Siemens Probing

SINUMERIK 840D sl/840D/840Di sl Measuring cycles

__________________________________________________________________________________________________________________________________________________________________________________________________________________

Preface

General 1

Parameter description 2

Measuring cycle help programs

3Measuring in JOG

4Measuring Cycles for Milling and Machining Centers

5Measuring Cycles for Turning Machines

6Miscellaneous functions

7Hardware/software

8Data description

9Start-up (hardware)

10Alarm, error, and system messages

11Adaptation of the Measuring Cycles to Previous Software Versions

12

Appendix A

List of abbreviations B

Parameter C

SINUMERIK 840D sl/840D/840Di sl Measuring cycles

Programming Manual

01/2008 6FC5398-4BP20-1BA0

Valid for Controls SINUMERIK 840D sl/840DE sl SINUMERIK 840D powerline/840DE powerline SINUMERIK 840Di sl/840DiE sl Software Version NCU system software for 840D sl/840DE sl 1.5 HMI Advanced 7.5 with measuring cycles 7.5

Safety GuidelinesSafety Guidelines

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGER indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken. CAUTION without a safety alert symbol, indicates that property damage can result if proper precautions are not taken. NOTICE indicates that an unintended result or situation can occur if the corresponding information is not taken into account.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

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

Prescribed Usage Note the following:

WARNING This device may only be used for the applications described in the catalog or the technical description and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly as well as careful operation and maintenance.

Trademarks All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG Automation and Drives Postfach 48 48 90327 NRNBERG GERMANY

Ordernumber: 6FC5398-4BP20-1BA0 11/2007

Copyright Siemens AG 2008. Technical data subject to change

Measuring cycles Programming Manual, 01/2008, 6FC5398-4BP20-1BA0 3

Preface Structure of the documentation

The SINUMERIK documentation is organized in 3 parts: General Documentation User documentation Manufacturer/service documentation A list of documents, updated on a monthly basis and indicating the available languages, is available on the Internet at: http://www.siemens.com/motioncontrol Select "Support" "Technical Documentation" "Overview of Documents". The Internet version of the DOConCD (DOConWEB) is available at: http://www.automation.siemens.com/doconweb Information on the range of training courses and FAQs (frequently asked questions) are available in the Internet under: http://www.siemens.com/motioncontrol and there under the menu item "Support"

Target group This Manual is intended for machine-tool programmers.

Benefits With the user manual, the target group can develop, write, test, and debug programs.

Standard scope The functionality of the standard scope (measuring cycle release SW 6.3) is described in this programming manual. The machinery construction OEM documents supplements or changes that he makes (the machinery construction OEM). Other functions not described in this documentation might be executable in the control. However, no claim can be made regarding the availability of these functions when the equipment is first supplied or in the event of servicing. For the sake of simplicity, this documentation does not contain all detailed information about all types of the product and cannot cover every conceivable case of installation, operation, or maintenance.

Preface

Measuring cycles 4 Programming Manual, 01/2008, 6FC5398-4BP20-1BA0

Technical Support If you have any questions, please contact our Hotline: Europe and Africa time zone A&D Technical Support Tel.: +49 (0) 180 / 5050 - 222 Fax: +49 (0) 180 / 5050 - 223 Internet: http://www.siemens.com/automation/support-request Email: mailto:[email protected] Asia and Australia time zone A&D Technical Support Tel.: +86 1064 719 990 Fax: +86 1064 747 474 Internet: http://www.siemens.com/automation/support-request Email: mailto:[email protected] America time zone A&D Technical Support Tel.: +1 423 262 2522 Fax: +1 423 262 2289 Internet: http://www.siemens.com/automation/support-request Email: mailto:[email protected]

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

Questions on the manual If you have any queries (suggestions, corrections) in relation to this documentation, please fax or e-mail us: Fax: +49 (0) 9131 / 98 - 63315 Email: mailto:[email protected] Fax form: See the reply form at the end of this publication

Preface


SINUMERIK Internet address http://www.siemens.com/sinumerik

Validity This User's Guide is valid for the following controls: Measuring cycles, version 7.3. Software versions stated in the programming manual refer to the 840D and their 810D equivalent, e.g. SW 5 (840D) corresponds to SW 3 (810D).

Structure of descriptions All cycles and programming options have been described according to the same internal structure, as far as this is meaningful and practicable. The various levels of information have been organized such that you can selectively access the information you need for the task in hand.

Supplementary devices The applications of SIEMENS controls can be expanded for specific purposes through the addition of special add-on devices, equipment and expansions supplied by SIEMENS.

Preface



Table of contents Preface ...................................................................................................................................................... 3 1 General.................................................................................................................................................... 17

1.1 Basics...........................................................................................................................................17 1.2 General prerequisites...................................................................................................................18 1.3 Behavior on block search, dry run, program testing, simulation..................................................19 1.4 Reference points on the machine and workpiece........................................................................22 1.5 Definition of the planes, tool types...............................................................................................24 1.6 Probes that can be used ..............................................................................................................27 1.7 Probe, calibration body, calibration tool.......................................................................................29 1.7.1 Measuring workpieces on milling machines, machining centers .................................................29 1.7.2 Measuring tools on milling machines, machining centers ...........................................................30 1.7.3 Measuring workpieces at the turning machines...........................................................................31 1.7.4 Measuring tools at lathes .............................................................................................................34 1.8 Measurement principle.................................................................................................................36 1.9 Measuring strategy for measuring workpieces with tool offset ....................................................41 1.10 Parameters for checking the measurement result and offset ......................................................44 1.11 Effect of empirical value, mean value, and tolerance parameters...............................................49 1.12 Overview of measuring cycle functions for milling technology ....................................................50 1.12.1 Tool measurement on milling machines, machining centers.......................................................50 1.12.2 Calibrating workpiece probes.......................................................................................................51 1.12.3 Workpiece measurement at one point .........................................................................................51 1.12.4 Measuring the workpiece parallel to the axis...............................................................................52 1.12.5 Measuring a workpiece at an angle .............................................................................................55 1.12.6 Measuring a surface at an angle..................................................................................................56 1.12.7 Measuring spheres ......................................................................................................................57 1.12.8 Workpiece measurement: Setting-up a corner ............................................................................58 1.13 Overview of measuring cycle functions for turning technology....................................................59 1.13.1 Measuring tools at lathes .............................................................................................................59 1.13.2 Calibrating workpiece probes.......................................................................................................60 1.13.3 Measuring workpieces at lathes: 1-point measurement ..............................................................61 1.13.4 Measuring workpieces at lathes: 2-point measurement ..............................................................62

2 Parameter description.............................................................................................................................. 63 2.1 Parameter concept of the measuring cycles................................................................................63 2.2 Parameter overview .....................................................................................................................65 2.2.1 Defining parameters.....................................................................................................................65 2.2.2 Result parameters........................................................................................................................67 2.3 Description of the most important defining parameters ...............................................................69 2.3.1 Measurement variant: _MVAR.....................................................................................................69

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2.3.2 Number of the measuring axis: _MA........................................................................................... 69 2.3.3 Tool number and tool name: _TNUM and _TNAME ................................................................... 70 2.3.4 Offset number: _KNUM............................................................................................................... 71 2.3.5 Offset number _KNUM extended for tool offset: up to 9 digits.................................................... 73 2.3.6 Correcting setup and additive offset in workpiece measurement: _DLNUM .............................. 74 2.3.7 Correcting the tool of a stored tool environment: _TENV ........................................................... 75 2.3.8 Example of automatic tool offset with and without saved tool environment in workpiece

measuring cycles ........................................................................................................................ 76 2.3.9 Variable measuring velocity: _VMS ............................................................................................ 77 2.3.10 Offset angle position: _CORA ..................................................................................................... 78 2.3.11 Tolerance parameters: _TZL, _TMV, _TUL, _TLL, _TDIF and _TSA.......................................... 78 2.3.12 Measurement path: _FA.............................................................................................................. 79 2.3.13 Probe type, probe number: _PRNUM ......................................................................................... 80 2.3.14 Empirical value, mean value: _EVNUM ...................................................................................... 81 2.3.15 Multiple measurement at the same location: _NMSP ................................................................. 82 2.3.16 Weighting factor for mean value calculation: _K......................................................................... 83

3 Measuring cycle help programs ............................................................................................................... 85 3.1 Package structure of the measuring cycles ................................................................................ 85 3.2 Measuring cycle subroutines....................................................................................................... 87 3.2.1 Overview ..................................................................................................................................... 87 3.2.2 CYCLE116: Calculation of center point and radius of a circle .................................................... 88 3.3 Measuring cycle user programs.................................................................................................. 90 3.3.1 General information..................................................................................................................... 90 3.3.2 CYCLE198: User program before undertaking measurement.................................................... 90 3.3.3 CYCLE199: User program after undertaking measurement....................................................... 90

4 Measuring in JOG.................................................................................................................................... 91 4.1 Overview ..................................................................................................................................... 91 4.2 Workpiece measurement ............................................................................................................ 94 4.2.1 Overview ..................................................................................................................................... 94 4.2.1.1 General information..................................................................................................................... 94 4.2.1.2 Operational sequence ................................................................................................................. 94 4.2.1.3 "Function interface of the measuring point softkeys (P1...P4)", in the PLC................................ 96 4.2.1.4 Measuring in JOG with active TRAORI....................................................................................... 97 4.2.2 Calibrating the workpiece probe ................................................................................................. 98 4.2.2.1 General information..................................................................................................................... 98 4.2.2.2 Calibrating probe length .............................................................................................................. 99 4.2.2.3 Calibrating probe radius ............................................................................................................ 100 4.2.3 Measure edge ........................................................................................................................... 101 4.2.3.1 General information................................................................................................................... 101 4.2.3.2 Setting the edge ........................................................................................................................ 103 4.2.3.3 Orienting the edge..................................................................................................................... 104 4.2.3.4 Distance 2 edges ...................................................................................................................... 106 4.2.4 Measuring corner ...................................................................................................................... 107 4.2.4.1 General information................................................................................................................... 107 4.2.4.2 Right-angled corner................................................................................................................... 108 4.2.4.3 Any corner................................................................................................................................. 110 4.2.5 Measuring pocket, hole or spigot .............................................................................................. 111 4.2.5.1 General information................................................................................................................... 111 4.2.5.2 Rectangular pocket or 1 hole or 1 spigot .................................................................................. 112 4.2.5.3 2 holes or 2 circular spigots ...................................................................................................... 115 4.2.5.4 3 holes or 3 circular spigots ...................................................................................................... 117 4.2.5.5 4 holes or 4 circular spigots ...................................................................................................... 118

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4.2.6 Align plane .................................................................................................................................120 4.2.6.1 General information ...................................................................................................................120 4.2.6.2 Measuring a plane that is oblique in space................................................................................121 4.2.7 Rejection, repetition, end of measurement ................................................................................122 4.2.7.1 Rejection and repetition of measurements ................................................................................122 4.2.7.2 Terminating the measurement ...................................................................................................123 4.2.8 Cascaded measurement............................................................................................................124 4.2.9 Support of set-up in JOG - after measurement..........................................................................125 4.2.9.1 General information ...................................................................................................................125 4.2.9.2 Example 1 ..................................................................................................................................126 4.2.9.3 Example 2 ..................................................................................................................................127 4.3 Measuring the tool .....................................................................................................................129 4.3.1 Overview of function and sequence...........................................................................................129 4.3.2 Calibrating the tool probe...........................................................................................................129 4.3.3 Measuring milling or drilling tools...............................................................................................131

5 Measuring Cycles for Milling and Machining Centers ............................................................................ 135 5.1 General prerequisites.................................................................................................................135 5.1.1 General information ...................................................................................................................135 5.1.2 Overview of measuring cycles ...................................................................................................135 5.1.3 Overview of the auxiliary programs required .............................................................................136 5.1.4 Call and return conditions ..........................................................................................................136 5.2 CYCLE971 tool: Measuring milling tools, drills ..........................................................................138 5.2.1 Function overview ......................................................................................................................138 5.2.2 Measurement and correction strategy .......................................................................................140 5.2.2.1 Measuring strategy ....................................................................................................................140 5.2.2.2 Compensation strategy ..............................................................................................................141 5.2.2.3 Compensation with correction table when measuring with rotating spindle ..............................142 5.2.3 Calibrating tool probes ...............................................................................................................144 5.2.3.1 Calibration..................................................................................................................................144 5.2.3.2 Programming example 1............................................................................................................146 5.2.3.3 Programming example 2............................................................................................................147 5.2.3.4 Operational sequence................................................................................................................149 5.2.4 Calibrating tool probes automatically.........................................................................................150 5.2.4.1 Automatic calibration..................................................................................................................150 5.2.4.2 Programming example...............................................................................................................152 5.2.4.3 Operational sequence................................................................................................................153 5.2.5 Measuring tool............................................................................................................................154 5.2.5.1 Measurement .............................................................................................................................154 5.2.5.2 Programming examples 1 ..........................................................................................................159 5.2.5.3 Programming example 2............................................................................................................161 5.2.5.4 Operational sequence................................................................................................................162 5.3 CYCLE976 calibrate workpiece probe.......................................................................................163 5.3.1 Function overview ......................................................................................................................163 5.3.2 Calibrating a workpiece probe in a hole of known hole center point .........................................166 5.3.2.1 General information ...................................................................................................................166 5.3.2.2 Programming example...............................................................................................................168 5.3.2.3 Operational sequence................................................................................................................169 5.3.3 Calibrating a workpiece probe in a hole of unknown hole center point .....................................170 5.3.3.1 General information ...................................................................................................................170 5.3.3.2 Programming example...............................................................................................................172 5.3.3.3 Operational sequence................................................................................................................173 5.3.4 Calibration of a workpiece probe on a surface ..........................................................................174 5.3.4.1 General information ...................................................................................................................174

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5.3.4.2 Programming example .............................................................................................................. 176 5.3.4.3 Operational sequence ............................................................................................................... 177 5.3.5 Calibrating a workpiece probe in the applicate determining probe length ................................ 177 5.3.5.1 General information................................................................................................................... 177 5.3.5.2 Programming example .............................................................................................................. 179 5.3.5.3 Operational sequence ............................................................................................................... 180 5.4 CYCLE977 workpiece: Measure hole/shaft/groove/web/rectangle parallel to axes ................. 181 5.4.1 Function overview ..................................................................................................................... 181 5.4.2 Measuring contour elements..................................................................................................... 185 5.4.2.1 General information................................................................................................................... 185 5.4.2.2 Programming example .............................................................................................................. 188 5.4.2.3 Operational sequence ............................................................................................................... 190 5.4.3 Measuring and tool offset.......................................................................................................... 193 5.4.3.1 General information................................................................................................................... 193 5.4.3.2 Programming example .............................................................................................................. 196 5.4.4 Measurement and ZO determination ........................................................................................ 198 5.4.4.1 General information................................................................................................................... 198 5.4.4.2 Programming example .............................................................................................................. 200 5.5 CYCLE978 workpiece: Measuring a surface parallel to the axis .............................................. 202 5.5.1 Function overview ..................................................................................................................... 202 5.5.2 Measuring the surface............................................................................................................... 204 5.5.3 Measurement and ZO determination ........................................................................................ 206 5.5.3.1 General information................................................................................................................... 206 5.5.3.2 Programming example .............................................................................................................. 207 5.5.4 Measuring and tool offset.......................................................................................................... 209 5.5.4.1 General information................................................................................................................... 209 5.5.4.2 Programming example .............................................................................................................. 210 5.6 CYCLE979 workpiece: Measure hole/shaft/groove/rib at an angle .......................................... 213 5.6.1 Function overview ..................................................................................................................... 213 5.6.2 Measure shaft, groove, web...................................................................................................... 216 5.6.2.1 General information................................................................................................................... 216 5.6.2.2 Operational sequence ............................................................................................................... 218 5.6.3 Measuring and tool offset.......................................................................................................... 221 5.6.3.1 General information................................................................................................................... 221 5.6.3.2 Programming example .............................................................................................................. 223 5.6.4 Measurement and ZO determination ........................................................................................ 225 5.6.4.1 General information................................................................................................................... 225 5.6.4.2 Programming example .............................................................................................................. 227 5.7 CYCLE998 workpiece: Angle measurement and ZO determination......................................... 229 5.7.1 Function overview ..................................................................................................................... 229 5.7.2 1-angle measurement ............................................................................................................... 232 5.7.2.1 General information................................................................................................................... 232 5.7.2.2 Programming example .............................................................................................................. 235 5.7.2.3 Operational sequence ............................................................................................................... 236 5.7.3 2-angle measurement ............................................................................................................... 240 5.7.3.1 General information................................................................................................................... 240 5.7.3.2 Programming example 1 ........................................................................................................... 241 5.7.3.3 Programming example 2 ........................................................................................................... 243 5.7.3.4 Operational sequence ............................................................................................................... 246 5.8 CYCLE961 workpiece: Setup inside and outside corner .......................................................... 248 5.8.1 Function overview ..................................................................................................................... 248 5.8.2 Setting up a corner with definition of distances and angles...................................................... 250 5.8.2.1 General information................................................................................................................... 250

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5.8.2.2 Programming example...............................................................................................................252 5.8.2.3 Operational sequence................................................................................................................254 5.8.3 Setting up a corner with 4 points................................................................................................256 5.8.3.1 General information ...................................................................................................................256 5.8.3.2 Programming example...............................................................................................................257 5.8.3.3 Operational sequence................................................................................................................259 5.9 CYCLE997 workpiece: Measuring a sphere and ZO determination..........................................261 5.9.1 Function overview ......................................................................................................................261 5.9.2 Measurement and ZO determination .........................................................................................266 5.9.2.1 General information ...................................................................................................................266 5.9.2.2 Operational sequence................................................................................................................268 5.9.3 Programming example CYCLE997............................................................................................271 5.9.4 CYCLE119: Arithmetic cycle for determining position in space.................................................273 5.9.4.1 General information ...................................................................................................................273 5.9.4.2 Programming example...............................................................................................................275 5.10 CYCLE996 workpiece: Measure kinematics..............................................................................276 5.10.1 General ......................................................................................................................................276 5.10.2 Measurement procedure............................................................................................................277 5.10.2.1 Proceed as follows.....................................................................................................................277 5.10.2.2 Measuring an individual rotary axis ...........................................................................................278 5.10.2.3 Measuring an individual ball position .........................................................................................280 5.10.2.4 Calculating and activating the swivel data records....................................................................280 5.10.3 Example of the procedure to measure the kinematics (CYCLE996) .........................................280 5.10.4 Activation of the function............................................................................................................281 5.10.5 Measuring kinematics ................................................................................................................282 5.10.6 Programming via a screen form.................................................................................................282 5.10.6.1 General ......................................................................................................................................282 5.10.6.2 Parameters of "1st, 2nd, 3rd measurement" screen form..........................................................284 5.10.6.3 Parameters of "Calculate kinematics" screen form....................................................................286 5.10.6.4 Result bit ....................................................................................................................................289 5.10.7 Programming using parameters.................................................................................................289 5.10.7.1 Programming using parameters.................................................................................................289 5.10.7.2 Result parameters, intermediate results ....................................................................................292 5.10.8 Programming example...............................................................................................................295

6 Measuring Cycles for Turning Machines................................................................................................ 297 6.1 General prerequisites.................................................................................................................297 6.1.1 General information ...................................................................................................................297 6.1.2 Overview of measuring cycles ...................................................................................................297 6.1.3 Overview of the auxiliary programs required .............................................................................297 6.1.4 Call and return conditions ..........................................................................................................298 6.2 CYCLE982, CYCLE972 Tool: Measure turning tools ................................................................300 6.2.1 Function overview ......................................................................................................................300 6.2.2 Calibrate tool probe (machine-related) ......................................................................................302 6.2.3 Determining dimensions of calibration.......................................................................................307 6.2.4 Measure turning tool (machine-related).....................................................................................307 6.3 CYCLE982 tool: Measure turning and milling tools ...................................................................313 6.3.1 Function overview ......................................................................................................................313 6.3.2 Calibrating tool probes ...............................................................................................................319 6.3.3 Measuring tool............................................................................................................................322 6.3.4 Automatic tool measurement .....................................................................................................331 6.3.5 Incremental calibration...............................................................................................................337 6.3.6 Incremental measurement .........................................................................................................341

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6.3.7 Milling tool: Suppression of start angle positioning _STA1....................................................... 347 6.3.8 Measuring drills - Special applications...................................................................................... 348 6.3.9 Measuring a tool with orientational tool carriers - 90 multiples of tool position (measuring

cycle release SW 6.3 and higher) ............................................................................................. 349 6.3.9.1 Overview of the functions.......................................................................................................... 349 6.3.9.2 Measuring turning tools - 90 multiples of the tool position ...................................................... 351 6.3.9.3 Measuring milling/drilling tools - 90 multiples of the tool position............................................ 353 6.4 CYCLE973 Calibrating workpiece probes................................................................................. 355 6.4.1 Function overview ..................................................................................................................... 355 6.4.2 Calibrating in the reference groove........................................................................................... 358 6.4.2.1 General information................................................................................................................... 358 6.4.2.2 Programming example .............................................................................................................. 360 6.4.2.3 Operational sequence ............................................................................................................... 361 6.4.3 Calibration on surface ............................................................................................................... 361 6.4.3.1 General information................................................................................................................... 361 6.4.3.2 Programming example .............................................................................................................. 363 6.4.3.3 Operational sequence ............................................................................................................... 364 6.5 CYCLE974 workpiece: 1-point measurement........................................................................... 365 6.5.1 Function overview ..................................................................................................................... 365 6.5.2 1-point measurement and ZO determination ............................................................................ 368 6.5.2.1 General information................................................................................................................... 368 6.5.2.2 Programming example .............................................................................................................. 369 6.5.2.3 Operational sequence ............................................................................................................... 370 6.5.3 1-point measurement and tool offset ........................................................................................ 370 6.5.3.1 General information................................................................................................................... 370 6.5.3.2 Programming example .............................................................................................................. 372 6.5.3.3 Operational sequence ............................................................................................................... 374 6.5.4 1-point measurement with reversal and tool offset ................................................................... 375 6.5.4.1 General information................................................................................................................... 375 6.5.4.2 Programming example .............................................................................................................. 376 6.6 CYCLE994 workpiece: 2-point measurement........................................................................... 378 6.6.1 Function overview ..................................................................................................................... 378 6.6.1.1 General information................................................................................................................... 378 6.6.1.2 Programming example .............................................................................................................. 383 6.6.1.3 Operational sequence ............................................................................................................... 385 6.7 Complex example for tool measurement .................................................................................. 387

7 Miscellaneous functions......................................................................................................................... 389 7.1 Log measurement results.......................................................................................................... 389 7.1.1 Overview of the logging cycles.................................................................................................. 389 7.1.2 Log file....................................................................................................................................... 389 7.1.3 Handling the log cycles ............................................................................................................. 390 7.1.3.1 General information................................................................................................................... 390 7.1.3.2 CYCLE100 Logging ON............................................................................................................ 390 7.1.3.3 CYCLE101 Logging OFF .......................................................................................................... 390 7.1.3.4 CYCLE105(PAR1) Creating log content ................................................................................... 391 7.1.3.5 CYCLE106(PAR1) Logging sequence control .......................................................................... 391 7.1.3.6 CYCLE113(PAR1,PAR2) Read system date and time............................................................. 391 7.1.3.7 CYCLE118(PAR1,PAR2,PAR3,PAR4,PAR5)........................................................................... 391 7.1.3.8 Programming example for formatting a single number............................................................. 392 7.1.3.9 Programming example for formatting three numbers ............................................................... 393 7.1.4 Variables when logging ............................................................................................................. 393 7.1.5 Selection of the log content....................................................................................................... 394

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7.1.6 Log format ..................................................................................................................................396 7.1.7 Log header .................................................................................................................................397 7.1.8 Example: Creating a measurement result log............................................................................398 7.2 Measuring cycle support in the program editor (up to measuring cycles SW 5.4) ....................401 7.2.1 Measuring cycle support files.....................................................................................................401 7.2.2 Load the measuring cycle support .............................................................................................402 7.2.3 Assigning calls and measuring cycles .......................................................................................402 7.2.4 Description of the parameterizing cycles ...................................................................................403 7.2.4.1 General information ...................................................................................................................403 7.2.4.2 Setting additional parameters - CYCLE_PARA .........................................................................403 7.2.4.3 Calibrate tool probe - CYCLE_CAL_TOOLSETTER..................................................................404 7.2.4.4 Calibration on surface - CYCLE_CAL_PROBE .........................................................................404 7.2.4.5 Calibration in groove - CYCLE_973...........................................................................................405 7.2.4.6 Calibration in hole - CYCLE_976 ...............................................................................................405 7.2.4.7 Measuring milling tools - CYCLE_971 .......................................................................................406 7.2.4.8 Measuring turning tools - CYCLE_972 ......................................................................................407 7.2.4.9 Hole, measure shaft CYCLE_977_979A.................................................................................407 7.2.4.10 Groove, measure web CYCLE_977_979B..............................................................................408 7.2.4.11 Measure rectangle - CYCLE_977_979C....................................................................................408 7.2.4.12 Single-point measurement - CYCLE_978..................................................................................409 7.2.4.13 Angle measurement - CYCLE_998............................................................................................409 7.2.4.14 Corner measurement with specification of angles - CYCLE_961_W.........................................410 7.2.4.15 Corner measurement with specification of points - CYCLE_961_P...........................................411 7.2.4.16 Single-point measurement - CYCLE_974..................................................................................411 7.2.4.17 Two-point measurement - CYCLE_994 .....................................................................................412 7.3 Measuring cycle support in the program editor (from measuring cycles SW 6.2) .....................413 7.3.1 Menus, explanation of the cycles...............................................................................................413 7.3.1.1 General information ...................................................................................................................413 7.3.1.2 Softkey bars for turning..............................................................................................................414 7.3.1.3 Softkey bars for milling...............................................................................................................416 7.3.1.4 Programming example...............................................................................................................418 7.3.2 Pre-setting of the measuring cycle support ...............................................................................419 7.4 Measuring result screens...........................................................................................................423

8 Hardware/software................................................................................................................................. 425 8.1 Hardware requirements .............................................................................................................425 8.1.1 General hardware prerequisites.................................................................................................425 8.1.2 Measuring probe connection......................................................................................................425 8.1.2.1 General information ...................................................................................................................425 8.1.2.2 SINUMERIK 810D, 840D powerline, 840Di...............................................................................425 8.1.2.3 SINUMERIK 840D sl (solution line) probe connection to X122, NCU 7x0 ................................430 8.1.3 Measuring in JOG ......................................................................................................................431 8.2 Software requirements...............................................................................................................432 8.2.1 How the measuring cycles are supplied ....................................................................................432 8.2.2 Software versions NC and MMC/HMI........................................................................................432 8.2.3 Options.......................................................................................................................................432 8.3 Function test...............................................................................................................................433

9 Data description..................................................................................................................................... 435 9.1 Machine data for machine cycle runs ........................................................................................435 9.1.1 Machine data that configure the memory ..................................................................................435 9.1.1.1 General information ...................................................................................................................435 9.1.1.2 Memory configuring machine data, SRAM ................................................................................436

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9.1.1.3 Memory configuring machine data, DRAM ............................................................................... 439 9.1.2 Other machine data................................................................................................................... 441 9.2 Cycle data ................................................................................................................................. 443 9.2.1 Data blocks for measuring cycles ............................................................................................. 443 9.2.1.1 General information................................................................................................................... 443 9.2.1.2 Data block GUD5.DEF.............................................................................................................. 443 9.2.1.3 Data block GUD6.DEF.............................................................................................................. 443 9.2.2 Data adjustment to a specific machine ..................................................................................... 448 9.2.3 Central values ........................................................................................................................... 449 9.2.4 Central bits ................................................................................................................................ 457 9.2.4.1 In data block GUD6.DEF........................................................................................................... 457 9.2.4.2 Detailed description................................................................................................................... 458 9.2.5 Central strings ........................................................................................................................... 461 9.2.6 Channel-oriented values ........................................................................................................... 462 9.2.7 Channel-oriented bits ................................................................................................................ 466 9.2.7.1 In data block GUD6.DEF........................................................................................................... 466 9.2.7.2 Detailed description................................................................................................................... 468 9.3 Data for measuring in JOG ....................................................................................................... 474 9.3.1 Machine data for ensuring operability ....................................................................................... 474 9.3.2 Modifying the GUD7 data block ................................................................................................ 476 9.3.3 Settings in data block GUD6..................................................................................................... 481 9.3.4 Loading files for measuring in JOG........................................................................................... 482

10 Start-up (hardware)................................................................................................................................ 485 10.1 Commissioning measuring cycles for the first time................................................................... 485 10.1.1 Requirements............................................................................................................................ 485 10.1.2 Overview of diskette in delivery form ........................................................................................ 485 10.2 Steps for commissioning measuring cycles for the first time .................................................... 487 10.2.1 General information................................................................................................................... 487 10.2.2 Step 0.1 set up memory configuring machine data................................................................ 487 10.2.3 Step 0.2 set up other machine data ....................................................................................... 487 10.2.4 Step 0.3 - set up machine data for measuring in JOG.............................................................. 488 10.3 Commissioning measuring cycles for HMI-Advanced PCU50 powerline up to

SW 06.03.18 and/or SW 06.04.08 ............................................................................................ 489 10.3.1 Requirements............................................................................................................................ 489 10.3.2 Step 1 load definition files ...................................................................................................... 489 10.3.2.1 General...................................................................................................................................... 489 10.3.2.2 Only for measuring in JOG up to measuring cycle release SW 6.02.16 .................................. 490 10.3.3 Step 2 load cycle programs.................................................................................................... 491 10.3.4 Step 3 load measuring cycle text files.................................................................................... 491 10.3.5 Step 4 load files for measurement result display ................................................................... 492 10.3.6 Step 5 load measuring cycle support ..................................................................................... 492 10.3.7 Step 6 activate measuring cycle support, configure .............................................................. 492 10.3.8 Step 7 - load and activate measuring in JOG ........................................................................... 493 10.3.9 Step 8 set measuring cycle data ............................................................................................ 493 10.4 Commissioning measuring cycles for HMI-Advanced PCU50 powerline as of

SW 06.03.19. and/or SW 06.04.10 and HMI-Advanced PCU50 Solutionline........................... 495 10.4.1 Requirements............................................................................................................................ 495 10.4.2 Step 1 load definition files ...................................................................................................... 495 10.4.3 Step 2 load other archive ....................................................................................................... 496 10.4.4 Step 3 - activate entry softkeys "Measure turning" and "Measure milling" for measuring

cycle support ............................................................................................................................. 497 10.4.5 Step 4 - activate softkey "Measuring cycles" in the "Commissioning" area.............................. 497

Table of contents


10.4.6 Step 5 - activate entry softkeys "Measure workpiece" and "Measure tool" for measuring in JOG in the machine's "JOG" area .............................................................................................498

10.4.7 Step 6 set measuring cycle data.............................................................................................498 10.5 Commissioning measuring cycles for HMI-Embedded PCU20 powerline.................................499 10.5.1 Requirements.............................................................................................................................499 10.5.2 Step 1 load definition files .......................................................................................................499 10.5.3 Step 2 load cycle programs.....................................................................................................499 10.5.4 Step 3 set measuring cycle data.............................................................................................499 10.5.5 Step 4 menu tree for extending measuring cycles..................................................................499 10.5.6 Step 5 configure measuring cycle support..............................................................................500 10.5.7 Step 6 incorporate text files.....................................................................................................500 10.5.8 Step 7 incorporate files for measurement result display.........................................................500 10.5.9 Step 8 incorporate measuring cycle support...........................................................................501 10.5.10 Step 9 incorporate displays for measuring cycle support .......................................................501 10.5.11 Step 10 - produce image file and program on a Flash card ......................................................502 10.6 Commissioning measuring cycles, HMI-Embedded TCU solution line SW 1.x.........................503 10.6.1 Requirements.............................................................................................................................503 10.6.2 Step 1 load archive .................................................................................................................503 10.6.3 Step 2 activate definition files..................................................................................................503 10.6.4 Step 3 - activate entry softkeys "Measure turning" and "Measure milling" for measuring

cycle support ..............................................................................................................................504 10.6.5 Step 4 - activate softkey "Measuring cycles" in the "Commissioning" area...............................504 10.6.6 Step 5 set measuring cycle data.............................................................................................504 10.7 Upgrading measuring cycles......................................................................................................505 10.7.1 General information ...................................................................................................................505 10.7.2 Upgrading measuring cycles for HMI-Advanced PCU50 powerline up to SW 06.03.18

and/or SW 06.04.08 ...................................................................................................................505 10.7.3 Upgrading measuring cycles for HMI-Advanced PCU50 powerline as of SW 06.03.19.

and/or as of SW 06.04.10 and HMI-Advanced PCU50 solution line .........................................506 10.7.3.1 Requirements.............................................................................................................................506 10.7.3.2 Step 1 load definition files .......................................................................................................507 10.7.3.3 Step 2 load other archive ........................................................................................................507 10.7.3.4 Step 3 update Bitmaps............................................................................................................508 10.7.4 Upgrading measuring cycles for HMI-Embedded PCU20 powerline.........................................508 10.8 Sequence for probe installation .................................................................................................509 10.9 Example of calculating the repeat accuracy ..............................................................................511

11 Alarm, error, and system messages ...................................................................................................... 513 11.1 General notes.............................................................................................................................513 11.2 Error rectification in the measuring cycles .................................................................................513 11.3 Overview of measuring cycle alarms .........................................................................................513

12 Adaptation of the Measuring Cycles to Previous Software Versions...................................................... 515 12.1 General information ...................................................................................................................515 12.2 Measuring cycle subroutines .....................................................................................................515

A Appendix................................................................................................................................................ 517 A.1 Overview of measuring cycle parameters..................................................................................517

B List of abbreviations............................................................................................................................... 561 C Parameter.............................................................................................................................................. 563

Table of contents


Glossary ................................................................................................................................................ 565 Index...................................................................................................................................................... 571


General 11.1 Basics

General information Measuring cycles are general subroutines designed to solve specific measurement tasks. They can be adapted to specific problems via parameter settings. When taking general measurements, a distinction is made between tool measurements and workpiece measurements.

Workpiece measurements

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General 1.2 General prerequisites


Tool measurements

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The wear and other tool parameters must be assigned the value 0. In _CBIT[14] you can set whether length L1 refers to the ball center point or the ball circumference.

Note _CBIT[14] see Subsection 9.2.4 (central bits).

Calibration A probe must be calibrated before it can be used. Calibration involves determining the triggering points (switching points), positional deviation (skew), and active ball radius of the workpiece probe and then entering them in special data fields _WP[ ] in data block GUD6.DEF. The default setting has data fields for 3 probes. Up to 99 are possible. Calibration can be performed on holes of a known size or workpiece surfaces with a sufficient form precision and low surface roughness. Use of special gauging blocks is not supported on milling and machine centers. Use the same measuring velocity for calibrating and measuring. A special cycle is available for calibration.

General 1.7 Probe, calibration body, calibration tool


1.7.2 Measuring tools on milling machines, machining centers

Tool probe The tool probes have dedicated data fields _TP[ ] and _TPW[ ] in data block GUD6.DEF. The triggering points (switching points), upper disk diameter and edge length are entered here.

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General 1.7 Probe, calibration body, calibration tool


Entry in tool memory Tool type (DP1): 1xy Length 1 - geometry (DP3): L1 Radius (DP6): r Length 1 - basic measurement (DP21):

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1: 300 mm/min. Cycles parameter _VMS is then =0. Other measuring velocities can be set by the user to a value of >0 in _VMS (see Chapter 2). The maximum permissible measuring velocity is derived from: the deceleration behavior of the axis. the permissible deflection of the probe. the signal processing delay.

Deceleration distance, deflection of probe

CAUTION Safe deceleration of the measuring axis to standstill within the permissible deflection path of the probe must always be ensured. Otherwise damage will occur!

A delay "t" typical of the control is taken into account in signal processing (IPO cycle) for the time between detection of the switching signal and output of the deceleration command to the measuring axis MD 10050: SYSCLOCK_CYCLE_TIME and MD 10070: IPO_SYSCLOCK_TIME_RATIO). This results in the deceleration path component. The following error of the measuring axis is reduced. The following error is velocity dependent and at the same time dependent on the control factor of the measuring axis (servo gain of the associated machine axis: servo gain factor). The deceleration rate of the axis must also be taken into account. Together they produce an axis-specific velocity-dependent deceleration distance. The servo gain factor is MD 32200: POSCTRL_GAIN. Axis acceleration / deceleration rate a is stored in MD 32300: MAX_AX_ACCEL. It may have a lesser effect due to other influences. Always used the lowest values of the axes involved in the measurement.

General 1.8 Measurement principle


Calculation of the deceleration path

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sb Deceleration path in mm v Measuring velocity in m/s t Delay signal in s a Deceleration in m/s2 s Following error in mm s = v / Kv v here in m/min Kv Servo gain in (m/min)/mm

Example of calculation: v = 6 m/min = 0.1 m/ s measuring velocity a = 1 m/s2 deceleration t = 16 ms signal delay Kv = 1 in (m/min)/mm The deflection of the probe = deceleration distance to zero speed of axis is: sb = 12.6 mm.

General 1.8 Measurement principle


The deceleration distance components are:

s = 6/ 1 = 6 mm Following error s2 = 1000 0.01 / 2 + 6 = 11 mm axis-specific component s1 = 1000 0.1 0.016 = 1.6 mm Percentage due to signal delay

Measuring accuracy A delay occurs between detection of the switching signal from the probe and transfer of the measured value to the control. This is caused by signal transmission from the probe and the hardware of the control. In this time a path is traversed that falsifies the measured value. This influence can be minimized by reducing the measuring speed. The rotation when measuring a mill on a rotating spindle has an additional influence. This can be compensated for by compensation tables. (see Section 5.2.2 CYCLE971 "Measurement and correction strategy"). The measurement accuracy that can be obtained is dependent on the following factors: Repeat accuracy of the machine Repeatability of the probe Resolution of the measuring system

Note

Repeat accuracy A test program for determining the overall repeatability of a machine is described in Section 10.4.

General 1.9 Measuring strategy for measuring workpieces with tool offset


1.9 Measuring strategy for measuring workpieces with tool offset The actual workpiece dimensions must be measured exactly and compared with the setpoint values to be able to determine and compensate the actual dimensional deviations on the workpiece. An offset value can then be ascertained for the tool used for machining.

Function When taking measurements on the machine, the actual dimensions are derived from the path measuring systems of the position-controlled feed axes. For each dimensional deviation determined from the set and actual workpiece dimensions there are many causes which essentially fall into 3 categories: Dimensional deviations with causes that are n o t subject to a particular trend, e.g.

positioning scatter of the feedforward axes or differences in measurement between the internal measurement (measuring probe) and the external measuring device (micrometer, measuring machine, etc.). In this case, it is possible to apply empirical values, which are stored in separate memories. The set/actual difference determined is automatically compensated by the empirical value.

Dimensional deviations with causes that a r e subject to a particular trend, e.g. tool wear or thermal expansion of the leadscrew.

Accidental dimensional deviations, e.g. due to temperature fluctuations, coolant or slightly soiled measuring points. Assuming the ideal case, only those dimensional deviations that are subject to a trend can be taken into account for compensation value calculation. Since, however, it is hardly ever known to what extent and in which direction accidental dimensional deviations influence the measurement result, a strategy (sliding averaging) is needed that derives a compensation value from the actual/set difference measured.

Mean value calculation Mean value calculation in conjunction with measurement weighting has proven a suitable method. The formula of the mean value generation chosen is:

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The mean value calculation takes account of the trend of the dimensional deviations of a machining series. The weighting factor k from which the mean value is derived is selectable. A new measurement result affected by accidental dimensional deviations only influences the new tool offset to some extent, depending on the weighting factor.



Computational characteristic of the mean value with different weightings k

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

The lower the value of k, the faster the formula will react when major deviations occur in computation or counter compensation. However, the effect of accidental variations will be that much greater.

The mean value Mi is calculated starting at 0 over the number of workpieces i, until the calculated mean value exceeds the range of "zero compensation"(cycle parameter _TZL, see Chapter 2). From this limit on, the calculated mean value is applied as an offset.

Once the mean value has been used for the offset, it is deleted from the memory. The next measurement then starts again with Miold = 0.



Table 1-2 Example of mean value calculation and offset Lower limit = 40 m

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Mi k = 2 [m]

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In the measurements with marked fields, tool compensation is performed with the mean value (calculated mean value >_TZL): If k=3 in the 7th and 10th measurement ( and ), If k=2 in the 3rd, 7th, and 9th measurement (, and ).

General 1.10 Parameters for checking the measurement result and offset


1.10 Parameters for checking the measurement result and offset For constant deviations not subject to a trend, the dimensional deviation measured can be compensated by an empirical value in certain measuring variants. For other compensations resulting from dimensional deviations, symmetrical tolerance bands are assigned to the set dimension which result in different responses.

Empirical value/mean value _EVNUM The empirical values are used to suppress dimensional deviations that are not subject to a trend.

Note If you do not want to apply any empirical values, _EVNUM = 0 must be set.

The empirical values themselves are stored in data block (GUD5) in field _EV[ ] empirical value. _EVNUM specifies the number of the empirical value memory. The actual/set difference determined by the measuring cycle is corrected by this valuebefore any further correction measures are taken. This is the case: for workpiece measurement with automatic tool offset. for single-point measurement with automatic zero offset. tool measurement. Mean value _EVNUM is active only for workpiece measurement with automatic tool offset. When calculating the mean value in a series of machining operations, the mean value determined by the measurement at the same measurement location on the previous workpiece can be taken into account (_CHBIT[4]=1). The mean values are stored in data block (GUD5) in field _MV[ ] Mean value. _EVNUM specifies the number of the mean value memory in this field.

Safe area_TSA The safe area is effective for almost all measuring variants and does not affect the offset value; it is used for diagnostics. If this limit is reached then the following can be assumed: a probe defect, or an incorrect setpoint position, or an illegal deviation from the setpoint position can be assumed.

Note

AUTOMATIC mode AUTOMATIC operation is interrupted and the program cannot continue. An alarm text appears to warn the user.



Dimensional difference check _TDIF _TDIF is active only for workpiece measurement with automatic tool offset and for tool measurement. This limit has no effect on generation of the compensation value either. When it is reached, the tool is probably worn and needs to be replaced.

Note An alarm text is displayed to warn the operator and the program can be continued by means of an NC start.

This tolerance limit is generally used by the PLC for tool management purposes (twin tools, wear monitoring).

Tolerance of the workpiece _TLL, _TUL Both parameters are active only for tool measurement with automatic tool offset. When measuring a dimensional deviation ranging between "2/3 tolerance of workpiece" and "Dimensional difference control", this is regarded 100 % as tool compensation. The previous average value is erased. This enables a fast response to major dimensional deviations.

Note When the tolerance limit of the workpiece is exceeded, this is indicated to the user depending on the tolerance position "oversize" or "undersize".

2/3 workpiece tolerance _TMV _TMV is active only for workpiece measurement with automatic tool offset. Within the range of "Lower limit" and "2/3 workpiece tolerance" the mean value is calculated according to the formula described in Section "Measuring strategy".

Note Mynew Mynew is compared with the zero compensation range: If Mynew is greater than this range, compensation is corrected by Mynew and the associated

mean value memory is cleared. If Mynew is less than this range, no compensation is carried out. to prevent excessively

abrupt compensations.



Weighting factor for mean value calculation _k _K is active only workpiece measurement with automatic tool offset. The weighting factor can be used to give a different weighting for each measurement. A new measurement result thus has only a limited effect on the new tool offset as a function of _K.

Lower limit (zero compensation area) _TZL _TZL active for Workpiece measurement with automatic tool offset Tool measurement and calibration for milling tools and tool probes This tolerance range corresponds to the amount of maximum accidental dimensional deviations. It has to be determined for each machine. No tool compensation is made within these limits. In workpiece measurement with automatic tool offset, however, the mean value of this measuring point is updated and re-stored with the measured actual/set difference, possibly compensated by an empirical value. The tolerance bands (range of permissible dimensional tolerance) and the responses derived from them are as follows: For workpiece measurement with automatic tool offset

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General 1.11 Effect of empirical value, mean value, and tolerance parameters


1.11 Effect of empirical value, mean value,