system commissioning and operation of 840D

1. 840D System Operation

   l .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 wheel and so on.

    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.

* Auto: 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 operations method: Select processing, the program outline, use the cursor to select the implementation of the program, the implementation can choose from the hard drive. 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 inside a fixed NCK buffer MDA, the MDA buffer can be stored in the program directory program can also be transferred from the program district 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 the corresponding axis, to re-implementation of the program, go to the re-positioning mode, press the corresponding axial movement button to return to the program a breakpoint, press start button program 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 will not impact on the NCK, but 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

1. 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:

(1) Power Module X161 in connection 9,112,48; drive the bus and device bus; the far right terminal resistor module (CNC and drive unit).

(2) MMC and the MCP, +24 V power supply should be careful polarity (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:

(1) MPI and OPI bus wiring must be correct.

(2) PCU or the 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:

(1) signal line and power lines as far as possible separated from a bit further;

(2) departure from the NC or the PLC, or to the NC or PLC was provided by the cable should be used SIEMENS

Cable;

(3) signal lines should not be too close to the external strong electromagnetic fields (such as motors and transformers);

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

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

(6) The following distances 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:

(1) process with a static module, should ensure that its normal grounding;

(2) can not prevent access to the electronic module, then please do not touch the module components, pins or the

He conductive parts;

(3) touch-component must ensure that the human body through the electrostatic discharge device (wrist strap, or shoes) and the earth with

Access;

(4) The module should be placed on conductive surface (put-static packing materials such as conductive rubber, etc.);

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

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

(7), a prerequisite for measuring

      - Measuring equipment grounding

      - Insulation instrument measuring the first pre-let electrical

(B) commissioning

l NC and PLC Fusakiyo

Power because it is the first time, start, it is necessary to do a total clear on the system or total reset.

1. NC Fusakiyo

NC Fusakiyo steps are as follows:

* The NC start switch S3-→ "1";

* Start the NC, such as the NC has been started, by clicking reset button S1;

* NC to start to be successful, seven-segment display shows "6", the S3-→ "0"; NC Fusakiyo implementation of the completion of

  NC General after the Qing, SRAM memory, the content is all Qingdiao, all machine data (Machine Data) has been preset to default values.

2. PLC Fusakiyo

  PLC Fusakiyo steps are as follows:

    * The PLC to start switch S4-→ "2"; => PS lantern light;

    · S4-→ "3" and maintained for 3 seconds until the light again, PS, etc.; => PS bright lights went out again;

    In 3 seconds within the rapid implementation of the following operations S4: "2" - → "3" - → "2"; => PS flashing lights first, then bright, PF lights (and sometimes does not shine PF, etc.);

    * Etc., etc. PS and PF bright, S4-→ "0"; => PS and PF lights turned off, while the PR lights.

    PLC Fusakiyo the completion of implementation, PLC Fusakiyo after the, PLC program can be spread through the STEP7 software systems, such as PLC Fusakiyo after the alarm on the screen can be used for an NCK reset (warm start).

Boot and startup

  After the first start, NCU status display (one seven-segment display and a reset button S1 2 status display lights and the two start switches S3 and S4.

  In determining the S3 and S4 are set to "0", then you can boot this time started, and after some dozens of seconds, when the seven-segment display shows "6", the show NCK power normal; At this point, "+ 5V "and" SF "lights, indicating that the system to normal; but drivers have not yet enabled, while the PLC status of" PR "lights, indicating that PLC is working correctly.

    MMC: MMC boot display to confirm, through the OP, and if it is MMC100.2, at the start of the end, the screen will be displayed below the line of information "Wait For NCU Connection: × × Seconds", such as MMC and the NCU communication is successful, SINUMERIK 810D/840D basic display will appear on the screen, generally at the "machine" operating area, while the MMC103, because it can be with a hard drive, so it there's a seven-segment display, such as the launch is successful it will MMC103 shows a "8".

    MCP: In the PLC to start the process, MCP all the lights stop flashing, once the successful launch of PLC, and the basic procedures into OB1 kinds of calls only if the FC19 or FC25, then the MCP is no longer on the flashing lights, this time MCP that can be used.

    DRIVE SYSTEM: only the NC, PLC, and MMC are normal startup, we finally consider the drive system. Must first complete the drive configuration, for MMC100.2, need the help of "SIMODRIVE 611D" Start-up Tool software, MMC103 can be done directly on the OP031 and then use the PLC signals can be handled accordingly.

   In this way, the system re-starts, SF lights should exterminate.

The meaning of element type

S1 starting a hardware reset button to reset; control and drive a complete restart after reset.

NMI S2 button to trigger and NMI on the processor to issue a request, NMI-Non-shielded mid -

S3 Rotary Switches NCK startup switch position 0: normal start-up position 1: The start position (the default value to start) to a value of 2 ... 7: reserved

 S4 Rotary Switches PLC mode selector switch position 0: PLC Run Location 1: PLC is running

Location 2: PLC stop position 3: Module Reset

    H1 (left column) light show light +5 V: supply voltage within tolerance when the light NF: NCK Kai

Dynamic process, the monitor is triggered, the lights CF: When the COM

Monitor outputs an alarm, this lights CB: by OPI interface into the

Line data transmission, the lights CP: through the number of PC-MPI interface

According to transmission, this light green light red light red light yellow light yellow

H2 (right column) light show light FR: PLC running PS: PLC to stop the state FF: When the PLC

Monitor outputs an alarm: This lights; when the PLC monitors the input

When an alarm: All four lights are bright FFO: PLC mandatory state

-: NCU571-573 is not available, reset when the short-lived light NCU573.2: PLC DP

CPU315 2DP on the state in this light there is "BUSF" tag lights

Destroy: DP is not configured or configured but all the lights from the station was not found

Flash: DP configuration, but one or more loss of light from the station

Liang: error (for example: No Token Passing Bus shortcut) green light

Red yellow yellow

H3 seven-segment digital tube software supports the output testing and diagnostic information. Startup is complete, is

Regular status shows "6"

840D NCU module control and display elements

l Data Backup

During debugging, in order to improve efficiency not do repetitive work, which required the commissioning of the backup data in a timely manner. In the machine tool factory, all the data for the machine to stay stalls, also need to back up the data.

  SINUMERIK 810D/840D The data is divided into three kinds: NCK data

                                     PLC Data

                                     MMC Data

There are two data backup methods:

1. Series Backup (Series Start-up):

Features: (1) is used to back loaded and start with the SW version of the system

     (2) includes data on full, the number of small files (*. arc)

     (3) data does not allow changes to all kinds of binary files (or known as PC format)

          Kinds of DATA)

Speed

Features: (1) is used to return a different SW versions of the system installed

    (2) The number of multiple files (a type of data, a file)

    (3) can be modified, most of the file with "tape format: the text format"

Data backup needs to do the following support tools:

  · PCIN Software

  · V24 cable (6FX2002-1AA01-0BF0)

  · PG740 (or better) or PC

※ As the MMC103 can bring floppy drive, hard disk, NC cards, etc.; its data backup is more flexible choice of different storage targets, with its case on specific steps:

* Data Backup

(1) In the main menu, select "Service" operating area;

(2) by extensions ")" - → "Series Start-up" Select archive contents

NC, PLC, MMC and define the archive file name;

(3) from the vertical menu, choose one as storage objectives:

V.24 - → refers to V.24 cable ships external computer (PC);

PG - → Programmer (PG);

Disk - → MMC brought the floppy in the floppy disk;

Archive - → hard disk drive;

NC Card - → NC Card.

    Select V.24 and PG, they shall "Interface" software key, set the V.24 interface parameters;

(4) If they choose to back up data to disk, then: "Archive" (vertical menu) - → "Start".

* Data Recovery

MMC103 the steps (from the hard disk to restore data):

    a: "Service";

    b: Extension key ")";

    c: "Series Start-up";

    d: "Read Start-up Archive" (vertical menu);

    e: find the archive file and select "OK";

    f: "Start" (vertical menu);

  Either data backup or data recovery, are carrying out the data transmission, transmission of the following principles:

1. Will always be ready to receive data before the party ready, at the receiving state;

二. At both ends of the same parameter setting.

The third talk programming

l Coordinate System

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 arriving tool

Location

  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 zero, coincides with the workpiece zero (the 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 coordinates M 12:00 XB

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

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

4. With the current workpiece zero Wa current workpiece coordinate system MAWZ

l 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 identifiers 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

l 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

Instruction:

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 axis of movement.

  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)

The fourth talk about setting parameters

In the NC debugging, the parameter setting is an important part of the parameter settings of the main contents of the data does not match the machine (Machine Data).

Machine data and setting data classification sheet

Regional Notes

From the 1000-1799 data for driving machine

From 9000-9999 Operation panel with machine data

From 10000-18999 General machine data

Aside from 19000-19999

20000-28999 from the data channel class machine

Aside from 29000-29999

30000-38999 shaft from the machine data

Aside from 39000-39999

From 41000-41999 common set of data

Channel category from the 42000-42999 set of data

43000-43999 shaft from the set of data

51000-61999 compiled from the cycle of using general-purpose machine data

From 62000-62999 compile-cycle machine data access classes

From 63000-63999 shaft machine data used to compile cycle

l Machine Tool Data Set

(1) General MD (General):

MD10000: This parameter setting machine all of the physical axis, such as the X-axis.

Channel MD (Channel Specific):

MD20000 - → set the channel name CHAN1

MD20050 [n] - → set the machine serial number used in the geometric axes, geometric axis Cartesian coordinate system to form the axis

MD20060 [n] - → set up all the geometric axes names

MD20070 [n] - → set exists for this machine shaft axis number

MD20080 [n] - → Set the channel axis of the machine programmed with the name of

The above parameters set, do a NCK reset!

(2) axis-related MD (Axis-specific):

  MD30130 - → Set Axis command port = 1

  MD30240 - → Set-axis feedback port = 1

  Such a two-parameter to "0", then the axis is simulation axis.

  At this point, once again NCK reset, it will face a 300,007 alarm.

l-driven data set

Configuration-driven data, due to more data-driven, for MMC100. 2 requires the help of "SIMODRIVE 611D START-UP TOOL" software, MMC103 can be carried out directly in the OP, generally need to set the following parameters:

Location: Set drive module position

Drive: Set this logical drive shaft No.

Active: Set whether to activate this module

Configuration is completed and valid, need to store what (SAVE) - → OK

At this point do a NCK reset. Post-show 300,701 police.

At this time for the gray of the original FDD, MSD becomes black, can choose a motor;

The steps are as follows: FDD-→ Motor Controller-→ Motor Selection-→ select the appropriate motor according to motor nameplate - → OK-→ OK-→ Calculation

Drive-by Drive + or switch to do the next axis:

MSD-→ MotorController-→ MotorSelection select the appropriate motor according to motor nameplate - → OK-→ OK-→ Calculation final - → Boot File-→ Save BootFile-→ Save All, do an NCK reset.

At this point, drive configured, NCU (CCU) positive SF red light should be exterminate, then, the shaft should be able to run.

Finally, if a particular set spindle axis, then the following steps:

(1) the first set to the shaft axis of rotation:

MD30300 = 1

MD30310 = 1

MD30320 = 1

  (2) Then, find the axis parameters, with AX +, AX-locate the axis:

MD35000 = 1

MD35100 = XXXX

MD35110 [0]

MD35110 [1]

MD35130 [0]

MD35130 [1] set the parameters related to speed

MD36200 [0]

MD36200 [1]

Do NCK reset

Launched, under the MDA lose SXXM3, spindle can be transferred.

l all the critical parameters configuration is completed, will allow the proper functioning of the following axis can be JOG, hand wheel, MDA lamp mode to change the shaft speed, observe the axis operation status. Sometimes, the operational status of the individual axis is not normal, ruled out after hardware failure and other reasons, you need to optimize.

l force model parameters

POWER ON (po) to re-power NCU module panel "RESET" button

NEW_CONF (cf) on the new configuration MMC software "Activate MD"

RESET (re), Fu Wei-control unit on the "RESET" button

IMMEDIATELY (so) after the value of inputs

Data area

$ MM_ working face of data

$ MN_ / $ SN_ General Machine Data / Set Data

$ MC_ / $ SC_ channel-specific machine data / setting data

$ MA_ / $ SA_ axis-specific machine data / setting data

$ MD_ drive machine data

Where

$ System variable

M Machine data

S configuration data in the machine debugging is often necessary to adjust the parameters are:

MD 10000: JOG speed setting

MD 10240: physical units, "0" British, "1" Metric

MD 20070: a valid channel number axis machine tools

MD 20080: channel name of the channel axis

MD 30130: setting refers to the output type, a value of "1" indicated that the shaft, "0" for the virtual axis

MD 30240: encoding type, "0" means non-coder, "1" bit relative encoder, "4" as an absolute encoders, spindle, the value of "1"

MD 30300: Rotary axis / spindle, a value of "1" indicates that the axis when the spindle

MD 34090: reference point for offset / offset coding absolute displacement

MD 34200: reference point model. A time when the absolute encoder to "0"

MD 35000: the specified machine tool spindle axis, "1" as the main

MD 36200: Shaft speed limit