Rexroth MTC 200 Tool Management Edition 01 Edition 01 Rexroth MTC 200 Tool Management Project Planning Manual Industrial Hydraulics Electric Drives and Controls Linear Motion and Assembly

R911296978Edition 01

Rexroth MTC 200Tool Management

Project Planning Manual

IndustrialHydraulics

Electric Drivesand Controls

Linear Motion andAssembly Technologies Pneumatics

ServiceAutomation

MobileHydraulics

About this Documentation Tool Management

DOK-MTC200-TOOLMAN*V23-PR01-EN-P

Rexroth MTC 200

Tool Management

Project Planning Manual


Document Number 120-1701-B302-01/EN

This documentation is used for project planning of tool management ofthe MTC 200 CNC control.

Description ReleaseDate

Notes

120-1701-B302-01/EN 01.2004 Valid as of version 23

� 2004 Bosch Rexroth AG

Copying this document, giving it to others and the use or communicationof the contents thereof without express authority, are forbidden. Offendersare liable for the payment of damages. All rights are reserved in the eventof the grant of a patent or the registration of a utility model or design(DIN 34-1).

The specified data is for product description purposes only and may notbe deemed to be guaranteed unless expressly confirmed in the contract.All rights are reserved with respect to the content of this documentationand the availability of the product.

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Note

Tool Management Contents I


Contents

1 Basics 1-1

1.1 Basic Idea ..................................................................................................................................... 1-1

1.2 Activation and Configuration ......................................................................................................... 1-2

1.3 Setup Lists and Tool Lists............................................................................................................. 1-2

Setup List ................................................................................................................................. 1-2

Tool List.................................................................................................................................... 1-3

Current Tool List ...................................................................................................................... 1-4

Equipment Check..................................................................................................................... 1-4

Operation without Setup List.................................................................................................... 1-6

1.4 Tool Group Management .............................................................................................................. 1-6

Redefinition of the Term “Tool Group” ..................................................................................... 1-6

Method of Operation ................................................................................................................ 1-7

Effects of the Setup List on the Tool Groups ........................................................................... 1-8

Parameter Value Assignment .................................................................................................. 1-9

Tool Data Elements ............................................................................................................... 1-10

NC Commands for Tool Groups ............................................................................................ 1-11

PLC Data Structures and Function Modules for Tool Groups ............................................... 1-11

Diagnosis ............................................................................................................................... 1-12

2 Elements of the Tool Data Record 2-1

2.1 Overview ....................................................................................................................................... 2-1

2.2 Basic Tool Data............................................................................................................................. 2-2

Tool Identification..................................................................................................................... 2-4

Location Data......................................................................................................................... 2-28

Units ....................................................................................................................................... 2-31

Technology Data.................................................................................................................... 2-32

User Tool Data....................................................................................................................... 2-33

Tool Group Data .................................................................................................................... 2-33

Other User Tool Data............................................................................................................. 2-41

2.3 Tool Edge Data ........................................................................................................................... 2-42

Tool Edge Identification ......................................................................................................... 2-43

Tool Life Data......................................................................................................................... 2-53

Geometry Data....................................................................................................................... 2-57

Geometry Limit Values........................................................................................................... 2-61

Wear Factors ......................................................................................................................... 2-62

User Tool Edge Data ............................................................................................................. 2-64

2.4 Grinding-Specific Tool Data ........................................................................................................ 2-65

Tool Code WGD DE 18.......................................................................................................... 2-67

II Contents Tool Management


Representation Type WGD DE 19......................................................................................... 2-69

3 NC Functions to Control Tool Management 3-1

3.1 Conditions ..................................................................................................................................... 3-1

Default Plane............................................................................................................................ 3-1

Tool Management Commands ................................................................................................ 3-2

3.2 Tool Storage Unit Motion Commands of the NC ........................................................................ 3-11

Tool Storage to Reference Position ‘MRF’ ............................................................................ 3-12

Tool Storage to Home Position ‘MHP’ ................................................................................... 3-13

Move Tool into Position ‘MTP’ ............................................................................................... 3-14

Move Programmed Pocket into Position ‘MMP’..................................................................... 3-15

MTP/MMP Commands and Tool Correction.......................................................................... 3-17

Freely Position Tool Axis ‘MMA’ ............................................................................................ 3-17

Moving to Free Location ‘MFP’ .............................................................................................. 3-18

Move to Old Position - ‘MOP’................................................................................................. 3-20

Tool Storage Ready ‘MRY’ .................................................................................................... 3-22

Enable Tool Storage for Manual Mode ‘MEN’ ....................................................................... 3-23

Moving Tool Storage Unit with Nonuniform Pocket Distribution ............................................ 3-24

3.3 Tool Changing Commands of the NC......................................................................................... 3-25

Performing a Complete Tool Change ‘TCH’ .......................................................................... 3-26

Change the Tool from the Magazine to the Spindle ‘TMS’ .................................................... 3-27

Change Tool from Spindle to Magazine ‘TSM’ ...................................................................... 3-27

Magazine Pocket Empty ? ‘TPE’............................................................................................ 3-28

Tool Spindle Empty? ‘TSE’ .................................................................................................... 3-28

4 PLC Functions to Control Tool Management 4-1

4.1 Tool Magazine Motion Control ...................................................................................................... 4-1

Tool Magazine Control Signals ................................................................................................ 4-2

4.2 Magazine Functions .................................................................................................................... 4-22

Tool Storage Unit Motion Commands of the PLC.................................................................. 4-22

Magazine Homing .................................................................................................................. 4-24

Tool Magazine Positioning..................................................................................................... 4-27

4.3 Tool Change Functions............................................................................................................... 4-32

Complete Tool Change .......................................................................................................... 4-32

Magazine-to-Spindle Tool Change ........................................................................................ 4-35

4.4 Tool Transfer Functions .............................................................................................................. 4-40

Tool Transfer Operation......................................................................................................... 4-40

Tool Transfer Procedure and Function Modules ................................................................... 4-41

Further Tool Transfer Functions ............................................................................................ 4-46

4.5 Combined Spindle/Turret Axis .................................................................................................... 4-48

Interrogating and Acknowledging Turret Mode Preselection................................................. 4-50

Interrogating and Acknowledging Spindle Mode Preselection .............................................. 4-52

5 Setting the Parameter Values of the Tool Storage Unit 5-1

5.1 Sequence of the Parameter Value Assignment............................................................................ 5-1

5.2 NC-Controlled Tool Storage Unit .................................................................................................. 5-3

Tool Management Contents III


Benefits of an NC-Controlled Tool Storage Unit ...................................................................... 5-3

Example: Assigning the Parameter Values of a Disk-Type Magazine .................................... 5-3

5.3 PLC-Controlled Tool Storage Unit ................................................................................................ 5-5

General .................................................................................................................................... 5-5

Example: Assigning the Parameter Values of a Disk-Type Magazine .................................... 5-5

6 Typical Applications 6-1

6.1 PLC-Controlled Turret ................................................................................................................... 6-1

Description of the Turret .......................................................................................................... 6-1


NC Programming ..................................................................................................................... 6-2

PLC Programming ................................................................................................................... 6-2

6.2 Combined Spindle/Turret Axis ...................................................................................................... 6-4

General .................................................................................................................................... 6-4

6.3 NC-Controlled Disk-Type Magazine ............................................................................................. 6-5

Description of the Magazine .................................................................................................... 6-5


NC Programming ..................................................................................................................... 6-7

PLC Programming ................................................................................................................... 6-9

6.4 PLC-Controlled Chain-Type Magazine ....................................................................................... 6-12

Description of the Magazine .................................................................................................. 6-12

Parameter Value Assignment ................................................................................................ 6-12

NC Programming ................................................................................................................... 6-13

PLC Module for Magazine Control......................................................................................... 6-14

PLC Module for Changing Tools............................................................................................ 6-16

PLC Module for Gripper Rotation .......................................................................................... 6-23

6.5 Additional Tool Carriers............................................................................................................... 6-24

General .................................................................................................................................. 6-24

Parameter Value Assignment ................................................................................................ 6-25

Selecting Additional Tool Carriers ......................................................................................... 6-25

7 Appendix 7-1

7.1 "NC Tool Commands" Overview................................................................................................... 7-1

7.2 Overview "SPS Interface Signals" ................................................................................................ 7-3

"Tool Storage Unit Control Signals" Overview......................................................................... 7-3

"Tool Storage Unit Status Signals" Overview .......................................................................... 7-4

7.3 "PLC Tool Transfer Commands" Overview................................................................................... 7-4

7.4 "Tool Data Record" Overview ....................................................................................................... 7-5

7.5 Read/Write Tool Data from the NC Program "TLD".................................................................... 7-13

Examples ............................................................................................................................... 7-16

8 Index 8-1

9 Service & Support 9-1

9.1 Helpdesk ....................................................................................................................................... 9-1

9.2 Service-Hotline.............................................................................................................................. 9-1

IV Contents Tool Management


9.3 Internet .......................................................................................................................................... 9-1

9.4 Vor der Kontaktaufnahme... - Before contacting us...................................................................... 9-1

9.5 Kundenbetreuungsstellen - Sales & Service Facilities ................................................................. 9-2

Tool Management Basics 1-1


1 Basics

1.1 Basic Idea

Tool management of the MTC 200 provides powerful functions for theconfiguration and for the handling of various magazine and turret types.Tool management is a permanent component of the NC control – it takescare of administrating all the tools and tool lists. Among other things,chain-type and disk-type magazines, as well as tool turrets, can be easilydesigned and operated. A user-friendly interface, combined with extensivefunctions in the NC and the PLC, are used to transfer tool data.

Besides tool length offset and tool edge / cutter radius compensation, toolmanagement provides an automatic tool life monitoring function, warninglimits and machining-related wear factors.

During machining, the MTC 200 replaces worn-out tools with tools of thesame designation (alternate tools), if such tools are available in the toolstorage unit.

The extended tool designation (up to 28 characters) permits anyoperation-related tool designation system to be retained on the controllevel.

Tool management permits "setup lists" to be used; these contain thecommand data for the tools (not in 22VRS). At the beginning of each newmachining process, an automatic comparison is performed between thespecified tool data (setup list) that is allocated to the NC program and thecurrent tool data (tool list). This comparison is known as an "equipmentcheck". It permits a check to be performed that almost totally excludescollisions and, consequently, damage to machines, workpieces and tools,as well as standstills during program execution.

Tool preparation is used for providing the tool data in parallel to themachining time. It can contain up to 99 tool lists per process. List number99 contains 999 magazine or turret locations, and can therefore be usedas a tool pool.

The MTC 200 permits both numerically controlled and PLC-controlledmagazines and turrets to be used in the same way.

Provided that it has been parameterized and programmed accordingly,each of the processes 0 - 6 is able to control a magazine, a turret oradditional tool carriers and the necessary tool changing proceduresbetween the existing spindles and grippers and the tool storage unit. Themovements of a tool storage unit can be executed independently of andasynchronously to the other axis movements of the process.

For numerically controlled magazines and turrets, tool managementperforms the complete machine control.

For PLC-controlled magazines and turrets, tool management alsoperforms extensive functions, such as looking for a vacant magazinelocation.

Tool group management supports the utilization of segmented toolstorages. It allows tools which are used for machining certain workpiecesor phases to be organized in up to 99 tool groups and to be changed in orout of the tool magazine.

Extensive functions in the machine parameters, in the PLC, in the NC andin the machine data are available to configure and operate toolmanagement.

Purpose

Tool data record

Setup lists

Tool preparation

Tool storage

Configuration and operation

1-2 Basics Tool Management


Configurable data records permit optimum adaptation to the individualtechnologies (boring, milling, turning, grinding, etc.), and to the individualmachine structures and machining processes.

Simultaneous employment of different production technologies (such asmilling and turning) on the same machine permits precise completemachining processes to be performed without reclamping the workpiece.

BTD Basic tool data

TSB Tool status bits

TG Tool group status bits

TED Tool edge data

TESB Tool edge status bits

1.2 Activation and Configuration

Tool management of the MTC 200 is generally activated for the entirecontrol by system parameter A00.052 Tool management. In order to beable to use tool management in the existing processes, processparameter Bxx.014 Tool management must also be set to "yes".

As soon as A00.052 Tool management has been set to "yes", additionalsystem parameters appear – these are used to optimally configure thetool data records to the requirements of the user (see section "Elementsof the Tool Data Record").

The structure of the tool data record is identical for all processes withinthe control.

Tool management is adapted to the mechanical tool storage found on themachine for

• NC-controlled magazines and turrets using the process parameters,axis parameters and the PLC, and for

• PLC-controlled magazines and turrets using the process parameters,axis parameters, the PLC, and the machine data.

1.3 Setup Lists and Tool Lists

Setup List

Using the setup list, the user can define the availability of all tools that arerequired for machining and, using the equipment check, ensure theirusability for the machining processes that are to be performed. The setuplist data reflects the required data of the tools that are to be employed (e.g.geometry limit values).

Note: From firmware version 23VRS, the MTC 200 will again supportfull functionality of the setup lists from its MTGUI.

The setup lists and the NC packages are loaded into the controller andsaved together through the storage function.

Abbreviations

Tool Management

Tool data records

Tool storage

Purpose

Handling



Using system parameter A00.053 Organization of setup lists, the userdefines whether a separate (program-specific) setup list is to be created foreach NC program or whether only one (station-specific) setup list is to becreated for a process.

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Fig. 1-1: Organization types of setup lists

Tool ListTool lists are used for preparing and saving tool data of the individualtools. The tool data always contain the basic tool data, which consist ofthe tool identification, the location data, the units, the technology data andat least one tool edge.

Besides the basic tool data, the tool data contain the data that arerequired for the tool edges (tool tip identification, geometry, tool life data,user-defined data) (see Chapter "Elements of the Tool Data Record").

With the help of the PC user interface, tool lists can be created, modified,and saved while machining is in progress. This enables the user to loadthe tool storage device for subsequent machining processes.

This permits the setup time of a new tool storage unit configuration to bereduced to a minimum. The operator loads the tool list prepared in theuser interface into the control and loads the tool magazine according tothe tool list.

Activation

Purpose

Preparation

Loading the tool list



Current Tool ListThe tool list that is currently contained in the control is known as the"current tool list".

As soon as a machining process has begun, the tool list in the PC losesits significance; solely the current tool list in the CNC reflects the currentstate of the tools within the magazine.

Note: Any modifications that concern the current workpiecearrangement, such as inserting, removing or moving a tool ormodifying the tool data, must be performed directly in thecurrent tool data.

The current tool list contains the current information about the locationand the state of the individual tools (e.g. current remaining tool life). Thecurrent tool list is generated from the tool list while taking the setup listinto account.

During the machining process, tool management continually updates thecurrent tool data, such as the location data, tool life data, and wear data.

Equipment CheckThe equipment check compares the required tool data (setup list) with theactual tool data (current tool list).

The equipment check is performed automatically whenever a program isrestarted after data of the setup or tool list have been modified andtransferred to the controller or after a different NC memory (A, B) hasbeen selected if interface signal PxxC.MGWTC (Process xx CommandMaGazine Without ToolCheck) has been set to log. '0'.

Tool management does not perform an automatic equipment check aftera restart if PxxC.MGWTC has been set to log. '1'.

In addition, NC command TID (Tool IDentification) permits the equipmentcheck to be executed at any position in the NC program, regardless ofinterface signal PxxC.MGWTC.

TID

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Fig. 1-2: Conditions for equipment check

Each tool that has been entered in the setup list triggers the followingsequence during the equipment check:

TID

Syntax



• Based on the tool identification (ID), tool management searches theentire current tool list for tools with the same name.

• Tool management first assigns the setup list-specific data to eachlocated tool. Any setup list-specific data that exist from a previouslymade comparison will be overwritten.

• If a tool is not contained in the tool list, it is entered as missing in thetool list of the user interface (sorted by T No.), i.e. tool status bit 1 'Tooldoes not exist' (� "!") is set.

• Tools in the tool list to which no entry can be assigned in the setup listare marked by tool management by setting tool status bit 2 'Tool notrequired' (� "?").

• Depending on the tool, the tool status bits that are responsible forlocation locking and location assignment are set or reset.

• Once the setup list-specific data have been assigned, toolmanagement checks the tool edge data and the basic tool data.

• For the tool edge data, the tool edge orientation, the existing geometry,and the wear state are checked. The result is shown using the relatedtool edge status bit.

• If the tool edge orientation and/or the tool geometry of at least one tooledge does not satisfy the requirements, this will be shown in toolstatus bit 5 ('Faulty tool edges' �"f").

• Accordingly, the wear state of the tool edges is shown in tool statusbits 17 and 18 ('Tool worn out' � "d" or 'Tool below warning limit'�"w") if at least one tool edge is worn out or below the warning limit.

• From the basic tool data of the tool list, tool management checks thecorrection type and the number of tool tips against the specificationsmade in the setup list. According to the result, it updates tool statusbits 3 and 4 'Incorrect correction type' (� "t") and 'Incorrect number oftool tips' (� "e").

• Tools with the same name that could be assigned to an entry in thesetup list (alternate tools) are summarized in alternate tool chains. The tools are arranged in the following sequence in each alternate toolchain:

• usable tools that have already been used, i.e. at least one tool edgehas a remaining tool life of less than 100%.

• usable tools that are still new, i.e. each tool edge has a remainingtool life of 100%.

• worn tools that would otherwise be usable

• broken tools that would otherwise be usable

• unusable tools.

Within these groups, the sequence is according to increasing duplonumbers.The first tool of every alternate tool chain becomes the processing tool(�"p") of this chain. All other usable tools are marked as replacementtools (�"s").

• If interface signal PxxC.MGITW (Process xx Command MaGazineIgnore Tool Worn Out) has been deleted, the NC program terminateswith an error message if there is an alternate tool chain that does nothave any usable tool. If the interface signal PxxC.MGITW is set, thebehavior is basically the same. However, tools that are worn and/orbroken, but otherwise usable, are counted as usable tools.

Basic tool data

Tool Edge Data

Generate alternate tool chains



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Fig. 1-3: Basic method of operation of equipment check (station-specificorganization of the setup list)

Operation without Setup ListThe PxxC.MGNSL (Process xx Command No Setup List) interface signalmust be set to '1' if the setup lists are not to be used.

In this case, the NC generates (internally and invisible to the user) anempty setup list, in which it generates an entry for each T number thatoccurs at least once in the current tool list. Then the NC uses this setuplist to execute the equipment check described above; however, theassignment between the entry in the generated setup list and theassociated tools in the tool list is made using the T number. Anypreviously existing setup list is not taken into account.

1.4 Tool Group Management

Redefinition of the Term “Tool Group”

Up to firmware version 22VRS, the term "tool group" together with theterm "tool technology group" has been used in connection with the type oftechnical utilization of the tools. Tool technology groups are e.g. "drillingtools" or "milling tools". The subdivisions of these technology groups havebeen described as "tool groups", e.g. "twist drill", "step drill", "end mill", or"angle cutter". From firmware version 23VRS, the term "tool group" isreplaced by the term "tool type group".

The term "tool group" is redefined from Version 23VRS. Now, it describesa group of different tools – also from different tool technologies – whichare stored in the tool storage for certain machining phases or workpiecesand which are changed into or out of the tool magazine together.

"Tool group" (old)

"Tool type group" (new)



Method of OperationThe option to combine in one tool group tools which are required forcertain machining stages or workpiece types, supports the utilization ofsegmented tool storages.

Each segment of the tool magazine is assigned to one group. After agroup is activated, only the tools within this group are used. This reducestraversing distances on tool change, e.g. in flexible production systems,machining centers or in transfer lines, to a minimum. In the case oflathes, the advantage lies in the common replacement of tools in a group(e.g. drilling and thread cutting) when a tool in the group is worn.

A tool group can have sister groups. The group 0 which comprises alltools which are not to be assigned to a group, is an exemption.

Tool groups are identified by a group number and a group duplo number.Groups of the same group number are linked according to ascendingduplo numbers.

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Fig. 1-4: Example for tool groups and sister groups

Tool groups are subject to the following regulations:

1. Up to 99 tool groups can be administered.

2. A tool group can comprise up to 999 tools. Note: The total number of tools is restricted to 999 per process (resp.tool management).

3. The tools in one tool group can comprise only sister tools in the samegroup.

4. A tool group can have up to 99 sister groups.

5. Additionally, the tool group has status bits of its own.

6. A tool group is considered worn once the first tool sister sequence ofthe group is worn.

7. After the wear of a group, the next alternate group is activatedautomatically and locked tool groups are excluded.If a tool is not available in the active alternate group or it is also notfound in other tool groups during correspondingly set tool searchmode (NC command TGSM), the CNC displays the error 314 "Tool ortool location not found".Only the respectively active duplo group is used for tool search in

Regulations and conditions



each tool group. This provides the possibility that the duplo groups ofa tool group should be equipped with the same tools.

8. The interface signal PxxS.MGWRN (Process xx Status MaGazineTool WaRNing) is set when the first tool alternate chain of the lastalternate group has reached the warning limit.

9. The interface signal PxxS.MGTWO (Process xx Status MaGazineTool WaRNing) is set when the first tool alternate chain of the lastalternate group is worn.

10. The last sister tool of a sequence in the last respective spare groupcan assume negative tool life.

11. A group is blocked and enabled by writing of the corresponding groupstatus bit.

12. There is always a group 0 which comprises all tools which are not tobe assigned to any group. There is no sister group for group 0.

The following search sequences are available as a tool search mode (NCcommand: TGSM)

Mode Search order Comment

0 Preselected group If the tool is not found in the preselectedgroup, the NC will indicate error 314 ”Toolor tool location not found”.

1 Preselected group,group 0

First, the tool is searched in the preselectedgroup, then in group 0.

2 Preselected group,groups 0..99

If the tool is not in the preselected group, itwill be searched for in ascending order inthe groups 0..99.

3 Groups 0 to 99 Irrespective of the enabled group, the tool issearched in ascending order in the groups0…99.

Fig. 1-5: Tool search mode in tool groups

If the requested tool is found in another than the preselected / enabledgroup, this group will be automatically enabled and preselected once thetool has been enabled.

Effects of the Setup List on the Tool GroupsThe components of the magazines are defined by the setup list. Tools notcomprised in the setup list are logically removed from all groups.

In the following example (Fig. 1-6), the setup list comprises the tools T1,T3 and T5. The tools T2, T4, T6 and T7 are not comprised in the setuplist and are accordingly removed from all tool groups (logically, notphysically).

Tool search mode



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T7

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Fig. 1-6: Effects of the Setup List on Tool Groups

The duplo groups are also linked when different tools (different Tnumbers) are comprised in the duplo groups. In the group status thestatus bit ”Group not required” (symbol ”?”) is set when all tools of thegroups have been removed by the equipment check.

Parameter Value Assignment

By means of machine parameter Bxx.073 "Number of tool groups", toolgroup management is enabled / disabled:

0: Do no activate group management (pre-assignment).

The group information in the tool is not evaluated. All tools areautomatically assigned to the enabled group 0 This group is always activeand can not be deselected. Addressing through the TLD command doesnot consider any group data and returns "0" as enabled group.

1..99: Define available tool groups.

Up to 99 tool groups can be defined. However, to attain an optimummemory allocation and access speed, only the number of groups that areactually needed should be entered.

Note: Any modification of machine parameter Bxx.073, "Number oftool groups", causes canceling of the control-internal tool list;however, it can be reloaded into the control through GUI.

Machine parameter Bxx.073"Number of tool groups"



Tool Data ElementsFor the management of tool groups, the tool data record of the MTC 200tool management has been extended by three data elements.

In the basic tool data, the data elements …

• 30 – Group number ...and...

• 31 – Group duplo number ...have been introduced.

Note: When the tool data element "Group number" includes thevalue "0", only this value "0" is permissible for the tool dataelement "Group duplo number". The permissible entry into thetool data element "Group number" is restricted by the machineparameter Bxx.073, "Number of tool groups"

• Bxx.073 = 0:Tool group number and tool group duplo number mustcomprise the value "0".

• Bxx.073 = n [1..99]The tool group number can be in the range [0..n], and thetool group duplo number in the range [0..99] (exception fortool group 0: only permissible tool group duplo number is0).

Tool data which disregard these restrictions cannot be loadedinto the control!

Furthermore, for each tool group there is the element…

• 32 – Group status

The group status can be accessed both through tool addressing andthrough group addressing.

Note: The data elements 30..32 are illustrated and shown in detail inthe Chapter “Elements of the Tool Data Record” in the “BasicTool Data” section.

After download of tool data, the group status of each group isautomatically initialized:

• The "Group not required" ("?") bit is set.

• The bits "Group disabled" ("L"), "Group worn out" ("d") and "Groupwarning limit reached" ("w") will be deleted.

During each equipment check (TID or implicit equipment check), a newgroup status is formed. Here, wear status is considered, and sister linkingof groups is performed. The following regulations apply:

1. A group is marked as "required" if it comprises at least one tool withthe T number required in the setup list. If there is not setup list, allgroups are automatically considered "required".

2. Groups belonging to a sister sequence must have at least one tooleach of the same T number.

3. The not worn out group with the smallest group duplo number will bethe processing group "p". All other groups which are not worn aresorted according to ascending duplo numbers and added as sistergroups ”s”.

Basic tool data

Group status initializationfollowing download of tool data

Group status formation duringequipment check



NC Commands for Tool GroupsTool group management is supported by the following NC commands:

• ToolGroup - "TG"

Use the NC command "TG <Gruppe>" to preselect a tool group. Theactive group can be read with "@<var>=TG (for a detailed description,see the Chapter “Tool Storage Movement Commands of the NC”,“Tool Group Administration” section).

• Tool Group Search Mode - "TGSM"

Use the NC command “TGSM=<Mode>” to define the tool searchmode and accordingly the implicit group enabling on entering the Tword. The mode can be read back with "@<var>=TGSM" (for adetailed description, see the Chapter “Tool Storage MovementCommands of the NC”, “Tool Group Administration” section).

• Tool Data - "TLD"The TLD command can be used to read and writethe tool data from the NC program; however, some restrictions applyto writing. In addressing, this command has been extended by theoptional elements “Group number” (G) and "Group duplo number"(GD) (see the Chapter “Access to Tool Data from the "TDL" NCProgram" for a detailed description).

PLC Data Structures and Function Modules for Tool GroupsThe PLC supports tool group management in the following manner:

• Data structure basic tool data – “TLBD“This data structure comprises the new elements “Group number”(G_NR) and "Group duplo number" (G_INDEX)

• Reading / writing tool data - "TLD_RD", "TLD_WR"Reading basic tool data - "TLBD_RD"Reading tool edge data - "TLED_RD"Deleting a tool - "TL_DELETE"Resetting a tool - "TL_RESET"These function modules contain the new elements "Group number"(GNR) and "Group duplo number" (GIND).

• Moving a tool - "TL_MOVE"This function module contains the elements "Group number"(SGNR) and "Group duplo number" (SGIND).

• Reading / writing group status “TLG_RD", "TLG_WR"New function module

Note: The PLC data structures and function modules affecting thetool groups are described in detail in the Chapter “StandardFunction Modules”, section “Tool Functions in the PLC” in theMTC 200 PLC interface description.



Diagnosis

NC Diagnosis MessagesThe following tables shows the specific NC diagnosis messages for the"Tool group management" function:

Diagnosis message (no. + text) Cause

314 Tool or tool location not found - There is no more tool group which is notdisabled or worn containing the selected tool.

- The selected tool was not found in the toolgroup preselected with TGSM.

322 Invalid function Tool group not available:- The group preselected with TG does not exist.

Fig. 1-7: NC diagnosis messages of tool group management

PLC Diagnosis MessagesAny programming errors in the PLC program may cause incorrectexecution of new or extended function blocks. In this case, the PLC willgenerate a corresponding error message.

The two following tables comprise all specific PLC error types and PLCerror numbers of tool group management:

PLC errortype

Function module Comment

-169 TLD_WR Writing tool data

-170 TLD_RD Reading Tool Data

-189 TLBD_RD Reading base tool data

-190 TLED_RD Reading tool edge data

-191 TL_RESET Resetting tool

-192 TL_DELETE Deleting tool

-193 TL_MOVE Moving tool

-213 TLG_RD Reading tool group status

-214 TLG_WR Writing tool group status

Fig 1-8: PLC error types of tool group management

PLCErrorno.

Comment Cause

1 Invalid inputparameter

- The value of the "PROC", "GNR" or "GIND" inputsis negative.- The "PROC" input is greater than 6.- The "GNR" input is greater than 99.- The "GIND" input is greater than 99.

2 Internal transfer error - General message error- invalid group number- invalid group index- invalid process number- group status bit cannot be changed

Fig. 1-9: PLC error numbers of tool group management

Tool Management Elements of the Tool Data Record 2-1


2 Elements of the Tool Data Record

2.1 Overview

The following overview tables contain the entire tool data record. Thetool data record consists of the setup list-specific data and of the toollist-specific data.

The tool data record of a tool consists of

• Basic tool data (see Chapter 2.2) and

• 1 to 9 tool edge data records (see section 2.3)

The number of tool edges and, therefore, of tool edge data records isset by system parameter A00.054 "Maximum tool edge number".

The "Data type in the PLC" column specifies the form in which theindividual data items are available in the PLC.

The data elements for which the number of a system parameter is listedin the column "Optional datum" are only available in the tool data recordif the entered system parameter is set.

The user can organize application-specific tool data and tool statuses inthe tool management function of the MTC 200. Here, information onmaximum speed and weight of a tool can be stored in the user data. Inthe user status bits, binary information can be stored, e.g. “Coolinglubricant required” or “Tools re-ground”. The following systemparameters allow for definition of the user tool data and user status bitsaccording to the requirements of the respective application:

• A00.061...A00.069 Designation of the user tool data 1..9

• A00.061...A00.069 Designation of the user edge data 1..5

• A00.061...A00.069 Designation of the user edge data 6-10

• A00.075 - A00.082 Symbol for user tool status bit 1..8

• A00.083 - A00.086 Symbol for user tool edge status bit 1-4

If tool management is to be used for a grinding machine, systemparameter A00.091 Tool technology must be set to "Grinding". Thefirst 5 tool edge user data (data elements 31 - 35) are assigned with thefollowing grinding-specific data:

• Min. spindle speed S min

• Max. spindle speed S max

• Max. grinding disk circumferential speed SUG max

• Angle of skew Angle of skew

• Current grinding wheel diameter Current wheel ∅

The first 5 tool user data are not allowed to be used by the user ifsystem parameter A00.091 Tool technology is set to "Grinding"!

Tool data record

Data type

Option

User defined tool data

"Grinding" technology data

2-2 Elements of the Tool Data Record Tool Management


2.2 Basic Tool Data

The data elements of the basic tool data exist once per tool; they can beclassified as follows:

• Tool identification,

• Location data,

• Units,

• Technology data,

• User data, and

• Group data (group status exists for each tool group)

Basic tool data (per tool) V23_20030728

DESIGNATION RANGE

DA

TA

TY

PE

in t

he

PL

C

UN

IT DE OPT. SL TL

Tool identification

Index address hexadecimal double word with32 bits

- 01 X X

ID (tool NAME) up to 28 characters* STRG28 - 02 X

Memory 0 - 2 - 03 X

Location 0 - 999 - 04 X

Tool number 1 - 9999999 DINT - 05 X X

Tool duplo number 1 - 9999 INT - 06 X

Correction type 1 - 5 USINT - 07 X X

Number of tool edges 1 - 9 USINT - 08 X X

Tool Status 0/1 (32 status bits) USINT - 09 X

Location data

Free half-locations 0 - 4 USINT - 10 X

Old pocket 1 - 999 INT - 11 X

Stor. of next setup tool 0 - 2 INT - 12 X

Loc. of next setup tool 1 - 999 INT - 13 X

Stor. of prev. setup tool 0 - 2 INT - 14 X

Loc. of prev. setup tool 1 - 999 INT - 15 X

Units

Time unit 0/1 (0: min, 1: cycl.) USINT - 16 X

Unit of length 0/1 (0: mm, 1: inches) USINT - 17 X X

Technology data

Tool code 0 - 9 USINT - 18 X X

Representation type 0 - 65535 INT - 19 X X



User data

User data 1 REAL 20 A00.061 X








User data 9

+/- 1.2 * 10-38 - +/- 3.4 * 10+38

and 0 (9 significant digits)

REAL

any

28 A00.069 X

Group data

29

Group number 0 - 99 BYTE - 30 X

Group duplo number 0 - 99 BYTE - 31 X

Group status 0/1 (16 status bits) WORD - 32 X

Comment up to 5 x 76 alphanumeric characters - 99 A00.057 X

WGD_all_V23_20030728.xls

Data element 99 ”Comment” is not loaded in the control.

* ASCII character string 32...126, at least 1 character >32

DE ... Data element SL ... Setup list-specific datum

R.TL ... Replacement tool TL ... Tool list-specific datum

CTRL29 ... STRING28 OPT ... Optional datum

In the following, all data elements (= “DE” column) of the basic tool dataare described group-wise in the order of the above illustration.



Tool Identification

Index address

Basic tool data

Date element 01 Index address

Relevant for:

Setup list (SL) X

Tool list (TL) X

Location list (LL)

Index addresses are automatically allocated by the control whenentering a tool. The index address can only be accessed in reading; it isused for control-internal management of the tools.

Tool name (ID)

Basic tool data

Data element 02 ID (TOOL NAME)

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

The tool name (also abbreviated as 'ID') can consist of a maximum of28 characters (ASCII set of characters 32 ... 126, min. 1 character > 32),providing a clear differentiation of the tools in use.

All utilized tools must be clearly named so that they can be uniquelyidentified based on their tool name.

Only tools that can substitute each other (alternate tools) are groupedunder one tool name.

Such tools can be further distinguished using an additional duplo number(see data element 06 'Duplo number').

The extended tool designation permits any company-related tooldesignation system to be retained on the control level.

Memory

Basic tool data

Data element 03 MEMORY

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

The 'Storage' (= “tool storage type”) data item is not shown directlywithin the tool list. Within the data record, it shows the type of locationthe tool is in:

DE 01

Explanation

DE 02

Explanation

DE 03

Explanation



0 := Magazine or turret location

1 := Spindle

2 := Gripper

NC record for interrogation of the tool storage in the process “P“ inwhich there is the tool “T” with the duplo number “D”:@101=TLD(P,1,T,D,0,3,0)

Location

Basic tool data

Data element 04 Location

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

Within the tool storage unit, the 'Location' data item determines thenumber of the tool pocket. For a spindle, it determines the number ofthe tool spindle, and for a gripper the gripper location that contains thetool.

Using the tool list, all locations of the tool storage unit and all existingspindles and grippers can be prepared with respect to data processingparallel to machining time for reception of the real tools.

WARNING

Risk of injuries to operators, as well as damageto machine and workpiece by faulty magazineconfiguration!� Once a tool list has been loaded into the control,

agreement between the actually existing magazineconfiguration and the tool list must be ensured.

NC record for interrogation of the tool storage in the process “P“ inwhich there is the tool “T” with the duplo number “D”:@101=TLD(P,1,T,D,0,4,0)

Example

DE 04

Explanation

Example



Tool number

Basic tool data

Data element 05 TOOL NUMBER

Relevant for:

Setup list (SL) X

Tool list (TL) X

Location list (LL)

Using the T word, which consists of a preceding address letter 'T' and atool number (up to seven digits) or a tool location number (up to sevendigits), a tool or a location can be accessed within the NC program.

A programmed tool number causes tool management to determine thecurrent location of the tool on the basis of the tool number anddesignation from the setup list using the designation and tool locationnumber from the tool list.

The assignment of the tool number (as it is used in the NC program) tothe tool (company-specific tool name) that is made via the setup listenables the NC program to access a tool.

If a setup list is not used, the current location is accessed directly via theallocation tool number <> tool location number within the tool list.

1. NC record for positioning the tool T1234 to reference position “b”(b=1..4) of the tool storage unit:MTP b T1234

2. NC record to change the tool T123 into the spindle (e.g. “simple”milling machine) for the case that the tool change cycle is called upthrough the jump flag “M6”:BSR .M6 T123

Tool Duplo Number

Basic tool data

Data element 06 DUPLO NUMBER

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

The tool duplo number provides for:

• an unambiguous identification of alternate tools (tools of the sametool name and the same T number) and

• defining the utilization sequence of the alternate tools for machining.

The alternate tools are used according to their duplo numbers. Provided itis neither worn out nor locked, an alternate tool with a lower duplo numberis used for machining before one with a higher duplo number.

The NC program employs the same T number for addressing alternatetools.

After the previous tool (tool of the same tool number and designation,and the next smaller duplo number) has been worn out or locked, the

DE 05

Explanation

Example

DE 06

Explanation



control selects a new alternate tool only if the same T number is invokedagain.

Note: If tools have the same T number and duplo number, toolmanagement employs the tools by their ascending locationnumbers.

Correction type

Basic tool data

Data element 07 Correction type

Relevant for:

Setup list (SL) X

Tool list (TL) X

Location list (LL)

The correction type defines the number of corrections of a tool and theirlocations (see Fig. 2-1).

• Correction type 1: (Drilling tool)A tool of correction type 1 has only one length compensation value(L3) that is always perpendicular to the current machining plane.

• Correction type 2: (Milling tool)In addition to the length compensation value (L3) that is alwaysperpendicular to the current machining plane, a tool of correctiontype 2 has a radius compensation value (R) inside the machiningplane.

• Correction type 3: (Lathing tool)A tool of this type includes 2 length compensation values (L1, L2)and one radius compensation value (R) inside the current machiningplane.

• Correction type 4: (Angle head tool)Tools of this type are able to perform a length compensation (L1, L2,L3) and a radius compensation (R) in the current machining plane inall three main axis directions (X, Y, Z). Length L3 is alwaysperpendicular to the current machining plane, while lengths L1 andL2 always lie within the current machining plane.

• Correction type 5: (Gripper)Tools of this type are able to perform a length compensation (L1, L2,L3) in all three main axis directions (X, Y, Z). Length L3 is alwaysperpendicular to the current machining plane, while lengths L1 andL2 always lie within the current machining plane.

In order to be used for the scheduled machining process, the correctiontype of the related tool in the magazine must coincide with the typerequested in the setup list.

DE 07

Explanation



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Fig. 2-1: Definition of the correction type



Number of tool edges

Basic tool data

DATA ELEMENT 08 NUMBER OF TOOL EDGES

Relevant for:

Setup list (SL) X

Tool list (TL) X

Location list (LL)

Each tool can have up to nine tool edge data records assigned,irrespective of the number of real tool edges the tool actually has.

To avoid wasting NC storage space, A00.054 Maximum tool edgenumber can be used to reduce the maximum number of tool edges toone tool edge per tool.

In order to be able to be used for the scheduled machining process, therelated tool must satisfy the number of tool edges that is requested in thesetup list.

Schneidenanzahl.FH7

Fig. 2-2: Examples for tools with different tool edge numbers

Tool Status (Bits)

Basic tool data

Data element 09 Tool Status

Relevant for:

Setup list (SL)

Tool list (TL)

Location list (LL)

1See description of theindividual bits

The tool status bits provide information about the current state of thetools and their locations.

DE 08

Explanation

DE 09



They can be subdivided into status bits that are specific to setup list,location, and tool:

• The setup list-specific status bits describe the state of a tool withrespect to the requirements of the setup list.

• The location-specific status bits reflect the status of a location.

• The tool-specific status bits describe the state of a tool.

The following table lists all tool status bits. The table is followed by adetailed explanation of the individual bits.

Classification



Tool status bits 1 -16 from basic tool data element 09Write

AccessType

Group name Group information

Sym

bo

l

Val

ue

Bit

Byt

e

Wo

rd

TM

OP

AS

P

SL

TL

PL

Comment

Tool not available ! 1

Tool available 01 X X X Tool is missing

Tool is not required ? 1Presence

Tool required 02

Tool not required formachining

Correction type wrong t 1Errorcorrection type correction type not faulty 0

3 X X X Correction type does notcomply with requirements

Incorrect number of tool edges e 1Errortool edge number Correct number of tool edges 0

4 X X XNumber of tool edgesdoes not comply withrequirements

Tool edge(s) incorrect f 1Error tool edge

Edge(s) not faulty 05

Tool edge data does notcomply with requirements

Tool code faulty $ 1Error tool code

Tool code not faulty 06

does not comply withrequirements

Reserved forextensions 7

Reserved forextensions 8

LOW

-Byt

e 0

... 7

Location locked B 1Location locking

Location not locked 09 X X X X X

ANP/BED: e.g. location isdamaged.TM: Tool will be entered

Reserved forextensions Upper half-location locking 10

Reserved forextensions Lower half-location locking 11

Upper Half-Location Reserved ) 1Upper half-locationreservation Upper half-location not reserved 0

12 X X X X Reserved for temp. movedtools

Lower Half-Location Reserved ( 1Lower half-locationreservation Lower half-location not reserved 0

13 X X X X Reserved for temp. movedtools

Reserved forextensions Upper half-location locking 14

Reserved forextensions

Lower half-location locking 15

Location assigned + 1Location reservation

Location not assigned 016

Hig

h-B

yte

0 ...

7

LOW

-WO

RD

0 ..

. 15

X X X There is a tool in thelocation

WSB_all_V22_20030918.xls

TM ... Tool Management SL ... Setup list-specific status bit

OP ... Operator TL ... Tool list-specific status bit

ASP ... Application-specific programs in PLC or NC

LL ... Location-specific status bit



Tool status bits 17 -32 from basic tool data element 09Write

AccessType


Sym

bo

l

Val

ue

Bit

Byt

e

Wo

rd

TM

OP

AS

PS

L-{

TL

PL

Comment

Tool is worn out d 1

tool is not worn out 017 X X

The remaining lifetime ofthe tool has elapsed(replace)

Warning limit is reached w 1Wear state

Warning limit not reached 018 X X The remaining lifetime is

about to expire (replace)

Machining tool p 1

No machining tool 019 X X

There is one machiningtool for each alternate toolgroup

Replacement tool s 1Name of alternate

no spare tool 020 X X

A spare tool is a tool thatcan still be used, nomachining tool

Tool with fixed location coding C 1Tool coding

Tool without fixed location coding 021 X X X X

Tool is only valid to bechanged on the predefinedtool location

Tool locked L 1Tool locking

Tool is not locked 022 X X X Tool must not be used

Tool broken D 1Tool breakage

Tool is not broken 023 X X X Tool is damaged, e.g. a

tool edge has broken off

Reserved forextensions. 24

LOW

-Byt

e 0

... 7

1User tool status 1

User tool status bit 1A00.075 0

25 X X X Any meaning

1User tool status 2



1User tool status 3



1User tool status 4



1User tool status 5



1User tool status 6



1User tool status 7



1User tool status 8


32

Hig

h-B

yte

0 ...

7

Hig

h-W

ord

0 ...

15

X X X Any meaning

WSB_all_V22_20030918.xls



ASP ... Application-specific programs in PLC or NC T Tool




Note:

• The group definitions in the left column of the previous table are onlyused for display (expedient reduction of the data for the end user).

• These group definitions are not taken into consideration within theCNC.

• Status bits with capital letters indicate that the user can change theirstatus via the GUI, the PLC, or the NC user program, if required.

• Status bits with lower case letters can not be influenced by the user.They are organized by the NC tool management.

Setup List-Specific Tool Status BitsIf a tool cannot be used for the subsequent machining process, thesetup list-specific status bits provide detailed information about thecause.

Exclusively the tool management updates the setup list-specific statusbits. Neither CNC nor PLC nor the operator can modify the states ofthese bits.

The setup list-specific status bits are not loaded into the PC when thetool list is saved.

Tool not available

Basic tool data


Tool status bit 1: Tool not available

Group information Value Symbol

Tool not available 1 !

Tool available 0

Relevant for: Write access:

Setup list (SL) X Tool management (TM) X

Tool list (TL) X Operator (OP)

Location list (LL) User-specific programs in PLC orNC (USP)

A tool marked with such a status bit is missing; it is not contained in thetool storage unit.

! (request to the operator)

During the equipment check

• Limitations for the operator:all GUI operating functions are permitted

• Limitations for the user program:all data manipulations are permitted

• Restrictions for tool management:starting the program is impossible

DE 09 Bit 1

Meaning

Symbol

Updating time

Effects



Tool is not required

Basic tool data


Tool status bit 2: Tool not required


Tool is not required 1 ?

Tool required 0




Location list (LL) User-specific programs in PLCor NC (USP)

A tool marked with such a status bit is not needed for the currentmachining process.

? (question to the operator)




• Restrictions for the tool management:no effects

Correction type wrong

Basic tool data


Tool status bit 3: Incorrect correction type


Correction type wrong 1 t

correction type not faulty 0




Location list (LL) User-specific programs inPLC or NC (USP)

A tool marked with such a status bit does not comply with the requiredcorrection type.

t (type)


DE 09 Bit 2

Meaning

Symbol

Updating time

Effects

DE 09 Bit 3

Meaning

Symbol

Updating time






Incorrect number of tool edges

Basic tool data


Tool status bit 4: Incorrect number of tool edges


Incorrect number of tool edges 1 e

Correct number of tool edges 0





The tool concerned does not possess the required number of tooledges.

e (edge)





Effects

DE 09 Bit 4

Meaning

Symbol

Updating time

Effects



Tool edge(s) incorrect

Basic tool data


Tool status bit 5: Tool edge(s) incorrect


Tool edge(s) incorrect 1 f

Edge(s) not faulty 0





There is at least one of the following faults for at least one tool edge:

• Wrong cutter position (e)

• L1 incorrect (1)



• R faulty (r)

f (fault)





Location-specific tool status bitThe location-specific status bits describe the status of a location. Theyare firmly allocated to specific locations and do not move along with thetool or the tool's data record.

They are also loaded into the PC when the tool list is saved.

DE 09 Bit 5

Meaning

Symbol

Updating time

Effects



Tool code incorrect

Basic tool data


Tool status bit 6: Tool code incorrect


Tool code incorrect 1 $

Tool code not incorrect 0





The entry in DE 18 Tool code in the basic tool data of the tool list doesnot correspond with the one in the setup list.

$





Tool Status Bits 7 and 8

Reserved for extensions.

Location locked

Basic tool data


Tool status bit 9: Location locked


Location locked 1 B

Location not locked 0


Setup list (SL) Tool management (TM) X

Tool list (TL) X Operator (OP) X

Location list (LL) X User-specific programs in PLC orNC (USP)

X

DE 09 Bit 6

Meaning

Symbol

Updating time

Effects

DE 09 Bit 7 and Bit 8

DE 09 Bit 9



• A locked location is not available to anybody.

• No tool may be stored in it.

• If the location contains a tool when locked, then the tool next to thelocation will not be available for machining.

• Tool management locks a location automatically while a tool isbeing entered using the 'Entering a tool' function.

B

Possible at any time



• Restrictions for tool management:

• Any transfer requests that concern a locked location are notpermitted (any attempt to do this will generate an error messageand the NC program will be interrupted).

• A locked location cannot be approached using MFP (the locationis not available)

• A tool in a locked location cannot be approached using MTP (thelocation and the tool are not available).

• A locked location can be approached only via the tool locationnumber using the MMP motion command or via MOP.

• In addition to the locations in the magazine, spindles and/orgrippers can also be locked.



Upper Half-Location Reserved

Basic tool data


Tool status bit 12: Upper half-location reserved


Upper half-location reserved 1 )

UPPER HALF-LOCATION NOTRESERVED

0


Setup list (SL) Tool management (TM)


Location list (LL) X User-specific programs in PLC orNC (USP)

X

Meaning

Symbol

Updating time

Effects




Tool status bit 12 is provided to identify the upper half-location of thetool location as "reserved".This status bit is not interpreted by the CNC. It can therefore be usedlike a user tool status bit.

)




• Restrictions for tool management:currently no effects

Lower Half-Location Reserved

Basic tool data


TOOL STATUS BIT 13: LOWER HALF-LOCATION RESERVED


Lower half-location reserved 1 (

Lower half-location not reserved 0




Location list (LL) X User-specific programs in PLCor NC (USP)

X

Tool status bit 13 is provided to identify the lower half-location of the toollocation as "reserved".This status bit is not interpreted by the CNC. It can therefore be usedlike a user tool status bit.

(







DE 09 Bit 12

Meaning

Symbol

Updating time

Effects

DE 09 Bit 13

Meaning

Symbol

Updating time

Effects




Location assigned

Basic tool data


Tool status bit 16: Location assigned


Location assigned 1 +

Location not assigned 0




Location list (LL) X User-specific programs in PLCor NC (USP)

There is a tool in the location concerned.

+

• In the tool list upon entry.

• In the current tool list when user interface input functions Insert,Remove, and Relocate are called.

• During each transfer.


• User program:all data manipulations are permitted

• Tool management:A tool transfer to such a location is not permitted.

Tool-specific tool status bitThe tool-specific status bits describe the state of a tool. They move alongwith the tool and/or its data record.

They are also loaded into the PC when a tool list is saved.

Each tool can have up to 8 user-related tool status bits (see MTC 200parameter description, system parameters Axx.075- Axx.082).

DE 09 Bit 16

Meaning

Symbol

Updating time

Effects



Tool is worn out

Basic tool data


Tool status bit 17: Tool worn out


Tool is worn out 1 d

tool is not worn out 0





• The remaining tool life of at least one tool edge is completely expired(remaining tool life <= 0).

• This bit is also set if tool status bit D ("Tool broken") is set, even if alltool edge remaining times of the tool are still in the positive range.

d (defective)

The tool management updates the 'Tool worn out' tool status bittogether with the tool edge status bit of the existing tool edges:

• during the equipment check,

• during a transition to a different tool edge,

• when an edge is requested again

• when the tool is placed back in the magazine (tool storage = maga-zine)

• when the tool is rotated out of the machining position (tool storage =turret),

• when a tool is canceled using T0(tool storage = turret or no tool storage present).

• if the data of the tool are modified using the interface or the PLC or ifthe tool is replaced

• Restrictions for the operator:• All interface user functions are permitted,

• The remaining tool life can be reset with tool editor function "Edit".

• Limitations for the user program:all data manipulations are permitted.

• Restrictions for tool management:• The tool is no longer available for further machining.

• A worn-out tool can still be used for machining if it is a tool of the"Machining tool" status for which no further replacement toolexists.

DE 09 Bit 17

Meaning

Symbol

Updating time

Effects



Warning limit is reached

Basic tool data


Tool status bit 18: Warning limit reached


Warning limit is reached 1 w

Warning limit not reached 0





• The remaining tool life of at least one tool edge has reached thewarning limit.

• This bit is also set if tool status bit D ("Tool broken") is set, even if alltool edge remaining times of the tool are still below the warning limit.

• Tools that have reached the warning limit should be replacedtogether with the worn-out tools as soon as possible.

w (warning limit)

Tool management updates this tool status bit together with the "Warninglimit reached" tool edge status bit of the existing tool edges:






• when a tool is canceled using T0 (tool storage = turret or no toolstorage present).

• if the data of the tool are modified using the interface or the PLC or ifthe tool is replaced

• Restrictions for the operator:• All interface user functions are permitted,

• The remaining tool life can be reset with tool editor function"Edit".

• Limitations for the user program:all data manipulations are permitted,

• Restrictions for tool management:A tool whose warning limit has been reached remains a "Machiningtool" until it is worn out or locked.

DE 09 Bit 18

Meaning

Symbol

Updating time

Effects



Note: If tool management determines that a tool has reached thewarning limit and that no further alternate tool is available,the status signal "w: Warning limit reached" (data element 09/ bit 18) is set towards the PLC.

Machining tool

Basic tool data


Tool status bit 19: Machining tool


Machining tool 1 p

No machining tool 0





• The "Machining tool" status bit characterizes a tool in a group ofalternate tools that becomes the active tool upon the next Tinvocation (via the tool number that is common to them all).

• The correction values and the tool life data of this tool are used forfurther machining.

p (primary tool)

• During the equipment check

• when the tool is brought back to the magazine (tool storage unit =magazine),

• when the tool is rotated out of the machining position (tool storage =turret)

• when a tool is canceled using T0 (tool storage = turret or no toolstorage present).



• Restrictions for tool management:the current machining tool is always used in the case of MTP

DE 09 Bit 19

Meaning

Symbol

Updating time

Effects



Replacement Tool

Basic tool data


Tool status bit 20: Replacement tool


Replacement tool 1 s

no spare tool 0





• A tool from a group of alternate tools is called a replacement tool if itis not yet worn out and does not have the "p machining tool" statusassigned.

• The duplo number specifies the sequence in which the replacementtools are employed.

s (secondary tool)







• Restrictions for tool management:the machining tool is always used first in the case of "MTP"

Following is an example for the selection of an active tool from analternate tool chain with 4 tools.

The following figure shows a table for the tool with T No. 77, which ispresent a total of 4 times. The activation order for the current processingtool is displayed in the next figure:

T No. Duplo No. Status Meaning

T77 D1 p Production tool

T77 D2 d Tool is worn out

T77 D31 s Alternate tool

T77 D4 d Tool is worn out

Fig. 2-3: Table for alternate tool selection

DE 09 Bit 20

Meaning

Symbol

Updating time

Effects

Example



��

��

��

��

��

SchwesterWZ.FH7

Fig. 2-4: Selection of replacement tools from an alternate tool sequence

Tool with fixed location coding

Basic tool data


Tool status bit 21: Tool with fixed location coding


Tool with fixed location coding 1 C

Tool without fixed locationcoding

0





X

Tool status bit 21 is used to identify if the tool should be brought back tothe original location in the tool magazine (tool basic data, DE 11 Oldlocation) or not.This status bit is not interpreted by the CNC.

C




• Restrictions for tool management:currently no effect

DE 09 Bit 21

Meaning

Symbol

Updating time

Effects



Tool locked

Basic tool data


Tool status bit 22: Tool locked


Tool locked 1 L

Tool is not locked 0





X

A locked tool is no longer available for machining.

L




• Restrictions for tool management:• A locked tool must not be taken into account for MTP.

• It is no longer available for machining, even if no further alternatetools exist.

Tool broken

Basic tool data


Tool status bit 23: Tool broken


Tool broken 1 D

Tool is not broken 0





X

A broken tool is no longer available for machining.

D


DE 09 Bit 22

Meaning

Symbol

Updating time

Effects

DE 09 Bit 23

Meaning

Symbol

Updating time





• Restrictions for tool management:• A broken tool must not be taken into account for MTP.

• A broken tool is no longer available for machining, even if noother replacement tool is available.

• If interface signal PxxC.MGITW (Command MaGazine IgnoreTool Worn Out) has been set, the NC program terminates with anerror message during the equipment check if there is an alternatetool sequence that does not have any usable tool, including a toolthat is worn or broken but otherwise usable.

Tool Status Bit 24


User Tool Status Bits 1 - 8

Basic tool data


TOOL STATUS BIT 25 - 32: USER TOOL STATUS BIT 1 - 8


User tool status bit 1 1 any

0





X

With the help of the user tool status bits 1 – 8, the project planner canstore binary information relating to the specific machine and/or the tool.Thus, information as e.g.: Tool has been re-cut, Tool hascooling/lubrication boring, or Tool requires cooling can be entered.

any (corresponding to a parameterization in the system parametersA00.075 … A00.082




• Limitations for tool management:is not taken into account in tool management.

Effects

DE 09 Bit 24

DE 09 Bit 25 to Bit 32

Meaning

Symbol

Updating time

Effects



Location Data

Free Half-Locations

Basic tool data

Data element 10 Free half-locations

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

The datum Free half-locations is not displayed and is currently notstored with an NC function. The project planner can use it to organizeinformation on assigned or free half-locations of the tool magazine. In thisway, it is for example possible for an application where above-averagewidth tools are used to block half or all the neighboring magazine locationsto prevent collisions in the tool storage.




• Limitations for tool management:is not taken into account in tool management.

Old location

Basic tool data

Data element 11 Old pocket

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

The datum Old pocket is not displayed. It is included in the data recordin order to be able to ensure the associated fixed location, in addition tothe other data items, for fixed location-encoded tools that are in aspindle.

DE 10

Meaning

Updating time

Effects

DE 11

Explanation



Storage of the next replacement tool

Basic tool data

Data element 12 STOR. OF NEXTREPLACEMENT TOOL

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

Data element 12 Storage of the next replacement tool describes thestorage unit in which the next tool of an alternate tool sequence can befound.

It indicates if the replacement tool is in a

• 0 = Magazine or turret location

• 1 = Spindle or

• 2 = Gripper.

Please remember that the alternate tool sequence is closed. Providedthat all tools are useable, this means that the last tool in this sequence isthe previous tool with respect to the first one (see fig. in "Location of theprevious replacement tool").

Location of the next replacement tool

Basic tool data

Data element 13 Loc. of next setup tool

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

Data element 13 Location of the next replacement tool describes thelocation at which the next tool of an alternate tool sequence can befound.

It contains the number of magazine or turret location, spindle, or gripper.


DE 12

Explanation

DE 13

Explanation



Storage of the previous replacement tool

Basic tool data

Data element 14 Stor. of prev. setup tool

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

Data element 14 Storage of the previous replacement tool describes thestorage unit in which the previous tool of an alternate tool sequence canbe found.

It indicates if the previous replacement tool is in a

• 0 = Magazine or turret location

• 1 = Spindle or

• 2 = Gripper.


Location of the previous replacement tool

Basic tool data

Data element 15 LOC. OF PREV. SETUP TOOL

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

Data element 15 Location of the previous replacement tool describesthe location at which the previous tool of an alternate tool sequence canbe found.

It contains the number of magazine or turret location, spindle, or gripper.

Please remember that the alternate tool sequence is closed. Providedthat all tools are useable, this means that the last tool in this sequence isthe penultimate tool with respect to the first one.

DE 14

Explanation

DE 15

Explanation



"��#�

"��#�

��$�"��#�

�%��$�"��#�

"��#�

Kette.FH7

Fig. 2-5: Display of an alternate tool sequence with three tools

Note: Data elements DE12 Storage of the next replacement tool,DE13 Location of the next replacement tool, DE14 Storageof the previous replacement tool and DE15 Location of theprevious replacement tool can be read only via a user-specific program in the PLC or NC with the help of theTLD_RD (PLC) or TLD (NC) commands.

Units

Time unit

Basic tool data

Data element 16 Time unit

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

Available time units are minutes [min] or NC cycles [cycle].

All tool life data of the tool or the alternate tools (with the exception ofthe remaining tool life in percent and warning limit in percent) aremeasured and updated in the time unit that is selected here.

When time unit "Cycles" is selected, a single cycle is defined as the timebetween tool deactivation (e.g. changing into the spindle) anddeactivation (removing from the spindle).

DE 16

Explanation



Unit of length

Basic tool data

Data element 17 UNIT OF LENGTH

Relevant for:

Setup list (SL) X

Tool list (TL) X

Location list (LL)

All geometry data items of a tool can be entered either in millimeters[mm] or in inches [inch].

The length unit in the setup list need not be the same as the one in thetool list. Upon loading into the controller, all geometry data items areconverted into the base unit for programming that is valid for theprocess.

Technology Data

Tool code

Basic tool data

Data element 18 Tool code

Relevant for:

Setup list (SL) X

Tool list (TL) X

Location list (LL)

Data element 18 Tool code is significant for "Grinding" technology,which is set with system parameter A00.091 Tool technology.

Please refer to the chapter 2.4 "Grinding-Specific Tool Data" for detailsof the tool code.

Representation type

Basic tool data

Data element 19 Representation type

Relevant for:

Setup list (SL) X

Tool list (TL) X

Location list (LL)

Data element 19 Representation type is significant for "Grinding"technology, which is set with system parameter A00.091 Tooltechnology.

Please refer to the chapter 2.4 "Grinding-Specific Tool Data" for detailsof the Representation type.

DE 17

Explanation

DE 18

Explanation

DE 19

Explanation



User Tool Data

User Tool Data 1 - 9

Basic tool data

Data element 20 -28 USER DATA 1 - 9

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

The tool user data items 1-9 in the basic tool data permit any user-relatedstatus information to be allocated to a tool.

When the required designation is entered in system parameters A00.061 -A00.069, the user data are accepted in the tool data record and aredisplayed in the offline tool list and the current tool list (see also MTC 200parameter description).

In the offline tool list, the user data can be prepared parallel to machiningtime in the same way as the other data items.

Examples of user data in the basic tool data are:

• the weight of the tool (influences e.g. the velocity of the toolchange),

• the maximum speed of the tool,

• the maximum dimensions of the tool (for collision checks).

Tool Group DataTool group data is relevant for tool group organization.

Group number

Basic tool data

Data element 30 Group number

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

The tool is assigned to a tool group. "0" or greater is a permissible valuefor the group number, the maximum number being limited by thecontents of the machine parameter Bxx.073 "Number of tool groups"(0..99).

DE 20 to 28

Explanation

DE 30

Explanation



Group duplo number

Basic tool data

Data element 31 Group duplo number

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

The tool group duplo number is used to:

• unambiguously identify alternate groups, and

• to define the utilization sequence of the alternate groups.

With one exception, the group duplo number may be in the range[0..99]. When the group number includes the value "0", only this value"0" is permissible for the tool data element "Group duplo number".

Group status

Basic tool data

Data element 32 Group status

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

The "Group status" data element exists for each tool group. It can beaccessed both through tool addressing and through group addressing.The following table lists all group status bits. The table is followed by adetailed explanation of the individual bits.

DE 31

Explanation

DE 32

Explanation



Tool groups: Group status data element 32 V23_20021112

Write

Access

Type

Status Status bit

Sym

bo

l

Val

ue

Bit

TM

OP

AS

P

GL

Comment

Group does not exist ! 1

Group exists 01 X X Tool in this group is

missing

Group not required ? 1Presence

Group required 02 X X no tool of this group

required

Group disabled L 1Group status

Group not disabled 03 X X X User-programmable

Group worn d 1

Group not worn out 04 X X

At least one alternatetool chain of group isworn out.


Warning limit not reached 05 X X

At least one alternatetool chain of grouphas reached thewarning limit

Machining group p 1

No machining group 06 X X Group is processing

group

Spare group s 1Name of alternate

No spare group 07 X X Group is alternate

group

Reserved forextension 8

1User group status 1

User group status bit 1


1User group status 2 User group status bit 2













any


WZG_all_V23_20021112.xls



ASP ... Application-spec. programs on the PLC or NC GL ... Tool group list-specific status bit




Group does not exist

Basic tool data


Group status bit 1: Group does not exist

Status information Value Symbol

Group does not exist 1 !

Group exists 0



Tool list (TL) Operator (OP)

Location list (LL)

Group list (GL) X

User-specific programs in PLC or NC(USP)

A tool group marked like this is considered as non-existing as it does notinclude any tool.

! (request to the operator)



• Limitations for the user program:All data manipulations are permitted.


Group not required

Basic tool data


Group status bit 2: Group is not required


Group not required 1 ?

Group required 0




Location list (LL)

Group list (GL) X


A tool group marked like this does not contain any of the tools in thesetup list. If there is not setup list, all groups are automaticallyconsidered "required".

? (question to the operator)

DE 32 Bit 1

Meaning

Symbol

Updating time

Effects

DE 32 Bit 2

Meaning

Symbol






• Limitations for Tool management:no effects

Group disabled

Basic tool data


Group status bit 3: Group disabled


Group disabled 1 L

Group not disabled 0



Tool list (TL) Operator (OP) X

Location list (LL) X

Group list (GL) X


A disabled tool group is no longer available for machining.

L




• Restrictions for tool management:

• A disabled tool group must not be taken into account for "MTP".

• ... is no longer available for machining.

Updating time

Effects

DE 32 Bit 3

Meaning

Symbol

Updating time

Effects



Group worn

Basic tool data


Group status bit 4: Group worn out


Group worn 1 d

Group not worn out 0




Location list (LL)

Group list (GL) X

User-specific programs in PLC orNC (USP)

A tool group is considered worn once the first tool sister sequence of thegroup is worn.

d (defective)




• Limitations for the tool management:A worn-out tool group is no longer available for machining.

Note: If tool management realizes that a tool group is worn out andthat there is no other alternate tool group available, theinterface signal PxxS.MGTWO is set.


Basic tool data


Group status bit 5: Warning limit reached







Location list (LL)

Group list (GL) X

User-specific programs in PLCor NC (USP)

This group status bit is set as soon as the first alternate tool sequenceof the the tool group has reached warning limit.

DE 32 Bit 4

Meaning

Symbol

Updating time

Effects

DE 32 Bit 5

Meaning



w (warning limit)




• Restrictions for the tool management:A tool group whose warning limit has been reached remains a"Machining group" until it is worn out or disabled.

Note: If tool management realizes that a tool group is worn out andthat there is no other alternate tool group available, theinterface signal PxxS.MGWRN is set.

Machining group

Basic tool data


Group status bit 6: Machining group


Machining group 1 p

No machining group 0




Location list (LL)

Group list (GL) X


The tool group with the smallest group duplo number which is not wornout and not disabled is marked as machining group.

p (primary tool group)




• Limitations for tool management:The tool is always removed from the machining group with “MTP”.

Symbol

Updating time

Effects

DE 32 Bit 6

Meaning

Symbol

Updating time

Effects



Spare group

Basic tool data


Group status bit 7: Spare group


Spare group 1 s

No spare group 0




Location list (LL)

Group list (GL) X


A tool group from a group of alternate tool groups is marked as sparegroup if it is not yet worn and does not have “machining group”status.

The group duplo number specifies the sequence in which the sparegroups are employed.

s (secondary tool group)




• Limitations for tool management:The tool is always removed from the machining group with “MTP”.

Group status bit 8


DE 32 Bit 7

Meaning

Symbol

Updating time

Effects

DE 32 Bit 8



User Group Status Bits 1 - 8

Basic tool data


Group status bit 9 -16: User group status bit 1 - 8


User group status bit n 1 any

0



Tool list (TL) Operator (OP) X

Location list (LL) X

Group list (GL) X


User group status bits 1 0.8 permit any user-related status informationto be allocated to a tool group.

any





Other User Tool Data

Comment

Basic tool data

Data element 99 COMMENT

Relevant for:

Setup list (SL) X

Tool list (TL)

Location list (LL)

Each entry in the setup list can be assigned a comment of up to 5 x 76characters, provided this has been selected in the system parameterA00.057 Comment (Assembly Instructions).

The comment can be used for related information for each group ofalternate tools (assembly instructions, for example).

Note: The comment is available on the user interface only.


Meaning

Symbol

Updating time

Effects

DE 99

Explanation



2.3 Tool Edge Data

The tool edge data are part of the tool data record and contain thegeometry and wear data of tools. Every tool data record can contain upto 9 tool edge data records. The max. number of tool edge data recordsis determined in system parameter A00.054 Maximum tool edgenumber.

The data elements of tool edge data records can be subdivided into thefollowing groups:

• Tool edge identification,

• Tool life data,

• Geometry data,

• Geometry limit values,

• Wear factors,

• User data.

The following table includes all data elements of a edge data record:

Tool edge data (per tool edge) V22_20030317

DESIGNATION RANGEDATA TYPE in

PLC UNIT DE OPT. SL TL

Tool edge identification

Tool edge position 0 - 8 USINT 01 X X

Tool edge status 0; 1 (16 status bits) WORD 02 X

Tool life data

Remaining tool life -99.9 - +100.00 REAL 03 A00.059 X

Warning limit +0.1 - +100.00 REAL%

04 A00.059 X

max. Utilization time0 - 9999999(0: tool life recognition switched off) REAL 05 A00.059 X

Time used 0 - 9999.999 REAL

min. orcycles

06 A00.059 X

Geometry Data

Length L1 DINT 07 X

Length L2 DINT 08 X

Length L3 DINT 09 X

Radius R DINT 10 X

Wear L1 DINT 11 A00.055 X



Wear R DINT 14 A00.055 X

Offset L1 DINT 15 A00.056 X



Offset R

-99999.9999 - +99999.9999

or

-9999.99999 - +9999.99999

DINT

mm

or

inches

18 A00.056 X



Geometry limit values

L1_min DINT 19 A00.060 X

L1_max DINT 20 A00.060 X





R_min DINT 25 A00.060 X

R_max

-99999.9999 - +99999.9999

or

-9999.99999 - +9999.99999

DINT

mm

or

inches

26 A00.060 X

Wear factors

Wear factor L1 DINT 27 A00.058 X



Wear factor R

-99999.9999 - +99999.9999or

-9999.99999 - +9999.99999DINT

mm/min orinch/min or

cycles30 A00.058 X

User data

User data 1 REAL any 31 A00.070 X




User data 5

+/- 1.2 * 10-38 - +/- 3.4 * 10+38und

0 ( 9 signifikante Stellen )REAL any 35 A00.074 X

User data 6 DINT any 36 A00.092 X




User data 10

-99999.9999 - +99999.9999or

-9999.99999 - +9999.99999

DINT any 40 A00.096 X

SD_all_V22_20030317.xls


OPT ... Optional datum TL ... Tool list-specific datum

All data elements of the tool edge data record will be described ingroups in the following.

Tool Edge Identification

Tool edge position

Tool Edge Data

Date element 01 Tool edge position

Relevant for:

Setup list (SL) X

Tool list (TL) X

Location list (LL)

Optional datum

DE 01



The tool edge position enables the tools of correction types 3 (turningtool) and 4 (angle head tool) to be measured with respect to thetheoretical tool tip 'P' without inaccuracies resulting from futuremachining.

"

�

�

!

�

#

�$

�

"

!

�

#

�

�$��

�&'�()�&'��)�&'�*)

�&'�()�&'��)�&'�*)

�&'�()�&'��)�&'�*)

�&'�()�&'��)�&'�*)

+

,

+-,

+

,

+

,

+

,

+

,

+

,

+

,

+,

+

,

+-,

+

,

+

,

+

,

+

,

+

,

+

,

+,

�

� �

�

SCHNEIDENLAGE.FH7

Fig. 2-6: Possible positions of a tool edge

Without tool edge radius / cutter radius compensation, the theoretical tooltip 'P' is the reference point for the controller.

Thus, the theoretical tool tip 'P' moves on the programmed contour. Withmovements that are not parallel to the axis, this leads to minorinaccuracies.

Explanation



.+

,

.

.+

,

�

.+

,.+

,

.+

,

+�� ,��.��

��

�� $�� /+/�&��)�� $�� /,/

%

&

UNSCHNEIDE.FH7

Fig. 2-7: Inaccuracies that occur when working without tool edge radius /cutter radius path compensation

The area hatched in Fig. 2-7: is not removed since the controller refersto the theoretical tool tip 'P'.

Note: The tool edge center 'S' is the reference point for the controlif length compensation is active and tool edge / cutter radiuscompensation is switched off.

When tool edge radius / cutter radius compensation is active, the CNCautomatically moves the actual contact point 'B' along the programmedcontour. Thus, the resulting contour is identical to the programmedcontour.



Tool edge status bits

Tool Edge Data

Data element 02 Tool edge status

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

Optional datum

The tool edge status bits provide information about the current state of therelated tool edge. They can be subdivided into status bits that are setuplist-specific and tool-specific.

Setup list-specific status bits 1 - 5 describe the status of a tool edge withrespect to the requirements of the setup list.

If a tool edge cannot be used for the subsequent machining process, thesetup list-specific status bits provide detailed information about the cause.

Exclusively tool management updates the setup list-specific status bits.Neither the CNC nor the PLC nor the operator can modify the states ofthese bits.

The setup list-specific status bits are not loaded into the PC when thetool list is saved.

Tool-specific tool edge status bits 9 - 16 describe the status of theassociated tool edges. They "move" along with the tool and/or its datarecord.

They are also loaded into the PC when a tool list is saved.

Up to four user-related tool edge status bits can be allocated to everytool edge (see MTC 200 Parameter description, system parameterAxx.083 ... Axx.086).

The following table lists all tool edge status bits. The table is followed bya detailed explanation of the individual bits.

DE 02:

Explanation

Setup list-specific tool edgestatus bits

Tool-specific tool edge statusbits



Tool edge status bit from tool edge data element 02Write

AccessType


Sym

bo

l

Val

ue

Bit

TM

OP

AS

PS

L

TL

Comment

Incorrect tool edgeorientation

o 1

Incorrect tool edge orientationTool edge orientation is notincorrect

01 X X Tool edge data do not correspond to

the definition

L1 incorrect 1 1L1 incorrect

L1 not incorrect 02 X X Tool edge data do not correspond to

the definition



the definition



the definition

R incorrect r 1R incorrect

R not incorrect 05 X X Tool edge data do not correspond to

the definition

Reserved for extensions 6



Tool edge worn out d 1

Tool not worn out 09 X X The tool edge can no longer be used

(replace)


Warning limit not reached 010 X X The remaining tool life of the tool edge

is near its end (replace)



1User tool edge status 1 User tool status bit 1

A00.083 013 X X X Any meaning






A00.086

any


SSB_all_V22_20030918.xls

TM ... Tool Management

OP ... Operator

TL ... Tool list-specific status bit

SL ... Setup list-specific status bit

ASP ... Application-specific programs in PLC or NC



Incorrect tool edge orientation

Tool Edge Data


Tool edge status bit 1: Tool edge orientation incorrect


Incorrect tool edge orientation 1 o

Tool edge orientation is notincorrect

0





The existing tool edge orientation does not correspond to the tool edgeorientation that is required by the setup list.

o (orientation)




• Restrictions for tool management:machining (starting the program) is impossible

Incorrect Tool Length L1

Tool Edge Data


Tool edge status bit 2: L1 incorrect


L1 incorrect 1 1

L1 not incorrect 0





The existing L1 tool length does not correspond to the requireddimensions (the individual tool dimensions are calculated fromgeometry, wear and offset).

DE 02 Bit 1

Meaning

Symbol

Updating time

Effects

DE 02 Bit 2

Meaning



1

In the tool list and in the setup list






Tool Edge Data


Tool edge status bit 3: L2 incorrect


L2 incorrect 1 2

L2 not incorrect 0






2






Symbol

Visualization

Updating time

Effects

DE 02 Bit 3

Meaning

Symbol

Visualization

Updating time

Effects




Tool Edge Data


TOOL EDGE STATUS BIT 4: L3 INCORRECT


L3 incorrect 1 3

L3 not incorrect 0






3






Incorrect Tool Radius R

Tool Edge Data


Tool edge status bit 5: R incorrect


R incorrect 1 r

R not incorrect 0





The existing R tool radius does not correspond to the requireddimensions (the individual tool dimensions are calculated fromgeometry, wear and offset).

DE 02 Bit 4

Meaning

Symbol

Visualization

Updating time

Effects

DE 02 Bit 5

Meaning



r






Tool Edge Status Bits 6, 7, and 8


Tool edge worn out

Tool Edge Data


Tool edge status bit 9: Tool edge worn out


Tool edge worn out 1 d

Tool not worn out 0





The remaining tool life of the tool edge is less than or equal to zero.

d




• when the tool is brought back to the magazine(tool = magazine),


• when a tool is canceled using T0(tool storage = turret or no tool storage present),

• if the data of the tool are modified using the interface or the PLC or ifthe tool is replaced.



Symbol

Visualization

Updating time

Effects

DE 02 Bit 6 to 8

DE 02 Bit 9

Meaning

Symbol

Updating time

Effects



• Limitations for tool management: A replacement tool must be used (if there is one) when the toolnumber concerned is invoked again


Tool Edge Data


TOOL EDGE STATUS BIT 10: WARNING LIMIT REACHED








The remaining tool life is less than the warning limit.

w




• when the tool is brought back to the magazine(tool = magazine),


• when a tool is canceled using T0(tool storage = turret or no tool storage present),

• if the data of the tool are modified using the interface or the PLC or ifthe tool is replaced.

• Limitations for the operator:all GUI operating functions are permitted,

• Limitations for the user program:all data manipulations are permitted,

• Restrictions for tool management:no immediate effects.

Tool Edge Status Bits 11 and 12


DE 02 Bit 10

Meaning

Symbol

Updating time

Effects




User Tool Edge Status Bits 1 - 4

Tool Edge Data


Tool edge status bit 13 - 16: User tool edge status bit 1 - 4


User tool edge status bit 1 - 4 1 any

0





X

User tool edge status bits 1 - 4 permit any user-related statusinformation to be allocated to a tool edge.

any





Tool Life Data

Remaining tool life

Tool Edge Data

Data element 03 REMAINING TOOL LIFE

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

Optional datum A00.059

The remaining tool life in percent specifies the wear state of a tool inpercent, irrespective of the tool / workpiece material combination and thetechnology data.


Meaning

Symbol

Updating time

Effects

DE 03:

Explanation



100*]Cycles[t

]Cycles[tt

100*[min]t

[min]t[%]t

Util

mRe[%]mRe

Util

mRemRe

=

=

tRem[%] Remaining tool life in percenttRem[min] Remaining tool life in min.tRem[cycles] Remaining tool life in cyclestUtil[min] max. utilization time in min.tUtlil[Cycles] max. utilization time in cycles

Fig. 2-8: Calculation of remaining tool life in percent

A new or resharpened tool has a remaining tool life of 100%.Correspondingly, a worn-out tool has a remaining tool life of <= 0%.

Based on the remaining tool life in percent, tool management monitorsand manages the wear state of the tool, irrespective of the tool /workpiece material combinations of the existing machining processes.

To monitor the actual remaining tool life with the theoretical tool lifedefined from the production planning, tool management can alsodetermine and manage negative remaining tool life. This allows thedetermination of the actual tool life, minimizing the tool costs.

Tool management updates the remaining tool life automatically inpercent:






• when a tool is canceled using NC command T0(tool storage = turret or no tool storage present).

The following requirements must be satisfied in order to permitmachining sequences to be taken into account in the calculation of theremaining tool life for a tool:

• an interpolation with feed movement must have been programmedfor the tool (G1, G2, G3) and

• the tool must be programmed (= active).

The calculation of the remaining tool life in percent is based on thefollowing formula:

100*]Cycles[tUtil

]Cycles[t[%]t[%]t

100*[min]t

[min]t[%]t[%]t

OnmpreviousRemRe

Util

OnmpreviousRemRe

−=

−=

First entry of remaining tool life

Negative remaining tool life

Update remaining tool life



tRem[%] remaining tool life after tool utilizationtRem. previous[%]remaining tool life before tool utilizationtOn[min] contact time of the tool in min. (all programmed tool

movements with feed rate)tOn[Cycles] contact time of the tool in cycles (all programmed tool

movements with feed rate)tUtil[min] max. utilization time in min.tUtlil[Cycles] max. utilization time in cycles

Fig. 2-9: Updating of remaining tool life in percent

Each time that updating occurs, tool management checks the remainingtool life and sets status "d" - Tool worn out (basic tool data - dataelement 09 / bit 17) if the remaining tool life of a tool has expired ordrops below the minimum value. If no further alternate tool that is notworn out is available for the tool whose remaining tool life is expired,interface signal PxxS.MGTWO (MaGazine Tool Worn Out) is settowards the PLC.

For more information, see the Chapter 4.1 "Tool Magazine MotionControl", section "Life Monitoring: Tool Worn Out "PxxS.MGTWO"" inthis document or in the MTC 200 PLC interface description "Lifemonitoring: Tool worn out "PxxS.MGTWO"".

Warning limit

Tool Edge Data

Data element 04 Warning limit

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)


The warning limit in percent is determined by the user and specifies theremaining tool life in percent at which tool management signals the "w"Warning limit reached status.

Each time that updating occurs, tool management checks the remainingtool life and sets the PxxS.MGWRN MGWRN (MaGazine WaRNing,Warning limit reached) interface signal towards the PLC if the remainingtool life of a tool has been reached and all alternate tools of this tool alsohave the status "Tool warning limit reached".

For more information, see the Chapter 4.1 "Tool Magazine MotionControl", section "Life Monitoring: Warning Limit Reached"PxxS.MGWRN"" in this document or in the MTC 200 PLC interfacedescription.

DE 04

Explanation



Max. utilization time

Tool Edge Data

Data element 05 max. utilization time

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)


The maximum utilization time is the cutting time in minutes or NC cyclesduring which a tool is used for cutting for a specific tool / materialcombination, from re-sharpening to worn-out state, and under equalcutting conditions. The Maximum utilization time is determined by the user.

Note: Entering '0' for the maximum utilization time switches off theservice life updating process of the tool concerned.

Time used

Tool Edge Data

Data element 06 Time used

Relevant for:

Setup list (SL) X

Tool list (TL)

Location list (LL)


DE 06 Time used is not displayed and currently not interpreted in theNC.

DE 05

Explanation

DE 06

Explanation



Geometry Data

When the corresponding correction is active, the dimensions of a tool arecompensated automatically using the geometry data.

The geometry data items are subdivided as follows:

Geometry (register) Wear (register) Offset (register)

Length L1

Length L2

Length L3

Radius R

Wear L1

Wear L2

Wear L3

Wear R

Offset L1

Offset L2

Offset L3

Offset R

The wear and offset registers can be activated using system parameters

• A00.055 Wear register, and

• A00.056 Offset register

Geometry tab: Length L1 / L2 / L3 / radius R

Tool Edge Data

Data element 07 Length L1



Data element 10 Radius R

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

Optional datum

The geometry registers are used as program-independent memories thatassist in compensating the tool dimensions.

Wear tab: Wear L1 / L2 / L3 / radius R

Tool Edge Data

Data element 11 Wear L1



Data element 14 Wear R

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)


The CNC uses wear registers for compensating the time-related wear ofthe tools with the help of the wear factors.

Explanation

DE 07 - 10

DE 11 - 14



To do this, it calculates the associated wear value at certain points intime (see 'Wear factors') and adds it to the existing values in the wearregisters.

As long as the wear factors (tool edge - data element 27 ... 30) have notbeen activated in the system parameters A00.058 Wear factors or are setto zero in the data records, the wear registers are exclusively available tothe user.

The wear registers can be influenced by

• Tool editor function "Edit" (see documentation "MTC 200 ToolManagement - Application Manual")

or by

• User-configurable HMI function "Acknowledge tool change /tool breakage" (see WinHMI documentation"MTC 200/ISP 200/MTA 200 WinHMI User Interface - ApplicationManual")

Besides resetting the remaining tool life in percent to 100%, all wearregisters belonging to the tool will be deleted and the tool will be enabledagain for processing (basic tool data - tool status bit 22 = "0").

Note: If the wear registers in system parameter A00.055 Wearregister are not selected, they will be internally set to zero.

Offset tab: Offset L1 / L2 / L3 / radius R

Tool Edge Data

Data element 15 Offset L1



Data element 18 Offset R

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)


The CNC does not influence the offset registers. Like the wear registers,they may be used for compensating dimensional deviations that aredetermined either by the user or by a measuring control action.

The offset registers may also be used as memories for additional offsets,such as for the compensation of adapter dimensions.

Note: If the offset registers in system parameter A00.056 Offsetregister are not selected, they will be internally set to zero.

DE 15 -18



Length CompensationThe length values 'L1', 'L2', 'L3' of a tool edge are calculated as follows:

correction D the of L3L3 Offset + L3 Wear + L3 Length = L3 correction Length



++

+

Fig. 2-10: Calculation of tool length

Note: The D corrections are active only if they are programmed in

• process parameter Bxx.029 D corrections and with

• NC commands G48 Tool lengths – positivecompensation or G49 Tool lengths – negativecompensation.

(see section "Tool Length Correction" in "MTC 200 NC ProgrammingInstructions")

�� 0��1��2�3�� 0�� 2�4$$�� 0�1(�� 0�1��

��-�� 0��1��

3��-��0��

4$$��-��0�1(��

LAENGENKORR.FH7

Fig. 2-11: Length compensation value "L3", example of a throwaway insert drill(without D corrections)



Radius CompensationThe radius compensation value 'R' of a tool edge is calculated asfollows:

correction D the of R R Offset + R Wear + R Radius = R correction Radius +

��-��(

0��1

��

5��-��0��

��-��0� ��

�� 0� ��2�5�� 0��2��$$�� *0*1(��

RADIUSKORR.FH7

Fig. 2-12: Radius compensation R example of a cutter head (without Dcorrection)



Geometry Limit Values

The geometry limit values enable the tools in the tool storage unit to bechecked with respect to their fitness for being employed in theforthcoming machining process.

Whether or not length and radius values of the related tool are suitablefor the machining process which is to be performed is verified during theequipment check when an NC program is started. Thus, it preventsstandstill periods during the machining process. The setup list is usedfor the equipment check if the PLC interface PxxC.MGNSL (Process xxCommand MaGazine No Setup List) is not set (= basic state).

Besides ensuring the availability of suitable tools for machining, thespecification of reasonable geometry limit values already permitscollisions to be prevented during programming.

Note: The geometry limit values of the setup list are not taken intoaccount in the calculation of tool compensation processes.

Maximum and minimum length / radius

Tool Edge Data

Data element 19 L1_min

Data element 20 L1_max





Data element 25 R_min

Data element 26 R_max

Relevant for:

Setup list (SL) X

Tool list (TL)

Location list (LL)


The maximum length: 'L1_max', 'L2_max' and 'L3_max' as well asthe minimum length: 'L1_min', 'L2_min' and 'L3_min' specify the limits ofthe individual lengths within which the planned machining processes canstill be executed.

The maximum radius: 'R_max' andthe minimum radius: 'R_min'specify the limits of the tool radius within which the intended machiningprocesses can still be performed.

A groove cutter shall bee used for machining a 30-mm deep groove.

• tool name (ID) : Groove cutter D12

• maximum length (L3_max) : 60 mm

• minimum length (L3_min) : 30 mm

Upon the start (of the advance or the reverse program), the CNCchecks whether there is at least one tool with the name 'Groove cutter

Explanation

DE 19 -26

Explanation

Example 1



D12' that is not shorter than the minimum length of 30 mm and notlonger than the maximum length of 60 mm.

A groove cutter is to be used for machining a 20-mm wide pocket(+ 0.02 mm / - 0.04 mm).

tool name (ID): Groove cutter D20maximum radius (R_max): 20.02/2 = 10.01 mmminimum radius (R_min): 19.96/2 = 9.98 mm

Upon the start (of the advance or the reverse program), the CNCchecks whether there is at least one tool with the name 'Groove cutterD20' that is not shorter than the minimum radius of 9.98 mm and notlonger than the maximum radius of 10.01 mm.

Wear FactorsThe wear factors can be used for compensating wear-related variationsin tool length and tool radius.

Length Wear Factors(L1, L2 and L3)

Tool Edge Data

Data element 27 WEAR FACTOR L1

Data element 28 Wear factor L2

Data element 29 Wear factor L3

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)


Length wear compensation is activated if tool length correction isactivated via G48 Tool length correction positive or G49 Tool lengthcorrection negative.

The compensation value used to adjust for tool length wear is calculatedin the tool management system by multiplying the duration of the toolmachining time by the length wear factor.

If the length wear factor is entered in mm/min or inch/min, the toolmanagement system uses the total time in which the tool was activewhile working motion was being carried out (all moves with theexception of G00 Rapid traverse) as the machining time.

However, if the tool wear factor is entered in mm/cycle or inch/cycle, thetool management system uses one cycle as the machining time. Thus, thecompensation value for tool length corresponds to the tool wear factor.

The tool management system automatically updates the machining timeand, thus, the compensation value for length wear





Example 2

DE 27 -29

Explanation




Radius Wear Factor (R)

Tool Edge Data

Data element 30 WEAR FACTOR R

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)


Radius wear compensation is activated when tool path compensation isactivated via G41 Tool path correction left or G42 Tool pathcorrection right.

The compensation value used to adjust for tool radius wear is calculatedin the tool management system by multiplying the duration of the toolmachining time by the radius wear factor.

If the radius wear factor is entered in mm/min or inch/min, the toolmanagement system uses the total time in which the tool was activewhile working motion was being carried out (all moves with theexception of G00 Rapid traverse) as the machining time.

However, if the radius wear factor is entered in mm/cycle or inch/cycle, thetool management system uses one cycle as the machining time. Thus, thecompensation value for tool radius corresponds to the radius wear factor.

The tool management system automatically updates the machining timeand, thus, the compensation value for radius wear






A large number of shafts are to be produced within a machining center.

Besides other machining steps, each CK45 shaft is to be fitted with afeather key groove that is to be machined using solid carbide tools.

From previous tests it is known that the width of the groove decrementsfrom one shaft to the next by an average 0.0052 mm.

To compensate this wear during production, a radius wear factor of0.0026 mm/cycle must be entered.

DE 30

Explanation

Example



User Tool Edge Data

User Tool Edge Data 1-10

Tool Edge Data

Data element 31 -40 USER DATA 1 -10

Relevant for:

Setup list (SL)

Tool list (TL) X

Location list (LL)

Optional datum DE 31 - 35 A00.070 - A00.074

Optional datum DE 36 - 40 A00.092 - A00.096

Tool edge user data 1 - 10 permit any tool edge to have any user-specificdata items assigned.

Grinding-specific task see chapter 2.4

By entering the requested designation into the system parameters

• A00.070 Tool edge user data 1 (PLC data type = REAL)

• ...

• A00.074 Tool edge user data 5 (PLC data type = REAL) and

• A00.092 Tool edge user data 6 (PLC data type = DINT)

• ...

• A00.096 Tool edge user data 10 (PLC data type = DINT),

the user data is accepted in each tool edge data record, and isdisplayed in the tool list and in the current tool list (see also MTC 200parameter description).

In the tool list, the user data can be prepared in the same way as the otherdata items.

Examples of user data in the tool edge data are:

• Cutting speed,• Feed per tooth,• Spindle speed,• Machining feed,• Dimensional correction internal buffer,• Average value, and• Empirical value

Note: User tool edge data items 1-5 are returned to the PLC asREAL values. User tool edge data items 6-10 are specifiedas DINT.

DE 31 -40

Explanation



2.4 Grinding-Specific Tool Data

For grinding wheel-specific tasks, the first five tool user data (dataelements 31 to 35 of the tool edge data) are reserved for grinding-specific parameters if system parameter A00.091 Tool technology isset to "Grinding". Further tool edge-specific user data can be used asrequired.

Note: In case of operation without setup list, the user mustenter the designations of required grinding wheel-specific parameters (data elements 31 to 35 of tool edgedata) manually for activation.

The data element is an editable element in the setup list and in the toollist. In operation with setup lists, the value from the setup list is acceptedin the tool list when the equipment check is performed. In operationwithout setup lists, the value in the tool list is assigned a default value.After the related data record has been activated in one of the spindles,the data element is the minimum permissible spindle speed commandvalue, taking the override into account. The specified minimumspindle speed is also taken into account as the minimum permissiblespeed value when the grinding wheel circumferential speed (SUG) isactive. The conversion upon active SUG is calculated according to theformula that is discussed in conjunction with the grinding wheelcircumferential speed.

• If setup lists are used for operation, the value 0 corresponds to thestate "Inactive checking".

• The data element is displayed according to the setting of the systemparameter A00.091 "Tool technology" in the setup list/tool list.

• If a corresponding tool data record has been activated formachining, the value is considered as the lower spindle speed limitthat must not be fallen below (including override). An errormessage is issued if the command value falls below this limit speed.

The data element is an editable element in the setup list and in the toollist. In operation with setup lists, the value from the setup list is acceptedin the tool list when the equipment check is performed. In operationwithout setup lists, the value in the tool list is assigned a default value.After the related data record has been activated in one of the spindles,the data element is the maximum permissible spindle command value,taking the override into account. The specified maximum spindlespeed is also taken into account as the maximum permissible speedvalue when the grinding wheel circumferential speed (SUG) is active.The conversion upon active SUG is calculated according to the formulathat is discussed in conjunction with the grinding wheel circumferentialspeed.


• The data element is displayed according to the setting of systemparameter A00.091 "Tool technology" in the setup list/tool list.

• If a corresponding tool data record has been activated formachining, the value is considered as the lower spindle speed limitthat must not be exceeded (including override). An error messageis issued if the command value exceeds this limit speed.

Minimum spindle speed(S min) DE 31

Maximum spindle speed

(S max) DE 32



π

π

*d

720*SUGS

*d

60000*SUGS

]inch[CURR

]s/ft[maxmin]/1[max

]mm[CURR

]s/m[maxmin]/1[max

=

=

Smax : maximum spindle speedSUGmax : max. grinding wheel circumferential speeddCURR : current grinding wheel diameter

Fig. 2-13: Calculation of max. spindle speed

The data element is an editable element in the setup list and in the toollist. In operation with setup lists, the value from the setup list is acceptedin the tool list when the equipment check is performed. In operationwithout setup lists, the value in the tool list is assigned a default value.After the related data record has been activated in one of the spindlesand the SUG has been activated (G66), the data element is themaximum permissible spindle command value, taking the overrideinto account.

720

S**dSUG

60000

S**dSUG

min]/1[max]inch[CURR]s/ft[max

min]/1[max]mm[CURR]s/m[max

π

π

=

=

SUGmax : max. grinding wheel circumferential speeddCURR : current grinding wheel diameterSmax : maximum spindle speed

Fig. 2-14: Calculation of max. grinding wheel circumferential speed

• The data element "max. grinding wheel circumferential speed" isonly interpreted when the SUG is active.


• The data element is displayed only in the setup/tool list for the threedefined tool codes 1, 2, and 3.

The "Angle of skew" is an editable element in the setup list and in thetool list. The data element is available only for tool code 2. TBA Theangle of skew is entered in degrees.

The "Grinding wheel diameter" data element is a pure display elementthat cannot be edited. The data element is available only in the tool list.The computation formula for the grinding wheel diameter depends onthe entered tool code and the existing geometry elements. The dataelement is displayed only for the three defined tool codes (1, 2, and 3).A value is not displayed if a correction type ≤ 3 is entered.

Maximum grinding wheelcircumferential speed

(SUG max) DE 33

Current grinding wheel diameter

(current grinding wheel ∅∅∅∅) DE 35



Tool Code WGD DE 18If system parameter A00.091 has been set to "Grinding" technology,data element 18 of basic tool data "Tool code" obtains the followingmeaning:

Tool code Meaning

0 Standard tool data record

1 Straight circumferential grinding wheel

2 Inclined grinding wheel

3 Surface grinding wheel

4 ... 9 No special function (standard tool data record)

Fig. 2-15: Tables of the tool codes

The tool code definition is required for grinding machines in order to beable to calculate the grinding wheel circumferential speed. Dependingon the type of grinding wheel, geometry register L1 or L2 is needed forcalculating the spindle speed from the programmed circumferentialspeed of the wheel.

The input of tool code 1-3 is relevant and processed only if the 'Tooltechnology' system parameter has been preset to 'Grinding'. In all othercases, the preset values of the data element are ignored.

Depending on the entered tool code, the associated tool edge datarecord (tool list and setup list) is displayed on the desktop. The grinding-specific (user) data items also depend on the selected correction type.In order to be able to utilize the grinding-specific (user) data expediently,a correction type ≥ 3 must be entered for the defined grinding wheels.

For the straight circumferential grinding wheel, the correction typeelement in the tool data record must be filled in with 3, 4 or 5.

The current wheel diameter is calculated via tool length compensationL1.

2)*1L1L1L(d WearOffsetCURR ++=

Fig. 2-16: Current wheel diameter for tool code 1

Tool code 0 - 3

Tool code 1

"Straight circumferential grindingwheel"



��

�

��GERADE_SCHEIBE.FH7

Fig. 2-17: Straight circumferential grinding wheel

For the angled grinding wheel, the correction type element in the tooldata record must be filled in with 3 or 5.

The current wheel diameter is calculated via tool length compensationL1 and the angle ϕ.

ϕcos

2)*1L1L1L(d

WearOffset

CURR

++=


��

�

��

ϕ

SCHRAEGE_SCHEIBE.FH7

Fig. 2-19: Inclined circumferential grinding wheel

Tool code 2

“Inclined grinding wheel”



For the surface-grinding wheel, the correction type element in the tooldata record must be filled in with 3, 4, or 5.

The current wheel diameter is calculated via tool length compensationL2.

2)*2L2L2L(d WearOffsetCURR ++=


�

��

��

PLANSCHEIBE.FH7

Fig. 2-21: Surface grinding wheel

Representation Type WGD DE 19

The representation type has a range of 0-65535. The data element canbe edited in the setup list and in the tool list. If the data element has avalue assigned in the setup list that is different than zero, the values arechecked for equality in the equipment check. In the case of adiscrepancy, bit 6 of the tool status bits is assigned the code "$". Anyfurther processing is not intended for the time being.

Tool code 3

“Surface grinding wheel”

Representation type



Tool Management NC Functions to Control Tool Management 3-1


3 NC Functions to Control Tool Management

3.1 Conditions

Default PlaneA Cartesian coordinate system is a prerequisite to utilize the toolcorrections appropriately. At least one of the three primary axes mustexist physically.

Depending on the application,

• one of the axes (e.g. drilling unit),

• two of the axes (e.g. lathe) or

• all three axes (e.g. milling machines) can exist physically.

Irrespectively of the actual number of axes, one of the three machiningplanes

• XY (G17, G20),

• ZX (G18, G21) and

• YZ (G19, G22)

can be selected.

With the functions for free plane selection (G20, G21, G22), any axisdesignation can be assigned to the axis meanings which define amachining plane.

Tool length compensation 'L3' always works perpendicularly to themachining plane. The length compensation 'L1' and 'L2’ and the tool edgeradius / cutter radius compensation always act within the machiningplane.

��

��

��

�

�

��

��

��

�

�

�

��

��

��

�

�

��

��

��

Ebene.FH7

Fig. 3-1: Effect of the tool compensation values 'L1', 'L2', 'L3' and 'R' as afunction of the selected machining plane

The machining plane is selected via NC commands 'G17', 'G18', 'G19','G20', 'G21' or 'G22' (see Chapter “Path Commands, Dimensions“, sub-chapter “Selection of Levels“ in the document “MTC 200 NCProgramming Instructions).

3-2 NC Functions to Control Tool Management Tool Management


Tool Management CommandsThe preparation of tools and tool data makes a distinction between themagazine and the turret in the sense that both a physical and a logical tooltransfer between the spindle and the magazine (in some cases also usinggrippers) is necessary, and in the sense that, with most magazines, it isnecessary to preselect the tool so that the magazine can be rotatedasynchronously for NC program execution.

The definition whether the given tool storage unit is a magazine or a turretis made in process parameter Bxx.015.

The following table contains an overview of all commands for the tool andtool data preparation. A detailed description of the commands is to befound in the following chapters.

NC tool commands (1) V23_20030122

Function Meaning Description

E Preselect tool edgeEdge

Syntax: E<EDG>EDG: Tool edge number

SPT Preselect tool spindleSpindle for Tool

Syntax: SPT<SPI>SPI: Spindle number

T Preselect toolTool

Syntax: T<TNP>TNP: Tool number or tool location

TG Preselect tool groupTool Group

Syntax: TG<GRP>GRP: number of the tool group (or 0)

TGSM Define tool search modeTool Group Search Mode

Syntax: TGSM<MODE>MODE: Search mode

Werkzeugbefehle_NC1_V23_20030122.xls



Preparing Tools and Tool Data for a MagazineMagazines can be subdivided into two different types:

• NC-controlled magazines

• PLC-controlled magazines

The difference between the two types is in the way the magazine ispositioned. With NC-controlled magazines, the controller-internal toolmanagement provides for positioning. The movement of PLC-controlledmagazines is handled by the PLC.

CNC

NC program.T12 MTP........MRY.....TMS.........M30

NC WZM

magazine

tool preselection

tool loading

T12

PLC

MMV

MMV_Q

TMS_Q

TMS

PLC-controlled

NC-controlled

T12

spindle 1

gripper

6 7

8

9

101112

2

1

3

4 5

: occupied: free

: occupied: free spindle 1

6

78910

11

12

21 3 4

5

gripper

cnc2.FH7

Fig. 3-2: Preselecting tools and preparing tool data for a magazine

When a magazine is employed, a distinction between a preselected tooland an active tool in a spindle is always made.



Syntax: T<constant> <command> e.g. T12 MTP

T<expression> <command> e.g. T=@0:10 MMP

T=(90-37) MTP

The numeric value that is assigned to address letter 'T' via a constant oran expression specifies the tool number (1 -9999999; 0 = tooldeselection) or the tool location number (0 - 999). By means of the NCcommands ‘MTP’ (Move Tool Position) and ‘MMP (Move MagazinePosition), positioning of the magazine is made (also refer to the Chapter“Tool storage motion commands of the NC”.

The selected tool is moved to the specified changing position. Up to themoment of the tool transfer, the data of this tool will not be taken intoaccount.

Calling ‘T0 MTP’ causes an empty magazine location to be moved to thechanging position.

In the case of nonexistent magazine locations, the T command mayactivate an additional tool zero offset (see Chapter 6.5 "Additional ToolCarriers").

Tool changing commands ‘TCH’ or ‘TMS (see also the Chapter “ToolChanging Commands of the NC”) are used for transferring thepreselected tool into the spindle and for providing the tool data. In thisprocess, the preselected tool becomes the active tool. In the defaultselection, tool edge 1 becomes the active tool edge.

Tool preselection

Preparing a tool



Preparing Tools and Tool Data for a TurretTurrets can be subdivided into two different types:

• NC-controlled turrets

• PLC-controlled turrets

The difference between the two types is in the way the turret is positioned.NC-controlled turrets are positioned by the controller-internal toolmanagement. The movement of PLC-controlled turrets is handled by thePLC.

CNC

NC program

.

T831 MTP

.

.

.

.

.

.

.

MRY

.

.

.

NC WZM

turret

tool loading

PLC

MMV

MMV_Q

PLC-controlled

NC-controlled

12

3

4

56

7

8

referencemarkT238

T125

T254

T91

T831

T238

T121

+

cnc3.FH7

Fig. 3-3: Preparing tools for a turret

Syntax: T<constant> <command> e.g. T12 MTP

T<expression> <command> e.g. T=@0:10 MMP

T=(90-37) MTP

The numeric value that is assigned to address letter 'T' via a constant oran expression specifies the tool number (1 -9999999; 0 = tooldeselection) or the tool location number (0 - 999). By means of the NCcommands ‘MTP’ (Move Tool Position) and ‘MMP (Move MagazinePosition), positioning of the turret is made (also refer to the Chapter “Toolstorage motion commands of the NC”.

The selected tool is moved in the machining position and the tool data isactivated. Tool edge 1 automatically becomes the active tool edge.

The invocation ‘T0 MTP’ does not bring about a turret movement. Merelythe tool data is deselected.

In the case of nonexistent turret locations, the T command may activatean additional tool zero offset (see Chapter 6.5 "Additional Tool Carriers").

Preparing a tool



The following parameter value selection is necessary for swiveling theturret asynchronously to the NC program execution:

• A00.052 Tool management: YES

• Bxx.014 Tool management: YES

• Bxx.015 Type of tool storage: Turret

• Bxx.044 Asynchronous turret movement: YES

Additionally, the PLC standard function ‘REV_SYNC’ (synchronousswiveling of the turret, see MTC 200 PLC interface description) may notbe active.

If the above-mentioned conditions are satisfied, NC command ‘MFP’,‘MTP’, ‘MMP’, ‘MOP’, ‘MHP’ or ‘MRF can be used for initiating the turretmovements. While the turret is swiveling, the NC continues programexecution. Using the MRY command or activating the ‘REV_SYNC’standard PLC function permits the turret swivel movements and NCprogram execution to be synchronized.

The activation of the tool compensation values depends on the setting ofparameter Bxx.057 ‘Activate tool correction for turret’.

The table below illustrates the effect of the parameter settings. Thefollowing NC program sequence is discussed:

G1 - ; Axis movements with T1 E1 as the active tool

T2 ; Preselection of the T2 tool

MTP ; Move programmed tool into position

E2 ; Activation of tool edge E2

MRY ; Wait until tool storage movement is terminated

Behavior

synchronous asynchronous

Activation of toolcompensation at start

Activation of toolcompensation at end

Activation of toolcompensation at start

Activation of toolcompensation at end

NCprogram

sequence

Active Presel. Active Presel. Active Presel. Active Presel.

G1 - T1 E1 T1 T1 E1 T1 T1 E1 T1 T1 E1 T1

T2 T0 E0 T2 T0 E0 T2 T0 E0 T2 T0 E0 T2

MTP T2 E1 T2 T2 E1 T2 T2 E1 T2 T0 E0 T2

E2 T2 E2 T2 T2 E2 T2 T2 E2 T2 T0 E2 T2

MRY T2 E2 T2 T2 E2 T2 T2 E1 T2 T2 E1 T2

Revolver.xls (Tabelle 2)

Fig. 3-4: Effects on process parameter Bxx.057

Note: Due to the dual function (spindle and turret axis) of theseaxes, asynchronous turret movements are not possible with"Combined spindle/turret axes".

Asynchronous turret movements



Tool edge invocationSyntax: E<constant> e.g. E2

E<expression> e.g. E=@0:12

E=(70-67)

The active tool is selected via address letter ‘E’, followed by a constant oran expression.

Besides loading the tool data, each tool transfer towards the spindlecauses 'Tool 1' to become the active tool. Accordingly, a tool call for aturret causes 'Tool 1' to become the active tool (in addition to providing thetool data).

‘Tool edge 1’ is most frequently used for machining. Thus, a separate tooledge selection is not necessary.

Internally, the tool edge invocation causes the related correction and toollife data to be provided. The tool management accesses this data duringthe subsequent machining process.

Selecting the Tool Spindle "SPT"If there are several spindles in a process, certain functions (such as toolselection E) require an effect on a spindle that is different than the firstone.

Syntax: SPT <spindle number [1-4]>

The first spindle is always active in the power-on state. If the tool is to berelated to a spindle that is different than the first one, the tool spindle mustfirst be selected using ‘SPT <spindle number>’.

• The tool spindle must be selected at least one NC block prior to afunction call.

• SPT <spindle number> has a modal effect until another spindlenumber overwrites it or until it is automatically set to the 1st

spindle atthe end of the program (RET) or by BST.

• Tool life monitoring, wear factors, tool path correction and tool lengthcompensation are valid for the tool of the selected tool spindle.

Alternatively to the MTP command, command "SPT <spindle number>"can also be used to select an additional tool carrier. After selection, thetool with the 1st

edge is active; the offset of the new machine zero point istaken into account. This offset is also calculated when tool compensation(G47) is inactive and is taken into account in the determination of thespindle speed for the constant surface speed (G96).

A detailed description of processing additional tool carriers can be foundin Chapter 6.5 "Additional Tool Carriers".

Additional tool carrier



Tool Group ManagementFrom firmware version 23VRS, tools required for machining one type ofworkpieces can be combined in a tool group to support segmented toolmagazines.

Tool groups are identified by a group number and a group duplo number.Groups of the same group number are linked according to ascendingduplo numbers.

Use the NC command TG to preselect a tool group. The tool searchmode is defined with the command TGSM. The tool preselected inconnection with tool group organization is taken into account in the toolstorage motion command MTP.

Note: See Chapter 1.4 "Tool Group Management" of thisdocumentation for a detailed description of the tool grouporganization.

Preselect a Tool Group “TG”

Tool Group

TG<Group number (constant)>TG<Group number (expressen)>@<Variable number> = TG

The examples below explain the possible syntax variations:

• TG3 ;direct allocation

• TG 3 ;direct allocation, white space

• TG=3 ;direct allocation

• TG=@195 ;allocation by variable

• TG=3+@195 ;Allocation by formula

• @195=TG ;Reading out of the active, i.e. currently effective ;tool group

Group number: 0…Bxx.073 ‘Number of tool groups‘

Use the NC command "TG <Group>" to preselect a tool group asmachining group. The active group can be read with "@<var>=TG". In anunparameterized group, the CNC reports the error 322 "Invalid function".After activation or Control Reset, the control preselects automatically thegroup 0.

N0333 TG3 T19 ;Enabling of tool group 3 as current ;machining group, with simultaneous ;preselection of tool

N1299 @101=TG ;Reading of the enabled tool group number

TG

Syntax

Value range

Meaning

Examples



Define tool search mode “TGSM”

Tool Group Search Mode

TGSM<Mode (constant)>TGSM<Mode (expression)>@<Variable number> = TGSM

The examples below explain the possible syntax variations:

• TGSM1 ;direct allocation

• TGSM1 ;direct allocation, white space

• TGSM=1 ;direct allocation

• TGSM=@196 ;allocation by variable

• TGSM=1+@196 ;allocation by formula

• @196=TGSM ;reading out of the currently effective tool ;search mode

The tool search mode and also the implicit group activation duringentering the T word can be influenced with the NC command"TGSM=<Mode>". The mode can be reread with "@<var>=TGSM".After activation or Control Reset, the control preselects automatically thetool search mode 0.

For <Mode>, the following search orders are available:

Mode Search order Comment

0 Preselected group If the tool is not found in the preselectedgroup, the NC will indicate error 314 ”Toolor tool location not found”.

1 Preselected group,group 0

First, the tool is searched in the preselectedgroup, then in group 0.

2 Preselected group,groups 0..99

If the tool is not in the preselected group, itwill be searched for in ascending order inthe groups 0..99.

3 Groups 0 to 99 Irrespective of the enabled group, the tool issearched in ascending order in the groups0…99.

Fig. 3-5: Tool search mode in tool groups

If the requested tool is found in another than the preselected / enabledgroup, this group will be automatically enabled and preselected once thetool has been enabled. In case of unsuccessful tool search, the CNCsignals error 314, “Tool or tool location not found”.

N0344 TGSM1 T19 ;Define tool search mode1, preselect tool ;and implicitly enable the tool group in ;which the tool has been found

N1266 @2:98 = TGSM G01 X78 F1200 ;Read the currently effective ;tool search mode and put axis in feed position

Changing ToolsThe process of changing tools is initiated by NC commands.

In most cases, changing tools also requires motions and activating /deactivating G codes. Thus, the entire program sequence should becombined in a subroutine or a cycle. This reduces the programming effortin the main program to selecting the tool via the T command and toinvoking the tool changing subroutine.

TGSM

Syntax

Meaning

Examples



Using a macro provides an elegant solution of the tool changinginvocation:

Maco:DEFINE M6 AS BSR .M6

Thus, invoking ‘T<XX> M6’ initializes a tool change in the NC program.The changing process proper is then programmed from the label ‘.M6’onwards.

Example: NC program:

...

...

...N0047 T12 M6 ; call of "Tool change"

N0048 G54 G0 X123 Y45 F350

...

...

...

‘Changing tools’ cycle:

N0000 .M6

N0001 G40 G47 G0 X100 Y100 Z50

•••

N0056 RTS

Note: Section "Typical Applications" contains examples ofprogramming tool storage units (magazines and turrets).



3.2 Tool Storage Unit Motion Commands of the NC

All tool storage unit motion is performed asynchronously relative to themotions on the other NC axes. The NC motion commands only initiate toolstorage unit motion and do not wait until the tool storage unit has completedthe motion. In the meantime, the NC program – and thus the process – canbe continued.

The command ‘MRY’ can be used to scan signals to determine whether themotion which was initiated is finished. In this way, the NC program is haltedand synchronized with the tool storage unit.

The following table contains an overview of all tool magazine motioncommands of NC. The table is followed by a detailed description ofcommands.



Tool storage enabled formanual mode

MEN Magazine Enable

Syntax: MEN

MFP

Move free pocket into changepositionMove next Free Pocket in Position

Syntax: MFP (POS, DIR)POS: position to be moved

DIR: rotational direction

Tool storage to home position

MHP

Move to Home Position

Syntax: MHP ( DIR )DIR: rotational direction

MMA

Freely position tool axisMove Magazine Access

Syntax: MMA ( POS, DIR )POS: position to be moved

DIR: rotational direction / mode

Move programmed pocketinto basic position

MMP Move Magazine Pocket in Position

Syntax: MMP (POS, DIR)POS: position to be moved


MOP

Move old pocket into positionMove Old Pocket in Position

Syntax: MOP ( POS, DIR, SPI )POS: position to be moved


SPI: Spindle

Move tool storage unit toreference position

MRFMove to Reference Position Toolstorage motion commands:Toolstorage to reference position ‘MRF’

Syntax: MRF

MRY

Tool storage ready?Magazine Ready

Syntax: MRY

Move programmed tool intoposition

MTPMove Tool Position

Syntax: MTP ( POS, DIR )POS: position to be moved





Tool Storage to Reference Position ‘MRF’

Move to Reference Position Tool storage motion commands:Tool storageto reference position ‘MRF’

(homing)

The 'MRF' command starts the process of returning the tool storage unitaxis to the reference position.

This command is comparable to G74 for the NC axes of a process. Afterthe control is powered on, the reference position must be established for thetool storage system before it can traverse to a particular position.

For this reason, the 'MRF' command must be programmed in the reverseprogram of a process which uses the tool storage system.

In the case of NC-controlled tool storage units, referencing is executed bysetting parameters (Cxx.013 for 'Combined spindle/turret axis', otherwiseusing the drive parameters).

In the case of PLC-controlled tool storage units, the ‘MRF’ NC command istransferred to the ‘MRF’ PLC function. The PLC must ensure that thereference is established and must acknowledge the ‘MRF’ function.

Before performing the MRF command, it is important to be certain that thetool storage movement does not prevent other NC axes from referencing.

reference mark

referencecam

reference mark

678

9

10

11 12 21

3

4

5

: occupied

: free

MRF.FH7

Fig. 3-6: Reference position using a chain magazine as example

MRF



Tool Storage to Home Position ‘MHP’


MHPMHP(DIR)

DIR: <constant><variable>

DIR: 0, 1, 2

DIR = 0: any directionDIR = 1: positive directionDIR = 2: negative direction

The 'MHP' command causes the tool storage unit to move to its homeposition. In this way, the tool management system ensures that the storagesystem is traversed to "Location 1" regardless of the type of axis or storageunit.

Optionally, you can enter the direction of the movement to the homeposition. The controller chooses the shortest way if a direction is notspecified.

The distance is specified using the following drive parameters:

• Reference dimension 1 (S-0-00052) with motor measuring system

• Reference dimension 2 (S-0-00054) with external measuring system

In the case of a PLC-controlled tool storage unit, tool management transfers'Location 1' (PLC interface signal "PxxS.MGCP magazine commandposition")to the PLC. Using the 'MMV' function, the PLC moves to the homeposition and takes 'Location 1' to the reference mark.

reference mark

reference cam

reference mark

6

78910

11

12

21 3 4

5

: occupied

: free

MHP.FH7

Fig. 3-7: Basic position using a chain magazine as example

The CNC does not wait until the tool storage unit has reached the homeposition. It continues to process the NC program while the tool storagemove is being carried out.

If this is not desirable, the MRY command tool storage ready? can beused to halt execution of the NC-program until the tool storage motion iscompleted.

MHP

Syntax

Expression

Value range

Meaning



Move Tool into Position ‘MTP’

Move Tool Position

Move programmed tool into position

MTPMTP(POS)MTP(POS,DIR)

POS: <constant><variable>


POS: 1, 2, 3, 4DIR: 0, 1, 2

POS = 1: bring preselected tool into position 1 (Bxx.021)POS = 2: bring preselected tool into position 2 (Bxx.022)POS = 3: bring preselected tool into position 3 (Bxx.023)POS = 4: bring preselected tool into position 4 (Bxx.024)DIR = 0: any directionDIR = 1: positive directionDIR = 2: negative direction

Tool storage motion commands:Move tool into position ‘MTP’ The MTPcommand initiates a tool storage move which places the tool selected viathe T-word in the NC-program in the specified position (change, installationor processing position).

Optionally, the position into which the selected tool is to be brought and thedirection to be taken when the tool is moved to the specified changeposition can also be declared.

Tool management chooses the shortest way and 'Position 1' if neitherdirection nor position is entered.

‘Tool edge 1’ of the tool automatically becomes the active tool edge.

If there are several tools with the same designation and the same T number(known as alternate tools) in the tool storage unit, tool managementautomatically selects the tool with the 'Machining tool' status.

With machines that feature a tool magazine which can be positionedduring the machining process, the ‘MTP’ command is frequently used forprepositioning the magazine.

'MPT' is usually programmed in the NC program together with the toolpre-selection 'T<XX>' immediately after changing the previous requiredtool. With this, the next tool is brought into the tool changing position whilethe process is running.

In particular, this command is employed for tool changers with dual armgrippers where the previously used tool is to be stored in the magazinepocket from which the new one is taken.

Like ‘MFP’, the 'T0 MTP' command moves the next free pocket to thespecified position.

The CNC does not wait until the tool storage unit has completed itsmotion. It continues to process the NC program while the move is beingcarried out.


An additional tool carrier for tool storage type "Turret" is also selected withthe T number and the MTP command; however, the turret is not

MTP

Syntax

Expression

Value range

Meaning



positioned. After selection, the tool with the 1st edge is active; the offset of

the new machine zero point is taken into account. This offset is alsocalculated when tool compensation (G47) is inactive and is taken intoaccount in the determination of the spindle speed for the constant surfacespeed (G96).

A detailed description of processing additional tool carriers can be foundin Chapter 6.5, “Additional Tool Carriers”.

Example: The ID cutting tool 'T91' that is located on a turret is to be moved to the second machining position (POS2) without running through the first machining position (POS1).

Therefore, define 'Position 2' for POS and a negative turningdirection of '2' for DIR.

POS1

12

3

4

56

7

8

T91 MTP(2,2)

referencemark

referencemark

POS2 POS2POS1

T238

T125

T254

T91

T831

T238

T121

T121

T254

T91

T238T125

T831

T238+

+3

21

45

6

7

8

required swivel process

MTP.FH7

Fig. 3-8: Positioning a tool with ‘MTP’

Move Programmed Pocket into Position ‘MMP’

Move Magazine Pocket in Position

(Move programmed pocket into position)

MMPMMP(POS)MMP(POS,DIR)



POS: 1, 2, 3, 4DIR: 0, 1, 2

POS = 1: bring preselected location into position 1 (Bxx.021)POS = 2: bring preselected location into position 2 (Bxx.022)POS = 3: bring preselected location into position 3 (Bxx.023)POS = 4: bring preselected location into position 4 (Bxx.024)DIR = 0: any directionDIR = 1: positive directionDIR = 2: negative direction

The MMP command initiates a tool storage unit move which places thelocation selected via the T word in the specified position (change,installation or processing position).

MMP

Syntax

Expression

Value range

Meaning



Optionally, the position into which the selected location is to be broughtand the direction to be taken when the tool is moved to the specified posi-tion can also be declared.

Tool management chooses the shortest way and 'Position 1' if neitherdirection nor position is specified.

‘Tool 1’ of the tool in the currently selected location automatically becomesthe active tool.

The MMP command is generally used for sorting work and for adding orremoving tools.

Note: When used with the T word, the 'MMP' command refersexclusively to pockets and not to tools. For this reason, if toolsare called according to the position using MMP, any sparetools which are present are ignored during a process unlessthey are explicitly programmed in the NC-program with the aidof the T-word and the corresponding location number.



Example: The ID cutting tool ‘T91’ in location 3 is to be replaced. To dothis, it must be moved to the loading/unloading position(POS3).

This can be done either by ‘jogging’ the turret or, forexample, using the 'T3 MMP (3,0)' command in the MDI(Manual Data Input). The pocket then moves along theshortest path possible (negative direction) to theloading/unloading position.

POS11

2

34

5

6

78

12

3

4

56

7

8

T3 MMP(3,0)

referencemark

referencemark

POS3 POS3

POS2 POS2POS1

T254T238

T125

T125

T238

T254

T91

T91

T831

T831T238

T121

T121

T238+

+

MMP.FH7

Fig. 3-9: Positioning a turret location with ‘MMP’



MTP/MMP Commands and Tool CorrectionBoth commands MTP/MMP have different time behavior in regard to theactivation of the tool correction. Depending on the turret type and usedcommand, the tool correction must be activated before or after the turretmovement.

Interaction of Bxx.044 and REV_SYNC

Bxx.044"Asynchronous turret movement"

Turret movementNO Yes

InputACTIVE = 0 synchronous asynchronous

REV_SYNC

InputACTIVE = 1 synchronous synchronous

Bxx044_REV_SYNC_V22_20030218.xls

Activation of tool compensation with MTP and MMP

Tool correctionPoint of

activation MTP MMP MRY

At the beginningEnable toolbefore turretmovement

Enable toolafter turretmovement -Synchronous turret

movement

At the endEnable toolafter turretmovement

Enable toolafter turretmovement -

At the beginningWhen tool is inposition thenactivation isperformed

immediately,otherwise only with

MRY

-Activate

tool comp.

Asynchronous turretmovement

At the end - - Activatetool comp.

Werkzeugkorrektur_MTP_MMP_V22_20030218.xls

TC: Tool correctionT Tool

Freely Position Tool Axis ‘MMA’

Move Magazine Axis

(freely position tool axis)

MMAMMA(POS)MMA(POS,DIR)

MMA

Syntax





POS: -214748.3648 to +214748.3647 with 4 decimal positionsDIR: 0, 1, 2, 3, 4

POS = axis position in mm, inches or units (default setting = 0)DIR = 0: shortest path (default setting)DIR = 1: positive directionDIR = 2: negative directionDIR = 3: longest pathDIR = 4: incremental path specification

Tool magazine command MMA executes free positioning of the tool axis.Here, any position (intermediate locations) can be absolutely or relativelyapproached by the NC program. Direct programming of the tool axisusing an axis name is not possible.

Tool management chooses the shortest way and position value 0 ifneither direction nor position is specified.

The MMA command deactivates the tool compensation for a tool turretand deselects the active tool (T0 is preselected). If the tool storage unit isa magazine, the tool that is located in the current tool spindle remainsactive.

The addressing of tool data using the tool axis position after freepositioning using command MMA is not possible. If the tool axis is in the"Free positioning" operating mode during a tool change using tool transfercommands (e.g. TSM, TMS, TCH), an error message is issued.

Note: It is mandatory that the tool axis be again positioned absolutelyon a valid magazine location before executing a tool changeusing the corresponding tool storage unit movementcommands.

Note: The command MMA is not supported for PLC-controlledmagazines/turrets and for tool magazine axes of axis type"Combined spindle/turret axis".Interface signal PxxS.MGCP (Process xx Status MagazineCommand Position) remains unchanged.



Moving to Free Location ‘MFP’

Move next Free Pocket in Position

(Move free pocket into change position)

MFPMFP(POS)MFP(POS,DIR)

Expression

Value range

Meaning

MFP

Syntax



POS <constant><variable>

DIR <constant><variable>

POS: 1, 2, 3, 4DIR: 0, 1, 2

POS = 1: bring next free location into position 1 (Bxx.021)POS = 2: bring next free location into position 2 (Bxx.022)POS = 3: bring next free location into position 3 (Bxx.023)POS = 4: bring next free location into position 4 (Bxx.024)DIR = 0: any directionDIR = 1: positive directionDIR = 2: negative direction

The MFP command initiates a tool storage motion to move the closestempty pocket to the specified position.

Optionally, the position into which the closest empty pocket is to bebrought and the direction to be taken when the tool is moved to the speci-fied position can also be declared.

Tool management chooses the shortest way and 'Position 1' if neitherdirection nor position is specified.

This command is used to place the tool located in the tool spindle or inthe gripper in the closest empty pocket in the magazine. This is especiallynecessary with tool changers which do not have grippers or which usesingle-arm systems when the old tool needs to be stored before a newtool can be used.



Example:The tool in 'Spindle 1' is to be brought back to the magazine.This requires the nearest free location to be moved to 'POS 2'. Due to thefact that the magazine may only be turned in the positive direction, theturning direction is declared as ‘1’.

Therefore 'Position 2' and a turning direction of '1' must be preselected.

Expression

Value range

Meaning



: occupied

: free spindle 1

6

78910

11

12

21 3 4

5POS 2

POS 1

+

loadingposition

gripper

spindle 1

loadingposition

gripper

MFP(2,1)

6 7

8

9

101112

2

1

3

4 5

POS 2

POS 1

+

reference markreference mark

MFP.FH7

Fig. 3-10: Positioning a free magazine location using ‘MFP’

Move to Old Position - ‘MOP’

Move Old Pocket in Position

MOPMOP(POS)MOP(POS,DIR,SPI)



SPI : <constant><variable>

POS: 1, 2, 3, 4DIR: 0, 1, 2SPI 1, 2, 3

POS = 1: bring old location into position 1 (Bxx.021)POS = 2: bring old location into position 2 (Bxx.022)POS = 3: bring old location into position 3 (Bxx.023)POS = 4: bring old location into position 4 (Bxx.024)DIR = 0: any directionDIR = 1: positive directionDIR = 2: negative direction

Tool storage motion commands:Move old pocket into position ‘MOP’ TheMOP command initiates a tool storage motion which moves the oldpocket of the tool located in the tool spindle to the position from which thetool was removed.

Optionally, the position, direction of rotation and the tool spindle can bedeclared.

If the position, sense of rotation, and spindle are not specified, toolmanagement chooses the old location for the tool in 'Spindle 1' and takesit to 'Position 1' via the shortest route possible.

If this command is used consistently, all tools will be returned to the pock-ets in which they were located before they were used in the machining

MOP

Syntax

Expression

Value range

Meaning



process. This keeps the tool storage unit in an orderly condition. This isdesirable, for example, when extra-wide tools always have to be stored inthe same magazine pocket.



Example:The tool in 'Spindle 1' (T256) is to be brought back to its originallocation in the magazine. Due to the fact that the magazine mayonly be turned in the positive direction, the turning direction isdeclared as ‘1’.

Declare ‘Position 2’ for POS, a positive direction of turn for DIRand the first spindle for SPI.

spindle 1

: occupied

: free spindle 1

6

78910

11

12

21 3 4

5POS 2

POS 1

+

loadingposition

gripper

loadingposition

gripper

MOP(2,1,1)

6

7 8 9 10

11

12

2 134

5

POS 2

POS 1

+

reference markreference mark

T256

old locationof T256

MOP.FH7

Fig. 3-11: Positioning the old location using ‘MOP’



Tool Storage Ready ‘MRY’

Magazine Ready

(Magazine movement completed ?)

If the last tool storage movement command has not yet been completed,the 'MRY' command temporarily interrupts the processing of the NCprogram.

The NC program does not resume processing until the programmedposition has been reached. This permits the tool storage axis to besynchronized with the NC program.

Example: Tool change program:

N0000 .M6 ;branch label for tool change

...

...

...

N0012 MTP(2,0) ;move programmed tool to Position 2

... ;on the shortest way

...

...

N0037 MRY ;wait until position 2 is reached

...

...

...

Example:

(NC program)•

•

•

MTP (2,0) ; move programmed tool to 'POS 2' on the shortest way MRY ; wait until position 2 is approached

•

•

•

MRY



Enable Tool Storage for Manual Mode ‘MEN’

Magazine Enable

(enable magazine)

The MEN command allows a tool magazine to be traversed manuallywhile the automatic mode of the machine is active. For example, thisallows a worn tool to be changed while production continues.

In order for the tool magazine to run in manual mode, the MEN commandmust be active in the NC program and the PLC must have selected themanual mode for the tool storage.

If the tool storage mode is changed to manual after a MEN command hasbeen performed, the CNC continues to execute the program for thisprocess until the next tool storage movement or tool change command isencountered. It then issues the corresponding status message:”*Waiting for tool storage move cmd to be completed”

When the system changes back to program-controlled mode, the statusmessage in the diagnostic box is cleared and the remaining commands areprocessed to completion.

All motion and tool change commands programmed in the NC-program(generally located in a tool change subroutine) request the tool storage.

If a further motion or tool change command follows before the change tomanual mode and after the tool storage system was enabled via MEM inthe NC-program, the tool storage unit cannot be traversed manually whilethe program is executing and continuing to the next MEN, BST, RET orControl-Reset. Tool Change Commands

MEN



Moving Tool Storage Unit with Nonuniform Pocket Distribution

NC-controlled tool magazines and tool turrets that have a nonuniformspacing of the tool positions can be easily operated using a machine datapage with the tool storage movement commands of the NC (MTP, MMP,MHP, etc.). Furthermore, additional axis positions can be specifiedregardless of the type of spacing of the tool storage (uniform ornonuniform spacing) for logical positions 1 to 4; any intermediate positioncan then be approached.

In this regard:

1. the number of the machine data page (100-299) in which the variablepositions are specified is to be entered in the process parameterBxx.072 ”Page No. for variable positions”.

2. the corresponding page in the machine data is to be created and thepositions of tool locations to be entered.

The NC evaluates the process parameter Bxx.072 for the runtime and thecorresponding machine data page and uses the highlighted positions tocalculate the absolute magazine positions of the tool storage axis. Aseparate page must be created for every process in multiprocessoperation.

Note: Process parameter Bxx.072 appears in the user interface onlyif "Yes" was entered in system parameter A00.052 "Toolmanagement" and in process parameter Bxx.014 "Toolmanagement".

The machine data page contains one absolute axis position each

• for positions P1-P4 (control variable LV1 = -1 to -4),

• for the position of home position (MHP command) (LV1 = 0),

• for all n magazine locations (LV1 = 1-n).

Detailed information regarding the setting of parameters as well as thestructure and definition of the machine data page can be found in thedescription of process parameter Bxx.072 "Page No. for variablepositions" in the "MTC 200/TRANS 200 Description of Parameters".

If nonuniform tool pocket distribution has been activated using processparameter Bxx.072 "Page No. for variable positions", the jogging of toolaxes refers to one of the four change positions P1-P4. For moreinformation, see the MTC 200 interface description in the section"Magazine jogging operating mode in case of variable tool pocketdistribution ‘PxxC.MGJGn’ ”

Notes:

• The nonuniform spacing function is not available when a combinedspindle/revolver axis or PLC-controlled tool storage units are used.

• When nonuniform pocket distribution is activated for NC-controlled toolturrets, parameters Bxx.021-Bxx.024 "Position 1-4" no longer have aneffect.

• Only the magazine position approached using a tool storagemovement command (e.g. MTP, MMP, jogging) is a valid position (P1-P4) for the tool change.

Tool storage unit movementcommands of NC

(MTP, MMP, MHP, etc.)

Process parameter Bxx.072"Page No. for variable pocket

positions" and correspondingmachine data page

Machine data entries

Effect on jogging the tool axis



3.3 Tool Changing Commands of the NC

Changing tools between magazine, spindle or gripper is initialized via thetool changing commands of the NC. Using the tool changing commandsis permitted only when magazines are used as tool storage units.

The following figure shows the basic sequence of a tool changingprocess.

� �

��

��

��

��

��

��

��

��

�� !��

�� !��

��

��

��!�

��"#�"$�� !��

��

CNC1.FH7

Fig. 3-12: General representation of a tool change



The following table contains an overview of all tool change commands ofthe NC. The table is followed by a detailed description of commands.



TCH Complete tool changeTool Change

Syntax: TCH (POS, SPI)POS: position to be moved

SPI: Spindle

TMS Change tool from magazineto spindle

Tool change from Magazine toSpindle

Syntax: TMS (POS, SPI)POS: position to be moved

SPI: Spindle

TPE Tool pocket

free?Tool Magazine Pocket Empty

Syntax: TPE

TSE Tool spindle free?

Tool Spindle Empty

Syntax: TSE

TSM Switch tool from spindle tomagazineTool change from Spindle toMagazine

Syntax: TSM (POS, SPI)POS: position to be moved

SPI: Spindle


Performing a Complete Tool Change ‘TCH’

Tool Change

(Complete tool change)

TCHTCH(POS)TCH(POS,SPI)

POS <constant><variable>

SPI <constant><variable>

POS: 1, 2, 3, 4SPI: 1, 2, 3

Tool exchange between spindle 'SPI' and position 'POS'.

The 'TCH' command initiates a tool exchanging process between thespindle 'SPI' and the magazine location in position 'POS'.

The CNC stops program execution while the tool change operation isproceeding under PLC control.

TCH

Syntax

Expression

Value range

Meaning



Optionally, the change position and tool spindle can be declared. If nodata are declared for the change position or tool spindle, tool manage-ment selects change position 1 and tool spindle 1.

The magazine must be correctly positioned before 'TCH' is called.

The TCH command is used in particular with double-arm gripper systems.

Change the Tool from the Magazine to the Spindle ‘TMS’

Tool Change from Magazine to Spindle

TMSTMS(POS)TMS(POS,SPI)


SPI: <constant><variable>

POS: 1, 2, 3, 4SPI: 1, 2, 3

Changing tools from position 'POS' to spindle 'SPI'.

The 'TMS' command initiates a tool changing process between themagazine locations in position 'POS' and the spindle 'SPI'.


Optionally, the change position and tool spindle can be declared. If nodata are declared for the change position or tool spindle, toolmanagement selects change position 1 and tool spindle 1.

Even before TMS is called up, the magazine pocket containing the toolwhich is to be exchanged must already be in the specified changeposition, and a tool may not be present in the tool spindle.

This command is needed for single-arm gripper systems or forgripperless tool changers if the change operation has to be divided into apick-and place-sequence.

Change Tool from Spindle to Magazine ‘TSM’

Tool Change from Spindle to Magazine

TSMTSM(POS)TSM(POS,SPI)


SPI: <constant><variable>

POS: 1, 2, 3, 4SPI: 1, 2, 3

Tool change from spindle 'SPI' to position 'POS'.

TMS

Syntax

Expression

Value range

Meaning

TSM

Syntax

Expression

Value range

Meaning



The ‘TSM’ command initiates a tool transfer between the spindle ‘SPI’ andthe magazine location in position ‘POS’.


Optionally, the change position and tool spindle can be declared. If nodata are declared for the change position or tool spindle, toolmanagement selects change position 1 and tool spindle 1.

Before 'TSM' is called , a tool must be present in the tool spindle and themagazine must have an empty location at the specified change position.

This command is needed for single-arm gripper systems or forgripperless tool changers if the change operation has to be divided into apick-and place-sequence.

Magazine Pocket Empty ? ‘TPE’

Tool Magazine Pocket Empty

The 'TPE' command checks whether the magazine or turret location thatis currently at 'position 1' is empty.

If this is the case, tool management immediately continues programexecution. Otherwise, program execution is stopped and an errormessage is generated.

Using this command permits collisions to be avoided when a tool isstored. The command must be used in the storage sequence of the toolchanging subroutine before a movement is performed.

Note: The ‘TPE’ command always refers to the location at ‘Position1’.

Tool Spindle Empty? ‘TSE’

Tool Spindle Empty

The 'TSE' command checks whether the tool location that is currently in'Spindle 1' is empty.

If this is the case, tool management immediately continues programexecution. Otherwise, program execution is stopped and an errormessage is generated.

Using this command permits collisions to be avoided when a tool isstored. The command must be used in the storage sequence of the toolchanging subroutine before a movement is performed.

Note: The ‘TSE’ command always refers to the location at ‘Spindle1’.

TPE

TSE

Tool Management PLC Functions to Control Tool Management 4-1


4 PLC Functions to Control Tool Management

4.1 Tool Magazine Motion Control

"Tool magazine motion control" is performed independently of the toolmagazine's drive mode (PLC or NC controlled).

Tool magazine motion commands are used for controlling the movementfrom the NC side. Tool magazine control and status signals are used forcontrolling the movement from the PLC side.

The following figure shows the basic operation of tool magazine motioncontrol:

Control logicof the tool

management

Axis module

NC-controlledtool storage

unit

Position Location

Tool storage unitmotion commands

MTPMMPMFPMOPMRFMHPMENMMAMRY

Tool storage unitcontrol and

status signals

PxxC.MGHOM PxxC.MGBP PxxC.MGMOV

:

NC PLC

Toolmanagement

Control logicMRFMMV

PLC-controlledtool storage unit

2-45.FH7

Fig. 4-1: Motion control of a tool magazine

4-2 PLC Functions to Control Tool Management Tool Management


The following notation is used for the tool magazine control signals andstatus signals of the PLC:

P x x y M G z z z

Process signalProcess number ( 00 - 06

Signal typeC = Control signal ( to NC )S = Status signal ( to PLC )

Tool storage unit signal MG (magazine)

Signal name2-46.FH7

Fig. 4-2: Explanation of symbolic operands

Tool Magazine Control SignalsThe following control signals are available:

Tool magazine control signals V22_20030123

Signal Meaning

Enabling the tool magazinePxxC.MGENA

Process xx Command Magazine Enable

Operation without setup list PxxC.MGNSL

Process xx Command Magazine no Setup List

Deactivating the Life Count PxxC.MGNTL

Process xx Command Magazine no Tool Calculation

Mode of tool storage unit PxxC.MGMAN

Process xx Command Magazine Mode Manual

Move tool storage unit to reference position PxxC.MGHOM

Process xx Command Magazine move to Homing

Tool storage to home position PxxC.MGBP

Process xx Command Magazine Base Position

Moving the tool storage unit by one location in the positive direction PxxC.MGPOS

Process xx Command Magazine Positive Direction

Moving the tool storage unit by one location in the negative direction PxxC.MGNEG

Process xx Command Magazine Negative Direction

Actual position PxxC.MGAP

Process xx Command Magazine Actual Position

Switches off the automatic equipment check PxxC.MGWTC

Process xx Command Magazine without Tool Check

Tool check ignores worn tools PxxC.MGITW

Process xx Command Magazine Ignore Tool Wornout

Magazine jog mode with variable tool locations PxxC.MGJGn n = (0, 1)

Process xx Command Magazine Jogging Mode Bit n

Wz_speicher_steuersignale_V22_klein_20030123.xls



Both control signals "PxxC.MGENA" and "PxxC.MGMAN" and"PxxC.MGMAN" must remain statically applied to enable the toolmagazine to be moved through the PLC.

With any other command, a positive flank of the control signal causes thefunction to be executed (i.e. the tool magazine to be moved).

Enabling the Tool Magazine "PxxCMGENA"

PxxC.MGENA = Process xx Command Magazine Enable

Control signal PLC → NC

PxxC.MGENA = 0: Tool magazine has not been enabledPxxC.MGENA = 1: Tool magazine has been enabled

Valid in all modes.

Moving the tool magazine and performing a tool change requires thissignal to be set. It is required for program mode and for manual mode.

Deactivating the signal during a movement of the tool magazine or a toolchanging process immediately interrupts the movement. The interruptedmovement is continued as soon as the signal has returned.

This permits security devices (such as a guard door) to be monitored.When such a device is opened, the "PxxC.MGENA" control signal causestool management to cancel axis enabling for an NC-controlled toolmagazine axis and to reset the "PxxS.MGENA"" status signal for the PLC.

Tool management shows the same response if, for example, an internalimmediate stop (e.g. by changing the mode) or a fault occurs or processenabling is canceled.

Note: In the case of PLC-controlled tool magazines and all toolchanging procedures, the "PxxS.MGENA" signal must betaken into account in all interconnections that initiate amovement. Movement is permitted only if the enabling signalis active (=1).

Using the enabling signals:

NC-controlledmagazine

PLC-controlledmagazine

tool changer

safety device

motioninterruption

motioninterruption

e.g. guard dooropen

internal axisrelease

PxxSMGENA

PxxCMGENA

internalimmediatestop

error

process release

axis module

PLCtool

managementmotioninterruption

2-47.FH7

Fig. 4-3: Using the enabling signals

Designation

Function



Deactivation of Automatic Equipment Check"PxxC.MGWTC"

PxxC.MGWTC = Process xx Command Magazine without Tool Check

Status signal PLC → NC

PxxC.MGWTC = 0: Automat. tool check can be executed

PxxC.MGWTC = 1: Automat. tool check is not executed

The signal is effective in all modes.

Generally, tool management does not perform an automatic tool checkupon a restart if the "PxxC.MGWTC" interface signal" has been set tologic "1".

Otherwise, an automatic tool check is executed according to the criteria inthe section "Tool check" in this document and in "MTC 200 NCProgramming Instructions".

Operation without Setup List "PxxC.MGNSL"

PxxC.MGNSL = Process xx Command Magazine no Tool Setup List


PxxC.MGNSL = 0: Tool assignment (T. no.) according to setup listPxxC.MGNSL = 1: Operation without setup list, tool assignment (T. No.) according to setup list


If interface signal "PxxC.MGNSL"" is set to logical "1", the NC internallygenerates an empty setup list that is invisible to the user; therein, it thencreates an entry for each part number which occurs at least once in thecurrent tool list. Any already existing setup list is left unconsidered. (Seealso section "Operation without setup list" in chapter "Setup lists and toollists" in this document.)

Tool Check Ignores Wornout Tools "PxxC.MGITW"

PxxC.MGITW = Process xx Command Magazine Ignore Tool Wornout


PxxC.MGITW = 0 Take worn-out tool into accountPxxC.MGITW = 1 Ignore worn-out tools


If PLC signal "PxxC.MGITW"" has been deleted (log. "0"), the NCprogram terminates with an error message during the tool check if there isan alternate tool sequence that does not have any usable tool. Otherwise,no error message is given.

If PLC signal "PxxC.MGITW"" has been set (log. "1"), the NC programterminates with an error message during the tool check if there is analternate tool sequence that does not have any usable tool, including atool that is worn or broken but otherwise usable. Otherwise, no errormessage is given.

Designation

Function

Designation

Function

Designation

Function



For further information, see the section "Tool check" in this document andin "MTC 200 NC Programming Instructions".

Switching off Tool Life Calculation "PxxC.MGNTL"

PxxC.MGNTL = Process xx Command Magazine no Tool LifeCalculation


PxxC.MGNTL = 0: No effect on the life countPxxC.MGNTL = 1: Life count is not enabled


The PLC can employ this signal to influence the NC's integrated tool lifecounter.

Tool management does not perform a life count for the currently activetool if this signal has been set to logic 1.

Operating Mode of Magazine "PxxC.MGMAN"

PxxC.MGMAN = Process xx Command Magazine Mode Manual


PxxC.MGMAN = 0: Tool magazine is allocated to the NCprogramPxxC.MGMAN = 1: Tool magazine is to be moved manually

Valid in all modes.

Provided that the NC does not need the tool magazine, the tool magazinemode can be selected independently of the mode of the related NCprocess.

Block diagram of a tool magazine mode selection:

&

tool storage unit shall bemoved manually

tool storageunit in manualmode

NC requires toolstorage unit

0

NC program

motion command for tool storage unit

MTP; MMP; MFP; MOP; MHP; MRF

BST/RET

MEN

CONTROL RESET

Tool management

> = 1

PxxSMGMAN

PxxCMGMAN

PxxSMGENQ

PLC

S

R

2-48.FH7

Fig. 4-4: Mode selection of a tool magazine

Designation

Function

Designation

Function



During program execution, a tool magazine can be moved manually onlyif the PLC has issued the "PxxC.MGMAN" control signal that tells toolmanagement that the tool magazine is to be moved manually.

The "PxxS.MGMAN" status signal indicates whether tool magazinecontrol can be transferred to the PLC or whether the tool magazine is inmanual mode. When tool magazine control is transferred to the PLC, itremains allocated to the PLC until the "PxxC.MGMAN" control signal isissued to switch over to program mode.

When the request "Move tool magazine manually" (PxxC.MGMAN: 0 →1) is issued if the "NC does not require the tool magazine, the mode isimmediately changed to "Tool magazine in manual mode". For thisprocess, the NC executes the program up to the next tool magazinecommand and issues the related status message: "Station waits forcompletion of magazine command".

When returning to program operation (PxxC.MGMAN: 1 → 0), the statusmessage in the diagnosis display is cleared and the pending toolmagazine command is processed.

Any tool magazine motion command ("MTP", "MMP", "MFP", "MOP","MHP", MMA und "MRF") that is programmed in the NC program sets the“tool magazine is needed by the NC“ request signal. That signal is resetby the NC commands "MEN" (Magazine Enable), "BST" (Branch withStop) und "RET" (Return to main program).

A "control reset" also cancels the "Tool magazine is needed by the NC"request.

Within an NC process, tool storage unit axes are used as asynchronousaxes. An NC-controlled tool magazine can therefore be manuallycontrolled during automatic mode.



Homing of Tool Magazine "PxxC.MGHOM"

PxxC.MGHOM = Process xx Command Magazine move to referenceposition (Homing)


PxxCMGHOM =0

tool storage unit homing1

neu_1.FH7

Fig. 4-5: Homing of tool magazine

Valid in all modes.

A positive flank on the "PxxC.MGHOM" control signal initiates toolmagazine homing.

With NC-controlled axes, tool management transfers the homingcommand to the servodrive axis module. With PLC-controlled toolmagazines, in contrast, the "MRF"" command is employed to transfer thehoming command to the PLC.

Thus, the "Tool magazine homing" control signal permits program-independent establishment of a tool magazine reference.

When incremental encoders are employed for the tool magazine axis, thereference position must be established once after the MTC 200 has beenswitched on. It makes sense for this function to be performedautomatically in the reverse program when homing of the other NC axesis performed.

With NC-controlled tool magazines, the reference cam, the associatedreference switch, and the zero impulse of the drive determine thereference position. The reference position of a PLC-controlled toolmagazine is usually defined by a reference cam and the associatedreference switch.

The reference position is not necessarily identical to the tool magazine'shome position.

Designation

Function



Moving the Tool Magazine to its Basic Position"PxxC.MGBP"

PxxC.MGBP = Process xx Command Magazine Base Position


��

��

neu_2.FH7

Fig. 4-6: Moving the tool magazine to its base position

Valid in all modes.

A positive flank of the "PxxC.MGBP" control signal tells tool managementthat the tool magazine must move to its basic position. Tool managementthen initiates the required movement.

With an NC-controlled tool magazine, the "Cxx.013 Reference position"axis parameter can be used for placing the basic position at any locationrelative to the tool magazine's actual reference position. When the PLCsets that signal, the NC moves to the basic position by bringing "Location1" to the reference mark.

"Magazine in basic position"

POS 1

reference mark

1 2 3 4 56

7891112 1013

1415

+

POS 2

2-49.FH7

Fig. 4-7: Moving the tool magazine to its basic position

With a PLC-controlled tool magazine, tool management specifies"Location 1" " for the PLC via interface signal "PxxSMGCP magazineposition after the PLC has set the "PxxS.MGBP Move tool magazine tobasic position" signal. For the PLC, moving to the basic position isequivalent to normal tool magazine positioning. It positions the toolmagazine so that "Location 1" is located at the reference mark (Bxx.021... Bxx.024).

Designation

Function

Example



Moving the Tool Storage Unit by One Pocket in thePositive Direction "PxxC.MGPOS"

PxxC.MGPOS = Process xx Command Magazine Positive Direction


��

��

neu_3.FH7

Fig. 4-8: Moving the tool storage unit by one location in the positive direction

Valid in all modes.

A positive flank of the "PxxC.MGPOS" control signal causes toolmanagement to move the tool magazine by one pocket so that the pocketwith the next higher identification number sits at the reference mark.

In an endlessly rotating tool magazine (e.g. a chain-type magazine),"Location 1" will follow at the reference mark after the last location hasbeen reached.

Similarly, with a non-endlessly rotating tool storage unit (e.g. a linearmagazine), "Location 1" will be brought to the reference mark after thelast location has been reached.

If the tool axis is not in a fixed magazine or turret location, the locationnext to the last valid fixed location is approaching upon jogging.

If the nonuniform tool location distribution has been activated with processparameter Bxx.072 "Page No. for variable position of locations", specialregulations (refer to section "Magazine Jog Mode with Variable ToolLocations "PxxC.MGJGn"") apply to the jogging of tool axes)

Moving Tool Magazine by one Pocket in the NegativeDirection "PxxC.MGNEG"

PxxC.MGNEG = Process xx Command Magazine Negative Direction


��

��

neu_4.FH7

Fig. 4-9: Moving the tool storage unit by one location in the negative direction

Valid in all modes.

A positive flank of the "PxxC.MGNEG" control signal causes toolmanagement to move the tool magazine back by one location so that thepocket with the next lower number sits at the reference mark.

In an endlessly rotating tool storage unit (e.g. a chain-type magazine), thelocation with the highest identification number will follow at the referencemark after "Location 1" has been reached.

Similarly, with a non-endlessly rotating tool storage unit (e.g. a linearmagazine), the location with the highest identification number will bebrought to the reference mark after "Location 1" has been reached.

Designation

Function

Designation

Function



If the tool axis is not in a fixed magazine or turret location, the locationnext to the last valid fixed location is approaching upon jogging.

If the nonuniform tool location distribution has been activated with processparameter Bxx.072 "Page No. for variable position of locations", specialregulations (refer to section "Magazine Jog Mode with Variable ToolLocations "PxxC.MGJGn"") apply to the jogging of tool axes)

Magazine Jog Mode with Variable Tool Locations"PxxC.MGJGn"

PxxC.MGJGn = Process xx Command Magazine Jogging Mode Bit n

2 control signals PLC → NC

PxxC.MGJG0

PxxC.MGJG1

Valid in all process modes.

If reference to a machine data page (MDP) for nonuniform tool locationdistribution has been activated with process parameter Bxx.072 (100 …299) "Page No. for variable position of locations", the following specialregulations apply to the jogging of tool axes :

• The jogging of tool axes refers to one of the four change positions P1-P4 (see Fig. 4-11) that have been freely defined in the user machinedata page. Instead of the firmly defined positions for the changepositions with the parameters Bxx.021..Bxx.024, the values of themachine data page are used.

• Using process control signals PxxC.MGJG0 and PxxC.MGJG1, thePLC defines the change position P1-P4 to which the jogging commandrefers.

The following table shows the effects of the two control signalsPxxC.MGJG0 and PxxC.MGJG1:

PxxC.MGJG1 PxxC.MGJG0Magazine jogging refers to change

position …

0 0 Axis position for changing position P1



1 1 Axis position for changing position P4PxxC_MGJGn_V22_20021126.xls

Fig. 4-10: Effect of PxxC.MGJG0 and PxxC.MGJG1

• With process control signals PxxC.MGPOS (Positive jogging) /PxxC.MGNEG (Negative jogging), the next/previous tool location ismoved to the selected position.

Designation

Function



Machine data page (MDP)

Control variable LV1 Value Meaning

-4 360 Axis position for changing position P4




0 Axis position for home position (MHP)

1 40 Axis position for magazine location 1









10 360 Axis position for magazine location 10Bxx_072_Werkzeugwechselposition_variable_V22_20030123.xls

Fig. 4-11: Example of a user machine data page for Bxx.072

The words "previous" and "next" tool location refer to the control variablenumber of the tool location.

• After changing of the change position (e.g. P1→P2, P2 ? P1) andsubsequent jogging, the tool location with the control variable numberwhich follows the last valid fixed location (in respect of the old changeposition, depending of the jog direction) is moved to the new changeposition. Accordingly, moving the tool storage unit by several toolpositions is possible.

Note: Upon activation of the variable locations for NC controlled toolmagazines, the parameters Bxx.021..Bxx.024 "Position 1..4”cease to have an effect. Instead, the logic positions 1 to 4 areread from the machine data page defined in the processparameter Bxx.072 "Page no. for variable locations” [travelvariable –4 (position 4)... -1 (position 1)].

Example



Actual Position "PxxC.MGAP"

PxxC.MGAP = Process xx Command Magazine Actual Position


PxxC.MGAP Actual position

Valid in all modes.

Note: Only required for PLC-controlled tool magazines.

The PLC employs this interface signal to inform tool management of thecurrent position of the tool magazine in relation to the reference mark.

With PLC-controlled tool magazines, position control must beimplemented in the PLC. For this purpose, the PLC tool managementtransfers the command position in the "PxxS.MGCP" interface signal andemploys the "MMV"" PLC function to indicate a necessary movement.The PLC must then ensure on its own that the specified commandposition is reached without delay.

While the tool magazine is moving, the PLC must employ the"PxxC.MGAP"" control signal for continually notifying tool management ofthe actual position.

Once the tool magazine has reached the command position (commandposition = actual position), the PLC must use the "MMV_Q" function toacknowledge that state to tool management.

Note: After the "MMV" motion command has been acknowledged,tool management does not verify whether the commandposition has actually been reached.

In a subsequent tool transfer between the magazine and thespindle/gripper, tool management always uses the locationthat is returned in "PxxC.MGAP" for the logical tool transfer.

Designation

Function



Tool Storage Unit Status SignalsTool management employs status signals to provide the PLC withinformation about the status of the tool magazine, regardless of the toolmagazine's drive mode. The following status signals are available:

Tool magazine status signals V22_20021104

Signal Meaning

Enabling the tool magazinePxxS.MGENA

Process xx Status Magazine Enable

Requesting the tool storage unit from the NC PxxS.MGREQ

Process xx Status Magazine Request

Tool storage unit in motion PxxS.MGMOV

Process xx Status Magazine Move

Tool storage unit in program or manual mode PxxS.MGMAN

Process xx Status Magazine Mode Manual

Tool magazine in home position PxxS.MGBP

Process xx Status Magazine Base Position

Command position PxxS.MGCP

Process xx Status Magazine Command Position

Life count monitoring: tool worn out PxxS.MGTWO

Process xx Status Magazine Tool Worn Out

Life count monitoring: warning limit reached PxxS.MGWRN

Process xx Status Magazine Warning

Tool error status PxxS.MGERR

Process xx Status Magazine Error

Wz_speicher_statussignale_V22_klein_20021104.xls

Enabling the Tool Magazine "PxxS.MGENA"

PxxS.MGENA = Process xx Status Enable for Magazine

Status signal NC → PLC

PxxS.MGENA = 0: No motion permittedPxxS.MGENA = 1: Motion for tool magazine enabled

Valid in all modes.

Only required for PLC-controlled tool magazines. The signal is set to logic"1" when a movement is initiated via tool management.

Tool management can employ the "PxxS.MGENA" status signal to stop amovement of the tool magazine and the sequence of the tool changingprocess at any time. Reasons to do this may come from a safety device(such as a guard door) that causes a "PxxC.MGENA" control signal to beissued to tool management. An error, removing the process enablingsignal, or an internal immediate stop (e.g. by changing the mode) mayalso cause the "PxxSMGENA" enabling signal to be removed.

Designation

Function



Note: In the case of PLC-controlled tool magazines and in all toolchanging processes, the "PxxS.MGENA" signal must be takeninto account in all interconnections which initiate a movement(e.g. actuating the valves which release a movement).Movement may occur only if the "PxxS.MGENA" release isactive.

Using the enabling signals:

NC-controlledmagazine

PLC-controlledmagazine

tool changer

safety device

motioninterruption

motioninterruption

e.g. guard dooropen

axis release

PxxSMGENA

PxxCMGENA

internal immediatestop

error

process release

axis module

PLCtool

managementmotioninterruption

2-50.FH7

Fig. 4-12: Enabling the tool magazine

Tool Magazine Request from NC "PxxS.MGREQ"

PxxS.MGREQ = Process xx Status Magazine Request


PxxS.MGREQ = 0: No request from the NCPxxS.MGREQ = 1: NC requires tool magazine

Valid in all modes.

The "PxxS.MGREQ" status signal is set if a tool magazine movementcommand addresses tool management within an executing program.

Designation

Function



Tool magazine request from the NC:

tool management

TCH, TSM, TMS,BST/RET

MEN > = 1

PLC

PxxS.MGREQNC requires tool

storage unit

motion command for tool storage unit

MTP; MMP; MFP; MOP; MHP; MRF

CONTROL RESET

S

R

2-51.FH7

Fig. 4-13: Requesting the tool magazine

During program mode, the "MEN" (Magazine enable), "BST" and "RET"command can be used for resetting the tool magazine request.

A control reset after a program stop also clears the tool magazine requestfrom tool management.

The PLC is only able to switch the tool magazine of a process to manualmode after the "NC needs tool magazine" request signal has beenremoved.

Tool Magazine in Motion "PxxS.MGMOV"

PxxS.MGMOV = Process xx Status Magazine Move


PxxS.MGMOV = 0: Tool magazine is at standstillPxxS.MGMOV = 1: Tool magazine is in motion

Valid in all modes.

The "PxxS.MGMOV" status signal is output whenever the tool magazineis moving. It is insignificant whether the movement has been initiated byan NC instruction or by a control signal from the PLC.

Tool management ignores any new PLC tool storage unit commands aslong as this status signal is active.

Tool Magazine in Program or Manual Mode"PxxSMGMAN"

PxxS.MGMAN = Process xx Status Magazine Manual


PxxS.MGMAN = 0: Tool magazine is allocated to the NCPxxS.MGMAN = 1: Tool magazine is allocated to the PLC

Valid in all modes.

Designation

Function

Designation



The "PxxS.MGMAN" status signal indicates whether or not the toolmagazine control has really been transferred to the PLC.

Tool management sets the "PxxS.MGMAN"signal when the PLC sets the"Tool magazine is to be moved manually" request signal ("PxxC.MGMAN"control signal), and there is no tool magazine request ("PxxS.MGREQ"status signal") from the NC at the same time.

Tool Magazine is in Basic Position "PxxS.MGBP"

PxxS.MGBP = Prodess xx Status Magazine is in Base Position


PxxS.MGBP = 0: The tool magazine is not in its basic positionPxxS.MGBP = 1: The tool magazine is in its basic position

Valid in all modes.

The "PxxS.MGBP" status signal is output when the tool magazine is in itsbasic position (location 1 at the reference mark).

This signal may be used for enabling machining if machining is possibleonly when the tool magazine is in its basic position (e.g. a tool magazinethat is swiveled into the working space).

Command Position "PxxS.MGCP"

PxxS.MGCP = Process xx Status Magazine Command Position


PxxS.MGCP command position

Valid in all modes (except with NC command "MMA").

Note: Only required for PLC-controlled tool magazines.

The tool management function employs the "PxxS.MGCP" storage unit totransfer to the PLC the command position (relative to the reference mark)which the PLC must adopt when it is told to do so via the "MMV" motionfunction.

The PLC must then ensure on its own that the specified commandposition is reached without delay.

While the tool magazine is moving, the PLC must employ the"PxxC.MGAP"" control signal for continually notifying tool management ofthe actual position.

Once the tool magazine has reached the command position (commandposition = actual position), the PLC must use the "MMV_Q" command toacknowledge the completion of the movement to the tool managementfunction.

Function

Designation

Function

Designation

Function



Command and actual position of PLC-controlled tool magazines:

MMV

command position

actual positiontool

managementtool storage

unit

MMV_Q

PLC

2-52.FH7

Fig. 4-14: Command and actual position of PLC-controlled tool magazines:

A PLC-controlled turret has 8 locations. Each location contains a tool.

Positioning a tool:

POS11

2

34

5

6

78

12

3

4

56

7

8

T3 MMP(3,0)

referencemark

referencemark

POS3 POS3

POS2 POS2POS1

T254T238

T125

T125

T238

T254

T91

T91

T831

T831T238

T121

T121

T238+

+

Mmp.FH7

Fig. 4-15: Positioning of a tool

The "T91 MTP (2)" command in the NC program calls up the "T91" IDcutting tool and puts it in working position.

Tool management first locates the tool in the magazine. Then itdetermines the command position relative to the reference mark thatmust be transferred to the PLC in order to get the "T91" tool to machiningposition "1".

To get the "T91" tool to position "2", tool management transfers location 6as the command position to the "PxxS.MGCP" interface signal and setsthe "MMV" command.

During the swiveling process, the PLC employs the "PxxC.MGAP" signalto continually update the current location in relation to the reference mark.

Once positioning has been completed, the PLC employs the "MMV_Q"standard interface function for acknowledgment.

Example



Life Monitoring: Tool Worn Out "PxxS.MGTWO"

PxxS.MGTWO = Process xx Status Magazine Tool Worn Out


PxxS.MGTWO = 0: The tools can still be usedPxxS.MGTWO = 1: At least one tool is worn out

Valid in all modes.

Effect of the "tool worn out" signal:

��

��

��

�� !"#$

�� !%&&

�� ' ��(��)

*�"+&%"

�� ,��&��,'��-%.&)

��'-%/(��)

�

&0�1��

�

&

2

2-54.FH7

Fig. 4-16: Effect of the signal ”Tool worn out”

Tool management sets the PxxS.MGTWO signal when there is at leastone non-empty alternate tool sequence where all the tools are worn. If all the non-empty alternate tool chains have at least one unworn tool,PxxS.MGTWO is cleared.If all alternate tool chains are empty, PxxS.MGTWO is also cleared.

The signal is updated:





• when a tool is canceled using T0 (tool storage unit = turret or no toolstorage unit present).

• when modifying the data of a tool with PLC function moduleTLD_WRor with NC command TLD

• when deleting a tool with PLC function module TL_DELETE or via theinterface,

• when resetting a tool to a remaining level time of 100% with PLCfunction module TL_RESET or via the interface, and

• upon online modification of a tool's data via the interface.

Designation

Function



Together with setting the "Tool worn out" signal, the tool managementsets the "PxxS.MGERR" tool error status.

Note: Until Firmware version 21VRS, both interface signalsPxxS.MGTWO and PxxS.MGWRNwere generally reset duringequipment check, also if for example all tools of an alternatetool chain were worn out. As of Firmware version 22VRS, thebehavior of both interface signals changed as follows:

• Both signals PxxS.MGTWO and PxxS.MGWRN alwaysrepresent the current state of the non-empty alternate toolchains.

• Prior to updating PxxS.MGWRN and PxxS.MGTWO thetwo tool edge status bits "tool edge warning limit reached"and "tool edge worn out" for all tool edges of the processand the tool edge status bits "tool warning limit reached"and "tool worn out" have been addressed.

• In the equipment check, the two tool status bits "Toolwarning limit reached" and "Tool worn out" are initialized forall tools in the tool list; based on this, PxxS.MGWRNandPxxS.MGTWOare initialized.

Life Monitoring: Warning Limit Reached "PxxS.MGWRN"

PxxS.MGWRN = Process xx Status Magazine Tool Warning


PxxS.MGWRN = 0: Tool has not yet reached warning limitPxxS.MGWRN = 1: Tool has reached warning limit

Valid in all modes.

Tool management sets the PxxS.MGWRNsignal when there is at leastone non-empty alternate tool sequence where all the tools have reachedthe warning limit. If all non-empty related tool chains include at least one tool which has notyet reached the warning limit, PxxS.MGWRN is cleared.If all alternate tool chains are empty, PxxS.MGWRN is also cleared.

The signal is updated:





• when a tool is canceled using T0 (tool storage unit = turret or no toolstorage unit present).

• when modifying the data of a tool with PLC function moduleTLD_WRor with NC command TLD

• when deleting a tool with PLC function module TL_DELETE or via theinterface,

• when resetting a tool to a remaining level time of 100% with PLCfunction module TL_RESET or via the interface, and

• upon online modification of a tool's data via the interface.

Designation

Function



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2-55.FH7

Fig. 4-17: Effect of the signal ”Warning limit reached”

Note: Until Firmware version 21VRS, both interface signalsPxxS.MGTWO and PxxS.MGWRNwere generally reset duringequipment check, also if for example all tools of an alternatetool chain were worn out. As of Firmware version 22VRS, thebehavior of both interface signals changed as follows:

• Both signals PxxS.MGTWO and PxxS.MGWRN alwaysrepresent the current state of the non-empty alternate toolchains.

• Prior to updating PxxS.MGWRN and PxxS.MGTWO thetwo tool edge status bits "tool edge warning limit reached"and "tool edge worn out" for all tool edges of the processand the tool edge status bits "tool warning limit reached"and "tool worn out" have been addressed.

• In the equipment check, the two tool status bits "Toolwarning limit reached" and "Tool worn out" are initialized forall tools in the tool list; based on this, PxxS.MGWRNandPxxS.MGTWOare initialized.

Tool Error Status "PxxS.MGERR"

PxxS.MGERR = Process xx Status Magazine Error


PxxS.MGERR = 0: No errorPxxS.MGERR = 1: There is an error

Valid in all modes.

Tool management employs this signal to inform the PLC about alldetected errors.

The "Tool error status" signal is set when

• the last tool in a group of alternate tools is worn out at program end;

• the tools in the magazine do not match the specifications in the setuplist; or

• a tool cannot be found when it is called via the "T word".

After the next "BST" or "RET", at the latest, the "Pxx.SMGERR" statussignal leads to setting of the "PxxS.ERROR" process error.

Effect of the "Tool error status" signal:

Designation

Function



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Fig. 4-18: Effect of the signal ”Tool error status”

The signal is only cleared after the next equipment check, when an NCprogram without a setup list is started, or when a "clear fault" or "controlreset" is issued.

An equipment check is performed whenever a different or a modifiedsetup or tool list is loaded into the MTC 200 or storage changeover isperformed.



4.2 Magazine Functions

With NC-controlled tool magazines, moving the tool magazine does notrequire any programming in the PLC. Merely the signals within the PLC-NC interface must be connected (e.g. jogging the tool magazine,enabling).

With a PLC-controlled tool magazine, homing and moving to a newlocation must both be programmed.

The tool magazine interface between PLC and NC must always beconnected, irrespective of the axis or tool magazine type.

Tool Storage Unit Motion Commands of the PLCThe PLC program permits different tool magazines and tool changers tobe adapted to the MTC 200 . Handling these modules is supported byBosch Rexroth standard functions.

Control logicof the tool

management

Axis module

NC-controlledtool storage

unit

Position Location

Tool storage unitmotion commands

MTPMMPMFPMOPMRFMHPMENMMAMRY

Tool storage unitcontrol and

status signals

PxxC.MGHOM PxxC.MGBP PxxC.MGMOV

:

NC PLC

Toolmanagement

Control logicMRFMMV

PLC-controlledtool storage unit

2-45.FH7

Fig. 4-19: General method of operation of the motion control of a toolmagazine

The NC instruction set provides commands for changing tools andmoving the tool magazine.



Either the NC itself (NC axis) or the PLC controls the movements of a toolmagazine.

If the tool storage unit is moved via the PLC, the "MRF" and "MMV"standard functions in the PLC interpret the type of the movement.

The "MRF" standard function initiates tool magazine homing. The"MRF_Q" standard function notifies the NC of the acknowledgment ofsuccessful tool magazine homing.

Homing the tool magazine by the PLC:

NC program tool management PLC program

MRF MRF

MRY MRF_Q

6-1.FH7

Fig. 4-20: Homing of tool magazine

If a tool magazine is to move to a new location, this is interpreted by the"MMV" standard function. The command position of the correspondingtool is transferred in the NC-PLC interface.

The PLC employs the "MMV_Q" standard function for reporting theacknowledgment of successful positioning.

Positioning the tool magazine by the PLC:

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6-2.FH7

Fig. 4-21: Positioning of tool magazine

Depending on the mechanical structure, changing tools is programmed indifferent ways. Special tool changing standard functions exist for thispurpose.

Homing

Positioning



The "TCH" standard function is used for interrogating the complete toolchanging process. Tools are changed between the tool magazine, gripperand spindle without any further action from the NC. The PLC programcontrols the entire tool changing procedure. The PLC employs the"TCH_Q" standard function for acknowledging the tool changing process.

If NC functions (such as axis movements) are necessary within the toolchanging process, the tool changing process is split up into smaller steps.

Changing tools is split up into the sub-steps of changing between toolmagazine and spindle and vice versa. The two tool changing directionsare sensed by the "TMS"" and "TSM" standard functions. The "TMS_Q"and "TSM_Q" functions are used for acknowledging the execution of thetool changing process.

Magazine Homing

Magazine Homing Interrogation "MRF"If the "MRF" NC command is used in the NC program for initiating toolmagazine homing, this can be evaluated in the PLC program by the"MRF" standard function.

MRF_1.bmp

Fig. 4-22: Homing of magazine

ACTIVE: 0 Function not active1 - Interrogation of NC command "Tool magazine homing"

PROC: Process number (0-6)

0 No NC command "Tool magazine homing" or function is not active1 NC command "Tool magazine homing" is active

Complete tool change

Tool change in sub-steps

Result of functionMRF



Magazine homing acknowledgment "MRF_Q"The "MRF_Q" standard function acknowledges tool magazine homing.

The "MRY" command can be used in the NC program for interrogatingthe execution of the tool magazine command.

MRF_Q.bmp

Fig. 4-23: Acknowledging homing of magazine

QUIT: 0 Function not active1 Acknowledgment of the NC command "Tool magazine homing"


0 NC command "Tool magazine homing" acknowledged or function is not active1 "NC command "Tool magazine homing" is acknowledged

"Tool Magazine Homing" Sequence between NC andPLC

NC ProgramProcess 1

( 1 )N010 MRF

( 5 )N011 MRY

PLC programProcess1

¦ (2) (3) ¦¦ +---------+ ¦¦ ¦MRF ¦ ¦+----------¦ACTIVE ¦ QMAGPOS ¦¦ 1 --¦PROC +-------------( ) ---------¦¦ +---------+ ¦¦ (4) ¦¦ +---------+ ¦¦ IREF ¦MRF_Q ¦ ¦+--¦ +-----¦QUIT ¦ X ¦¦ 1 --¦PROC +-------------( ) ---------¦¦ +---------+ ¦

Result of functionMRF_Q



Timing of tool magazine homing:

(1)NC command +----------------------------------------------------+MRF ----+ +--------

(2)PLC function +------------------------------------------------+MRF --------+ +--------

(5)PLC function +-----+MRF_Q ------------------------------------------------------+ +-----

(3)Output +------------------------------------------+QMAGPOS ------------+ +----------

(4)Input +-----------IREF ------------------------------------------------------+

Actual toolmagazinelocation xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx11111111111

(1) The "Tool magazine homing" (MRF) command is processed in theNC program and output to the PLC.

(2) The "MRF" standard function recognizes the NC homing command inthe PLC program.

(3) Tool magazine homing is initiated in the PLC program by setting theoutput.

(4) The "Homing switch" input shows the homing position of the toolmagazine. The movement is stopped and the NC homing commandis acknowledged.

(5) The "MRY" command in the NC program is used for interrogating thecompletion of tool storage unit homing.



Program by way of example: PLC-controlled, endlesslyrotating tool magazine

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Fig. 4-24: PLC-controlled, endlessly rotating tool magazine

Tool Magazine PositioningThe tool magazine must be moved to be able to utilize different tools inone working cycle and to move the programmed tool to the requiredlocation (tool change, loading or machining location).



Interrogation of New Magazine Location "MMV"If the NC program executes an NC command that causes the toolmagazine to move (e.g. "MTP", "MFP", etc.), this can be interpreted in thePLC program by the "MMV" standard function.

MMV.bmp

Fig. 4-25: Evaluating movement of magazine

ACTIVE: 0 Function not active1 Interrogation of NC command "Position tool magazine"


0 No NC command "Tool magazine positioning" or function is not active1 NC command "Tool magazine positioning" is active

Acknowledgment of new magazine location "MMV_Q"The "MMV_Q" standard function acknowledges the rotation of a toolmagazine". The NC command that initiates the movement was executedby the PLC program. The "MRY" command can be used in the NCprogram for interrogating the execution of the command.

MMV_Q.bmp

Fig. 4-26: Acknowledging movement of magazine

QUIT: 0 Function not active1 Acknowledgement of NC command "Position tool magazine"


0 NC command "Tool magazine positioning" acknowledged or function is notactive

1 NC command is acknowledged

Result of functionMMV

Result of functionMMV_Q



Sequence of Tool Magazine Positioning between NC andPLC

NC programProcess 1

( 1 )N010 T3 MTP

( 7 )N011 MRY

PLC programProcess1

¦ (2) (3) ¦¦ +---------+ ¦¦ ¦MMV ¦ ¦+----------¦ACTIVE ¦ QMAGPOS ¦¦ 1 --¦PROC +-------------( ) ---------¦¦ +---------+ ¦¦ Input Evaluation ¦+---¦ +---------------------- (4) ¦¦ Count impulse ¦¦ (5) +---------+ (6) ¦¦Comm.loc.-¦ = ¦ +---------+ ¦¦ ¦ ¦ ¦MMF_Q ¦ ¦¦ Act.loc.-¦ +----¦QUIT +- ¦¦ +---------+ 1-¦PROC ¦ ¦¦ +---------+

Timing of tool magazine positioning:

(1)NC command +----------------------------------------------------+T3 MTP ----+ +-------

(2)PLC function +------------------------------------------------+MMV --------+ +-------

(7)PLC function +-----+MMV_Q ------------------------------------------------------+ +----

(3)Output +-----------------------------------------+QMAGPOS ------------+ +---------

(7)Input ---------------+ +--+ +----------ICNT +-----------------+ +-----------------+

Actual toolmagazinelocation xxxxx33333333333333333333333333333333333333333333333333333333333333

Actual toolmagazinelocation 11111111111111111111111111111122222222222222222222222222223333333333

(1) The "T3 MTP"command is processed in the NC program and outputto the PLC.

(2) The "MMV" standard function is used for recognizing the toolmagazine rotation command in the PLC program.

(3) Tool magazine rotation is initiated in the PLC program by setting theoutput.

(4) A "Count cam" input sensing logic generates the current actual toolmagazine location.

(5) The programmed tool magazine location is reached when thecommand location and the actual location of the tool magazine arethe same.

(6) The tool magazine movement is stopped and the NC tool magazinecommand is acknowledged.

(7) The "MRY" command in the NC program is used for sensing thecompletion of the movement of the tool magazine to a new commandlocation.



Program by way of example: PLC-controlled, endlesslyrotating tool magazine

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Fig. 4-28: PLC-controlled, endlessly rotating tool magazine (continued)



4.3 Tool Change Functions

Tool change functions are required only if a magazine is used for tool storageand if tools must be exchanged (via grippers) between the spindle and themagazine during machining.

Tool change functions are not permitted in conjunction with turrets or insystems that employ only one spindle.

Due to the different mechanical structures of the tool changing systems,the tool changing process proper must always be implemented in thePLC. To support programming, the MTC 200 provides special tool changecommands.

A tool change process is always initiated in the NC program, executed inthe PLC, and acknowledged before NC block processing is continued.

The PLC employs the "TCH" command to interrogate a complete toolchange and performs it between magazine, gripper(s) and spindle withoutany further NC action.

The tool change sequence must be split into smaller steps if changingtools requires NC functions (such as axis movements) to be performed.

The "TMS" and "TSM" NC commands enable the PLC to sense the partialchange processes "Magazine-to-spindle tool change" and "Spindle-to-magazine tool change".

The PLC signals to the NC a successful completion of a complete orpartial change processes by means of a corresponding acknowledgmentsignal. When the NC has issued for example the TMS command, the PLCfirst has to confirm acknowledgment with TMS_Q before the NCcontinues with the next block.

Processing of tool change commands in the PLC always consists of thefollowing sub-steps:

1. Interrogate NC Commands,

2. Initiate and interrogate mechanical actions, e.g. "Clamp tool";

3. Signal logic tool transfer to tool management by means of the tooltransfer functions;

4. Acknowledge the NC command.

The interface functions explained below must explicitly be used for eachprocess requiring tool management.

Complete Tool ChangeIn the NC program, the general tool change not subdivided into NCprogram sub-steps is initiated with the “TCH”command. The entirechange process is performed when this command is programmed. Thenext command in the NC program will be executed only after the toolchange has been performed and acknowledged.

In the PLC program, the change process is split into partial processes.The tool transfer commands are used for notifying the MTC 200 of thecurrent tool location (e.g. spindle, magazine). The "TCH" command isacknowledged only after the entire change process has been completed.

Tool change functions onlyallowed for magazines

Start through the NC program

Handling and acknowledgmentin the PLC



Complete Tool Change "TCH"The "TCH" standard function in the PLC program permits a complete toolchange "TCH" that is active in the NC program to be interrogated.

TCH.bmp

Fig. 4-29: Interrogate tool change

ACTIVE: 0 Function not active1 Interrogation of "Complete tool change"

PROC: Process number (0-6)POS: Position (1-4)SPINDLE: Spindle number (1-3)

0 No "Complete tool change" or function is not active1 NC command "Complete tool change" is active

Complete tool change acknowledgment "TCH_Q"The "TCH_Q" standard function in the PLC program is used foracknowledging the execution of the complete tool change. This completeshandling of the tool change in the PLC, i.e. all mechanical processes (e.g.unclamp tool, clamp tool) and all logic tool transfer commands have beenterminated. The NC program is continued when the tool change isacknowledged.

TCH_Q.bmp

Fig. 4-30: Acknowledging a complete tool change

QUIT: 0 Function not active1 Acknowledgment "Complete tool change"


0 NC command "Tool change from magazine to spindle" acknowledged orfunction is not active

1 NC command "Tool change from magazine to spindle" is acknowledged

Result of functionTCH

Result of functionTCH_Q



Complete tool change sequence

NC programProcess 1

( 1 )N010 TCH

( 7 )N011 ...

...

PLC programProcess1

¦ ¦¦ +---------+ ¦¦ ¦TCH ¦ (2) ¦+-----------------------------¦ACTIVE +------+ ¦¦ 1 --¦PROC ¦ ¦ ¦¦ +---------+ ¦ ¦¦ +---------------------+ ¦¦ ¦ initiates complete ¦ (3)¦ +--------- tool change ¦¦ ¦¦ +-------------------------------------------+ ¦¦ ¦ physical and ¦ ¦ (4)¦ ¦ logical tool change ¦ ¦¦ +-------------------------------------------+ ¦¦ ¦¦ complete tool ------------------------+ ¦ (5)¦ change executed ¦ ¦¦ +----------------------------+ ¦¦ ¦ +---------+ ¦¦ ¦ ¦TCH_Q ¦ ¦ (6)¦ +-----------¦QUIT +-- ¦¦ 1 --¦PROC ¦ ¦¦ +---------+ ¦

Timing of complete tool change:

(1)NC command +----------------------------------------------------+TCH ----+ +--------

(2)PLC function +------------------------------------------------+TCH --------+ +--------

(6) (7)PLC function +-----+TCH_Q ------------------------------------------------------+ +-----

(3) (4)Tool changing +---------------------------------------------+proc. running --------+ +-----------

(5)Ready message Tool change +-----------completed ------------------------------------------------------+

(1) In the NC program, the complete tool change is initiated by the "TCH"command and output to the PLC. The NC program now waits until thePLC acknowledges the tool change.

(2) The "TCH" standard function permits the complete NC tool change tobe recognized in the PLC program.

(3) The tool change sequence is initiated in the PLC program.

(4) Usually, the sequence of a complete tool change consists of severalactions (e.g. open/close gripper, clamp/unclamp clamping device inspindle) and of tool transfer messages to tool management (see tooltransfer functions).

(5) The complete tool change has been performed. This can be checkedin the PLC program using feedback messages (end positions).

(6) The "TCH_Q" standard function is used for acknowledging the NCtool change command.



(7) The NC program recognizes the completion of the complete toolchange. The NC program is continued.

Magazine-to-Spindle Tool ChangeBesides the complete tool change command "TCH" , the NC instructionset contains special tool change commands. Tool change is subdividedinto several single steps initiated by the NC between magazine, gripperand spindle, or directly between magazine and spindle.

On the NC side, the entire tool change process can be split into individualsteps (such as "clamp/unclamp tool", magazine movements to approacha new tool, or axis and spindle movements in the magazine).

PLC interface functions for tool transfer messages are used for notifyingtool management of the tool location. A further interface function is usedin the PLC program for acknowledging the completion of the tool changeprocess.

Interrogation of the Magazine-to-Spindle Tool Change"TMS"In the PLC program, the standard “TMS” function is used to interrogatewhether a tool change between magazine and spindle “TMS” is active.

TMS.bmp

Fig. 4-31: Evaluating a magazine-to-spindle tool change

ACTIVE: 0 Function not active1 Interrogation "Magazine-to-spindle tool change"


0 No "Magazine-to-spindle tool change" or function is not active1 NC command "Magazine-to-spindle tool change" is active.

Result of functionTMS



Acknowledgment of Magazine-to-Spindle Tool Change"TMS_Q"The "TMS_Q" standard function is used in the PLC program foracknowledging the completion of the magazine-to-spindle tool change.This completes tool change processing in the PLC. The NC program iscontinued when the tool change is acknowledged.

TMS_Q.bmp

Fig. 4-32: Acknowledging a magazine-to-spindle tool change

QUIT: 0 Function not active1 Acknowledgement "Magazine-to-spindle tool change"


0 NC command "Tool change from magazine to spindle" has already beenacknowledged or function is not active

1 NC command "Tool change from magazine to spindle" is acknowledged

Magazine-to-Spindle Tool Change Sequence

NC programProcess 1

( 1 )N010 TMS

( 7 )N011 ...

...

PLC programProcess1

¦ ¦¦ +---------+ ¦¦ ¦TMS ¦ (2) ¦+-----------------------------¦ACTIVE +------+ ¦¦ 1 --¦PROC ¦ ¦ ¦¦ +---------+ ¦ ¦¦ +---------------------+ ¦¦ ¦ Initiates tool ¦ (3)¦ +--------- ch. from mag. ¦¦ to spindle ¦¦ +-------------------------------------------+ ¦¦ ¦ physical and ¦ ¦ (4)¦ ¦ logical tool change ¦ ¦¦ +-------------------------------------------+ ¦¦ ¦¦ Magazine-to-spindle -----------------------+ ¦ (5)¦ tool change executed ¦ ¦¦ +----------------------------+ ¦¦ ¦ +---------+ ¦¦ ¦ ¦TMS_Q ¦ ¦ (6)¦ +-----------¦QUIT +-- ¦¦ 1 --¦PROC ¦ ¦¦ +---------+ ¦

Result of functionTMS_Q



Timing of magazine-to-spindle tool change:

(1)NC command +----------------------------------------------------+TMS ----+ +--------

(2)PLC function +------------------------------------------------+TMS --------+ +--------

(6) (7)PLC function +-----+TMS_Q ------------------------------------------------------+ +-----



(1) In the NC program, the magazine-to-spindle tool change is initiated bythe "TMS" command and output to the PLC. The NC program nowwaits until the tool change is acknowledged.

(2) The "TMS" standard function in the PLC program recognizes themagazine-to-spindle tool change.

(3) A tool change sequence is initiated in the PLC program.

(4) Usually, a magazine-to-spindle tool change sequence consists of anaction (e.g. clamping the clamping device in the spindle) and a tooltransfer message to tool management (see tool transfer functions).

(5) The magazine-to-spindle tool change has been completed. This canbe checked in the PLC program using feedback messages.

(6) The "TMS_Q" standard function is used for acknowledging the NCtool change command.

(7) The NC program recognizes the completion of the magazine-to-spindle tool change. The NC program is continued.



Interrogation of Spindle-to-Magazine Tool Change "TSM"In the PLC program, the standard “TSM” function is used to interrogatewhether a tool change between spindle and magazine “TSM” is active.

TSM.bmp

Fig. 4-33: Evaluating a spindle-to-magazine tool change

ACTIVE: 0 Function not active1 Interrogation "Spindle-to-magazine tool change"

PROC: Process number (0-6)SPINDLE: Spindle number (1-3)POS: Position (1-4)

0 No "Spindle-to-magazine tool change" or function is not active1 NC command "Spindle-to-magazine tool change" is active

Acknowledgment of Spindle-to-Magazine Tool Change"TSM_Q"

The "TSM_Q" standard function is used in the PLC program foracknowledging the completion of the spindle-to-magazine tool change.With this step, the tool change process in the PLC is terminated, i.e. themechanical actions and logic tool transfer functions required to effect atool change have been completed. The NC program is continued whenthe tool change is acknowledged.

TSM_Q.bmp

Fig. 4-34: Acknowledging a spindle-to-magazine tool change

QUIT: 0 Function not active1 Acknowledgement "Spindle-to-magazine tool change"

PROC: Process number (0-6)SPINDLE: Spindle number (1-3)POS: Magazine position offset (1-4)

0 NC command "Spindle-to-magazine tool change" acknowledged or function isnot active

1 NC command "Spindle-to-magazine tool change" is acknowledged

Result of functionTSM

Result of functionTSM_Q



Spindle-to-Magazine Tool Change Sequence

NC programProcess 1

( 1 )N010 TSM

( 7 )N011 ...

...

PLC programProcess1

¦ ¦¦ +---------+ ¦¦ ¦TSM ¦ (2) ¦+-----------------------------¦ACTIVE +------+ ¦¦ 1 --¦PROC ¦ ¦ ¦¦ +---------+ ¦ ¦¦ +---------------------+ ¦¦ ¦ Initiates tool ¦ (3)¦ +--------- ch. from spin.¦¦ to magazine ¦¦ +-------------------------------------------+ ¦¦ ¦ physical and ¦ ¦ (4)¦ ¦ logical tool change ¦ ¦¦ +-------------------------------------------+ ¦¦ ¦¦ Spindle-to-magazine -----------------------+ ¦ (5)¦ tool change executed ¦ ¦¦ +----------------------------+ ¦¦ ¦ +---------+ ¦¦ ¦ ¦TSM_Q ¦ ¦ (6)¦ +-----------¦QUIT +-- ¦¦ 1 --¦PROC ¦ ¦¦ +---------+ ¦

Timing of spindle-to-magazine tool change:

(1)NC command +----------------------------------------------------+TSM ----+ +--------

(2)PLC function +------------------------------------------------+TSM --------+ +--------

(6) (7)PLC function +-----+TSM_Q ------------------------------------------------------+ +-----



(1) In the NC program, the spindle-to-magazine tool change is initiated bythe "TSM" command and output to the PLC. The NC program nowwaits until the tool change is acknowledged.

(2) The "TSM" standard function permits the NC tool change commandto be recognized in the PLC program.

(3) A tool change sequence is initiated in the PLC program.

(4) Usually, a spindle-to-magazine tool change sequence consists of anaction (e.g. unclamping the clamping device in the spindle) and a tooltransfer message to tool management (see tool transfer functions).

(5) The spindle-to-magazine tool change has been completed. This canbe checked in the PLC program using feedback messages.

(6) The "TSM_Q" standard function is used for acknowledging the NCtool change command.



(7) The NC program recognizes the completion of the spindle-to-magazine tool change. The NC program is continued.

4.4 Tool Transfer Functions

Tool transfer functions are used for the logic (administrative) transfer oftools between magazine, gripper and spindles.

Tool Transfer OperationMTC 200 tool management monitors the current location of the tools of aprocess. Besides being in a magazine pocket or in a spindle, a tool canbe in a gripper during the tool changing process.

Any transport of a tool between these locations that is initiated by the PLCprogram must be reported to tool management via the tool transfercommands.

The mechanical tool transfers are always initiated by tool transferstandard functions in the PLC (e.g. clamping or unclamping of toolclamping devices in spindles; opening or closing grippers).

The tool transfer messages from the PLC notify NC tool management ofthe transfer of a tool. A defined handshake procedure between PLC andNC that employs the tool transfer function eventually leads to a logicexchange of the tools in tool management.

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ToolTransfer.FH7

Fig. 4-35: Method of operation of a tool transfer

The following table gives an overview of the tool transfer options:

Tool transfer

from to ABBREVIATION

Magazine Spindle XMS

Magazine Gripper XMG

Spindle Magazine XSM

Spindle Gripper XSG

Gripper Magazine XGM

Gripper Spindle XGSWerkzeugtransferbefehle_V22_20021126.xls

Fig. 4-36: Overview of tool transfer commands

There are standard interface functions available for tool transfer. The"XMS" standard function (magazine-to-spindle tool transfer) in the PLCprogram initiates the tool transfer from the magazine to the spindle.

Example



The tool management function checks the requested tool transfer forerrors. The "XMS_NA" standard function (no permission for magazine-to-spindle tool transfer) permits errors to be interrogated.

A tool transfer is completed by the "XMS_Q" ("magazine-to-spindle tooltransfer terminated" acknowledgment) standard function in the PLCprogram.

The "XMS_CA" (abort magazine-to-spindle tool transfer) standardfunction permits incorrect tool transfers to be aborted.

The following sections give a more detailed description of the sequence oftool transfer functions using magazine-to-spindle tool transfer as anexample.

Tool Transfer Procedure and Function Modules

Magazine-to-Spindle Tool Transfer "XMS"With the “XMS“ standard function, the magazine-to-spindle tool transferwith respect to data processing is initiated in the PLC program, i.e. thePLC announces a tool transfer to the tool management function. The toolmanagement function checks the requested tool transfer and reports theresult to the PLC.

XMS.bmp

Fig. 4-37: Interrogating a magazine-to-spindle tool transfer

ACTIVE: 0 Function not active1 Initiate magazine-to-spindle tool transfer


0 Function is not active ("INIT"=0), or magazine-to-spindle tool transfer hasbeen initiated

1 Magazine-to-spindle tool transfer is initiated

Result of functionXMS



Magazine-to-Spindle Tool Transfer Permitted "XMS_PA"The tool management function checks a requested tool transfer withrespect to data processing and reports the result to the PLC. The"XMS_PA" standard function in the PLC program enables the feedbackmessage "tool transfer permitted" to be interrogated.

XMS_PA.bmp

Fig. 4-38: Interrogating a tool transfer permission

ACTIVE: 0 Function not active1 Interrogation of "Magazine-to-spindle tool transfer permitted"


0 Function is not active ("ACTIVE"=0) or magazine-to-spindle tool is notpermitted

1 Magazine-to-spindle tool transfer is permitted

Magazine-to-Spindle Tool Transfer not Permitted"XMS_NA"The tool management function checks a requested tool transfer withrespect to data processing and reports the result to the PLC. Any errorcaused by the requested tool transfer can be interrogated with the"XMS_NA" standard function.

XMS_NA.bmp

Fig. 4-39: Interrogating a tool transfer permission

ACTIVE: 0 Function not active1 Interrogation of "Magazine-to-spindle tool transfer is not permitted"


0 Function is not active ("ACTIVE"=0) or magazine-to-spindle tool transfer ispermitted.

1 Magazine-to-spindle tool transfer is not permitted

Result of functionXMS_PA

Result of functionXMS_NA



Acknowledgment of Magazine-to-Spindle Tool Transfer"XMS_Q"A tool transfer with respect to data processing that has been permittededby the tool management function is terminated by the "XMS_Q" standardfunction in the PLC program.

XMS_Q.bmp

Fig. 4-40: Acknowledging a tool transfer

ACTIVE: 0 Function not active ("QUIT"=0)1 Terminate magazine-to-spindle tool transfer


The "QUIT" input is passed on.

Aborting Magazine-to-Spindle Tool Transfer "XMS_CA"The "XMS_CA" standard function permits the tool transfer with respect todata processing to be aborted in the event of a malfunction during thetransfer.

XMS_CA.bmp

Fig. 4-41: Aborting a tool transfer

ACTIVE: 0 Function not active1 Abort magazine-to-spindle tool transfer


The "CANCEL" input is passed on.

Result of functionXMS_Q

Result of functionXMS_CA



Tool transfer sequence

+----------------------+ +-----------------------------------------------+¦ Tool management ¦ ¦ PLC program ¦¦ Process 1 ¦ ¦ Process 1 ¦¦ ¦ ¦ ¦ ¦ ¦¦ ¦ ¦ ¦ (1) ¦ ¦¦ ¦ ¦ ¦ +---------+ ¦ ¦¦ ¦ ¦ ¦ ¦XMS ¦ ¦ ¦¦ ¦ ¦ +----------¦INIT ¦ ¦ ¦¦ ¦ ¦ ¦ 1--¦PROC ¦ ¦ ¦¦ ¦ ¦ ¦ 1--¦POS ¦ MXMS ¦ ¦¦ ¦ ¦ ¦ 1--¦SPINDLE +--------------( )---¦ ¦¦ (2) ¦ ¦ ¦ +---------+ ¦ ¦¦ +-----------¦-----¦--¦---------------+ ¦ ¦¦ +----------------+ ¦ ¦ ¦ ¦ ¦¦ ¦Tool management ¦ ¦ ¦ ¦ ¦ ¦¦ ¦checks ¦ ¦ ¦ ¦ ¦ ¦¦ ¦requested ¦ ¦ ¦ ¦ ¦ ¦¦ ¦tool transfer ¦ ¦ ¦ ¦ ¦ ¦¦ ¦of the PLC ¦ ¦ ¦ ¦ ¦ ¦¦ +----------------+ ¦ ¦ ¦ ¦ ¦¦ ¦ +--------¦-----¦--¦---------------+ ¦ ¦¦ ¦ ¦ ¦ ¦ +---------+ ¦ ¦¦ ¦ ¦ ¦ ¦ ¦XMS_PA ¦ (3) ¦ ¦¦ ¦ ¦ ¦ +----------¦ACTIVE ¦ ¦ ¦¦ ¦ ¦ ¦ ¦ 1--¦PROC ¦ ¦ ¦¦ ¦ ¦ ¦ ¦ 1--¦POS ¦ MXPA ¦ ¦¦ ¦ ¦ ¦ ¦ 1--¦SPINDLE +--------------( )---¦ ¦¦ ¦ ¦ ¦ ¦ +---------+ ¦ ¦¦ +-----------¦-----¦--¦---------------+ ¦ ¦¦ ¦ ¦ ¦ +---------+ ¦ ¦¦ ¦ ¦ ¦ ¦XMS_NA ¦ (4) ¦ ¦¦ ¦ ¦ +----------¦ACTIVE ¦ ¦ ¦¦ ¦ ¦ ¦ 1--¦PROC ¦ ¦ ¦¦ ¦ ¦ ¦ 1--¦POS ¦ MXNA ¦ ¦¦ ¦ ¦ ¦ 1--¦SPINDLE +--------------( )---¦ ¦¦ ¦ ¦ ¦ +---------+ ¦ ¦¦ ¦ ¦ ¦ ¦ ¦¦ ¦ ¦ ¦ +---------+ ¦ ¦¦ ¦ ¦ ¦ MXPA ¦XMS_Q ¦ (5) ¦ ¦¦ ¦ ¦ +-( )------¦QUIT ¦ ¦ ¦¦ ¦ ¦ ¦ 1--¦PROC ¦ ¦ ¦¦ ¦ ¦ ¦ 1--¦POS ¦ X ¦ ¦¦ ¦ ¦ ¦ 1--¦SPINDLE +--------------( )---¦ ¦¦ (6) ¦ ¦ ¦ +---------+ ¦ ¦¦ +-----------¦-----¦--¦---------------+ ¦ ¦¦ +----------------+ ¦ ¦ ¦ ¦ ¦¦ ¦Tool management ¦ ¦ ¦ ¦ ¦ ¦¦ ¦executes ¦ ¦ ¦ ¦ ¦ ¦¦ ¦requested ¦ ¦ ¦ ¦ ¦ ¦¦ ¦tool transfer ¦ ¦ ¦ ¦ ¦ ¦¦ ¦of the PLC ¦ ¦ ¦ ¦ ¦ ¦¦ +----------------+ ¦ ¦ ¦ ¦ ¦¦ ¦ ¦ ¦ ¦ ¦¦ ¦ ¦ ¦ ¦ ¦¦ ¦ ¦ ¦ +---------+ ¦ ¦¦ ¦ ¦ ¦ CLRERR MXNA ¦XMS_CA ¦ (7) ¦ ¦¦ ¦ ¦ +-+ +------+ +-----¦CANCEL ¦ ¦ ¦¦ ¦ ¦ ¦ 1--¦PROC ¦ ¦ ¦¦ ¦ ¦ ¦ 1--¦POS ¦ X ¦ ¦¦ ¦ ¦ ¦ 1--¦SPINDLE +------( )---¦ ¦¦ (8) ¦ ¦ ¦ +---------+ ¦ ¦¦ +-----------¦-----¦--¦-----------------------+ ¦ ¦¦ +----------------+ ¦ ¦ ¦ ¦ ¦¦ ¦Tool management ¦ ¦ ¦ ¦ ¦ ¦¦ ¦aborts ¦ ¦ ¦ ¦ ¦ ¦¦ ¦requested ¦ ¦ ¦ ¦ ¦ ¦¦ ¦tool transfer ¦ ¦ ¦ ¦ ¦ ¦¦ ¦of the PLC ¦ ¦ ¦ ¦ ¦ ¦¦ +----------------+ ¦ ¦ ¦ ¦ ¦¦ ¦ ¦ ¦+----------------------+ +-----------------------------------------------+



Tool transfer timing:

(1)FK input +----------------------------------------------------+XMS ----+ +--------

(2)FK output +-----------+XMS --------+ +---------------------------------------------

FK input +------+XMS_PA --------+ +--------------------------------------------------

(3)FK output +---------------------------------+XMS_PA ----------+ +---------------------

(5) (6)FK input +---------------------------------+XMS_Q ------------------------+ +-------

FK output +---------------------------------+XMS_Q ------------------------+ +-------

(1) The magazine-to-spindle tool transfer with respect to data processingis initiated by the "XMS"standard function in the PLC program.

(2) The tool management function checks the requested tool transferwith respect to data processing. The check of the mechanicalpreconditions of tool transfer are an integral part of the PLC userprogram.

(3) The "XMS_PA" standard function checks in the PLC program whetherthe requested tool transfer is permitted (XMS_PA: eXchange toolfrom Magazine to Spindle Positive Acknowledge).

(4) The "XMS_NA" standard function checks in the PLC programwhether the requested tool transfer with respect to data processing isnot permitted (XMS_NA: eXchange tool from Magazine to SpindleNegative Acknowledge).

(5) If mechanical tool transfer as well as tool transfer in respect of dataprocessing is permitted, the "XMS_Q" standard function in the PLCprogram completes the tool transfer.

(6) The tool management function performs the logical tool transfer.

(7) The requested tool transfer with respect to data processing can beaborted with the "XMS_CA" standard function if it is not permitted.

(8) The tool management function aborts the mechanical tool transfer.



Further Tool Transfer FunctionsUpon activation of the "XFER_CHK" function, the tool transfer alwaysrefers to the current actual magazine location.

The tool transfer functions between:

• magazine and gripper,

• spindle and magazine,

• spindle and gripper,

• gripper and magazine, and

• gripper and spindle

execute in the same way as the tool transfer between magazine andspindle.

The following functions are available for tool transfer:

PLC tool transfer commands V22_20021029

from to initiate permitted terminate not permitted abort

Magazine Spindle XMS XMS_PA XMS_Q XMS_NA XMS_CA

Magazine Gripper XMG XMG_PA XMG_Q XMG_NA XMG_CA

Spindle Magazine XSM XSM_PA XSM_Q XSM_NA XSM_CA

Spindle Gripper XSG XSG_PA XSG_Q XSG_NA XSG_CA

Gripper Magazine XGM XGM_PA XGM_Q XGM_NA XGM_CA

Gripper Spindle XGS XGS_PA XGS_Q XGS_NA XGS_CA

Werkzeugtransferbefehle_SPS_V22_20021029.xls

Fig. 4-42: Overview of tool transfer commands

Checking a Tool Transfer "XFER_CHK"Tool management of the MTC 200 is performed in the NC section. Thetool change moves the tools between magazine, gripper and spindle. Tooltransfer standard functions in the PLC initiate and acknowledge the tooltransitions (e.g. clamping or unclamping of tool clamping devices inspindles; opening or closing grippers). Up to Version 04.10, initiating atool transfer is possible only with an active tool change command (e.g.TCH, TSM, TMS) of the NC. If tool change is not active, an errormessage is generated when a tool transfer with respect to dataprocessing is initiated.

Activating the "XFER_CHK" standard function suppresses the errormessage in the event of a tool transfer without tool change active. Thus, atool change may also be performed outside an active NC tool changecommand. Furthermore, it is now possible when XFER_CHK is active toadd tools to the tool list or to shift and cancel tools from the operatorinterface as well as from the PLC while the NC program is running;however, this does not apply for the currently active tool or the tool in thereference spindle. This function is used e.g. for changes of the magazinecomponents parallel to machining time, as far as this is mechanicallyfeasible.

If the function has not been activated or is not used, error handlingresponds as before. An error message is generated when a tool transfer



without active tool change is initiated. While an NC program is running,tools cannot be added, shifted, or cancelled.

XFER_CHK.bmp

Fig. 4-43: Checking a tool transfer

ACTIVE: 0 Function is not activated. Error message with tool transfer withoutactive tool change for the specified process

1 Suppress error message with tool transfer without active toolchange for the specified process


The ACTIVE input is passed on.

Function result = ACTIVEResult of functionXFER_CHK



4.5 Combined Spindle/Turret Axis

The combined spindle/turret axis (CST axis) is a special axis type that isused for controlling a tool turret with driven tools.

The special feature of this axis type is the fact that, using a servodrive,both tools (spindle mode) and turret (turret mode) can be driven. Thecontrol automatically selects spindle or turret operating mode on the basisof the programmed NC commands (tool change or spindle command).

Turret mode is preselected whenever a tool magazine movementcommand is executed in the NC program. Once the turret has beenpositioned, the NC automatically switches back to spindle mode.

The interrogation of the mode is controlled by two standard PLCfunctions:

• interrogating the magazine axis preselection: "MAG_ACT" and

• interrogating spindle preselection: "SPDL_ACT"".

There are two more PLC standard functions for acknowledging the modeselection:

• acknowledging the magazine axis preselection: "MAG_Q" and

• acknowledging the spindle preselection "SPDL_Q".

Note: Detailed documentation regarding the CST axis can be foundin the "MTC 200 Combined Spindle/Turret Axis" description offunctions.

General Technical Notes on Application

To improve the processing of exceptions when using CST axes, thefollowing items need to be complied with:

Following a control reset (e.g. switching on/off or parameter transfer),spindle mode is the default selection in the control. A subsequent spindlemovement command (e.g. "M3 S1000") starts the axis motionimmediately. To move the axis, the NC does not require anacknowledgment from the PLC in this case. Omitting the acknowledgmentsignal will not lead to an error message in this case.

The CST axis must not be moved if the turret is in a mechanicalintermediate position after a control reset. The system does not disable amovement that is caused by the execution of a spindle command and/orthe execution of an MRF command. Thus, the programmer must set the"AxxC.MHOLD" axis command in this case.

To ensure that the tool turret is in a defined position after a control reset,process parameter Bxx.032 "Home position required" in the machineparameters must be set to "yes" and "MRF" must be programmed in thereverse program. This ensures that the CST axis is homed after thereverse program has been executed and that the mechanical system is ina defined position (the NC requests spindle mode after reference pointreturn). Using the corresponding acknowledgment signal, the NCmonitors any turret mode after the "MRF" command has been executed.

Behavior after control reset

Undefined tool turret position

Measure for defined tool turretposition



Note: Prior to each changeover to turret mode, the NC issues aspindle positioning command with a correspondingchangeover request to the PLC. This ensures that a definedswitching position is undertaken before the couplingprocedure. In other words, "M19 S0" is internally added tocommand "MRF", as is the case for all other magazinecommands, as long as this has not already been programmedin the NC user program.

If the mechanical turret system is in a defined operating state (turret modeor spindle mode) before power is activated (PxxS.POWER=0), and if thisstate is acknowledged by the PLC, the NC transfers this operating stateas a request to the PLC. The request remains when power is applied(PxxS.POWER=1) A control reset (PxxC.CLEAR=1) can be used to clearthe pending request after power has been applied (PxxS.POWER=0).

Once the corresponding operating state (turret or spindle mode) has beenacknowledged for the first time, the acknowledgment signal must remainapplied as long as the operating state is requested by the NC if the NCrequests spindle or turret mode after power has been applied(PxxS.POWER=1). Canceling the acknowledgment signal will causeprocess error #321 "CST acknowledgment is missing" to be issued in thiscase.

The request is reset when a control reset is executed. If the "Bxx.036Manual axis jogging causes reset" parameter has been set to "Yes", thecorresponding request will also be reset when a spindle jog command isactivated.

If the combined spindle/turret axis has not been homed, command "MRF"(Tool magazine homing) will always be performed before a tool magazinemotion command is executed. Once homing has been completed, therequired turret movement is carried out immediately.

If the spindle has not yet been oriented, a spindle orientation with "M19S0" is performed internally before an “MRF" is executed.

If a tool magazine movement command is being processed in the NC, theNC sends a request to switch the turret mechanical system from spindlemode to turret mode to the PLC. At the same time, the axis is switched toturret mode within the NC (axis processor). If the PLC does notacknowledge turret mode, a control reset (PxxC.CLEAR=1 andPxxS.ERROR=0) can be used for aborting the changeover process. Afterthe control reset has been completed, the NC requests spindle modeagain. The axis is also switched back to spindle mode in the axisprocessor.

Spindle mode is the main mode of the CST axis. As a result, a switch toturret mode occurs only by executing tool magazine movementcommands (e.g. MTP in the NC program or PxxC.MGPOS via PLC).Once this command has been completed, the NC sends the PLC arequest for switching the mechanical turret system from turret mode tospindle mode. At the same time, the axis is switched back to spindlemode. If the PLC does not acknowledge spindle mode, a control resetcan be used for aborting the changeover process. The spindle moderequest from the NC is cleared during this process.

Executing a control reset resets the pending request (e.g. spindlerequest). If process parameter "Bxx.036 Manual axis jogging causesreset" has been set to "Yes", the spindle request will also be canceledwhen the spindle is jogged.

Behavior upon power activation

Acknowledging requests

Home

Aborting a changeover process

Primary mode of operation



Interrogating and Acknowledging Turret Mode PreselectionThe control preselects turret mode whenever a command is programmedin the NC program that initiates a turret movement. The "MAG_ACT"standard function can be used in the PLC for interrogating the mode.

MAG_ACT.bmp

Fig. 4-44: Actively interrogating a magazine

ACTIVE: 0 Function not active1 Interrogation of turret mode preselection active

PROC: Process number

0 Function is not active or turret mode preselection is not active1 Turret mode preselection is active

The "MAG_Q" standard function is used for acknowledging that turretmode selection has been performed. Once turret mode has beenacknowledged for the first time, the acknowledgment signal must beactive as long as turret mode is selected. Canceling the acknowledgmentduring turret mode will cause a process error to be generated.

MAG_Q.bmp

Fig. 4-45: Acknowledge magazine

QUIT: 0 Function not active1 Acknowledgment of turret mode preselection (must be active the

whole time)PROC: Process number

The QUIT input is passed on.

Result of functionMAG_ACT

Result of functionMAG_Q



Turret mode preselection procedure:

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Interrogating and Acknowledging Spindle Mode PreselectionThe controller preselects spindle mode whenever the NC program doesnot execute a command that initiates a turret movement. The"SPDL_ACT" standard function can be used in the PLC for interrogatingthis mode.

SPDL_ACT.bmp

Fig. 4-47: Actively interrogating a spindle

ACTIVE: 0 Function not active1 Interrogation of spindle mode preselection is active

PROC: Process number

0 Function is not active or spindle mode preselection is not active1 Spindle mode preselection is active

The "SPDL_Q" standard function is used for acknowledging that spindlemode selection has been performed. After the control has been switchedon, spindle mode will be selected even if there is no acknowledgment.Once spindle mode has been acknowledged for the first time, theacknowledgment signal must be active as long as spindle mode isselected. Canceling the acknowledgment during spindle mode will causea process error to be generated.

SPDL_Q.bmp

Fig. 4-48: Acknowledging spindle mode

QUIT: 0 Function not active1 Acknowledgment of spindle mode preselection (must be active

the whole time)PROC: Process number

The QUIT input is passed on.

Result of functionSPDL_ACT

Result of functionSPDL_Q



Spindle mode preselection procedure:

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Fig. 4-49: Preselection of spindle mode



Tool Management Setting the Parameter Values of the Tool Storage Unit 5-1


5 Setting the Parameter Values of the Tool StorageUnit

5.1 Sequence of the Parameter Value Assignment

The following flow diagram shows the steps that are required for settingthe parameter values of a tool storage unit:

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5-2 Setting the Parameter Values of the Tool Storage Unit Tool Management


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Fig. 5-1: Procedure for setting the parameters of a tool magazine



5.2 NC-Controlled Tool Storage Unit

Benefits of an NC-Controlled Tool Storage UnitCompared with conventional PLC control, using a servodrive forcontrolling an NC-controlled tool storage unit via the MTC yields variousbenefits:

• The PLC programming effort required for adaptation, and thecommissioning time are significantly reduced.

• Compared with PLC-controlled systems, NC axes are more reliable,service-friendlier and less subject to wear.

• For numerically controlled servo axes, reliable monitoring functionsand fault diagnostics are available in the firmware. The MTC monitorsand controls all states of the NC axes, including the paths between thetool storage locations.

Example: Assigning the Parameter Values of a Disk-Type Magazine

The tool storage unit whose parameter values are to be assigned consistsof a full disk with 24 locations that are positioned directly by a globalservodrive via a reduction gearbox.

The spindle fetches the tools directly from the tool storage unit andreturns them there. There are no grippers for the tool transfer.

.

.

.• A00.052 Tool management Yes• A00.032 – A00.051 Type of axis Digital rotary axis

.

.

.

.

.

.• Bxx.014 Tool management Yes• Bxx.015 Type of tool storage Magazine• Bxx.016 Endlessly rotating tool storage Yes• Bxx.017 Number of tool storage locs. 24• Bxx.018 Number of tool spindles 1• Bxx.019 Number of tool grippers 0• Bxx.020 Axis number of tool storage axis 4• Bxx.021 Position 1 (Offset from reference mark) 3

If the magazine is in its home position so that a magazine location is ina changing position, the 'tool change position' process parameter canbe determined as the number of locations between the changingposition and location 1. The count direction is the direction in which themagazine locations are numbered (= positive direction of movement).Position 2 (offset to the reference mark) Position 3 (offset to thereference mark)

• Bxx.022 Position 2 (Offset from reference mark) 0• Bxx.023 Position 3 (Offset from reference mark) 0• Bxx.024 Position 4 (Offset from reference mark) 0

.

.

Tool storage

System Parameters

Process parameters



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Fig. 5-2: Determining position 1 (offset to the reference mark) of a disk-typemagazine

The values of the axis parameters of the NC-controlled tool storage axismust be assigned in the same manner as the axis parameter values ofany other rotary axis. Merely axis parameter Cxx.022 'Parametric joggingdistance' requires particular attention.

The 'Parametric jogging distance' parameter is used for informing theMTC of the distance between the tool locations.

] [ locations tool of Number

[units] revolution per Gradation= distance jogging Parametric

[mm] locations tool of Distance = distance jogging Parametric

axisRotary

axis Linear

The second formula is valid for turret, disk-type, drum-type and chain-typemagazines.

Notes: If a tool storage unit is used in which certain sectors do notpossess tool pockets (such as a semi-disk magazine), thenumber of locations that is required for determining the'Parametric jogging distance' parameter must arithmetically beextrapolated to the full circle, using the same gradation.Provided that 'Parametric jogging distance' (PxxC.JOGM0 = 1,PxxC.JOGM1 = 1, PxxC.JOGM2 = 1) has been preselected inthe PLC for the jog keys, the parameter permits the individualmagazine locations to be approached in jogging mode.

Axis parameters



5.3 PLC-Controlled Tool Storage Unit

General

The tool storage unit of a PLC-controlled tool storage system is actuatedby an asynchronous drive, or by hydraulic or pneumatic elements.Sensors (such as reference point or count cams with the relatedswitches) usually provide the necessary position data.

Note that there is a pocket at the tool changing position when the toolstorage unit is at its home position (MHP).

If the home position is not equipped with a separate cam and a relatedswitch, the reference point cam must mechanically be adjusted such thatthere is a magazine location at the tool changing position when themagazine is in its reference position.

Software adjustment between reference position and home position is notpossible.

Example: Assigning the Parameter Values of a Disk-Type Magazine

The tool storage unit whose parameter values are to be assigned consistsof a full disk with 24 locations (as described in the above example forparameterization of an NC controlled disk magazine). There is a cam forreference point return and homing.

The spindle fetches the tools directly from the tool storage unit andreturns them there. There are no grippers for the tool transfer.

.

.

.• A00.052 Tool management Yes• A00.032 – A00.051 Type of axis -

.

.

.

.

.

.• Bxx.014 Tool management Yes• Bxx.015 Type of tool storage Magazine• Bxx.016 Endlessly rotating tool storage Yes• Bxx.017 Number of tool storage locs. 24• Bxx.018 Number of tool spindles 1• Bxx.019 Number of tool grippers 0• Bxx.020 Axis number of tool storage axis 0

The 'Axis number of tool storage axis' parameter must be set to '0'.This shows the MTC that a PLC-controlled changer is being used.

• Bxx.021 Position 1 (Offset from reference mark) 3

If the tool storage unit is at the reference or home position, location 22is at the change position (position 1).

• Bxx.022 Position 2 (Offset from reference mark) 0• Bxx.023 Position 3 (Offset from reference mark) 0• Bxx.024 Position 4 (Offset from reference mark) 0

Components

Home position

Tool storage

System Parameters

Process parameters



.

.

.

Tool Management Typical Applications 6-1


6 Typical Applications

6.1 PLC-Controlled Turret

Description of the TurretLathes usually employ very quickly rotating turrets. If the turret is notrotated using a servomotor, but rather, for example, using a power pack,the control of this movement is not undertaken by the NC, but rather bythe PLC. A main spindle is usually used as the drive for tools that mayhave to be driven.

ABB2_1.WMF

Fig. 6-1: PLC-controlled turret with driven tools

Parameter Value AssignmentHere, we want to provide some information about the parameter valueassignments of a PLC-controlled turret:

• Axx.052 Tool management: YES

• Axx.091 Tool technology: Turning/milling


• Bxx.015Type of tool storage: Turret

• Bxx.044 Asynchronous turret movements: NO

• Bxx.057 Activate tool correction for turret: At end

• Bxx.016 Endlessly rotating tool storage: YES

System Parameters

Process parameters

6-2 Typical Applications Tool Management


• Bxx.017Number of tool storage locations n: 12

• Bxx.018 Number of tool spindles: 0

• Bxx.019 Number of tool grippers: 0

• Bxx.020 Axis number of tool storage axis: 0

Please refer to the MTC 200/TRANS 200 Parameter Description fordetails about the parameter value assignments.

NC ProgrammingN0000 .M6 [Tool changing program]N0001 MTP ;Move programmed tool into positionN0002 G48 MRY ;Activate tool length compensation

;wait until mgazine movement iscompletedN0003 RTS ;Exit subroutine

PLC ProgrammingThe "MMV" function is used in the PLC program for interpreting the turretmovement. The rotation is initiated by triggering a hydraulic valve(MAGPOS). The "M_MAGAP" signal returns the actual turret position.This data element exists as a byte. In order to be able to compare theactual position (P00C.MGAP) and the command position (P00S.MGCP),the data element must be converted into INT format. The tool storage unitmotion command is acknowledged if the actual value and the commandvalue are identical.

To simplify matters in the following description, the turret only rotates inthe positive direction.

(*Output of the tool storage command*)┌─────────┐│MMV │

2#1─┤ACTIVE │0─┤PROC ├─S(M_MMV)└─────────┘

MMV.......................... ........................................ .......... MMV2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INTM_MMV........................ MMV active.............................. .......... BOOL

(*Rotate the turret in the positive direction*)┌─────────┐

M_MMV─┤:= ├┬S(MAGPOS)└─────────┘├R(MAGNEG)

│┌─────────┐└┤:= O─>>noMMV└─────────┘

M_MMV........................ MMV active.............................. .......... BOOLMAGPOS....................... Rotate turret in positive direction..... .......... BOOLMAGNEG....................... Rotate turret in negative direction..... .......... BOOLnoMMV........................ ........................................ .......... Flag

(*Converting the actual position of the turret: BYTE -> INT*)┌─────────┐│BYTE_INT │

M_MAGAP─┤BYTE_ ├─P00C.MGAP└─────────┘

BYTE_INT..................... ........................................ .......... BYTE_INTM_MAGAP...................... Flag actual turret position............. .......... BYTEP00C.MGAP.................... Current turret position................. .......... INT



noMMV:(*Acknowledgement of tool storage unit movement if actual position *)(*(M_MAGAP) equals the command position (M_MAGCP)*)

┌─────────┐│= │ ┌─────────┐

P00S.MGCP─┤ │ │& │P00C.MGAP─┤ ├─┤ │ ┌─────────┐

└─────────┘ │ │ │MMV_Q │M_MMV─┤ ├─────────────┤QUIT │

└─────────┘ 0─┤PROC ├┬R(MAGPOS)└─────────┘├R(MAGNEG)

└R(M_MMV)P00S.MGCP.................... Turret command position................. .......... INTP00C.MGAP.................... Current turret position................. .......... INTMMV_Q........................ ........................................ .......... MMV_QM_MMV........................ MMV active.............................. .......... BOOL0............................ Process number.......................... .......... INTMAGPOS....................... Rotate turret in positive direction..... .......... BOOLMAGNEG....................... Rotate turret in negative direction..... .......... BOOLM_MMV........................ MMV active.............................. .......... BOOL

(*Jogging the turret in manual mode*)┌─────────┐

P00S.POWER─┤:= ├─P00C.MGENA└─────────┘

P00S.POWER................... Power enabled........................... .......... BOOLP00C.MGENA................... Turret enabled.......................... .......... BOOL

┌─────────┐P00S.MGREQ─O:= ├─P00C.MGMAN

└─────────┘P00S.MGREQ................... Turret required......................... .......... BOOLP00C.MGMAN................... Turret manual/program mode.............. .......... BOOL

┌─────────┐│& │

IMAGPOS─┤ │QHAND─┤ │

IZWEIHAND─┤ ├─P00C.MGPOS└─────────┘

IMAGPOS...................... Key 'Rotate turret in pos. direction' .. .......... BOOLQHAND........................ LED manual mode......................... .......... BOOLIZWEIHAND.................... Key for two-handed operation............ .......... BOOLP00C.MGPOS................... Rotate turret in pos. direction ........ .......... BOOL

┌─────────┐│& │

IMAGNEG─┤ │QHAND─┤ │

IZWEIHAND─┤ ├─P00C.MGNEG└─────────┘

IMAGNEG...................... Key 'Rotate turret in neg. direction'... .......... BOOLQHAND........................ LED manual mode......................... .......... BOOLIZWEIHAND.................... Key for two-handed operation............ .......... BOOLP00C.MGNEG................... Rotate turret in neg. direction ........ .......... BOOL

Fig. 6-2: Example of a PLC program



6.2 Combined Spindle/Turret Axis

GeneralLathes increasingly employ very quickly rotating turrets. They arefrequently driven by an AC servodrive that swivels the turret and drivesthe tools.

ABB3_1.WMF

Fig. 6-3: Combined spindle/turret axis with servodrive

In the combined spindle/turret (CST) axis, both the tool and the turretdrive are controlled via the NC. The special characteristic is that only onedrive is employed for this task. This function requires the “Combinedspindle/turret axis” axis type to be preselected within the NC systemparameters.

Special turret commands need not be programmed within the NCprogram.

In turret mode, use the standard magazine commands (MTP, MMP, MRF)for moving the turret.

In spindle mode, the tool drive is triggered via the general spindle controlcommands (Mx03, Mx04, Mx05, Mx19, where x = No. of spindle).

Note: Detailed documentation regarding the CST axis can be foundin the "MTC 200 Combined Spindle/Turret Axis" description offunctions.



6.3 NC-Controlled Disk-Type Magazine

Description of the MagazineThe following example shows the NC tool changing program and theassociated PLC module for a three-axis horizontal milling machine with atool changer whose magazine axis is numerically controlled.

feed motorY axis

Y slide

X slide

Z slide

tool

main spindle drive

feed motorX axis

disk-type magazine Y

X Z

ABB4_1.FH7

Fig. 6-4: Three-axis milling machine with numerically controlled disk magazine

The tool magazine consists of a semi-disk with seven magazine locationsthat is positioned by a servodrive via a reduction gearbox.

This changing method permits a tool change to be performed without agripper, directly between the spindle and the magazine.

To be picked up, the tool is positioned such that the tool that is to bemounted is at the changing position. The three-axis unit then approachesthe magazine from the rear and mounts the tool in the spindle (1). Toremove the tool from the magazine, the spindle rotates by 90° (2) andmoves laterally away from the magazine (3). Next, the disk-type magazineis moved back to its home position.

ABB4_2.FH7

Fig. 6-5: Taking up a tool in the spindle



Depositing a tool is done in the reverse sequence. First, an emptymagazine location is moved to the changing position. The unit with thetool in the spindle then moves sideways into the magazine (4), rotates thetool by 90° (5), opens the collet in the spindle, and moves away towardsthe rear (6).

ABB4_3.FH7

Fig. 6-6: Depositing a tool in the magazine

The movement of the disk-type magazine is controlled exclusively via theNC. The tool storage unit motion commands are used for this purpose.Using the MOP command, the tool that is to be stored is placed into itsold magazine location. Using MTP, the new tool is moved to the changingposition. The MHP command provides for approaching the home position.Using MRY (Wait until magazine movement is terminated), eachmagazine movement is synchronized with the NC program execution.

Parameter Value Assignment

The tool storage unit axis is an NC axis (rotary axis). Thus, it must also beentered in the system parameters. Make sure that "YES" is entered inparameter A00.052 (Tool management).

The following specifications must be made in the parameters of theprocess in which tool management is carried out and to which themagazine's NC axis is allocated:


• Bxx.015 Type of tool storage: Magazine

• Bxx.016 Endlessly rotating tool storage: NO





The tool storage unit axis is entered as the fourth axis in the systemparameters.

"Parametric jogging distance" (Cxx.022) remains to be mentioned asanother axis parameter of the tool storage unit axis. It is 30° and resultsfrom the geometry of the semi-disk (180°) and the number of free spacesbetween the tool storage locations (7). This number of free locationsequals "the number of locations - 1".

180° / (7-1) = 30°

System Parameters

Process parameters

Axis parameters



NC ProgrammingN0000 .M6 [Changing tools]

N0001 M5 ;Spindle stop

N0002 G61 ;Precise stop ON

N0003 G90 G53 G47 G40 ;ABS M zero point WZL-OFF WZR-OFF

N0004 @1=TLD(,0,1,1,0,5,) BEQ .EM_SPI ;Jump if spindle empty

N0005 REV .r_1.0 ;Jump flag

;

; The spindle is not empty

; Store old tool in empty magazine location

N0006 G00 X-100 Y0 Z0 REV .r_1.1 ;Position 3-axis unit

N0007 MOP REV .r_1.2 ;Approach old magazine location

N0008 M19 S0 ;Position spindle

N0009 MRY ;Wait until magazine mvmt. is completed

N0010 @10=TLD(,0,1,1,0,11,) ;Read the old ML of T_old

N0011 @11=TLD(,0,0,@10,0,9,16) BEQ .MP_OK ;Old ML occupied ?

N0012 HLT [old magazine location occupied] ;Issue message

N0013 RET ;Jump back

N0014 .MP_OK G00 X0 REV .r_1.3 ;Move to changing position

N0015 M17 REV .r_1.35 ;Cone blowout ON

N0016 M19 S90 REV .r_1.4 ;Turn spindle

N0017 M11 REV .r_2.4 ;Open clamping device

N0018 TSM REV .r_2.4 ;Tool change spindle -> magazine

N0019 G04 F0.3 REV .r_2.3 ;Dwell time of 0.3s

N0020 G00 Z115 REV .r_2.2 ;Drive spindle back

N0021 BTE .NOTOL1 ;Jump if T0 is programmed

N0022 BRA .NEWTOL ;Jump

;

; No tool in the spindle

N0023 .EM_SPI ;Jump flag

N0024 BTE .NOTOL2 ;Jump if T0 is programmed

N0025 REV .r_3.0 ;Reverse vector

N0026 G00 X-100 Y0 Z115 ;Position spindle

N0027 G00 X0 REV .r_3.1 ;Position spindle

;

; Changing a new tool into the spindle

N0028 .NEWTOL

N0029 MTP REV .r_3.2 ;Move programmed tool into position

N0030 M17 ;Cone blowout ON

N0031 M19 S90 ;Position spindle

N0032 M11 ;Open clamping device

N0033 MRY REV .r_3.3 ;Wait until magazine mvmt. is completed

N0034 G00 Z0 ;Approach change position

N0035 M10 ;Close clamping device

N0036 M18 ;Cone blowout OFF

N0037 TMS REV .r_4.4 ;Tool change magazine -> spindle



N0038 G4 F0.8 REV .r_4.3 ;Dwell time of 0.8s

N0039 M19 S0 REV .r_4.2 ;Turn spindle

N0040 G00 X-100 REV .r_4.1 ;Move spindle out of magazine

N0041 MHP REV .r_4.0 ;Move magazine to home position

N0042 MEN ;Enable magazine for manual mode

N0043 G62 ;Block change on the fly

N0044 G48 ;Tool length compensation ON

N0045 MRY RTS ;Wait until magazine mvmt. is completed

;

; T0 was programmed, and the tool in the spindle

; has been brought back to the magazine

N0046 .NOTOL1 ;Jump flag

N0047 MHP REV .r_2.1 ;Move magazine to home position

N0048 G00 X-100 REV .r_2.0 ;Move spindle out of magazine






;

; T0 is programmed, and there is no tool in the spindle

N0054 .NOTOL2 ;Jump flag



N0057 RTS ;Exit subroutine

N0058 .M6ERR ;Jump flag

;

; Reverse program for changing tools

;

N0059 .r_1.4 @1=TLD(0,0,1,1,0,9,16) BEQ .r_2.4 ;Jump if clamp isempty


N0061 .r_1.35 M18 ;Cone blowout OFF

N0062 .r_1.3 M19 S0 ;Position spindle

N0063 .r_1.2 G00 X-100 ;Move spindle out of magazine

N0064 .r_1.1 MHP ;Move magazine to home position

N0065 .r_1.0 G00 X-100 Y0 Z115 ;Move three-axis unit freely




;

N0069 .r_2.4 G04 F0.3 ;Dwell time of 0.3s

N0070 .r_2.3 G00 Z115 ;Drive spindle back





N0073 .r_2.0 MEN ;Enable magazine for manual mode



;

N0076 .r_3.3 ;Jump flag

N0077 M11 M18 ;Open clamping device


N0079 G00 Z115 ;Drive spindle back


N0081 .r_3.1 MHP Z115 ;Move magazine to home position

N0082 .r_3.0 MRY ;Wait until magazine mvmt. is completed

N0083 G00 X-100 Y0 Z115 ;Move three-axis unit freely




;

N0087 .r_4.4 G04 F0.8 ;Dwell time of 0.3s




N0091 .r_4.0 MEN ;Enable magazine for manual mode


N0093 G48 ;Tool length compensation ON


PLC ProgrammingThe tool change is initiated in the NC by tool changing command TMS orTSM. The changing process proper is then implemented in single steps inthe PLC using standard functions. The corresponding PLC module isshown here.

Note: Tool storage unit axes are not provided with a processoverride (PxxC.OVRD), but rather with a separate axisoverride (AxxC.OVRD).

(*NC command "Changing tools from magazine to spindle"*)┌─────────┐TMS

2#1─┤ACTIVE │PROC─┤PROC │POS─┤POS │

SPINDLE─┤SPINDLE O─>>noTMS└─────────┘

TMS.......................... ........................................ .......... TMS2#1.......................... ........................................ .......... DualPROC......................... Process number.......................... .......... INTPOS.......................... Position................................ .......... INTSPINDLE...................... Spindle number.......................... .......... INTnoTMS........................ ........................................ .......... Flag



(*Initiate magazine-to-spindle tool transfer*)┌─────────┐│XMS │

ICLAMP─OINIT │PROC─┤PROC │POS─┤POS │

SPINDLE─┤SPINDLE ├─x└─────────┘

XMS.......................... ........................................ .......... XMSICLAMP....................... Return message: clamping device closed.. .......... BOOLPROC......................... Process number.......................... .......... INTPOS.......................... Position................................ .......... INTSPINDLE...................... Spindle number.......................... .......... INTx............................ Auxiliary flag.......................... .......... BOOL

(*Close spindle clamp if tool transfer is permitted*)┌─────────┐│XMS_PA │

2#1─┤ACTIVE │PROC─┤PROC │POS─┤POS │

SPINDLE─┤SPINDLE ├─S(QCLAMP)└─────────┘

XMS_PA....................... ........................................ .......... XMS_PA2#1.......................... ........................................ .......... DualPROC......................... Process number.......................... .......... INTPOS.......................... Position................................ .......... INTSPINDLE...................... Spindle number.......................... .......... INTQCLAMP....................... Spindle clamping activation............. .......... BOOL

(*Acknowledge tool transfer and tool change if*)(*spindle clamping is open*)

┌─────────┐│& │ ┌─────────┐

ICLAMP─┤ │ │XMS_Q │IUNCLAMP─O ├─────────────┤QUIT │

└─────────┘ PROC─┤PROC │ ┌─────────┐POS─┤POS │ │TMS_Q │

SPINDLE─┤SPINDLE ├─────────────┤QUIT │└─────────┘ PROC─┤PROC │

POS─┤POS │SPINDLE─┤SPINDLE ├─x

└─────────┘ICLAMP....................... Return message: clamping device closed.. .......... BOOLXMS_Q........................ ........................................ .......... XMS_QIUNCLAMP..................... Return message: clamping device open.... .......... BOOLPROC......................... Process number.......................... .......... INTPOS.......................... Position................................ .......... INTSPINDLE...................... Spindle number.......................... .......... INTTMS_Q........................ ........................................ .......... TMS_QPROC......................... Process number.......................... .......... INTPOS.......................... Position................................ .......... INTSPINDLE...................... Spindle number.......................... .......... INTx............................ Auxiliary flag.......................... .......... BOOL

noTMS:(*NC Command "Changing tools from spindle to magazine"*)

┌─────────┐│TSM │

2#1─┤ACTIVE │PROC─┤PROC │

SPINDLE─┤SPINDLE │POS─┤POS O─>>noTSM

└─────────┘TSM.......................... ........................................ .......... TSM2#1.......................... ........................................ .......... DualPROC......................... Process number.......................... .......... INTSPINDLE...................... Spindle number.......................... .......... INTPOS.......................... Position................................ .......... INTnoTSM........................ ........................................ .......... Flag

(*Initiate spindle-to-magazine tool transfer*)┌─────────┐│XSM │

2#1─┤INIT │PROC─┤PROC │

SPINDLE─┤SPINDLE │POS─┤POS ├─x

└─────────┘XSM.......................... ........................................ .......... XSM2#1.......................... ........................................ .......... DualPROC......................... Process number.......................... .......... INTSPINDLE...................... Spindle number.......................... .......... INTPOS.......................... Position................................ .......... INT



x............................ Auxiliary flag.......................... .......... BOOL

(*Close spindle clamp if tool transfer is permitted*)┌─────────┐│XSM_PA │

2#1─┤ACTIVE │PROC─┤PROC │

SPINDLE─┤SPINDLE │POS─┤POS ├─R(QCLAMP)

└─────────┘XSM_PA....................... ........................................ .......... XSM_PA2#1.......................... ........................................ .......... DualPROC......................... Process number.......................... .......... INTSPINDLE...................... Spindle number.......................... .......... INTPOS.......................... Position................................ .......... INTQCLAMP....................... Spindle clamping activation............. .......... BOOL

(*Acknowledge tool transfer and tool change if*)(*spindle clamping is open*)

┌─────────┐│& │ ┌─────────┐

IUNCLAMP─┤ │ │XSM_Q │ICLAMP─O ├─────────────┤QUIT │

└─────────┘ PROC─┤PROC │ ┌─────────┐SPINDLE─┤SPINDLE │ │TSM_Q │

POS─┤POS ├─────────────┤QUIT │└─────────┘ PROC─┤PROC │

SPINDLE─┤SPINDLE │POS─┤POS ├─x

└─────────┘IUNCLAMP..................... Return message: clamping device open.... .......... BOOLXSM_Q........................ ........................................ .......... XSM_QICLAMP....................... Return message: clamping device closed.. .......... BOOLPROC......................... Process number.......................... .......... INTSPINDLE...................... Spindle number.......................... .......... INTPOS.......................... Position................................ .......... INTTSM_Q........................ ........................................ .......... TSM_QPROC......................... Process number.......................... .......... INTSPINDLE...................... Spindle number.......................... .......... INTPOS.......................... Position................................ .......... INTx............................ Auxiliary flag.......................... .......... BOOL

noTSM:



6.4 PLC-Controlled Chain-Type Magazine

Description of the MagazineMachine tools frequently use tool changing systems that employ a doublegripper for changing the tools between the spindle and the magazine. Thistype of tool transfer is particularly common in machining centers.

ABB5_1.WMF

Fig. 6-7: Chain-type magazine with double gripper

This type of tool storage unit is usually controlled by the PLC. Thefollowing sections describe the parameter value assignments, the NCprogram and the PLC program of the magazine that is shown in Fig. 6-7.

Parameter Value AssignmentThis is a PLC-controlled magazine. Thus, the tool storage unit is notassigned to an NC axis and, consequently, only system parameters andprocess parameters need to be discussed here.

In the system parameters, make sure that "YES" is entered in parameterAxx.052 (Tool management).

Our example requires the process parameters to be set to the followingvalues:


• Bxx.015 Type of tool storage: Magazine

• Bxx.016 Endlessly rotating tool storage: YES



System Parameters

Process parameters





NC ProgrammingN0000 .M6 [Changing tools]

; Change in a new tool?

N0001 .M6_TOL

N0002 @8=TLD(,0,1,1,0,5,) ;Read the tool No. in spindle 1

N0003 @8=@8-T BEQ .M6_T0 ;If T_old=T_new -> .M6_T0

;

; Magazine positioning

N0004 BTE .M6_BAC ;T0 programmed ?

N0005 MTP ;Move to programmed pocket

N0006 BRA .M6_TCH ;Jump to .M6_TCH

N0007 .M6_BAC ;Jump flag

N0008 MFP ;Move to free pocket

;

; Tool change

N0009 .M6_TCH ;Jump flag

N0010 G40 G47 G53 G90 M9 ;Tool compens. off, machine zero point

;Absolute dimension

N0011 G0 Z392 M19 S90 MRY REV .RM6_2 ;Position Z axis;move spindle to changing position; wait until magazine movement stops

N0012 Q1 REV .RM6_3 ;Close gripper

N0013 Q2 REV .RM6_4 ;Open clamping device

N0014 TMS REV .RM6_5 ;Tool change magazine -> spindle

N0015 Q7 REV .RM6_6 ;Extend gripper

N0016 Q3 REV .RM6_7 ;Turn gripper

N0017 Q8 REV .RM6_8 ;Retract gripper

N0018 Q6 REV .RM6_9 ;Open clamping device

N0019 Q5 REV .RM6_10 ;Open gripper

N0020 TSM REV .RM6_12 ;Tool change spindle -> magazine

N0021 G48 [ ] RTS ;Tool length compensation ON

;

; Changing tools not necessary (tool is already in the spindle)

; or T0 has been programmed

N0022 .M6_T0 ;Jump flag

N0023 G48 [ ] RTS ;Tool length compensation ON

; ********Reverse vectors for the tool changing program*********

N0024 .RM6_3 Q6 ;Close clamping device

N0025 .RM6_2 Q5 ;Open gripper

N0026 RTS ;Exit subroutine

;

N0027 .RM6_4 TMS ;Tool change magazine -> spindle

N0028 .RM6_5 Q7 ;Extend gripper



N0029 .RM6_6 Q3 ;Turn gripper

N0030 .RM6_7 Q8 ;Retract gripper

N0031 .RM6_8 Q6 ;Close clamping device

N0032 .RM6_9 Q5 ;Open gripper

N0033 .RM6_10 TSM ;Tool change magazine -> spindle

N0034 .RM6_12 G48 [ ] RTS ;Tool length compensation ON

PLC Module for Magazine ControlTo home the magazine, the "MRF" command is issued in the NC reverseprogram. This process is now implemented in the PLC and acknowledgedat the end. Using the "MRY" command, the NC waits for thisacknowledgement before it continues the execution of the reverseprogram.

(*NC command "Magazine homing"*)┌─────────┐│MRF │

2#1─┤ACTIVE │0─┤PROC O─>>noMRF└─────────┘

MRF.......................... ........................................ .......... MRF2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INTnoMRF........................ ........................................ .......... Flag

(*Initiate positive magazine movement*)┌─────────┐

2#1─┤:= ├┬S(QMAGPOS)└─────────┘└R(QMAGNEG)

2#1.......................... ........................................ .......... DualQMAGPOS...................... Trigger positive magazine rotation...... VAR_OUTPUT BOOLQMAGNEG...................... Trigger negative magazine rotation...... VAR_OUTPUT BOOL

(*Stop magazine movement when reference cam is reached*)┌─────────┐

IREF─┤:= ├┬R(QMAGPOS)└─────────┘├R(QMAGNEG)

│┌─────────┐└┤:= O─>>noMRF└─────────┘

IREF......................... Reference cam........................... VAR_INPUT. BOOLQMAGPOS...................... Trigger positive magazine rotation...... VAR_OUTPUT BOOLQMAGNEG...................... Trigger negative magazine rotation...... VAR_OUTPUT BOOLnoMRF........................ ........................................ .......... Flag

(*Report magazine location 1 as actual position*)┌─────────┐

1─┤:= ├─P00C.MGAP└─────────┘

1............................ ........................................ .......... ANY_INTP00C.MGAP.................... Current magazine location............... .......... INT

(*Acknowledging NC command "Magazine homing"*)┌─────────┐│MRF_Q │

2#1─┤QUIT │0─┤PROC ├─x└─────────┘

MRF_Q........................ ........................................ .......... MRF_Q2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INTx............................ Auxiliary flag.......................... .......... BOOL

noMRF:

If a command is issued in the NC that causes the magazine to move, thiscommand is executed by the "MMV" standard function in the PLC. NCcommands that bring about a tool movement are, in this case:

• MTP (move programmed tool into position)

• MFP (move to free magazine location)

Homing

Magazine positioning



The NC does not wait until the tool storage unit has completed itsmovement. It continues NC program execution in parallel to themovement. If this is not desired, the "MRY" command can be used forstopping NC program execution. Program execution will be continued onlyafter the "MMV" function in the PLC has been acknowledged.

To simplify representation, the magazine in our example rotates only inthe positive direction.

(*NC command "Moving tool storage unit"*)┌─────────┐│MMV │

2#1─┤ACTIVE │0─┤PROC O─>>noMMV└─────────┘

MMV.......................... ........................................ .......... MMV2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INTnoMMV........................ ........................................ .......... Flag

(*Rotate the magazine in the positive direction*)┌─────────┐

2#1─┤:= ├┬S(QMAGPOS)└─────────┘└R(QMAGNEG)

2#1.......................... ........................................ .......... DualQMAGPOS...................... Trigger positive magazine rotation...... VAR_OUTPUT BOOLQMAGNEG...................... Trigger negative magazine rotation...... VAR_OUTPUT BOOL

(*If the impulse from the count cam is not applied -> noMMV*)┌─────────┐

MCNT─┤:= O─>>noMMV└─────────┘

MCNT......................... Flank evaluation from count cam......... .......... BOOLnoMMV........................ ........................................ .......... Flag

(*If the current magazine location >24 -> ADD*)┌─────────┐│< │

P00C.MGAP─┤ │24─┤ ├─>>ADD

└─────────┘P00C.MGAP.................... Actual magazine position................ .......... INT24........................... Maximum number of magazine locations ... .......... ANY_INTADD.......................... ........................................ .......... Flag

(*If the current magazine location >24: actual location = 0*)┌─────────┐

0─┤:= ├─P00C.MGAP└─────────┘

0............................ ........................................ .......... ANY_INTP00C.MGAP.................... Actual magazine position................ .......... INT

ADD:(*Increase actual location by 1*)

┌─────────┐│+ │

P00C.MGAP─┤ │1─┤ ├─P00C.MGAP└─────────┘

P00C.MGAP.................... Actual magazine position................ .......... INT1............................ ........................................ .......... ANY_INTP00C.MGAP.................... Actual magazine position................ .......... INT

(*If actual location = command location: acknowledge "Moving tool storage unit"*)┌─────────┐│= │ ┌─────────┐

P00C.MGAP─┤ │ │MMV_Q │P00S.MGCP─┤ ├─────────────┤QUIT │

└─────────┘ 0─┤PROC ├┬R(QMAGPOS)└─────────┘└R(QMAGNEG)

P00C.MGAP.................... Actual magazine position................ .......... INTMMV_Q........................ ........................................ .......... MMV_QP00S.MGCP.................... Command magazine position............... .......... INT0............................ Process number.......................... .......... INTQMAGPOS...................... Trigger positive magazine rotation...... VAR_OUTPUT BOOLQMAGNEG...................... Trigger negative magazine rotation...... VAR_OUTPUT BOOL

noMMV:



PLC Module for Changing ToolsWith the magazine that is shown here, the tool changing process properalways consists of four different tool transfers:

1. Transfer of the new tool from the magazine to the gripper

2. Transfer of the old tool from the spindle to the gripper

3. Transfer of the new tool from the gripper to the spindle

4. Transfer of the old tool from the gripper to the magazine

Between steps 2 and 3, the gripper rotates by 180°. The tool changingprocess is activated from the NC using the TMS and TSM commands. Inthe PLC, TMS includes transfers 1 and 2, and TSM correspondinglyincludes tool transfers 3 and 4 (see fig. below).

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ABB5_2.FH7

Fig. 6-8: Distribution of the tool change commands

Note: A tool transfer command (e.g. XMS, XSM, XMG, etc.) can beissued in the PLC only after a preceding tool transfercommand has been acknowledged and, consequently,completed.

All gripper movements are activated by Q functions in the NC. This signalis used in the PLC for triggering a hydraulic valve. The return messagefrom the valve (end position reached) is used for acknowledging the Qfunction. Except for the gripper function (which is described in section"PLC Module for Gripper Rotation"), the individual auxiliary functions willnot be explained in this context.



Tool Change Command TMS(*NC command "Changing tools from magazine to spindle"*)

┌─────────┐│TMS │

2#1─┤ACTIVE │0─┤PROC │1─┤POS │1─┤SPINDLE ├─S(TMS_ACT)└─────────┘

TMS.......................... ........................................ .......... TMS2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INT1............................ Position to be moved to................. .......... INT1............................ Spindle number.......................... .......... INTTMS_ACT...................... TMS flag active......................... .......... BOOL

(*General reset*)┌─────────┐│>=1 │

MXMG_CA─┤ │MXSG_CA─┤ ├┬R(TMS_ACT)

└─────────┘├R(MXMG_ACT)├R(MXMG_PA)├R(MXMG_NA)├R(XMG_OK)├R(MXSG_ACT)├R(MXSG_PA)├R(MXSG_NA)└R(XSG_OK)

MXMG_CA...................... XMG_CA flag OK.......................... .......... BOOLMXSG_CA...................... XSG_CA flag OK.......................... .......... BOOLTMS_ACT...................... TMS flag active......................... .......... BOOLMXMG_ACT..................... XMG flag active......................... .......... BOOLMXMG_PA...................... XMG flag OK............................. .......... BOOLMXMG_NA...................... XMG flag NA............................. .......... BOOLXMG_OK....................... XMG flag OK............................. .......... BOOLMXSG_ACT..................... XSG flag active......................... .......... BOOLMXSG_PA...................... XSG flag OK............................. .......... BOOLMXSG_NA...................... XSG flag NA............................. .......... BOOLXSG_OK....................... XSG flag OK............................. .......... BOOL

(*Initiate magazine-to-gripper tool transfer*)┌─────────┐│& │

TMS_ACT─┤ │ ┌─────────┐MXMG_PA─O │ │XMG │MXMG_ACT─O ├─────────────┤INIT │

└─────────┘ 0─┤PROC │1─┤POS │1─┤GRIP ├─S(MXMG_ACT)└─────────┘

TMS_ACT...................... TMS flag active......................... .......... BOOLMXMG_PA...................... XMG flag OK............................. .......... BOOLXMG.......................... ........................................ .......... XMGMXMG_ACT..................... XMG flag active......................... .......... BOOL0............................ Process number.......................... .......... INT1............................ Position to be moved to................. .......... INT1............................ Gripper number.......................... .......... INTMXMG_ACT..................... XMG flag active......................... .......... BOOL

(*Load tool in gripper if tool transfer is permitted*)┌─────────┐│XMG_PA │

2#1─┤ACTIVE │0─┤PROC │1─┤POS │1─┤GRIP ├─S(MXMG_PA)└─────────┘

XMG_PA....................... ........................................ .......... XMG_PA2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INT1............................ Position to be moved to................. .......... INT1............................ Gripper number.......................... .......... INTMXMG_PA...................... XMG flag OK............................. .......... BOOL



(*Issue error message if tool change position is not permitted*)┌─────────┐│XMG_NA │

2#1─┤ACTIVE │0─┤PROC │1─┤POS │1─┤GRIP ├─S(MXMG_NA)└─────────┘

XMG_NA....................... ........................................ .......... XMG_NA2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INT1............................ Position to be moved to................. .......... INT1............................ Gripper number.......................... .......... INTMXMG_NA...................... XMG flag NA............................. .......... BOOL

(*Acknowledge tool transfer if tool is loaded*)┌─────────┐│XMG_Q │

MXMG_PA─┤QUIT │0─┤PROC │1─┤POS │1─┤GRIP ├─S(XMG_OK)└─────────┘

XMG_Q........................ ........................................ .......... XMG_QMXMG_PA...................... XMG flag OK............................. .......... BOOL0............................ Process number.......................... .......... INT1............................ Position to be moved to................. .......... INT1............................ Gripper number.......................... .......... INTXMG_OK....................... XMG flag OK............................. .......... BOOL

(*Abort tool changing process if error message of tool management *)┌─────────┐│& │ ┌─────────┐

ICTRLRES─┤ │ │XMG_CA │MXMG_NA─┤ ├─────────────┤CANCEL │

└─────────┘ 0─┤PROC │1─┤POS │1─┤GRIP ├─MXMG_CA└─────────┘

ICTRLRES..................... PB control reset........................ %I12.3.0.. BOOLXMG_CA....................... ........................................ .......... XMG_CAMXMG_NA...................... XMG flag NA............................. .......... BOOL0............................ Process number.......................... .......... INT1............................ Position to be moved to................. .......... INT1............................ Gripper number.......................... .......... INTMXMG_CA...................... XMG_CA flag OK.......................... .......... BOOL

(*Initiate spindle-to-gripper tool transfer*)┌─────────┐│& │

TMS_ACT─┤ │XMG_OK─┤ │ ┌─────────┐XSG_OK─O │ │XSG │

MXSG_ACT─O ├─────────────┤INIT │└─────────┘ 0─┤PROC │

1─┤SPINDLE │2─┤GRIP ├─S(MXSG_ACT)└─────────┘

TMS_ACT...................... TMS flag active......................... .......... BOOLXMG_OK....................... XMG flag OK............................. .......... BOOLXSG_OK....................... XSG flag OK............................. .......... BOOLXSG.......................... ........................................ .......... XSGMXSG_ACT..................... XSG flag active......................... .......... BOOL0............................ Process number.......................... .......... INT1............................ Spindle number.......................... .......... INT2............................ Gripper number.......................... .......... INTMXSG_ACT..................... XSG flag active......................... .......... BOOL

(*Load tool in gripper if tool transfer is permitted*)┌─────────┐│XSG_PA │

2#1─┤ACTIVE │0─┤PROC │1─┤SPINDLE │2─┤GRIP ├─S(MXSG_PA)└─────────┘

XSG_PA....................... ........................................ .......... XSG_PA2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INT1............................ Spindle number.......................... .......... INT2............................ Gripper number.......................... .......... INTMXSG_PA...................... XSG flag OK............................. .......... BOOL



(*Issue error message if tool change position is not permitted*)┌─────────┐│XSG_NA │

2#1─┤ACTIVE │0─┤PROC │1─┤SPINDLE │2─┤GRIP ├─S(MXSG_NA)└─────────┘

XSG_NA....................... ........................................ .......... XSG_NA2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INT1............................ Spindle number.......................... .......... INT2............................ Gripper number.......................... .......... INTMXSG_NA...................... XSG flag NA............................. .......... BOOL

(*Acknowledge tool transfer if tool is loaded*)┌─────────┐│XSG_Q │

MXSG_PA─┤QUIT │0─┤PROC │1─┤SPINDLE │2─┤GRIP ├─S(XSG_OK)└─────────┘

XSG_Q........................ ........................................ .......... XSG_QMXSG_PA...................... XSG flag OK............................. .......... BOOL0............................ Process number.......................... .......... INT1............................ Spindle number.......................... .......... INT2............................ Gripper number.......................... .......... INTXSG_OK....................... XSG flag OK............................. .......... BOOL


ICTRLRES─┤ │ │XSG_CA │MXSG_NA─┤ ├─────────────┤CANCEL │

└─────────┘ 0─┤PROC │1─┤SPINDLE │2─┤GRIP ├─MXSG_CA└─────────┘

ICTRLRES..................... PB control reset........................ %I12.3.0.. BOOLXSG_CA....................... ........................................ .......... XSG_CAMXSG_NA...................... XSG flag NA............................. .......... BOOL0............................ Process number.......................... .......... INT1............................ Spindle number.......................... .......... INT2............................ Gripper number.......................... .......... INTMXSG_CA...................... XSG_CA flag OK.......................... .......... BOOL

(*Acknowledge tool change if tool transfer is acknowledged*)┌─────────┐│& │

TMS_ACT─┤ │ ┌─────────┐XMG_OK─┤ │ │TMS_Q │XSG_OK─┤ ├─────────────┤QUIT │

└─────────┘ 0─┤PROC │1─┤POS │1─┤SPINDLE ├┬R(TMS_ACT)└─────────┘├R(XMG_OK)

├R(XSG_OK)├R(MXMG_PA)├R(MXSG_PA)├R(MXMG_ACT)└R(MXSG_ACT)

TMS_ACT...................... TMS flag active......................... .......... BOOLXMG_OK....................... XMG flag OK............................. .......... BOOLTMS_Q........................ ........................................ .......... TMS_QXSG_OK....................... XSG flag OK............................. .......... BOOL0............................ Process number.......................... .......... INT1............................ Position to be moved to................. .......... INT1............................ Spindle number.......................... .......... INTTMS_ACT...................... TMS flag active......................... .......... BOOLXMG_OK....................... XMG flag OK............................. .......... BOOLXSG_OK....................... XSG flag OK............................. .......... BOOLMXMG_PA...................... XMG flag OK............................. .......... BOOLMXSG_PA...................... XSG flag OK............................. .......... BOOLMXMG_ACT..................... XMG flag active......................... .......... BOOLMXSG_ACT..................... XSG flag active......................... .......... BOOL



Tool Change Command TSM(*NC command "Changing tools from spindle to magazine"*)

┌─────────┐│TSM │

2#1─┤ACTIVE │0─┤PROC │1─┤SPINDLE │1─┤POS ├─S(TSM_ACT)└─────────┘

TSM.......................... ........................................ .......... TSM2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INT1............................ Spindle number.......................... .......... INT1............................ Position to be moved to................. .......... INTTSM_ACT...................... TSM flag active......................... .......... BOOL

(*General reset*)┌─────────┐│>=1 │

MXGM_CA─┤ │MXGS_CA─┤ ├┬R(TSM_ACT)

└─────────┘├R(MXGM_ACT)├R(MXGM_PA)├R(MXGM_NA)├R(XGM_OK)├R(MXGS_ACT)├R(MXGS_PA)├R(MXGS_NA)└R(XGS_OK)

MXGM_CA...................... XGM_CA flag OK.......................... .......... BOOLMXGS_CA...................... XGS_CA flag OK.......................... .......... BOOLTSM_ACT...................... TSM flag active......................... .......... BOOLMXGM_ACT..................... XGM flag active......................... .......... BOOLMXGM_PA...................... XGM flag OK............................. .......... BOOLMXGM_NA...................... XGM flag NA............................. .......... BOOLXGM_OK....................... XGM flag OK............................. .......... BOOLMXGS_ACT..................... XGS flag active......................... .......... BOOLMXGS_PA...................... XGS flag OK............................. .......... BOOLMXGS_NA...................... XGS flag NA............................. .......... BOOLXGS_OK....................... XGS flag OK............................. .......... BOOL

(*Initiate gripper-to-magazine tool transfer*)┌─────────┐│& │

TSM_ACT─┤ │ ┌─────────┐MXGM_ACT─O │ │XGM │XGM_OK─O ├─────────────┤INIT │

└─────────┘ 0─┤PROC │2─┤GRIP │1─┤POS ├─S(MXGM_ACT)└─────────┘

TSM_ACT...................... TSM flag active......................... .......... BOOLMXGM_ACT..................... XGM flag active......................... .......... BOOLXGM.......................... ........................................ .......... XGMXGM_OK....................... XGM flag OK............................. .......... BOOL0............................ Process number.......................... .......... INT2............................ Gripper number.......................... .......... INT1............................ Position to be moved to................. .......... INTMXGM_ACT..................... XGM flag active......................... .......... BOOL

(*Load tool in gripper if tool transfer is permitted*)┌─────────┐│XGM_PA │

2#1─┤ACTIVE │0─┤PROC │2─┤GRIP │1─┤POS ├─S(MXGM_PA)└─────────┘

XGM_PA....................... ........................................ .......... XGM_PA2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INT2............................ Gripper number.......................... .......... INT1............................ Position to be moved to................. .......... INTMXGM_PA...................... XGM flag OK............................. .......... BOOL



(*Issue error message if tool change position is not permitted*)┌─────────┐│XGM_NA │

2#1─┤ACTIVE │0─┤PROC │2─┤GRIP │1─┤POS ├─S(MXGM_NA)└─────────┘

XGM_NA....................... ........................................ .......... XGM_NA2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INT2............................ Gripper number.......................... .......... INT1............................ Position to be moved to................. .......... INTMXGM_NA...................... XGM flag NA............................. .......... BOOL

(*Acknowledge tool transfer if tool is loaded*)┌─────────┐│XGM_Q │

MXGM_PA─┤QUIT │0─┤PROC │2─┤GRIP │1─┤POS ├─S(XGM_OK)└─────────┘

XGM_Q........................ ........................................ .......... XGM_QMXGM_PA...................... XGM flag OK............................. .......... BOOL0............................ Process number.......................... .......... INT2............................ Gripper number.......................... .......... INT1............................ Position to be moved to................. .......... INTXGM_OK....................... XGM flag OK............................. .......... BOOL


ICTRLRES─┤ │ │XGM_CA │MXGM_NA─┤ ├─────────────┤CANCEL │

└─────────┘ 0─┤PROC │2─┤GRIP │1─┤POS ├─MXGM_CA└─────────┘

ICTRLRES..................... PB control reset........................ %I12.3.0.. BOOLXGM_CA....................... ........................................ .......... XGM_CAMXGM_NA...................... XGM flag NA............................. .......... BOOL0............................ Process number.......................... .......... INT2............................ Gripper number.......................... .......... INT1............................ Position to be moved to................. .......... INTMXGM_CA...................... XGM_CA flag OK.......................... .......... BOOL

(*Initiate gripper-to-spindle tool transfer*)┌─────────┐│& │

TSM_ACT─┤ │MXGS_ACT─O │ ┌─────────┐XGM_OK─┤ │ │XGS │XGS_OK─O ├─────────────┤INIT │

└─────────┘ 0─┤PROC │1─┤GRIP │1─┤SPINDLE ├─S(MXGS_ACT)└─────────┘

TSM_ACT...................... TSM flag active......................... .......... BOOLMXGS_ACT..................... XGS flag active......................... .......... BOOLXGM_OK....................... XGM flag OK............................. .......... BOOLXGS.......................... ........................................ .......... XGSXGS_OK....................... XGS flag OK............................. .......... BOOL0............................ Process number.......................... .......... INT1............................ Gripper number.......................... .......... INT1............................ Spindle number.......................... .......... INTMXGS_ACT..................... XGS flag active......................... .......... BOOL

(*Load tool in gripper if tool transfer is permitted*)┌─────────┐│XGS_PA │

2#1─┤ACTIVE │0─┤PROC │1─┤GRIP │1─┤SPINDLE ├─S(MXGS_PA)└─────────┘

XGS_PA....................... ........................................ .......... XGS_PA2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INT1............................ Gripper number.......................... .......... INT1............................ Spindle number.......................... .......... INTMXGS_PA...................... XGS flag OK............................. .......... BOOL



(*Issue error message if tool change position is not permitted*)┌─────────┐│XGS_NA │

2#1─┤ACTIVE │0─┤PROC │1─┤GRIP │1─┤SPINDLE ├─S(MXSG_NA)└─────────┘

XGS_NA....................... ........................................ .......... XGS_NA2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INT1............................ Gripper number.......................... .......... INT1............................ Spindle number.......................... .......... INTMXSG_NA...................... XSG flag NA............................. .......... BOOL

(*Acknowledge tool transfer if tool is loaded*)┌─────────┐│XGS_Q │

MXGS_PA─┤QUIT │0─┤PROC │1─┤GRIP │1─┤SPINDLE ├─S(XGS_OK)└─────────┘

XGS_Q........................ ........................................ .......... XGS_QMXGS_PA...................... XGS flag OK............................. .......... BOOL0............................ Process number.......................... .......... INT1............................ Gripper number.......................... .......... INT1............................ Spindle number.......................... .......... INTXGS_OK....................... XGS flag OK............................. .......... BOOL


ICTRLRES─┤ │ │XGS_CA │MXGS_NA─┤ ├─────────────┤CANCEL │

└─────────┘ 0─┤PROC │1─┤GRIP │1─┤SPINDLE ├─MXGS_CA└─────────┘

ICTRLRES..................... PB control reset........................ %I12.3.0.. BOOLXGS_CA....................... ........................................ .......... XGS_CAMXGS_NA...................... XGS flag NA............................. .......... BOOL0............................ Process number.......................... .......... INT1............................ Gripper number.......................... .......... INT1............................ Spindle number.......................... .......... INTMXGS_CA...................... XGS_CA flag OK.......................... .......... BOOL

(*Acknowledge tool change if tool transfer is acknowledged*)┌─────────┐│& │

TSM_ACT─┤ │ ┌─────────┐XGM_OK─┤ │ │TSM_Q │XGS_OK─┤ ├─────────────┤QUIT │

└─────────┘ 0─┤PROC │1─┤SPINDLE │1─┤POS ├┬R(TSM_ACT)└─────────┘├R(XGM_OK)

├R(XGS_OK)├R(MXGM_PA)├R(MXGS_PA)├R(MXGM_ACT)└R(MXGS_ACT)

TSM_ACT...................... TSM flag active......................... .......... BOOLXGM_OK....................... XGM flag OK............................. .......... BOOLTSM_Q........................ ........................................ .......... TSM_QXGS_OK....................... XGS flag OK............................. .......... BOOL0............................ Process number.......................... .......... INT1............................ Spindle number.......................... .......... INT1............................ Position to be moved to................. .......... INTTSM_ACT...................... TSM flag active......................... .......... BOOLXGM_OK....................... XGM flag OK............................. .......... BOOLXGS_OK....................... XGS flag OK............................. .......... BOOLMXGM_PA...................... XGM flag OK............................. .......... BOOLMXGS_PA...................... XGS flag OK............................. .......... BOOLMXGM_ACT..................... XGM flag active......................... .......... BOOLMXGS_ACT..................... XGS flag active......................... .......... BOOL



PLC Module for Gripper RotationThe gripper that is used here cannot rotate endlessly. It can only swingbetween the end positions of 0° and 180°. This means that the positionmust be stored in the PLC program. This is done using a retain variable(see PLC Programming Instructions).

The retain variable of this tool changing process is "G0_G180".

(*Auxiliary function output "Rotate gripper"*)┌─────────┐│Q_FKT │

2#1─┤ACTIVE │0─┤PROC │3─┤NR O─>>noQ3└─────────┘

Q_FKT........................ ........................................ .......... Q_FKT2#1.......................... ........................................ .......... Dual0............................ Process number.......................... .......... INT3............................ ........................................ .......... INTnoQ3......................... ........................................ .......... Flag

(*if gripper is at 0° (G0_G180=Reset) -> GR_180*)┌─────────┐

G0_G180─O:= ├─>>GR_180└─────────┘

G0_G180...................... Gripper position S=0 R=180.............. .......... BOOLGR_180....................... ........................................ .......... Flag

(*Rotate gripper to 0°*)┌─────────┐

2#1─┤:= ├┬S(MROT)└─────────┘└S(QGR_0)

2#1.......................... ........................................ .......... DualMROT......................... Gripper movement active................. .......... BOOLQGR_0........................ Valve activation -> 0°.................. .......... BOOL

┌─────────┐│& │

IGR_0─┤ │IGR_180─O │QGR_0─┤ │MROT─┤ ├┬S(MGR0_Q)

└─────────┘├R(MROT)└R(G0_G180)

IGR_0........................ End position return message 0°.......... .......... BOOLIGR_180...................... End position return message 180°........ .......... BOOLQGR_0........................ Valve activation -> 0°.................. .......... BOOLMROT......................... Gripper movement active................. .......... BOOLMGR0_Q....................... Gripper acknowledgement flag 0°......... .......... BOOLMROT......................... Gripper movement active................. .......... BOOLG0_G180...................... Gripper position S=0 R=180.............. .......... BOOL

┌─────────┐2#1─┤:= ├─>>Q3_Q

└─────────┘2#1.......................... ........................................ .......... DualQ3_Q......................... ........................................ .......... Flag

(*Rotate gripper to 180°*)GR_180:

┌─────────┐2#1─┤:= ├┬S(MROT)

└─────────┘└S(QGR_180)2#1.......................... ........................................ .......... DualMROT......................... Gripper movement active................. .......... BOOLQGR_180...................... Valve activation -> 180°................ .......... BOOL

┌─────────┐│& │

IGR_0─O │IGR_180─┤ │QGR_180─┤ │

MROT─┤ ├┬S(MGR180_Q)└─────────┘├R(MROT)

└S(G0_G180)IGR_0........................ End position return message 0°.......... .......... BOOLIGR_180...................... End position return message 180°........ .......... BOOLQGR_180...................... Valve activation -> 180°................ .......... BOOLMROT......................... Gripper movement active................. .......... BOOLMGR180_Q..................... Gripper acknowledgement flag 180°....... .......... BOOLMROT......................... Gripper movement active................. .......... BOOL



G0_G180...................... Gripper position S=0 R=180.............. .......... BOOL

(*Acknowledge auxiliary function output "Rotate gripper"*)Q3_Q:

┌─────────┐│>=1 │ ┌─────────┐

MGR0_Q─┤ │ │Q_FKT_Q │MGR180_Q─┤ ├─────────────┤QUIT │

└─────────┘ 0─┤PROC │3─┤NR ├┬R(MGR0_Q)└─────────┘└R(MGR180_Q)

MGR0_Q....................... Merker Quit. Greifer 0°................. .......... BOOLQ_FKT_Q...................... ........................................ .......... Q_FKT_QMGR180_Q..................... Merker Quit. Greifer 180°............... .......... BOOL0............................ Process number.......................... .......... INT3............................ ........................................ .......... INTMGR0_Q....................... Gripper acknowledgement flag 0°......... .......... BOOLMGR180_Q..................... Gripper acknowledgement flag 180°....... .......... BOOL

noQ3:

6.5 Additional Tool Carriers

GeneralIn addition to the turret locations, up to 4 additional tool carriers can beconfigured for stationary single tools in the MTC 200 (process parameterBxx.018 "Number of tool spindles/carriers). This is significant especiallyfor lathes. All together, 4 additional tools per process are possible.

The zero offsets (ZO) of the additional tool carriers are stored in machinedata page 21 "Additional tool carriers". When an additional tool isactivated, the NC automatically activates the zero offset stored in themachine data; this is then taken into account during the determination ofthe spindle velocity for the constant cutting velocity (G96).

X +

Z +

M

T

L1

L2

Machine zero point {Z0;X0}:

Tool carrier reference point isbrought in alignment with spindle

reference point

Tool turret(Main tool carrier)

Tool offset:

Difference between themachine zero point (turret)

and the tool carrier referencepoint of the additional tool

Additional toolcarrier (fixed)

Maschinennullpunkt.FH7

Fig. 6-9: Lathe with additional tool carrier

After initialization (control reset), the tool zero offset of the turret/magazineis active. Now every tool, whether in the turret or in an available toolcarrier, can be activated in the NC program using the T number and theMTP command. The initial state is restored with "MTP T0" or "MTPT<turret space>". Alternatively to the MTP, command "SPT <spindleindex>" can also be used to select an additional tool.



The zero offsets of the free tool carriers can be used for the "Magazine"tool storage type. If no magazine spaces are present, the T commandalso activates the zero offset of the active reference spindle.

Parameter Value AssignmentThe number of additional tool carriers is defined in process parameterBxx.018 "Number of tool spindles/carriers". The value range lies between0 and 4.

The corrections for the turret (control variable LV2=0) and for up to 4 freetool carriers (LV2=1-4) are provided for each process (control variableLV1) in machine data page 21. The entered values refer to the machinecoordinate system, i.e. the offset is fixed to the X-, Y- and Z-axismeaning, regardless of the level.

For end processing (G31), the rotation direction of transformation canalso be influenced for the X-axis because the tool carrier can be locatedin front of or behind the center of rotation. Machine data element"Rotation direction for transformation" indicates whether thetransformation for end processing (G31) is to work in the negative (value= 1) or the positive (value = 0) X-direction. If tool carriers are present(parameter Bxx.018 > 0), machine data element "Rotation direction fortransformation" is used for specific tool carriers in place of axis parameterCxx.076 "Rotation direction for transformation" .

Note: The zero offsets of the additional tool carriers are not activatedas long as no machine data page 21 has been loaded into theNC.

Selecting Additional Tool CarriersAs before, turret tools are selected by entering the T number and the MTPcommand; the MTP command is used to position the turret.

An additional tool carrier is also selected with the T number and the MTPcommand; however, the turret is not positioned. After selection, the toolwith the 1st

edge is active; the offset of the new machine zero point istaken into account. This offset is taken into account even if toolcompensation is inactive (G47).

In the case of tool storage type "Magazine" (parameter Bxx.015), the MTPcommand has no effect on additional tool carriers. For this tool storagetype, an existing offset in taken into account in the machine data byactivating the reference spindle.

The following table shows which commands are affected by the activationof the tool reference point offset for the given tool storage type:



CommandsType of toolmagazine

Locations

T<n MTP SPT <n>

Initialization

Tool carrieronly

Activates offsetof tool carrier ofT<n>

- Activates offsetof tool carrier ofT<n>

Activates offsetof tool carrier 1

Turret locationsonly

- - - Activates offsetof tool turret

Turret

Turret locations+ tool carrier

- Activates offsetof tool carrier orof turret,depending onlocation T<n>

Activates offsetof tool carrier ofT<n> (n=0 fortool turret)

Activates offsetof tool turret

Tool carrier /spindles only

Activates offsetof tool spindle /carrier T<n>



Magazine

Magazinelocations + toolcarrier



Fig. 6-10: Activation of tool points offset

The offset of the additional tool carrier defines the new machine zeropoint. The offset always affects the axis meanings X, Y, and Z. The offsetalways affects G96.

Tool Management Appendix 7-1


7 Appendix

7.1 "NC Tool Commands" Overview

Tool commands of the NC V23_20030218


Preselect tool edge Syntax: E<EDG>

EDG: Tool edge numberE

Edge

Tool storage enabled for manualmode

MEN

Magazine Enable

Syntax: MEN

Move free pocket into changeposition

Syntax: MFP (POS, DIR)

POS: position to be movedMFP

Move next Free Pocket in Position DIR: rotational direction

Tool storage to home position Syntax: MHP ( DIR )

DIR: rotational directionMHP


Freely position tool axis Syntax: MMA ( POS, DIR )

POS: position to be movedMMA

Move Magazine Axis DIR: rotational direction / mode

Move programmed pocket into basicposition

Syntax: MMP (POS, DIR)

POS: position to be movedMMP

Move Magazine Pocket in Position DIR: rotational direction

Move old pocket into position Syntax: MOP ( POS, DIR, SPI )

POS: position to be moved


MOP

Move Old Pocket in Position SPI: Spindle

Move tool storage unit to referenceposition

MRF

Move to Reference Position Toolstorage motion commands:Toolstorage to reference position "MRF"

Syntax: MRF

Tool storage ready? Syntax: MRY

MRY

Magazine Ready

Move programmed tool into position Syntax: MTP ( POS, DIR )

POS: position to be movedMTP

Move Tool Position DIR: rotational direction

Preselect tool spindle Syntax: SPT<SPI>

SPI: Spindle numberSPT

Spindle for Tool

7-2 Appendix Tool Management



Preselect tool Syntax: T<TNP>

TNP: Tool number or tool locationT

Tool

Complete tool change Syntax: TCH (POS, SPI)

POS: position to be movedTCH

Tool Change SPI: Spindle

TG

Preselect tool group

Tool Group

Syntax: TG<GRP>

GRP: number of the tool group (or 0)

TGSM

Define tool search mode

Tool Group Search Mode

Syntax: TGSM<MODE>

MODE: Search mode

Switch tool from magazine to spindle Syntax: TMS (POS, SPI)

POS: position to be movedTMS

Tool change from Magazine toSpindle

SPI: Spindle

Tool magazine pocket free? Syntax: TPE

TPE

Tool Magazine Pocket Empty

Tool spindle free?

TSE

Tool Spindle Empty

Syntax: TSE

Switch tool from spindle to magazine Syntax: TSM (POS, SPI)

POS: position to be movedTSM

Tool change from Spindle toMagazine

SPI: Spindle

Werkzeugbefehle_NC__All_V23_20030218.xls



7.2 Overview "SPS Interface Signals"

"Tool Storage Unit Control Signals" Overview

Tool magazine control signals V22_20030122

Signal MeaningPLC →→→→

NC

Enabling the tool magazine 0 Tool magazine enabling signal is missing

PxxC.MGENA Process xx Command Magazine Enable 1 Tool magazine enabling signal is present

Operation without setup list 0 Tool assignment (T. No.) according to setuplist PxxC.MGNSL

Process xx Command Magazine no Setup List 1 Tool assignment (T. No.) according to toollist

Deactivating the Life Count 0 Tool life count is not influenced

PxxC.MGNTL Process xx Command Magazine no Tool Life calculation

1 Tool life count is switched off

Mode of tool storage unit 0 Tool magazine is allocated to the NCprogram PxxC.MGMAN

Process xx Command Magazine Mode Manual 1 Tool magazine is to be moved manually(PLC)

Move tool storage unit to reference position

PxxC.MGHOM Process xx Command Magazine move to Homing

Initiates homing of the tool magazine

Tool storage to home position

PxxC.MGBP Process xx Command Magazine Base Position

Informs tool management that the toolmagazine is to move to the home position.

Moving the tool storage unit by one location in thepositive direction PxxC.MGPOS Process xx Command Magazine Positive Direction

Moves the tool storage unit by one locationin the positive direction

PxxC.MGNEG

Moving the tool storage unit by one location in thenegative direction

Process xx Command Magazine Negative Direction

Moves the tool storage unit by one locationin the negative direction

Actual position

PxxC.MGAP Process xx Command Magazine Actual Position

The PLC informs tool management of thecurrent position of the tool magazine inrelation to the reference mark.

Deactivation of the automatic tool check 0 Automatic equipment check can beexecuted PxxC.MGWTC

Process xx Command Magazine without Tool Check 1 Automatic equipment check is not executed

Tool check ignores worn-out tools 0 Worn-out tools taken into account

PxxC.MGITW Process xx Command Magazine Ignore Tool Worn Out

1 Ignore worn-out tools

Magazine jog mode with variable tool locations

PxxC.MGJGn n = (0, 1) Process xx Command Magazine Jogging Mode Bit n

Specifies the change position to whichmagazine jogging refers

Wz_speicher_steuersignale_V22_groß_20030122.xls



"Tool Storage Unit Status Signals" Overview

Tool magazine status signals V22_20030123

Signal MeaningPLC →→→→

NC

Enabling the tool magazine 0 No movement permitted

PxxS.MGENA Process xx Status Magazine Enable 1 Enabling tool magazine for movement

Requesting the tool storage unit from the NC 0 No request from NC

PxxS.MGREQ Process xx Status Magazine Request 1 NC needs tool magazine

Tool storage unit in motion 0 Tool magazine has stopped

PxxS.MGMOV Process xx Status Magazine Move 1 Tool magazine is moving

Tool storage unit in program or manual mode 0 The tool magazine is allocated to the NC

PxxS.MGMAN Process xx Status Magazine Mode Manual 1 The tool magazine is allocated to the PLC

Tool magazine in home position 0 The tool magazine is not in its basicposition

PxxS.MGBP Process xx Status Magazine Base Position 1 The tool magazine is in its basic position

Command position

PxxS.MGCP Process xx Status Magazine Command Position

Magazine for transferring the commandposition, relative to the reference mark, ofthe tool storage unit to the PLC

Life count monitoring: tool worn out 0 The tools can still be used

PxxS.MGTWO Process xx Status Magazine Tool Worn Out 1 At least one tool is worn out

Life count monitoring: warning limit reached 0 The tool has not yet reached its warninglimit

PxxS.MGWRN Process xx Status Magazine Warning 1 The tool has reached its warning limit

Tool error status 0 There is no error

PxxS.MGERR Process xx Status Magazine Error 1 There is an error

Wz_speicher_statussignale_V22_groß_20030123.xls

7.3 "PLC Tool Transfer Commands" Overview

PLC tool transfer commands V22_20021029

from to initiate permitted terminate not permitted abort

Magazine Spindle XMS XMS_PA XMS_Q XMS_NA XMS_CA

Magazine Gripper XMG XMG_PA XMG_Q XMG_NA XMG_CA

Spindle Magazine XSM XSM_PA XSM_Q XSM_NA XSM_CA

Spindle Gripper XSG XSG_PA XSG_Q XSG_NA XSG_CA

Gripper Magazine XGM XGM_PA XGM_Q XGM_NA XGM_CA

Gripper Spindle XGS XGS_PA XGS_Q XGS_NA XGS_CA

Werkzeugtransferbefehle_SPS_V22_20021029.xls



7.4 "Tool Data Record" Overview

Basic tool data (per tool) V23_20030319

DESIGNATION RANGE

DA

TA

TY

PE

in t

he

PL

C

UN

IT DE OPT. SL TL

Tool identification

Index address hexadecimal double word with 32 bits - 01 X X

ID (tool NAME) up to 28 characters STRG28 - 02 X

Memory 0 - 2 - 03 X

Location 0 - 999 - 04 X

Tool number 1 - 9999999 DINT - 05 X X

Tool duplo number 1 - 9999 INT - 06 X

Correction type 1 - 5 USINT - 07 X X

Number of tool edges 1 - 9 USINT - 08 X X

Tool Status 0/1 (32 status bits) USINT - 09 X

Location data

Free half-locations 0 - 4 USINT - 10 X

Old pocket 1 - 999 INT - 11 X

Stor. of next setup tool 0 - 2 INT - 12 X

Loc. of next setup tool 1 - 999 INT - 13 X

Stor. of prev. setup tool 0 - 2 INT - 14 X

Loc. of prev. setup tool 1 - 999 INT - 15 X

Units

Time unit 0/1 (0: min, 1: cycl.) USINT - 16 X

Unit of length 0/1 (0: mm, 1: inches) USINT - 17 X X

Technology data

Tool code 0 - 9 USINT - 18 X X

Representation type 0 - 65535 INT - 19 X X

User data









User data 9

+/- 1.2 * 10-38 - +/- 3.4 * 10+38

and 0 (9 significant digits)

REAL 28 A00.069 X



Group data

29

Group number 0 - 99 BYTE - 30 X

Group duplo number 0 - 99 BYTE - 31 X

Group status 0/1 (16 status bits) WORD - 32 X

Comment up to 5 x 76 alphanumeric characters - 99 A00.057 X

WGD_all_V23_20030319.xls

Data element 99 ”Comment” is not loaded in the control.


R.TL ... Replacement tool TL ... Tool list-specific datum

CTRL29 ... STRING28 OPT ... Optional datum



Tool status bits 1 – 16 frombasic tool data, data element 09

V22_20030519

Writeaccess

Type


Sym

bo

l

Val

ue

Bit

Byt

e

Wo

rd

TM

OP

AS

P

SL

TL

PL

Comment

Tool not available !

Tool available 0X X X Tool is missing

Tool is not required ? 1Presence

Tool required 0 2 X X XTool not required formachining

Correction type wrong t 1Errorcorrection type correction type not faulty 0 3 X X X

Correction type does notcomply with requirements

Incorrect number of tooledges

e 1ErrorNumber of tool edges

Correct number of tool edges 04 X X X

Number of tool edgesdoes not comply withrequirements

Tool edge(s) incorrect f 1Error tool edge

Edge(s) not faulty 0 5 X X X

Tool edge data does notcomply with requirements

Tool code incorrect $ 1Error tool code

Tool code not incorrect 0 6 X X X

Tool data do notcorrespond to thedefinition

Reserved for extension7

Reserved for extension8

LO

W B

YT

E

0

- 7

Location locked B1

Location lockingLocation not locked 0

9 X X X X X

ASP/OP:e.g. location is damagedTM:tool is entered

Reserved for extension Upper half-location locking10

Reserved for extension Lower half-location locking11

Upper half-location reserved ) 1Upper half-locationreservation

Upper half-location notreserved

0 12 X X X X

Reserved for temp.moved tools

Lower half-location reserved ( 1Lower half-locationreservation

Lower half-location notreserved

0 13 X X X X

Reserved for temp.moved tools

Reserved for extension Upper half-location covering14

Reserved for extension Lower half-location covering15

Location assigned + 1Location reservation Location not assigned 0 16

HIG

H -

BY

TE

0 ...

7

LO

W W

OR

D

0

- 15

X X X

There is a tool in thelocation

WSB_all_V22_20030519_1.xls



ASP ... Application-specific programs in PLC or NC OPT ... Optional datum




Tool status bits 17 – 32 frombasic tool data, data element 09

V22_20030519

Writeaccess Type


Sym

bo

l

Val

ue

Bit

Byt

e

Wo

rd

TM

OP

AS

P

SL

TL

PL

Comment

Tool is worn out d 1

tool is not worn out 017 X X

The remaining lifetime ofthe tool has elapsed(replace)

Warning limit is reached w 1Wear statusWarning limit not reached 0

18 X XThe remaining lifetime isabout to expire (replace)

Machining tool p 1

No machining tool 019 X X

There is one machining toolfor each alternate toolgroup

Replacement tool s 1Alternateidentification

no spare tool 020 X X

A spare tool is a tool thatcan still be used, nomachining tool

Tool with fixed location coding C 1Tool coding

Tool without fixed location coding 021 X X X X

The tool may only bechanged to the predefinedtool location

Tool locked L 1Tool locking

Tool is not locked 022 X X X Tool must not be used

Tool broken 1Tool breakage

Tool is not broken

D

023 X X X

Tool is damaged, e.g. atool edge has broken off

Reserved forextension 24

LO

W B

YT

E

0

- 7

Axx.075 1User tool status 1 User tool status bit 1

025 X X X

Any meaning

1User tool status 2 User tool status bit 2 Axx.076

026 X X X

Any meaning


027 X X X

Any meaning


028 X X X

Any meaning


029 X X X

Any meaning


030 X X X

Any meaning


031 X X X

Any meaning


any

032

HIG

H -

BY

TE

0 ...

7

HIG

H W

OR

D

0

- 15

X X XAny meaning

WSB_all_V22_20030519_2.xls



ASP ... Application-specific programs in PLC or NC OPT ... Optional datum




Tool groups: Group status data element 32 V23_20021112

Status Status bit Symbol Value Bit Write

Access

Type Comment

TM OP ASP GL

Presence Group does not exist ! 1 1 X X

Group exists 0

Tool in this groupmissing

Group not required ? 1 2 X X

Group required 0

No tool of this

Group required

Group status Group disabled L 1 3 X X X User-programmable

Group not disabled 0

Wear state Group worn d 1 4 X X

Group not worn 0

At least one toolalternate sequence ofthe group is worn out.

Warning limit isreached

w 1 5 X X

Warning limit notreached

0

At least one toolalternate sequence ofthe group hasreached warning limit

Name of alternate Machining group p 1 6 X X

No machining group 0

Group is machininggroup

Spare group s 1 7 X X

No spare group 0

Group is alternategroup

8Reserved forextension

User group status 1 any 1 9 X X XUser group status bit1

0

Any meaning

User group status 2 any 1 10 X X X Any meaningUser group status bit2

0


0


0


0


0


0


0

WZG_all_V23_20021112.xls



ASP ... Application-spec.

programs on the PLC or NC

OPT ... Optional datum

GL Tool group list-specific status bit




Tool edge data (per tool edge) V22_20030317

DESIGNATION RANGE

DA

TA

TY

PE

in P

LC UNIT

DE

OP

T.

SL

TL

Tool edge identification

Tool edge position 0 - 8 USINT 01 X X

Tool edge status 0; 1 (16 status bits) WORD 02 X

Tool life data

Remaining tool life -99.9 - +100.00 REAL 03 A00.059 X

Warning limit +0.1 - +100.00 REAL%

04 A00.059 X

max. utilization time0 - 9999999(0: tool life recognition switched off) REAL 05 A00.059 X

Time used 0 - 9999.999 REAL

min. orcycles

06 A00.059 X

Geometry Data

Length L1 DINT 07 X

Length L2 DINT 08 X

Length L3 DINT 09 X

Radius R DINT 10 X




Wear R DINT 14 A00.055 X




Offset R

-99999.9999 - +99999.9999

or

-9999.99999 - +9999.99999

DINT

mm

or

inches

18 A00.056 X

Geometry limit values







R_min DINT 25 A00.060 X

R_max

-99999.9999 - +99999.9999

or

-9999.99999 - +9999.99999

DINT

mm

or

inches

26 A00.060 X

Wear factors




Wear factor R

-99999.9999 - +99999.9999or

-9999.99999 - +9999.99999DINT

mm/min orinch/min or

cycles30 A00.058 X



User data





User data 5

+/- 1.2 * 10-38 - +/- 3.4 * 10+38and

0 ( 9 significant digits)REAL any 35 A00.074 X





User data 10

-99999.9999 - +99999.9999or

-9999.99999 - +9999.99999DINT any 40 A00.096 X

SD_all_V22_20030317.xls


OPT ... Optional datum TL ... Tool list-specific datum



Tool edge status bit from tool edge data element 02V22_20030317

Writeaccess Type


Sym

bo

l

Val

ue

Bit

TM

OP

AS

P

SL

TL

Comment

Incorrect tool edge orientation o 1Incorrect tool edgeposition

Tool edge orientation is not incorrect 01 X X

Tool edge data do notcorrespond to thedefinition

L1 incorrect 1 1L1 incorrect L1 not incorrect 0

2 X XTool edge data do notcorrespond to thedefinition





R incorrect r 1R incorrect R not incorrect 0


Reserved for extensions6



Tool edge worn out d 1

Tool not worn out 09 X X

The tool edge can nolonger be used(replace)


Warning limit not reached 010 X X

The remaining tool lifeof the tool edge is nearits end (replace)



1User tool edge status 1 User tool edge status bit 1 Axx.083

013 X X X

Any meaning


014 X X X

Any meaning

Axx.085 1User tool edge status 3 User tool edge status bit 3

015 X X X

Any meaning


any

016 X X X

Any meaning

SSB_all_V22_20030317.xls



ASP ... Application-spec. programs on the PLC or NC OPT ... Optional datum



7.5 Read/Write Tool Data from the NC Program "TLD"

Mit dem TLD-Befehl The TLD command (Tool Data) can be used to readall the tool data in the tool list from the NC program and to write them;however, some restrictions apply to writing.

The individual data elements are addressed by means of codes.Depending on both types of addressing ...

• Addressing via location and magazine (A=0)

• Addressing via tool number and tool duplo number (A=1) ...

the two following variants of TLD command are possible:

TLD ( P, A, SA, L, E, DE, S, G, GD )

Symbol Designation

GD Group duplonumber

G Group number

S Status

DE Data element

E Tool edge

L Location

SA Storage type

A Addressing

P ProcessTLD_0_V23_20030130.xls

TLD ( P, A, T, WD, E, DE, S, G, GD )

Symbol Designation

GD Group duplonumber

G Group number

S Status

DE Data element

E Tool edge

TD Tool duplonumber

T T No.T No.

A Addressing

P ProcessTLD_1_V23_20030130.xls

Syntax



The two illustrations below explain in detail the parameters of the TLDcommand:

TLD Addressing via Location and Magazine Type V23_20030319

Designation Symbol Value range / meaning

Process P 0 ... 6 Process number

Addressing A 0 Addressing via location and magazine type

Storage type SA

0

Magazine /turret

1

Spindle

2

Gripper

3

Toolchangeposition

7

Address active tool

Location L 1 ... 999 1 ... 4 1 ... 4 1 ... 4 0

Tool edge E 0 1 ... 9

Basic tool data Tool Edge Data

Data element DE 3 ... 89

Tool Status 10 ... 3132

Groupstatus

1 2 3 ... 40

Status S ---1 ... 32

Tool statusbits

---1 ... 16Group

status bits---

1 ... 16

Tool edge statusbits

---

Group no. G not relevant not relevant

Group duplonumber GD not relevant not relevant

TLD Addressing via Tool and Duplo Number V23_20030319

Designation Symbol Value range / meaning

Process P 0 ... 6 Process number

Addressing A 1 Addressing via tool and T-duplo number

Tool number(T)

T 1 ... 9999999 Tool number

T duplo no. TD 1 ... 9999 Tool duplo number

Tool edge E 0 1 ... 9

Basic tool data Tool Edge DataData element DE 3 ... 8 9

Tool Status

10 ... 31 32Groupstatus

1 2 3 ... 40

Status S ---1 ... 32

Tool statusbits

---1 ... 16Group

status bits---

1 ... 16

Tool edge statusbits

---

Group no. G0 ... 99 Group affiliation of the tool

No info: active group

Group duplonumber GD

0 ... 99 Group duplo affiliation of the toolNo info: duplo no. of the active group

TLD_V23_20030319.xls

Value range andmeaning of the parameters



All data present in the tool list can be read. The individual data elementsare addressed by means of codes. The identifiers of the individual dataelements are represented in the following tables:

• Basic tool data

• Tool status bit from data element 09 Base tool data

• Group status bits from data element 32 Base tool data

• Tool Edge Data

• Tool edge status bit from tool edge data element 02

• A variable can be inserted instead of constants.

• An arithmetic expression instead of a constant or variable is notpermitted.

• The optional parameters need not be specified.

• The commas that are used for delimiting the parameters must alwaysbe set.

• The CNC inserts the current process if a process [0-6] is not specified.

• If the parameter address [0/1] is not specified, the CNC inserts a valueof 0 and interprets the two subsequent parameters as storage unit andpocket.

• If the duplo number [1-9999] is not specified, the CNC inserts theduplo number of the related processing tool.

• If the tool edge [0-9] is not specified, the CNC inserts a value of 0, thusaccessing the basic tool data.

• The parameter status [1-32] is to be specified only if a tool status bit ora tool edge status bit or a group status bit is accessed.

• If the group number [0..99] is not specified, the CNC inserts thenumber of the enabled group.

• If the group duplo number [0..99] is not specified, the CNC inserts theduplo number of the enabled group.

The validity of the programmed parameter values can be checked onlywhen the command is executed (i.e. at the runtime of the NC program). Ifone of the parameters is incorrect or invalid, the CNC initiates animmediate stop and issues the error message:

• You cannot write to setup list-specific data elements.

• You may not write to any tool, tool edge or group status bit that isallocated to tool management.

• You cannot write to a location, storage unit or tool number dataelement.

• If one of these conditions is not observed when a data element iswritten, the CNC initiates an immediate stop and issues the errormessage:

General requirements for theTLD command

Optional parameters for the TLDcommand

General verifications for the TLDcommand

Limitations of writing with theTLD command

Illegal access to a data element !

Incorrect parameter [no. of the incorrectparameter] for data access command!



Examples

Reading with the TLD command

Example:

The tool number of the tool in spindle 2 is assigned to a variable.

@55 = TLD ( , 0, 1, 2, 0, 5, )

Symbol Designation

S Status

DE Data element 5 → Tool number

E Tool edge 0 → Basic tool data

L Location 2 → 2

SA Storage type 1 → Spindle

→→→→ Spindle 2

A Addressing 0 → Addressing via location andmagazine

P Process Empty → current process

TLD_Beispiel_1_lesen_V22_20021114.xls



Example:

The duplo number of tool 1 is assigned to a variable.

@200 = TLD ( , 1, 1, , 0, 6, )

Symbol Designation

S Status

DE Data element 6 → Duplo number


D Duplo number Empty → duplo number of thecorresponding processing tool

T Tool No. 1 → Tool 1

A Addressing 1 → Addressing via tool and duplotype



Interrogation whether a tool change is required

@ 0: 0 = TLD ( , 0, 1, 1, 0, 5, ) Reads the tool number of the first spindle and stores it in variable 0 of the process.

@ 0: 0 = @ 0: 0 - T BEQ .M6_T0 Interrogation whether a tool change is required


The sum of radius, wear and offset is written into a variable

@152 = TLD ( , 1, 9, , 1, 10, ) + TLD ( , 1, 9, , 1, 14, ) + TLD ( , 1, 9, , 1, 18, )




Writing with the TLD command

Example:

The duplo number of tool 1 is set to 5.

TLD ( , 1, 1, , 0, 6, ) = 5

Symbol Designation

S Status

DE Data element 6 →→→→ Duplo number


D Duplo number Empty →→→→ duplo number of thecorresponding processing tool


A Addressing 1 → Addressing via tool and duplo type


TLD_Beispiel_1_schreiben_V22_20021114.xls



Example:

The duplo number of tool 1 is set to 6

TLD ( , 1, 1, , 0, 6, ) = 3 + 1 + 2

Symbol Designation

S Status

DE Data element 6 →→→→ Duplo number


D Duplo number Empty →→→→ duplo number of thecorresponding processing tool


A Addressing 1 → Addressing via tool and duplo type





Example:

The last used or preselected tool is disabled

@55 = T

TLD ( 3, 1, @55, , 0, 9, 22 ) = 1

The number or current tool is saved in avariable

Symbol Designation

S Status 22 → Tool block: Value 1 → Tool disabled

DE Data element 9 → Tool status bits


D Duplo number Empty → duplo number of thecorresponding processing tool

T Tool No. @55 → Tool number = Content of variable @55

A Addressing 1 → Addressing via tool and duplotype

P Process 3 → Process 3


Tool Management Index 8-1


8 Index

$$ 2-69

AA00.032 5-3, 5-5A00.051 5-3, 5-5A00.052 1-2, 3-6, 5-3, 5-5, 6-6A00.053 1-3A00.054 2-1, 2-9, 2-42A00.055 2-57, 2-58A00.056 2-57, 2-58A00.058 2-58A00.061 2-1, 2-33A00.069 2-1, 2-33A00.070 2-1, 2-64A00.074 2-1, 2-64A00.075 2-1A00.082 2-1A00.083 2-1A00.086 2-1A00.091 2-1, 2-32, 2-65, 2-67A00.092 2-1, 2-64A00.096 2-1, 2-64Abort magazine-to-spindle tool transfer - XMS_CA 4-41, 4-43, 4-45Aborting a changeover process 4-49Aborting magazine-to-spindle tool transfer 'XMS_CA' 4-43Acknowledgement complete tool change ‘TCH_Q’ 4-33Acknowledging requests 4-49Acknowledgment of magazine-to-spindle tool change 'TMS_Q' 4-36Acknowledgment of magazine-to-spindle tool transfer 'XMS_Q' 4-43Acknowledgment of spindle-to-magazine tool change 'TSM_Q' 4-38Actual position - PxxC.MGAP 4-12, 4-16, 4-17Additional tool carrier 3-4, 3-5, 3-7, 3-14Additional tool carriers 6-24Alternate group 1-7, 1-8Alternate tool chain 1-5Alternate tool sequence 2-30Alternate tools 2-6Approach intermediate locations 3-18Automatic equipment check 1-4Automatic Equipment Check 1-4Axis jogging causes reset - Bxx.036 4-49AxxC.MHOLD 4-48

BBasic tool data 2-2Branch command, with Stopp - BST 4-6Branch with stop - BST 4-15BST 4-6, 4-15, 4-20Bxx.014 1-2, 3-6, 5-3, 5-5, 6-1, 6-6, 6-12Bxx.015 3-6, 5-3, 5-5, 6-1, 6-6, 6-12Bxx.016 5-3, 5-5, 6-1, 6-6, 6-12Bxx.017 5-3, 5-5, 6-2, 6-6, 6-12Bxx.018 5-3, 5-5, 6-2, 6-6, 6-12Bxx.019 5-3, 5-5, 6-2, 6-6, 6-13Bxx.020 5-3, 5-5, 6-2, 6-6, 6-13Bxx.021 4-11, 5-3, 5-5Bxx.022 5-3, 5-5Bxx.023 5-3, 5-5Bxx.024 4-11, 5-3, 5-5Bxx.029 2-59Bxx.032 4-48

8-2 Index Tool Management


Bxx.036 4-49Bxx.044 3-6, 6-1Bxx.057 3-6, 6-1Bxx.072 4-9, 4-10, 4-11

CCancel tool transfer from magazine to spindle - XMS_CA 4-44Cartesian coordinate system 3-1Changing tools 3-9Combined spindle/turret axis 4-48, 6-4 See Interrogating and acknowledgingturret mode preselection; Interrogating and acknowledging spindle modepreselectionCommand position - PxxS.MGCP 4-12, 4-16, 4-17Complete tool change 4-32Complete tool change

Timing 4-34Complete tool change 'TCH' 4-33Complete tool changel

Sequence 4-34Constant surface speed 3-7, 3-15, 6-24Control reset 4-48, 4-49Current grinding wheel diameter 2-66Current tool list 1-4Cxx.022 5-4, 6-6

DDefault plane 3-1Defined tool turret position 4-48Diagnosis messages 1-12Drilling tool 2-7

EEnable tool magazine for manual mode - MEN 4-6Enabling the tool magazine - PxxC.MGENA 4-13Enabling the tool magazine - PxxS.MGENA 4-13, 4-14End of program with reset - RET 4-6, 4-15End processing 6-25Equipment check 1-4, 1-9, 1-10Equipment check ignores wornout tools - PxxC.MGITW 4-4Equipment check, Deactivation of automatic - PxxC.MGWTC 4-4Equipment check, Deactivation of the automatic - PxxC.MGWTC 4-4Equipment check, Deactivation of the automatic - PxxC.MGWTC 4-4Equipment check, deactivation of the automatic - PxxC.MGWTC 4-4Error #321 4-49

FFixed location-encoded tools 2-28Free plane selection 3-1Freely position tool axis ‘MMA’ 4-6

GG00 2-62, 2-63, 6-7, 6-8, 6-9G04 6-7, 6-8, 6-9G17 3-1G18 3-1G19 3-1G20 3-1G21 3-1G22 3-1G31 6-25G40 3-10, 6-7, 6-13G41 2-63G42 2-63G47 3-10, 3-15, 6-7, 6-13



G48 2-59, 2-62, 6-2, 6-8, 6-9, 6-13, 6-14G49 2-59, 2-62G53 6-7, 6-13G54 3-10G61 6-7G62 6-8, 6-9G66 2-66G74 3-12G90 6-7, 6-13G96 3-7, 3-15, 6-24Geometry registers 2-57Grinding-Specific Tool Data 2-65Group 0 1-7, 1-8, 1-9Group duplo number 1-7, 1-10, 1-11Group number 1-7, 1-10, 1-11Group status 1-9, 1-10

Initialization 1-10New formation 1-10

HHMI function

Acknowledge tool change/ tool breakage 2-58Home 4-49Home position 3-13Home position required - Bxx.032 4-48Home position, magazine in 4-6Homing magazine

Magazine homing acknowledging 'MRF_Q' 4-25PLC-controlled, endlessly rotating tool magazine 4-27

Homing magazine - MRF 4-26Homing of tool magazine - MRF 4-6, 4-7, 4-23, 4-25, 4-26, 4-48, 4-49Homing of tool magazine - PxxC.MGHOM 4-7Homing, acknowledge magazine - MRF_Q 4-23, 4-25, 4-26Homing, interrogation magazine - MRF 4-7, 4-23, 4-24, 4-26, 4-48Homing, magazine - MRF 4-24, 4-26Homing, tool magazine - MRF 4-6, 4-7, 4-23, 4-25, 4-26, 4-48, 4-49

IInclined grinding wheel 2-68Interrogating and acknowledging spindle mode preselection 4-52Interrogating and acknowledging turret mode preselection 4-50Interrogation of spindle-to-magazine tool change 'TSM' 4-38

JJogging mode

with nonuniform spacing of tool positions 3-24with nonuniform tool location distribution 4-9, 4-10

LLathe

Additional tool carriers 6-24Lathing tool 2-7Length compensation 2-59Length wear factors 2-62Life count monitoring

Tool worn out - PxxS.MGTWO 4-19, 4-20Warning limit reached - PxxS.MGWRN 4-19, 4-20

Life monitoringTool worn out - PxxS.MGTWO 4-18, 4-19, 4-20Warning limit reached - PxxS.MGWRN 4-19Warning limit reached - PxxS.MGWRN 4-19, 4-20

Location data 2-28Location, free 4-6, 4-28Location, old, move to - MOP 4-6Location, programmed 4-6Location-specific tool status bit 2-16



MM19 S0 4-49M3 4-48Machine parameter

Bxx.073 ‘Number of tool groups‘ 1-9, 1-10Machining planes 3-1MAG_ACT 4-50MAG_ACT 4-48MAG_Q 4-48, 4-50Magazine

Numerically controlled 1-1PLC-controlled 1-1

Magazine axis, acknowledgement of preselection with comb. spindle/turret axis -MAG_Q 4-48, 4-50Magazine axis, interrogation of preselection with comb. spindle/turret axis -MAG_ACT 4-48, 4-50Magazine functions 4-22 See Magazine homing; position tool magazine

Homing the tool magazine by the PLC - Overview 4-23Positioning the tool magazine by the PLC - Overview 4-23

Magazine homing 4-24Magazine homing interrogation 'MRF' 4-24

Magazine homing - MRF 4-24Magazine homing interrogation - MRF 4-25Magazine jog mode with variable tool locations - PxxC.MGJGN 4-10Magazine location, new - acknowledgement - MMV_Q 4-23, 4-28, 4-29Magazine location, new - interrogation - MMV 4-23, 4-28, 4-29Magazine location, new - request - MMV 4-29Magazine-to-spindle tool change

Sequence 4-36Magazine-to-spindle tool change - TMS 4-37Magazine-to-spindle tool change, acknowledgement - TMS_Q 4-36, 4-37Magazine-to-spindle tool change, interrogation - TMS 4-36, 4-37Magazine-to-spindle tool transfer not permitted - XMS_NA 4-41, 4-42, 4-45Magazine-to-spindle tool transfer permitted - XMS_PA 4-42, 4-45Magazine-to-spindle tool transfer XMS 4-41Magazine-to-spindle tool transfer, acknowledgement - XMS_Q 4-41, 4-43, 4-45Magazine-to-spindle tool transfer, initialization - XMS 4-40, 4-41, 4-44, 4-45Magazine-to-spindle transfer permitted - XMS_PA 4-44, 4-45Magazine-to-spindle transfer, acknowledgement - XMS_Q 4-45Magazine-to-spindle transfer, initialization - XMS 4-45Manual mode, enable tool magazine for - MEN 4-6Manual mode, tool magazine enabled for - MEN 4-15Maximum grinding wheel circumferential speed 2-66Maximum spindle speed 2-65MEN 3-23, 4-6, 4-15MFP 3-6, 3-19, 4-6, 4-28MHP 3-6, 3-13, 3-24, 4-6Milling tool 2-7Minimum spindle speed (S min) 2-65MMA 3-18, 4-6MMP 3-6, 3-15, 3-24, 4-6MMV 3-13, 4-12, 4-16, 4-17, 4-23, 4-28, 4-29, 6-2, 6-3, 6-14, 6-15MMV_Q 4-12, 4-16, 4-17, 4-23, 4-28, 4-29, 6-3, 6-15MOP 3-6, 3-20, 4-6Motion control of a tool magazine

Moving the tool magazine by one pocket in the negative direction 'PxxC.MGNEG' 4-9Moving the tool storage unit by one pocket in the positive direction 'PxxC.MGPOS' 4-9

Motion control of a tool storage unitTool storage unit status signals 4-13

Move magazine to home position - MHP 4-6Move programmed location into position - MMP 4-6Move selected tool in position - MTP 4-29Move selected tool into position - MTP 4-6, 4-29Move selelcted tool in position bringen - MTP 4-28Move to free location - MFP 4-6Move to free position - MFP 4-28Move to old location - MOP 4-6Moving the tool magazine by one pocket in the negative direction - PxxC.MGNEG4-9



Moving the tool magazine to its basic position - PxxC.MGBP 4-8Moving the tool storage unit by one pocket in the negative direction -PxxC.MGNEG 4-9Moving the tool storage unit by one pocket in the positive direction -PxxC.MGPOS 4-9MRF 3-6, 3-12, 4-6, 4-7, 4-23, 4-24, 4-25, 4-26, 4-48, 4-49, 6-14MRF_Q 4-23, 4-25, 4-26, 6-14MRY 3-6, 3-22, 4-25, 4-26, 4-28, 4-29MTP 3-6, 3-14, 3-24, 4-6, 4-28, 4-29, 6-24

NNC commands

TLD 1-9NC commands for tool groups 1-11NC controlled tool storage unit 5-3

Assigning the parameter values of a disk-type magazine 5-3NC-controlled disk-type magazine 6-5Nonuniform spacing of tool positions 3-24Nonuniform tool location distribution 4-9, 4-10Number of tool edges 2-9

OOffset register 2-57Operating mode of magazine - PxxC.MGMAN 4-5, 4-6Operating mode of the tool magazine - PxxC.MGMAN 4-3Operation without setup list 1-6Operation without setup list - PxxC.MGNSL 4-4

PPLC function blocks

Diagnosis messages 1-12PLC-controlled chain-type magazine 6-12PLC-controlled tool storage unit 5-5

Assigning the parameter values of a disk-type magazine 5-5PLC-controlled turret 6-1Position tool magazine

Interrogation magazine to new location 'MMV' 4-28PLC-controlled, endlessly-rotating tool magazine 4-30

Positions, page no. for variable - Bxx.072 4-11Positioning of tool magazine

PLC-controlled, endlessly rotating tool magazine 4-30Positions 1-4 3-24Power activation 4-49Power is on - PxxS.POWER 4-49Preparing a tool 3-4Preparing tools and tool data

selecting tool spindle ‘SPT’ 3-7Preparing tools and tool data for a magazine 3-3Preparing tools and tool data for a turret 3-5PxxC.CLEAR 4-49PxxC.MGAP 4-12PxxC.MGBP 4-8PxxC.MGENA 4-3, 4-13PxxC.MGHOM 4-7PxxC.MGITW 1-5, 2-27, 4-4PxxC.MGJGn 4-10PxxC.MGMAN 4-3, 4-5, 4-6, 4-16PxxC.MGNEG 4-9, 4-10PxxC.MGNSL 1-6, 2-61, 4-4PxxC.MGNTL 4-5PxxC.MGPOS 4-9, 4-10PxxC.MGWTC 1-4, 4-4PxxS.ERROR 4-20PxxS.MGBP 4-16PxxS.MGCP 3-18, 4-12, 4-16, 4-17PxxS.MGENA 4-3, 4-13, 4-14PxxS.MGERR 4-19, 4-20



PxxS.MGMAN 4-6, 4-15, 4-16PxxS.MGMOV 4-15PxxS.MGREQ 4-14, 4-16PxxS.MGTWO 1-8, 2-38, 2-55, 4-18, 4-19, 4-20PxxS.MGWRN 1-8, 2-39, 2-55, 4-19, 4-20PxxS.POWER 4-49

QQ_FKT 6-23, 6-24Q_FKT_Q 6-24

RRadius compensation 2-60Radius wear factor 2-63Reference mark, offset 1 to - Bxx.021 4-11Reference mark, offset 4 to - Bxx.024 4-11Reference position 3-12Remaining tool life in percent 2-53Replacement tool s 2-24Request of magazine tool by NC - PxxS.MGREQ 4-16Reset, Axis jogging causes - Bxx.036 4-49Reset, end of program with - RET 4-6Reset, end of program with - RET 4-15RET 4-6, 4-15, 4-20REV_SYNC 3-6Rotation direction of transformation 6-25

SS max 2-65S min 2-65Segmented tool magazines 3-8Segmented tool storages 1-7Setting the parameter values of the tool storage unit 5-1Setup list 1-2, 1-8, 1-9, 1-10Setup-list-specific tool status bit 2-13Sister group 1-7, 1-10Sister tool 1-8SPDL_ACT 4-48SPDL_Q 4-48, 4-52Spindle mode 4-49Spindle-to-magazine tool change - TSM 4-39Spindle, acknowledgement of preselection with comb. spindle/turret axis -SPDL_Q 4-52Spindle, interrogation of the preselection with comb. spindle /turret axes -SPDL_Q 4-48Spindle, interrogation of the preselection with comb. spindle /turret axes -SPDL_ACT 4-48Spindle-to-magazine tool change

Sequence 4-39Spindle-to-magazine tool change - TSM 4-39Spindle-to-magazine tool change, acknowledgement - TSM_Q 4-38, 4-39Spindle-to-magazine tool change, interrogation - TSM 4-39SPT <spindle number> 3-7, 6-24Straight circumferential grinding wheel 2-67SUG max 2-66Surface grinding wheel 2-69

TTCH 3-4, 3-26, 3-27, 4-24, 4-32, 4-33, 4-34, 4-35, 6-13TCH_Q 4-24, 4-33, 4-34Technology data 2-32TG 1-11TGSM 1-11Theoretical tool tip 2-44TID 1-4



Timing of magazine-to-spindle tool change 4-37Timing of spindle-to-magazine tool change 4-39Timing of tool magazine homing 4-26Timing of tool magazine positioning 4-29TL_DELETE 1-11, 4-18, 4-19TL_MOVE 1-11TL_RESET 1-11, 4-18, 4-19TLBD_RD 1-11TLD 1-11, 4-18, 4-19, 7-13TLD command 1-11TLD_RD 1-11TLD_WR 4-18, 4-19TLED_RD 1-11TLG_RD 1-11TLG_WR 1-11TMS 3-4, 3-27, 4-24, 4-32, 4-35, 4-36, 4-37, 6-7, 6-9, 6-10, 6-13, 6-16, 6-17, 6-18, 6-19TMS_Q 4-24, 4-36, 4-37, 6-10, 6-19Tool change 1-7

Interrogation of the magazine-to-spindle tool change ‘TMS’ 4-35Magazine-to-spindle tool change 4-35

Tool change from magazine into the spindle - TMS 4-24, 4-32, 4-36Tool change from magazine to spindle, acknowledgement - TMS_Q 4-24, 4-37Tool change from magazine to spindle, interrogation - TMS 4-24, 4-32, 4-37Tool change from spindle to magazine, acknowledgement - TSM_Q 4-24Tool change from spindle into the magazine - TSM 4-32Tool change from spindle to magazine, interrogation - TSM 4-24, 4-32, 4-38Tool change from tool to spindle - TMS 4-37Tool change positions 3-24, 4-10Tool change, acknowledgement - TCH_Q 4-24, 4-33, 4-34Tool change, complete 4-24, 4-32, 4-33, 4-34, 4-35Tool change, inquiry - TCH 4-32Tool change, interrogation - TCH 4-24, 4-32, 4-33, 4-34Tool changing commands of the NC 3-25Tool changte from spindle into the magazine - TSM 4-24Tool data elements for tool group administration 1-10Tool data record 2-1Tool Edge Data 2-42Tool edge identification 2-43Tool edge invocation 3-7Tool editor

Edit 2-21, 2-22, 2-58Tool error status - PxxS.MGERR 4-19, 4-20Tool exchange 3-26Tool group 1-7, 1-8, 1-9, 3-8

Important regulations 1-7PLC data structures and function modules 1-11Preselect 1-11Read active group 1-11

Tool group administrationNC diagnosis messages 1-12PLC diagnosis messages 1-12

Tool group data 2-33Tool group duplo number 3-8Tool group management 1-9, 1-11, 3-8

Define number of tool groups 1-9Tool group number 3-8Tool identification 2-4Tool life calculation, switching off - PxxC.MGNTL 4-5Tool life data 2-53Tool life monitoring

Tool life monitoring - PxxS.MGTWO 4-19, 4-20Warn limit reached - PxxS.MGWRN 4-19, 4-20

Tool list 1-3Tool magazine in program or manual mode - PxxS.MGMAN 4-6Tool magazine positioning

Acknowledgement magazine to new location 'MMV_Q' 4-28Tool magazine enable - PxxC.MGENA 4-3Tool magazine enabled for manual mode - MEN 4-15Tool magazine in motion - PxxS.MGMOV 4-15Tool magazine in program or manual mode - PxxS.MGMAN 4-15, 4-16



Tool magazine is in basic position - PxxS.MGBP 4-16Tool magazine motion control 4-1

Tool magazine control signals 4-2Tool magazine offset 1 to the reference mark - Bxx.021 4-11Tool magazine offset 4 to the reference marke- Bxx.024 4-11Tool magazine operating mode - PxxC.MGMAN 4-16Tool magazine ready? - MRY 4-25, 4-26, 4-28, 4-29Tool magazine request from NC - PxxS.MGREQ 4-14Tool number 2-6Tool preselection 3-4Tool search mode 1-8

Define 1-11Read 1-11

Tool, selected 4-6, 4-28, 4-29Tool sister group 1-7Tool status (bits) 2-9Tool storage unit motion commands of the NC 3-11Tool technology group 1-6Tool transfer

Checking a tool transfer 'XFER_CHK' 4-46Procedure and function modules 4-41Sequence 4-44

Tool transfer from magazine to spindle is not allowed - XMS_NA 4-44Tool transfer from magazine to spindle, acknowledgement - XMS_Q 4-44Tool transfer functions 4-40

Method of operation 4-40Tool transfer with respect to the current magazine actual magazine location 4-46

Tool transfer timing 4-45Tool transfers, deactivate check - XFER_CHK 4-46Tool type group 1-6Tool-specific tool status bit 2-20Touch point 'B' 2-45TPE 3-28TSE 3-28TSM 3-27, 3-28, 4-24, 4-32, 4-38, 4-39, 6-7, 6-9, 6-10, 6-11, 6-13, 6-14, 6-16, 6-20, 6-21, 6-22TSM_Q 4-24, 4-38, 4-39, 6-11, 6-22Turret mode 4-49Typical applications 6-1

UUndefined tool turret position 4-48Units 2-31User tool data 2-33User tool edge data 2-64

WWait until position is approached - MRY 4-25, 4-29Wear factors 2-62Wear registers 2-57

XXFER_CHK 4-46XFER_CHK 4-46XMS 4-40, 4-41, 4-44, 4-45, 6-10, 6-16XMS_CA 4-41, 4-43, 4-44, 4-45XMS_NA 4-41, 4-42, 4-44, 4-45XMS_PA 4-42, 4-44, 4-45, 6-10XMS_Q 4-41, 4-43, 4-44, 4-45, 6-10

ZZero offsets

additional tool carrier 3-4, 3-5, 3-7, 3-15of additional tool carriers 6-24

Tool Management Service & Support 9-1


9 Service & Support

9.1 Helpdesk

Unser Kundendienst-Helpdesk im Hauptwerk Lohram Main steht Ihnen mit Rat und Tat zur Seite.Sie erreichen uns

Our service helpdesk at our headquarters in Lohr amMain, Germany can assist you in all kinds of inquiries.Contact us

- telefonisch - by phone: 49 (0) 9352 40 50 60über Service Call Entry Center Mo-Fr 07:00-18:00- via Service Call Entry Center Mo-Fr 7:00 am - 6:00 pm

- per Fax - by fax: +49 (0) 9352 40 49 41

- per e-Mail - by e-mail: [email protected]

9.2 Service-Hotline

Außerhalb der Helpdesk-Zeiten ist der Servicedirekt ansprechbar unter

After helpdesk hours, contact our servicedepartment directly at

+49 (0) 171 333 88 26

oder - or +49 (0) 172 660 04 06

9.3 Internet

Unter www.boschrexroth.com finden Sieergänzende Hinweise zu Service, Reparatur undTraining sowie die aktuellen Adressen *) unsererauf den folgenden Seiten aufgeführten Vertriebs-und Servicebüros.

Verkaufsniederlassungen

Niederlassungen mit Kundendienst

Außerhalb Deutschlands nehmen Sie bitte zuerst Kontakt mitunserem für Sie nächstgelegenen Ansprechpartner auf.

*) Die Angaben in der vorliegenden Dokumentation könnenseit Drucklegung überholt sein.

At www.boschrexroth.com you may findadditional notes about service, repairs and trainingin the Internet, as well as the actual addresses *) ofour sales- and service facilities figuring on thefollowing pages.

sales agencies

offices providing service

Please contact our sales / service office in your area first.

*) Data in the present documentation may have becomeobsolete since printing.

9.4 Vor der Kontaktaufnahme... - Before contacting us...

Wir können Ihnen schnell und effizient helfen wennSie folgende Informationen bereithalten:

detaillierte Beschreibung der Störung und derUmstände.

Angaben auf dem Typenschild der betreffendenProdukte, insbesondere Typenschlüssel undSeriennummern.

Tel.-/Faxnummern und e-Mail-Adresse, unterdenen Sie für Rückfragen zu erreichen sind.

For quick and efficient help, please have thefollowing information ready:

1. Detailed description of the failure andcircumstances.

2. Information on the type plate of the affectedproducts, especially type codes and serialnumbers.

3. Your phone/fax numbers and e-mail address,so we can contact you in case of questions.

9-2 Service & Support Tool Management


9.5 Kundenbetreuungsstellen - Sales & Service Facilities

Deutschland – Germany vom Ausland: (0) nach Landeskennziffer weglassen!from abroad: don’t dial (0) after country code!

Vertriebsgebiet Mitte Germany Centre

Rexroth Indramat GmbHBgm.-Dr.-Nebel-Str. 2 / Postf. 135797816 Lohr am Main / 97803 Lohr

Kompetenz-Zentrum Europa

Tel.: +49 (0)9352 40-0Fax: +49 (0)9352 40-4885

S E R V I C E

C A L L E N T R Y C E N T E RMO – FR

von 07:00 - 18:00 Uhr

from 7 am – 6 pm

Tel. +49 (0) 9352 40 50 [email protected]

S E R V I C E

HOTLINEMO – FR

von 17:00 - 07:00 Uhrfrom 5 pm - 7 am

+ SA / SOTel.: +49 (0)172 660 04 06

oder / orTel.: +49 (0)171 333 88 26

S E R V I C E

ERSATZTEILE / SPARESverlängerte Ansprechzeit- extended office time -

♦ nur an Werktagen- only on working days -

♦ von 07:00 - 18:00 Uhr- from 7 am - 6 pm -

Tel. +49 (0) 9352 40 42 22

Vertriebsgebiet Süd Germany South

Bosch Rexroth AGLandshuter Allee 8-1080637 München

Tel.: +49 (0)89 127 14-0Fax: +49 (0)89 127 14-490

Vertriebsgebiet West Germany West

Bosch Rexroth AGRegionalzentrum WestBorsigstrasse 1540880 Ratingen

Tel.: +49 (0)2102 409-0Fax: +49 (0)2102 409-406

+49 (0)2102 409-430

Gebiet Südwest Germany South-West

Bosch Rexroth AGService-Regionalzentrum Süd-WestSiemensstr.170736 Fellbach

Tel.: +49 (0)711 51046–0Fax: +49 (0)711 51046–248

Vertriebsgebiet Nord Germany North

Bosch Rexroth AGWalsroder Str. 9330853 Langenhagen

Tel.: +49 (0) 511 72 66 57-0Service: +49 (0) 511 72 66 57-256Fax: +49 (0) 511 72 66 57-93Service: +49 (0) 511 72 66 57-783

Vertriebsgebiet Mitte Germany Centre

Bosch Rexroth AGRegionalzentrum MitteWaldecker Straße 1364546 Mörfelden-Walldorf

Tel.: +49 (0) 61 05 702-3Fax: +49 (0) 61 05 702-444

Vertriebsgebiet Ost Germany East

Bosch Rexroth AGBeckerstraße 3109120 Chemnitz

Tel.: +49 (0)371 35 55-0Fax: +49 (0)371 35 55-333

Vertriebsgebiet Ost Germany East

Bosch Rexroth AGRegionalzentrum OstWalter-Köhn-Str. 4d04356 Leipzig

Tel.: +49 (0)341 25 61-0Fax: +49 (0)341 25 61-111



Europa (West) - Europe (West)

vom Ausland: (0) nach Landeskennziffer weglassen, Italien: 0 nach Landeskennziffer mitwählenfrom abroad: don’t dial (0) after country code, Italy: dial 0 after country code

Austria - Österreich

Bosch Rexroth GmbHElectric Drives & ControlsStachegasse 131120 Wien

Tel.: +43 (0)1 985 25 40Fax: +43 (0)1 985 25 40-93

Austria – Österreich

Bosch Rexroth GmbHElectric Drives & ControlsIndustriepark 184061 Pasching

Tel.: +43 (0)7221 605-0Fax: +43 (0)7221 605-21

Belgium - Belgien

Bosch Rexroth AGElectric Drives & ControlsIndustrielaan 81740 TernatTel.: +32 (0)2 5830719- service: +32 (0)2 5830717Fax: +32 (0)2 5830731 [email protected]

Denmark - Dänemark

BEC A/SZinkvej 68900 Randers

Tel.: +45 (0)87 11 90 60Fax: +45 (0)87 11 90 61

Great Britain – Großbritannien

Bosch Rexroth Ltd.Electric Drives & ControlsBroadway Lane, South CerneyCirencester, Glos GL7 5UH

Tel.: +44 (0)1285 863000Fax: +44 (0)1285 863030 [email protected] [email protected]

Finland - Finnland

Bosch Rexroth OyElectric Drives & ControlsAnsatie 6017 40 Vantaa

Tel.: +358 (0)9 84 91-11Fax: +358 (0)9 84 91-13 60

France - Frankreich

Bosch Rexroth SASElectric Drives & ControlsAvenue de la Trentaine(BP. 74)77503 Chelles Cedex

Tel.: +33 (0)164 72-70 00Fax: +33 (0)164 72-63 00Hotline: +33 (0)608 33 43 28

France - Frankreich

Bosch Rexroth SASElectric Drives & ControlsZI de Thibaud, 20 bd. Thibaud(BP. 1751)31084 Toulouse

Tel.: +33 (0)5 61 43 61 87Fax: +33 (0)5 61 43 94 12

France – Frankreich

Bosch Rexroth SASElectric Drives & Controls91, Bd. Irène Joliot-Curie69634 Vénissieux – Cedex

Tel.: +33 (0)4 78 78 53 65Fax: +33 (0)4 78 78 53 62

Italy - Italien

Bosch Rexroth S.p.A.Via G. Di Vittorio, 120063 Cernusco S/N.MI

Hotline: +39 02 92 365 563Tel.: +39 02 92 365 1Service: +39 02 92 365 326Fax: +39 02 92 365 500Service: +39 02 92 365 503

Italy - Italien

Bosch Rexroth S.p.A.Via Paolo Veronesi, 25010148 Torino

Tel.: +39 011 224 88 11Fax: +39 011 224 88 30

Italy - Italien

Bosch Rexroth S.p.A.Via Mascia, 180053 Castellamare di Stabia NA

Tel.: +39 081 8 71 57 00Fax: +39 081 8 71 68 85

Italy - Italien

Bosch Rexroth S.p.A.Via del Progresso, 16 (Zona Ind.)35020 Padova

Tel.: +39 049 8 70 13 70Fax: +39 049 8 70 13 77

Italy - Italien

Bosch Rexroth S.p.A.Via Isonzo, 6140033 Casalecchio di Reno (Bo)

Tel.: +39 051 29 86 430Fax: +39 051 29 86 490

Netherlands - Niederlande/Holland

Bosch Rexroth Services B.V.Technical ServicesKruisbroeksestraat 1(P.O. Box 32)5281 RV Boxtel

Tel.: +31 (0) 411 65 16 40+31 (0) 411 65 17 27

Fax: +31 (0) 411 67 78 14+31 (0) 411 68 28 60

[email protected]

Netherlands – Niederlande/Holland

Bosch Rexroth B.V.Kruisbroeksestraat 1(P.O. Box 32)5281 RV Boxtel

Tel.: +31 (0) 411 65 19 51Fax: +31 (0) 411 65 14 83 www.boschrexroth.nl

Norway - Norwegen

Bosch Rexroth ASElectric Drives & ControlsBerghagan 1 or: Box 30071405 Ski-Langhus 1402 Ski

Tel.: +47 (0)64 86 41 00Fax: +47 (0)64 86 90 62Hotline: +47 (0)64 86 94 82 [email protected]

Spain - Spanien

Bosch Rexroth S.A.Electric Drives & ControlsCentro Industrial SantigaObradors s/n08130 Santa Perpetua de MogodaBarcelona

Tel.: +34 9 37 47 94 00Fax: +34 9 37 47 94 01

Spain – Spanien

Goimendi S.A.Electric Drives & ControlsParque Empresarial ZuatzuC/ Francisco Grandmontagne no.220018 San Sebastian

Tel.: +34 9 43 31 84 21- service: +34 9 43 31 84 56Fax: +34 9 43 31 84 27- service: +34 9 43 31 84 60 [email protected]

Sweden - Schweden

Bosch Rexroth ABElectric Drives & Controls- Varuvägen 7(Service: Konsumentvägen 4, Älfsjö)125 81 Stockholm

Tel.: +46 (0)8 727 92 00Fax: +46 (0)8 647 32 77

Sweden - Schweden

Bosch Rexroth ABElectric Drives & ControlsEkvändan 7254 67 Helsingborg

Tel.: +46 (0) 42 38 88 -50Fax: +46 (0) 42 38 88 -74

Switzerland West - Schweiz West

Bosch Rexroth Suisse SAElectric Drives & ControlsRue du village 11020 Renens

Tel.: +41 (0)21 632 84 20Fax: +41 (0)21 632 84 21

Switzerland East - Schweiz Ost

Bosch Rexroth Schweiz AGElectric Drives & ControlsHemrietstrasse 28863 ButtikonTel. +41 (0) 55 46 46 111Fax +41 (0) 55 46 46 222



Europa (Ost) - Europe (East)

vom Ausland: (0) nach Landeskennziffer weglassen

from abroad: don’t dial (0) after country code

Czech Republic - Tschechien

Bosch -Rexroth, spol.s.r.o.Hviezdoslavova 5627 00 Brno

Tel.: +420 (0)5 48 126 358Fax: +420 (0)5 48 126 112

Czech Republic - Tschechien

DEL a.s.Strojírenská 38591 01 Zdar nad SázavouTel.: +420 566 64 3144Fax: +420 566 62 1657

Hungary - Ungarn

Bosch Rexroth Kft.Angol utca 341149 Budapest

Tel.: +36 (1) 422 3200Fax: +36 (1) 422 3201

Poland – Polen

Bosch Rexroth Sp.zo.o.ul. Staszica 105-800 Pruszków

Tel.: +48 22 738 18 00– service: +48 22 738 18 46Fax: +48 22 758 87 35– service: +48 22 738 18 42

Poland – Polen

Bosch Rexroth Sp.zo.o.Biuro Poznanul. Dabrowskiego 81/8560-529 Poznan

Tel.: +48 061 847 64 62 /-63Fax: +48 061 847 64 02

Romania - Rumänien

East Electric S.R.L.Bdul Basarabia no.250, sector 373429 Bucuresti

Tel./Fax:: +40 (0)21 255 35 07+40 (0)21 255 77 13

Fax: +40 (0)21 725 61 21 [email protected]

Romania - Rumänien

Bosch Rexroth Sp.zo.o.Str. Drobety nr. 4-10, app. 1470258 Bucuresti, Sector 2

Tel.: +40 (0)1 210 48 25+40 (0)1 210 29 50

Fax: +40 (0)1 210 29 52

Russia - Russland

Bosch Rexroth OOOWjatskaja ul. 27/15127015 Moskau

Tel.: +7-095-785 74 78+7-095 785 74 79

Fax: +7 095 785 74 77 [email protected]

Russia - Russland

ELMIS10, Internationalnaya246640 Gomel, Belarus

Tel.: +375/ 232 53 42 70+375/ 232 53 21 69

Fax: +375/ 232 53 37 69 [email protected]

Turkey - Türkei

Bosch Rexroth OtomasyonSan & Tic. A..S.Fevzi Cakmak Cad No. 334295 Sefaköy - IstanbulTel.: +90 212 413 34-00Fax: +90 212 413 34-17

Slowenia - Slowenien

DOMELOtoki 2164 228 Zelezniki

Tel.: +386 5 5117 152Fax: +386 5 5117 225 [email protected]



Africa, Asia, Australia – incl. Pacific Rim

Australia - Australien

AIMS - Australian IndustrialMachinery Services Pty. Ltd.28 Westside DriveLaverton North Vic 3026Melbourne

Tel.: +61 3 93 14 3321Fax: +61 3 93 14 3329Hotlines: +61 3 93 14 3321

+61 4 19 369 195 [email protected]

Australia - Australien

Bosch Rexroth Pty. Ltd.No. 7, Endeavour WayBraeside Victoria, 31 95Melbourne

Tel.: +61 3 95 80 39 33Fax: +61 3 95 80 17 33 [email protected]

China

Shanghai Bosch RexrothHydraulics & Automation Ltd.Waigaoqiao, Free Trade ZoneNo.122, Fu Te Dong Yi RoadShanghai 200131 - P.R.China

Tel.: +86 21 58 66 30 30Fax: +86 21 58 66 55 [email protected] [email protected]

China

Shanghai Bosch RexrothHydraulics & Automation Ltd.4/f, Marine TowerNo.1, Pudong AvenueShanghai 200120 - P.R.China

Tel: +86 21 68 86 15 88Fax: +86 21 58 40 65 77

China

Bosch Rexroth China Ltd.15/F China World Trade Center1, Jianguomenwai AvenueBeijing 100004, P.R.China

Tel.: +86 10 65 05 03 80Fax: +86 10 65 05 03 79

China

Bosch Rexroth China Ltd.Guangzhou Repres. OfficeRoom 1014-1016, Metro Plaza,Tian He District, 183 Tian He Bei RdGuangzhou 510075, P.R.China

Tel.: +86 20 8755-0030+86 20 8755-0011

Fax: +86 20 8755-2387

China

Bosch Rexroth (China) Ltd.A-5F., 123 Lian Shan StreetSha He Kou DistrictDalian 116 023, P.R.China

Tel.: +86 411 46 78 930Fax: +86 411 46 78 932

China

Melchers GmbHBRC-SE, Tightening & Press-fit13 Floor Est Ocean CentreNo.588 Yanan Rd. East65 Yanan Rd. WestShanghai 200001

Tel.: +86 21 6352 8848Fax: +86 21 6351 3138

Hongkong

Bosch Rexroth (China) Ltd.6th

Floor,Yeung Yiu Chung No.6 Ind Bldg.19 Cheung Shun StreetCheung Sha Wan,Kowloon, Hongkong

Tel.: +852 22 62 51 00Fax: +852 27 41 33 44

[email protected]

India - Indien

Bosch Rexroth (India) Ltd.Electric Drives & ControlsPlot. No.96, Phase IIIPeenya Industrial AreaBangalore – 560058

Tel.: +91 80 51 17 0-211...-218Fax: +91 80 83 94 345

+91 80 83 97 374

[email protected]

India - Indien

Bosch Rexroth (India) Ltd.Electric Drives & ControlsAdvance House, II FloorArk Industrial CompoundNarol Naka, Makwana RoadAndheri (East), Mumbai - 400 059

Tel.: +91 22 28 56 32 90+91 22 28 56 33 18

Fax: +91 22 28 56 32 93

[email protected]

India - Indien

Bosch Rexroth (India) Ltd.S-10, Green Park ExtensionNew Delhi – 110016

Tel.: +91 11 26 56 65 25+91 11 26 56 65 27

Fax: +91 11 26 56 68 87

[email protected]

Indonesia - Indonesien

PT. Bosch RexrothBuilding # 202, CilandakCommercial EstateJl. Cilandak KKO, Jakarta 12560

Tel.: +62 21 7891169 (5 lines)Fax: +62 21 7891170 - [email protected]

Japan

Bosch Rexroth Automation Corp.Service Center JapanYutakagaoka 1810, Meito-ku,NAGOYA 465-0035, Japan

Tel.: +81 52 777 88 41+81 52 777 88 53+81 52 777 88 79

Fax: +81 52 777 89 01

Japan

Bosch Rexroth Automation Corp.Electric Drives & Controls2F, I.R. BuildingNakamachidai 4-26-44, Tsuzuki-kuYOKOHAMA 224-0041, Japan

Tel.: +81 45 942 72 10Fax: +81 45 942 03 41

Korea

Bosch Rexroth-Korea Ltd.Electric Drives and ControlsBongwoo Bldg. 7FL, 31-7, 1GaJangchoong-dong, Jung-guSeoul, 100-391

Tel.: +82 234 061 813Fax: +82 222 641 295

Korea

Bosch Rexroth-Korea Ltd.1515-14 Dadae-Dong, Saha-guElectric Drives & ControlsPusan Metropolitan City, 604-050

Tel.: +82 51 26 00 741Fax: +82 51 26 00 747 [email protected]

Malaysia

Bosch Rexroth Sdn.Bhd.11, Jalan U8/82, Seksyen U840150 Shah AlamSelangor, Malaysia

Tel.: +60 3 78 44 80 00Fax: +60 3 78 45 48 00 [email protected] [email protected]

Singapore - Singapur

Bosch Rexroth Pte Ltd15D Tuas RoadSingapore 638520

Tel.: +65 68 61 87 33Fax: +65 68 61 18 25 sanjay.nemade

@boschrexroth.com.sg

South Africa - Südafrika

TECTRA Automation (Pty) Ltd.71 Watt Street, MeadowdaleEdenvale 1609

Tel.: +27 11 971 94 00Fax: +27 11 971 94 40Hotline: +27 82 903 29 23 [email protected]

Taiwan

Bosch Rexroth Co., Ltd.Taichung Branch1F., No. 29, Fu-Ann 5th Street,Xi-Tun Area, Taichung CityTaiwan, R.O.C.

Tel : +886 - 4 -23580400Fax: +886 - 4 [email protected]@[email protected]

Thailand

NC Advance Technology Co. Ltd.59/76 Moo 9Ramintra road 34Tharang, Bangkhen,Bangkok 10230

Tel.: +66 2 943 70 62 +66 2 943 71 21Fax: +66 2 509 23 62Hotline +66 1 984 61 52 [email protected]



Nordamerika – North AmericaUSAHeadquarters - Hauptniederlassung

Bosch Rexroth CorporationElectric Drives & Controls5150 Prairie Stone ParkwayHoffman Estates, IL 60192-3707

Tel.: +1 847 6 45 36 00Fax: +1 847 6 45 62 [email protected] [email protected]

USA Central Region - Mitte

Bosch Rexroth CorporationElectric Drives & ControlsCentral Region Technical Center1701 Harmon RoadAuburn Hills, MI 48326

Tel.: +1 248 3 93 33 30Fax: +1 248 3 93 29 06

USA Southeast Region - Südwest

Bosch Rexroth CorporationElectric Drives & ControlsSoutheastern Technical Center3625 Swiftwater Park DriveSuwanee, Georgia 30124

Tel.: +1 770 9 32 32 00Fax: +1 770 9 32 19 03

USA SERVICE-HOTLINE

- 7 days x 24hrs -

+1-800-REX-ROTH+1 800 739 7684

USA East Region – Ost

Bosch Rexroth CorporationElectric Drives & ControlsCharlotte Regional Sales Office14001 South Lakes DriveCharlotte, North Carolina 28273

Tel.: +1 704 5 83 97 62+1 704 5 83 14 86

USA Northeast Region – Nordost

Bosch Rexroth CorporationElectric Drives & ControlsNortheastern Technical Center99 Rainbow RoadEast Granby, Connecticut 06026

Tel.: +1 860 8 44 83 77Fax: +1 860 8 44 85 95

USA West Region – West

Bosch Rexroth Corporation7901 Stoneridge Drive, Suite 220Pleasant Hill, California 94588

Tel.: +1 925 227 10 84Fax: +1 925 227 10 81

Canada East - Kanada Ost

Bosch Rexroth Canada CorporationBurlington Division3426 Mainway DriveBurlington, OntarioCanada L7M 1A8

Tel.: +1 905 335 5511Fax: +1 905 335 4184Hotline: +1 905 335 5511 [email protected]

Canada West - Kanada West

Bosch Rexroth Canada Corporation5345 Goring St.Burnaby, British ColumbiaCanada V7J 1R1

Tel. +1 604 205 5777Fax +1 604 205 6944Hotline: +1 604 205 5777 [email protected]

Mexico

Bosch Rexroth Mexico S.A. de C.V.Calle Neptuno 72Unidad Ind. Vallejo07700 Mexico, D.F.

Tel.: +52 55 57 54 17 11Fax: +52 55 57 54 50 [email protected]

Mexico

Bosch Rexroth S.A. de C.V.Calle Argentina No 3913Fracc. las Torres64930 Monterrey, N.L.

Tel.: +52 81 83 65 22 53+52 81 83 65 89 11+52 81 83 49 80 91

Fax: +52 81 83 65 52 [email protected]

Südamerika – South AmericaArgentina - Argentinien

Bosch Rexroth S.A.I.C."The Drive & Control Company"Rosario 2302B1606DLD CarapachayProvincia de Buenos Aires

Tel.: +54 11 4756 01 40+54 11 4756 02 40+54 11 4756 03 40+54 11 4756 04 40

Fax: +54 11 4756 01 36+54 11 4721 91 53

[email protected]

Argentina - Argentinien

NAKASEServicio Tecnico CNCCalle 49, No. 5764/66B1653AOX Villa BalesterProvincia de Buenos Aires

Tel.: +54 11 4768 36 43Fax: +54 11 4768 24 13Hotline: +54 11 155 307 6781 [email protected] [email protected] [email protected] (Service)

Brazil - Brasilien

Bosch Rexroth Ltda.Av. Tégula, 888Ponte Alta, Atibaia SPCEP 12942-440

Tel.: +55 11 4414 56 92+55 11 4414 56 84

Fax sales: +55 11 4414 57 07Fax serv.: +55 11 4414 56 86 [email protected]

Brazil - Brasilien

Bosch Rexroth Ltda.R. Dr.Humberto Pinheiro Vieira, 100Distrito Industrial [Caixa Postal 1273]89220-390 Joinville - SC

Tel./Fax: +55 47 473 58 33Mobil: +55 47 9974 6645 [email protected]

Columbia - Kolumbien

Reflutec de Colombia Ltda.Calle 37 No. 22-31Santafé de Bogotá, D.C.Colombia

Tel.: +57 1 368 82 67+57 1 368 02 59

Fax: +57 1 268 97 [email protected]@007mundo.com

Tool Management


Notes

Printed in GermanyDOK-MTC200-TOOLMAN*V23-PR01-EN-PR911296978

Bosch Rexroth AGElectric Drives and ControlsP.O. Box 13 5797803 Lohr, GermanyBgm.-Dr.-Nebel-Str. 297816 Lohr, GermanyPhone +49 93 52-40-50 60Fax +49 93 52-40-49 [email protected]

Documents

Rexroth MTC 200 Tool Management Edition 01 Edition 01 Rexroth MTC 200 Tool Management Project Planning Manual Industrial Hydraulics Electric Drives and Controls Linear Motion and Assembly