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SINUMERIK 840D sl. Service - Functions. Manual (2018-2020) - page 42

R2: Rotary axes

14.2 Modulo 360 degrees

Note

Modulo partition axes

By aligning the two following machine data, indexing positions of 360° modulo indexing axes

can be implemented in the same way as for the 360° modulo range:

● MD30503 $MA_INDEX_AX_OFFSET

● MD30340 $MA_MODULO_RANGE_START

See the examples in Chapter "Indexing axes, "Example 3: Rotary modulo axis as equidistant

indexing axis (Page 859)" and the following chapters.

360° modulo rotary axis: Positioning behavior for G90 (modal absolute programming)

The standard behavior for G90 is set via the machine data:

MD30455 $MA_MISC_FUNCTION_MASK, bit 2 = <value>

<value>

Meaning

0

The 360° modulo rotary axis positions corresponding to AC as standard for G90 program-

ming:

● Target position > Current position: Move in positive traversing direction

● Target position < Current position: Move in negative traversing direction

1

For G90 programming, the 360° modulo rotary axis positions as standard corresponding

to DC, i.e. the shortest path.

Position display in the 360° modulo representation

Activating the position display at the user interface in the 360° modulo representation is realized

using the axis-specific machine data:

MD30320 $MA_DISPLAY_IS_MODULO = 1

NC/PLC interface signals

Activating the traversing range limits

In principle, the traversing range of a 360° modulo rotary axis is infinity. This is the reason that

axis-specific traversing range limits to not apply as standard, such as software limit switches

and working error limits. The traversing range limits of a 360° modulo rotary axis can be

activated using the subsequent absolute axis-specific NC/PLC interface signal, possibly

initiated via an M/H function in the NC program:

DB31, ... DBX12.4 = 1 (360° modulo rotary axes: Activate traversing range limits)

Extended Functions

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R2: Rotary axes

14.2 Modulo 360 degrees

r

r

r

r

r

r

① Direction of rotation +/-

② Software limit switch +/-

Figure 14-4

360° modulo rotary axis with software limit switch

Feedback signal, activation of the traversing range limits

The feedback signal that the traversing range limits of a 360° modulo rotary axis are active in

the NC, is realized using the axis-specific NC/PLC interface signal:

DB31, ... DBX74.4 == 1 (modulo rotary axes: traversing range limits active)

Example: Changing the traversing range limits

Pallet 1 with several clamped workpieces is machined on a 360° modulo rotary axis. The pallet

1 is then swapped for a pallet 2 with a built-on axis. The traverse range now has to be monitored.

Parameterization:

● MD30300 $MA_IS_ROT_AX[ AX5 ] = 1

● MD30310 $MA_ROT_IS_MODULO[ AX5 ] = 1

● MD36110 $MA_POS_LIMIT_PLUS[ AX5 ] = 340

● MD36100 $MA_POS_LIMIT_MINUS[ AX5 ] = 350

Extract from part program:

Program code

Comment

M123

; Insert pallet 1 with quadruple clamping

; PLC: deactivate traversing range limits of the

; B axis => DB35, DBX12.4=0

STOPRE

; Trigger a preprocessing stop

S1000 M3

G4 F2

G1 X0 Y300 Z500 B0 F5000

CYCLE84(500,400,0,350,0,1,4,10,,0,500,1000) ; drilling cycle

G0 Z540 B0

Extended Functions

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R2: Rotary axes

14.3 Programming rotary axes

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① POS[C] = ACP(100); Traverse in positive direction of rotation to

position 100°

② POS[C] = ACN(300); Traverse in negative direction of rotation to

position 300°

③ POS[C] = ACP(240); Traverse in positive direction of rotation to

position 240°

④ POS[C] = AC(0); Traverse in negative direction of rotation to position

0°

Figure 14-5

Absolute programming for modulo rotary axes

Absolute programming along the shortest path (DC)

Example of absolute programming on the shortest path for a modulo rotary axis as positioning

axis:

POS[<axis name>] = ACP(<value>)

● <value>: Target position of the modulo rotary axis in the range between 0° and 359.999°

Negative values are also possible if a range offset has been realized with the following

machine data:

- MD30340 $MA_ MODULO_RANGE_START

- MD30330 $MA_MODULO_RANGE

● DC: Absolute programming of the target position for moving by the shortest direction of

rotation.

Note

If the route is the same in both directions (180°), movement in in the positive direction of

rotation.

Programming examples

Starting position of modulo rotary axis C = 0° (see figure below).

Extended Functions

768

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R2: Rotary axes

14.3 Programming rotary axes

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① POS[C] = DC(100); Traverse by shortest path to position 100°

② POS[C] = DC(300); Traverse by shortest path to position 300°

③ POS[C] = DC(240); Traverse by shortest path to position 240°

④ POS[C] = DC(60); Traverse by shortest path to position 60°

; in positive direction of rotation

Figure 14-6

Absolute programming with shortest path for modulo rotary axes

Block-search response

After block search with calculation, the collected search run positions can be read by modulo,

converted using the system variable $AC_RETPOINT[<axis>].

Supplementary conditions for ASUB after block search with calculation

In this instance, as well as with the cross-channel block-search tool SERUPRO, the modulo

conversion simulated in the block search must be performed in the part program.

Incremental programming (IC, G91)

Example for positioning axis: POS[axis name] = IC(+/-value)

● The value identifies the rotary-axis traversing distance. The value can be negative and ≥

+/-360°.

● The value's sign unequivocally defines the rotary-axis traversing direction.

● Application example: milling a spiral groove across several revolutions

Example

Programming

Effect

POS[C]=IC(720)

C axis traverses to 720° incrementally in the positive direction

(two revolutions)

POS[C]=IC(-180)

C axis traverses to 180° incrementally in the negative direction

Extended Functions

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R2: Rotary axes

14.3 Programming rotary axes

Program example: Modulo rotary axes as endlessly rotating rotary axis

Program code

LOOP:

POS[C] = IC(720) ; Traverse as positioning axis by 270°

GOTOB LOOP

; Return to Label LOOP

14.3.3

Rotary axis without modulo conversion

Deactivating modulo conversion

→ set MD30310 $MA_ROT_IS_MODULO = 0.

Absolute programming (AC, G90)

Example for positioning axis: POS[axis name] = AC (+/- value)

● The value and its sign uniquely identify the rotary-axis target position. The value can be ≥

+/-360°. The position value is limited by the software limit switch positions.

● The traversing direction is defined by the control according to the signed rotary axis actual

position.

● If ACP or ACN is programmed, alarm 16810, "ACP traverse instruction cannot be used", or

alarm 16820 "ACN traverse instruction cannot be used", is output.

● Application example:

Linear motion (cam gear) are coupled to the rotary axis, thus certain end positions may not

be passed.

Example:

Programming

Effect

POS[C] = AC (-100)

Rotary axis C traverses to position -100°;

traversing direction depends on the starting position

POS[C] = AC (1500)

Rotary axis C traverses to position 1500°

Absolute programming along the shortest path (DC)

POS[axis name] = DC(value)

Even if the rotary axis is not defined as a modulo axis, the axis can still be positioned with DC

(Direct Control). The behavior is the same as that of a modulo axis.

Extended Functions

770

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R2: Rotary axes

14.3 Programming rotary axes

● The value identifies the rotary axis target position in a range from 0° to 359.999° (modulo

360°). Alarm 16830, "Incorrect modulo position programmed", is output for values with a

negative sign or ≥ 360º.

● With DC (Direct Control), the rotary axis approaches the programmed absolute position

within one revolution along the shortest path (traversing movement max. ±180°).

● The control calculates the direction of rotation and the traverse path according to the current

actual position (in relation to modulo 360°). If the path to be traversed is the same in both

directions (180°), the positive direction of rotation has priority.

● DC application example: the rotary table is required to approach the changeover position

in the shortest time (and, therefore, via the shortest path) possible.

● If DC is programmed for a linear axis, alarm 16800, "DC traverse instruction cannot be

used", is output.

Example:

Programming

Effect

POS[C] = AC (7200)

Rotary axis C traverses to position 7200°;

traversing direction depends on the starting position

POS[C] = DC (300)

Rotary axis C approaches "modulo" position 300°

along the shortest path

Thus, C traverses through 60° with a negative direction of rotation

and stops at absolute position 7140°.

POS[C] = AC (7000)

Rotary axis C traverses to position 7000° absolute,

C traverses through 140° with a negative direction of rotation

Note

In this example, it would be advisable to activate the modulo 360º display (MD30320

$MA_DISPLAY_IS_MODULO = 1).

Incremental programming (IC, G91)

Example for positioning axis: POS[axis name] = IC(+/- value)

When programming with incremental dimensions, the rotary axis traverses along the same

path as for the modulo axis. In this case, however, the traversing range is limited by the

software limit switches.

● The value identifies the rotary axis traversing distance.

The value can be negative and ≥ +/-360°.

● The sign of the value defines the rotary axis traversing direction.

Extended Functions

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R2: Rotary axes

14.4 Activating rotary axes

Limited traversing range

The traversing range is limited just the same as for linear axes. The range limits are defined

by the "plus" and "minus" software limit switches.

14.3.4

Other programming features relating to rotary axes

Offsets

TRANS (absolute) and ATRANS (additive) can be applied to rotary axes.

Scalings

SCALE or ASCALE are not suitable for rotary axes, since the control always bases its modulo

calculation on a 360º full circle.

Preset actual value memory

PRESETON is possible.

Indexing axes

See Section "T1: Indexing axes (Page 843)".

14.4

Activating rotary axes

Procedure

The procedure for activating rotary axes is the same as that for linear axes with a small number

of exceptions. It should be noted that, as soon as the axis is defined as a rotary axis (MD30300

$MA_IS_ROT_AX = 1), the axis-specific-machine-/setting-data units are interpreted by the

control as follows:

Positions

In "degrees"

Velocities

In "rev/min"

Accelerations

In "rev/sec²"

Jerk limitation

In "rev/sec³"

Extended Functions

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R2: Rotary axes

14.4 Activating rotary axes

Special machine data

Special rotary-axis machine data may also have to be entered, depending on the application:

MD30310 $MA_ROT_IS_MODULO

Modulo conversion for positioning and program-

ming

MD30320 $MA_DISPLAY_IS_MODULO

Modulo conversion for position display

MD10210 $MN_INT_INCR_PER_DEG

Computational resolution for angular positions

The following overview lists the possible combinations of these machine data for a rotary axis:

Possible combinations of rotary-axis machine data

MD30300

MD30310

MD30320

Application

Comment

permitted

0

0

0

Yes

The axis is a linear axis (default).

1

0

0

Yes

The axis is a rotary axis; modulo conver-

sion is not used for positioning, i.e. the

software limit switches are active; the po-

sition display is absolute.

1

0

1

Yes

The axis is a rotary axis; modulo conver-

sion is not used for positioning, i.e. the

software limit switches are active; the po-

sition display is modulo;

application: for axes with an operating

range of +/-1000°, for example

1

1

1

Yes

The axis is a rotary axis; positioning is per-

formed with modulo conversion, i.e. the

software limit switches are inactive, the

operating range is unlimited; the position

display is modulo (setting most frequently

used for rotary axes); axis with/without

working-area limitation can be used.

1

1

0

Yes

The axis is a rotary axis; positioning is per-

formed with modulo conversion, i.e. the

software limit switches are inactive, the

operating range is unlimited; the position

display is absolute; axis with/without work-

ing-area limitation can be used.

0

0 or 1

0 or 1

Not recom-

Axis is not a rotary axis;

mended

therefore, the other MD are not evaluated.

JOG velocity for rotary axes

SD41130 $SN_JOG_ROT_AX_SET_VELO (JOG speed for rotary axes)

The above setting data can be used to define a valid JOG velocity for all rotary axes (see also

Section "H1: Manual traversing (Page 143)").

Extended Functions

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R2: Rotary axes

14.7 Data lists

14.6

Examples

Fork head, inclined-axis head

Rotary axes are frequently used on 5-axis milling machines to swivel the tool axis or rotate the

workpiece. These machines can position the tip of a tool on any point on the workpiece and

take up any position on the tool axis. Various milling heads are required, depending on the

application. The figure shows a fork head and an inclined-axis head as example rotary-axis

arrangements.

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14.7

Data lists

14.7.1

Machine data

14.7.1.1

General machine data

Number

Identifier: $MN_

Description

10210

INT_INCR_PER_DEG

Computational resolution for angular positions

14.7.1.2

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

30300

IS_ROT_AX

Axis is rotary axis

30310

ROT_IS_MODULO

Modulo conversion for rotary axis

Extended Functions

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R2: Rotary axes

14.7 Data lists

Number

Identifier: $MA_

Description

30320

DISPLAY_IS_MODULO

Actual value display modulo

30330

MODULO_RANGE

Modulo-range size

30340

MODULO_RANGE_START

Modulo-range starting position

30455

MISC_FUNCTION_MASK

Axis functions

36100

POS_LIMIT_MINUS

Minus software limit switch

36110

POS_LIMIT_PLUS

Plus software limit switch

14.7.2

Setting data

14.7.2.1

General setting data

Number

Identifier: $SN_

Description

41130

JOG_ROT_AX_SET_VELO

JOG velocity for rotary axes

14.7.2.2

Axis/spindle-specific setting data

Number

Identifier: $SA_

Description

43420

WORKAREA_LIMIT_PLUS

Plus working-area limitation

43430

WORKAREA_LIMIT_MINUS

Minus working-area limitation

14.7.3

Signals

14.7.3.1

Signals to axis/spindle

Signal name

SINUMERIK 840D sl

SINUMERIK 828D

Traversing-range limitation for modulo axis

DB31,

DBX12.4

DB380x.DBX1000.4

14.7.3.2

Signals from axis/spindle

Signal name

SINUMERIK 840D sl

SINUMERIK 828D

Status of software limit switch monitoring for modulo axis

DB31,

DBX74.4

DB390x.DBX1000.4

Extended Functions

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S3: Synchronous spindle

15.1 Brief description

Selecting/de-selecting

Part program commands are used to select/deselect the synchronous operation of a pair of

synchronous spindles.

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Extended Functions

778

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S3: Synchronous spindle

15.1 Brief description

Figure 15-2

Synchronous operation: Polygonal turning

15.1.2

Synchronous mode

Description

<axial expression>:

can be:

- Axis name

- Spindle name

<axis name>:

C (if spindle has the name "C" in axis operation.)

<spindle name>:

Sn, SPI(n) where n = spindle number

<Spindle number>:

1, 2, ... according to the spindle number defined in

MD35000 $MA_SPIND_ASSIGN_TO_MACHAX

(FS, LS, offset):

LS = Leading Spindle, FS = Following Spindle,Off-

set = read programmable offset of following spin-

dle using system variables

$P_COUP_OFFS[Sn]

Programmed position offset of the synchronous

spindle

Synchronous spindle pair

Synchronous operation involves a following spindle (FS) and a leading spindle (LS), referred

to as the synchronous spindle pair. The following spindle imitates the movements of the leading

spindle when a coupling is active (synchronous operation) in accordance with the defined

functional interrelationship.

Synchronous mode

Synchronous mode (also referred to as “Synchronous spindle operation”) is another spindle

operating mode. Before synchronous mode is activated, the following (slave) spindle must

have been switched to position control. Synchronous operation is activated for the following

spindle when the coupling is activated. As soon as the coupling is deactivated, the following

spindle switches back to open-loop control mode.

As soon as synchronous operation is active for the following spindle, the following interface

signal is reported to the PLC:

IS "Synchronous mode" (DB31, ... DBX84.4) = 1.

Number of synchronous spindles

It is possible to couple several following spindles to one leading spindle. The number of

following spindles on this leading spindle depends on the respective version of the appropriate

software versions.

Any number of following spindles in any channels of one NCU or a different NCU can be

coupled to this leading spindle.

Extended Functions

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S3: Synchronous spindle

15.1 Brief description

Program code

Comment

; are set and the block change

; is enabled.

N54 M0

N57 COUPOF(S2,S1)

N99 M30

Reset and recovery

Resetting the IS "Disable synchronization" (DB31, ... DBX31.5) has no effect on the following

spindle offset. If the offset motion of the following spindle has been suppressed by the VDI

interface signal, then the offset is not automatically applied when the VDI signal is reset.

Synchronization is recovered as follows:

● By repeating the part program operation COUPON (FS, LS, offset) with IS "Disable

synchronization" (DB31, ... DBX31.5) = 0.

COUPON (FS, LS, offset) can be written e.g. in an ASUB.

● By setting the IS "Resynchronize" (DB31, ... DBX31.4) = 1

Read offset

The following system variables can be used to read three different position offset values of the

following spindle from the part program and synchronized actions. The variable

$P_COUP_OFFS[Sn] is only available in the part program.

Description

NC variable

Programmed position offset of the synchronous spindle

$P_COUP_OFFS[Sn]

Position offset of synchronous spindle, setpoint end

$AA_COUP_OFFS[Sn]

Position offset of synchronous spindle, actual value end

$VA_COUP_OFFS[Sn]

"Feedrate stop/spindle stop"

By configuring bit 4 in MD30455 MISC_FUNCTION_MASK, the behavior of the axial IS

"Feedrate stop/Spindle stop" (DB31, ... DBX4.3) is defined for the following spindle.

Bit 4 = 0 compatibility method:

Canceling feed enable for the following spindle decelerates the coupling assembly.

Bit 4 = 1:

Feedrate enable refers only to the interpolation component (SPOS),..) and does not affect the

coupling.

Note

Other configuration options for axis functions using MD30455 $MA_MISC_FUNCTION_MASK:

References:

Function Manual, Basic Functions; Rotary Axes (R2), Section: Programming rotary axes

Extended Functions

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S3: Synchronous spindle

15.1 Brief description

The size of the tolerance windows is set with machine data of the FS. Reaching of the

synchronism is influenced by the following factors:

● AV, DV: Position variance between FS and LS

● VV: Difference in speed between FS and LS

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Synchronism monitoring with COUPON and synchronism test mark WAITC with

synchronization on a turning leading spindle

Extended Functions

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793

S3: Synchronous spindle

15.2 Programming

Threshold values

The relevant position or velocity tolerance range for the following spindle in relation to the

leading spindle must be specified in degrees or 1 rev/min.

● Threshold value for "Coarse synchronism"

axis spec. MD37200: AV, DV: COUPLE_POS_TOL_COARSE

MD37220: VV: COUPLE_VELO_TOL_COARSE

● Threshold value for "Fine synchronism"

axis spec. MD37210: AV,DV: COUPLE_POS_TOL_FINE

MD37230: VV: COUPLE_VELO_TOL_FINE

Speed/acceleration limits

In synchronous mode, the speed and acceleration limit values of the leading spindle are

adjusted internally in the control in such a way that the following spindle can imitate its

movement, allowing for the currently selected gear stage and effective speed ratio, without

violating its own limit values.

For example, the LS is automatically decelerated to prevent the FS from exceeding the

maximum speed in order to maintain synchronism between the spindles.

15.2

Programming

Coupling commands with leading-spindle programming

Command

Function

COUPDEF(FS, LS, ...)

Define coupling or change for configured coupling

COUPON(FS, LS, POSFS)

Switch the coupling on

COUPONC(FS, LS)

Activate coupling with transfer of the currently effective speed

of the following spindle

COUPOF(FS, LS, POSFS, POSLS)

Switch the coupling off

COUPOFS(FS, LS, POSFS)

Deactivate coupling with stop of the following spindle

COUPDEL (FS, LS)

Delete coupling

COUPRES (FS, LS)

Reactivate configured coupling data

Coupling commands without leading-spindle programming

Command

Function

COUPOF(FS, POSFS, POSLS)

Switch the coupling off

COUPOFS(FS, POSFS)

Deactivate coupling with stop of the following spindle

COUPDEL(FS)

Delete coupling

COUPRES(FS)

Reactivate configured coupling data

Extended Functions

794

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S3: Synchronous spindle

15.2 Programming

COUPDEL (FS, LS)

Note

COUPDEL impacts on an active coupling, deactivates it and deletes the coupling data. Alarm

16797 is therefore meaningless.

The following spindle adopts the last speed. This corresponds to the behavior associated with

COUPOF(FS, LS).

Activate original coupling parameters

Language command "COUPRES" can be used to re-activate the configured coupling

parameters.

COUPRES (FS, LS)

The parameters modified using COUPDEF (including the transformation ratio) are subsequently

deleted.

Language command "COUPRES" activates the parameters stored in the machine and setting

data (configured coupling) and activates the default settings (user-defined coupling).

Programmable block change

It is possible to mark a point in the NC program using the "WAITC" language command. The

system waits at this point for fulfillment of the synchronism conditions for the specified FS and

delays changes to new blocks until the specified state of synchronism is reached (see "Figure

15-3 Synchronism monitoring with COUPON and synchronism test mark WAITC with

synchronization on a turning leading spindle (Page 793)").

WAITC (FS)

Advantage: The time between activating the synchronous coupling and reaching synchronism

can be used in a meaningful way, technologically speaking.

Note

Basically, it is always possible to write WAITC. If the spindle indicated is not active as FS, the

command for this spindle is without effect.

If no synchronism condition is indicated, the check is always performed for the synchronism

condition programmed/configured on the respective coupling, at least for the setpoint

synchronism.

Examples:

WAITC(S2),

:

WAITC(S2, "Fine"),

:

WAITC(S2, ,S4, "Fine")

Extended Functions

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797

S3: Synchronous spindle

15.2 Programming

Example:

$AA_COUP_OFFS[S2]

If an angular offset is programmed with COUPON, this coincides with the value read after reading

the setpoint synchronization.

Reading the programmed angular offset

The position offset last programmed between the FS and LS can be read in the NC part

program by means of the following axial system variables:

$P_COUP_OFFS[<axial expression>]

Note

After cancellation of the servo enable signal when synchronous operation and follow-up mode

are active, the position offset applied when the controller is enabled again is different to the

originally programmed value.

$P_COUP_OFFS only returns the value originally programmed. $AA_COUP_OFFS and

$VA_COUP_OFFS return the current value. The programmed offset can be recreated with

NST DB31, ... DBX31.4 (resynchronization).

15.2.4

Automatic selection and deselection of position control

Behavior in speed control mode

In DV coupling mode, program instructions COUPON, COUPONC and COUPOF, COUPOFS are

used to activate and/or deactivate position control for the leading spindle as required. If there

are several following spindles on the leading spindle, then in speed-controlled mode, the

first DV activates coupling position control for the leading spindle and the last DV coupling

deactivates coupling position control for the leading spindle if SPCON is not programmed.

The leading spindle does not need to be located in the same channel as the following spindle.

Automatic selection with COUPON and COUPONC

Depending on the coupling type, the effect of COUPON and COUPONC on the position control

for synchronous operation is as follows:

Coupling type

DV

AV

VV

Following spindle FS

Position control ON

Position control ON

No action

Leading spindle LS

Position control On ¹

No action

No action

¹ The position control is activated by a COUPON and COUPONC instruction if at least one

following spindle has been coupled to it with coupling type DV.

Extended Functions

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S3: Synchronous spindle

15.3 Configuration

Automatic deselection with COUPOF and COUPOFS

Depending on the coupling type, the effect of COUPOF and COUPOFS on the position control

is as follows:

Coupling type

DV

AV

VV

Following spindle FS

Position control OFF ²

Position control OFF ²

No action ²

Leading spindle LS

Position control OFF ³

No action

No action

²COUPOF and COUPOFS without position specification

Speed control mode is activated for the following spindle. Positioning mode is activated with

COUPFS with a stop position. Position control is not deactivated if the following spindle was

located in position-controlled spindle mode using SPCON or COUPFS was programmed with

position.

³ With COUPOF position control is deactivated if there are no more couplings of the DV coupling

type for this leading spindle. Position control is retained if the leading spindle is in positioning

mode or axial mode or was in position-controlled spindle mode using SPCON.

15.3

Configuration

Note

One synchronous-spindle coupling can be configured for each channel.

Table 15-1

Machine data

Number

Name: $MC_

Function

MD21300

COUPLE_AXIS_1[<n>]

Machine axes of the synchronous-spindle coupling:

● <n> = 0: Machine axis number of the following spindle

● <n> = 1: Machine axis number of the leading spindle

Machine axis numbers in accordance with: MD20070 $MC_AXCONF_MA-

CHAX_USED (machine axes in the channel)

Machine axis numbers == 0: No coupling configured. The following system data

is then not relevant.

Note: The machine axes configured for the synchronous-spindle coupling cannot

be changed using program commands.

MD21320

COUPLE_BLOCK_

Block change release after activating the synchronous operation ¹⁾:

CHANGE_CTRL_1

● Immediately

● On reaching "Synchronism fine"

● On reaching "Synchronism coarse"

● On reaching "Synchronism setpoint"

Note: No change protection¹⁾, the block change release can be changed with the

COUPDEF command.

Extended Functions

Function Manual, 12/2018, A5E40874029B AB

801

S3: Synchronous spindle

15.3 Configuration

Number

Name: $MC_

Function

MD21310

COUPLING_MODE_1

Coupling type ¹⁾:

● Actual value coupling

● Setpoint value coupling

● Speed coupling

Note: No change protection¹⁾, the coupling type can be changed for deactivated

coupling with the COUPDEF command.

MD21330

COUPLE_RESET_

Behavior of the synchronous-spindle coupling with regard to NC Start, NC Stop

MODE_1

and Reset.

MD21340

COUPLE_IS_WRITE_

Change protection for coupling

PROT_1

1) See MD21340 $MC_COUPLE_IS_WRITE_PROT_1

Table 15-2

Setting data

Number

Name: $SC_

Function

SD42300

COUPLE_RATIO_1[<n>]

Speed transmission ratio: FS / LS = numerator / denominator ¹⁾:

● <n> = 0: Numerator (FS)

● <n> = 1: Denominator (LS)

Note: No change protection¹⁾, the transmission ratio can be changed with the

COUPDEF command.

1) See MD21340 $MC_COUPLE_IS_WRITE_PROT_1

15.3.1

Response of the synchronous-spindle coupling for NC Start

The behavior of the synchronous-spindle coupling during NC Start depends on the setting in

the following machine data:

Configured synchronous-spindle coupling

Response

MD21330 $MC_COUPLE_RESET_MODE_1

Maintain coupling

Bit 0 = 0

Deselect coupling

Bit 0 = 1

Activate configured data

Bit 5 = 1

Switch the coupling on

Bit 9 = 1

Programmed synchronous-spindle coupling

Response

MD20112 $MC_START_MODE_MASK

Maintain coupling

Bit 10 = 0

Deselect coupling

Bit 10 = 1

Extended Functions

802

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S3: Synchronous spindle

15.4 Points to note

15.3.2

Behavior of the synchronous-spindle coupling for reset

The behavior of the synchronous operation for reset and at program end depends on the setting

in the following machine data:

Configured synchronous-spindle coupling

Response

MD21330 $MC_COUPLE_RE-

MD20110 $MC_RE-

SET_

SET_MODE_MASK

MODE_1

Maintain coupling

Bit 1 = 0

Bit 0 = 1

Deselect coupling

Bit 1 = 1

Bit 0 = 1

Activate configured data

Bit 6 = 1

Bit 0 = 1

Programmed synchronous-spindle coupling

MD20110 $MC_RESET_MODE_MASK

Maintain coupling

Bit 0 = 1, Bit 10 = 1

Deselect coupling

Bit 0 = 1, Bit 10 = 0

15.4

Points to note

15.4.1

Special features of synchronous mode in general

Control dynamics

When using the setpoint coupling, the position control parameters of FS and LS (e.g. K_V factor)

should be matched with one another. If necessary, different parameter blocks should be

activated for speed control and synchronized mode. The control parameters of the following

spindle may differ from position control, feedforward control and parameter block, as also in

the uncoupled case, set using MD30455 $MA_MISC_FUNCTION_MASK (see Section

"Special points regarding start-up of a synchronous spindle coupling (Page 816)").

Precontrol

Due to the improved control system dynamic response it provides, feedforward control for the

following and leading spindles in synchronous mode is always active.

It can, however, be deselected for FS and LS with axis-specific MD32620 $MA_FFW_MODE.

If MD32620 $MA_FFW_MODE is set to zero, there are function limitations. Position control

can no longer be activated in motion with SPCON. SPOS, M19 or SPOSA are therefore not

possible. The NC part program cannot deactivate the feedforward control for LS and FS with

FFWOF.

The feedforward control mode (speed or torque feedforward control) is defined in axis-specific

MD32620 $MA_FFW_MODE (see also Section "K3: Compensations (Page 253)").

Extended Functions

Function Manual, 12/2018, A5E40874029B AB

803

S3: Synchronous spindle

15.4 Points to note

Program code

Comment

N65 M0

; (Note tolerances, see above)

Note

The axis enable signals can be canceled to interrupt a movement overlaid on the following

spindle (e.g. SPOS). This component of the movement is not affected by IS "NC/PLC interface

signal" DB31, ... DBX31.4 (resynchronization), but is restored by the REPOS operation.

Supplementary condition

IS DB31, ... DBX31.4 (resynchronization) has any effect only if there is a defined offset

position between the following spindle and leading spindle.

This is the case following COUPON with offset positions such as COUPON(...,77) or SPOS,

SPOSA, M19 for the following spindle with a closed coupling..

15.4.3

Synchronous mode and NC/PLC interface signals

Note

During synchronous operation, the effect of the associated interface signal for the leading (LS)

or following spindle (FS) on the coupling must always be considered.

Spindle override (DB31, ... DBB19)

Only the spindle override value of the LS is active in synchronous operation.

Spindle disable (DB31, ... DBX1.3)

LS

FS

coupling

Response

0

0

off

Setpoints are output

0

1

off

No setpoint output for FS

1

0

off

No setpoint output for LS

1

1

off

No setpoint output for LS and FS

0

0

ON

Setpoints are output

0

1

ON

Spindle disable not effective for FS

1

0

ON

Spindle disable also effective for FS, no setpoint output

1

1

ON

No setpoint output for LS and FS

Extended Functions

Function Manual, 12/2018, A5E40874029B AB

807

S3: Synchronous spindle

15.4 Points to note

Controller enable (DB31, ... DBX2.1)

LS: Resetting the "controller enable" during synchronous operation

If the controller enable of the LS is reset during synchronous operation for active setpoint

coupling, a control-internal switching is made to the actual value coupling. If the controller

enable is reset while the LS is traversing, the LS is stopped and an alarm issued. Synchronous

operation remains active.

LS and FS: Selection of synchronous operation without controller enable

If the "controller enable" for LS and FS is not set for selected synchronous operation, it will be

activated. LS and FS, however, are not traversed until controller enable for LS and FS has

been granted.

LS and FS: Setting the "Controller enable"

The position assumed by a spindle with setting the "controller enable" depends on DB31, ...

DBX1.4 == <value> (follow-up operation):

<value>

Assumed spindle position

0

Position when controller enable is canceled

1

Current position

Note

It is recommended for synchronous spindles during a block search, to write the DB31, ...

DBX2.1 interface signal (controller enable) always together for FS and LS. If this is not done,

the block search, for example, stops after a FS machining because the controller enable of

the LS is not pending.

Note

Synchronism error

If the DB31, ... DBX2.1 interface signal (controller enable) is canceled for the FS after Spindle

Stop without the coupling being deactivated beforehand, then any synchronism error resulting

from external intervention will not be compensated when the "controller enable" is activated

again. This causes any programmed angular relationship between FS and LS to be lost.

The angular relationship can be restored by resynchronizing: DB31, ... DBX31.4 = 1

(resynchronization)

Follow-up mode (DB31, ... DBX1.4)

For follow-up operation, the set position is regularly set to the current actual position:

DB31, ... DBX1.4 == 1 (follow-up operation) AND DB31, ... DBX2.1 == 0 (controller enable)

Extended Functions

808

Function Manual, 12/2018, A5E40874029B AB

S3: Synchronous spindle

15.4 Points to note

NC Start (DB21, ... DBX7.1)

(See Section "Response of the synchronous-spindle coupling for NC Start (Page 802)")

Note

NC Start after NC Stop does not deselect synchronous operation.

15.4.4

Differential speed between leading and following spindles

When does a differential speed occur?

A differential speed develops, e.g. with turning machine applications, when two spindles

oppose one other. Through the signed addition of two speed sources, a speed component is

derived from the leading spindle via the coupling factor. In addition to this, for the following

spindle a speed (S...) and a direction of rotation (M3/M4) can be programmed.

Generally, to achieve synchronous operation, a coupling factor is used with a value of '-1'. This

sign reversal then results in a differential speed for the following spindle as compared to an

additional programmed speed.

This typical behavior in relation to the NC is illustrated in the following diagram.

6

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6

IROORZLQJ VSLQGOH

0 6

0

6

6HW VSHHG

(QDEOH E\

3/&

6SHHG

6SHHG

LQWHUSRODWRU

LQWHUSRODWRU

&RXSOLQJ IDFWRU

&28321

USP

USP

USP

[

USP

$FWXDO

VSHHG

0

0

Extended Functions

Function Manual, 12/2018, A5E40874029B AB

811

S3: Synchronous spindle

15.4 Points to note

Example

Program code

Comment

N01 M3 S500

; S1 rotates in the positive direction with 500 rpm

; the master spindle is spindle 1

N02 M2=3 S2=300

; S2 rotates in the positive direction with 300 rpm

N05 G4 F1

N10 COUPDEF(S2,S1,-1)

; Coupling factor -1:1

N11 COUPON(S2,S1)

; Activate coupling. The speed of the following spindle

S2 results from the speed of the leading spindle S1 and

the coupling factor.

N26 M2=3 S2=100

; Programming the differential speed, S2 is the follow-

ing spindle.

Application

Manufacturing operations with positioned leading spindle and rotating tools require exact

synchronism with the counter spindle which then functions like a following spindle. A turret

rotating about the following spindle allows parts to be machined with different tool types.

The following diagram shows an application in which the tool is positioned parallel to the main

spindle.

0DLQ VSLQGOH ZLWK ZRUNSLHFH

&RXQWHUVSLQGOH ZLWK GULYHQ

WRRO LQ UHYROYHU

;

:RUNSLHFH

7RRO

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=

7XUQLQJ WRRO

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Q

Q

/HDG VSLQGOH

)ROORZLQJ VSLQGOH

Figure 15-4

Single-slide lathe with revolver around the Z axis

Extended Functions

812

Function Manual, 12/2018, A5E40874029B AB

S3: Synchronous spindle

15.4 Points to note

● The gear stage(s) of FS and LS for synchronous operation

● The following coupling properties are still applicable for permanently configured

synchronous spindle coupling:

- Block change response in synchronous spindle operation:

MD21320 $MC_COUPLE_BLOCK_CHANGE_CTRL_1

- Coupling cancellation response:

MD21330 $MC_COUPLE_RESET_MODE_1

- Write-protection for coupling parameters:

MD21340 $MC_COUPLE_IS_WRITE_PROT_1

- Transformation parameters for synchronous spindle coupling:

SD42300 $SC_COUPLE_RATIO_1[n]

Command behavior of FS and LS for setpoint coupling

In order to obtain the best possible synchronism in setpoint couplings, the FS and LS must

have the same dynamic response as the response to setpoint changes. The axial control loops

(position, speed and current controllers) should each be set to the optimum value so that

variances can be eliminated as quickly and efficiently as possible.

The dynamic response adaptation function in the setpoint branch is provided to adapt different

axis dynamic responses without loss of control quality (see also Section "K3: Compensations

(Page 253)"). The following control parameters must each be set optimally for the FS and LS:

● K_V factor (MD32200 $MA_POSCTRL_GAIN)

● Feedforward control parameters

MD32620 $MA_FFW_MODE

MD32610 $MA_VELO_FFW_WEIGHT

MD32650 $MA_AX_INERTIA

MD32800 $MA_EQUIV_CURRCTRL_TIME

MD32810 $MA_EQUIV_SPEEDCTRL_TIME

Behavior during loss of synchronism:

● Axis-specific MD32620 $MA_FFW_MODE

We recommend setting the feedforward control mode of the following axis to speed

feedforward control with Tt symmetrization MD32620 = 3.

This feedforward control mode can be further optimized for a more secure symmetrization

process by changing the axis-specific machine data:

Machine data

Meaning

MD32810 EQUIV_SPEEDCTRL_TIME

Equivalent time constant speed control loop for

feedforward control

MD37200 COUPLE_POS_TOL_COURSE

Threshold value for "Coarse synchronism"

MD37210 COUPLE_POS_TOL_FINE

Threshold value for "Fine synchronism"

MD37220 COUPLE_VELO_TOL_COURSE

Velocity tolerance 'coarse'

MD37220 COUPLE_VELO_TOL_FINE

Velocity tolerance 'fine'

In such cases, higher threshold values for the synchronism signals and larger position and/or

speed tolerances result in more stable results.

Extended Functions

Function Manual, 12/2018, A5E40874029B AB

817

S3: Synchronous spindle

15.7 Data lists

Program code

Comment

N75 SPCON(2)

; Bring following spindle into closed-loop po-

sition control

N80 COUPON (S2, S1, 45)

; On-the-fly coupling to offset position = 45

degrees

N200 FA [S2] = 100

; Positioning speed = 100 degrees/min

N205 SPOS[2] = IC(-90)

; Traverse with 90° overlay in negative direc-

tion

N210 WAITC(S2, "Fine")

; Wait for "fine" synchronism

N212 G1 X.., Y.. F...

; Machining

N215 SPOS[2] = IC(180)

; Traverse with 180° overlay in positive direc-

tion

N220 G4 S50

; Dwell time = 50 revolutions

; of master spindle

N225 FA [S2] = 0

; Activate configured velocity (MD)

N230 SPOS[2] = IC (-7200)

; 20 rev. with configured velocity

; in neg. direction

N350 COUPOF (S2, S1)

; On-the-fly decoupling, S = S2 = 3000

N355 SPOSA[2] = 0

; Stop FS at zero degrees

N360 G0 X0 Y0

N365 WAITS(2)

; Wait for spindle 2

N370 M5

; Stop FS

N375 M30

15.7

Data lists

15.7.1

Machine data

15.7.1.1

NC-specific machine data

Number

Identifier: $MN_

Description

10000

AXCONF_MACHAX_NAME_TAB

Machine axis name

15.7.1.2

Channelspecific machine data

Number

Identifier: $MC_

Description

20070

AXCONF_MACHAX_USED

Machine axis number valid in channel

21300

COUPLE_AXIS_1

Definition of synchronous spindle pair

21310

COUPLING_MODE_1

Type of coupling in synchronous spindle mode

Extended Functions

822

Function Manual, 12/2018, A5E40874029B AB

S3: Synchronous spindle

15.7 Data lists

Number

Identifier: $MC_

Description

21320

COUPLE_BLOCK_CHANGE_CTRL_1

Block change behavior in synchronous spindle opera-

tion

21330

COUPLE_RESET_MODE_1

Coupling abort behavior

21340

COUPLE_IS_WRITE_PROT_1

Coupling parameters are write-protected

15.7.1.3

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

30455

MISK_FUNCTION_MASK

Axis functions

30550

AXCONF_ASSIGN_MASTER_CHAN

Reset position of channel for axis change

32200

POSCTRL_GAIN

Servo gain factor (K_V factor)

32400

AX_JERK_ENABLE

Axial jerk limitation

32410

AX_JERK_TIME

Time constant for axial jerk filter

32420

JOG_AND_POS_JERK_ENABLE

Initial setting for axial jerk limitation

32430

JOG_AND_POS_MAX_JERK

Axial jerk

32610

VELO_FFW_WEIGHT

Feedforward control factor for speed feedforward control

32620

FFW_MODE

Feedforward control mode

32650

AX_INERTIA

Moment of inertia for torque feedforward control

32800

EQUIV_CURRCTRL_TIME

Equivalent time constant current control loop for feed-

forward control

32810

EQUIV_SPEEDCTRL_TIME

Equivalent time constant speed control loop for feedfor-

ward control

34080

REFP_MOVE_DIST

Reference point approach distance

34090

REFP_MOVE_DIST_CORR

Reference point offset

34100

REFP_SET_POS

Reference point value

35000

SPIND_ASSIGN_TO_MACHAX

Assignment of spindle to machine axis

37200

COUPLE_POS_TOL_COARSE

Threshold value for "Coarse synchronism"

37210

COUPLE_POS_TOL_FINE

Threshold value for "Fine synchronism"

37220

COUPLE_VELO_TOL_COARSE

Speed tolerance "coarse" between leading and follow-

ing spindles

37230

COUPLE_VELO_TOL_FINE

Speed tolerance "fine" between leading and following

spindles

15.7.2

Setting data

15.7.2.1

Channelspecific setting data

Number

Identifier: $SC_

Description

42300

COUPLE_RATIO_1

Transmission parameters for synchronous spindle operation

Extended Functions

Function Manual, 12/2018, A5E40874029B AB

823

S3: Synchronous spindle

15.7 Data lists

15.7.3

Signals

15.7.3.1

Signals to channel

Signal name

SINUMERIK 840D sl

SINUMERIK 828D

NC Start

DB21,

DBX7.1

DB320x.DBX7.1

NC Stop axes plus spindle

DB21,

DBX7.4

DB320x.DBX7.4

15.7.3.2

Signals from channel

Signal name

SINUMERIK 840D sl

SINUMERIK 828D

Dry run feedrate selected

DB21,

DBX24.6

DB170x.DBX0.6

Feedrate override selected for rapid traverse

DB21,

DBX25.3

DB170x.DBX1.3

15.7.3.3

Signals to axis/spindle

Signal name

SINUMERIK 840D sl

SINUMERIK 828D

Axis/spindle disable

DB31,

DBX1.3

DB380x.DBX1.3

Follow-up mode

DB31,

DBX1.4

DB380x.DBX1.4

Position measuring system 1, position measuring system 2 DB31,

DBX1.5/6

DB380x.DBX1.5/6

Controller enable

DB31,

DBX2.1

DB380x.DBX2.1

Distance-to-go/Spindle RESET

DB31,

DBX2.2

DB380x.DBX2.2

Spindle stop/feed stop

DB31,

DBX4.3

DB380x.DBX4.3

Traversing keys for JOG

DB31,

DBX4.6/7

DB380x.DBX4.6/7

Re-synchronize spindle 1, re-synchronize spindle 2

DB31,

DBX16.4/5

DB380x.DBX2000.4/5

Delete S value

DB31,

DBX16.7

DB380x.DBX2000.7

Feedrate override valid

DB31,

DBX17.0

DB380x.DBX2001.0

Invert M3/M4

DB31,

DBX17.6

DB380x.DBX2001.6

Spindle override

DB31,

DBB19

DB380x.DBB2003

Re-synchronizing

DB31,

DBX31.4

-

Disable synchronization

DB31,

DBX31.5

-

15.7.3.4

Signals from axis/spindle

Signal name

SINUMERIK 840D sl

SINUMERIK 828D

Referenced/synchronized 1, referenced/synchronized 2

DB31,

DBX60.4/5

DB390x.DBX0.4/5

Synchronous mode

DB31,

DBX84.4

DB390x.DBX2002.4

Synchronism fine

DB31,

DBX98.0

DB390x.DBX5002.0

Synchronism coarse

DB31,

DBX98.1

DB390x.DBX5002.1

Extended Functions

824

Function Manual, 12/2018, A5E40874029B AB

S3: Synchronous spindle

15.7 Data lists

Signal name

SINUMERIK 840D sl

SINUMERIK 828D

Actual value coupling

DB31,

DBX98.2

DB390x.DBX5002.2

Superimposed motion

DB31,

DBX98.4

DB390x.DBX5002.4

Leading spindle LS/LA active

DB31,

DBX99.0

DB390x.DBX5003.0

Following spindle FS/FA active

DB31,

DBX99.1

DB390x.DBX5003.1

15.7.4

System variables

System variable

Description

$P_COUP_OFFS[following spindle]

Programmed offset of the synchronous spindle

$AA_COUP_OFFS[following spindle]

Position offset for synchronous spindle (setpoint)

$VA_COUP_OFFS[following spindle]

Position offset for synchronous spindle (actual value)

For a more detailed description of system variables, see:

References:

List Manual System Variables

Extended Functions

Function Manual, 12/2018, A5E40874029B AB

825

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