View
13
Download
0
Category
Preview:
Citation preview
STL6 COMPACT TURRET LATHE Operator’s Manual
800-476-4849 | 170 Aprill Drive | Ann Arbor, Michigan 48103
TableofContentsI.UnloadingMachine.....................................................................................................................3
LiftingandTransporting.....................................................................................................4
UnloadingofMachine........................................................................................................4
II.DeliveryandTestRunning..........................................................................................................5
Installation..........................................................................................................................5
Cleaning..............................................................................................................................5
Levelling..............................................................................................................................5
EnvironmentalRequirements............................................................................................5
ElectricandAirRequirements............................................................................................6
III.SafetyGuidelines.......................................................................................................................6
Overview............................................................................................................................6
SafetyLabels.......................................................................................................................7
DangerandWarningLabelsDisplayedonMachine.....................................................7
SafetyCategoryGuidelines..........................................................................................7
BasicPointsofSafety–BeforeStartingtheMachine........................................................8
PersonalProtectiveEquipment(PPE)andSafety...............................................................9
ToolsandWorkHoldingBestPractices..............................................................................9
SafetyGuidelinesRelatedtoMaintenance......................................................................10
HazardControl.................................................................................................................11
IV.MachineToolOverview..........................................................................................................12
Characteristics..................................................................................................................12
ApplicationRange.............................................................................................................12
CNCControlSystem.........................................................................................................12
MachineComponents–X-andZ-axis..............................................................................13
WorkHolding....................................................................................................................13
AxesMotionDirection......................................................................................................13
WayLubeSystem.............................................................................................................13
PositiveDisplacementManifold.......................................................................................13
V.OperationBoard......................................................................................................................14
SystemOperationArea....................................................................................................14
Introduction................................................................................................................14
2
FurtherInformation....................................................................................................14
KeyCombinations.......................................................................................................16
ElementsontheMCP(MachineControlPanel)Front.....................................................18
Pre-DefinedInsertionStrips.............................................................................................18
CoordinateSystems..........................................................................................................19
MachineCoordinateSystem............................................................................................20
WorkpieceCoordinateSystem.........................................................................................21
RelativeCoordinateSystem.............................................................................................21
WorkpieceFixturing.........................................................................................................21
VI.SoftwareInterface..................................................................................................................21
ProtectionLevels..............................................................................................................24
ProtectionLevel1.......................................................................................................25
ProtectionLevel3-6...................................................................................................25
ProtectionLevel7.......................................................................................................25
VII.TurningonandReferencingMachine....................................................................................28
OperatingSequence.........................................................................................................28
VIII.SettingUpToolsandWorkOffsets.......................................................................................29
Overview..........................................................................................................................29
SettingUpTools...............................................................................................................29
CreateaNewCuttingEdge...............................................................................................30
EnteringToolOffsets........................................................................................................30
ActivatingtheToolandStartingSpindle..........................................................................31
SelectingtheHandwheel..................................................................................................32
MeasuringtheToolManually..........................................................................................33
IX.SettinguptheWorkpiece........................................................................................................36
MeasuringtheWorkpiece................................................................................................36
EnteringandModifyingData...........................................................................................38
SettingTimeCounter........................................................................................................39
SettingRParameters........................................................................................................40
Setting“Rel”CoordinateSystem......................................................................................42
SettingJogData................................................................................................................43
X.PartProgramming....................................................................................................................43
CreatingFilesorFolders...................................................................................................44
3
CreatingaProgramDirectory...........................................................................................44
EditingPartPrograms.......................................................................................................45
BlockEditingOptions.......................................................................................................44
SearchforStrings.............................................................................................................44
ManagingPartPrograms..................................................................................................47
RenamingPrograms.........................................................................................................47
ViewingandExecutingRecentPrograms........................................................................48
ContourProgramming......................................................................................................48
ProgrammingaContour...................................................................................................50
Undercuts.........................................................................................................................57
XI.AutomaticMachining..............................................................................................................60
Simulation........................................................................................................................61
XII.MachineToolSettingsandAdjustments................................................................................62
XIII.CommonFaults.....................................................................................................................63
Removal............................................................................................................................63
RestartMachineAfterMakingAdjustments....................................................................68
XIV.MachineMaintenance..........................................................................................................68
DailyMaintenance...........................................................................................................68
WeeklyInspection............................................................................................................68
MonthlyInspectionandMaintenance.............................................................................69
XV.M-CodeList............................................................................................................................69
XVI.PLCFunctionParameters......................................................................................................71
4
I. UnloadingMachine
LiftingandTransporting
1) Size,weightandcentralpositionaremarkedonthecrate(ifapplicable).
2) Besuretohaveaforkliftwithsufficientforklength,sizeandloadcapacity,inadditionto
asafety-mindedandwell-trainedoperator.Packagelifting:seeFigure2.1-liftsmoothly
andsteadily-avoiddamagetomachine,riggingequipment,orbystanders.
Figure2.1Lifting
UnloadingofMachine
1) Unloadmachine(s)asclosetotheinstallationsiteaspossible.
2) Ifthemachinecomesinacrate,removethetopfirst,thensides.Thoroughlylookover
machineandnoteanydamage.
3) Afterunloading,pleasechecktheconditionofmachine,ifthereareanyproblems,
pleasecontactrelateddepartmentofDetroitMachineToolsat1-800-476-4849.
4) Removeboxes,additionaloptions/accessories,andtoolingthataresecuredtothepallet
floor.
5) Removefasteninghardwarethatsecuresmachinetopallet.Typically,onamill,there
willbe4boltssecuringmachinetothepallet,andonalathe,4-6.
5
II. DeliveryandTestRunning
Installation
1) Afterplacingmachineinthedesignatedspot,pleasereadalltherelatedtechnical
documentscarefully.
2) Lookovertheconnectionsofanymechanicalandelectricalparts.
3) Makesurethatthefixedbracessecuringthecarriageandturrethavebeenremoved
beforeoperatingmachine.
4) Checkthepowersupply,lubricationsystem,coolantsystemandoillevel.Iftheoillevel
isnotsufficient,fillwithspecifiedwaylube.
Cleaning
1) Afterinstallation,cleantheanti-corrosivegreaseonmachine,tooling,andaccessories.
2) Applyaliberalcoatofoilonthemachineandtoolingtoavoidrustaftercleaning.
Levelling
1) Properlylevellingalatherequirestimeandamachinistlevelcapableof.0005”in8”or
better.Takeyourtimenowtosavehoursofaggravationlaterwhenyourtoolsare
cuttingunwantedtapers.
2) Levellingshouldbedonewhentemperatureinshophasstabilizedtoanormaloperating
temperature.
3) PlacemachinistlevelacrosswaysparalleltotheXaxis.Itiscriticalthatthisreadingbe
thesameonboththeheadstockandtailstockendoftheways.Thiswilleliminatetwist
ofthelathebedthuseliminatingtapers.LevellingparalleltoZisnotascritical,butthe
procedureisthesameasX.
EnvironmentalRequirements
1) Thetemperaturerangeshouldbebetween50°F-104°F.Toreachalevelofprecision
andrepeatabilitythemachinetoolenvironmentshouldbeaconsistent68°F.
2) Paycloseattentionwhenweldingequipmentisbeingoperatednearthemachinetool.
3) Therelativehumidityofconditionshouldbelessthan75%toprotectelectrical
componentsanddetectingelements.
6
ElectricandAirRequirements
1) Powersupplyis220V,60Hz,3-phase(differentcountrieswithdifferentrequirements),
voltagefluctuationcanbearound±10%.Ifthepowersupplyisnotstable,avoltage
regulatorshouldbeaddedtothelines.
2) Hydraulicoilshouldmeetspecificationsofhydraulicunitmanufacturer.
3) Ifyourmachineisequippedwithpneumaticcomponents,90P.S.I.ofcleandryair
shouldbesupplied.
III. SafetyGuidelines-ALWAYSREMEMBERSAFETYFIRST!
Overview1) Itisstronglyrecommendedthatyoureadthismanualtounderstandthoroughlythe
contents.Properusewillcreateasafeworkingenvironmentandprolongthelifeof
yourmachine.
2) Thismachineisprovidedwithvarioussafetydevicestoprotecttheoperatorand
machine,howeverthesecannotcoverallaspectsofsafety.Theoperatormust
thoroughlyreadandunderstandthecontentofthismanualbeforethemachineis
turnedonandoperated.
3) Theoperatorshouldalsotakeintoconsiderationsafetyaspectsrelatedtotheir
environmentalconditions,materialsandtools.
4) NeveroperateaCNCmachinewithoutpropertrainingorconsultingthespecific
operator’smanualforthatmachineandcontroltype.
5) NeverattempttoprogramaCNCmachinewithoutpropertrainingorconsultingthe
specificprogrammer’smanualforthatmachineandcontroltype.
6) Neitherthemanufacturer,itsrepresentativesnordealerscanassumeresponsibilityfor
anymishaps,damageorpersonalinjurywhichmayoccurasaresultofimproper
operation,orfromfailuretoobservethesafetyprecautionsmentionedinthismanual.
7
SafetyLabelsAlwaysobservethesafetyinstructionsinscribedonthenameplatesfixedtothemachine.DONOTremoveordamagethesenameplatesDONOTattempttooperateorturnonthemachineuntilyouhavereadandunderstoodthemanualssuppliedwiththemachine.
DangerandWarningLabelsDisplayedonMachine
SafetyCategoryGuidelinesThreecategoriesofsafetyguidelineshavebeenusedthroughoutthismanual.Pleasetakenoteofthesesymbolsandunderstandtheirmeanings.
Ifthisactionisnotavoided,itcouldresultinseriousinjuryorevendeath.Itmayalsocausepermanentdamagetoyourmachine.
Ifthisactionisnotavoided,itmaycausepotentialharmtoyourhealthresultinginseriousinjury.Thistoohasthepotentialtocauseseriousdamagetoyourmachine.
Ifthisactionisnotavoided,itmaycausepotentialharmtoyourhealthsuchasminortomoderateinjury.Notavoidingthisactioncouldresultindamagetoyourmachine.
8
BasicPointsofSafety–BeforeStartingtheMachine• MemorizethepositionoftheEMERGENCYSTOPBUTTONonthe
machinesothatyoucanpressitimmediatelyfromanypositioniscaseofemergencies.
• MakesurethatallsafetycoversarefittedandelectricalboxesareclosedandsecuredbeforethepowerisswitchedtoON.
• DONOTmodifythemachineinanywaythatwillaffectsafety.
• Checkallelectricalcablesfordamagebeforestartingmachine,everytime,topreventelectricalshock.Therearehighvoltageterminalsontheelectricalcontrolpanel,motors,junctionboxesandotherequipment.DONOTtouchanyofthesecomponentsunderanycircumstanceswhenthepowersupplyisON.
• DONOTEVERoperatethemachinewhileundertheinfluenceofdrugsoralcohol.
• DONOToperatethemachineifyousufferfromdizziness.________________________________________________________________________
• DONOTtoucharotatingtoolholderorworkpiecewhilethemachineisinoperationmode.
• Alwaysunplugthemainplugwhenthemachineisnotinuse.
• DONOTpaint,soil,damage,modifyorremoveanyofthesafetynameplates.Ifthedetailsbecomeillegibleorifthenameplateislost,obtainareplacementfromDetroitMachineToolsandmountitintheoriginallocation.
• Ifmorethanonepersonisoperatingthemachine,DONOTproceedtothenextstepwithoutinformingtheotheroperator(s)thatyouareabouttodoso.
________________________________________________________________________
• DONOTsubjectthemachine,controlbox,operatorpanel,orelectricalcontrolpaneltoahighvoltagesurge.
• Closeallcoversandjunctionboxesbeforerunningthemachine.DONOTremoveanysafetycoverswhilethemachineisinautomaticoperationmode.
9
PersonalProtectiveEquipment(PPE)andSafety• Alwaystiebacklonghairtoprevententanglingwithrotatingtools.• Alwayswearpersonalsafetyequipment–eye,ear,andother
protectiveequipment.• Alwayswearaprotectivemaskwhenmachiningmagnesiumalloys.• Neverwearlooseorbaggyclothingnorjewelrytopreventgetting
caughtinmovingparts.• Alwaysuseworkgloveswhenloadingandunloadingworkpiecesor
toolsandremovingchipsfromtheworkareatoprotectyourhandsfromsharpchipsandburnscausedbyheatgeneratedduringmachining.
• DONOThandlecoolantwithbarehandstoavoidirritation.
• Takecarenottoplaceanypartofyourbodyinpossiblepinchpoints
onthemachine.ToolsandWorkHoldingBestPractices
• Alwaysusepropercuttingtoolsandworkholdingclampssuitablefortheworkandwithinthespecificationsofthemachine.Neveruseblunttools.Alwaysreplaceworntoolsassoonastheyareidentified.
• DONOTstallthemachineduringcuttingduetoimproperfeedanddepthofcutsuitablefortheworkpiecematerial.
• DONOToperatethespindleabovetheratedspeedofthearbors/toolholdersandcuttingtoolsyouexpecttomountanduseinanymachiningoperation.
• DONOTremoveoradjustswitchestoincreaseaxistravelbeyondthemachinespecifications.
• Avoidcontactwithcuttingedgeswhenhandlingtoolsorchangingtoolsbyhand.
• Checkthatthemachineisnotoperatingwhenloadingatoolmagazine.
_____________________________________________________________________
10
• Checkthattheseatingsurfacesarecleanbeforeinstallingtoolsandthatthetoolsaresetcorrectly.Testtoolsbeforeuse.
• Donotextendbarstockoutofthechuckmorethantwotothreetimesthediameterwithoutpropersupport.
• Makesurethedrawbarandthetoolholdersaretightenedtothepropercuttingconditionsbeforeactualcuttingoperationsbegin.
• DoublecheckthatthecorrecttooldatahasbeeninputtedintotheCNCprogram.
• Makesurethatallworkandfixturesareclampedsecurelybeforestartingmachine.
• Onlyusetoolswithinthelimitsspecifiedbythemanufacturer.
• Onlytightentoolstorecommendedtorquevalue.
• Checkthatthespindledirectioniscorrectforright-handorleft-handoperation.
• Conductadryruntoensuretheprogramiscorrect.SafetyGuidelinesRelatedtoMaintenance
• Alwaysdisconnectthepowertothemachinebeforecarryingoutanymaintenancework.
• Afterthepowerhasbeenswitchedoffforaminimumof60minutes,checkvoltagewithamulti-meterorequivalentmetertomakesurethereisnoresidualvoltage.
• Maintenanceofelectricalandmechanicalcomponentsshouldonlybecarriedoutbyindividualswithworkingknowledgeofthemachinetool.
• DONOTremoveormodifyswitches._______________________________________________________________________
• DONOTallowchipstoaccumulateintheworkenvelope.DONOTwipetheworkpieceorclearawaychipswithyourhandoraragwhilethespindleisinoperation.
11
• Warmupthespindleandaxismotionbeforerunningthemachineinautomaticmode.
• DONOToperatethekeyboardoroperationpanelswitcheswhenwearinggloves.
• DONOTdisconnectthemainpowercablewithoutswitchingofftheCNCandPCconnections.
• Cleanthemachineareasaftermaintenanceiscompleted.
HazardControlThethreestepsinvolvedinrecognizinganddealingwithhazards:1) SpottheHazard-Ahazardisanythingthatcouldhurtyouorsomeoneelse,isunsafe,or
couldcauseanaccident.Useallyoursensestospothazards.Lookaround,listen,noticeanystrangesmells(likesmokeorchemicals)anduseyourknowledgeaboutthingsthatmightbedangerous.
2) AssesstheRisk-Figureouthowlikelyitisforthehazardtohurtsomeoneandhowbadly.Alwaystellsomeoneabouthazardsyoucannotfixyourselfandrememberitismoreurgenttomakethechangesifthehazardislikelytocauseseriousinjury.
3) MinimizetheRisk-Fixthehazardyourselfifyoucan,ortellsomeonewhoisabletofixit.Thebestwaytofixthehazardistogetridofit,butasthisisnotalwayspossible,therearesomewaysyoucanmakethehazardlessdangerous:
• Substituteitforalesshazardousmaterialoritem.• Isolateittoanareawhereit’sfurtheroutofharm’swaysuchasalockedroom.• Addsafeguards-forexample,putclearguardsaroundcuttingorslicing
equipmentorwarningsignsforpeopletosee.• Usepersonalprotectiveequipmentandclothinganytimeyouareworkingwith
hazardousmaterialsand/orequipment.• ElectricalHazards:Installelectricdroppersinsteadofusingextensioncords.• ToxicChemicals:Substitutelesstoxicmaterials(polishes,adhesivesetc).• Noises:Installcanopiestothenoisiestmachines.• Flyingparticles:Isolation,setasidespecificareasforgrinding.• Machiningdust:Engineercontrols,installandusedustextractionequipment.• Slip/Triphazards:Adoptbetterhousekeepingprocedures.• Fatigue:Rotatejobtasksamongworkers.• Newequipment:Trainallstaffoneverypieceofequipmenttoassisthazardous
breakdowns.
12
IV. MachineToolOverview
Characteristics
1) FlashFLserieslathesaredesignedtobehighlystable,whereaccuracy,easeofoperation,
operatorergonomics,installation,andtransportationarealltakenintoconsideration.
2) Thelathestructureiscastinaveryspecificcontrolledenvironmentthatproducesamore
durable, mechanically consistent and more stable iron than standard grey iron. This
processcastingwasdevelopedintheU.S.A,moreinformationcanbefoundHERE
3) Pre-loadedball screws/nut assemblies areequippedonbothX/Z axis. Pre-loadedaxis
assembliesprovidesuperiormovement,higheraccuracy,andlongerservicelife.
4) AutoMateCNCmachinesareequippedstandardwithanautomatic lubepump.Sliding
surfaces, screws, and bearings are all lubricated equally by means of the positive
displacementmanifolds.
ApplicationRange
TheFlashFLseriesmachinetoolisaflatbedlinearguideCNCmachinetool.Itiscontrolledbya
CNCsystem,withlinearinterpolation,arcinterpolation,threadinterpolation.Thismachinetool
canperformturning,drilling,boring,reaming,rigidtappingandthreadinginoneclamping.Our
machinetoolscanbefoundinvarious industries(auto,naval,aviation)aswellaseducational
settingsandhomeshops.
CNCControlSystem
AutoMateCNCmachines comestandardwith theSiemensSinumerik808DBasic, anewCNC
specificallydevelopedforbasicCNCmillingandturningcenters.
§ 808Dsupports3axis,plusspindle,i.e.positioningandCaxismovements
§ Minimummovementis1μmand0.1μmoptional,Max.cuttingspeedis100m/min.
§ CustomizablePLClogic.PLCladderdiagramcanbeonlineeditedandrealtimemonitored.
§ Partsprogramcanbeeditedbackgroundwhileotheroperationsarebeingcarriedout.
§ Onthe808dAdvanced,programfilescanbetransferredvianetworkcable.
§ Filetransfer,systemupdates,parameter/PlcchangescanbemadeviaUSBport
13
MachineComponents–X-andZ-axis
XandZaxismovementsarecontrolledbyACservomotorsdirectlycoupledtotheballscrews
viaspidercoupling.
WorkHolding
AutoMateCNCsuppliesmachineswithvariousworkholdingsolutions.Pleaseconsultyour
specificchuck/colletclosermanual,orcallatechnicianat800-476-4849.
AxesMotionDirection
XaxisTurret/GangPlateDirection–LathesWCSarethesameregardlessofwherethetool
positionis.
• Thespindlecenterlineispart0
• Movementawayfromcenteris(+)
• Movementtowardsthecenteris(-)
• ZaxisTurretleftandrightdirections
• Rightispositivedirection(+)
• Leftisnegativedirection(-)
Themechanicalzeroaxisisattheextremepositioninapositivedirection,andtheaxistravels
are according to machine specification 36100 POS_LIMIT_MINUS and 35110
POS_LIMIT_PLUS which limits the max travel. The Axis travels in positive and negative
directions.Theseareyoursoftlimits.Ifyoursimulatorseesavalueoutsideofthelimits,the
machinewillalarmout.
WayLubeSystem
Thismachinetoolisequippedwithautomaticlubepump.Thegearedrotationalpumpoffers
highperformanceandgoodvolumeefficiency.Allmachineshaveapositivedisplacement
manifoldensuringoilisdistributedevenlytoalllubricationpoints.Timingintervalandpurge
volumearecontrollable,andeachpumpisoutfittedwithalowlubelevelalarm.
PositiveDisplacementManifold
§ Waylubepumpisactivated,andoilispushedintomainoilline.
14
§ Asthepumpcontinuestopressurizeoil inthemainline,oil is forced intomanifold
compartment.
§ Whenpumpstopspurging,themanifoldvalveopensautomatically.Whenthevalve
isopen,volumeinthemachinelinesisnowbiggerthanthemainlinecreatingvacuum
andsiphoningoiltoalllubricationpoints.
Parameter Meaning Unit FactoryDefault
MD14510[24] Intervaltime min 30
MD14510[25] Lubricatetime S 10
V. OperationBoard
SystemOperationAreaIntroduction-ElementsonthePPU(PanelProcessingUnit)front
①VerticalandhorizontalsoftkeysCallsspecificmenufunctions
⑦On-boardassistantkeyProvidesstep-by-stepguidebasedoncommissioninginstructions
②Returnkey ⑧Helpkey
15
Returnstothenexthigher-levelmenu Callshelpinformation
③MenuextensionkeyReservedforfutureuse
⑨Cursorkeys*
④AlphabeticandnumerickeysToentertheuppercharacteronthekey,holddownthefollowingkey:
⑩Operatingareakeys*
⑤Controlkeys* ⑪USBinterface*
⑥AlarmcancellationkeyCancelsalarmsandmessagesthataremarkedwiththissymbol
⑫StatusLEDs*
Furtherinformation
Controlkeys
Deletesacharacterselectedtotheleftofthecursor
Deletestheselectedfileorcharacter
• Indentsthecursorbyseveralcharacters• Togglesbetweentheinputfieldandtheselectedprogramname
• Confirmsyourentryofavalue• Opensadirectoryorprogram
Cursorkeys
Reservedforfutureuse
Movesthecursortotheendofaline
Scrollsupwardsonamenuscreen
Scrollsdownwardsonamenuscreen
16
• Togglesbetweenentriesintheinputfield• Entersthe"Set-upmenu"dialogatNCstart-up
Operatingareakeys
Toopenthesystemdatamanagementoperatingarea,pressthefollowingkeycombination:
Enablesuser-definedextensionapplications,forexample,generationofuserdialogswiththeEasyXLanguagefunction.Formoreinformationaboutthisfunction,refertotheSINUMERIK808DFunctionManual.
StatusLEDs
LED"POK"Lightsupgreen:ThepowersupplyfortheCNCisswitchedon.
LED"RDY"Lightsupgreen:TheCNCisreadyforoperation.
LED"TEMP"Unlit:TheCNCtemperatureiswithinthespecifiedrange.Lightsuporange:TheCNCtemperatureisoutofrange.
USBinterface
ConnectstoaUSBdevice,forexample:
• AnexternalUSBmemorysticker,totransferdatabetweentheUSBstickerandtheCNC
• AnexternalUSBkeyboardwhichfunctionsasanexternalNCkeyboard
1.1 SINUMERIK808Doperatorpanels
KeyCombinationsKeyCombinations Description
<ALT>+<X Opensthemachiningoperatingarea:
<ALT>+<V Openstheprogrameditingoperatingarea:
+
>
>
17
<ALT>+<C > Openstheoffsetparametersoperatingarea:
<ALT>+<B Openstheprogrammanagementoperatingarea:
<ALT>+<M > Opensthediagnosticsoperatingarea:
· <ALT>+ <N> Opensthesystemdatamanagementoperatingarea:
· + <ALT>+<H > Callstheonlinehelpsystem<ALT>+<L> Enablesinputoflowercaseletters
<ALT>+<S ApplicableonlywhentheuserinterfacelanguageisChineseCallstheinputmethodeditorforenteringChinesecharacters
<=> Callsthepocketcalculator.Notethatthisfunctionisnotapplicablein"MDA"mode.
<CTRL>+< B> Selectstextinprogramblocks<CTRL>+< C> Copiestheselectedtext<CTRL>+< D> Showspre-definedslidesonthescreen<CTRL>+< P> Capturesscreens<CTRL>+< R> RestartstheHMI<CTRL>+< S> Savesstart-uparchives
>
>
18
ElementsontheMCP(MachineControlPanel)Front
①Emergencystopkey
Stopsallmachinemotionsimmediately⑥ User-definedkeys*
(allwithLEDstatusindicators)
②Handwheelkey(withLEDstatusindicator)Controlstheaxismovementwithexternalhandwheels
⑦ Axistraversingkeys*
③ ToolnumberdisplayDisplaysthecurrenttoolnumber
⑧ Spindlecontrolkeys
④Operatingmodekeys(allwithLEDstatusindicators)
⑨ Programstatekeys*
⑤ Programcontrolkeys*(allwithLEDstatusindicators)
⑩ FeedrateoverrideswitchTraversestheselectedaxisatthespecifiedfeedrateoverride
Pre-DefinedInsertionStripsTheMCPpackageincludestwosetsofpre-definedstrips.Onesetisformilling,theotherforturningIfyourcontrolsystemisoftheSINUMERIK808Dmillingvariant,replacethepre-insertedstripswiththemilling-specificstrips.
19
TheMCPpackagealsoincludesanA4-sizedblankplasticsheetwithdetachablestrips.Ifyouhavecustomizedcomponentsonyourmachine,replaceinsertionstripswithappropriatelabels.Inthe\04040000\examples\MCPfolderoftheToolboxDVDfortheSINUMERIK808D,thereisasymbollibraryfileandaninsertionstriptemplatefile.Tomakecustomizedinsertionstrips,followthestepsbelow:
1. Copythedesiredsymbolsfromthesymbollibraryfiletothedesiredlocationsintheinsertionstriptemplate.
2. PrintthetemplatetotheA4-sizedblankplasticsheet.3. Detachtheinsertionstripsfromtheblankplasticsheet.4. Pulloutthepre-insertedstripsfromtheMCP.5. InsertthecustomizedstripsonthebackoftheMCP.
CoordinateSystemsAsarule,acoordinatesystemisformedfromthreemutuallyperpendicularcoordinateaxes.Thepositivedirectionsofthecoordinateaxesaredefinedusingtheso-called"3-fingerrule"oftherighthand.Thecoordinatesystemisrelatedtotheworkpieceandprogrammingtakesplaceindependentlyofwhetherthetoolortheworkpieceisbeingtraversed.Whenprogramming,itisalwaysassumedthatthetooltraversesrelativetothecoordinatesystemoftheworkpiece,whichisintendedtobestationary.
20
Thefigurebelowillustrateshowtodeterminetheaxisdirections.
MachineCoordinateSystemTheorientationofthecoordinatesystemrelativetothemachinedependsonthemachinetype.Itcanberotatedindifferentpositions.Thedirectionsoftheaxesfollowthe"3-fingerrule"oftherighthand.Seenfromthefrontofthemachine,themiddlefingeroftheright-handpointsintheoppositedirectiontotheinfeedofthespindle.
Theoriginofthiscoordinatesystemisthemachinezero.Thispointisonlyareferencepointwhichisdefinedbythemachinemanufacturer.Itdoesnothavetobeapproachable.Thetraversingrangeofthemachineaxescanbeinthenegativerange.
90°90°
90°
<
21
WorkpieceCoordinateSystemTodescribethegeometryofaworkpieceintheworkpieceprogram,aright-handed,rightangledcoordinatesystemisalsoused.TheworkpiecezerocanbefreelyselectedbytheprogrammerintheZaxis.IntheXaxis,itliesintheturningcenter.RelativeCoordinateSystemInadditiontothemachineandworkpiececoordinatesystems,thecontrolsystemprovidesarelativecoordinatesystem.Thiscoordinatesystemisusedtosetreferencepointsthatcanbefreelyselectedandhavenoinfluenceontheactiveworkpiececoordinatesystem.Allaxismovementsaredisplayedrelativetothesereferencepoints.WorkpieceFixturingFormachining,theworkpieceisclampedonthemachine.Theworkpiecemustbealignedsuchthattheaxesoftheworkpiececoordinatesystemruninparallelwiththoseofthemachine.AnyresultingoffsetofthemachinezerowithreferencetotheworkpiecezeroisdeterminedalongtheZaxisandenteredinadataareaintendedforthesettableworkoffset.IntheNCprogram,thisoffsetisactivatedduringprogramexecution,forexample,usingaprogrammedG54command.
VI. SoftwareInterface Screenlayout
Statusarea Applicationarea
① Activeoperatingarea ⑧ Actualvaluewindow② Activeoperatingmode ⑨ T,F,Swindow③ Alarmandmessage④ promptarea ⑩Operatingwindowwithprogram
blockdisplay
⑤ Currenttimeanddate Tipandsoftkeyarea⑥ Programfilename ⑪ Informationline⑦ Programstatusindication ⑫ Horizontalsoftkeybar⑧ Activeprogramcontrol⑨ modes ⑬ Verticalsoftkeybar
Statusarea
22
Display Meaning
① Activeoperatingarea
Machiningoperatingarea
Systemdatamanagementoperatingarea
Programeditingoperatingarea
Programmanagementoperatingarea
Offsetparametersoperatingarea
Diagnosticsoperatingarea
② Activeoperatingmode
"REFPOINT"mode
"JOG"mode
Incrementaltraversein"JOG"mode
"MDA"mode
"AUTO"mode
Display Meaning
23
③
Alarmsandmessages
DisplaysactivealarmswithalarmtextThealarmnumberisdisplayedinwhiteletteringonaredbackground.Theassociatedalarmtextisshowninredlettering.Anarrowindicatesthatseveralalarmsareactive.Thenumbertotherightofthearrowindicatesthetotalnumberofactivealarms.Whenmorethanonealarmisactive,thedisplayscrollsthroughthealarmsinsequence.Anacknowledgementsymbolindicatesthealarmcancelcriterion.
DisplaysmessagesfromNCprogramsMessagesfromNCprogramsdonothavenumbersandappearingreenlettering.
④ Currenttimeanddate
⑤ Filenameofthecurrentpart
program
⑥
Programstate RESET Programcanceled/defaultstate
RUN Programisrunning
STOP Programstopped
⑦ Programcontrolin"AUTO"mode
Tipandsoftkeyarea
Screenitem Display Description
14
5
2 3
24
①
ReturnsymbolReturnstothenexthigher-levelmenuwiththefollowingkey:
② Informationline
Displaysnotesandinformationfortheoperatorandfaultstates
Screenitem Display Description
③ HMIstatusinformation
�/�
Lowercaseletterinputactive
RS232connectionactive
ConnectstoPLCProgrammingTool
④ Horizontalsoftkeybar
⑤ Verticalsoftkeybar
ProtectionlevelsTheSINUMERIK808Dprovidesaconceptofprotectionlevelsforenablingdataareas.Differentprotectionlevelscontroldifferentaccessrights.ThecontrolsystemdeliveredfromSIEMENSissetbydefaulttothelowestprotectionlevel7(withoutpassword).Ifthepasswordisnolongerknown,thecontrolsystemmustbereinitializedwiththedefaultmachinedata.Allpasswordsarethenresettodefaultpasswordsforthissoftwarerelease.
NOTICE
25
Beforeyoubootthecontrolsystemwithdefaultmachinedata,makesurethatyouhavebackedupyourdata;otherwise,alldataislostafterrebootingwithdefaultmachinedata.
Protectionlevel Lockedby Area
0 Siemenspassword Siemens,reserved
1 Manufacturerpassword Machinemanufacturers
2 Reserved
3-6 End-userpassword(Defaultpassword:"CUSTOMER")
Endusers
7 Nopassword Endusers
Protectionlevel1Protectionlevel1requiresamanufacturerpassword.Withthispasswordentry,youcanperformthefollowingoperations:
● Enteringorchangingallmachinedata
● ConductingNCcommissioning
Protectionlevel3-6Protectionlevel3-6requiresanend-userpassword.Withthispasswordentry,youcanperformthefollowingoperations:
● Enteringorchangingpartofthemachinedata
● Editingprograms
● Settingoffsetvalues
● Measuringtools
Protectionlevel7Protectionlevel7issetautomaticallyifnopasswordissetandnoprotectionlevelinterfacesignalisset.Theprotectionlevel7canbesetfromthePLCuserprogrambysettingthebitsintheuserinterface.Inthemenuslistedbelowtheinputandmodificationofdatadependsonthesetprotectionlevel:
● Tooloffsets
● Workoffsets
● Settingdata
26
● RS232settings
● Programcreation/programcorrection
Youcansettheprotectionlevelforthesefunctionareaswiththedisplaymachinedata(USER_CLASS...). 1.4.3 Thehelpsystem
TheSINUMERIK808Dcontrolsystemprovidescomprehensiveonlinehelp.Whenevernecessary,youcancallthehelpsystemfromanyoperatingarea.
Thehelpsystem
Pressthiskeyorthekeycombination<ALT>+<H>tocallthehelpsystemfromanyoperatingarea.Ifacontext-sensitivehelpexists,Window"①"opens;otherwise,Window"③"opens.
①Callsthecontext-sensitivehelpforthecurrenttopic:• Currentoperatingwindow• Alarmsselectedinthealarmspecificoperationarea• Machinedataorsettingdataselected
②CallstheOEM-developedPDFmanual
27
③Displaysallavailablehelpinformation:• Siemenshelpmanuals• OEM-developedhelpmanuals,ifany
SoftkeysinWindow"①"
UsethissoftkeytoselectcrossreferencesAcrossreferenceismarkedbythecharacters"≫...≪".Note:Thissoftkeyisdisplayedonlyifthecurrentpagecontainsacrossreference.
Searchesforaterminthecurrenttopic
Continuessearchforthenexttermthatmatchesthesearchcriteria
Exitsthehelpsystem
SoftkeysinWindow"②"
Zoomsinthecurrentview
Zoomsoutthecurrentview
Zoomsthecurrentviewtopagewidth
Jumpstothedesiredpage
Searchesforaterminthecurrenttopic
Continuessearchforthenexttermthatmatchesthesearchcriteria
Exitsthehelpsystem
SoftkeysinWindow"③"
28
Expandshierarchicaltopics
Collapseshierarchicaltopics
Navigatesupwardsthroughthehierarchicaltopics
Navigatesdownwardsthroughthehierarchicaltopics
Openstheselectedtopicinthecurrenttopicrelevant
windowFunctionsthesameaspressingthefollowingkey:
Searchesforaterminthecurrenttopic
Continuessearchforthenexttermthatmatchesthesearchcriteria
Exitsthehelpsystem
VII. TurningonandReferencingMachineOperatingSequence
1. Switchonthepowersupplyforthecontrolsystemandthemachine.2. Releaseallemergencystopbuttonsonthemachine.3. Pressthecorrespondingaxistraversekeytoreferenceorhomethataxis
ByDefault,yourCNCmachinewillbein“Ref.Point”onbootup.
29
VIII. SettingUpToolsandWorkOffsetsOverviewInthischapter,wewilllearnhowto:
● Createthetoolsandcuttingedges.
● Enter/modifythetoolandworkoffsets.
● Enterthesettingdata.
SettingUpTools
OperatingSequence1. Selectthedesiredoperatingarea.
2. Openthetoollistwindow.
3. Openthelower-levelmenufortooltypeselection.
4. Selectadesiredtooltypewiththecorrespondingsoftkey.
5. Enterthetoolnumber(valuerange:1to31999;preferablyenteravaluelessthan100)andpositionofthecuttingedgeinthefollowingwindow.Thecontrolsystemsupportsamaximumof64toolsor128cuttingedges.
6. Usethissoftkeytoconfirmyoursettings.Thewindow
belowshowstheinformationofthenewtoolcreated.
30
CreateaNewCuttingEdge
1. Selectthedesiredoperatingarea.
2. Openthetoollistwindow.
3. Selectthetooltowhichyoudesiretoaddacuttingedge.
4. Openthelower-levelmenuforcuttingedgesettings.
5. Pressthissoftkeytocreateanewcuttingedgefortheselectedtool.Thecontrolsystemautomaticallyaddsthenewcuttingedgetothetoollist.
Notethatthemachinecanbeloadedwithamaximumof128cuttingedges,andamaximumofninecuttingedgescanbecreatedforeachtool.
6. Youcanenterdifferentlengthsandradiiforeachcuttingedgeaswell.
Otheroptionsforsettingupthecuttingedges: Resetall offsetvaluesoftheselectedcuttingedgetozero
Deletethe selectedcuttingedgeEnteringToolOffsetsThetooloffsetsconsistofthedatadescribingthegeometry,thewearandthetooltype.Eachtoolcontainsadefinednumberofcuttingedgeparametersdependentonthetooltype.
31
Besidesenteringthetooloffsetsinthetoollist,youcanalternativelydeterminethetooloffsetsbymeasuringthetoolmanually.
1. Selectthedesiredoperatingarea.
2. Openthetoollistwindowwhichcontainsalistofthetoolsandcuttingedgesthathavebeencreated.
3. Usethecursorkeystonavigateinthelist.
4. Enterthevaluesasrequiredintheinputfields(seetablebelowfortheparameterdescriptions).
5. Usethiskeyormovethecursortoconfirmyourentries.
ActivatingtheToolandStartingSpindle
1. Selectthedesiredoperatingarea.
2. Switchto"JOG"mode.
3. Openthe"T,S,M"window.
4. Enterthedesiredvaluesforthetoolnumber,cuttingedgenumberandspindlespeed(forexample,T1,D1and500rpm)inthe"T,S,M"window.
5. Usethiskeyormovethecursortoconfirmyourentries.
6. Selecttherotationdirectionofthespindleasrequired.
• M3:Spindlerotatesclockwise
• M4:Spindlerotatescounterclockwise
32
7. PressthiskeyontheMCPtoactivatethetoolandstartthe
SelectingtheHandwheel
1. Selectthedesiredoperatingarea.
2. PressthiskeyontheMCP.
3. Pressthedesiredaxistraversingkeywiththehandwheelicon.Thehandwheelisassigned.
Alternatively,youcanassignthehandwheelsusingthesoftkeys:
1. Selectthedesiredoperatingarea.
2. Openthemachinedatawindow.
3. Usethissoftkeytoopenthebasicmachinedatalist.Searchforthegeneralmachinedata"14512USER_DATA_HEX[16]"withcursorkeysorthefollowingsoftkeyandthenset14512[16].7=1.
+
33
4. Confirmyourinput.
5. Pressthisverticalsoftkeytoactivatethevaluechange.Notethatthecontrolsystemrestartstoacceptthenewvalue.
6. After the control system has booted, select the desiredoperatingarea.
7. PressthiskeyontheMCP.
8. Press this vertical softkey to open the handwheelassignmentwindow.
9. Select the desired handwheel number with the cursor
left/rightkey.
10. Presstherelevantaxissoftkeyforhandwheelassignment
ordeselection.
The symbol "☑" that appears in the window indicates ahandwheelhasbeenassignedtothespecificaxis.
MeasuringtheToolManuallyMeasuringthetoolintheXdirection
1. Selectthedesiredoperatingarea.
2. Switchto"JOG"mode.
3. Openthemanualtoolmeasurementwindow.
34
4. PressthisverticalsoftkeytomeasurethetoolintheX
direction.
5. MovethetooltoapproachtheworkpieceintheXdirection.
6. Switchto"HANDWHEEL"mode.
7. Selectasuitableoverridefeedrate,andthenusethehandwheeltomovethetooltoscratchtherequiredworkpieceedge.
8. Entertheworkpiecediameterinthe"Ø"field(forexample,50mm).
9. SavethelengthvalueintheXaxis.Thetooldiameter,
radius,andcuttingedgepositionarealltakenintoaccount.
...
35
MeasuringthetoolintheZdirection
1. Selectthedesiredoperatingarea.
2. Switchto"JOG"mode.
3. Openthemanualtoolmeasurementwindow.
4. PressthisverticalsoftkeytomeasurethetoolintheZdirection.
5. MovethetooltoapproachtheworkpieceintheZ
direction.
6. Switchto"HANDWHEEL"mode.
7. Selectasuitableoverridefeedrate,andthenusethehandwheeltomovethetooltoscratchtherequiredworkpieceedge.
8. Enterthedistancebetweenthetooltipandtheworkpieceedgeinthe"ZØ"field,thatis"0".
9. SavethelengthvalueintheZaxis.
Repeattheaboveoperationsforothertoolsandmakesureyoumeasureallthetoolsbeforemachining,whichalsoeasesthetoolchangingprocess.
...
36
IX. SettinguptheWorkpieceAfterthemachineapproachesthereferencepoint,theactualvalueoftheaxiscoordinateisbasedonthemachinezero(M)ofthemachinecoordinatesystem.Amachiningprogram,however,isalwaysbasedontheworkpiecezero(W)oftheworkpiececoordinatesystem.Thisoffsetmustbeenteredastheworkoffset.Besidesmeasuringtheworkoffsetsbyscratchingtheworkpiecewiththetool,youcanalsoenterthevaluesasrequiredbyproceedingthroughthefollowingsteps.
OperatingSequence
1. Selectthedesiredoperatingarea.
2. Openthelistofworkoffsets.Thelistcontainsthevaluesofthebasicoffsetoftheprogrammedworkoffsetandtheactivescalingfactors,themirrorstatusdisplayandthetotalofallactiveworkoffsets.
3. Usethecursorkeystopositionthecursorbarintheinputfieldstobemodifiedandenterthevalues.
4. Confirmyourentries.Thechangestotheworkoffsetsare
activatedimmediately.
MeasuringtheWorkpieceYouneedtoselectthewindowwiththerelevantworkoffset(e.g.G54)andtheaxisyouwanttodeterminefortheoffset.ThefollowinggraphisanexampleabouthowtodeterminetheworkoffsetintheZaxis.
37
OperatingSequence1. Selectthedesiredoperatingarea.
2.Switchto"JOG"mode.
3.Openthelistofworkoffsets.
4.Openthewindowformeasuringtheworkoffsets.Notethatthisverticalsoftkeyisactiveonlyin"JOG"mode.
5.Traversethetool,whichhasbeenmeasuredpreviously,toapproachtheworkpieceintheZdirection.
6. Switchto"HANDWHEEL"mode.
7. Selectasuitableoverridefeedrate,andthenusethehandwheeltomovethetooltoscratchtherequiredworkpieceedge.
8. Selecttheoffsetplanetosavein(forexampleG54).
9. Pressthisverticalsoftkey.TheworkoffsetoftheZaxisis
calculatedautomaticallyanddisplayedintheoffsetfield.
Repeattheoperationtosetupthe“X”Axis.
...
38
EnteringandModifyingData
1. Selectthedesiredoperatingarea.
2. Openthesettingdatawindow.
3. Positionthecursorbarintheinputfieldstobemodifiedandenterthevalues(seetablebelowfortheparameterdescriptions).
Usethiskeyormovethecursortoconfirmyourentries.
① Thefeedratein"JOG"mode.Ifthefeedratevalueiszero,thecontrolsystemwillusethevaluestoredinthemachinedata.
⑤ Programmableupperspeedlimitationatconstantcuttingrate(G96).
② Thespeedofthespindle. ⑥ Thefeedratewhichcanbeenteredherewillbeusedinsteadoftheprogrammedfeedratein"AUTO"modeifthecorrespondingfunctionisselected.
12
345
6
7
39
③ A limitation of the spindle speed in theMax.(G26)/
⑦ Forthreadcutting,astartpositionforthespindleis
④ Min. (G25) fields can only be performedwithin the limit values defined in themachinedata.
SettingTimeCounter
1. Selectthedesiredoperatingarea.
2. Openthesettingdatawindow.
3. Openthetimecounterwindow.
4. Positionthecursorbarintheinputfieldstobemodifiedandenterthevalues(seetablebelowfortheparameterdescriptions).
5. Usethiskeyormovethecursortoconfirmyourentries.Parametersinthewindowfortimersandworkpiececounters
12345678
40
① Thetotalnumberofworkpiecesproduced(totalactual)
⑤ TheruntimeoftheselectedNCprograminsecondsThedefaultvalueis0eachtimeanewNCprogramstartsup.MD27860canbesettoensurethatthisvaluewillbedeletedevenifthereisajumptothebeginningoftheprogramwithGOTOSorintheeventofASUBS(usedfortoolchangein"JOG"and"MM+"modes)andPROG_EVENTsstarting.
SettingRParameters1. Selectthedesiredoperatingarea.
2. OpenthelistofRparameters.
3. Usethecursorkeystonavigateinthelist,andenterthevaluesintheinputfieldstobemodified.
Note:YoucansearchforyourdesiredRvariablewiththefollowingsoftkey.Bydefault,thefunctionsearchestheRnumber.
YoucanpressthefollowingsoftkeytoactivatetheoptionofsearchingbyRname.DefinetheRnameasdesired,ifnecessary.
4. Usethiskeyormovethecursortoconfirmyourentries.
41
Additional“JogMode”Settings
①Opensthe"T,S,M"windowwhereyoucanactivatetools,setspindlespeedanddirection,andselectaGcodeorotherMfunctionforactivatingthesettableworkoffset.
⑥Displaystheaxisfeedrateintheselectedcoordinatesystem.
②Switchesthedisplaytotherelativecoordinatesystem.Youcansetthereferencepointinthiscoordinatesystem.
⑦Displaystheaxispositiondataintherelativecoordinatesystem.
③Opensthetoolmeasurementwindowwhereyoudeterminethetooloffsetdata.Fordetailedinformationaboutthiswindow,refertoSection"Measuringthetool(manually)(Page33)".
⑧Displaystheaxispositiondataintheworkpiececoordinatesystem.
④Opensthe"ManualMachinePlus"userinterface.Thissoftkeyisvisibleonlyifthissoftwareoptionispreconfiguredbythemachinemanufacturer.Fordetailedinformationaboutthiswindow,refertothemanual"ManualMachinePlus(Turning)".
⑨Displaystheaxispositiondatainthemachinecoordinatesystem.
⑤OpensthesettingswindowwhereyoucansetJOGfeedrateandvariableincrementvalues.
42
①Displaystheaxesthatexistinthemachine
coordinatesystem(MCS),workpiececoordinatesystem(WCS),orrelativecoordinatesystem(REL).Ifyoutraverseanaxisinthepositive(+)ornegative(-)direction,aplusorminussignappearsintherelevantfield.Iftheaxisisalreadyintherequiredposition,nosignisdisplayed.
④DisplaysthecurrentlyactivetoolnumberTwiththecurrentcuttingedgenumberD.
②Displaysthecurrentpositionoftheaxesintheselectedcoordinatesystem.
⑤Displaystheactualaxisfeedrateandthesetpoint(mm/minormm/rev).
③Displaysthedistancetraversedbyeachaxisin"JOG"modefromtheinterruptionpointintheconditionofprograminterruption.Fordetailedinformationaboutprograminterruption,refertoSection"Startingandstopping/interruptingapartprogram(Page84)".
⑥Displaystheactualvalueandthesetpointofthespindlespeed(r.p.m.).
Setting“Rel”CoordinateSystem
1. Selectthedesiredoperatingarea.
2. Switchto"JOG"mode.
3. Pressthissoftkeytoswitchthedisplaytotherelativecoordinatesystem.
4. Usethecursorkeystoselecttheinputfield,andthenenterthenewpositionvalueofthereferencepointintherelativecoordinatesystem.
43
SettingJogData
1. Selectthedesiredoperatingarea.
2. Switchto"JOG"mode.
3. Pressthishorizontalsoftkeytoopenthefollowingwindow:
4. Entervaluesintheinputfieldsandconfirmyourentries.
5. Ifnecessary,pressthisverticalsoftkeytoswitchbetweenthemetricandinchdimensionsystems.
Pressthis softkeytoconfirmyourchange.
Pressthis softkeytoexit.
X. PartProgramming
1 StoresNCprogramsforsubsequentoperations
2 ManagesandreadsOEMCYCLES3 TransferfilesviaUSB4 TransferfilesviaRS2325 Backupmanufacturerfiles6 Backupuserfiles7 Showsrecentlyaccessedfiles8 ExecutescurrentProgram9 Createsnewfileordirectory10 Searchesfilesordirectories11 Selectsallfilesforsubsequentoperation12 Copiesselectfiles/folderstoclipboard13 Pastesfiles/foldersfromclipboard14 Restorestolastoperation15 Opensadditionalsoftkeys
44
CreatingFilesorFoldersTocreateapartprogram,followthesesteps:1. Selectthedesiredoperatingarea.
2. Enterthefolderforthenewprogramtobecreated.
3. Pressthisverticalsoftkey.
4. Pressthissoftkeytoactivatethewindowforcreatinganewprogram.
5. Enterthenameofthenewprogram.Ifyoudesiretocreateamainprogram,itisunnecessarytoenterthefileextension".MPF".Ifyoudesiretocreateasubprogram,youmustenterthefileextension".SPF".Thecharacterlengthofaprogramnameislimitedto24Englishcharactersor12Chinesecharacters.Itisrecommendedthatyoudonotuseanyspecialcharactersintheprogramname.
6. Pressthissoftkeytoconfirmyourentry,andthenewpartprogrameditorwindowopenssubsequently.Entertheblocksinthewindow,whicharesavedautomatically.Thenewprogramiscreatedsuccessfully.
CreatingaProgramDirectory
Tocreateaprogramdirectory,followthesesteps:1. Selectthedesiredoperatingarea.
2. Enteradesiredfolderforthenewdirectorytobecreated.
3. Pressthisverticalsoftkey.
4. Pressthissoftkeytoactivatethewindowforcreatinganewprogramdirectory.
5. Enterthenameofthenewdirectoryandpressthissoftkeytoconfirm.
45
EditingPartPrograms
1. Selectthedesiredoperatingarea.
2. Entertheprogramdirectory.
3. Usethissoftkeyorthecursorkeystoselecttheprogramfiletobeedited.
4. Pressthiskeytoopentheprogramfile.Thesystemswitchesovertotheprogrameditorwindow.
5. Edittheblocksinthewindowasrequired(seetablebelowforthedescriptionsofeditingoptions).Anyprogramchangesareautomaticallystored.
BlockEditingOptions
Replacestheblocknumberfromthecurrentcursortotheprogramend
Searchesforstrings
Selectsthetextsegmentbeforethecursor
Copiesthetextsegments
Pastesthetextsegments
46
SearchforStringsProceedthroughthefollowingstepstosearchforstrings:
1. Pressthissoftkeyintheopenedprogrameditorwindow.
2. Pressthissoftkeytosearchviatext.Alternatively,youcansearchwithagivenlinenumberbypressingthefollowingsoftkey:
3. Enterthesearchtextorlinenumberintheinputfield,andpressthiskeytoselectastartingpointforsearch.
4. Pressthissoftkeytostartthesearch,orotherwise,pressthefollowingsoftkeytocancelthesearch:
EditingPartProgramsinMDAMode
In"MDA"mode,youcancreatenewprogramsorloadexistingprogramsfromdirectoriesonthecontrolsystem.Proceedthroughthefollowingstepstoeditpartprograms:
1. Selectthedesiredoperatingarea.
2. Switchto"MDA"mode.
47
ManagingPartPrograms1. Selectthedesiredoperatingarea.
2. Selectthestoragemediuminwhichyouwishtoperformthesearch.
3. Pressthisverticalsoftkeytoopenthesearchwindow.
4. Enterthecompletenamewithextensionoftheprogramfiletobesearchedinthefirstinputfieldinthesearchwindow.Tonarrowyoursearch,youcanenterthedesiredtextinthesecondfield.
5. Usethiskeytochoosewhethertoincludesubordinatefoldersorobserveupper/lowercase.
6. Pressthissoftkeytostartthesearch,orotherwise,pressthefollowingsoftkeytocancelthesearch:
RenamingPrograms
1. Selectthedesiredoperatingarea.
2. Choosethedesiredstoragelocationandpositionthecursoronthefileordirectorywhichyouwouldliketorename.
3. Presstheextensionsoftkeytoaccessmoreoptions.
4. Pressthisverticalsoftkeytoopenthewindowforrenaming.
48
5. Enteradesirednewnamewiththeextensionintheinputfield.
6. Pressthissoftkeytoconfirmyourentry,orpressthefollowingsoftkeytocancel:
ViewingandExecutingRecentPrograms1. Selectthedesiredoperatingarea.
2. Pressthissoftkeytoopenthelistofrecentfiles.Notethateventhedeletedfilesarealsodisplayedinthelist.
3. Positionthecursoronafileandpressthisverticalsoftkeytostartexecutingtheprogram.
ContourProgrammingFreecontourprogrammingenablesyoutocreatesimpleandcomplexcontours.Acontoureditor(FKE)calculatesanymissingparametersforyouassoonastheycanbeobtainedfromotherparameters.Youcanlinktogethercontourelementsandtransfertotheeditedpartprogram.
Thecontourcalculatorforturningtechnologyprovidesthefollowingfunctionsforthispurpose:
• Togglingbetweenradius/diameterprogramming(DIAMON,DIAMOF,DIAM90)• Chamfer/radiusatthestartandendofthecontour• Undercutsastransitionelementsbetweentwoaxiallyparallelstraightlines,whereone
runshorizontallyandtheothervertically(FormE,FormF,threadundercutacc.toDIN,generalundercut)
Proceedthroughthefollowingstepstoopenthecontoureditorwindow:
49
1. Selectthedesiredoperatingarea.
2. Enterthedesiredprogramfolder.3. Selectaprogramfile,andpressthiskeytoopenit
intheprogrameditor.
4. Pressthissoftkeytoopenthecontoureditorwindow.
① Anelementwasselectedusingthecursor
keys.Thissoftkeyenlargestheimagesectionoftheselectedelement.
⑤ Pressthissoftkeytotogglebetweentheselections.Thissoftkeyfunctionsthesameaspressingthefollowingkey:
② Zoomsthegraphicin/out/automatically. ⑥ Definesapoleforcontourprogrammingin
polarcoordinates.ThepolecanonlybeenteredinabsoluteCartesiancoordinates.
③ Whenyouselectthissoftkey,youcanmovetheredcross-hairwiththecursorkeysandchooseapicturedetailtodisplay.Whenyoudeactivatethissoftkey,theinputfocusispositionedinthecontourchainagain.
⑦ Exitsthecontoureditorandreturnstotheprogrameditorwindow,withouttransferringthelasteditedvaluestothemainprogram.
④ Ifyoupressthissoftkey,helpgraphicsaredisplayedinadditiontotherelevantparameter.Pressingthesoftkeyagainexitsthehelpmode.
⑧ Savesthesettingsforthestartpoint.
50
ProgrammingaContour1. Selectthedesiredoperatingarea.
2. Selectthissoftkey.
3. Selectaprogramwithcursorkeys.
4. Pressthiskeytoopentheprogram.
5. Pressthissoftkeytoopenthecontoureditor.
Recompile
Whentheprogrameditedinthecontoureditorisopenedintheprogrameditor,ifyoupositiontheeditorcursorinacommandlineofthecontourprogramandthenpressthissoftkey,themainscreenofthecontoureditoropensandyoucanrecompiletheexistingcontour.
SettingaStartPointWhenenteringacontour,beginatapositionwhichyoualreadyknowandenteritasthestartingpoint.
51
Selectthedesiredoperatingarea.Enterdesiredfolderbuypressingthe“Input”Key.
Selectfile,andpress“Input”keytoopenfileintotexteditorwindow.
Press“Cont.”keytoopenthecontoureditorwindow.
Pressingthe“Alternative”keywillallowusertotogglebetweenselections.
Youcandefineapoleforcontourprogrammingbypressingthissoftkey.
Pressthe“Accept”softkeytocreateastartingpoint.
ProgrammingContourElements
① OpenstheprogramforprogrammingaverticallineintheXdirection.
⑤ Accessadditionalsoftkey.
② OpenswindowforprogrammingintheZaxisdirection.
⑥ Returnstotheeditorwithoutacceptinganycurrentchanges.
52
③ Openswindowforangulardialog. ⑦ Acceptsdefinedcontour.
④ Opensthearcprogrammingwindow.
Pressthissoftkeytodisplayaselectionlistofalltheparametersfortheselectedcontourelement.Ifyouleaveanyparameterinputfieldsblank,thecontrolassumesthatyoudonotknowtherightvaluesandattemptstocalculatethesefromthesettingsoftheotherparameters.Thecontourisalwaysmachinedintheprogrammeddirection.
Inputswitchover
Thissoftkeyisdisplayedonlyincaseswherethecursorispositionedonaninputfieldwithseveralswitchoversettings.
Selectdialog
Someparameterconfigurationscanproduceseveraldifferentcontourcharacteristics.Insuchcases,youwillbeaskedtoselectadialog.Byclickingthissoftkey,youcandisplaytheavailableselectionoptionsinthegraphicdisplayarea.Selectthissoftkeytomakethecorrectselection(greenline).Confirmyourchoicewiththefollowingsoftkey:
Changeaselecteddialog
Ifyouwanttochangeanexistingdialogselection,youmustselectthecontourelementinwhichthedialogwasoriginallychosen.Bothalternativesaredisplayedagainwhenyouselectthissoftkey.
Clearaparameterinputfield
Youcandeletethevalueintheselectedparameterinputfieldwiththissoftkeyorthefollowingkey:
53
Saveacontourelement
Ifyouhaveenteredtheavailabledataforacontourelementorselectedadesireddialog,pressingthissoftkeyallowsyoutostorethecontourelementandreturntothemainscreen.Youcanthenprogramthenextcontourelement.
Appendcontourelement
Usethecursorkeystoselecttheelementinfrontoftheendmarker.Usethesoftkeystoselectthecontourelementofyourchoiceandenterthevaluesyouknowintheinputscreenforthatelement.Confirmyourinputswiththefollowingsoftkey:
Selectcontourelement
Positionthecursoronthedesiredcontourelementinthecontourchain,andselectitusingthiskey.Theparametersfortheselectedelementwillthenbedisplayed.Thenameoftheelementappearsatthetopoftheparameterizationwindow.Ifthecontourelementcanberepresentedgeometrically,itishighlightedaccordinglyinthegraphicdisplayarea,i.e.thecolorofthecontourelementchangesfromwhitetoblack.
Modifyingcontourelement
Youcanusethecursorkeystoselectaprogrammedcontourelementinthecontourchain.Pressthiskeytodisplaytheparameterinputfields.Theparameterscannowbeedited.
Insertacontourelement
Usethecursorkeysinthecontourchaintoselectthecontourelementinfrontofthepositionforthenewelement.Thenselectthecontourelementtobeinsertedfromthesoftkeybar.Afteryouhaveconfiguredtheparametersforthenewcontourelement,confirmtheinsertoperationbypressingthefollowingsoftkey:
Subsequentcontourelementsareupdatedautomaticallyaccordingtothenewcontourstatus.
54
Deletecontourelement
Usethecursorkeystoselecttheelementyouwishtodelete.Theselectedcontoursymbolandassociatedcontourelementintheprogramminggraphicarehighlightedinred.Thenpressthissoftkeyandconfirmthequery.
Closethecontour
Bypressingthissoftkey,youcanclosethecontourfromtheactualpositionwithastraightlinetothestartingpoint.
Undoaninput
Byselectingthissoftkeyyoucanreturntothemainscreenwithouttransferringthelasteditedvaluestothesystem.
Contoursymbolcolors
Themeaningofthesymbolcolorsinthecontourchainontheleftofthemainscreenisasfollows:
Icon Significance
Selected Symbolcolorblackonaredbackground->ElementisdefinedgeometricallySymbolcolorblackonalight-yellowbackground->Elementisnotdefinedgeometrically
Notselected Symbolcolorblackonagraybackground->ElementisdefinedgeometricallySymbolcolorwhiteonagraybackground->Elementisnotdefinedgeometrically
ParametersforContourElements
55
① Togglebetweenincremental/absolutepositioning.
④ Specifiesasidecontour.Graphicswindowwillreflectgeometrydata.
② Selectsachamferorradiusfortransitioningintonextelement
⑤ Graphicswindow.Pan/Zoom/Movetoviewgeometrydata.
③ Inputfieldfortypingindescriptivecomments.Allcommentsmustbeginwitha;atthebeginningofline.
⑥ Contourchainwindow.
① Directionofrotationofthecirculararc: ④ Absolute/IncrementalpositionsofcirclecenterpointinX/Zdirections.
56
② Radiusofcircle. ⑤ Contourchainthatincludesstartpointandallgeometryelements.
③ Absolute/Incrementalpositions ⑥ Graphicswindowwhichdisplaysgeometryelements
Transitions
Thefollowingadditionalparametersaredisplayedafteryoupressthissoftkey:
Parameter Description
α1 StartinganglewithreferencetoXaxis
α2 Angletoprecedingelement;tangentialtransition:α2=0
β1 EndanglewithreferencetoXaxis
β2 AngleofapertureofcircleAtransitionelementcanbeusedwheneverthereisapointofintersectionbetweentwoneighboringelements;thiscanbecalculatedfromtheinputvalues.Youcanchoosetoinserteitheraradius(RND),achamfer(CHR)oranundercutasthetransitionelementbetweenanytwocontourelements.Thetransitionisalwaysfixedtotheendofacontourelement.Youselecttransitionelementsintheparameterinputscreenfortherelevantcontourelement.
Radiusorchamferatthestartortheendofaturningcontour:Insimpleturningcontoursachamferorradiusmustoftenbeappendedatthestartandendofthecontour.Achamferorradiusterminatesanaxis-parallelcontoursectionontheblank:
Figure4-2 Contourwithradiusorchamfer
57
Youselectthedirectionoftransitionforthecontourstartinthestartingpointscreen.Youcanchoosebetweenchamferandradius.Thevalueisdefinedinthesamemannerasforthetransitionelements.Inaddition,fourdirectionscanbeselectedinasingleselectionfield.Youselectthedirectionofthetransitionelementforthecontourendintheendscreen.Thisselectionisalwaysproposed,evenifprecedingelementswereassignednotransition.ContourchainOnceyoucompleteorcanceltheprogrammingofacontourelement,youcannavigatearoundthecontourchain(leftonthemainscreen)usingthecursorkeys.Thecurrentpositioninthechainiscolor-highlighted.Theelementsofthecontourandpole,ifapplicable,aredisplayedinthesequenceinwhichtheywereprogrammed.Youcanselectanexistingcontourelementwiththefollowingkeyandreassignitsparameters:
Anewcontourelementisinsertedafterthecursorwhenyouselectoneofthecontourelementsontheverticalsoftkeybar;theinputfocusisthenswitchedtotheparameterinputontherightofthegraphicdisplay.Programmingalwayscontinuesaftertheelementselectedinthecontourchain.Youcandeletetheselectedelementfromthechainbyselectingthefollowingsoftkey:
GraphicswindowThegraphicswindowdisplaystheprogressofthecontourchainasyouconfiguretheparametersforthecontourelements.Theelementyouhaveselectedisdisplayedinblackinthegraphicswindow.Thecontourisdisplayedtotheextentitcanbeinterpretedbythecontrolonthebasisofparameterinputs.Ifthecontourisstillnotdisplayedintheprogramminggraphic,furthervaluesmustbeentered.Checkthecontourelementsyouhavealreadyprogrammed,ifrequired.Youmayhaveforgottentoenteralloftheknowndata.Thecoordinatesystemscalingisautomaticallyadaptedtochangesinthecompletecontour.Thepositionofthecoordinatesystemisdisplayedinthegraphicswindow.Anelementwasselectedusingthecursorkeys.Pressingthefollowingsoftkeyallowsyoutoenlargetheimagesectionoftheselectedelement:UndercutsTheformEandFundercutandformDIN76andgeneralthreadundercutfunctionsareonlyactivatedwhentheturningtechnologyisenabled.FormEandFundercutsaswellasthreadundercutsareavailableonlyiflevelG18isset.Undercutsarepermittedonlyoncontouredgesoftherotationalbody,whichruninthedirectionofthelongitudinalaxis(usuallyparalleltotheZaxis).Thelongitudinalaxisisidentifiedbythemachinedata.
58
ThemachinedataMD20100$MC_DIAMETER_AX_DEFforturningmachinescontainsthenameofthetransverseaxis(usuallyX).TheotheraxisinG18isthelongitudinalaxis(usuallyZ).IfMD20100$MC_DIAMETER_AX_DEFdoesnotcontainanameorcontainsanamethatdoesnotconformtoG18,therearenoundercuts.Undercutsonlyappearoncornersbetweenhorizontalandverticalstraightlines,includinganystraightlines,whichareat0°,90°,180°or270°.Atoleranceof±3°isrequiredhere,sothatconicalthreadsarealsopossible(theseundercutsdonotmeetthestandardinthiscase).SelectinganundercutformWhenyouchoosethetransitionelementinthecontourprogrammingwindow,youcanusethefollowingsoftkeytoselectanundercutasatransitionelement:
Youcansubsequentlydefinetheundercutformbytogglingbetweentheselectionsinthecorrespondinginputfields.
Inthecaseofstandardthreadundercuts,thecharacteristicsizeofthethreadpitchisP.Thedepth,lengthandtransitionradiusoftheundercutarecalculatedaccordingtotheDINstandard.The(metric)threadpitchesspecifiedinDIN76canbeused.Theentryanglecanbefreelyselectedinthe30°-90°range.Ifthediameterisknownwhenselectingtheundercut,anappropriatethreadpitchissuggested.FormsDIN76A(externalcontrol)andDIN76C(internalcontrol)areavailable.Theprogramdetectsthetwoformsautomaticallyusingtheirgeometryandtopology.BasedonthethreadundercutaccordingtoDIN,youcanusethegeneralundercuttypetocreatespecificundercuts,e.g.forinchthreads.SpecifyingContourElementsUsingPolarCoordinatesThedescriptiongivenaboveofdefiningthecoordinatesofcontourelementsappliestothespecificationofpositionaldataintheCartesiancoordinatesystem.Alternatively,youhavetheoptiontodefinepositionsusingpolarcoordinates.Whenprogrammingcontours,youcandefineapoleatanytimepriortousingpolarcoordinatesforthefirsttime.Programmedpolarcoordinatessubsequentlyrefertothispole.Thepoleismodalandcanbere-definedatanytime.ItisalwaysenteredinabsoluteCartesiancoordinates.ThecontourcalculatorconvertsvaluesenteredaspolarcoordinatesintoCartesiancoordinates.Positionscanbeprogrammedinpolarcoordinatesonlyafterapolehasbeenspecified.ThepoleinputdoesnotgenerateacodefortheNCprogram.
59
PoleThepolarcoordinatesarevalidinthelevelselectedwithG17toG19.Thepoleisacontourelementthatcanbeedited,whichitselfdoesnotcontributetothecontour.Itcanbeenteredwhenthestartingpointofthecontourisdefinedoranywherewithinthecontour.Thepolecannotbecreatedbeforethestartingpointofthecontour.Thissoftkeyallowsyoutospecifyapoleandcanonlybeenteredinabsolute
Cartesiancoordinates.Thissoftkeyisalsopresentinthestartingpointscreen.Thisenablesthepoletobeenteredatthestartofacontour,sothatthefirstcontourelementcanbeenteredinpolarcoordinates.FurthernotesIfthestraightlinethatwasgeneratedwithclosecontourislinkedtothestartelementofthecontourwitharadiusorchamfer,theradiusorchamfermustbespecifiedexplicitlyasfollows:
● Closecontour,inputkey,enterradius/chamfer,acceptelement.Theresultthencorrespondsexactlytowhatwouldoccuriftheclosingelementweretobeenteredwiththeradiusorchamfer.
Closecontourcanonlybeusedforenteringcontourelementsinpolarcoordinatesifthestartingpointofthecontourwassettopolarandthesamepoleisstillvalidwhenthecontourisclosed.Inputswitchover:Cartesian/polarThefollowingcontourelementscanbeenteredoptionallyinpolarcoordinatesonlyafterapolehasbeendefined,whetherthiswasdoneattheoutsetorlaterintheprocess:
● Circulararcs,● Straightlines(horizontal,vertical,anydirection)
ToswitchoverbetweenCartesianandpolarcoordinates,additionaltogglefieldsaredisplayedintheprogrammingwindowsforthecontourelementsofobliquelinesandcirculararcs.Atogglefieldisnotdisplayedifnopoleexists.InputfieldsanddisplayfieldsarethenonlyavailableforCartesianvalues.Absolute/incrementalinputAbsoluteandincrementalpolarcoordinatescanbeinputfor"polar/Cartesian".Theinputfieldsanddisplayfieldsarelabeledinkandabs.Absolutepolarcoordinatesaredefinedbyanabsolutedistancetothepolethatisalwayspositiveandanangleintherangeof0°...+/-360°.Whenabsolutedimensionsarespecified,theangularreferenceisbasedonahorizontalaxisoftheworkingplane,e.g.XaxiswithG17.Thepositivedirectionofrotationrunscounter-clockwise.Ifthereareseveralinputpoles,thedefinitivepoleisalwaysthelastpolebeforetheinputoreditedelement.Incrementalpolarcoordinatesrelatetoboththedefinitivepoleandtheendpointoftheprecedingelement.
60
Foranincrementalinput,theabsolutedistancetothepoleiscalculatedusingtheabsolutedistancefromtheendpointoftheprecedingelementtothepoleplusthelengthincrementthatwasentered.Theincrementcanbepositiveornegative.Theabsoluteangleiscalculatedaccordinglyusingtheabsolutepolarangleoftheprecedingelementplustheangularincrement.Hereitisnotnecessaryfortheprecedingelementtohavebeenenteredaspolar.Incontourprogramming,thecontourcalculatorconvertstheCartesiancoordinatesoftheprecedingendpointusingthedefinitivepoleintopolarcoordinates.Thisalsoappliesiftheprecedingelementhasbeengiveninpolarcoordinates,sincethiscouldrelatetoanotherpoleifapolehasbeeninsertedinthemeantime.
Polechangeexample
XI. AutomaticMachiningPressingthe“Machine”and“Auto”softkeyontheMCUpanel
61
1. Zoomsintheactualvaluewindow. 6. DisplayscurrentG/Mcodes2. Selectprogramtest,dryrun,Optional
stop,andblockskipping7. Displaysauxiliaryfunctions.
3. Searchfordesiredblocklocation 8. Displayscurrentfeedrate.4. Activatessimulation 9. Displayscycletimes/partcounter5. Fixesincorrectprogramblocks SimulationByusingthebroken-linegraphics,theprogrammedtoolpathcanbetraced.Beforetheautomaticmachining,youneedtoperformthesimulationtocheckwhetherthetoolmovesintherightway.
Selectthedesiredoperatingarea.
Movecursortoselectprogramforsimulation.Press“Input”keytoopenprogram.
Switchto“Auto”mode.
Pressthissoftkeytoentersimulationmode.
Pressthiskeytostartstandardsimulation.
Ifyouarenotcurrentlyin“Auto”mode,youwillseetheabovemessage.Pressthe“Auto”softkey,andhitcyclestartagain.
ProgrammingUsingSiemensDialect ForfurtherprogramminginstructionsonusingSiemenscycles,pleaseclickthelinkbelow.
62
ClickPictureorHEREtodownload.pdfmanual.
ProgrammingUsingISOGCodeLanguageForfurtherprogramminginstructionsonusingSiemenscycles,pleaseclickthelink
below.
ClickPictureorHEREtodownload.pdfmanual.
63
XII. MachineToolSettingsandAdjustments
Themachinehaspassedqualifiedcommissionandinspectioninourfactory,theuserdoesnot
have to readjust. After the machine has been in service for an extended period of time,
adjustmentstotheballscrewassemblymaybenecessary.Followtheprocedurebelow:
• JogCarriagetomiddleoftravel
• Powerdownmachine
• Removecablesfromaxismotor
• Removescrewssecuringmotortolathecasting
• Pullmotorinthedirectionofballscrew
• Removejamnutsonbothendsofballscrew
• Tightenprecisionlocknutsatbothends
• Retorquejamnuts
XIII. CommonFaultsRemoval
IfyourCNCmachinetoolhasafault,checktoseeifsupplyvoltage,airsupplyifnecessary,and
breakersareinanoperablestate.Pleasegiveusacallifyouhavequestions.
Commonfaultitems,andfaultcausesandhandlingmethodslistedbelow.
Number CommonFault FaultCause HandlingMethods
Spindle
1
Beltneeds
adjustment
Adjustorreplacethebelt
Figure8-1:BallScrewStructure
64
Spindlerunning
noise
Beltpulleyofmain
motorisloose
Adjustlocknutontaper-lock
Spindlebearingshave
beenworndown
Replacebearings
2 Spindlespeed
inaccurate
Spindledrivewith
problem
Checkspindledrivesystem,check
faultcodesonspindledrive
3 Spindleorientation
inaccurate
Timingpulleyisloose. Adjustlocknutontaper-lock,
reorientation
Spindledriveerror Checkspindledrivesystem,correct
output,reorientation
Axes
4
Axispositionnot
returningtozero
FaultyLimitSwitch
Checklimitswitchintegrity.Limit
switchesmustbefreeofdebrisand
coolant
Tripdogneeds
adjustment.
Checkandadjustzeroposition
5 Backlash Spidercouplerloose Tightensetscrewssecuringnutto
ballscrew,andnuttoaxismotor
Ballscrewnutsloose Checkscrewsintegrity,adjustwhen
necessary.
6
Axisrunningwith
noise
Lackoflubricationoil Stopmachinetocheckthe
lubricationoilsupplydelivery
system.
Ballscrewbearingis
broken
Stopmachinetocheck,repairor
replace
Ballscrewnutis
broken
Stopmachinetocheck,repairor
replace
65
Guidewayisbroken Stopmachinetocheck,repairor
replace
AutoLubricationSystem
7
Nolubrication
pressure
Pumpisnotworking Checkcontrolcircuitandpump,
repairandreplace
Oilcircuitwithair
bubbles
Removeoillinesandmanually
operatepumptoremoveairfrom
withinlines.
Oilfracturesorloose Checkandtightenalloilpipeand
replacebrokenlines
Debriswithinoil Replacewithcleanoilasrequired
CoolantSystem
8 Nocoolantflow Directionofcoolant
pumpmotorrotation
iswrong
Swaplegsoncoolantmotorlines
U/V/W
Lowcoolantlevel Fillunitwithspecifiedcoolant.
ProcessingQualityProblem
9
Machiningoutside
specifiedtolerance
Ballscrewplayistoo
large
Checktheplayinballscrewoutlined
above
Checktooloffset
library
Checkwear/radialvaluesorcorrect
Ballscrewlocknuts
loose
Checklocknuts,andtightenif
necessary
10
T.I.R.outof
tolerance
Spindlebearingsloose Indicatespindleboreandcheck
T.I.R.Tightenbearings
Spindlebearings
damaged
Replacebearings
66
11 Taperofwork
pieceisoutof
tolerance
Parallelismofspindle
centerlineandZaxis
isoutoftolerance
Checkbedfortwistwithamachinist
level
Misalignmentof
spindleandZaxisis
outofalignment
Adjustmisalignmentquantityof
spindleaxisandZaxis
12
Inaccuratethreads Mainbeltloose Tensioningmainbelt
Processprogram Checkprocessprogram
Settingofsystem
servoparameter
Optimizeservoparameter
13
Breakingtaps
inconsistent
Thechoiceofcutting
fluid
Choosesuitablecuttingfluidin
accordancetomaterial.
Wrongfeeds/speeds Choosesuitablecuttingspeed
Processprogram Chooserigidtappingprogramming
The choice of tool
holder
Choosededicatedtappingholder
Setting of system
parameter
Adjusttappingparameter
TurretIndexing
14 Turretremains
unlockedafter
indexing,even
aftermotorstops
running,still
withoutcirculate
finishedsign
SSR(solidstaterelay)
fault
ReplaceSSR(solidstaterelay)
Turretcontrolsystem
fault
Checkwhetherthemotorpower
switchisclosedin5milliseconds
afterproximityswitchsendsout
signal,itcanbecheckedwith
oscilloscope
Proximityswitchfault Replaceproximityswitch
67
15
Turretspinspast
specifiedtool
position
Encoderfault Turnturretcrankandcheckencoder
signal,ifitisinvalid,replace
encoder
Proximityswitchfault Turnturretcrankandcheck
proximityswitchsignal,ifitis
invalid,replaceproximityswitch
Controlcircuitfault Checkdifferentsignals(suchastool
request,encoder,feedback,
proximityswitch,etc.),whether
theyareinthecorrectorder,and
whethertheyareavailableinthe
righttime
16 Indexingwith
abnormalnoise
Looseconnections Torquefastenerstospecsoutlined
inturretmanual
17 ToolrotationIs
rough
Loadofturretdiscis
imbalance
Repositiontoolstoimprovebalance
18 Turretmotor
overheatingalarm
Indexingcycletoo
frequently
Decreaseindexingcycletimesper
minute(Maximum10times/min)
Powersupplyisoutof
balance
Checkthe3-phasevoltage,change
orafterifitnecessary
Communication
19
Unabletouse
RS232
communication
Operation Checkrelatedsystemoperation
manuals
Parameter Checkwhethertheparametersof
thetransmissionsoftwareare
unifiedwiththerelatedsystem
transmissionparameters.
Transmissioncable CheckwhethertheRS232serialport
iscorrect,checkwhetherthe
68
operationboxRS232interfaceto
thesystemofattachmentiscorrect
Systemfault Checksystemalarm
RestartMachineAfterMakingAdjustments
1) Afterrepairandadjustment,cleanandremovevarioustoolsandremovetrashfrom
workplace.
2) BeforerunningthemachineinAUTOmode,operatethemachineinmanualmodeto
makesureeverythingisfunctioningproperly.
3) RechecktoolandworkoffsetsbeforerunninginAUTOmode.
XIV. MachineMaintenanceDailyMaintenance
1) LubricationSystem--Checkwhethertheoilsupplypressureofthelubricationsystemis
innormalstate,ifaproblemarises,adjusttonormalrequirements.Keepthewaylube
oilintheoptimaloperatingrange.Oilreservoirisclearlymarked.
2) Theoperatorshouldcleanmachineattheendofday.Removecoolantanddebrisfrom
waycovers,carriage,andATC/toolblocksanddisposeasnecessary.
3) Ifusingawashdownhose,donotdirectsprayintoelectricalcabinetoraxismotors.
4) Donotusehighpressureairtocleanmachinetool.
WeeklyInspection1) ElectricControlCabinetofMachineTool–Checkthecontrolsystemandelectrical
componentsintheelectriccabinet,makesuretheyarecleanandwithoutdust.Check
theworkingconditionoftheelectricalcabinetfansandcleanfilterswhennecessary.
2) MotorsandLimitSwitches–Checkifthereisanydust,chipsandsludgegatheredonthe
motorandswitches,cleanasnecessary.
3) CoolingSystem–Checkwhetherthecoolantinsystemisinthenormalcondition.
Agitate,replaceoradjustconcentrationwhennecessary.
69
MonthlyInspectionandMaintenance1) GuideWaysandBallScrews–Overanextendedperiodoftime,debrisandcoolantcan
collectbelowtheaxiswaycovers.Removethewaycoversandcleanwaysandscrewsas
necessary.Donotusecompressedair.Simplywipedownslidingsurfacesandscrews,
andlubricatewithfreshwaylubewhenfinished.
2) ElectricalDevices
a. Checktheoperationofallelectricalsafetydevicesincludingthelowlevelalarmon
thelubricationsystem,limitswitch,homingswitchandsoon.
b. Checkallthecables,conduitlines,checkingforwearanddamage.
c. Checkthegeneraloperationandcleanlinessoftransformerandmotor.Note:ifany
problemsarefound,fixasnecessaryorcallourtechnicaldepartmentforguidance.
XV. M-CodeListM00 ProgramStop
M01 OptionalStop
M02 ProgramEnd
M03 SpindleClockwise
M04 SpindleCounter-clockwise
M05 SpindleStop
M06 AutomaticToolChange
M08 CoolantOn
M09 CoolantOff
M10 ChuckClamp
M11 ChuckRelease
M19 SpindleOrientation
M30 ProgramStop
M66 RobotArmSignal
70
PLCWarningInformationPleasereferencethePLCmanualfromSiemensforfurtherinformation.Belowisapartiallistof
PLCalarmsthataremanufacturespecific.
700002 Programmedtoolpositiondisagreeswithactual
Description Toolnumberdoesnotmatchrequiredtool
Solution 1.T.S.MchangedtotoolNo.1
2.Checkservomodule,turretmotorencoderandtheconnection
betweenmotorandturret.
700003 Lowwaylubepumppressure
Description Press lubrication start button, lubrication pump unit pressure
detectionswitchnotclosed
Solution Checkpumpcirculationcircuitfortrappedairordebris
700004 Waylubelevellow
Description Upperleveldetectionswitchoflubricationpumpunitnotclosed
Solution 1.Checkcapacityinsideoiltank
2.Checkliquidlevelswitch
700006 Coolantpumpmotoroverload
Description Waterpumpcircuitbreakerinsideelectricalcabinettripped
Solution Check if breaker set overload current matches with coolant
pump,andcheckifmotorisoverload.
700016 Drivernotready
Description PPUandservomodulenotready
Solution Checkthetwomodulesanditswiring
700031 MCPpanelfailure
Description Machineoperationpanelfailure
Solution Checkpanelandassociatedwiring
700032 Turretinunlockstate
Description Remindermessage
Solution
71
700033 Turrethandwheelisactive
Description Remindermessage
Solution
700034 Closechuckbeforeoperation
Description Reminderinformation.
Solution Closechuckandresumeoperation
700035 SafetyDoorisopen
Description Closedoorandresumeoperation
Solution Closedoorandresumeoperation
700036 Guarddooropen,cannotoperate
Description Reminderinformation
Solution Operateitafterclosingguarddoor
700037 ChuckUnclamped,
Description Reminderinformation
Solution Closechuck,resumeoperation
700038 Xaxishandwheeliseffective
Description Reminderinformation
Solution
700039 Zaxishandwheeliseffective
Description Reminderinformation
Solution
XVI. PLCFunctionParametersCNC Machine PLC
Parameter
Meaning
MD14510[20] =0Withoutguarddoor
72
=1Withguarddoor
MD14510[21] =0Withoutlivetooling
=1Withlivetooling
MD14510[22] =0Withouthydraulictailstock
=1Withhydraulictailstock
MD14510[24] Lubricationintervalunit:Min.(setvalue30min)
MD14510[25] Lubricationtimeunit:MS(Setvalue10ms)
MD14510[26] =0Footswitchtype1(Note1)
=1Footswitchtype2(Note1)
MD14510[27] =0Withoutrobot(Robotarm)
=1Withrobot(Robotarm)
MD14510[28]
=1Turretjogbuttoneffective;Turrethandwheeleffective
=0Turretjogbuttoninvalid;TurrethandwheelinvalidT
=0,andMD14510[21]=1;Livetoolingeffective
MD14512[0]:
Bit0 =0Withouthydraulictailstockrelease/clamp
=1Withhydraulictailstockrelease/clamp
Bit1 =0Withouthydraulictailstocksleevepositiondefectiveswitch
=1Withhydraulictailstocksleevepositiondefectiveswitch
Bit2 =0Servoturret
=1Hydraulicturret
Bit3 =012-stationservoturret
=18-stationhydraulicturret
Bit4 =012-stationhydraulicturret
=18-stationhydraulicturret
Bit5 =0Withoutchipconveyor
=1Withchipconveyor
Recommended