at least ten years, it is generally no need to replace. NCU BOX also a battery inside, and fans together, it's life generally three years or so, to save the NCK inside the programs and data, because of the protection of capacitor charging, you can replace the battery after the NCK full power, but time can not be more than 15 minutes

This is the same as two battery models. Model: 6FC5247-0AA18-0AA0

(Note: the replacement battery it is best to make a few NCK and the PLC, data backup, Siemens 840C battery in the CSB board, must be the case of electricity in the system to replace!)

4.840D system data backup

840D system data are many, including NCK data, PLC data and MMC data, which NCK and PLC data is by the battery to maintain, and it directly affects the loss of the normal operation of NC, while the data is stored in the MMC MMC hard disk (MMC103), or Flash EPROM inside (MMC100.2), which under normal circumstances, the loss of NC data only affect the display and input.

System data backup methods are the following three

(1) backup to MMC's hard disk (only MMC103 adaptation), it is recommended best MMC, NCK and the PLC's data separately for backup, the file name is best to use the system default file name plus the date.

(2) backup to a floppy disk or through the RS232 port on the backup to an external computer.

(3) back to the NCK above the PCMCIA card, the card is an NC system, installed programs 8M of Flash EPROM card. It is about 5M or so of space can be used to store backup data. This feature is only in the MMC software version 5.0 and above to be used. Such data without a hard drive backup methods particularly suitable for the MMC100.2.

5. MMC103 file structure

· MMC103's hardware is actually a band MPI (OPI) interface PC. Software is running on the WINDOWS operating system on a man-machine interface software. As the MMC version of the software not the same as its operation, the operating system are not the same, there are early WIN32, the mid-WIN95 and now WINNT, to run in WIN95 environment MMC Ver5.3 example shows the file structure MMC.

· MMC103 hard disk is divided into two partitions, C: drive and D: drive, where D is mainly used to store the hard disk drive and partition number of backup files, including several versions of the system brought about by MMC system backup, but also used to install software to use as a temporary storage area. C drive is mainly stored WINDOWS operation of the system files, MMC's system files, machine tool manufacturers developed a number of add-on software and user programs and data.

· C drive under the directory structure:

C drive has the following directories under the main

MMC2: Siemens, is mainly used to store system files, Siemens there are also some standard configuration files in this directory, the directory the file is best not to modify the. Windows storage running Windows system files and other documents under Windows environment,

Add_on: Siemens add-on products, such as remote diagnostics. OEM used to store tools on their own development

Products.

USER: storing the user's own profile, not the same as all the standard configuration files are stored in this directory, such as alarm settings for the service.

DH: used to store data associated with the NCK, NCK its file structure and file structure, have a piece subdirectories, the workpiece main program directory, a subdirectory subroutine, the standard fixed-cycle subdirectory, the user such as a fixed cycle of subdirectories. User alarm texts are generally the existence of the directory the following subdirectories inside MB.

These are the MMC103's file structure, in general, the user's own files are stored in the back of four directories inside, so MMC data backup is mainly a backup four directories and files.

Note: MMC earlier version of the user's own configuration files and system configuration files are stored in the system files directory.

· MMC103 alarm server configuration

MMC103 configuration are mostly. INI file for the suffix to achieve, such as knives library display, all kinds of operating mode password level required to operate, as well as alarm settings for the server, the following set up to alert the server to home shows the configuration file changes.

MMC is responsible for the display of alarm text, alarm text stored in MMC2 and DH the following subdirectories inside the MB, the file name format Alxx_xx.com, of which the first two XX said alarm contents of the text, followed by two XX said that the language of the text alert . For example ALP_UK.COM said yes PLC alarm text, language is English. And the relevant alarm display settings are stored in MBDDE.INI file.

Note: The user directory the following configuration files covering MMC2 directory configuration files. WINDOWS system configuration files of all the sum can not exceed 60KB.

6.611 series of drives and motors works

* 611 series AC variable speed drive is a device that by controlling the power supply, the frequency of AC motor to achieve speed control purposes. The main part is from a DC to AC into the rectifier and the DC into an AC variable frequency inverter component. Due to the different interface signals,

The characteristics of servo motor

Because of the motion control, CNC machine tools demanding, and requires a good dynamic characteristics, a large speed range and accurate position control precision, and therefore it requires a special servo motor drive systems generally use the Siemens synchronous servo motor, spindle is Precision induction motor, its principles and general principles of the same squirrel-cage motors, synchronous servo motor and induction motors The biggest difference is not the same as the structure of the rotor. synchronous motors have a staggered distribution of the rotor pole, and therefore require a corresponding test rotor position detection component, replacement of components when these tests also need to re-adjust, the following is commonly used in three kinds of motor Siemens distinction:

· 1FT5 and 1FT6/1FK6 difference between motor

Both the motor is basically the same principle, but not the same as the structure and detection devices, 1FT5 AC servo motor used in the system, while 1FT6 motors are used in the digital servo system.

Stator winding structure is different, 1FT6 motor stator winding structure allows the motor current is much closer to being the cosine waveforms

1FT5 motor tachometer generator is used to detect the speed of the motor with the sharing circle on the Hall element to detect the relative position of the rotor, and 1FT6 motor is used to detect a position encoder motor speed, the motor encoder in addition the conventional A, B, and R phase are cosine signals, there are two C phase and D phase is cosine signals to detect the rotor position.

1FK6 1FT6 motors, like principles, only a little difference in the mechanical structure, 1FK6 more 1FT6 economy.

l Note: The replacement of the motor encoder should pay attention to the encoder zero position, replace the encoder to ensure that when you replace the front and rear rotor is not moving when the encoder wheel on a shell on the signs on signs and the relative position of the same, if the This relative position has changed only through the oscilloscope to adjust. the location of the encoder does not affect the motor is running, such as not running smoothly, the current is too large, and even affect the motor life.

7. Servo motor and spindle motor of the difference between

Rotor structure is different, the spindle motor rotor and squirrel cage rotor motor, like the absence of magnetic poles, which does not require the corresponding rotor position detection signal, 1PH7 spindle motor encoder model ERN1381, 1FT6/1FK6 the motor encoder type To ERN1387, the main difference is that ERN1381 no additional C-phase and D believe that number, and therefore do not need to re-adjust the replacement of the encoder, ERN1387 can be used in 1PH motors, but in turn ERN1381 can not be used in the feed motor.

Spindle motor power of a great general, and thus the motor structure of cooling demand is higher.

Not the same scope of work, servo motor operates at the lowest speed and rated speed constant torque between the areas, while the spindle motor operates at rated speed and maximum speed constant power between the areas, because to achieve a great speed range of spindle the motor rated speed is generally very low

Common repair techniques

ERN1387 Encoder Replacement Method

1. Unloading open motor rear cover, rear cover encoder

2. Release encoder mounting screws

3. Rotating rotor shaft, so that the encoder rotor encoder on the signs and marks on the shell overlap

4. Remove encoder, attention to handling the time out to make use of a special screw top to avoid damage to the encoder

5. Rotation of new encoders, so that the two signs coincide encoder

6. According to the above reverse order to install the encoder

Note: In the process of installing the encoder, to ensure that the rotor different, otherwise they will lose the relative position of the rotor, if the loss of the relative position of the old motor will need to use the oscilloscope to adjust the installation position of the encoder, the new motor can be based on a sign of rotor shaft to adjust the encoder to determine the installation location, which can be mechanical adjustments, you can also adjust the drive parameters MD1016 to set an offset value, but the method can only be used in the 840D, through this method to adjust the motor change to other machine tool use may be due to the different driving parameters can not work properly.

* Zero adjustment

Adjustment steps are as follows: startup - → machine data - → Axis MD - → parameter adjustments: 34100 (axis coordinate value in the reference power) Amendment, if the change finished, now and in the original difference of 10mm, will be adjusted parameters 34100 to 10.

Can also 34090 (reference point offset) to modify: It is now zero difference with the original zero, the number.

* A simple power module detection method:

As the power module is the main parts of high-power tubes, with the following methods can be broadly detect power tube is good or bad:

Multimeter hit resistance profile, with a multimeter is the table T received a power module DC voltage input terminals P600, the land received a three-phase power tube power output U2, V2, W2, the time should be infinite resistance, exchange multimeter two tables T, the resistance should be rare. the multimeter pen received the M600 on a table, repeat the above process, the results should be, and above just the opposite.

Motor temperature alarm processing

Motor which is equipped with thermal resistance of the signal through the signal cable back to the driver control panel inside, when the temperature reaches alarm value, the system to produce alarm, end feedback can be detected when the corresponding resistance value, the alarm if you need to shield , the 611D can be in the driving parameters MD1608 (the control panel of the 611A is a parameter MD64) to set a value of less than 100, you can mask the alarm, the method can only be used in diagnosis.

611A spindle encoder alarm control unit shield

Driver control panel connected encoder can be monitored, if there is an exception, then generate a corresponding alarm, 611A spindle control panel can be the parameter MD P-90 bit 2 set a screen of the alarm.

611D-driven V / F control

Sometimes, in order diagnostic, drivers need to be open-loop frequency control, this method can only be used for diagnostic purposes, and the speed can not be set too high. MD1014 is a set driving parameters shall be open-loop frequency control

Driven optimization

CNC driven by the current loop, velocity loop and position loop composed of the optimization in general from the inside and outer layers of optimization, but because of current loop parameters of the motor and power module model is established with the factory default parameter, the general does not require optimization, it is optimization optimize the speed of the first ring, and then you can optimize the position loop.

Speed loop optimization, generally related to the speed loop gain and speed loop time constant, the speed loop time constant and gain the greater the lower the speed loop and more stable, but the accuracy and dynamic characteristics of the worse, in general, the speed loop time constant is located in 10ms, while the speed loop and speed loop gain adjustment in making the order is about to respond to a 20-40 overshoot.

Position loop optimization involves the position loop gain and acceleration, before adjustment can reduce the acceleration value, and further increase the value of position loop gain to ensure the system is stable, and then increase the acceleration at an appropriate value, and to adapt the mechanical properties of machine tools, pay attention to the same group of interpolation axis position loop gain to be consistent, otherwise it will affect the machining accuracy.

Axis shield deal

Sometimes the need for a single axis shield, concrete steps are as follows:

Parameters in the corresponding axis, the set MD13030 and MD13024 0

In the drive configuration menu, find the corresponding module, set to "no active" can be, when the shaft on the virtual axis, the corresponding module and the motor can be removed, if you want to restore to the above parameters The value can be back to the original.

Axis load processing: Sometimes because of the need for machine tools should be dismantled or loading of the shaft, such as rotary indexing head, this time to plug the encoder and motor power outlet, Ran do not want the operator to change the above parameters, this time to PARKING temporary set to the shaft axis, the specific method is also reset the axis DB3X.DBX1.5 and 1.6 can.

.. If your tool change is through subroutine calls. You can change the position of spindle orientation. SPOS =** (is that you transfer a good position. Either plus or minus. Either entered directly. According to the current value of SPOS to decide, SPOS There are some of these: SPOS = "AC" () SPOS = "ACP" () and other programming reference manual.

2. If it is executed by T * M6. You can view the parameters 10715 / 10716 subroutine parameter to see what Nago. And then change the subroutine also in SPOS =** (value). If you find inside a subroutine, The SPOS = 0. you can change the 34090 [1] or 34080 [1] to complete you want to change the angle.

Access to 1,071,510,716 parameters. You can STARTUP inside MACHINE DATA Lane GENERAL MD. Which can be found. Take a look at what is subroutine. On the inside subroutines or procedures set inside the user program. But it is best not to change. By changing the 34080 [1] or 34090 [1] to be completed.

After the completion of spindle orientation in general. You can manually transferred to the spindle tool changing position of the quasi-stop. And in DIAGNOSIS inside view inside SERVICE DISPLY spindle CURRENT MEASURING SYSTEM 2 look. Spindle position. And then be modified.

There. Change Machine factory according to the specific methods, the general set of values there are upper and lower limits. If - 0.5 degrees according to circumstances.

SM up to 8 modules

A maximum of four

Power supply module (PS) for the PLC and the NC to provide power supply 24V and 5V.

Interface Module (IM) is used for the interconnection between class.

Signal modules (SM) using the machine PLC input / output modules, there are two kinds of input type and output type.

二. Hardware Interface

840D System Interface

840D system, MMC, HHU, MCP through an MPI cable hanging in the NCU above, MPI is the Siemens PLC, a multi-point communication protocol, and therefore the agreement is open, but OPI is the 840D system for NC part of the components of a special The communication protocol is MPI, a special case, does not have open, than the traditional MPI communications faster, MPI communication speed is 187.5K baud rate, while the OPI is 1.5M.

In addition to an OPI port NCU above, there is a MPI, a Profibus interface, Profibus interface can access all of the equipment with a Profibus communications capabilities. Profibus communications cable and MPI cable, are both a dual-core shielded cable.

X101 control panel interface (OPI)

X102 PROFIBUS Interface

X112 aside Interface (NCU and NCU communication)

X111 SIMATIC Interface (IM361)

X122 PC MPI Interface (MPI)

X121 I / O interface (cable distribution box)

H1/H2 error and status lights

H3 7 segment display

S1/S2 Reset / NMI button

S3 NCK Start Switch

S4 PLC Switch Start

X130A SIMODRIVE 611D Interface

X130B digital module I / O expansion interface (only NCU573)

X172 Device Bus Interface

X173 PCMCIA slot (X173)

In MPI, OPI, and Profibus communications cable must be received at both ends of the terminal resistance, resistance is the 220 in Europe, all the good or bad if you want to test cable can be seen in NCU-side open socket cover, the amount of A, B between the two lines resistance, under normal circumstances should be 110 Europe.

二. 611 Series driver and interface composition of

1.611 series of drives into analog 611A, the number 611D and the common type 611U. Are the modular structure, mainly in the following modules:

? Power Module Power Supply Module is to provide the drive and numerical control system power, including the maintenance of normal work of the system weak and supply of 600V power module using DC voltage. According to DC voltage control mode, which in turn are divided into open-loop control, closed-loop control of UE modules and I / R module, UE module does not supply the feedback system, its normal for the DC voltage of about 570V, and when braking energy is large, voltage can be as high as more than 640 volts. I / R module voltage has remained at around 600V

? Control module control module to achieve the speed of the servo axes ring and closed-loop control of current loop

? Power module to the servo motor to provide variable frequency and voltage AC power supply

? Monitoring module is mainly weak supply capacity of the power module to add.

? Filter module for filtering the power role.

? Reactance voltage play a steady role.

2.611 Power Module Interface Signals

611 module interface signals are the following groups:

(1) Power Interface

U1 V1 W1 main control loop three-phase power input port

X181 Power Supply input port, use is often associated with the main power supply shorted, and some systems the power to make machines work properly after the driver is also available for some time, the terminal voltage of 600V and P500 M500 terminals shorted, such as 600V voltage not immediately discharge is completed, but also the maintenance of normal work-driven control panel for some time. P600M600 is a 600V DC voltage output terminal.

(2) Control Interface

64 control the enable input, the signal to all connected modules at the same time effective, the signal is removed, all the speed of the shaft for a given voltage is zero, axis with the greatest acceleration parking. After a certain time delay, cancel pulse enable 63-pulse enable input, the signal to all connected modules at the same time effective, the signal after the abolition of all the shaft power cancellation axis movement in the form of free parking.

48 main circuit relay, the signal off, the main control circuit power supply disconnect the main relay.

112 debug or standard mode, the signal tends to be used in transmission-line debugging in general, on the receiving system, 24V.

X121 module ready signal and the module overheating signal. No. ready signal and the module DIP switch settings on, when the S1.2 = ON, the module fails, ready to signal cancellation, and S1.2 = OFF, the module has failures and to make energy (63,64) signal cancellation, will be ready to cancel the signal, so when the replacement of the module to check the top of the module DIP switch settings, otherwise the module may not work correctly. All modules connected to motor overload and overheat alarm output will be triggered by overheating.

NS1/NS2 the main relay closure enabled, only the signal is high, the main power relay is possible too. Relay the signal used to decide in closed-chain conditions.

AS1/AS2 the main relay state, the main relay the signal to reflect the closed state, the main relay is closed when high.

9/19/R 9 is a 24V output voltage, 19 is a 24V ground, R alarm reset signal for the module.

(3) Other auxiliary interface

X351 device bus, for connecting the module behind the power to use.

X141-voltage detection terminal, used for diagnostic and other purposes.

7: P24, +24 V 45: P15, +15 V 44: N15,-15V

10: N24,-24V 15: M, 0V

Power supply module has six lights above, respectively, directed modules fault and working condition. Under normal circumstances, said green light enable signal loss (63 and 64), yellow light signals that the module is ready, when 600V DC voltage has reached the allowable value of the system work properly.

Power supply module to enable normal work conditions:

48,112,63,64 then high, NS1 and NS2 shorted, appears as a yellow light, other lights are not bright. DC bus voltage should be 600V or so.

3.611 drive control module interface signals

(1) 611D drive control module interface signals

611D CNC control module and the system is mainly through a data bus connected to the basic there is not much of interface signals.

X431: axis pulse enable, the signal is low, the shaft power to withdraw, generally the signal directly with the shorted 24V

X432: BERO terminal, the interface used for BERO switch signal input port.

X34, X35 analog output ports, including two analog port (X1, X2) as a diagnostic test module, which can be used to track the amount of some figures, such as speed, voltage and current, etc. and put it into a 0 to 5V analog voltage output, the specific output signal through the numerical control system selection, Ir analog output port is fixed and the output motor current in phase R analog value.

X411: Motor encoder interface, input the motor encoder signals, as well as the motor thermistor, in which the motor thermistor value is through the socket 13 and 25 pin input, the thermal resistance at room temperature under 580 Europe , 155 degrees, more than 1200 in Europe, then control panel off the power and generate electrical power machines overheating alarm. (1PH7 motor temperature detection signal connected to the same 1FT6/1FK6 motor)

X411: direct measurement of system input port, enter the direct position measurement signal, generally positive cosine voltage signals

* 611D control panel of the speed loop and current loop inside the parameters set in the NCK, so no need to replace the control panel to reset the parameters.

. 840D System Operation

SINUMERIK840D/810D or SINUMERIK FM-NC is the machine's CNC control systems, CNC control system through the control panel perform the following basic functions:

• Develop and modify the part program

* Implementation of the part program

* Manual control

* Read in / read out the part program and data

* Edit the program data

* Cancel alarm display and alarm

* Edit the machine data

In an MMC or MMC, or between a few or several NC 1 NC to establish communication links between the (M: N, m-MMC devices and n-NCK/PLC devices)

User interface include:

* Display components, such as monitoring devices, LED, etc.;

* Operating components, such as keys, switches, hand-lun. q

840D system with CNC machine tools with automatic, manual, programming, back to a reference point, manual data entry and other functions.

Manual: Manual is mainly used to adjust the machine tool, manual and step manual with continuous manual, and sometimes need to go to a certain length, you can choose the variable INC mode, enter the length of run can be.

Automatic: 840D procedure is generally where the implementation of NCK of RAM, so MMC103 or PCU50, it was necessary should first program loaded into the NCK years, but for a particularly long process, you can choose the hard disk where the implementation of specific operational method To: Select processing, the program outline, use the cursor to select the implementation of the program, select from the hard drive the implementation of both. in automatic mode, if the MMC with SINDNC software, you can also run programs from a network hard drive.

MDA: MDA with the almost automatic, except that it paragraph by paragraph, the procedures can be input, not necessarily a complete program that exists NCK inside a fixed buffer MDA, the MDA buffer can be stored in the program directory program, district can also be transferred from a procedural program to MDA buffer.

REPOS: re-positioning capabilities, and sometimes in the program run automatically when you need to stop and test the tool away parts, and then followed by the implementation of procedures, require re-positioning capabilities, methods of operation mode in the automatic suspension of program execution, go to the manual, remove the corresponding the shaft, to re-execute the program, go to the re-positioning mode, press the corresponding axial movement button to return to the program a breakpoint, press start button process to continue. Note that in this process can not press the reset button.

Program to simulate: 840D to support the program before running a formal graphical simulation program in order to reduce the failure rate, but because of the different MMC systems, simulation of the method is not, as in MMC103, the program to simulate entirely on the implementation of the MMC, so the simulation does not NCK will have an impact, but in MMC100.2 on the program to simulate the NCK inside the implementation, and procedures for the practical implementation of the case, so be sure to simulate the selection process before the tests, but also to improve simulation speed, you can also choose to run empty.


二. System connection and commissioning

(A) the hardware connection

SINUMERIK810D/840D the system's hardware to connect in two ways:]

First, according to their interface requirements, first CNC and drive unit, MMC, PLC of three parts are connected to the right:

Source Module X161 kinds of 9,112,48 connection; drive the bus and device bus; the far right terminal resistor module (CNC and drive unit).

(2) MMC and the MCP polarity of the 24V power supply should be careful (MMC).

(3) PLC Module attention to the power line connection; bearing in mind the SM connection.

Second, the hardware of the three parts are interconnected, the connection should pay attention to:

PI, and OPI bus wiring must be correct.

CU or NCU and S7 of the IM module connection.

2. Check

In the correct completion of all mechanical and electrical installation work can be carried out electricity and commissioning work; while the first thing to do is to start the preparatory work, it can ensure that the control system and its components to start normally, and to meet the EMC test conditions

Full system connection is completed the necessary examination needs to be done, as follows:

* Shield: (1) to ensure that the cables used in line with Siemens to provide the wiring diagram of the requirements;

(2) to ensure that the signal-point field shielding at both ends connected with the rack or chassis.

For external devices (such as printers, programmers, etc.), the standard single-ended shielded cable can also be used. But once the control system for normal operation, it should not answer any of these external devices is appropriate; if we must access at both ends of the connecting cable should be shielded.

· EMC (Electromagnetic Compatibility) test conditions:

The signal line and power lines as far as possible separated from a bit further;

Departure from the NC or the PLC to the NC or the PLC may live cables should be used to provide cable SIEMENS;

Signal lines should not be too close to the external strong electromagnetic fields (such as point machines and transformers);

HC / HV pulse circuit cables must be completely separated from all other cable laying;

If the signal line can not be separated from other cables, it should take the shield threading pipe (metal);

The following distance should be as small as possible:

- The signal line and signal line

- Signal line side pre-supplementary equipotential

- And other potential clients and PE (come together)

* Protection ESD (Electromaqnetic Sensitive Device) components test conditions:

Dealing with a static module, should ensure that its normal grounding;

Such as avoiding electronic modules can not take office, then please do not touch the module components, pins or other conductive parts;

Touch the components must ensure that the human body through the electrostatic discharge device (wrist strap, or shoes) and the earth connection;

Module should be designed to conductive surface on the north (put-static packaging materials such as conductive rubber, etc.);

Modules should not be close to the VDU, monitor or TV (Away from the screen, and 10cm);

Modules Do not rechargeable electrical insulation material contact (such as plastics and fabrics);

A prerequisite for measuring

- Measuring equipment grounding

- Insulation instrument measuring the first pre-let electrical

Coordinates

1. Workpiece Coordinate System

Workpiece zero is the original origin of workpiece coordinate system

Cartesian coordinates: The coordinates of the point reached to determine the coordinates of the point

Polar coordinates: The radius and angle to measure the workpiece or part of the workpiece

2. Absolute coordinates: All positional parameters associated with the current effective starting point that will be accessible location tool

Incremental Coordinates: If the size is not the key to the origin, but relative to the other points on the workpiece, it is necessary to use an incremental coordinates. The incremental coordinates to determine the size and dimensions of these conversions can be avoided. Incremental coordinates refer to the previous power position data for the tool movement is used to describe the tool moving distance

3. Plane: The two axes to determine a plane, the first three axis perpendicular to that plane and determine the direction of the tool cross-section. Programming, to determine the processing surface in order to facilitate control system can accurately calculate the tool offset value.

Identify the direction of plane cross-section

G17 X / Y Z

G18 Z / X Y

G19 Y / Z X

4. Zero position

In the NC machine tool can determine the origin and reference point for the different position of these reference points:

* For the machine tool positioning

• The size of the workpiece program

They are:

M = Machine 12:00

A = chuck 12:00, age spots coincide with the workpiece (value for lathes)

W = Workpiece 12:00 12:00 = Program

B = starting point, you can give each program to determine the starting point, the starting point is the first tool a starting place for processing

R = reference point, with the cam and measurement systems to determine the location, you must first know the distance to the machine zero, so as to accurately set the axis position:

Establish coordinate system R

1. Of machine tools with machine zero M coordinates X B

2. Base coordinate system (also can make the workpiece coordinate system W)

3. The workpiece with the workpiece coordinate system W 12:00

4. Band is currently one know how to zero Wa of the workpiece

The current workpiece coordinate system M A W Z

The establishment of axes

When programming is usually used in the following axes:

Machine shaft: You can set the data in the machine tool axis identifier, identifier: X1, Y1, Z1, A1, B1, C1, U1, V1, AX1, AX2, etc.;

Channel axis: all in a mobile channel axis identifier: X, Y, Z, A, B, C, U, V

Geometric axis: major axis, generally have X, Y, Z;

A specific axis: no need to determine the geometric relationship between a particular axis, such as the turret position of U, Tailstock V;

The path axis: determine the path and tool movement, the path is programmed feed rate and effective, in the NC program using FGROUP to determine the path axis;

Synchronization axis: mean from the programming point of origin to destination mobile synchronization axis;

Positioning axis: Typical positioning shaft from the parts carrying, unloading the loader, knives library / turret, etc. identifier: POS, POSA, POSP, etc.

Directive axis (axis synchronized movement): the instruction is generated by the synchronized movement directive axis, they can be positioned to start and stop can be completely synchronized with the workpiece program. Axis is an independent interpolation instruction, each instruction has its own shaft axis interpolation and feed rate

Connecting shaft: NCU box refers to the connection with another real axis, their position will be subject to the control of the NCU, the connection shaft can be dynamically assigned to different channels of NCU

PLC-axis: The specific features of the PLC with the PLC axes to move, their movements with all the other all of the axes are not synchronized, moving the movement arises from the path and synchronized campaigns are nothing to do;
* Geometric axes, synchronization and positioning axes are the axes can be programmed.

* According to the movement commands are programmed with a feed rate of F, so that shaft produces movement.

* Synchronizing shaft axis synchronized movement with the path and use the same move all the time path of axes.

* Positioning axis movement and all other axes asynchronous, these mobile campaigns has nothing to do with the path and synchronized movement.

* PLC by the PLC control shaft, and produce all the other axes are not synchronized with the movement of mobile movement has nothing to do with the path and synchronized campaigns

Programming Language

* Programming address and the meaning of

Address the meaning of

Program numbered addresses N

10 program segment number

G Preparatory Function

X, Y, Z position data interpolation parameters

F Feed

S spindle speed

T Tool number

D Tool offset number

M Miscellaneous Functions

H Accessibility

* Data Type

Type of meaning range of values

INT unsigned integer ± (231-1)

REAL real numbers (with decimal points) ± (10-300 ... 100 300)

BOOL code is determined by a ASSCII characters 0 ... 255

STRING string, in [...] in the string sequence of values 0 ... 255

Up to 200 characters

AXIS Axis name (axis address) channel on the name of an arbitrary axis

FRAME translation, rotation, scale and image of the geometrical parameters

* Directive:

1. G command

· G90: origin of reference coordinate system retaining wall, in the workpiece coordinate system in the preparation of tools to run point program.

G91: near the point of reference date, the preparation of tools to run from the program.

GO: fast-moving so fast tool positioning, movement around the workpiece near the tool change point, or

G1: Tool along with the shaft, slash or any other space orientation parallel to the line of mobile home.

G2: the arc in a clockwise direction on a track to run

G3: anti-clockwise on the circular track to run

G4: pause time effect (F ... in seconds; S ... used to determine the number of spindle rotation time)

G17: No tool radius compensation

G18: Cutter Radius Compensation to the contours of the left side

G19: Cutter Radius Compensation to the contours of the right side of

G40: lift the tool radius compensation

G41: active tool radius compensation, tool machining direction along the contour to run to the right side of

G42: active tool radius compensation, tool machining direction along the contour to run to the left of

G53: Non-modal access, including the programmed bias

G54 ... G57: Call No. 1 to No. 4 can be set to zero bias

G94: linear feed rate in mm / min, inches / min

G95: rotating feed rate mm / turn, inch / turn

2. M command

M0: Programming Stop

M1: choose to stop

M2: main program entry procedure at the beginning of the end of

M30: end of the process

M17: Subroutine end

M3: active spindle clockwise rotation

M4: Active spindle counterclockwise rotation

M5: Active Spindle Stop

M6: ATC instructions

3. Other

F: Feed Rate

S: active spindle speed (unit: rev / min)

T: Call Tool

D: Tool offset number (range: 1 ... 32000)
If it is grating back to zero, please refer to the following the following methods:

If your foot is the grating with a distance of coded reference point of grating ruler, then mark (usually behind the Heidenhain grating ruler marked with C have this function), return a reference point do not need to switch back to zero, the parameter set as follows:

1,34200 = 3 using the type of optical grating

2,34300 [1] = 20mm linear grating-foot grid spacing mark a reference point (LS486C to 20mm)

3,34060 [1] = 40 return to reference point distance = 2 times the largest mobile linear grating-foot grid spacing of the reference point mark

4,34000 = 0 do not use feed cam shaft to return a reference point, that is, without a reference point return deceleration switch signal (DB31.DBX12.7)

5,34090 = XXX to return a reference point offset value

6,34310 [1] = 0.020 signal optical grating pitch (LS486C to 0.020mm)

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