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SINUMERIK 840D sl. Service - Functions. Manual (2018-2020) - page 71

TE1: Clearance control - 840D sl only

18.1 Brief description

System overview

An overview of the system components required for clearance control in conjunction with

SINUMERIK 840D sl is provided in the following diagram.

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Figure 18-1

System components for clearance control with SINUMERIK 840D sl

1D- / 3D machining

Clearance control can be used for 1D and 3D machining with up to five interpolatory axes.

● 1D machining

For 1D machining, only one axis is affected by the clearance control. For example, axis Z,

as shown in the machine configuration described in the system overview (see previous

diagram). Clearance control acts only in the direction of the Z axis.

● 3D machining

Three linear axes are used to position the tool. One or two rotary axes are used for the

orientation of the tool vector (5-axis machining). Up to three linear axes are controlled by

the clearance control. Compensation motion can be specified in the directions of the

following vectors:

- Tool orientation vector (normal case)

- Any programmable vector (compensation vector)

Special functions

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18.2 Clearance control

18.2

Clearance control

18.2.1

Control dynamics

Control loop gain K_V

The dynamic response of the closed control loop (sensor - open-loop control - axis) is

determined by the maximum closed-loop control gain K_V.

The closed-loop control gain K_V is defined as:

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Clearance control characteristics

Clearance control is based on the two characteristics shown in the following diagram:

● Clearance sensor characteristic (sensor property)

● Clearance control characteristic (can be parameterized via machine data)

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Figure 18-2

Correlation between characteristics: Clearance sensor and clearance control

● The clearance sensor measures the actual distance from the workpiece surface and returns

as its output variable a voltage in [V], which is almost directly proportional to the distance.

● The clearance control function uses the parameterized voltage/velocity characteristic from

the voltage provided by the clearance sensor to calculate a compensatory velocity for the

clearance-controlled axes that is appropriate for the clearance.

Special functions

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18.2 Clearance control

18.2.3

Control loop structure

The figures below provide an overview of how the clearance control function is embedded in

the control loop structure of the NC position controller and the internal structure of the function.

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Control structure, position controller with clearance control (principle)

Special functions

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18.2 Clearance control

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Figure 18-4

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18.2.4

Compensation vector

Standard compensation vector

The compensation vector of the clearance control and the tool orientation vector are normally

identical. Consequently, the compensation movement of the clearance control is normally

always in the direction of the tool orientation.

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Clearance control with standard compensation vector

Special functions

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18.2 Clearance control

Note

In all the figures in this section, the traversing movement of the machining head needed in

order to machine the workpiece is in the direction of the Y coordinate, i.e. perpendicular to the

drawing plane.

As long as the tool orientation, and hence the compensation vector, is perpendicular to the

workpiece surface, no disadvantage for the machining process results from the compensation

movements of the clearance control.

If a tool setting angle is needed for technological reasons, with the result that the tool orientation

is no longer perpendicular to the workpiece surface, the machining point on the workpiece

surface is shifted during compensation movements of the clearance control along the standard

compensation vector.

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Figure 18-6

Standard compensation vector

The reason for the shift in the machining point is the X component (K_X) of the compensation

vector parallel to the workpiece surface. The TCP of the tool, and thus the machining point B,

is shifted by this amount.

Programmable compensation vector

When using the programmable compensation vector, the compensation movements of the

clearance control are in the direction of the programmed vector, and not in the direction of the

tool orientation.

The X component specified above (K_X) is omitted because the programmable compensation

vector is defined perpendicular to the workpiece surface. This does not cause the machining

point (B) to be shifted as a result of the compensation movement of the clearance control.

Special functions

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18.2 Clearance control

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Figure 18-7

Programmable compensation vector

Changes in orientation

Based on the above observations, a different behavior also results when the orientation of the

machining head is changed while the clearance control is active.

In the following diagram the normal case is shown on the left (compensation vector == tool

orientation vector); and the case with the programmed compensation vector is shown on the

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Change in orientation of the machining head

The meaning of the individual positions of the machining head is as follows:

1. Programmed position of the machining head

2. Actual position of the machining head with clearance control active before the orientation

change

Special functions

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18.5 Startup

4. The direction axes may not participate in an axis coupling, e.g. transformation, electronic

gear, etc.

5. To ensure that the dynamic response of the path is not limited by the dynamic response of

the direction axes, the following machine data for the direction axes must be set equal to

or more than the corresponding values of the geometry axes of the channel:

- MD32000 $MA_MAX_AX_VELO[x] (maximum axle velocity)

- MD32200 $MA_POSCTRL_GAIN[x] (Kv factor)

- MD32230 $MA_MAX_AX_ACCEL[x] (position controller structure configuration)

x = axle number

The following machine data is used to specify which channel axis is the direction axis:

● MD62528 $MC_CLC_PROG_ORI_AX_MASK (progr. orientation vector: axis mask)

Each machine data bit corresponds to a channel axis.

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● Coordinate X = channel axis corresponding to bit a

● Coordinate Y = channel axis corresponding to bit b

● Coordinate Z = channel axis corresponding to bit c

with a < b < c

Current difference angle

The difference angle is the angle between the tool orientation vector and the compensation

vector. If the current difference angle of the clearance control is to be output in a system

variable $AC_PARAM[n], index n of the system variable should be entered in the following

machine data:

MD65530 $MC_CLC_PROG_ORI_ANGLE_AC_PARAM ()

Permissible limit angle

The permissible limit angle specifies the maximum difference angle allowed between the tool

orientation vector and the compensation vector. The limit angle is configured via the following

machine data:

MD65520 $MC_CLC_PROG_ORI_MAX_ANGLE ()

Special functions

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18.5 Startup

● MD36040 $MA_STANDSTILL_DELAY_TIME[<x>] (standstill monitoring time delay)

● MD36060 $MA_STANDSTILL_VELO_TOL[<x>] ("axis/ spindle stopped" velocity/speed

threshold)

<x> = axis number of clearance-controlled machine axis

18.5.6

Starting up clearance control

Clearance sensor

The clearance sensor outputs should be connected to the I/O modules that were activated

using the following machine data:

● MD10362 $MN_HW_ASSIGN_ANA_FASTIN (I/O address of the I/O module) (hardware

assignment of fast analog NC inputs)

● MD10366 $MN_HW_ASSIGN_DIG_FASTIN (I/O address of the I/O module) (hardware

assignment of external digital NC inputs)

(See also Section " "Supplementary conditions > I/O modules (Page 722)").

Test control direction

Proceed as follows to test the control direction of the clearance control function:

● Activating the clearance control function using the part program with CLC(1) (see Chapter

"Activating and deactivating clearance control (CLC) (Page 705)")

● Generate an input voltage, e.g. via the following synchronized action:

Program code

N100 $AC_TIMER[1]=2.5

N110 ID = 1 EVERY $AC_TIMER[1] >= 2.5 DO $AC__TIMER[1]=0

N120 ID = 2 WHENEVER $AC_TIMER[1] < 2.0 DO $A_OUTA[6] = 100000.0 *

($AC_TIMER[1] - 1.0)

N130 ID = 3 WHENEVER $AC_TIMER[1] >= 2.0 DO $A_OUTA[6] = 0.0

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Figure 18-9

Output voltage for synchronized action

The voltage specification for the analog output $A_OUTA[6] used in the synchronized action

is subtracted from the clearance sensor input voltage by the clearance control function and

therefore has the opposite polarity to the input signal.

Special functions

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18.6 Programming

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Interpolation of the compensation vector

The compensation vector must be oriented by programming the direction axes at [1, 0, 0]

before part program block N100. In part program block N100, the end position of the

compensation vector is oriented by programming the direction axes at [0, 0, -1].

The intermediate values are generated by path interpolation of all axes programmed in the

part program block:

● Geometry axes for the movement of the machining head

● Direction axes of the compensation vector

It is necessary to break the movement down into part program blocks N100 and N200, because

an antiparallel orientation of the compensation vector of [1, 0, 0] at the start of the movement

and [-1, 0, 0] at the end of the movement (semi-circle) would otherwise result. In this case, the

interpolator would interpolate only the X coordinate of the compensation vector, and the

orientation of the compensation vector would remain unchanged.

Antiparallel orientation of the compensation vector

When an antiparallel orientation of the compensation vector is programmed in a part program

block, the following alarm is displayed:

● Alarm "75018 Channel number Block number CLC in programmable direction, error ID: 1"

Note

Interpolation of the compensation vector

The interpolation of the compensation vector is not a genuine vector interpolation, as

described above, but results from the interpolation of the actual positions of the direction

axes.

Consequently, if the compensation vector changes due to the workpiece contour, the

interpolation of the direction axes is included in the path interpolation of the geometry axes. In

order to minimize the impact of the direction axes on the path interpolation, it is recommended

to configure the dynamic response of the direction axes at least equal to or greater (by a factor

of approx. 10) than the dynamic response of the geometry axes.

Special functions

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18.6 Programming

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Response of the CLC offset vector when CLC_GAIN=0.0

Reset

Within a part program, a modified gain factor must be reset by means of explicitly programming

CLC_GAIN=1.0.

RESET behavior

CLC_GAIN=1.0 becomes effective after a power on reset, NC RESET or end of program.

18.6.3

Limiting the control range (CLC_LIM)

Syntax

CLC_LIM(lower limit, upper limit)

Lower limit, upper limit

Format and value range as machine data:

● MD62505 $MC_CLC_SENSOR_LOWER_LIMIT[n] (lower clearance control motion limit)

● MD62506 $MC_CLC_SENSOR_UPPER_LIMIT[n] (upper clearance control motion limit)

CLC_LIM(...) is a procedure call and must therefore be programmed in a dedicated part

program block.

Special functions

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18.6 Programming

Functionality

The maximum control range for clearance control can be modified on a block-specific basis

using CLC_LIM. The maximum programmable lower/upper limit is limited by the limit value

preset in the relevant machine data:

● MD62505 $MC_CLC_SENSOR_LOWER_LIMIT[1] (lower clearance control motion limit)

● MD62506 $MC_CLC_SENSOR_UPPER_LIMIT[1] (upper clearance control motion limit)

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Value range limits for lower and upper limit

The control range limit is effective in relation to the current programmed setpoint position of

the axis. If the limits are changed so that the actual position is located outside the limit, the

clearance control automatically effects travel back to the limit range.

Reset

Within a part program, a modified control range limit can be reset by explicitly programming

CLC_LIM without a "CLC_LIM( )" argument. This reapplies the limits from the following

machine data:

● MD62505 $MC_CLC_SENSOR_LOWER_LIMIT[0] (lower clearance control motion limit)

● MD62506 $MC_CLC_SENSOR_UPPER_LIMIT[0] (upper clearance control motion limit)

RESET response

The default setting from the above-mentioned machine data becomes effective after power on

reset, NC RESET and end of program.

Special functions

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18.7 Function-specific display data

Types of variable

The display data is available both as channel-specific GUD (Global User Data) variables and

as OPI variables.

18.7.1

Channel-specific GUD variables

The "clearance control" technological function provides the following channel-specific GUD

variables for HMI applications:

● SINUMERIK HMI Advanced

● SINUMERIK Operate

Table 18-1

Channel-specific GUD variables

GUD variables

Description

Unit

Access

CLC_DISTANCE[0]

Current position offset

mm

read only

CLC_DISTANCE[1]

Absolute minimum of position off-

mm

read/write

set

CLC_DISTANCE[2]

Absolute maximum of position off-

mm

read/write

set

CLC_VOLTAGE[0]

Current sensor input voltage

V

read only

CLC_VOLTAGE[1]

Absolute minimum of sensor input

V

read/write

voltage

CLC_VOLTAGE[2]

Absolute maximum of sensor input

V

read/write

voltage

Once the technological function has been started up successfully, the GUD variables listed

are not displayed automatically on the HMI interface.

SINUMERIK HMI Advanced

Proceed as follows to create and display the GUD variables in HMI Advanced.

1. Setting the password

Enter the password for protection level 1: (machine manufacturer).

2. Activate the "definitions" display.

Operating area switchover > Services > Data Selection

3. If no SGUD.DEF file is yet available:

Operating area switchover > Services > Data admin > New...

● Name: SGUD

● Type: Global data/system

Confirm with OK.

This opens the file in the editor.

Special functions

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18.7 Function-specific display data

18.7.2

OPI variable

The technology function "Clearance control" provides the following channel-specific OPI

variables as display data for the HMI application:

OPI variable

Description

Unit

Access

CLC[0]

Current position offset

mm

read only

CLC[1]

Absolute minimum of position offset

mm

read/write

CLC[2]

Absolute maximum of position offset

mm

read/write

CLC[3]

Current sensor input voltage

V

read only

CLC[4]

Absolute minimum of sensor input

V

read/write

voltage

CLC[5]

Absolute maximum of sensor input

V

read/write

voltage

CLC[6]

1st component of the normalized

-

read only

tool orientation vector

CLC[7]

2nd component of the normalized

-

read only

tool orientation vector

CLC[8]

3rd component of the normalized

-

read only

tool orientation vector

OPI variables still have to be registered or defined in the system in order that they can be

accessed.

Defining OPI variables

The following operator actions must be carried out to define OPI variables.

1. Create the CLC-specific definition file: CLC.NSK

Note:

We recommend that you create the file in the \OEM directory rather than in the \MMC2

directory so that it is not overwritten when a new software version is installed.

2. Define the CLC-specific OPI variables.

Add the following line to the CLC.NSK file:

LINK("CLC" ,200,"2 1 1 1 1F# /NC 5 0 1",100)

3. Create/expand the user-specific definition file: USER.NSK

(See item 1: Note)

4. The call of the CLC-specific definition file CLC.NSK must be added to the USER.NSK

definition file. To do this, insert the following line:

CALL(CLC.NSK)

Using LinkItem

In order to use the OPI variables in a DDE control, the "LinkItem" property of the DDE control

must be set in accordance with the following example:

label1.LinkItem = "CLC[u1,1,9](" "!d%15.4lf" ")"

The format string can be modified if necessary.

Special functions

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18.9 Supplementary conditions

The following code lines provide an example of how the variables supplied by means of NCDDE

access can be distributed on a field of labels:

FOR i = 0 To 8

label2.Caption[i] = Trim$(Mid$(label1.Caption, 1+15*i, 15))

NEXT

18.8

Function-specific alarm texts

For details of the procedure for creating function-specific alarm texts, see Section "Creating

alarm texts (Page 679)".

18.9

Supplementary conditions

18.9.1

I/O modules

The analog output voltage of the distance sensor for the A/D conversion must be connected

to the NC using an I/O module with an analog input.

Connection options

The SIMATIC ET 200S I/O for SINUMERIK 840D sl is connected via PROFIBUS DP. The

clearance sensor is connected via an analog S7 I/O module.

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I/O modules connection for SINUMERIK 840D sl

Suitable I/O modules

As the A/D conversion time directly affects the deadtime of the clearance control servo loop,

only one I/O module may be used with low conversion time.

Special functions

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18.10 Data lists

18.10

Data lists

18.10.1

Machine data

18.10.1.1

NC-specific machine data

Number

Identifier: $MN_

Description

10300

FASTIO_ANA_NUM_INPUTS

Number of active analog NC inputs

10350

FASTIO_DIG_NUM_INPUTS

Number of active digital NC input bytes

10362

HW_ASSIGN_ANA_FASTIN

Hardware assignment of external analog NC inputs

0...7

10712

NC_USER_CODE_CONF_NAME_TAB

List of renamed NC identifiers

18.10.1.2

Channelspecific machine data

Number

Identifier: $MC_

Description

28090

MM_NUM_CC_BLOCK_ELEMENTS

Number of compile cycle block elements (DRAM)

28100

MM_NUM_CC_BLOCK_USER_MEM

Memory for compile cycle block elements (DRAM) in

kB

28254

MM_NUM_AC_PARAM

Number of parameters for synchronized actions

Clearance control

62500

CLC_AXNO

Axis assignment for clearance control

62502

CLC_ANALOG_IN

Analog input for clearance control function

62504

CLC_SENSOR_TOUCHED_INPUT

Input bit assignment for the "sensor collision" signal

62505

CLC_SENSOR_LOWER_LIMIT

Lower motion limit of clearance control

62506

CLC_SENSOR_UPPER_LIMIT

Upper motion limit of clearance control

62508

CLC_SPECIAL_FEATURE_MASK

Special functions and operating modes of the clear-

ance control

62510

CLC_SENSOR_VOLTABE_TABLE_1

Coordinate voltage of interpolation points sensor char-

acteristic 1

62511

CLC_SENSOR_VELO_TABLE_1

Coordinate velocity of interpolation points sensor char-

acteristic 1

62512

CLC_SENSOR_VOLTAGE_TABLE_2

Coordinate voltage of interpolation points sensor char-

acteristic 2

62513

CLC_SENSOR_VELO_TABLE_2

Coordinate velocity of interpolation points sensor char-

acteristic 2

62516

CLC_SENSOR_VELO_LIMIT

Clearance control movement velocity

62516

CLC_SENSOR_ACCEL_LIMIT

Clearance control movement acceleration

62520

CLC_SENSOR_STOP_POS_TOL

Positional tolerance for status message "Clearance

control zero speed"

Special functions

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18.10 Data lists

Number

Identifier: $MC_

Description

62521

CLC_SENSOR_STOP_DWELL_TIME

Dwell time for status message "Clearance control zero

speed"

62522

CLC_OFFSET_ASSIGN_ANAOUT

Modification of the setpoint distance by means of sen-

sor signal override

62523

CLC_LOCK_DIR_ASSIGN_DIGOUT

Assignment of the digital outputs for disabling the CLC

movement

62524

CLC_ACTIVE_AFTER_RESET

Clearance control remains active after RESET

62525

CLC_SENSOR_FILTER_TIME

PT1 filtering time constant of sensor signal

62528

CLC_PROG_ORI_AX_MASK

Programmed orientation vector: Axis mask

62529

CLC_PROG_ORI_MAX_ANGLE

Programmed orientation vector: Maximum difference

angle

62530

CLC_PROG_ORI

Programmed orientation vector: Index of the $AC_PAR-

AM variables for the output of the current difference

angle

18.10.1.3

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

32070

CORR_VELO

Axis velocity for handwheel, external zero offsets, SA

clearance control

32410

AX_JERK_TIME

Time constant for axis jerk filter

32610

VELO_FFW_WEIGHT

Feedforward control factor for velocity feedforward con-

trol

36000

STOP_LIMIT_COARSE

Exact stop coarse

36010

STOP_LIMIT_FINE

Exact stop fine

36040

STANDSTILL_DELAY_TIME

Delay time zero speed monitoring

36060

STANDSTILL_VELO_TOL

Axis/ spindle velocity stopped

36750

AA_OFF_MODE

Value calculation mode for axial position override

18.10.2

Drive parameters (SINAMICS S120)

Number

Short name

Long name

p1414[0...n]

n_soll_filt current

Speed setpoint filter activation 1, 2

p1415[0...n]

n_soll_filt 1 type

Speed setpoint filter 1 type

p1416[0...n]

n_soll_filt 1 T

Speed setpoint filter 1 time constant

p1417[0...n]

n_soll_filt 1 fn_n

Speed setpoint filter 1 denominator natural frequency

p1418[0...n]

n_soll_filt 1 D_n

Speed setpoint filter 1 denominator damping

p1419[0...n]

n_soll_filt 1 fn_z

Speed setpoint filter 1 numerator natural frequency

p1420[0...n]

n_soll_filt 1 D_z

Speed setpoint filter 1 numerator damping

p1421[0...n]

n_soll_filt 2 type

Speed setpoint filter 2 type

p1422[0...n]

n_soll_filt 2 T

Speed setpoint filter 2 time constant

Special functions

Function Manual, 12/2018, A5E40874099B AB

727

TE1: Clearance control - 840D sl only

18.10 Data lists

Number

Short name

Long name

p1423[0...n]

n_soll_filt 2 fn_n

Speed setpoint filter 2 denominator natural frequency

p1424[0...n]

n_soll_filt 2 D_n

Speed setpoint filter 2 denominator damping

p1425[0...n]

n_soll_filt 2 fn_z

Speed setpoint filter 2 numerator natural frequency

p1426[0...n]

n_soll_filt 2 D_z

Speed setpoint filter 2 numerator damping

18.10.3

Signals

18.10.3.1

Signals to channel

DB number

Byte.bit

Description

21, ...

1.4

Stop CLC motion

21, ...

1.5

Feedrate override acts on CLC

18.10.3.2

Signals from channel

DB number

Byte.bit

Description

21, ...

37.3

CLC is active

21, ...

37.4-5

CLC motion has stopped

21, ...

37.4

CLC motion at lower motion limit

21, ...

37.5

CLC motion at upper motion limit

Special functions

728

Function Manual, 12/2018, A5E40874099B AB

TE3: Speed/torque coupling, master-slave

19

19.1

Brief description

A master-slave coupling is a speed setpoint coupling between a master and any number of

slave axes - performed at the position controller level - with and without torque equalization

control. The coupling can be permanently switched on, dynamically switched on/off and

reconfigured.

Note

The following restrictions apply for the SINUMERIK 828D with regard to the "Master-slave

coupling":

● Only one master-slave grouping is possible. (Exception: control variant "SW28x(1) CNC-

SW Milling Adv. Export (me822) with max. two master-slave groupings).

● Only one slave axis can be coupled to the master axis.

Applications

Possible applications of a master-slave coupling include:

● Increase the power for mechanically coupled drives

● Compensating gear and gear tooth flank play by entering a pre-tensioning torque

Dynamic master-slave coupling of two axes

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Function Manual, 12/2018, A5E40874099B AB

729

TE3: Speed/torque coupling, master-slave

19.2 Coupling diagram

19.2

Coupling diagram

If the coupling is closed, the slave axis is traversed only with the load-side setpoint speed of

the master axis. It is therefore only speed-controlled, not position-controlled. There is no

differential position control between the master and slave axis.

The torque required between the master and slave axis is distributed using the torque

equalization controller. When using different motors, this distribution can be adapted to the

specific requirements using a weighting factor.

A tension can be established between the master and slave axes by entering a supplementary

torque (tensioning torque).

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Special functions

730

Function Manual, 12/2018, A5E40874099B AB

TE3: Speed/torque coupling, master-slave

19.3 Configuring a coupling

19.3

Configuring a coupling

Static assignment

For a speed setpoint coupling and torque equalization control, the static assignment of master

and slave axis is defined separately in the following machine data:

● Speed setpoint coupling

MD37250 $MA_MS_ASSIGN_MASTER_SPEED_CMD[<slave axis>] =

<machine axis number of the master axis for the speed setpoint coupling>

● Torque equalization control

MD37252 $MA_MS_ASSIGN_MASTER_TORQUE_CTR[<slave axis>] =

<machine axis number of the master or slave axis for torque equalization control>

(see Section "Tension torque (Page 736)")

Dynamic assignment (only 840D sl)

The assignment of master and slave axes can be dynamically changed using the following

program commands.

Defining assignments

Assignment of one or several slave axes to a master axis:

MASLDEF (<slave axis_1>, <slave axis_2>, ..., <master axis>)

In principle, any number of slave axes can be assigned. The assignment is kept even after an

operating mode change, reset and end of part program.

Deleting assignments

Delete assignment of one or several slave axes to their associated master axis:

MASLDEL (<slave axis_1>, <slave axis_2>, ...)

An active coupling is first implicitly switched off before deleting the assignment.

Axis assignment for speed setpoint coupling and torque equalization control

For the speed setpoint coupling, the slave axis refers to the master axis specified when defining

the assignment (MASLDEF).

The axis to which the slave axis refers for torque equalization control is defined in the following

machine data:

MD37253 $MA_MS_FUNCTION_MASK[<slave axis>], bit 1 = <value>

<value>

Description

0

In the case of dynamic assignment (MASLDEF), the slave axis for the torque equalization

control - as well as for speed setpoint coupling - refers to the master axis of the master-

slave grouping.

1

In the case of dynamic assignment (MASLDEF), the slave axis for the torque equalization

control refers to the axis, master or slave axis of the master-slave grouping specified in

machine data:

MD37252 $MA_MS_ASSIGN_MASTER_TORQUE_CTR<slave axis> = <axis>

Special functions

Function Manual, 12/2018, A5E40874099B AB

731

TE3: Speed/torque coupling, master-slave

19.3 Configuring a coupling

(See Section "Tension torque (Page 736)")

Supplementary conditions

The following supplementary conditions must be observed for the dynamic assignment:

● When the coupling is switched on, a change to the assignment using MASLDEF has no

effect. The change only becomes effective the next time that the coupling is switched off.

● The same master axis is always used for the speed setpoint coupling and torque

equalization control.

● A plausibility check of the assignment is only made when the coupling is switched on.

User-specific standard assignment after reset (only 840D sl)

A user-specific standard assignment, which is always effective after a reset, can be defined

in PROG_EVENT.SPF using the program commands MASLDEF and MASLDEL.

The following machine data should be set in order that PROG_EVENT.SPF is executed for a

reset: MD20108 $MC_PROG_EVENT_MASK.Bit 2 = 1

Example: Dynamic change of the assignment (only 840D sl)

The assignment of slave axis AX3 is changed from master axis AX1 to master AX2. To do this,

the coupling must be temporarily switched off (see Section "Closing/opening a coupling

(Page 739)").

Programming

Description

①

MASLDEF (AX3, AX1)

Assignment of slave axis AX3 to master axis AX1

②

MASLON (AX3)

Switching on the coupling

③

MASLDEL (AX3)

Switch off the coupling and cancel the assignment between AX3 and AX1

④

MASLDEF (AX3, AX2)

Assignment of slave axis AX3 to master axis AX2

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Special functions

732

Function Manual, 12/2018, A5E40874099B AB

TE3: Speed/torque coupling, master-slave

19.4 Torque compensatory controller

General supplementary conditions

Please note the following general supplementary conditions:

● A slave axis can only be assigned to one master axis

● A master axis can be assigned several slave axes

● A slave axis must not be a master axis or be in another master-slave relationship.

Note

Drive optimization

At a SINAMICS S120 drive unit, a maximum of three drives can be optimized or measured

at the same time (speed controller optimization / function generator). Therefore, for a

coupling with more than three coupled drives at the same time, we recommend that these

are distributed over several drive units.

19.4

Torque compensatory controller

The torque compensatory controller (PI control) calculates a load-side initial speed setpoint.

The additional speed setpoint can be differently entered via the following machine data:

MD37254 $MA_MS_TORQUE_CTRL_MODE[<slave axis>] = <value>

<value>

Input of the additional speed setpoint at:

0

Master and slave axis (default value)

1

Slave axis

2

Master axis

3

No additional setpoint injection

Note

Several slave axes

For a master-slave grouping with one master and several slave axes, the input of the additional

speed setpoint to the master and slave axes - set as standard in MD37254 - can result in

instability. For multiple slave axes, injection of an additional speed setpoint should only be

applied in the slave axes:

MD37254 $MA_MS_TORQUE_CTRL_MODE = 1

SINAMICS S120: Current setpoint filter

Up to four current setpoint filters (p1656 - p1674, function block diagram [5710]) can be

activated in the SINAMICS S120. In a master-slave group, it is recommended that, for the

master and all of the slave axes, only filters with the same data be activated at any one time.

Special functions

Function Manual, 12/2018, A5E40874099B AB

733

TE3: Speed/torque coupling, master-slave

19.4 Torque compensatory controller

Scaling

Scaling of the machine data for the gain factor (P component) (MD37256

$MA_MS_TORQUE_CTRL_P_GAIN) and the speed setpoint limiting (MD37260

$MA_MS_MAX_CTRL_VELO) is defined in the following machine data:

MD37253 $MA_MS_FUNCTION_MASK[<slave axis>], bit 0 = <value>

<value>

Description

0

MD37256 and MD37260 are internally multiplied with the following factor: 1 / interpolator

clock cycle ¹⁾

1

MD37256 and MD37260 are accepted unchanged

1) The interpolator cycle is displayed with MD10071 $MN_IPO_CYCLE_TIME

Note

We recommend not changing MD37256 and MD37260:

MD37253 $MA_MS_FUNCTION_MASK[<slave axis>], bit 0 = 1

Gain factor (P component)

The gain factor of the torque compensatory controller is set in the following machine data as

a percentage of the ratio of the maximum load-side axis velocity of the slave axis (MD32000

$MA_MAX_AX_VELO) to its rated torque (SINAMICS S120: p2003):

MD37256 $MA_MS_TORQUE_CTRL_P_GAIN[<slave axis>]

Note: Scaling via MD37253 $MA_MS_FUNCTION_MASK[<slave axis>], bit 0

Integral time (I component)

The integral time of the torque compensatory controller is set in the following machine data:

MD37258 $MA_MS_TORQUE_CTRL_I_TIME[<slave axis>]

The I component is deactivated as standard.

Speed setpoint limiting

The speed setpoint calculated by the torque compensatory controller can be limited using the

following machine data. The input is a percentage referred to the maximum, load-side axis

velocity of the slave axis (MD32000 $MA_MAX_AX_VELO).

MD37260 $MA_MS_MAX_CTRL_VELO[<slave axis>]

Note: Scaling via MD37253 $MA_MS_FUNCTION_MASK[<slave axis>], bit 0

Special functions

734

Function Manual, 12/2018, A5E40874099B AB

TE3: Speed/torque coupling, master-slave

19.5 Tension torque

19.5

Tension torque

The tension torque is a supplementary torque which is switched to the active torque

equalization controller. This means that a mechanical tension can be established between

axes within a master-slave grouping. Establishing a tension is not only possible between the

master and a slave axis, but also between two slave axes by declaring one of the slave axes

the reference axis for the torque equalization controller.

Setting

The tension torque is entered as a percentage of the rated torque of the slave axis and is active

immediately:

MD37264 $MA_MS_TENSION_TORQUE[<slave axis>] = <tension torque>

As can be seen from the structure of the torque equalization controller (Chapter "Torque

compensatory controller (Page 733)"), the tension torque is entered via a PT1 filter. The filter

time constant is set using the following machine data:

MD37266 $MA_MS_TENSION_TORQ_FILTER_TIME[<slave axis>] = <time constant>

A value for the filter time constant greater than 0 activates the filter.

NOTICE

No axis equalization

If a tension torque is entered without a mechanical coupling between the master and slave

axis then this causes the axes to move.

Note

Minimum tension torque

The tension torque chosen must be high enough to ensure that the resulting torque does not

drop below the minimum required tension even during acceleration.

Reducing the motor temperature rise

The tension torque can be reduced when the motor is at a standstill to reduce the motor

temperature rise.

Example 1 (840D sl): Static coupling and establishing a tension in pairs

A master-slave application is parameterized so that one master axis is assigned three slave

axes and a tension torque is entered for one axis pair. As a consequence, the master axis

alone does not have to establish the tension torque with respect to all of the slave axes.

Assumption regarding machine axes:

● 1st to 4th machine axis: AX1, AX2, AX3, AX4

Special functions

736

Function Manual, 12/2018, A5E40874099B AB

TE3: Speed/torque coupling, master-slave

19.5 Tension torque

Static coupling for all slave axes

● MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX2] = 1

● MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX3] = 1

● MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX4] = 1

Axis

Reference axis of the speed set-

Reference axis of the torque equal-

Input of the torque equalization

point coupling

ization controller

contr.

MD37250 = value

MD37252 = value

MD37254 = value

Value

Description

Value

Description

Value

Description

AX1

0

No reference axis

0

No reference axis

0

Master and slave

AX2

1

Master axis, AX1

1

Master axis, AX1

0

Master and slave

AX3

1

Master axis, AX1

0

No reference axis

3

No input

AX4

1

Master axis, AX1

3

2nd slave axis, AX3

0

Master and slave

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Example 1: Torque equalization control in pairs

Example 2 (840D sl): Dynamic coupling with 1x4 and 2x2 axes grouped in pairs

Assumption regarding machine axes:

● 1st to 4th machine axis: AX1, AX2, AX3, AX4

Dynamic coupling for all slave axes:

● MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX2] = 0

● MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX3] = 0

● MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX4] = 0

For a dynamic coupling, the master axis specified when defining the coupling (MASLDEF) is,

as standard, the reference axis for speed setpoint coupling and torque equalization control.

Special functions

Function Manual, 12/2018, A5E40874099B AB

737

TE3: Speed/torque coupling, master-slave

19.5 Tension torque

The definition of reference axis AX3 for the torque equalization control of the 3rd slave axis

AX4 is required for the application "1x4 axes" where the following machine data is set:

MD37253 $MA_MS_FUNCTION_MASK[AX4], Bit 1 = 1 (see part program)

Axis

Reference axis of the speed set-

Reference axis of the torque equal-

Input of the torque equalization

point coupling

ization controller

contr.

MD37250 = value

MD37252 = value

MD37254 = value

Value

Description

Value

Description

Value

Description

AX1

0

No reference axis

0

No reference axis

0

Master and slave

AX2

0

No reference axis

0

No reference axis

0

Master and slave

AX3

0

No reference axis

0

No reference axis

3

No input

AX4

0

No reference axis

3

Machine axis AX3

0

Master and slave

Program code

Comment

PROC MASL_SWITCH IPRTLOCK DISPLOF

IF MASL_REQUEST==4

;

Activate "1x4 axes"

MASLOF(AX2, AX4)

;

Switch off coupling

MASLDEL(AX2, AX4)

;

Delete coupling

$MA_MS_FUNCTION_MASK[AX4]=

;

MD37253, bit1 = 1:

$MA_MS_FUNCTION_MASK[AX4] B_OR 'B10'

;

Reference axis of the torque equalization controller

;

from AX4, is AX3 (MD37252)

NEWCONF

;

Activate machine data change

STOPRE

MASLDEF(AX2, AX3, AX4, AX1)

;

Define assignment for "1x4 axes"

MASLON(AX2, AX3, AX4)

;

Switch on couplings

MASL_ACTIVE=4 MASL_REQUEST=0

;

Feedback signal: "1x4 axes" switched-in

ENDIF

IF MASL_REQUEST==2

;

Activate "2x2 axes"

MASLOF(AX2, AX3, AX4)

;

Switch off coupling

MASLDEL(AX2, AX3, AX4)

;

Delete coupling

$MA_MS_FUNCTION_MASK[AX4]=

;

MD37253, bit1 = 0:

$MA_MS_FUNCTION_MASK[AX4] B_AND

;

Reference axis of the torque equalization controller

'HFFFD'

;

from AX4, is the master axis defined

;

with MASLDEF

NEWCONF

STOPRE

MASLDEF(AX2, AX1)

;

Define assignment for the 1st "2x2 axes"

MASLDEF(AX4, AX3)

;

Define assignment for the 2nd "2x2 axes"

MASLON(AX2, AX4)

;

Switch on couplings

MASL_ACTIVE=2 MASL_REQUEST=0

;

Feedback signal: "2x2 axes" switched on

ENDIF

RET

Special functions

738

Function Manual, 12/2018, A5E40874099B AB

TE3: Speed/torque coupling, master-slave

19.6 Closing/opening a coupling

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19.6

Closing/opening a coupling

Default setting

After the control has booted, the following machine data defines whether the coupling is

permanently switched on (static) or can be dynamically switched on/off and reconfigured:

MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[<slave axis>] = <switch on mode>

Statically switching on a coupling

MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[<slave axis>] = 1

After the control boots, the coupling is statically switched on.

By writing the machine data in the part program or synchronized action with subsequent warm

restart NEWCONF, then a static coupling can also be switched off/on at a later time.

Example: Switching the static coupling for slave axis AX2 off and on

Program code

Comment

N100 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX2] = 0

; Coupling type: static -> dynamic

N110 NEWCONF

; Activate machine data.

N120 MASLOF(AX2)

; Switch off coupling.

N200 PRESETON(AX2,...)

; E.g. actual value setting of the slave axis.

N300 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX2] = 1

; Coupling type: dynamic -> static, switch on cou-

pling.

Special functions

Function Manual, 12/2018, A5E40874099B AB

739

TE3: Speed/torque coupling, master-slave

19.7 Response on activation/deactivation

$AA_MASL_STAT[<slave axis>]

Value

Description

0

1) The coupling of the slave axis is not active.

2) The specific axis is not a slave axis

> 0

The coupling is active.

<value> == machine axis number of the master axis

NC/PLC interface signal

The current coupling state of a slave axis can be read using the following axis-specific NC/PLC

interface signal:

DB31, ... DBX96.7 (master/slave coupling active)

Setpoint state

Requests to switch on/off a master-slave coupling (NC/PLC interface signal and/or program

commands) that consecutively follow one another mutually overwrite one another. The

effective setpoint state results from the last chronological request (see Section "Response on

activation/deactivation (Page 741)").

19.7

Response on activation/deactivation

On/off at standstill (axis)

A request to switch on/off the coupling only becomes effective when the master and slave axis

are at a standstill (zero speed):

DB31, ... DBX61.4 == 1 (axis/spindle stationary)

In this case, the coupled axes must be in the closed-loop controlled mode.

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Special functions

Function Manual, 12/2018, A5E40874099B AB

741

TE3: Speed/torque coupling, master-slave

19.7 Response on activation/deactivation

- MD37272 $MA_MS_VELO_TOL_FINE ("Tolerance fine").

Note

The "Speed tolerance coarse" signal can be used to implement a monitoring function

on the PLC side that checks a coupled master-slave grouping for loss of speed

synchronism.

The "Speed tolerance fine" signal can be used to directly derive the time taken to close

the coupling mechanically and switch on the torque equalization controller.

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Coupling operation at different speeds

Switch off without braking

If the coupling is switched off with the MASLOF program command, the coupling will be switched

off immediately for spindles in speed control mode. The slave spindles maintain their speeds

at the time that the coupling is switched off until a new speed is programmed.

Special functions

744

Function Manual, 12/2018, A5E40874099B AB

TE3: Speed/torque coupling, master-slave

19.8 Supplementary conditions

Switch off with braking

If the coupling is switched off with the MASLOFS program command, the coupling will be

switched off immediately for spindles in speed control mode and the slave spindles braked.

Note

The implicit preprocessing stop is omitted for MASLON and MASLOF. The missing preprocessing

stop means that the $P system variables of the slave spindles do not supply updated values

until reprogrammed.

Coupling characteristics

The behavior regarding the program commands MASLON, MASLOF, MASLOFS, MASLDEL (only

840D sl) and the NC/PLC interface signal: DB31, ... DBX24.7 (master/slave on) is, for spindles

in the open-loop speed controlled mode, set using the following machine data:

MD37263 $MA_MS_SPIND_COUPLING_MODE[<slave spindle>] = <value>

<value>

Description

0

Coupling and disconnection take place only at standstill.

The current coupling state is retained until all axes involved have actually come to a stand-

still. The MASLOFS and MASLOF operations are identical; the slave spindle is not decelerated

automatically.

1

Coupling and disconnection takes place immediately and therefore during motion.

During coupling, the slave spindles are accelerated automatically to the current speed of

the master spindle.

On disconnection, the slave spindles rotating at this time retain their speeds until next speed

programming. However, a slave spindle disconnected with MASLOFS decelerates automat-

ically.

19.8

Supplementary conditions

19.8.1

Functional boundary conditions

General

● Master and slave axes must be on the same NCU.

● A coupling is closed or opened independent of the channel state the next time that the axis

is at a standstill.

● Slave axes can only be traversed via the master axis when the coupling is closed.

● A coupled slave axis cannot be switched further via the axis container.

● A requested axis interchange of coupled slave axes is not executed.

Special functions

Function Manual, 12/2018, A5E40874099B AB

745

TE3: Speed/torque coupling, master-slave

19.8 Supplementary conditions

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Coupling between container spindle S3 and auxiliary motor AUX (prior to rotation)

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Figure 19-8

Coupling between container spindle S3 and auxiliary motor AUX (after to rotation)

Hardware and software limit switches

If the software or hardware limit switch is overtraveled by a slave axis, the master-slave

grouping is stopped via the master axis. The relevant slave axis is shown in the alarm. The

limit switch of the slave axis is overtraveled by the amount of the deceleration distance of the

master axis.

Special functions

Function Manual, 12/2018, A5E40874099B AB

751

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