SINUMERIK 840D sl. Service - Functions. Manual (2018-2020)

Axis couplings

14.5 Generic coupling

Programming

Offset of the input value

Syntax:

CPLINTR[FAx,LAx]= <value>

Designation:

Coupling Lead In Translation Displacement

Functionality:

Defines the offset value for the input value of the LAx leading axis.

Value:

Type: REAL

Default value:

Example:

Programming

Comment

CPLINTR[X2,X1]=-50

; The input value of the leading axis X1 is moved in the

negative direction by the value 50.

Scaling the input value

Syntax:

CPLINSC[FAx,LAx]= <value>

Designation:

Coupling Lead In Scale Factor

Functionality:

Defines the scaling factor for the input value of the LAx leading axis.

Value:

Type: REAL

Default value:

Example:

Programming

Comment

CPLINSC[X2,X1]=0.5

; The input value of the leading axis X1 is multiplied

with the factor 0.5.

Offset of the output value

Syntax:

CPLOUTTR[FAx,LAx]= <value>

Designation:

Coupling Lead Out Translation Displacement

Functionality:

Defines the offset value for the output value of coupling the following axis

FAx to leading axis LAx.

Value:

Type: REAL

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Default value:

Example:

Programming

Comment

CPLOUTTR[X2,X1]=100

; The output value of the coupling of the following axis

X2 with leading axis X1 is displaced by the value 100 in

the positive direction.

Scaling of the output value

Syntax:

CPLOUTSC[FAx,LAx]= <value>

Designation:

Coupling Lead Out Scale Factor

Functionality:

Defines the scaling factor for the output value of coupling the following

axis FAx with leading axis LAx.

Value:

Type: REAL

Default value:

Example:

Programming

Comment

CPLOUTSC[X2,X1]=3

The output value of the coupling of the following axis X2

with leading axis X1 is multiplied with factor 3.

Note

The following setting data used in the existing coupling type "Master value coupling" is

considered in generic coupling independently of the set coupling type (CPSETTYPE):

SD43102 $SA_LEAD_OFFSET_IN_POS[FAx] (offset of master value)

SD43104 $SA_LEAD_SCALE_IN_POS[FAx] (scaling of master value)

SD43106 $SA_LEAD_OFFSET_OUT_POS[FAx] (offset of function value of the curve table)

SD43108 $SA_LEAD_SCALE_OUT_POS[FAx] (scaling of function value of the curve table)

These setting data have the following effect:

• on all leading axes that are coupled with the following axis via a curve table. This must be

taken into account for couplings with more than one leading axis!

• in addition to the CP key words CPLINTR, CPLINSC, CPLOUTTR and CPLOUTSC.

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14.5 Generic coupling

14.5.5.15

Synchronism monitoring stage 1 (CPSYNCOP, CPSYNFIP, CPSYNCOV, CPSYNFIV)

Synchronism monitoring stage 1

In each interpolator clock cycle, the synchronous operation of the coupling group is monitored

- both on the setpoint and actual value sides. The synchronous operation monitoring responds

as soon as the synchronous operation difference (the difference between the setpoint or

actual value of the following axis and the value calculated from the setpoints or actual values of

the leading axes according to the coupling rule) reaches one of the following programmed

threshold values:

• At setpoint / actual value coupling (see "Coupling relationship (CPLSETVAL) (Page 627)"):

- "Coarse" position synchronous operation threshold value

- "Fine" position synchronous operation threshold value

• For velocity coupling (see "Coupling relationship (CPLSETVAL) (Page 627)"):

- Threshold value of "Coarse" speed synchronous operation

- Threshold value of "Fine" speed synchronous operation

The actual synchronous operation difference can be read out with the following CP system

variables:

System variable

Meaning

$AA_SYNCDIFF [FAx]

Synchronous operation difference of the setpoint

$VA_SYNCDIFF [FAx]

Synchronous operation difference of the actual value

Note

Synchronous operation differences are signed and enable the advance or delay of the following

axis to be determined.

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14.5 Generic coupling

Status of the coupling during synchronous operation

State

Description

Not synchronized

Provided the synchronous operation difference is greater than the

threshold value for position "coarse" synchronous operation or

"coarse" speed synchronous operation, the coupled group is desig-

nated as non-synchronous.

"Coarse" synchronous operation

The synchronous operation difference has reached the threshold

reached

value for "coarse" position synchronous operation or "coarse" speed

synchronous operation.

In case the actual value-based synchronous operation difference, the

following NC/PLC-interface signal is set:

DB31, ... DBX98.1 (coarse synchronous operation)

"Fine" synchronous operation

The synchronous operation difference has reached the threshold

reached

value for "fine" position synchronous operation or "fine" speed syn-

chronous operation.

In case the actual value-based synchronous operation difference, the

following NC/PLC-interface signal is set:

DB31, ... DBX98.0 (fine synchronous operation)

The status of the coupling for the synchronous operation can be read with the following system

variables:

System variable

Meaning

$AA_SYNC [FAx]

State of the coupling

Value

State

Not synchronized

"Coarse" synchronous operation reached

"Fine" synchronous operation reached

Signal reaction

Synchronous operation signals themselves do not stop the involved axes, but can release them

via synchronized action or NC/PLC interface signals (see Section "Extended stop and retract

(Page 893)").

Configuration

The threshold values for the first stage of the synchronous operation monitoring will be adjusted:

• For setpoint / actual value coupling in the machine data:

- MD37200 $MA_COUPLE_POS_TOL_COARSE (threshold value for "coarse synchronism")

- MD37210 $MA_COUPLE_POS_TOL_FINE (threshold value for "fine synchronism")

• For speed coupling in the machine data:

- MD37220 $MA_COUPLE_VELO_TOL_COARSE ("coarse" speed tolerance)

- MD37230 $MA_COUPLE_VELO_TOL_FINE ("fine" speed tolerance)

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14.5 Generic coupling

Programming

CP keywords can also be used to program the threshold values for the first stage of the

synchronous operation monitoring:

"Coarse" position synchronous operation threshold value

Syntax:

CPSYNCOP[FAx]= <value>

Designation:

Coupling Synchronous Difference Coarse Position

Functionality:

Defines the threshold value for the "Coarse' position synchronous oper-

ation.

Value:

Type: REAL

The default value corresponds to the setting in the machine data:

MD37200 $MA_COUPLE_POS_TOL_COARSE [FAx]

"Fine" position synchronous operation threshold value

Syntax:

CPSYNFIP[FAx]= <value>

Designation:

Coupling Synchronous Difference Fine Position

Functionality:

Defines the threshold value for the "Fine" position synchronous opera-

tion.

Value:

Type: REAL

The default value corresponds to the setting in the machine data:

MD37210 $MA_COUPLE_POS_TOL_FINE [FAx]

Threshold value of "Coarse" speed synchronous operation

Syntax:

CPSYNCOV[FAx]= <value>

Designation:

Coupling Synchronous Difference Coarse Velocity

Functionality:

Defines the threshold value for the "Coarse'' speed synchronous opera-

tion.

Value:

Type: REAL

The default value corresponds to the setting in the machine data:

MD37220 $MA_COUPLE_VELO_TOL_COARSE [FAx]

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Threshold value of "Fine" speed synchronous operation

Syntax:

CPSYNFIV[FAx]= <value>

Designation:

Coupling Synchronous Difference Fine Velocity

Functionality:

Defines the threshold value for the "Fine" velocity synchronous opera-

tion.

Value:

Type: REAL

The default value corresponds to the setting in the machine data:

MD37230 $MA_COUPLE_VELO_TOL_FINE [FAx]

Example

Program code

Comment

CPDEF=(S2) CPLA[S2]=(S1)

; Definition of a spindle coupling:

Leading spindle S1 to following spindle S2

CPON=(S2) CPSYNCOP[S2]=0.5

; Activation of the coupling with following spin-

CPSYNFIP[S2]=0.25

dle S2. The threshold values for the position syn-

chronous operation are set to 0.5 ("coarse") and

0.25 ("fine").

Supplementary conditions

• When considering the synchronous operation difference, an active coupling cascade is not

taken into account. This means: if in the considered coupling module, the leading axis is a

following axis in another coupling module, the current actual or setpoint position is still used

as input variable for the calculation of the synchronous operation difference. This

synchronous operation difference therefore does not show the total synchronous operation

error of the cascade.

• If the leading axis is not a real axis, but a simulated axis, then the actual value is not available

for the synchronous operation monitoring of the actual value. In this case, the modeled

actual values (according to the machine data setting) are used.

14.5.5.16

Synchronous operation monitoring stage 2 (CPSYNCOP2, CPSYNFIP2)

Synchronism monitoring stage 2

For active CP position coupling (setpoint or actual value coupling, see "Coupling relationship

(CPLSETVAL) (Page 627)"), after reaching the "COARSE"/"FINE" block change criterion (see "Block

change behavior (CPBC) (Page 629)"), the second stage of the synchronous operation

monitoring can be used to monitor that one of the threshold values of the first stage is

maintained on the actual value side, independent of the synchronism tolerance.

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14.5 Generic coupling

The following two threshold values must configured or programmed for the second stage of

synchronous operation monitoring:

• "Coarse" 2 position synchronous operation threshold value

• "Fine" 2 position synchronous operation threshold value

Technical backg7round

As part of the "synchronous operation reached" and "exit synchronous window" monitoring

functions, for a correct assessment of any problems that arise during the multi-edge turning

(surface, waste, etc. ) and sometimes also for oscillating synchronous spindle it is often very

useful to define a tolerance range independent of the coarse/fine synchronous operation

tolerances of the first stage of the synchronous operation monitoring (similar to exact stop and

standstill monitoring for axes) in order to obtain a configurable error message or warning.

Configuration

The threshold values for the second stage of the synchronous operation monitoring are set in

the machine data:

MD37202 $MA_COUPLE_POS_TOL_COARSE_2 (second threshold value for "coarse synchronous

operation")

MD37212 $MA_COUPLE_POS_TOL_FINE_2 (second threshold value for "fine synchronous

operation")

Note

If the appropriate threshold value = 0, the associated monitoring is inactive. This is also the

default value so that the compatibility with older software versions is retained.

Programming

CP keywords can also be used to program the threshold values for the second stage of the

synchronous operation monitoring:

"Coarse" 2 position synchronous operation threshold value

Syntax:

CPSYNCOP2[FAx]= <value>

Designation:

Coupling Synchronous Difference Coarse Position 2

Functionality:

Defines the second threshold value for the "Coarse' position synchro-

nous operation.

Value:

Type: REAL

The default value corresponds to the setting in the machine data:

MD37202 $MA_COUPLE_POS_TOL_COARSE_2 [FAx]

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"Fine" 2 position synchronous operation threshold value

Syntax:

CPSYNFIP2[FAx]= <value>

Designation:

Coupling Synchronous Difference Fine Position 2

Functionality:

Defines the second threshold value for the "Fine" position synchronous

operation.

Value:

Type: REAL

The default value corresponds to the setting in the machine data:

MD37212 $MA_COUPLE_POS_TOL_FINE_2 [FAx]

The programming applies similarly to the general CP behavior in the part program only with the

next switching command; for synchronized actions, immediately.

Sequence

Starting

The second stage of the synchronous operation monitoring function starts with active coupling

as soon as the following conditions are fulfilled:

• The setpoint synchronous operation is reached:

DB31, ... DBX99.4 (synchronization running) = 0

• The actual value related "coarse"/"fine" synchronous operation of the tolerance of the first

stage of the synchronous operation monitoring (see "Synchronism monitoring stage 1

(CPSYNCOP, CPSYNFIP, CPSYNCOV, CPSYNFIV) (Page 644)") is reached:

DB31, ... DBX98.1 (coarse synchronous operation) = 1 / DB31, ... DBX98.0 (fine synchronous

operation) = 1

Monitor

As long as the synchronism difference of the actual the threshold values for "fine" 2 position

synchronous operation and "coarse" 2 position synchronous operation are not exceeded, the

following NC/PLC interface signals are set:

DB31, ... DBX103.4 (synchronous operation 2 fine)

DB31, ... DBX103.5 (synchronous operation 2 coarse)

If, due to temporary overload in machining process (e.g. infeed feedrate for multi-edge

machining too high), the following axis/spindle can no longer follow the specifications of the

leading axis(n)/spindle(s) and the deviation is greater than the set tolerance, the violation of the

"fine"/"coarse" tolerance displays a display alarm that can be deleted:

Alarm 22026 "Channel %1 Block %2 Following axis/spindle %3 Synchronism (2): Coarse

tolerance exceeded"

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Alarm 22025 "Channel %1 Block %2 Following axis/spindle %3 Synchronism (2): Fine tolerance

exceeded"

This does not interrupt the machining.

Note

Both alarms can also occur simultaneously.

Exit

The second stage of the synchronous operation monitoring ends in the following cases:

• Deactivation of the coupling (for the power-down command: CPOF, CPDEL, CPLOF, CPLDEL)

• New synchronization request by:

- CPON / CPLON / CPDO / CPLOF

- DB31, ... DBX31.4 (synchronize following spindle) = 1

- Internal synchronization requests

If, in these cases, the start conditions are satisfied again, the monitoring will be restarted.

• For coupled block changes (CPLNUM, CPLDEN, CPLCTID) in synchronized actions

• Resetting the setpoint synchronous operation because of missing enable signals for the

following spindle (emergency stop, alarm responses)

The DB31, ... DBX103.4/5 signals are reset when the monitoring is ended.

Boundary conditions

Exclusion conditions

No monitoring is performed in the following cases:

• MD37202 or MD37212 = 0.

• Speed coupling is active (CPLSETVAL="CMDVEL").

• DB31, ... DBX31.5 (inhibit synchronization of the FS) = 1

• Rapid stop of the following axis/spindle or one of the active leading axes/spindles.

• SERUPRO or block search is active.

• For channel-related run-in when the following axis/spindle or an active leading axis/spindle

does not really move.

• DB31, ... DBX63.3 (axis/spindle disable active) = 1 for the following axis/spindle or for one of

the active leading axes/spindles.

"Track the synchronous operation deviation" is active

Monitoring is suspended while the "track the synchronous operation deviation" function is

active (DB31, ... DBX31.6 = 1; see "Tracking the deviation from synchronism (Page 674)").

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14.5 Generic coupling

Synchronous operation monitoring level 2 for the traditional coupling types

For the traditional coupled motion, master value coupling, electronic gearbox and synchronous

spindle coupling types, the "stage 2 synchronous operation monitoring" is available only with

the CP adaptive cycles (see "Adaptive cycles (Page 659) ").

Example

Program code

Comment

G0 Z-300 X50

CPDEF=(S2) CPLA=(S1) CPLNUM=2 CPLDEN=1

; Gear ratio in accordance with tool.

CPBC="FINE"

M3 S2000

CPON=(S2) CPLA=(S1) CPSYNCOP2[X]=1.6

; Block change is performed on reaching "fine synchronous

CPSYNFIP2[X]=0.8

operation".

; Synchronous operation monitoring stage 2 is also activa-

ted

; (tolerances: coarse 1.6, fine 0.8).

X20

G1 Z-200

; Machining block, material removal.

; Synchronous operation determines the quality.

CPOF=(S2)

; Deselect coupling, deactivate the monitoring function.

14.5.5.17

Reaction to stop signals and commands (CPMBRAKE)

The response of the following axis to certain stop signals and commands can be defined with the

CP keyword CPMBRAKE.

Programming

Syntax:

CPMBRAKE[FAx]= <value>

Designation:

Coupling Mode Brake

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Functionality:

CPMBRAKE is a bit-coded CP keyword that defines the braking behavior of

the following axis FAx for the following events:

Bit

Event

• NST DB31, ... DBX4.3 (feed stop / spindle stop) present

• CP SW limit stop is set (see "CP SW limit monitoring

(Page 668)")

Note:

Bit 0 is significant only for a "Freely programmable" coupling type

(CPSETTYPE=CP).

Value Meaning

The brake is not transferred to the leading axes.

The brake is transferred to the leading axes depending

on the context.

1 - 31

Reserved

The following rules apply for the programming:

• CPMBRAKE must be programmed in one block with CPDEF or CPON (⇒

can only be programmed for an inactive coupling).

• While defining a coupling, the following values are captured without the

explicit programming of CPMBRAKE:

Bit 0 = 1 for pre-processing couplings with CPSETTYPE=CP (otherwise

bit 0 = 0)

Examples

Example 1:

Programming

Comment

CPDEF=(AX5) CPLA[AX5]=(AX4) CPMBRAKE[AX5]=0

;

Defining a coupling (lead-

ing axis Ax4 with following

axis Ax5). NST "feed stop /

spindle stop" or "CP SW lim-

it stop" should not brake

the coupling group.

Example 2:

Programming

Comment

CPDEF=(S2) CPLA[S2]=(S1)

;

Definition of a spindle coupling:

Leading spindle S1 with following spindle S2

CPON=(S2) CPMBRAKE[S2]=1

;

Activation of the coupling with following

spindle S2. NST "feed stop / spindle stop"

or "CP SW limit stop" should brake the cou-

pling group.

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14.5.5.18

Response to certain NC/PLC interface signals (CPMVDI)

The CP keyword CPMVDI can be used to define the coupling module's response to certain NC/PLC

interface signals.

Programming

Syntax:

CPMVDI[FAx]= <value>

Designation:

Coupling Mode VDI Signal

Functionality:

CPMVDI is a bit-coded CP keyword, which defines the response of the cou-

pling module of following axis FAx to certain NC/PLC interface signals.

The bit combination operators B_OR, B_AND, B_NOT, and B_XOR can be

used to set individual bits.

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Bit

Meaning

Reserved.

The effect of NC/PLC interface signal

DB31, ... DBX1.3 (axis/spindle disable)

on the following axis/spindle can be set via bit 3:

Bit 3 = 0

DB31, ... DBX1.3 has no effect on the following axis/

spindle. The state of the following axis/spindle with ref-

erence to the axis/spindle disable is derived solely from

the state of the leading axes/spindles.

Bit 3 = 1

DB31, ... DBX1.3 has an effect on the following axis/spin-

dle. The state of the leading axes/spindles with reference

to the axis/spindle disable is not imposed on the follow-

ing axis/spindle.

Note:

If bit 3 = 1, the axis/spindle disable state of the following axis/spindle

only has an effect if the program test or SERUPRO states are not active

(see also bit 5).

Bit 4 is used to define the enable for the dependent motion compo-

nents when the NC/PLC interface signal DB31, … DBX1.3 (axis/spindle

disable) has an effect on the following axis/spindle:

Bit 4 = 0

Dependent motion components of the leading axes/

spindles become effective irrespective of the state of the

axis/spindle disable of the relevant leading axis/spindle.

Bit 4 = 1

Dependent motion components of the leading axes/

spindles only become effective if the state of the axis/

spindle disable of the leading axis/spindle matches that

of the axis/spindle disable of the following axis/spindle.

Otherwise, the components are suppressed.

Note:

Bit 4 is only of significance if bit 3 is set, i.e. if the NC/PLC interface

signal DB31, … DBX1.3 (axis/spindle disable) has an effect on the

following axis/spindle (see bits 3 and 5).

The effect of NC/PLC interface signal

DB21, ... DBX25.7 (program test selected) or

DB21, ... DBX1.7 (activate program test)

on the following axis/spindle can be set via bit 5:

Bit 5 = 0

DB21, ... DBX25.7 or DB21, ... DBX1.7 has no effect on

the following axis/spindle. The state of the following ax-

is/spindle with reference to the axis/spindle disable is

derived solely from the state of the leading axes/spin-

dles.

Bit 5 = 1

If the "program test" state is active for an axis of the

coupling module, then for the following axis/spindle, its

own state is active regarding the axis/spindle disable.

The state of the leading axes/spindles with reference to

the axis/spindle disable is not imposed on the following

axis/spindle.

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Note:

When bit 5 is set, the program test state still has an effect on the

following axis/spindle, even if the leading axes/spindles have a differ-

ent state.

Bit 6 is used to define the enable for the dependent motion compo-

nents when the NC/PLC interface signal DB21, … DBX25.7 (program

test selected) or DB21, ... DBX1.7 (activate program test) has an ef-

fect on the following axis/spindle:

Bit 6 = 0

Dependent motion components of the leading axes/

spindles become effective irrespective of the state of the

axis/spindle disable of the relevant leading axis/spindle.

Bit 6 = 1

Dependent motion components of the leading axes/

spindles only become effective if the state of the axis/

spindle disable of the leading axis/spindle matches that

of the axis/spindle disable of the following axis/spindle.

Otherwise, the components are suppressed.

Note:

Bit 6 is only of significance if bit 5 is set, i.e. if the program test state

has an effect on the following axis/spindle (see bits 3 and 5).

Reserved.

Note

The axis/spindle disable, which is set for the following axis/spindle via the NC/PLC interface signal

DB31, ... DBX1.3, can be overwritten by the program test (DB21, ... DBX25.7 or DB21, ... DBX1.7)

and SERUPRO states; this is also the case for every other axis/spindle.

Effect of bits 3/5 and 4/6

The effects of the different motion components on the following axis/spindle as a function of the

associated axis/spindle disable are illustrated in the table below:

A/S disable

CPMVDI

FA_Total

Meaning

LA₁

LA₂

Bit 3/5

Bit 4/6

for FA

FA_Cmd +

Real movement.

FA_DEP1 +

FA_DEP2

FA_Cmd +

Real movement.

FA_DEP1 +

FA_DEP2

FA_Cmd +

Simulated

FA_DEP1 +

movement

FA_DEP2

Alarm 16773,

different lead-

ing axis states

with ref. to the

A/S disable

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A/S disable

CPMVDI

FA_Total

Meaning

LA₁

LA₂

Bit 3/5

Bit 4/6

for FA

FA_Cmd +

Real move-

FA_DEP1 +

ment, FA spin-

FA_DEP2

dle disable has

no effect.

FA_Cmd +

Simulated

FA_DEP1 +

movement, FA

FA_DEP2

spindle disable

has an effect.

FA_Cmd +

Simulated

FA_DEP2

movement, as

bit 4 is set,

FA_DEP1 is sup-

pressed.

Alarm 16694

bit 4/6 = 1 is on-

ly supported if

bit 3/5 = 1.

Alarm 16694

bit 4/6 = 1 is on-

ly supported if

bit 3/5 = 1.

A/S disable:

Axis/spindle disable

This refers to the resulting internal state of the axis/spindle disa-

ble. The spindle disable, which is set via the NC/PLC interface

signal DB31, … DBX1.3 (axis/spindle disable), can be overwritten

by states such as program test (DB21, … DBX25.7 or

DB21, … DBX1.7) and SERUPRO, thus generating an axis/spindle

state which differs from the NC/PLC interface signal.

FA:

Following axis

LA₁:

Leading axis 1

LA₂:

Leading axis 2

FA_Total:

Total setpoint value of the following axis

FA_Cmd:

Independent motion component of the following axis

FA_DEP1:

Dependent motion component of leading axis 1

FA_DEP2:

Dependent motion component of leading axis 2

Real movement:

Real movement means that positioning movements are transfer-

red to the position control.

Simulated movement:

Simulated movement means that no positioning movements are

transferred to the position control. The real machine axis remains

stationary. This corresponds to the state of an activated axis/spin-

dle disable or program test.

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Note

The states in the columns for leading axes 1 and 2 also apply if there are several leading axes/

spindles, which have the same state with reference to the axis/spindle disable.

14.5.5.19

Alarm suppression (CPMALARM)

The CP keyword CPMALARM can be used to suppress coupling-related alarms.

Programming

Syntax:

CPMALARM[FAx]= <value>

Designation:

Coupling Mode Alarm

Functionality:

CPMALARM is a bit-coded CP keyword for suppressing special coupling-rela-

ted alarm outputs.

The bit combination operators B_OR, B_AND, B_NOT, and B_XOR can be

used to set individual bits.

Bit

Value

Meaning

= 1

Alarm 16772 is suppressed.

= 1

Alarm 16773 is suppressed.

= 1

Alarm 16774 is suppressed.

= 1

Alarm 22012 is suppressed.

= 1

Alarm 22013 is suppressed.

= 1

Alarm 22014 is suppressed.

= 1

Alarm 22015 is suppressed.

= 1

Alarm 22016 is suppressed.

= 1

Alarm 22025 is suppressed.

= 1

Alarm 22026 is suppressed.

= 1

Alarm 22040 is suppressed for the cyclic check in

case of previously activated position control for fol-

lowing and leading spindles.

= 1

Alarm 16771 is suppressed.

12 - 31

Reserved.

The default values correspond to the settings in the machine data:

• MD11410 $MN_SUPPRESS_ALARM_MASK (mask for suppressing special

alarm outputs)

• MD11415 $MN_SUPPRESS_ALARM_MASK_2 (suppress alarm outputs)

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Example

Program code

Comment

CPMALARM[X2]='H300'

; The 22025 and 22026 alarms are suppressed for the cou-

pling of the X2 following axis.

14.5.6

Coupling cascading

Coupling cascades

The coupling modules can be connected in series. The following axis/spindle of a coupling

module then becomes the leading axis/spindle of another coupling module. This results in a

coupling cascade.

Multiple coupling cascades in series is also possible. The internal computation sequence of the

individual coupling modules is performed so that there is no position offset in the coupling

relationship. This also applies for a cross-channel cascading.

Example:

Two new coupling modules are created. For the coupling module with following axis X2, the

leading axis X1 is defined. For the coupling module with following axis X2, the leading axis X2

and A1 are defined.

Programming

CPDEF=(X2) CPLA[X2]=(X1) CPDEF=(A2) CPLA[A2]=(X2) CPLA[A2]=(A1)

Supplementary conditions

• The availability of cascading is option-based (see Section "Requirements (Page 609)").

• Cascades between couplings of existing coupling functions and couplings of generic

couplings are not possible.

• A ring coupling is not permitted. It is rejected with alarm 16778:

"Ring coupling with following axis FAx and leading axis LAx not allowed"

(A ring coupling occurs when a following axis is also a leading axis of its own coupling

module or a leading axis in a series-connected coupling module).

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14.5 Generic coupling

14.5.7

Compatibility

14.5.7.1

Adaptive cycles

The provision of adaptive cycles as fixed component of the NC software ensures a syntactic and

functional compatibility to coupling calls of existing coupling types (coupled motion, master

value coupling, electronic gearbox and synchronous spindle). This means that as long as the

manufacturer/user does not need new coupling characteristics, it is not necessary to modify

present coupling calls and any dependent application components (e.g. PLC evaluation of

coupling signals).

Assignment to existing coupling commands

The number of adaptive cycles corresponds to the number of existing coupling commands. The

assignment is as follows:

Coupling commands

Adaptive cycle

TRAILON

cycle700

TRAILOF

cycle701

LEADON

cycle702

LEADOF

cycle703

COUPDEF

cycle704

COUPON

cycle705

COUPONC

cycle706

COUPOF

cycle707

COUPOFS

cycle708

COUPDEL

cycle709

COUPRES

cycle710

EGDEF

cycle711

EGON

cycle712

EGONSYN

cycle713

EGONSYNE

cycle714

EGOFC

cycle715

EGOFS

cycle716

EGDEL

cycle717

Storage location

Adaptive cycles are stored in the directory "CST".

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14.5 Generic coupling

User-specific adaptive cycles

If necessary (functional completion) the user can copy an adaptive cycle to the directory "CMA"

or "CUS" and apply changes there. When reading adaptive cycles, the sequence CUS → CMA →

CST is observed and cycle variants are taken over on a first found basis, i.e. the adaptive cycles

copied into the directory CMA / CUS by the user are selected on a priority basis.

Note

When upgrading the NC software, a log file is saved in the "CST" directory (Changelog),

indicating necessary changes of the adaptive cycles.

14.5.7.2

Coupling types (CPSETTYPE)

Coupling types

If presetting of coupling types (coupled motion, master value coupling, electronic gearbox and

synchronized spindle) is required, when creating the coupling module (CPON/CPLON or CPDEF/

CPLDEF), the keyword CPSETTYPE needs to be used also.

Programming

Syntax:

CPSETTYPE[FAx]= <value>

Designation:

Coupling Set Type

Functionality:

Defines the presettings of coupling characteristics (coupling type).

Value:

Type: STRING

Range of values:

"CP"

Freely programmable

"TRAIL"

Coupling type "Coupled motion"

"LEAD"

Coupling type "Master Value Coupling"

"EG"

Coupling type "Electronic gearbox"

"COUP"

Coupling type "Synchronized spindle"

Default value:

"CP"

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Example:

Program code

Comment

CPLON[X2]=(X1) CPSETTYPE[X2]="LEAD"

; Creates a coupling module for following

axis X2 with leading axis X1 and acti-

vates the coupling module. Coupling prop-

erties are set such that they correspond

to the existing master value coupling

type.

Default settings

Presettings of programmable coupling characteristics for various coupling types can be found in

the following table:

Keyword

Coupling type

Default

Coupled motion

Master value cou-

Electronic gear

Synchronous

(CP)

(TRAIL)

pling

(EG)

spindle

(LEAD)

(COUP)

CPDEF

CPDEL

CPLDEF

CPLDEL

CPON

CPOF

CPLON

CPLOF

CPLNUM

1.0

CPLDEN

1.0

CPLCTID

Not set

CPLSETVAL

CMDPOS

CPFRS

BCS

MCS

CPBC

NOC

FINE

IPOSTOP

CPFPOS + CPON

Not set

CPFPOS + CPOF

Not set

CPFMSON

CFAST

CCOARSE

NRGT

CFAST

CPFMON

STOP

VL¹⁾: STOP

VL¹⁾: CONT

STOP

CONT

HL²⁾: CONT

CPFMOF

STOP

VL¹⁾: STOP

STOP

CONT

HL²⁾: STOP

CPLPOS + CPON

Not set

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Keyword

Coupling type

Default

Coupled motion

Master value cou-

Electronic gear

Synchronous

(CP)

(TRAIL)

pling

(EG)

spindle

(LEAD)

(COUP)

CPMRESET

NONE

MD20110

CPMSTART

NONE

MD20112

CPMPRT

NONE

MD20112 /

MD22620³⁾

CPLINTR

0.0

CPLINSC

1.0

CPLOUTTR

0.0

CPLOUTSC

1.0

CPSYNCOP

MD37200

CPSYNFIP

MD37210

CPSYNCOP2

MD37202

CPSYNFIP2

MD37212

CPSYNCOV

MD37220

CPSYNFIV

MD37230

CPMBRAKE

Bit 0

CPMVDI

Bit 3

Bit 4

Bit 5

Bit 6

CPMALARM

MD11410

MD11415

Legend:

¹⁾Pre-processing

²⁾Main run

³⁾depends additionally on MD22621

- not relevant or not allowed

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Additional properties

Value ranges or availability of additional properties of a set coupling type (CPSETTYPE) can be

found in the following table:

Default

Coupled motion

Master value

Electronic gear

Synchronous spin-

(CP)

(TRAIL)

coupling (

(EG)

dle

LEAD)

(COUP)

Number of

≦ 5

≦ 2

≦ 5

leading axes

Following axis

Axis/spindle

Spindle

type

Defining/delet-

CPDEF/CPDEL

CPON/CPOF

CPDEF/CPDEL

ing coupling

module

CPON/CPOF

Defining/delet-

CPLDEF/CPLDEL

CPLON/CPLOF

CPLDEF/CPLDEL

ing leading axis

CPLON/CPLOF

Cascading

+/-

Dynamic obser-

+/-

vation

of the leading

spindle

Implicit selec-

+/-

tion/deselec-

tion of state

control¹⁾

Legend:

¹⁾See also Chapter "Synchronous spindle (Page 489)"

- not relevant or not allowed

Availability of the specified characteristics depends on the available version (see Section

"Requirements (Page 609)").

Example:

The coupled motion coupling type (CPSETTYPE="TRAIL") allows a maximum of two leading

axes and cascading. However, this is not available in the basic version, but requires the CP-

EXPERT option.

Constraints

• CPSETTYPE can be programmed in synchronized actions.

• If the coupling type (CPSETTYPE) is set, certain coupling characteristics are preset and

cannot be changed. Subsequent change attempts with keywords cause an error and are

rejected with an alarm:

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CPSETTYPE=

TRAIL

LEAD

COUP

CPDEF

Alarm 16686

CPDEL

Alarm 16686

CPLDEF

CPLDEL

CPON

Alarm 16686

CPLON

CPOF

Alarm 16686

CPLOF

CPRES

Alarm 16686

CPLNUM

Alarm 16686

CPLDEN

Alarm 16686

CPLCTID

Alarm 16686

CPLSETVAL

Alarm 16686

with CMDVEL

CPFRS

Alarm 16686

with BCS

CPBC

Alarm 16686

CPFPOS + CPON

Alarm 16686

CPFPOS + CPOF

Alarm 16686

CPFMSON

Alarm 16686

CPFMON

Alarm 16686

with ADD/STOP

with STOP

CPFMOF

Alarm 16686

with ADD/STOP

with ADD

CPLPOS + CPON

Alarm 16686

CPMRESET

Alarm 16686

CPMSTART

Alarm 16686

CPMPRT

Alarm 16686

CPMBRAKE

Alarm 16686

Number of leading

Alarm 16672

axes (∑ LA)

with ∑ LA > 2

with ∑ LA > 1

with ∑ LA > 5

with ∑ LA > 1

Following axis type

Alarm 14092

with axis

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14.5.7.3

Projected coupling (CPRES)

If the coupling type "Synchronous spindle" is set, (see CPSETTYPE), the coupling properties

contained in machine data can be activated instead of the programmed coupling properties.

Further information

Synchronous spindle (Page 489)

Programming

Syntax:

CPRES= (<following spindle>)

Designation:

Coupling Restore

Functionality:

Activates projected data of the synchronous spindle coupling to following

spindle FAx.

Following spindle: Type: AXIS

Value range:

All defined spindle names in the channel

Example:

Programming

Comment

CPLON[S2]=(S1) CPSETTYPE[S2]="COUP"

; Creates a coupling module for follow-

ing spindle S2 with leading spindle S1

and activates the coupling module. Cou-

pling properties are set such that they

correspond to the existing synchronous

spindle coupling type.

CPRES=(S2)

; Activates projected data of the syn-

chronous spindle coupling to following

spindle S2.

Boundary conditions

• CPRES is only allowed when the coupling type "Synchronous spindle"

(CPSETTYPE="COUP") is set.

• Application of CPRES to an already active coupling results in a new synchronization.

• Applying CPRES to an undefined coupling module does not result in any action.

14.5.8

Cross-channel coupling, axis replacement

The following and leading axes must be known to the calling channel.

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Following axis

The following axis is requested for replacement in the channel when programming a CP keyword

in the part program, depending on the axis replacement projection (MD30552) with the

language command GETD.

Axis change of the following axis after activating the coupling module is only permitted in the

channel. Changing from channel to main run and vice versa is still possible, however a change

across channel boundaries is not. Supplementary conditions and properties still apply to axis

change. The axis replacement via channel axes is released again after deactivating the coupling

module.

Further information

Function Manual Basic Functions; Mode groups, channels, axis replacement

Leading axes

Axis change of leading axes can be performed independently of the state of the coupling.

14.5.9

Behavior with rotary axes

Rotary axes as leading or following axes

It is possible to couple rotary axes to a linear axis and vice versa. Note that a direct assignment

of degrees to mm must be performed using the coupling rule.

Example:

A = Rotary axis, X = Linear axis

Programming

Comment

N10 G0 A0 X0

; Traverse motion:

X = 0 mm, A = 0 degrees

N20 CPON=(A) CPLA[A]=(X) CPLNUM[A,X]=2

; A coupling module for rotary ax-

is A with linear axis X as lead-

ing axis is created and activa-

ted. The coupling value is 2.

N30 X100

; Traverse motion:

X = 100 mm, A = 200 degrees (=

100*2)

Modulo reduced rotary axes as leading axes

With modulo reduced rotary axes as leading axes, the input variable is not reduced during the

reduction of the leading axis. The non-reduced position is still taken as the input variable, i.e. the

traversed distance is considered.

Example:

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A = Modulo reduced rotary axis, X = Linear axis

Programming

Comment

N10 G0 A0 X0

; Traverse motion:

X = 0 degrees, X = 0 mm

N20 CPON=(X) CPLA[X]=(A) CPLNUM[X,A]=0.5

; A coupling module for linear ax-

is X with rotary axis A as lead-

ing axis is created and activa-

ted. The coupling value is 0.5.

N30 A200

; Traverse motion:

A = 200 degrees, X = 100 mm

(= 200*0.5)

N40 A=IC(200)

; A traverses through 200 degrees

in a positive direction to 400

degrees, Display A = 40. X tra-

verses through 100 mm to 200.

N50 A=IC(100)

; A traverses from 40 degrees to

140 degrees, X traverses through

additional 50mm to 250.

N60 A=ACP(80)

; A traverses in the positive di-

rection to 50 degrees, the tra-

versing path is 300 degrees in

the positive direction. X traver-

ses correspondingly by 150 mm in

the positive direction. The end

position is therefore X = 400.

'PMMPXJOH BYJT

3FEVDUJPO PG MFBEJOH BYJT CZ

-FBEJOH BYJT "

Figure 14-12

Example: Modulo reduced rotary axis to linear axis

(...)

Position indication for X, A

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14.5.10

Behavior during POWER ON, ...

Power on

No coupling is active at power ON. Coupling modules are not available.

RESET

The behavior on RESET can be set separately for each coupling module (see CPMRESET). The

coupling can be activated, deactivated or the current state can be retained.

Mode change

The coupling remains active during a mode change. The coupling is suppressed (not

deselected!) only in JOG-REF mode when referencing a following axis.

Reference point approach

G74 of the following axis is not possible with an active coupling. An alarm is output.

If the JOG-REF mode is selected and the following axis is traversed, the coupling is suppressed.

The coupling is only performed after JOG-REF mode is cancelled.

SERUPRO

The SERUPRO procedure will simulate the generic coupling and provide values for a restart.

With axial couplings, the simulation always assumes a setpoint coupling, which means, when

there is an actual value coupling, this is switched to setpoint coupling during the SERUPRO

procedure. This can mean that the simulation is not performed correctly.

Further deviations from the real procedure can occur due to increased simulation speed and

canceled axis dynamics limitations.

14.5.11

CP SW limit monitoring

14.5.11.1

Function

What is the purpose of the function?

The "CP-SW limit monitoring" function improves the braking response of a following axis or a

following spindle in axis operation when approaching a software limit switch.

Advantages:

• This avoids that the software limit switch is passed.

• If possible, synchronous operation of the coupling is kept.

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Availability

The "CP SW limit monitoring" function can only be activated for following axes from:

• Generic couplings, type "Freely programmable" (CPSETTYPE[FAx] = "CP")

• Couplings (generic coupling with CPSETTYPE[FAx] not equal to "CP", coupled motion,

electronic gearbox, master value coupling or synchronous spindle) with a maximum of one

active leading axis/spindle

In all other cases (and in the event of non-activation of the "CP SW limit monitoring") the previous

function of the software limit switch monitoring is in effect.

Monitoring and setting the brake

The "CP-SW limit monitoring" function checks, in every IPO cycle, as to whether the movement

of the following axis/spindle can be enabled for the following IPO cycle, so that the axis can

always stop in plenty of time before the software limit switch. If this is not the case, for the

following axis, a "CP-SW limit stop" is set; this signifies unconditional direction-specific braking

along the contour.

Transferring the brake to the axes

Setting the brake means that the coupling-independent motion component (CMD and CORR

component) of the following axis is stopped. On the other hand, the coupling-dependent

motion component (DEP component) of the following axis can only be braked by braking the

leading axes.

For couplings (generic coupling with CPSETTYPE[FAx] not equal to "CP", coupled motion,

electronic gearbox, master value coupling or synchronous spindle) with a maximum of one

active leading axis/spindle, the brake is also set for the (only) active leading axis in the collision

direction (depending on the coupling factor).

For generic couplings, type "freely programmable" (CPSETTYPE[FAx] = "CP"), the brake is only

transferred to all of the active leading axes, if the coupling property CPMBRAKE[FAx] Bit 0 = 1 has

been programmed (see "Reaction to stop signals and commands (CPMBRAKE) (Page 651)").

The collision direction depends on the coupling factor for the specific leading axis: With a

negative coupling factor, the collision direction reverses, there is no transfer for a coupling factor

of "zero". For non-linear couplings (e.g. curve table), the coupling factor is derived from the

gradient, determined as linear approximation.

Note

A brake set for a following axis can only influence its leading axes as long as the coupling is active.

Braking behavior

The normal acceleration ramp is used when braking the axes towards the software limit switch

along the contour, maintaining the coupling definition.

When braking, the stop state 75 "brake request" and situation-dependent, the higher priority

stop states 22 "wait: spindle enable missing", 12 "wait for axis/spindle release" or 71 "wait for

enable, transformation axis" are displayed.

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If the following axis is stationary as result of the "CP-SW limit stop", and cannot approach the

software limit switch any closer, then the following alarm is displayed:

10625 "%?C{channel %1: %}block %3 following axis/spindle %2 with CP-SW limit stop %4"

This means that up to the "final" stopping position, the situation can be somewhat relieved by

moving the following axis in the opposite direction.

Note

For the "CP-SW limit monitoring", coupling involves maintaining synchronous operation. As a

consequence, it cannot be guaranteed that the axis stops at precisely the correct position, if the

coupling rule is to be maintained. If the brake is to be transferred to the leading axes, and the

interpolators brake as required, then the leading axis comes to a standstill in front of the

software limit switch. The maximum distance to the software limit switch is then obtained from

the actual maximum acceleration rate of the following axes multiplied by the square of the

interpolation cycle time.

Retraction

The user is responsible for retraction.

For diagnostic purposes, there are:

• the stop state 75 "brake request"

(if an axis has a travel command, but stops or may not traverse as a result of a braking request)

• and the system variables:

$AA_BRAKE_STATE (actual brake status)

$AA_BRAKE_CONDB (context-sensitive conditions for the interpolator stop in the BCS)

$AA_BRAKE_CONDM (context-sensitive conditions for the interpolator stop in the MCS)

including the OPI variables aaBrakeState, aaBrakeCondB and aaBrakeCondM derived from

these.

Example for retraction:

1. acknowledge alarm 10625.

2. Switch to the JOG mode.

3. Traverse the leading axis using the traversing keys so that the following axis moves away from

the software limit switch.

14.5.11.2

Parameterization

Activation

The "CP SW limit monitoring" function is activated on an axis-for-axis basis using machine data:

MD30455 $MA_MISC_FUNCTION_MASK (axis functions)

Bit

Value

Meaning

CP SW limit monitoring is not active.

CP SW limit monitoring is active.

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14.5.11.3

Programming

Transferring the brake to the leading axes

For generic couplings, type "freely programmable" (CPSETTYPE[FAx] = "CP"), by programming

the coupling property CPMBRAKE (see "Reaction to stop signals and commands (CPMBRAKE)

(Page 651)") it can be set as to whether the brake of the following axis, initiated using the "CP-

SW limit monitoring" function, should also be transferred to the leading axes.

14.5.11.4

Boundary conditions

Possible fault sources

If the axes do not brake as required, this could be due to the following reason:

At least one leading axis does not react to the brake, because it is also a leading axis in its own

right (cascade), and the brake is not transferred to its leading axes. A brake is only transferred to

the leading axes (recursive), if the following applies for the following axes involved:

CPSETTYPE[FAx] = "CP" and CPMBRAKE[Fax] bit 0 = 1

Even if all of the axes brake as required, the contour can be violated as a result of different

acceleration rates and/or coupling factors if these values have not been appropriately

configured and/or programmed.

Even if all of the previous preconditions are fulfilled, there are still some reasons why it cannot

be avoided that a following axis passes a software limit switch:

• The actual maximum acceleration of a leading axis changes.

• The actual maximum acceleration of the following axis becomes smaller.

• The velocity of the following axis when switching in the coupling or when the CP-SW limit

monitoring responds is already so high that with the actual

maximum acceleration it is no longer possible to stop the axis in the appropriate time.

If the axis cannot be stopped in the appropriate time, then as before, the previous software limit

switch monitoring responds, and stops the following axis at the software limit switch.

Braking response for transformations

If the axis to be braked is the output of a transformation, and it has a (MCS) travel command in

the collision direction, then the brake is transferred to all input axes of the transformation in both

directions, and a path stop is executed for this transformation. However, the following

exceptions apply: It does not apply to the independent axes of the transformation. For

TRANSMIT and TRAANG, these are the axes specified in machine data

$MC_TRAFO_AXES_IN_*[2]. For the transformations, braking is only transferred to their

dependent input axes.

DRF offset

Setting a CP-SW limit stop can cause a DRF movement to be canceled, as shown in the following

example:

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The basic motion is path motion with extremely low velocity in the positive direction. A larger

DRF correction motion applies to this in the opposite direction. This results in a travel command

in the negative direction. If these movements are now stopped using a CP-SW limit stop, then for

standard machine data, this means that DRF motion is canceled, and only path motion is

continued after the stop is withdrawn.

NCU link

The following restriction must be taken into account for cross-NCU couplings based on lead-link

axis and axis container:

As the leading axis can be interpolated on another NCU, it can take between one and two IPO

cycles for the brake to be transferred to the NCU of the leading axis.

14.5.11.5

Examples

Example 1: Generic coupling type "freely programmable" (CPSETTYPE[FAx] = "CP")

Configuration:

MD26110 $MA_POS_LIMIT_PLUS[AX2]=15 ;

Position of the 1st software limit

switch of the following axis for the

traversing range limit in the positive

direction

MD30455 $MA_MISC_FUNCTION_MASK[AX2] = 'H800' ; Bit 11 = 1 (CP-SW limit monitoring is

activated)

Programming:

; start position of X and Y

N100 G0 X0 Y0

; coupling activation FA=Y LA=X

; set with CPMBRAKE bit 0 (transfer of the brake to the leading axis)

N120 CPON=Y CPSETTYPE="CP" CPLA=X CPLDEN=2 CPMBRAKE B_OR='H1'

N140 G4 F2

; traverse leading axis X

N200 G1 X=1000 F1000

Example 2: Couplings with a maximum of one active leading axis/spindle

With the following calls, the CP-SW limit monitoring is executed - including the transfer of the

brake to the leading axis - if MD30455 MA_MISC_FUNCTION_MASK[AX2] bit 11 is set:

TRAILON(Y,X,0.5) ;

Definition and switching in the coupling of the coupled motion

axis Y two leading axis X.

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EGDEF(Y,X,1) ;

Definition of an EG axis group with setpoint coupling

from X to Y (following axis).

EGON( Y,"FINE",X,1,2) ;

Activating coupling.

14.5.12

Disturbance characteristic

14.5.12.1

Rapid stop

Function

The rapid stop stops the axis / spindle without ramp, i.e. the velocity setpoint value is specified

as zero. This default applies the brakes at the current limit. The servo enable is retained.

The rapid stop is set at:

• Stop A and Stop C (Safety Integrated)

• Alarms with rapid stop as configured braking behavior

• Reaching the hardware limit switch and rapid stop as configured braking behavior:

MD36600 $MA_BRAKE_MODE_CHOICE = 1

Switchover to actual-value coupling.

The actual values of the leading spindle are used to calculate the setpoint values as soon as the

rapid stop of the leading spindle is reported to a generic coupling.

The changeover to actual value coupling takes place smoothly and remains active till the servo

enable as well as the pulse enable is available again to the leading spindle and no more position

offset takes place. The setpoint value calculation is programmed as with CPLSETVAL only if

these conditions are fulfilled.

Note

A rapid stop that was initiated on reaching the hardware limit switch does not changeover the

actual value coupling.

Response of the following spindle

If a rapid stop is detected for a leading spindle and the following spindle does not execute any

rapid stop by itself, then the following spindle tries to follow the dynamics of the movement of

the leading spindle defined within its framework. As position synchronization is generated,

there may be oscillations in the following axis in relation to the position to be approached.

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The start of a rapid stop for a leading axis/spindle is detected across NCUs.

Note

A simultaneous rapid stop of the leading and following spindle is executed in the synchronized

spindle coupling type (CPSETTYPE="COUP") during a servo alarm.

14.5.13

Tracking the deviation from synchronism

14.5.13.1

Fundamentals

Deviation from synchronism

Workpiece machining operations which are to be carried out both on the face front and the face

rear require a workpiece transfer to another workpiece receptacle (e.g. a counterspindle chuck).

When workpieces are transferred from front to rear machining, a position offset may result from

the closing of the workpiece receptacle. This could be down to square-edged workpieces or due

to the generation of an angular momentum when the workpiece receptacle (chuck) is closed

quickly during a movement. Depending on the resistance of the workpiece, the tension can be

detected by means of an increase in the current consumption of both the motors involved in the

coupling and/or by means of the workpiece being subjected to torsion.

This could lead to the following NC/PLC interface signals being reset, according to the

synchronism tolerance which has been set, and the magnitude of the offset:

DB31, ... DBX98.1 (coarse synchronous operation) and/or

DB31, ... DBX98.0 (fine synchronous operation)

For the setpoint coupling, the position and velocity setpoints are calculated precisely in

accordance with the programmed coupling rule and output to the Control Units. If identical

drives and a rigid workpiece are used, this will lead to a regulative deviation at the leading and

following spindle, half due to a setpoint difference and half due to an actual value difference.

Function

The "track the deviation from synchronism" function serves to detect the position offset which

has been imposed on the actual value and to correct the following spindle when calculating the

setpoint.

Requirement

A coupling closed via the part/chuck must be in place in order to use this function.

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Versions

There are two different options for determining the deviation from synchronism:

1. The deviation from synchronous operation is determined by the NC (see "Measuring the

deviation from synchronism (Page 675)").

2. The deviation value is already known and entered by the user directly (see "Entering the

deviation from synchronism directly (Page 678)").

In both cases, the deviation value is then incorporated into the setpoint value calculation for the

following spindle, as a correction value.

Availability

The "track the deviation from synchronism" function was developed for machine couplings

(CPFRS="machine"). This means that it is also available for the "synchronous spindle"

coupling type (CPSETTYPE="COUP").

Like the other higher-level movements, the availability of the function (e.g. speed difference)

depends on the option (see "Requirements (Page 609)").

14.5.13.2

Measuring the deviation from synchronism

The controller measures the difference between the setpoint positions and actual positions

when the following spindle is operating in synchronism. This results in a correction value, which

is saved in a system variable.

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Requirements

The following requirements must be met to enable the controller to calculate the correction

value:

•

Requirements if the set coupling type is "synchronous spindle" (CPSETTYPE="COUP"):

- The coupling has precisely one leading spindle (requirement is met

if CPSETTYPE="COUP").

- The coupling factor (quotient from CPLNUM and CPLDEN) is 1 or -1.

- The following value is derived from the setpoint position ("DV") or the actual position

("AV") of the leading spindle.

- Setpoint synchronism must be achieved:

DB31, ... DBX99.4 (synchronization running) = 0

- Setpoint synchronism must not decline again.

- No overlaid movement (DB31, ... DBX98.4 = 0) must be present.

- A dynamics limit is required for the leading spindle, in order to exclude the possibility of

the following spindle being subjected to excessive demands.

•

Requirements for a free generic coupling with CPFRS="machine":

- The configured spindles are coupled.

- The coupling has precisely one leading spindle.

- The coupling factor (quotient from CPLNUM and CPLDEN) is 1 or -1.

- The following value is derived from the setpoint position (CPLSETVAL="CMDPOS") or

the actual position (CPLSETVAL="ACTPOS") of the leading spindle.

- Setpoint synchronism must be achieved:

DB31, ... DBX99.4 (synchronization running) = 0

- Setpoint synchronism must not decline again.

- No overlaid movement (DB31, ... DBX98.4 = 0) must be present.

- A dynamics limit is required for the leading spindle, in order to exclude the possibility of

the following spindle being subjected to excessive demands.

Note

Dynamics limit for the leading spindle

The "dynamics limit for the leading spindle" property is specified automatically when the

"synchronous spindle" coupling type (CPSETTYPE="COUP") is set. In the case of other coupling

types, it is the particular responsibility of the user/machine manufacturer to provide suitable

measures to ensure that the following spindle cannot become dynamically overloaded.

Activation

Measuring and tracking of the deviation from synchronism are activated by setting the following

NC/PLC interface signal to "1":

DB31, ... DBX31.6 (track synchronism)

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The signal only has an effect on the following spindle.

Note

In the following cases, signal DB31, ... DBX31.6 (track synchronism) is ignored:

• Axis/spindle disable is active (DB31, ... DBX1.3 = 1).

• Program test is selected.

• SERUPRO is active.

If one of these situations arises when the "track the deviation from synchronism" function is

already active, the function will be deactivated.

Time when measurement is performed

The time when the measurement is performed and the correction value is calculated depends

on the bit 7 setting made in the following item of machine data:

MD30455 $MA_MISC_FUNCTION_MASK (axis functions)

Bit

Value

Meaning

The correction value is calculated continuously, as long as the NC/PLC interface signal

DB31, ... DBX31.6 (track synchronism) is set and setpoint synchronism is active (cyclic

calculation).

The correction value is only calculated at the time when the NC/PLC interface signal

DB31, ... DBX31.6 (track synchronism) changes from 0 to 1 (edge evaluation).

Note

If a temporal extension is taken into account when relieving the tension between the leading

and the following spindle, bit 7 should be set to 0. The interface signal is then state-controlled.

The time required to relieve the tension can depend on various factors (e.g. K_V factor of position

control, accelerating power of the motors) and must be determined by way of experiment.

Measuring sequence

The NC/PLC interface signal DB31, ... DBX31.6 (track synchronism) can only become effective

once setpoint synchronism has been achieved:

DB31, ... DBX99.4 (synchronization running) = 0

The actual values of the following spindle are read within the interpolation cycle and the

difference between them and the setpoint position is calculated, either for as long as signal

DB31, ... DBX31.6 is activated, or just once on that signal's rising edge (the frequency will

depend on the setting of bit 7 in MD30455; see the section titled "Time when measurement is

performed").

The correction value is the difference between the setpoint and actual-value synchronism

positions. This value is saved for the corresponding following spindle in the following system

variable:

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$AA_COUP_CORR[S<n>] (following spindle: correction value for synchronous spindle coupling)

Note

You must ensure that the velocity of the leading and following axes is kept as constant as

possible and that no acceleration jump occurs for the duration of the measurement.

Example

When the coupling of the synchronous spindle [S2] is activated, a position offset of 77 degrees

is also programmed:

CPON=S2 ... CPFPOS[S2]=AC(77)

When the workpiece receptacle is closed, this results in a mechanical position offset, which leads

to an actual-value position offset of 81 degrees.

When the "track the deviation from synchronism" function is activated (DB31, ... DBX31.6 = 1)

and setpoint synchronism has been achieved (DB31, ... DBX99.4 = 0), the actual-value position

offset ($VA_COUP_OFFS[S2] = 81) is compared with the setpoint position offset

($AA_COUP_OFFS[S2] = 77). This results in a correction value of 4 degrees, which is saved in

system variable $AA_COUP_CORR[S2].

14.5.13.3

Entering the deviation from synchronism directly

If the deviation value is known, it can be written directly to the system variable $AA_COUP_CORR

for the corresponding following spindle. This is executed via a part program or synchronized

action.

Note

Please note that the system variable can only be written once the mechanical coupling has been

created. Otherwise a new offset may arise when closing the chuck.

Requirements

To enable the system variable $AA_COUP_CORR to be written from the part program or

synchronized actions, a generic machine coupling must have been activated at least once for the

corresponding following spindle since the most recent controller power-up was performed.

14.5.13.4

Synchronism correction

If correction value $AA_COUP_CORR[S<n>] is a value other than zero and a generic machine

coupling has been active for following spindle S<n> (by means of CPFRS="machine"

or CPSETTYPE="COUP"), the following NC/PLC interface signal is set:

DB31, ... DBX103.0 (synchronism correction is taken into account)

The correction value is incorporated into the setpoint value calculation for the following spindle,

in the coupling module. Resetting the setpoint by the coupling offset relieves the tension

between the leading and following spindles.

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The synchronism signals are produced by comparing the actual values with the corrected

setpoints. Once a correction process has been undertaken, the synchronism signals should be

present again:

DB31, ... DBX98.1 (coarse synchronism) and/or

DB31, ... DBX98.0 (fine synchronism)

The correction value can be implemented and the synchronism signals produced as well, since

the whole point of the "tracking the deviation from synchronism" function is to improve

synchronism when tension is present. When implementing this value, the accelerating power is

restricted to no more than 10% of the maximum acceleration and velocity.

When $AA_COUP_CORR[S<n>] has been implemented in full, the following NC/PLC interface

signal is set:

DB31, ... DBX99.2 (synchronism correction implemented)

This still applies even if $AA_COUP_CORR[S<n>] is zero and no correction needs to be

implemented.

When synchronism correction is complete, the NC/PLC interface signal DB31, ... DBX31.6 (track

synchronism) must be reset to "0" in order to restore the rigidity of the coupling.

The correction value is not changed again once signal DB31, ... DBX31.6 has been reset or once

the coupling has been deactivated (with CPOF). The system variable $AA_COUP_CORR[S<n>]

then returns a constant value.

The correction value is taken into account until it is reset by setting system variable

$AA_COUP_CORR[S<n>] to "0", which must be done, at the very latest, once the workpiece is

removed from the spindle.

Note

The setpoint correction by means of the system variable $AA_COUP_CORR[S<n>] impacts on all

subsequent following spindle programming in the same way as a position offset, similar to a DRF

offset in the machine.

14.5.13.5

Diagnostics for synchronism correction

The current value of $AA_COUP_CORR (correction value for tracking the deviation in

synchronism) is displayed in the "Axis/Spindle Service" window, under the "Position offset for the

leading axis/spindle setpoint" line, for the purposes of diagnostics.

System variable $AA_COUP_CORR_DIST ($AA_COUP_CORR distance-to-go) can be used to

determine how much of the correction value is still be implemented.

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14.5.13.6

Resetting synchronism correction

Versions

Synchronism correction can be reset in the following ways:

• Writing value "0" to variable $AA_COUP_CORR[S<n>].

Synchronism correction is suppressed via a ramp with reduced accelerating power (just as

when a correction value is implemented).

• Resetting synchronism correction via the PLC.

On the rising edge of the NC/PLC interface signal:

DB31, ... DBX31.7 (reset synchronism correction)

, the variable $AA_COUP_CORR[S<n>] is set to zero and synchronism correction is reset as

follows:

- If the spindle is in speed control mode, the correction movement is stopped. The existing

synchronism correction is then transferred to the setpoint position.

- In all other cases, the synchronism correction that has already been implemented is reset

in exactly the same way as when variable $AA_COUP_CORR[S<n>] is set to zero.

Requirements

A requirement for resetting synchronism correction is that the correction value is not currently

being calculated (see Section "Measuring the deviation from synchronism (Page 675)").

End of the reset procedure

When the reset procedure is complete, the following NC/PLC interface signal is set:

DB31, ... DBX99.2 (synchronism correction implemented)

If the NC/PLC interface signal DB31, ... DBX103.0 (synchronism correction is taken into account)

is also reset, so too can the NC/PLC interface signal DB31, ... DBX31.7 (reset synchronism

correction) be reset.

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14.5 Generic coupling

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Note

If the correction path has not been traversed in full and the NC/PLC interface signal

DB31, ... DBX31.7 (reset synchronism correction) has not been reset, writing to variable

$AA_COUP_CORR[S<n>] will not have any effect.

14.5.13.7

Limitations and constraints

Several following spindles

If a leading spindle has several following spindles, each of these following spindles can be

processed with the axial NC/PLC interface signal DB31, ... DBX31.6 (track synchronism)

separately from one another.

Writing variable $AA_COUP_CORR

System variable $AA_COUP_CORR is only written from the part program or synchronized actions

when a generic machine coupling has been activated for the corresponding axis/spindle at least

once.

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14.5 Generic coupling

Correction value

If the correction value $AA_COUP_CORR is being written via a part program/synchronized action,

as well as being determined due to the "track the deviation from synchronism" function being

activated (DB31, ... DBX31.6 = 1), the most recent event to occur is always the one that takes

effect.

Resetting synchronism correction

Writing correction value $AA_COUP_CORR (via a part program or synchronized action or when

performing a calculation) has no effect when synchronism correction is being reset.

Response to channel/mode group reset

Synchronism correction is not reset in the event of a channel/mode group reset, it is retained

instead.

Response to search for reference and zero mark synchronization

If a search for reference or zero mark synchronization procedure is performed for spindles,

synchronism correction is reset automatically.

The system variable $AA_COUP_CORR must not be set during the search for reference/zero mark

synchronization and, as a result, no measurement may be taken for the deviation from

synchronism either.

Furthermore, the synchronism correction must have been implemented in full before the search

for reference/zero mark synchronization is started.

Response to an interruption

If an interruption occurs (e.g. emergency stop), synchronism correction is reset automatically,

the existing synchronism correction is transferred to the setpoint position, and the NC/PLC

interface signal DB31, ... DBX99.2 (synchronism correction implemented) is set.

If, once the interruption has been dealt with, the generic machine coupling remains active and

the NC/PLC interface signal DB31, ... DBX31.6 (track synchronism) is set, the following applies:

• If the signal is level-triggered (MD30455 $MA_MISC_FUNCTION_MASK, bit 7 = 0), the

deviation from synchronism is measured and written to $AA_COUP_CORR; the setpoints are

corrected accordingly.

• If the signal is edge-triggered (MD30455 $MA_MISC_FUNCTION_MASK, bit 7 = 1) and the

deviation from synchronism is to be measured, a new rising edge of the NC/PLC interface

signal DB31, ... DBX31.6 (track synchronism) needs to be executed.

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14.5.14

Examples

14.5.14.1

Programming examples

Direct switch on/off with one leading axis

A coupling module is created and activated with following axis X2 and leading axis X1. The

coupling factor is 2.

CPON=(X2) CPLA[X2]=(X1) CPLNUM[X2,X1]=2

CPOF=(X2)

; The coupling is deactivated and the created

coupling module is deleted with CPOF.

Direct switch on/off with two leading axes

A coupling module is created and activated with following axis X2 and leading axes X1 and Z.

The coupling factor regarding leading axis X1 is 2, the coupling factor regarding leading axis Z

is 3.

CPON=(X2) CPLA=(X1) CPLNUM[X2,X1]=2 CPLA=(Z) CPLNUM[X2,Z]=3

CPOF=(X2)

; The coupling is deactivated and the created

coupling module is deleted with CPOF.

Selective switch-off with two leading axes

A coupling module is created and activated with following axis Y and leading axes X and Z. The

coupling factor regarding leading axis X is 2, the coupling factor regarding leading axis Z is 1.2.

CPON=(X2) CPLA[X2]=(X1) CPLNUM[X2,X1]=2 CPLA[X2]=(Z) CPLNUM[X2,Z]=1.2

CPOF=(X2) CPLA[X1]=(Z)

; The coupling with leading axis Z is deactiva-

ted with CPOF, the coupling with leading axis

X1 is retained. The created coupling module

remains created.

Selective switch-on/off with three leading axes

A coupling module is created and activated with following axis X2 and leading axes X1, Z and A.

N10 CPDEF=(X2) CPLA[X2]=(X1) CPLA[X2]=(Z) CPLA[X2]=(A)

N20 CPON=(X2)

; All leading axes become active, i.e. all

contribute a position component accord-

ing to the coupling rule (coupling com-

ponent) to axis X2.

N30 CPOF=(X2)

; All leading axes are deactivated.

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14.5 Generic coupling

N40 CPLON[X2]=(X1)

; Leading axis X1 is activated, only this

axis supplies a coupling component.

Leading axes Z and A remain deactivated.

N50 CPLON[X2]=(A)

; Leading axis X1 remains active, leading

axis A is deactivated, X1 and A contrib-

ute coupling components (→ selective

switch-on is additive, the condition of

the other leading axes is retained).

N60 CPLON[X2]=(Z) CPLOF[X2]=(A)

; Leading axis Z is activated, leading ax-

is A deactivated. Leading axes X 1and Z

are now active.

N70 CPLOF[X2]=(X1)

; Leading axis X1 is deactivated. Leading

axis Z remains active.

Definition/deletion of a coupling module

With CPDEF a coupling module is created and activated with following axis X2 and leading axes

X1 and Z. The coupling is not activated. Following axis X2 does not follow the coupling rule!

CPDEF=(X2) CPLA[X2]=(X1) CPLNUM[X2,X1]=2 CPLA[X2]=(Z) CPLNUM[X2,Z]=3

Activation can be done with CPON, deactivation with CPOF.

After the deactivation of the coupling relationship to all leading axes, the coupling object can be

deleted. Reserved memory is released:

CPDEL=(X2)

14.5.14.2

Adapt adaptive cycle

Target

Coupled motion in the machine co-ordinate system must be possible with the existing coupling

command TRAILON. The adaptive cycle for TRAILON is supplemented with the coupling

characteristic "Co-ordinate reference" (CPFRS).

Procedure

1. Copy adaptive cycle 700 from directory "CST" to directory "CMA".

2. Supplement cycle 700 with the following entry:

CPFRS[_FA]="MCS"

3. Comment to cycle changes (e.g. user version number and change date).

4. Save cycle.

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14.6 Dynamic response of following axis

;*CHANGE : 07.01.02.00 Mar 08, 2006

;$PATH=/_N_CST_DIR/_N_CYCLE700_SPF

;USER V1.1 Mar 22, 2006

;classic TRAILON(FA,LA,Factor)

PROC CYCLE700(AXIS _CPF=NO_AXIS, AXIS _CPL=NO_AXIS,REAL _CPLF=1) IPTRLOCK SBLOF DISPLOF ICYCOF

;*IF _CPLF==0 GOTOF _CPOF

CPLON[_CPF]=(_CPL) CPSETTYPE[_CPF]="TRAIL" CPLNUM[_CPF,_CPL]=(_CPLF) CPFRS[_CPF]="MCS"

RET

_CPOF:

IF ($P_TECCYCLE==TRUE)

IF ($AA_CPSETTYPE[_CPF]<>"TRAIL") GOTOF _EXIT

ELSE

IF ($PA_CPSETTYPE[_CPF]<>"TRAIL") GOTOF _EXIT

ENDIF

IF _CPL==NO_AXIS

CPSETTYPE[_CPF]="TRAIL" CPOF=(_CPF)

ELSE

CPSETTYPE[_CPF]="TRAIL" CPLOF[_CPF]=(_CPL)

ENDIF

_EXIT: RET

;* SysError 500918 therefore IF command commented

Figure 14-14

Cycle 700 after adaption. Changes are indicated by a colored bar.

14.6

Dynamic response of following axis

14.6.1

Parameterized dynamic limits

The dynamics of the following axis is limited with the following machine data values:

MD32000 $MA_MAX_AX_VELO (maximum axis velocity)

MD32300 $MA_MAX_AX_ACCEL (Maximum axis acceleration)

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14.6 Dynamic response of following axis

14.6.2

Programmed dynamic limits

14.6.2.1

Programming (VELOLIMA, ACCLIMA)

Reducing or increasing dynamics limits

The dynamic limits of the following axis (FA) specified through MD32000 and MD32300 can be

reduced or increased from the part program:

Command

Meaning

VELOLIMA[FA]

Reducing or increasing the maximum Axis velocity

ACCLIMA[FA]

Reducing or increasing the maximum Axis acceleration

The values specified during the programming of VELOLIMA[FA] and ACCLIMA[FA] are

process values. They define the proportion with which the parameterized dynamic limits

(MD32000 and MD32300) are to be considered:

Range of values

Meaning

1 ≤ value < 100

effects a Reduction in the dynamic limit

100 ≤ value < 200

effects an increase in the dynamic limit

The dynamic limits for the velocity and acceleration of the following axis are then calculated as

follows:

Maximum axis velocity = MD32000 $MA_MAX_AX_VELO * VELOLIMA[FA]

Maximum axis acceleration = MD32300 $MA_MAX_AX_ACCEL * ACCLIMA[FA]

Note

The reduction / increase is effected on the overall dynamics of the axis, i.e., on the sum of the axis

component from overlay and coupling.

Programming in synchronized actions

The possibility of programming VELOLIMA[FA] and ACCLIMA[FA] in synchronized actions

depends on the coupling type:.

Coupling type

Part program

Synchronized actions

Tangential correction

Coupled motion

Master value coupling

Electronic gearbox

Synchronous spindle

Generic coupling

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14.6 Dynamic response of following axis

Synchronization between following and leading axes

The acceleration characteristics set and the dynamics offsets set change the duration for

synchronization between following and leading axes during acceleration operations as follows:

Dynamic offset

Effect

Dynamic reduction

Prolongs the synchronism difference.

The monitoring from leading to following value may exceed the al-

lowed range for extended periods.

Dynamic increase

Shortens the synchronism difference.

The monitoring of leading and following values may exceed the al-

lowed range for short periods.

Note

The user must restore the technological synchronization between machining and the

synchronism difference.

Acceleration mode

Only BRISKA is available for the following axis, i.e., abrupt axis acceleration. Acceleration

modes SOFTA and DRIVEA are not available for the following axes described.

Furthermore, it is also possible to configure the positions controller as a PI controller.

CAUTION

Application faults

This option can only be used in conjunction with servo trace and with the appropriate technical

knowledge of the control.

Further information

• CNC Commissioning Manual: NC, PLC, drive

• Velocities, setpoint/actual value systems, closed-loop control (Page 135)

POWER ON

During POWER ON the values of VELOLIMA and ACCLIMA are initialized to 100%.

Mode change

The dynamic offsets remain valid only on transition from AUTO → JOG mode.

RESET

The validities of the (VELOLIMA and ACCLIMA) dynamic offsets after RESET depend on the

setting in the channel-specific machine data:

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14.6 Dynamic response of following axis

MD22410 $MC_F_VALUES_ACTIVE_AFTER_RESET (F Function is active even after RESET)

Value

Meaning

The values of VELOLIMA[FA] and ACCLIMA[FA] are set to 100% after RESET.

The last programmed values of VELOLIMA[FA] and ACCLIMA[FA] are also active after RESET.

This response also applies for dynamics offsets set using static synchronized actions. If this is not

the case even when MD22410 = 0, then the IDS synchronized action should trigger a repeat or

continuous writing of the dynamic offset.

Further information

Function Manual Synchronized Actions

14.6.2.2

Examples

Electronic gearbox

Axis 4 is coupled to X via an electronic gearbox coupling. The acceleration capability of the

following axis is limited to 70% of maximum acceleration. The maximum permissible velocity is

limited to 50% of maximum velocity. After POWER ON, the maximum permissible velocity is set

to 100% again.

N120 ACCLIMA[AX4]=70

N130 VELOLIMA[AX4]=50

; reduced speed

N150 EGON(AX4,"FINE",X,1,2)

N200 VELOLIMA[AX4]=100

; full speed

Master value coupling

Axis 4 is coupled to X via a master value coupling. The acceleration capability of the following

axis is limited to 80% of maximum acceleration.

N120 ACCLIMA[AX4]=80

; 80%

N130 LEADON(AX4,X,2)

; Activate coupling

Master value coupling with synchronized action

Axis 4 is coupled to X via a master value coupling. The acceleration response is limited to position

80% by static synchronized action 2 from position 100.

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14.7 General supplementary conditions

N120 IDS=2 WHENEVER $AA_IM[AX4] > 100 DO ACCLIMA[AX4]=80

N130 LEADON(AX4,X,2)

14.6.2.3

System variables

For geometry axis, channel axis, machine axis and spindle axis, the following readable system

variables are available in the part program and synchronous actions:

Identifier

Data type

Description

Unit

Preprocessing

$PA_ACCLIMA[n]

REAL

Acceleration offset set with ACCLIMA[Ax]

$PA_VELOLIMA[n]

REAL

Velocity offset set with VELOLIMA[Ax]

Main run

$AA_ACCLIMA[n]

REAL

Acceleration offset set with ACCLIMA[Ax]

$AA_VELOLIMA[n]

REAL

Velocity offset set with VELOLIMA[Ax]

Note

Reading the main run variables, implicitly triggers a preprocessing stop.

14.7

General supplementary conditions

Note

Drive optimization

At a SINAMICS S120 drive unit, a maximum of 3 drives can be optimized or measured at the same

time (speed controller optimization/function generator). Therefore, for a coupling with more

than 3 coupled drives at the same time, we recommend that these are distributed over several

drive units.

Note

Block search with active coupling

For an active coupling, it is recommended to only use block search type 5, "Block search via

program test" (SERUPRO) for a block search.

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14.8 Data lists

14.8

Data lists

14.8.1

Machine data

14.8.1.1

NC-specific machine data

Number Identifier: $MN_

Description

11410

SUPPRESS_ALARM_MASK

Screen form for suppressing special alarm outputs

11415

SUPPRESS_ALARM_MASK_2

Suppress alarm outputs

11660

NUM_EG

Number of possible electronic gears

11750

NCK_LEAD_FUNCTION_MASK

Functions for master value coupling

11752

NCK_TRAIL_FUNCTION_MASK

couple motion functions

18400

MM_NUM_CURVE_TABS

Number of curve tables (SRAM)

18402

MM_NUM_CURVE_SEGMENTS

Number of curve segments (SRAM)

18403

MM_NUM_CURVE_SEG_LIN

Number of linear curve segments (SRAM)

18404

MM_NUM_CURVE_POLYNOMS

Number of curve table polynomials (SRAM)

18406

MM_NUM_CURVE_TABS_DRAM

Number of curve tables in DRAM

18408

MM_NUM_CURVE_SEGMENTS_DRAM

Number of curve segments in DRAM

18409

MM_NUM_CURVE_SEG_LIN_DRAM

Number of linear curve segments (DRAM)

18410

MM_NUM_CURVE_POLYNOMS_DRAM

Number of curve polynomials in DRAM

18450

MM_NUM_CP_MODULES

Maximum number of allowed CP coupling modules

18452

MM_NUM_CP_MODUL_LEAD

Maximum number of allowed CP master values

14.8.1.2

Channelspecific machine data

Number Identifier: $MC_

Description

20110

RESET_MODE_MASK

Definition of control basic setting after run-up and RESET/

part program end

20112

START_MODE_MASK

Definition of control basic setting after run-up and RESET

22620

START_MODE_MASK_PRT

Definition of the control basic settings for special start

22621

ENABLE_START_MODE_MASK_PRT

Activation of MD22620

20900

CTAB_ENABLE_NO_LEADMOTION

Curve tables with jump of following axis

20905

CTAB_DEFAULT_MEMORY_TYPE

Default memory type for curve tables

21300

COUPLE_AXIS_1

Projection synchronous spindle pair

Axes and spindles

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Axis couplings

14.8 Data lists

14.8.1.3

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

30130

CTRLOUT_TYPE

Setpoint output type

30132

IS_VIRTUAL_AX

Axis is virtual axis

30455

MISC_FUNCTION_MASK

Axis functions

35040

SPIND_ACTIVE_AFTER_RESET

Own spindle RESET

37160

LEAD_FUNCTION_MASK

Functions for master value coupling

37200

COUPLE_POS_TOL_COARSE

Threshold value for "Coarse synchronous operation"

37202

COUPLE_POS_TOL_COARSE_2

Second synchronous operation monitoring: Threshold

value for "Coarse synchronous operation"

37210

COUPLE_POS_TOL_FINE

Threshold value for "Fine synchronous operation"

37212

COUPLE_POS_TOL_FINE_2

Second synchronous operation monitoring: Threshold

value for "Fine synchronous operation"

37220

COUPLE_VELO_TOL_COARSE

Velocity tolerance "coarse"

37230

COUPLE_VELO_TOL_FINE

Velocity tolerance "fine"

37500

ESR_REACTION

Reaction definition with extended stop and retract

37550

EG_VEL_WARNING,

Threshold value for speed warning threshold

37560

EG_ACC_TOL

Threshold value for the signal "Axis is accelerating"

14.8.2

Setting data

14.8.2.1

Axis/spindle-specific setting data

Number

Identifier: $SC_

Description

43100

LEAD_TYPE

Definition of master value type

43102

LEAD_OFFSET_IN_POS

Offset of master value with coupling to this axis

43104

LEAD_SCALE_IN_POS

Scaling of master value with coupling to this axis

43106

LEAD_OFFSET_OUT_POS

Offset of the function value of the curve table

43108

LEAD_SCALE_OUT_POS

Scaling of the function value of the curve table

14.8.3

System variables

Electronic gear (EG) and master value coupling

Identifier

Meaning

$AA_EG_ACTIVE

Coupling for leading axis b is active, i.e. switched on

$AA_EG_AX

Name for nth leading axis

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14.8 Data lists

Identifier

Meaning

$AA_EG_DENOM

Numerator of the coupling factor for leading axis b

$AA_EG_NUMERA

Numerator of the coupling factor for leading axis b

$AA_EG_NUMLA

Number of leading axes defined with EGDEF

$AA_EG_SYN

Synchronized position of leading axis b

$AA_EG_SYNFA

Synchronous position of following axis a

$AA_EG_TYPE

Type of coupling for leading axis b

$AA_IN_SYNC[FA]

Synchronization status of the following axis

$AA_LEAD_P

Current leading position value (modulo reduced).

$AA_LEAD_P_TURN

current leading value - position component lost as a result of modulo reduction.

$AA_LEAD_SP

simulated master value - position MCS

$AA_LEAD_SV

Simulated master value - velocity

$AA_LEAD_V

Current leading velocity value

$AA_SYNC

Coupling status of the following axis for leading value coupling.

$P_EG_BC

Block change criterion for EG activation calls: EGON, EGONSYN. WAITC = immediate

synchronism fine or coarse and setpoint synchronous operation.

$VA_EG_SYNCDIFF

Synchronism difference

Generic coupling

Identifier

Meaning

$AA_ACCLIMA

Acceleration correction (main run) set with ACCLIMA

$AA_COUP_ACT

Coupling type of a following axis/spindle

$AA_COUP_CORR

Following spindle - correction value for tracking the deviation in synchronism

$AA_COUP_CORR_DIST

$AA_COUP_CORR distance-to-go

$AA_COUP_OFFS

Setpoint position offset

$AA_CPACTFA

Name of active following axis

$AA_CPACTLA

Name of active leading axis

$AA_CPBC

Block change criterion

$AA_CPDEFLA

Name of defined leading axis

$AA_CPFACT

Coupling type of the following axis/spindle.

$AA_CPFCMDPT

Axis setpoint position for all coupling components

$AA_CPFCMDVT

Axis setpoint speed for all coupling components

$AA_CPFMOF

Behavior of the following axis at switch-off

$AA_CPFMON

Behavior of the following axis at switching on

$AA_CPFMSON

Synchronization mode

$AA_CPFRS

Coupling reference system

$AA_CPLCMDP

Axis setpoint component of the leading axis

$AA_CPLCMDV

Axis setpoint speed component of the leading axis

$AA_CPLCTID

Table number of the active curve table

$AA_CPLDEN

Denominator of the coupling factor

$AA_CPLNUM

Numerator of the coupling factor

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14.8 Data lists

Identifier

Meaning

$AA_CPLSETVAL

Coupling reference of the leading axis

$AA_CPLSTATE

State of the coupling

$AA_CPSYNCOP

Threshold value of position synchronism "Coarse" (main run)

$AA_CPSYNCOV

Threshold value of velocity synchronism "Coarse" (main run)

$AA_CPSYNFIP

Threshold value of position synchronism "Fine" (main run)

$AA_CPSYNFIV

Threshold value of velocity synchronism "Fine" (main run)

$AA_CPLINSC

Scaling factor of the input value of a leading axis (main run)

$AA_CPLINTR

Offset value of the input value of a leading axis (main run)

$AA_CPLOUTSC

Scaling factor of the output value of the coupling (main run)

$AA_CPLOUTTR

Offset value of the output value of the coupling (main run)

$AA_CPLTYPE

Type of coupling

$AA_CPMRESET

State of the coupling after RESET

$AA_CPMSTART

State of the coupling after program start

$AA_CPNACTFA

Number of active following axes

$AA_CPNACTLA

Number of active leading axes

$AA_CPNDEFLA

Number of defined leading axes

$AA_CPSETTYPE

Preset coupling type

$AA_EG_ACTIVE

Coupling for leading axis b is active

$AA_EG_AX

Name for nth leading axis

$AA_EG_BC

Block change criterion

$AA_EG_DENOM

Denominator of the coupling factor

$AA_EG_NUMERA

Numerator of the coupling factor

$AA_EG_NUM_LA

Number of leading axes defined with EGDEF

$AA_EG_SYN

Synchronized position of the leading axis

$AA_EG_SYNFA

Synchronized position of the following axis

$AA_EG_TYPE

Type of coupling

$AA_IN_SYNC[FA]

Synchronization status of the following axis

$AA_JERKLIMA

Jerk correction set with JERKLIMA (main run)

$AA_LEAD_SP

Simulated master value - position with LEAD

$AA_LEAD_SV

Simulated master value - speed with LEAD

$AA_LEAD_P_TURN

Current leading value - position component lost as a result of modulo reduction.

$AA_LEAD_P

Current leading value - position (modulo reduced)

$AA_LEAD_V

Current leading velocity value

$AA_SYNC

Coupling status of following axis

$AA_SYNCDIFF[FA]

Synchronism difference of the setpoint

$AA_SYNCDIFF_STAT[FA]

Status of the synchronism difference of the setpoint

$AA_TYP/TYPE

Axis type

$AA_VELOLIMA

Velocity correction set with VELOLIMA (main run)

$PA_ACCLIMA

Acceleration correction set with ACCLIMA (pre-processing)

$PA_CPFACT

Coupling type of the following axis/spindle.

$PA_CPFPOSSTAT

Validity of synchronous and stop position

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Axis couplings

14.8 Data lists

Identifier

Meaning

$PA_CPSYNCOP

Threshold value of position synchronism "Coarse" (pre-processing)

$PA_CPSYNCOV

Threshold value of velocity synchronism "Coarse" (pre-processing)

$PA_CPSYNFIP

Threshold value of position synchronism "Fine" (pre-processing)

$PA_CPSYNFIV

Threshold value of velocity synchronism "Fine" (pre-processing)

$PA_CPLINSC

Scaling factor of the input value of a leading axis (pre-processing)

$PA_CPLINTR

Offset value of the input value of a leading axis (pre-processing)

$PA_CPLOUTSC

Scaling factor of the output value of the coupling (pre-processing)

$PA_CPLOUTTR

Offset value of the output value of the coupling (pre-processing)

$PA_CPSETTYPE

Preset coupling type

$PA_JERKLIMA

Jerk correction set with JERKLIMA (pre-processing)

$PA_VELOLIMA

Velocity correction set with VELOLIMA (pre-processing)

$VA_COUP_OFFS[S2]

Actual-value position offset of the synchronous spindle

$VA_EG_SYNCDIFF

Synchronism difference

$VA_EG_SYNCDIFF_S

Synchronism difference with sign

$VA_SYNCDIFF[FA]

Synchronism difference of the actual value

$VA_SYNCDIFF_STAT[FA]

Status of the synchronism difference

$P_COUP_OFFS[S2]

Programmed position offset of the synchronous spindle

$P_EG_BC

Block change criterion

Dynamics of following axis

Identifier

Meaning

$AA_ACCLIMA

Main run acceleration correction set with ACCLIMA

$AA_VELOLIMA

Main run speed correction set with VELOLIMA

$PA_ACCLIMA

Preprocessing acceleration correction set with ACCLIMA

$PA_VELOLIMA

Preprocessing speed correction set with VELOLIMA

Axes and spindles

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Manual traversing

15.1

Overview

Application

Even on modern, numerically controlled machine tools, a facility must be provided that allows

the user to traverse the axes manually.

Examples:

• Setting up the machine

Especially when setting up a new machining program, a manual traversing of the machine

axes is required. Where coordinate offset or rotation is selected, manual travel can even be

performed in the transformed workpiece coordinate system.

• Retraction of the tool after a program abort

After a program abort due to a power failure or RESET, the operator must manually retract the

tool from its current machining position. The transformations and coordinate systems used

for machining must remain active while this is done.

JOG mode

Manual traversing of axes is performed in JOG mode.

If JOG mode is active for the current mode group, this is reported to the PLC via the

corresponding interface signal:

DB11 DBX6.2 (BAG1: operating mode JOG)

DB11 DBX26.2 (BAG2: operating mode JOG)

DB11 DBX186.2 (BAG10: operating mode JOG)

Further information:

Function Manual Basic Functions; Mode group, channel, program operation, reset response

Display

If JOG mode is active, the basic JOG screen is displayed on the operator interface. This main

screen contains values relating to position, feedrate, spindle, and tool.

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Manual traversing

15.1 Overview

Manual traversing in the BCS and WCS

The user has the option of traversing axes in the basic coordinate system (BCS) or workpiece

coordinate system (WCS).

• Manual traversing in the BCS

Each axis can be traversed manually.

• Manual traversing in the WCS

Only the axes declared as geometry axes can be manually traversed in the WCS (channel-

specific). Any coordinate offsets or rotations that have been selected remain active.

Manual traversing of several axes

Several axes can be manually traversed at the same time in JOG mode. However, there is no

interpolatory relationship.

Control via the PLC interface

Manual traversing is controlled via the PLC interface.

See Section "Control via the PLC interface (Page 698)".

A separate PLC interface exists in each case for machine axes (axis-specific), geometry axes

(channel-specific), and orientation axes (channel-specific).

Parameter assignment (general)

For the manual traversing of axes, there are parameterizable properties, which are valid for all

JOG movements regardless of the traversing variant and the selected JOG function. These are

described under "Parameter assignment (general) (Page 699)".

Traversing variants

The following manual traversing variants are possible in JOG mode:

• Continuous traversing with the traversing keys of the machine control panel in jog or

continuous mode

See Section "Continuous manual traversing (Page 704)".

• Incremental traversing with the traversing keys of the machine control panel in jog or

continuous mode

See Section "Incremental manual traversing (Page 707)".

• Traversing of axes via electronic handwheels

See Section "Manual traversing using a handwheel (Page 712)".

Manual traversing of the spindle

Spindles can also be traversed manually in JOG mode. Essentially, the same conditions apply as

for manual traversing of axes. Spindles can be traversed in JOG mode using the traversing keys

continuously or incrementally, in jog or continuous mode, or using the handwheel. The function

is selected and activated via the axis-/spindle-specific PLC interface in the same way as for the

machine axes. The axis-specific machine data also applies to the spindles.

Axes and spindles

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Manual traversing

15.1 Overview

Special features to be observed during manual traversing of spindles can be found in Section

"Manual traversing of the spindle (Page 726)".

Manual traversing of geometry axes

Manual traversing of geometry axes is used for traversing for which transformations and frames

have to be active. The geometry axes are traversed in the most recently valid coordinate system.

Special features to be observed during manual traversing of geometry axes (and orientation

axes) can be found in Section "Manual traversing of geometry axes/orientation axes

(Page 727)".

Additional functions

In addition to various traversing variants, further functions can be selected in JOG mode:

• REF (reference point approach)

• REPOS (repositioning)

• Approach of configured fixed points

See Section "Approaching a fixed point in JOG (Page 730)".

• Approach of a definable position

See Section "Position travel in JOG (Page 737)".

• Traverse geometry axes along a circular arc

See Section "Circular travel in JOG (Page 742)".

• JOG retract (retraction movement in the tool direction after a program abort due to a power

failure or RESET)

See Section "Retraction in the tool direction (JOG retract) (Page 751)".

Use of handwheels in automatic mode

Handwheels can also be used in automatic mode:

• Handwheel override in AUTOMATIC mode with path specification and/or velocity override

(Page 761)

• Contour handwheel/path input using handwheel (option) (Page 768)

• Correction of the tool wear for machining in AUTOMATIC mode by means of additional

incremental work offset using the handwheel (DRF) (Page 761)

Monitoring

For manual traversing, limitations apply, which are monitored in the controller.

See Section "Monitoring functions (Page 777)".

Switching from JOG mode to AUTOMATIC/MDI mode

It is only possible to switch operating modes from JOG to AUTOMATIC or MDI if all axes in the

channel have reached "coarse exact stop".

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Manual traversing

15.2 Control via the PLC interface

Further information:

Function Manual Basic Functions; Mode group, channel, program operation, reset response

Commissioning

For information on the commissioning of electronic handwheels, see Section "Start-up:

Handwheels (Page 778)".

15.2

Control via the PLC interface

The JOG functions in the NC are activated via the PLC interface from the machine control panel

(MCP). To do this, the input signals of the machine control panel from the PLC must be

transferred to the input interface of the NC in the NC/PLC interface. In this way, the machine

manufacturer can simply adapt the functionality of manual traversing to the machine tool

through the PLC user program. You can use this, for example, to change the assignment between

the direction keys of the machine control panel and the traversing requests to the NC with regard

to the machine and geometry axes.

Basic procedure

The following figure shows the basic procedure for the selection of a JOG function from the

machine control panel (MCP) to the NC.

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① The operator selects, for example, the "Continuous traversing" machine function on the machine control panel for a

machine axis.

The input signals of the MCP are transferred cyclically from the basic PLC program in the data blocks of the MCP input

interface.

② The PLC user program reads the input signals of the MCP. The input signals can be linked with any other signals in

accordance with the current machine or machining situation. Finally, the PLC user program writes the corresponding

request signals to the NC in the respective axis-specific NC/PLC interface.

The basic PLC program transfers the request signals in the internal input interface to the NC.

③ After activation of the requested function, the NC writes the feedback in the internal output interface to the PLC. The

basic PLC program cyclically transfers the output signals in the respective axis-specific NC/PLC interface

Axes and spindles

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Manual traversing

15.3 Parameter assignment (general)

Further information

Detailed information on the configuration and integration of machine control panels in the PLC

user program can be found in the Function Manual PLC.

SINUMERIK 840D sl. Service - Functions. Manual (2018-2020) - page 13