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SINUMERIK 840D sl. Service - Functions. Manual (2018-2020) - page 69

M3: Coupled axes

10.6 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

Activation

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

allowed range for short periods.

Note

The user must restore the technological synchronization between machining and the

synchronism difference.

Acceleration mode

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

modes SOFTA and DRIVEAare 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.

References:

● CNC Commissioning Manual: NC, PLC, Drive

● Function Manual, Basic Functions; Velocities, Setpoint-Actual Value Systems, Closed-

Loop Control (G2)

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:

Special functions

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M3: Coupled axes

10.6 Dynamic response of following axis

MD22410 $MC_F_VALUES_ACTIVE_AFTER_RESET (F Function is active even after

RESET)

Value

Meaning

0

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

1

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.

References:

Function Manual, Synchronized Actions

10.6.2.2

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

Special functions

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M3: Coupled axes

10.7 General supplementary conditions

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.

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

N130 LEADON(AX4,X,2)

10.6.2.3

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.

10.7

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.

Special functions

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M3: Coupled axes

10.8 Data lists

10.8

Data lists

10.8.1

Machine data

10.8.1.1

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

10.8.1.2

Channelspecific machine data

Number

Identifier: $MC_

Description

20110

RESET_MODE_MASK

Definition of control basic setting after run-up and RE-

SET/part program end

20112

START_MODE_MASK

Definition of control basic setting after run-up and RE-

SET

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

Special functions

552

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M3: Coupled axes

10.8 Data lists

10.8.1.3

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"

10.8.2

Setting data

10.8.2.1

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

10.8.3

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

Special functions

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10.8 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

Special functions

554

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M3: Coupled axes

10.8 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

Special functions

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M3: Coupled axes

10.8 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

10.8.4

Signals

10.8.4.1

Signals to axis/spindle

Signal name

SINUMERIK 840D sl

SINUMERIK 828D

Feedrate override

DB31, ... DBX0.0-7

DB380x.DBB0

Axis disable

DB31, ... DBX1.3

DB380x.DBX1.3

Controller enable

DB31, ... DBX2.1

DB380x.DBX2.1

Activate handwheel

DB31, ... DBX4.0-2

DB380x.DBX4.0/1

Feed stop

DB31, ... DBX4.3

DB380x.DBX4.3

Enable following axis overlay

DB31, ... DBX26.4

DB380x.DBX5002.4

Synchronize following spindle

DB31, ... DBX31.4

DB380x.DBX5007.4

Special functions

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M3: Coupled axes

10.8 Data lists

Signal name

SINUMERIK 840D sl

SINUMERIK 828D

Disable synchronization

DB31, ... DBX31.5

DB380x.DBX5007.5

Track synchronism

DB31, ... DBX31.6

DB380x.DBX5007.6

Reset synchronism correction

DB31, ... DBX31.7

DB380x.DBX5007.7

10.8.4.2

Signals from axis/spindle

Signal name

SINUMERIK 840D sl

SINUMERIK 828D

Limiting of differential speed

DB31, ... DBX83.1

DB390x.DBX2001.1

Spindle in setpoint range, differential speed

DB31, ... DBX83.5

DB390x.DBX2001.5

Speed limit exceeded, total speed

DB31, ... DBX83.6

DB390x.DBX2001.6

Actual direction of rotation clockwise, total speed

DB31, ... DBX83.7

DB390x.DBX2001.7

Synchronous mode

DB31, ... DBX84.4

DB390x.DBX2002.4

Synchronism fine

DB31, ... DBX98.0

DB390x.DBX5002.0

Synchronism coarse

DB31, ... DBX98.1

DB390x.DBX5002.1

Actual value coupling

DB31, ... DBX98.2

DB390x.DBX5002.2

Overlaid movement

DB31, ... DBX98.4

DB390x.DBX5002.4

Velocity warning threshold

DB31, ... DBX98.5

DB390x.DBX5002.5

Acceleration warning threshold

DB31, ... DBX98.6

DB390x.DBX5002.6

Leading spindle active

DB31, ... DBX99.0

DB390x.DBX5003.0

Following spindle active

DB31, ... DBX99.1

DB390x.DBX5003.1

Synchronism correction implemented

DB31, ... DBX99.2

DB390x.DBX5003.2

Following axis accelerated

DB31, ... DBX99.3

DB390x.DBX5003.3

Synchronization in progress

DB31, ... DBX99.4

DB390x.DBX5003.4

Maximum velocity reached

DB31, ... DBX99.5

DB390x.DBX5003.5

Maximum acceleration reached

DB31, ... DBX99.6

DB390x.DBX5003.6

Synchronism correction is taken into account

DB31, ... DBX103.0

DB390x.DBX5007.0

Synchronism 2 fine

DB31, ... DBX103.4

DB390x.DBX5007.4

Synchronism 2 coarse

DB31, ... DBX103.5

DB390x.DBX5007.5

Special functions

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R3: Extended stop and retract

11.2 Control-managed ESR - 840D sl only

11.2.2

Drive-independent reactions

Generator operation

Generator operation is a drive function. Using the "Vdc control" function, the SINAMICS S120

drive unit can monitor the DC link group for undervoltage. When an adjustable voltage value

is fallen below, then the drive intended for the purpose is switched into generator operation.

The kinetic energy of the drive is used to buffer the DC link voltage. This allows the axes that

are still moving to be stopped and retracted in an ordering fashion on the NC side.

Note

At the instant that it is switched into generator operation, if an axis is in closed-loop position

control, then additional alarms can occur.

References

For detailed information on the SINAMICS S120 drive function "Vdc control", see:

Function Manual SINAMICS S120 Drive Functions

11.2.3

Power failure detection and bridging

DC link voltage limit values

The DC link is monitored against the limit values shown in the following diagram:

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Figure 11-1

DC link voltage limit values

The drive and DC link pulses are cancelled at specific voltage levels, which means that the

drives coast-down. If this behavior is not desired, the excess energy can be discharged using

Special functions

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561

R3: Extended stop and retract

11.2 Control-managed ESR - 840D sl only

a resistor module. The operating range of the resistor module (shown highlighted in the

diagram) lies below the critical voltage level.

Note

The pulse power of the resistor module is greater than the infeed power.

Monitoring the intermediate circuit minimum voltage limit

The DC link voltage can be monitored against a limit value that can be parameterized in the

drive:

● p1248 (DC link voltage - lower voltage threshold)

When the limit value is fallen below, the following signal is set in the message word (MELDW)

of the PROFIdrive telegram:

● MELDW.Bit4 = 1 (VDC_min controller is active (Vdc link < p1248))

The signal can be used in the NC to initiate ESR responses.

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Monitoring the DC link voltage

11.2.4

NC-controlled extended stop

Axis-specific parameterization

The NC-controlled extended stopping for a machine axis is activated using machine data:

Special functions

562

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R3: Extended stop and retract

11.2 Control-managed ESR - 840D sl only

MD37500 $MA_ESR_REACTION[<axis>] = 22

Note

Path axes

If NC-controlled extended stopping is parameterized for a path axis, then the corresponding

behavior is also transferred to all other path axes of the channel.

Leading and following axis

During the extended stopping, a following axis of an electronic gearbox follows the leading

axes according to the parameterized/programmed motion principle. That is why independent

braking is not possible for the following axis during the times specified in MD21380

$MC_DELAY_TIME1 and MD21381 $MC_ESR_DELAY_TIME2. MD21380

$MC_DELAY_TIME1MD21381 $MC_ESR_DELAY_TIME2 A prerequsite for correct

functioning of ESR is that all necessary enable signals must be set and remain set.

Channel-specific parameterization

The timing within a channel is parameterized using the following machine data:

● MD21380 $MC_ESR_DELAY_TIME1[<axis>] (delay time ESR axes)

● MD21381 $MC_ESR_DELAY_TIME2[<axis>] (ESR time for interpolatory braking)

Time sequence

After initiating ESR, the axis continues to traverse with the actual speed. After a delay time

has expired (..._TIME1), the axis is braked, interpolating.

The set time (..._TIME 2) is the maximum time available for interpolatory braking. After this

time has expired, a setpoint of 0 is output for the axis, and the follow-up mode is activated.

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MD21380 $MC_ESR_DELAY_TIME1 (delay time, ESR axes)

T2

MD21381 $MC_ESR_DELAY_TIME2 (ESR time for interpolatory braking)

n₁

Actual speed, which could be braked to a standstill within T2

n₂

Actual speed, which could not be braked to a standstill within T2 ⇒ fast braking

Special functions

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11.2 Control-managed ESR - 840D sl only

Initiating the retraction

Retraction motion LIFTFAST is initiated in a channel, if, in this channel there is an axis for

which retraction motion is enabled ($AA_ESR_ENABLE == 1) - and the trigger for fast

retraction ($AC_ESR_TRIGGER = 1) is set.

Requirement

● The retraction position must be programmed in the NC program.

● The enable signals must be set and remain set for retraction motion.

11.2.5.2

Parameterization: Machine data

Activation

NC-controlled retraction for an axis is activated using machine data:

MD37500 $MA_ESR_REACTION = 21

Delay times

Two different retraction times can be parameterized for the retraction:

● MD21380 $MC_ESR_DELAY_TIME1 = <delay time: Traversing motion>

● MD21381 $MC_ESR_DELAY_TIME2 = <delay time: Interpolatory braking>

To perform retraction motion, the sum of the two delay times are available. After the total delay

time has expired, fast braking is initiated for the retraction axes with a setpoint of 0 - with

subsequent switchover into follow-up (tracking) operation.

Mirroring

The machine data is used to set, whether, for active "Mirroring" function (DB31, … DBX97.2),

the retraction direction should be mirrored for "Fast retraction from the contour" (LIFTFAST):

MD21202 $MC_LIFTFAST_WITH_MIRROR = TRUE

The mirroring of the retraction direction only refers to the direction components perpendicular

to the tool direction.

Stop behavior

The stop response for lift motion is set on a channel-for-general basis using the following

machine data:

MD21204 $MC_LIFTFAST_STOP_COND, <bit> = <value>

Bit

Val-

Description

ue

0

Response to the axis-specific NC/PLC interface signal DB31 DBB4.3 (feed stop) or context-

sensitive interpolator stop.

0

Retraction motion is stopped for axis-specific feed stop or context-sensitive interpolator

stop

1

Retraction motion is not stopped for axis-specific feed stop or context-sensitive interpo-

lator stop

Special functions

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11.2 Control-managed ESR - 840D sl only

Bit

Val-

Description

ue

1

Response to the channel-specific NC/PLC interface signal DB21, ... DBB6.0 (feed inhibit)

0

Retraction motion stop for feed disable in the channel

1

No retraction motion stop for feed disable in the channel

Note

Influence of the interface signals

● The axis-specific NC/PLC interface signal DB31 DBB4.3 (feed stop) influences the

complete retraction motion. All axis motion defined using POLFMASK and POLFMLIN are

stopped.

● The channel-specific NC/PLC interface signal, DB21, ... DBB7.3 (NC stop) has no effect

on the retraction movement.

See also

Lift fast with linear relation of axes (Page 597)

11.2.5.3

Parameterization: System variable

Axis-specific function enable

An axis is enabled for retraction on an axis-for-axis basis using system variable:

$AA_ESR_ENABLE[<axis>] = 1

Channel-specific initiation

Retraction motion is initiated on a channel-for-channel basis using system variable:

$AC_ESR_TRIGGER = 1

Retraction is then realized in all channel axes for which the following applies:

$AA_ESR_ENABLE[<axis>] == 1 AND MD37500 $MA_ESR_REACTION[axis] == 21 OR 22

11.2.5.4

Programming (POLF, POLFA, POLFMASK, POLFMLIN)

Syntax

POLF(<axis>)=<position>

POLFA(<axis>,<type>,<position>)

POLFA(<axis>,<type>)

POLFMASK(<axis_1>,<axis_2>,...)

POLFMLIN(<axis_1>,<axis_2>,...)

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Meaning

POLF:

Address for specifying the target position of the retraction axis

POLF is modal.

<axis>:

Channel axis name of the retraction axis

<position>:

Retraction position

Type:

REAL

The geometry axis is retracted in the WCS. For all other chan-

nel axes in the MCS.

With the same identifiers for geometry and channel/machine

axis, retraction is in the WCS.

POLFA:

Predefined subprogram call for the specification of the retraction position of single

axes

<axis>:

Channel axis name of the retraction axis

<type>:

Position specification mode

Type:

INT

Value:

0

Mark position value as invalid

1

Position value is absolute

2

Position value is incremental (distance)

Note:

If an axis is not a single axis or if the type is missing or type=0,

then a corresponding alarm is output.

<position>:

Retraction position (see above) (optional)

Note:

The position value is also accepted with type=0. Only this value

is marked as invalid and has to be reprogrammed for retraction.

POLFMASK:

Predefined subprogram call for selection of the axes that are to be retracted after

tripping of rapid lift independently of one another.

<axis_1>,…:

Names of the axes that are to be traversed to their positions

defined with POLF during rapid lift.

All the axes specified must be in the same coordinate system.

POLFMASK() without specification of an axis deactivates the rapid lift for all axes

that have been retracted independently of one another.

POLFMLIN:

Predefined subprogram call for selection of the axes that are to be retracted after

tripping of rapid lift in linear relation.

<axis_1>,…:

See above.

POLFMLIN() without specification of an axis deactivates the rapid lift for all axes

that have been retracted in linear relation.

Note

Before rapid retraction to a fixed position can be enabled via POLFMASK or POLFMLIN, a

position must have been programmed with POLF for the selected axes.

Note

If axes are enabled one after the other with POLFMASK, POLFMLIN or POLFMLIN, POLFMASK,

then the last definition always applies for the particular axis.

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Note

The positions programmed with POLF and the activation by POLFMASK or POLFMLIN are

deleted when the part program is started. This means that the user must reprogram the values

for POLF and the selected axes in POLFMASK or POLFMLIN in each part program.

Note

If, when using the abbreviated form POLFA only the type is changed, then the user must ensure

that either the retraction position or the retraction path contains a practical and sensible value.

In particular, the retraction position and the retraction path have to be set again after a warm

restart.

Example: Retracting an individual axis

Program code

Comment

MD37500 $MA_ESR_REACTION[AX1]=21

; NC-controlled retraction.

$AA_ESR_ENABLE[AX1]=1

POLFA(AX1,1,20.0)

; AX1 is assigned the axial retraction

position 20.0 (absolute).

$AA_ESR_TRIGGER[AX1]=1

; Retraction starts from here.

11.2.5.5

Boundary conditions

General supplementary conditions

Exceptions

Retraction and/or rapid lift is not executed for the following axes:

● Axes, which are not permanently assigned a channel

● Axes, which are in the open-loop speed-controlled mode (spindles)

● Axes, which are interpolated as positioning spindles (SPOS/SPOSA)

Modulo rotary axes

Modulo rotary axes respond to rapid lift as follows:

● For incremental programming of the target position, the latter is approached without modulo

offset.

● With absolute programming, the target position is approached time-optimized with the use

of modulo offsets. This is almost identical to positioning via the shortest path.

Utilizing the axis dynamics

The retraction movement is interpolated linearly, using the maximum acceleration and speed

of the axes involved in POLFLIN.

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The capacitance specified in the table for the minimum energy content (E

min

for C_min) takes into

account a component tolerance of -20% (worst case).

Note

It is recommended that the SIZER configuration tool be used to determine the total capacitance

of the DC link available.

Table 11-1

SINAMICS infeeds (ALMs): Nominal and minimum buffer times

ALM

Max. capacitance

Energy content

Energy content E_min

Backup time t_Pmax

Buffer time t_Pmin for

C_max[μF]

E_max for C_max [Ws]

for C_min [Ws]

for P_max [ms]

P_max [ms]

P_max[kW]

16

20000

1800

1440

101,25

81,00

36

20000

1800

1440

45,00

36,00

55

20000

1800

1440

29,46

23,56

80

20000

1800

1440

20,25

16,20

120

20000

1800

1440

13,50

10,80

Energy balance

When configuring retraction motion, it is always necessary to consider the energy flow

(balance) to find out whether an additional capacitor module or a generator axis (with

correspondingly dimensioned flywheel effect) is required - or not.

Stopping as energy supply

From approx. the third interpolator clock cycle, the speed setpoints of the configured stopping

or retraction axes change. After this time the braking phase starts (if no drive independent

shutdown is projected for this axis).

As soon as the braking process is initiated, the energy released in this manner is available for

retraction motion. An energy balance must be used to ensure that the kinetic energy of the

braking axes is sufficient for retraction.

The energy balance shows the maximum setting for the interpolator clock cycle time, which

will allow a safe emergency retraction to be executed.

Example

With a 16 kW unit under maximum load and minimum intermediate circuit capacity it should

be possible to execute an emergency retraction without generator operation. Interpolator clock

cycle time may theoretically not be more than 4.86 ms, i.e. in this case a maximum of 4 ms

could be set.

If necessary, a more powerful NCU must be chosen in order to achieve optimal conditions.

Special functions

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If one of the two enable signals is not available, then in the case of ESR, the axis responds

corresponding to the following table:

Enable signals

Response in the case of ESR

● $AA_ESR_ ENABLE[<axis>] = 1

For the axis, implicit NC-controlled stopping becomes active, corresponding

to MD37500, $MA_ESR_REACTION[<axis>] = 22.

● No enable via POLFMASK

● $AA_ESR_ ENABLE[<axis>] = 0

Axis is a path axis:

For the axis, the ESR response is implicitly changed to NC-controlled stop-

● Enable via POLFMASK(<axis>)

ping. The response corresponds then to a configuration of MD37500,

$MA_ESR_REACTION[<axis>] = 22

Axis is a special axis:

The axis is stopped with rapid stop.

Examples for axes with path relationship

For the subsequent examples, two path axes X and Y are assumed, which are configured as

NC-controlled retraction axes and are programmed for the retraction positions:

● MD37500, $MA_ESR_REACTION[X] = 21

● MD37500, $MA_ESR_REACTION[Y] = 21

● POLF[X]=<retraction position> LFPOS

● POLF[Y]=<retraction position> LFPOS

Initial situation

Response in the case of ESR

● $AA_ESR_ ENABLE[X] = 1

Retraction motion in X and Y.

● $AA_ESR_ ENABLE[Y] = 1

● POLFMASK(X,Y)

● Program traversing motion: Y

● $AA_ESR_ ENABLE[X] = 0

X does not have ESR enable. As X is a path axis, for X, the ESR response

is implicitly changed to 22 (stopping). This is the reason that X continues to

● $AA_ESR_ ENABLE[Y] = 1

traverse corresponding to the programmed traversing motion.

● POLFMASK(X,Y)

Y executes retraction motion.

● Program traversing motion: X and Y

After the delay time for ESR axes expires, MD21380, $MC_ESR_DE-

LAY_TIME1, X is stopped with the path acceleration.

● $AA_ESR_ ENABLE[X] = 1

X has no retraction enable (POLFMASK). X does not execute any retraction

motion. As X is a path axis, for X, the ESR response is implicitly changed to

● $AA_ESR_ ENABLE[Y] = 1

22 (stopping). This is the reason that X continues to traverse corresponding

● POLFMASK(Y)

to the programmed traversing motion.

● Program traversing motion: X

Y executes retraction motion.

After the delay time for ESR axes expires, MD21380, $MC_ESR_DE-

LAY_TIME1, X is stopped with the path acceleration.

● $AA_ESR_ ENABLE[X] = 1

Y has not been enabled for retraction (POLFMASK). see lines above, syntax

Y does not execute retraction motion. As Y is a path axis, for Y, the ESR

● $AA_ESR_ ENABLE[Y] = 1

response is implicitly changed to 22 (stopping). This is the reason that Y

● POLFMASK(X)

continues to traverse corresponding to the programmed traversing motion.

● Program traversing motion: X and Y

X executes retraction motion.

After the delay time for ESR axes expires, MD21380, $MC_ESR_DE-

LAY_TIME1, Y is stopped with the path acceleration.

Special functions

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Examples for axes without path relationship

For the subsequent examples, path axes X and a command axis B are assumed, which are

configured as NC-controlled retraction axis:

● MD37500, $MA_ESR_REACTION[X] = 21

● MD37500, $MA_ESR_REACTION[B] = 21

Initial situation

Response in the case of ESR

● $AA_ESR_ ENABLE[X] = 1

B is not enabled for ESR. As B is not a path axis, B is immediately stopped

with a rapid stop.

● $AA_ESR_ ENABLE[B] = 0

X executes retraction motion.

● POLFMASK(X)

● Program traversing motion: X and B

● $AA_ESR_ ENABLE[X] = 1

B is not enabled for retraction (POLFMASK). However, as B is enabled for

ESR, for B, the ESR response is implicitly changed to 22 (stopping). This is

● $AA_ESR_ ENABLE[B] = 1

the reason that B continues to traverse corresponding to the programmed

● POLFMASK(X)

traversing motion.

● Program traversing motion: X and B

Y executes retraction motion.

After the delay time for ESR axes expires, MD21380, $MC_ESR_DE-

LAY_TIME1, B is stopped with axial acceleration.

11.2.10.2

POWER OFF/POWER ON

If the user-specific retraction logic is programmed within motion synchronized actions, then it

must be observed that this is still not active when the control boots (POWER ON). A retraction

logic, which should be active after POWER ON, must therefore lie in an ASUB started from

the PLC or must be called event-controlled.

References

For detailed information about event-driven program calls see:

Function Manual, Basic Functions; Mode Group, Channel, Program Operation, Reset

Response (K1), Section: Eventcontrolled program calls

11.2.10.3

Operating mode change, NC Stop, reset

Static synchronized actions (IDS keyword) can be used for user-specific retraction logic as the

following system states or state change have no influence on this:

● Operating mode change, e.g. DB11 DBX0.0 (AUTOMATIC)

● NC stop, e.g. DB21, ... DBX7.3 (NC stop)

● Reset, e.g. DB21, ... DBX7.7 (reset)

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Note

NC stop and command axes

Traversing command axes is interrupted for an NC stop.

Note

POLF/POLFMASK reset and program commands

For reset, the programmed absolute retraction positions (POLF) and the enable signals for the

retraction axes (POLFMASK) are not deleted.

11.2.10.4

Part program start, NC start

In order that a defined initial state is available when a part program starts, the programmed

absolute retraction positions and the enable signals of the retraction axes are deleted when

the part program starts.

Note

Retraction positions and enable signals

When a part program starts, the absolute retraction positions (POLF) and the enable signals

of the retraction axes (POLFMASK) must be reprogrammed corresponding to the actual

requirements.

11.2.10.5

Alarm behavior

The alarm response depends on the axis in which a fault occurs:

● Fault in an axis outside the axis grouping of an electronic gear:

This axis switches off "normally". Extended stopping and retraction continue to operate as

before - or are initiated by such a fault.

● Error in a leading axis (LA):

selective switchover to actual value linkage already during stop, otherwise as previously.

● Error in a following axis (FA):

- Carry out retract: Retraction axis may not be a following axis, that is, no conflict.

- Carry out stop: The following axis may react with uncontrollable behavior. Saving the

workpiece/tool must be left to the retraction; however, the stop should not disrupt the

process any further.

Special functions

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ESR executed autonomously in the drive can also be used in combination with control-

managed ESR. This also allows stopping and retraction motion in the drives if they are no

longer specified from the control, e.g. as a result of a communication failure.

Note

DRIVE-CLiQ

For possibly occurring DRIVE-CLiQ errors, in order to keep the reaction to the functions of the

drive-autonomous ESR as low as possible, within the scope of ESR, we recommend that the

motor modules involved are not connected through a line-type topology, but instead are directly

connected to the Control Unit (CU).

Link axes

The "Drive-autonomous extended stop and retract (ESR)" function cannot be used in

conjunction with link axes.

Requirements

The following conditions must be fulfilled:

● SINAMICS and SINUMERIK software version: ≥ V4.4

● Servo drive object, PROFIdrive telegram: 102 - 199

● Servo drive object, function module "ESR" active

The function module "Extended stop and retract (ESR)" must be activated via the drive

wizard of SINUMERIK Operate. For a description of the drive wizard, see: SINUMERIK

Operate online help.

● Servo drive object, generator operation (Vdc control) active in a drive

● Control unit drive object, PROFIdrive telegram: 390, 391

● The 24 V power supply for the modules is buffered via CSM or UPS

11.3.2

Configuring stopping in the drive

Drive integrated shutdown is configured via the following drive parameters:

Parameter

Description

p0888

ESR: Configuration

Value

Meaning

1

Extended stopping (function integrated in the drive)

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Parameter

Description

p0891

ESR: Off ramp

Value

Meaning

0

OFF3 (default)

The drive is braked along the OFF3 down ramp by immediately entering n_set

= 0 (p1135: OFF3 ramp-down time).

1

OFF1

By immediately entering n_set = 0, the drive is braked along the ramp gener-

ator down ramp (p1121: ramp-function generator ramp-down time).

Parameter

Description

p0892

ESR: Timer

The drive travels at a constant velocity for the configured time with the speed setpoint

that was present when the fault occurred.

6SHHG Q

S

S

$86

$86

7

7

7LPH W

T1

Time at which stopping was triggered

T2

Instant in time after the time that was configured in p0892 has expired

OFF3/OFF1

Braking ramp as a function of p0891

Figure 11-3

Response to drive-integrated stopping

Feedback signal

The stop status is returned to the control (see Section "Feedback of the ESR status

(Page 585)").

References

For a detailed description of drive parameters, refer to:

SINAMICS S120/S150 Parameter Manual

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11.3.3

Configuring retraction in the drive

Drive integrated retraction is configured using the following drive parameters:

Parameter

Description

p0888

ESR: Configuration

Value

Meaning

2

Extended retraction (function integrated in the drive)

Parameter

Description

p0891

ESR: Off ramp

Value

Meaning

0

OFF3 (default)

The drive is braked along the OFF3 down ramp by immediately entering n_set

= 0 (p1135: OFF3 ramp-down time).

1

OFF1

By immediately entering n_set = 0, the drive is braked along the ramp gener-

ator down ramp (p1121: ramp-function generator ramp-down time).

Parameter

Description

p0892

ESR: Timer

The parameter specifies the total time that elapses to reach the speed specified in

p0893 followed by constant velocity travel.

This is followed by an OFF1 or OFF3 ramp depending on the parameterization in p0891.

Parameter

Description

p0893

ESR: Speed

The parameter specifies the speed (retraction speed) that is reached when initiating

retraction via an OFF3 ramp.

Special functions

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6SHHG Q

S

S

$86

S

$86

$86

7

7

7

7LPH W

T1

Instant in time that retraction was initiated

T2

Instant in time when the retraction speed specified in p0893 is reached

T3

Instant in time after the time that was configured in p0892 has expired

Figure 11-4

Behavior for drive-integrated retraction

Feedback signal

The retract status is returned to the control (see Section "Feedback of the ESR status

(Page 585)").

References

For a detailed description of drive parameters, refer to:

SINAMICS S120/S150 Parameter Manual

11.3.4

Configuring generator operation in the drive

The generator mode for the drive-autonomous ESR is configured using the following drive

parameters:

Parameter

Description

p0888

ESR: Configuration

Value

Meaning

3

Generator operation (Vdc controller)

Parameter

Description

p1240

Vdc controller or Vdc monitoring configuration

Value

Meaning

2

When reaching the lower DC link voltage threshold (p1248) - for ESR - the

motor is braked in order to utilize its kinetic energy to buffer the DC link.

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Parameter

Description

p1248

Lower DC link voltage threshold

Setting the lower threshold for the DC link voltage. For p1240 = 2, this threshold is used

as setpoint limit for the Vdc_min controller.

'& OLQN YROWDJH 9

S

S

U

7

7

7LPH W

p1244

Upper DC link voltage threshold

p1248

Lower DC link voltage threshold

r0208

Rated power unit line supply voltage.

The pulses are canceled if the DC link voltage drops below 0.9*r0208

T1

Instant in time at which generator operation was triggered

T2

Instant in time at which generator operation was exited

Figure 11-5

Configuring_drive_integrated_generator_operation

Generator minimum speed

The lower limit of the motor speed of the generator axis is configured using drive parameter

p2161:

Parameter

Description

p2161

Speed threshold value 3

Speed threshold value for the message: |n_act| < speed threshold value 3

Feedback signal

The generator operation status is returned to the control (see Section "Feedback of the ESR

status (Page 585)").

References

A detailed description of drive parameters and the Vdc control can be found in:

● SINAMICS S120/S150 List Manual

● SINAMICS S120 Function Manual; Section "Servo control" > "Vdc control"

Special functions

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11.3.5

ESR is enabled via system variable

The ESR response of an axis, configured via drive parameter, must be programmed on a user-

specific basis in a part program/synchronized action using the following axis-specific system

variable:

$AA_ESR_ENABLE[<axis>]

Value

Meaning

1

ESR responses enabled in the drive

0

ESR responses inhibited in the drive

11.3.6

Triggering ESR via system variable

Triggering ESR responses, configured via drive parameter and enabled via

$AA_ESR_ENABLE[<axis>], must be programmed on a user-specific basis in a part program/

synchronized action via the following NC-specific system variable:

$AN_ESR_TRIGGER

Value

Meaning

1

trigger drive-integrated ESR reactions that have been released

0

do not trigger drive-integrated ESR reactions that have been released

Note

The trigger signal must be active in the part program/synchronized action for at least 2 IPO

cycles to ensure that the PROFIdrive telegram is transferred to the drive.

Mapping in the drive unit

System variable $AN_ESR_TRIGGER is mapped to drive parameter p0890.0. Interconnecting

drive parameter p0890.0 with the corresponding information in telegram 390 or 391 to the

Control Unit is realized automatically when the drive unit commissions the ESR reactions.

References

For a detailed description of drive parameters, refer to:

SINAMICS S120/S150 List Manual

11.3.7

Feedback of the ESR status

The drive signals back the actual ESR status to the control using the message word (MELDW)

of the cyclic PROFIdrive telegram. In the PLC, the status can be read via system variables

and NC/PLC interface signals.

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System variable

The system variables can be evaluated in the part program / synchronized action, for example,

in order to trigger the drive-autonomous ESR (see Section "Triggering ESR via system

variable (Page 585)") or to acknowledge the ESR reactions triggered in the drive (see Section

"Acknowledge ESR reactions (Page 586)").

Interrelationship between signals

MELDW

System variable

NC/PLC interface signal

Meaning

MELDW.Bit 9

$AA_ESR_STAT.Bit 2

DB31, … DBX95.2

ESR: Reaction triggered or generator operation

active (r0887.12)

(r0887.12)

MELDW.Bit 4

$AA_ESR_STAT.Bit 3

DB31, … DBX95.1

ESR: DC link undervoltage (p1248)

(r0056.15)

MELDW.Bit 2

$AA_ESR_STAT.Bit 4

DB31, … DBX95.3

ESR, generator operation: Speed lower than min-

imum (p2161)

(r2199.0)

11.3.8

Acknowledge ESR reactions

Acknowledging axis-specific drive-independent ESR reactions must be programmed on a user-

specific basis in a part program/synchronized action. After the ESR reaction in the drive has

been completed, an edge change must be generated in the system variables

$AA_ESR_ENABLE: 1→0→1. In order that the drive-integrated ESR reactions can be

retriggered, the system variable $AN_ESR_TRIGGER must also be reset to a value of 0.

Special functions

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System variable and drive parameters

The following diagram shows the relationship between system variables and drive parameters

when triggering and acknowledging ESR reactions.

$$B(65B(1$%/(> D[LV!@

$1B(65B75,**(5

$$B(65B67$7 %,7 > D[LV!@

U

(65 WULJJHUHG

U

(65 UHDFWLRQ EHLQJ H[HFXWHG

① NC: Enabling the ESR reaction via $AA_ESR_ENABLE = 1 (axis-specific)

② NC: Triggering ESR responses via $AN_ESR_TRIGGER = 1

③ Drive: The triggering of the ESR reaction has been detected (CU_STW.2 == 1) ⇒

r0887.12 = 1 AND r0887.13 = 1

Feedback signal to the NC via $AA_ESR_STAT.BIT2 = 1 (axis-specific)

④ NC: Acknowledging the ESR reaction via $AA_ESR_ENABLE = 0 (axis-specific)

Black: At instant in time ④, the ESR reaction no longer runs (r0887.13 == 0) ⇒

⑤ Drive: Reset "ESR triggered": r0887.12 = 0

Feedback signal to the NC via $AA_ESR_STAT.BIT2 = 0 (axis-specific)

⑥ NC: The ESR reaction can be re-enabled ⇒

$AA_ESR_ENABLE = 1 AND $AN_ESR_TRIGGER = 0

Red: At instant in time ④, the ESR reaction still runs (r0887.13 == 1) ⇒

⑤ Drive: "ESR initiated" is only reset (r0887.12 = 0), if the ESR response in the drive has been

completed: r0887.13 == 0

Feedback signal to the NC via $AA_ESR_STAT.BIT2 = 0 (axis-specific)

⑥ See ⑥ above

Figure 11-6

Sequence: Trigger and acknowledge drive-integrated ESR reactions

11.3.9

Configuring ESR in the part program

Configuring drive-autonomous ESR functions "stop" and "retract" can be changed using the

commands from the part program described in the following.

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11.3.9.1

Stopping (ESRS)

Syntax

ESRS(<access_1>,<stopping time_1>[,...,<axis_n>,<stopping time_n>])

Meaning

ESRS:

Using the function, drive parameters can be changed regarding the drive-au-

tonomous "stop" ESR function.

Special situations:

● Must be alone in the block

● Triggers a preprocessing stop

● Cannot be used in synchronized actions

● A maximum of five axes can be programmed per function call; n = 5

<axis_n>:

For the specified axis, writes to drive parameter p0888 (configuration): p0888

= 1

Data type:

AXIS

Range of values:

Channel axis name

<stopping

For the axis specified under <Axis_n>, writes to drive parameter p0892 (tim-

time_n>:

er): P0892 = <stopping time_n>

Unit:

s

Data type:

REAL

Range of values:

0.00 - 20.00

11.3.9.2

Retraction (ESRR)

Syntax

ESRR(<axis_1>,<retraction distance_1>,<retraction

velocity_1>[,...,<axis_n>,<retraction distance_n>,<retraction

velocity_n>])

Special functions

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Meaning

ESRR:

Using the function, drive parameters can be changed regarding the drive-au-

tonomous "retract" ESR function.

Special situations:

● Must be alone in the block

● Triggers a preprocessing stop

● Cannot be used in synchronized actions

● A maximum of five axes can be programmed per function call; n = 5

<axis_n>:

For the specified axis, writes to drive parameter p0888 (configuration): p0888

= 2

Data type:

AXIS

Range of values:

Channel axis name

<retraction

For the axis specified under <Axis_n>, writes to drive parameter p0893 (re-

velocity_n>:

traction speed):

p0893 = (<retraction velocity> based on the currently effective total transmis-

sion ratio converted into the corresponding retraction speed)

Unit:

mm/min, inch/min, degrees/min (depending on the unit of

the axis)

Data type:

REAL

Range of values:

0.00 - MAX

<retraction

For the axis specified under <Axis_n>, writes to drive parameter p0892 (re-

distance_n>:

traction time):

p0892 = <retraction distance_n> / <retraction velocity _n>

Unit:

mm, inches, degrees (depending on the unit of the axis)

Data type:

REAL

Range of values:

MIN - MAX

Note

Retraction speed

It should be ensured that the drive can reach the programmed retraction speed (see

parameters <retraction velocity_n>) within the retraction time (see parameter <retraction

distance _n>). The settings in the following drive parameters should be checked:

● p1082[0...n] (maximum speed)

● p1135[0...n] (OFF3 ramp-down time)

Retraction path

The conversion of the retraction path into a retraction duration for drive parameter p0892 is

performed under the assumption that the retraction motion is triggered at axis standstill (see

"Figure 11-5 Configuring_drive_integrated_generator_operation (Page 584)").

If retraction motion is triggered while the axis is traversing, the actually traversed retraction

distance differs from the programmed retraction distance due to the fact that traversing motion

is superimposed on the retraction motion.

Special functions

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R3: Extended stop and retract

11.4 Boundary conditions

ESR reactions that are not influenced by safety reactions

In order that drive-autonomous ESR reactions in conjunction with Safety Integrated are not

influenced by safety reactions as a result of STOP E, STOP F executed in parallel or

communication failure, then the appropriate delay times must be configured in the drive

regarding safety reactions and the corresponding safety trigger sources to trigger the drive-

autonomous ESR reactions.

Delay times

Delay times in the drive are configured using the following drive parameters:

● p9554 (transition time from STOP E to "Safe Operating Stop" (SOS))

● p9555 (transition time STOP F to STOP B)

● p9580 (wait time after which the pulses are safely cancelled after bus failure)

● p9697 (delay time for the pulse suppression after bus failure)

Safety trigger sources

Using a BICO interconnection of drive parameter p0890 (BI: ESR trigger) ESR reactions can

also be triggered with the safety reactions STOP E, STOP F and communication failure:

Parameter

BICO interconnection

Effect: Trigger ESR reactions for

with:

p0890[1]

r9721[15]

Safety STOP E

p0890[2]

r9723[1]

Safety STOP F

p0890[3]

r9723[2]

Safety communication failure

References

A detailed description of the drive parameters and the BICO technology can be found in:

● SINAMICS S120/S150 List Manual

● SINAMICS S120 Function Manual; Chapter "Fundamentals of drive technology" > "BICO

technology: Interconnecting signals"

11.4

Boundary conditions

Transformation

If NC-controlled extended stopping and retraction is activated for anaxis involved in an active

transformation, then extended stopping and retraction must also be activated for all other axes

involved in the transformation. Otherwise, when activating extended stopping and retraction,

it is possible that the transformation group will ungrouped.

Special functions

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R3: Extended stop and retract

11.5 Examples

Program code

Comment

N90 X155 Z-128 K10

; dto.

N100 X145 Z-168 K10

; dto.

N110 X120 I10

; dto.

N120 G0 Z0 LFOF

; Fast retraction for thread cutting OFF

N130 POLFMASK()

; Disable retraction of all axes

11.5.3

Rapid lift using ASUB and fast input

Activating ASUB using the LIFTFAST program command (rapid lift) via fast input 1:

Program code

Comment

N10 SETINT (1) PRIO=1 ABHEB_Y LIFTFAST

; ASUB activation, fast input 1

N20 LFPOS

; Retraction via POLF/POLFMASK ON

N30 POLF[X]=19.5 POLF[Y]=33.3

; Retraction positions axis X Y, absolute

N40 POLF[Z]=100

; Retraction position axis Z, absolute

N50 X0 Y0 G0

;

N60 POLFMASK(X, Y)

; Enable retraction, axis X Y

N70 Z100 G1 F1000

; Retraction response, axial: X, Y (abs.)

N80 POLFMASK(Z)

; Disable retraction, axis X Y and

; Enable retraction, axis Z

N90 Y10

; Retraction response, axial: Z (abs.)

N100 POLFMASK()

; Disable retraction of all axes

11.5.4

Rapid lift, absolute and incremental

Retraction to absolute positions and through an incremental distance:

Program code

Comment

N10 $AA_ESR_ENABLE[X]=1

; Enable retraction, axis X

N20 $AA_ESR_ENABLE[Z]=1

; Enable retraction, axis Z

N30 $AA_ESR_ENABLE[Y]=1

; Enable retraction, axis Y

N40 LFPOS

; Retraction via POLF/POLFMASK ON

N50 POLF[X]=IC(3.0) POLF[Y]=-4.0

; Retraction position axis X, incremental

; Retraction position axis Y, absolute

N60 POLF[Z]=100

; Retraction position axis Z, absolute

N70 G0 X0 Y0 Z0

;

N80 POLFMASK(X, Y)

; Enable retraction, axis X Y

N90 Z100 G1 F1000

; Retraction response, axial: X (inc.), Y (abs.)

N100 POLF[X]=10

; Retraction position axis X, absolute

N110 Y0 G1 F1000

; Retraction response, axial: X, Y (abs.)

N120 POLFMASK(Z)

; Disable retraction, axis X Y and

; Enable retraction, axis Z

N130 Y10

; Retraction response, axial: Z (abs.)

Special functions

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R3: Extended stop and retract

11.6 Data lists

Program code

Comment

N140 POLFMASK()

; Disable retraction of all axes

11.5.5

Lift fast with linear relation of axes

Retracting in a linear relationship, absolute and incremental

Program code

Comment

N10 $AA_ESR_ENABLE[X]=1

; Enable retraction, axis X

N20 $AA_ESR_ENABLE[Y]=1

; Enable retraction, axis Y

N30 $AA_ESR_ENABLE[Z]=1

; Enable retraction, axis Z

N40 LFPOS

; Retraction via POLF/POLFMASK ON

N50 POLF[X]=IC(3.0) POLF[Z]=-4.0

; Retraction position axis X, incremental

; Retraction position axis Z, absolute

N60 POLF[Y]=100

; Retraction position axis Z, absolute

N70 X0 Y0 Z0 G0

; ---

N80 POLFMLIN(X, Y)

; Enable retraction, axis X Y, linear

; Relationship

N85 POLFMASK(Z)

; Enable retraction, axis Z

N90 Z100 G1 F1000

;

Retraction response:

;

- linear relation: X (inc.), Y (abs.)

;

- axial: Z (abs.)

N95 POLF[X]=10

; Retraction position axis X, absolute

N100 Y0 G1 F1000

;

Retraction response:

;

- linear relation: X (inc.), Y (abs.)

;

- axial: Z (abs.)

N110 POLFMLIN()

; Disable retraction, axis X Y

N120 Y10

; Retraction response, axial: Z (abs.)

N130 POLFMASK()

; Disable retraction of all axes

11.6

Data lists

11.6.1

Machine data

11.6.1.1

Channelspecific machine data

Number

Identifier: $MC_

Description

21204

LIFTFAST_STOP_COND

Stop characteristics for rapid lift

21380

ESR_DELAY_TIME1

Delay time (STOPBYALARM, NOREAD) for ESR axes

21381

ESR_DELAY_TIME2

Time for interpolatory braking of ESR axes

Special functions

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R3: Extended stop and retract

11.6 Data lists

11.6.1.2

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

37500

ESR_REACTION

Reaction definition with extended stop and retract

11.6.2

System variables

Identifier

Meaning

$A_DBB

Read/write data byte from/to PLC

$A_IN

Digital input

$A_OUT

Digital output

$AA_ESR_ENABLE[<axis>]

Enable "Extended stop and retract"

$AA_TYP[<axis>]

Axis type

$AA_ESR_TRIGGER[<axis>]

Initiate ESR for PLC controlled axis (single axis)

$AC_ALARM_STAT

Alarm status in the channel

$AC_ESR_TRIGGER

Trigger ESR, channel-specific

$AC_STAT

Channel status

11.6.3

Signals

11.6.3.1

Signals to channel

Signal name

SINUMERIK 840D sl

SINUMERIK 828D

Feedrate disable

DB21, ... DBX6.0

11.6.3.2

Signals to axis/spindle

Signal name

SINUMERIK 840D sl

SINUMERIK 828D

Feed stop

DB31, ... DBX4.3

Special functions

598

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R3: Extended stop and retract

11.6 Data lists

11.6.3.3

Signals from axis/spindle

Signal name

SINUMERIK 840D sl

SINUMERIK 828D

ESR: DC link undervoltage (p1248)

DB31, ... DBX95.1

DB390x.DBX4003.1

ESR: Reaction triggered / generator operation active

DB31, ... DBX95.2

DB390x.DBX4003.2

(r0887.12)

ESR, generator operation: Speed lower than minimum

DB31, ... DBX95.3

DB390x.DBX4003.3

(p2161)

Special functions

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S9: Setpoint exchange - 840D sl only

12.1 Brief description

Example

;

;

60&

;

;

;

;

'5,9( &/L4

60&

60&

1&8

$FWLYH /LQH

6LQJOH 0RWRU

'RXEOH 0RWRU

0RGXOH

0RGXOH

0RGXOH

1

a 0

0

①

Motor with encoder

②

Mechanical switchover device

③

Gearbox 1

④

Encoder 1 (e.g. for the milling head)

⑤

Gearbox 2

⑥

Encoder 2 (e.g. for the spindle)

Figure 12-1

Setpoint switchover with 2 axes

Special functions

602

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S9: Setpoint exchange - 840D sl only

12.3 Flow diagram

12.3

Flow diagram

$;

7UDYHO FRPPDQG WUDYHO UHTXHVW

LV DFWLYH

'% '%;

25

25

25

$;

<HV

'ULYH FRQWURO

DFWLYH"

'% '%;

1R

$;

&ORVH EUDNH

5HOLQTXLVK GULYH FRQWURO

'% '%;

6ZLWFKRYHU PHFKDQLFDO V\VWHP

$;

5HTXHVW GULYH FRQWURO

'% '%;

$;

'ULYH FRQWURO

DFWLYH"

1R

'% '%;

<HV

$;

$;

7UDFNLQJ IROORZ XS PRGH

7UDFNLQJ IROORZ XS PRGH

LV VZLWFKHG RYHU

LV VZLWFKHG RYHU

'% '%;

'% '%;

$;

6HW FRQWUROOHU HQDEOH

'% '%;

2SHQ EUDNH

Figure 12-2

Sequence when switching over the setpoint from machine axes AX1 to AX2

Special functions

606

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S9: Setpoint exchange - 840D sl only

12.5 Data lists

Reference:

SINUMERIK Safety Integrated Manual

12.5

Data lists

12.5.1

Machine data

12.5.1.1

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

30130

CTRLOUT_TYPE

Output type of setpoint

30200

NUM_ENCS

Number of encoders

30220

ENC_MODULE_NR

Actual-value assignment:

Drive number / measurement circuit number

30230

ENC_INPUT_NR

Actual-value assignment:

Input on drive module/measuring circuit module

Special functions

608

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T3: Tangential control - 840D sl only

13

Using the "Tangential control" function, a rotary axis is coupled as following axis to two

geometry axes as leading axes, so that the alignment of the following axis is a function of the

path tangent of the leading axes.

<

;

&

|

① Initial position and positive direction of rotation of the following/rotary axes C

② Angle of the path tangent in machining plane X/Y

③ Offset angle = 270° or -90°

④ Rounding clearance and present angular deviation

The path-defining leading axes, geometry axes X and Y and rotary axis C the following axis

of the tangential coupling can be seen in the diagram. The rotary axis is tracked with a

programmable offset angle of 270° with respect to the path tangent. At the block transition

from N10 to N20, the contour has a discontinuous transition or corner. As a result of a dynamic

response that is too low, the following axis cannot follow the path tangent over part of the path

(blue). However, the dynamic response of the following axis is sufficient so that it can precisely

follow circular blocks N20 and N30 further along the contour.

Properties

The tangential coupling sets itself apart as a result of the following features:

● The leading axes of the tangential coupling must be two geometry axes.

● The following axis of the tangential coupling must be a rotary axis.

● The tangential coupling can be defined, activated, deactivated and deleted in the NC

program.

● Tangential control is defined for the basic and the workpiece coordinate system.

● The positive direction of the path tangent is the same as the traversing direction of the path.

● For an offset angle of 0° between the rotary axis and the path tangent, shows the 0° direction.

● The axes of the tangential coupling must be the channel axes of the same channel.

Special functions

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T3: Tangential control - 840D sl only

13.2 Programming

Meaning

TANG(...):

Define tangential coupling

<following axis>:

Axis name of the following axis (rotary axis)

Data type:

AXIS

Range of values:

Channel axis names

<leading axis_1>

Axis names of the leading axes (geometry axes) ¹⁾

<leading axis_2>:

Data type:

AXIS

Range of values:

Geometry axis names of the channel

<coupling factor>:

Factor n of the angle change of the following axis for changing the path

tangent of the leading axes:

Angle change_{following axis} = angle change_{path tangent} * n

Data type:

REAL

Default value:

1.0

<coordinate system>:

Active coordinate system ²⁾

Data type:

CHAR

Value:

"B":

Basic coordinate system (default value)

"W":

Workpiece coordinate system (not availa-

ble)

<optimization>:

Optimization type

Data type:

CHAR

Value:

"S":

Standard (default value)

The dynamic response of the rotary axis

has no effect on the leading axes If the dy-

namic response of the rotary axis is greater

than required for tracking, this method is

sufficiently precise. If the dynamic re-

sponse of the rotary axis is not great

enough to follow the change in the path

tangent, the orientation of the rotary axis

will deviate from the target orientation

along an undefined rounding clearance.

"P":

The dynamic response of the rotary axis is

considered in the path planning of the lead-

ing axes.

For this purpose, on activation of the tan-

gential coupling with TANGON(), two addi-

tional parameters must be specified:

● Rounding clearance

● Angular tolerance

See Section "Activating the coupling (TAN-

GON) (Page 614)"

Note

With kinematic transformations, we recom-

mend using optimization method "P."

Note

Default values do not have to be programmed explicitly.

Special functions

612

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T3: Tangential control - 840D sl only

13.2 Programming

1)

Note

As the leading axes for tangential coupling, the geometry axes must be used that travel along the

programmed path in the machine coordinate system (MCS) with reference to the initial position of the

machine. For example, if swivel cycle CYCLE800 is used on a milling machine with a swivel head,

depending on how the cycle is configured, interpolation will be performed in the WCS, e.g. with the

geometry axes X and Y. The tangential coupling, however, must be defined with the geometry axes as

the leading axes, which travel along the programmed path in the MCS. For this purpose, the geometry

axes in the non-swiveled condition of the machine must be used as the leading axes.

²⁾ Note

The basic coordinate system (BCS) must not be rotated with respect to the MCS. For example, if the

BCS is rotated with the ROT command or with the swivel cycle CYCLE800, the tangential control is no

longer correct.

13.2.2

Activating intermediate block generation (TLIFT)

If the tangent change of the following axis at any position along the programmed path of the

leading axes exceeds the limit parameterized in machine data MD37400

$MA_EPS_TLIFT_TANG_STEP, further path planning will depend on the set behavior at

corners. Without use of the predefined procedure TLIFT(...), the path is traversed in

accordance with the rounding behavior programmed in connection with TANG(...) (Page 611)

and TANGON(...) (Page 614).

Activating intermediate block generation

If TLIFT(...) is programmed after TANG(...), an intermediate block automatically generated by

the control is inserted at this point when a corner is detected during preprocessing.

When the program is executed, the leading axes are stopped when the intermediate block is

reached. In the intermediate block, the following axis is rotated with maximum axis dynamics

toward the path tangent of the following block. The leading axes are then traversed further on

the programmed path.

Deactivating intermediate block generation

To deactivate intermediate block generation, the tangential coupling must be defined again

using TANG(...), but without subsequent activation of intermediate block generation by means

of TLIFT(...).

Syntax

TLIFT(<following axis>)

Meaning

TLIFT(...):

Activate corner detection with intermediate block calculation

<following axis>:

Axis name of the following axis (rotary axis)

Data type:

AXIS

Range of values:

Channel axis names

Special functions

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T3: Tangential control - 840D sl only

13.2 Programming

Meaning

TANGON(...):

Activate tangential coupling

<following axis>:

Axis name of the following axis (rotary axis)

Data type:

AXIS

Range of values:

Channel axis names

<offset angle>:

Offset angle of following axis with respect to the path tangent

The reference point is the zero point of the rotary axis.

Data type:

REAL

<rounding clearance>:

Maximum permissible rounding clearance

If the rounding clearance is increased due to the dynamic conditions,

the path velocity of the leading axes is reduced.

Data type:

REAL

<angular tolerance>:

Maximum permissible tolerance with respect to the specified angle be-

tween the following axis zero setting and the path tangent

Data type:

REAL

13.2.4

Deactivating the coupling (TANGOF)

Via the predefined procedure TANGOF(...), a tangential coupling defined with TANG(...)

(Page 611) and activated with TANGON(...) (Page 614) is deactivated. The following axis is

then no longer aligned with the path tangent of the leading axis. However, the coupling of the

following axis to the leading axes is retained even after deactivation, which prevents the

following functions, for example:

● Plane change

● Geometry axis switchover

● Definition of a new tangential coupling for the following axis

Final cancellation of the connection of the coupling of the following axis to the leading axes is

not completed until the coupling has been deleted with TANGDEL(...) (Page 616).

Programming

TANGOF(<following axis>)

Meaning

TANGOF(...):

Deactivate a tangential coupling

<following axis>:

Axis name of the following axis (rotary axis)

Data type:

AXIS

Range of values:

Channel axis names

Special functions

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T3: Tangential control - 840D sl only

13.2 Programming

13.2.5

Deleting a coupling (TANGDEL)

A tangential coupling defined with TANG(...) (Page 611) will be retained even after deactivation

of the tangential coupling with TANGOF(...) (Page 615). The existing tangential coupling then

continues to prevent, for example, the following functions:

● Plane change

● Geometry axis switchover

● Definition of a new tangential coupling for the following axis

With the predefined procedure TANGDEL(...), the existing tangential coupling is deleted after

the tangential coupling has been deactivated with TANGOF(...).

Syntax

TANGDEL(<following axis>)

Meaning

TANGDEL(...):

Delete a tangential coupling defined with TANG()

Effective:

Non-modal

<following axis>:

Axis name of the following axis whose tangential coupling is to be de-

leted

Data type:

AXIS

Range of values:

Channel axis names

Examples

Leading axis change

Before a new tangential coupling can be defined with another leading axis for the following

axis, the existing tangential coupling must first be deleted.

Program code

Comment

N10 TANG(A, X, Y, 1)

; Define tangential couping for following axis A: A to

X and Y

N20 TANGON(A)

; Activate tangential coupling for following axis A

N30 X10 Y20

N80 TANGOF(A)

; Deactivate tangential coupling for following axis A

N90 TANGDEL(A)

; Delete tangential coupling for following axis A

N120 TANG(A, X, Z)

; Define new tangential coupling for following axis A

N130 TANGON(A)

; Activate new tangential coupling for following axis A

Special functions

616

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