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SINUMERIK 840D sl. Service - Functions. Manual (2018-2020) - page 78

Clearance control (CLC/CLCX)

5.5 Startup

• It is important that the stroke of the sinusoidal movement, which is twice as large as

CLC_SIN_GEN_AMPL specifies, remains completely within the sensitive range of the sensor.

• Select CLC_SIN_GEN_AMPL so that it corresponds to about one third of the largest entry of

the sensor characteristic curve.

Example:

CLC_SIN_GEN_AMPL = 0.354 * $MC_CLC_SENSOR_DIST_TABLE[ <highestIndexUsed>]

reaches 70% of the sensitive sensor range.

If CLC_RTD_PROG_DIST does not exceed the remaining 30%, the delay can be evaluated

correctly.

• After a few periods of sine movement executed within the M0 block, the GUD variable

CLC_SENSOR_MATCH[0] displays the evaluated delay in seconds.

Figure 5-4

Determination of the sensor delay

Determine and adjust measured data

Modern clearance sensors connected via an isochronous PROFINET IO A/D converter should

show a delay in the range of a few milliseconds or even less, largely independent of frequency.

The example above shows a time delay of 0.123 ms.

If you get a stable and positive delay during the measurement, transfer the measured sensor

delay in seconds as compensation value to the following machine data:

• MD62519 $MC_CLC_SENSOR_DELAY_COMP_TIME = CLC_SENSOR_MATCH[0]

• Execute NEWCONFIG or RESET to make the compensation value effective.

CLCX compares the position information read by the sensor with the position information of the

encoder.

This is required for the "POS mode" and usually for any sensor-controlled approach starting at a

distance outside the sensitive range of the sensor.

If you repeat the measurement with an already correctly determined entry in

$MC_CLC_SENSOR_DELAY_COMP_TIME, CLC_SENSOR_MATCH[0] will still show the delay of the

uncompensated sensor.

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5.5 Startup

• MD36040 $MA_STANDSTILL_DELAY_TIME[<x>] (Delay time for standstill monitoring)

• MD36060 $MA_STANDSTILL_VELO_TOL[<x>] (Threshold velocity/speed 'Axis/spindle in

stop')

<x> = identifier of the clearance-controlled machine axis

5.5.6

Configuration of the basic MD of CLCX

Basic machine data

Table 5-2

Machine data for configuration of CLCX

Machine data

Description

MD62500 $MC_CLC_AXNO

> 0: Activates the 1D clearance control for the channel axis with the specified axis

number. This axis must not be a modulo rotary axis.

n < 0: activates the 3D clearance control.

A prerequisite for activating the 3D clearance control is that at least one of the

first four 5-axis transformations possible in the channel is configured.

-1: the first 5-axis transformation configured with $MC_TRAFO_TYPE_n in the

channel (16 <= transformer type <=149) defines the three Cartesian axes on

which clearance control acts.

-4: the fourth 5-axis transformation configured in the channel is selected.

MD 62502 $MC_CLC_ANALOG_INPUT

Number of the analog input to which the clearance sensor is connected.

MD62507

Start address of the real-time variables $A_DBR / $A_DBB (e.g. 1000)

$MC_CLC_A_DB_RT_VAR_START_INDEX

The CLCX function reads and writes to the $A_DBx variables that follow this start

address. Therefore 100 bytes from this start address should not be used for other

functions.

MD $MC_CLC_SENSOR_TOUCHED_INPUT

Number of the digital input to be used for collision monitoring (provided the

sensor outputs a tip-touch signal).

MD62528 $MC_CLC_PROG_ORI_AX_MASK

Axis mask for simulated axes when using the 3D-CLC function with freely pro-

grammed direction specification.

MD28090 $MC_MM_NUM_CC_BLOCK_ELE-

Configures the number of block elements that can be used for compile cycles.

MENTS

Each instance of the CLCX in the channel requires 4 block elements.

MD28100

Configures the size of the dynamic memory available for compile cycles in the

$MC_MM_NUM_CC_BLOCK_USER_MEM

internal block. Each instance of the CLCX in the channel requires 20 KB.

MD28150 $MC_MM_NUM_VDIVAR_ELE-

Number of block elements available for writing PLC variables. Recommended

MENTS

value for programming synchronized actions to use the CLCX function: 20

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5.5 Startup

"New" machine data for CLCX

Table 5-3

Additional machine data for CLCX

Number

Identifier: $MC_

Description

62503

CLC_ANALOG_IN_HW_NORM_FACT

Normalization of the internal voltage values to the input voltage in

Volts

62507

CLC_A_DB_RT_VAR_START_INDEX

Start index of the CLCX real-time variable $A_DBx

62509

CLC_DISTANCE_SETPOINT

Defines a default distance that is used after reset as long as no

distance has been explicitly programmed.

62511

CLC_SENSOR_DIST_TABLE_1 [0... 15 ]

First clearance table for linearization of the sensor characteristic

curve

62513

CLC_SENSOR_DIST_TABLE_2 [ 0... 15 ]

Second clearance table for linearization of the sensor characteristic

curve

62514

CLC_DISTANCE_CTRL_GAIN

Defines the default value of the CLC circuit gain. This value is effec-

tive in "GAIN mode" after reset as long as no GAIN value has been

explicitly programmed.

62515

CLC_PLUS_DIR_GAIN_FACTOR

Increase the gain factor if the current distance of the sensor be-

comes smaller than the programmed distance setpoint.

62518

CLC_SENSOR_JERK_TIME

Jerk filter for smoothing the non-sensor-controlled CLCX motion.

62519

CLC_SENSOR_DELAY_COMP_TIME

Value to compensate for the delay time of the sensor used. This

adjustment is required for the sensor-guided approach from large

distances and for the POS mode.

62525

CLC_SENSOR_FILTER_TIME

• Index0: Time constant of the mean value filtering of the sensor

input signal.

• Index1: Time constant of the mean value filtering for internal

calculation of the tip-touch signal.

62526

CLC_TIP_TOUCH_DISTANCE

Threshold value for triggering internal tip-touch monitoring.

62527

CLC_MODE_SWITCH_DIST_ERROR

Threshold value for automatic switching from POS mode to GAIN

mode and vice versa.

An entry >0 activates the automatic switchover.

Table 5-4

List of redeclared machine data for CLCX

Number

Identifier:

Description

10712

$MN_NC_USER_CODE_CONF_NAME_TAB[0]

-

= "OMA1"

10712

$MN_NC_USER_CODE_CONF_NAME_TAB[1]

-

= "CLC_DIST"

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5.5 Startup

"Old" machine data for CLC

This machine data is no longer provided or used by CLCX.

Table 5-5

CLC machine data that is no longer required

Number

Identifier: $MC_

Description

62511

CLC_SENSOR_VELO_TABLE_1 [0 ... 15 ]

First velocity table for linearization of the sensor characteristic curve

62513

CLC_SENSOR_VELO_TABLE_2 [ 0 ... 15 ]

Second velocity table for linearization of the sensor characteristic

curve

62522

CLC_OFFSET_ASSIGN_ANAOUT

Assignment of internal additional analog value to sensor signal

62523

CLC_LOCK_DIR_ASSIGN_DIGOUT

Assignment of digital output for interlock CLC

List of redeclared machine data for CLC.

Table 5-6

List of redeclared machine data for CLC

Number

Identifier:

Description

10712

$MN_NC_USER_CODE_CONF_NAME_TAB[0

-

] = "OMA1"

10712

$MN_NC_USER_CODE_CONF_NAME_TAB[1

-

] = "CLC_GAIN"

10712

$MN_NC_USER_CODE_CONF_NAME_TAB[2

-

] = "OMA2"

10712

$MN_NC_USER_CODE_CONF_NAME_TAB[3

-

] = "CLC_VOLT"

5.5.7

Definition of the real-time variables for synchronized actions

Real-time variables

CLCX uses the following two data types to display and operate its own real-time variables:

• "$A_DBR; variables of data type "REAL".

• "$A_DBB" variables of data type "BYTE".

The individual $A_DBx variables are located at fixed byte offsets starting with the configured

start address (via MD62507 $MC_CLC_A_DB_RT_VAR_START_INDEX). For clear use of the

variables in synchronized actions, it is recommended to assign functionally descriptive names to

the $A_DBx variables using MACRO definitions. In the "NC/PLC variables" operating menu of the

SINUMERIK Operate, the same names can be entered manually in the "Comment" column of the

variable list. This view allows the variables to be displayed and operated during commissioning.

The name selection of this documentation uses the prefix CLC_RT* for variables that require

input and CLC_RTD* for variables that are only used to display states of the CLCX. RTD stands for

"Real-Time Display". The SINUMERIK Operate allows you to save or load a commented variable

view.

In the delivery package of the CLCX you will find the file "clcxSynActVar.xml". If you adapt this

file with regard to the variable start address you have selected and copy it to the "HMI Data/

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Clearance control (CLC/CLCX)

5.5 Startup

Template/User/VariableMasks" directory, you can directly load the variable view shown in the

following figure.

Figure 5-5

Real-time variables CLCX

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5.6 Programming

5.6.2

NC commands and Synact variables

NC variables and synchronized actions variables for operation

Table 5-7

NC variables and synchronized actions variables

Name

Type

Description

Action on reset

CLC(<intArg>)

NC procedure

Modal NC command.

CLCX is switched off

Must be programmed in a separate block

with CLC(0)

Switches CLC on and off

<intArg>: 1

Switch on without tip-touch monitoring

<intArg>: 2

Switch on with activated tip-touch monitoring

<intArg>: 3

Switch on with "3d free direction programming"

<intArg>: 4

Switch on with "3d free direction programming with

tip-touch monitoring".

<intArg>: 0

Switch off by synchronizing the servo position

<intArg>: -1

Switch off by moving back to the switch-on position

CLC_SEL(<intArg>)

NC procedure

Modal NC command

The last selected table

Selects the voltage clearance table to be used for lin-

remains active when

earizing the clearance sensor. A new setting is only

CLCX is switched off or

effective if CLC is activated.

a RESET is performed.

Table 1 is selected by

1: MD 62510 / MD 62511

default

2: MD 62512 / MD 62513

when the program is

10...20: Voltage clearance table defined by GUD vari-

started.

able

CLC_LIM( <realArg1>,

NC procedure

Modal NC command

MD 62505 [0]

<realArg2>)

Defines the limits of CLC motion relative to the switch-

and

ing-on position:

MD 62506 [0]

initialize the limit val-

<realArg1>: Lower limit

ues

<realArg2>: Upper limit

CLCX_PREP_DATA(SEN-

NC function

Non-modal NC command

Unchanged

SOR_GUD_TAB)

Checks the up to 11 additional clearance voltage ta-

bles created in GUD and makes them available for ap-

plication with the command CLC_SEL(10..20) - provi-

ded that the GUD definitions of all tables were free of

errors.

CLC_DIST=<realValue>

NC address

Modal NC command

MD 62509

<realValue> defines the clearance between the sensor

initializes the clear-

tip and the sheet metal.

ance

CLC_GAIN=<realValue>

NC address

This NC address of the old CLC is no longer supported

MD 62514

in CLCX.

initializes the GAIN

The GAIN factor set with MD 62514 can now be

changed by the synchronized action variable

CLC_RT_GAIN_FACTOR.

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5.6 Programming

Name

Type

Description

Action on reset

CLC_RT_DIST_OFFSET

SynAct variable

Real-time offset in mm, which is added to the clear-

Initialized with zero

$A_DBR[x+0]

ance setpoint programmed with CLC_DIST=<>

CLC_RT_GAIN_FACTOR

SynAct variable

Real-time factor by which the CLC loop gain set by the

Is initialized with 1.0

$A_DBR[x+16]

MD $MC_CLC_DISTANCE_CTRL_GAIN is multiplied.

CLC_RT_MOVE_POS_REL

SynAct variable

Relative distance in mm to which the CLC axis jumps

Unchanged

$A_DBR[x+4]

when the command CLC_RT_TECH_CMD=10 is given

or when "tip-touch monitoring" is triggered.

CLC_RT_MOVE_POS_ABS

SynAct variable

Absolute MCS position in mm to which the CLC axis

Unchanged

$A_DBR[x+8]

jumps when the command CLC_RT_TECH_CMD=11 is

given. In the 3D case: absolute jump position within

the CLC coordinate system.

CLC_RT_TECH_CMD

SynAct variable

Real-time command that triggers the following ac-

Initialized with zero

$A_DBB[x+12]

tions:

• Jump-up of the CLC motion

• Freezing of the CLC motion

• Switch to the mode for determining the sensor de-

lay time

For a complete list of commands, see Available tech-

nology commands (Page 59).

With CLC_RT_TECH_MODE=0 the active technology

command is terminated and the sensor-controlled

mode is reactivated.

CLC_RT_CTRL_MODE

SynAct variable

Selects the control mode:

Bit_0 is initialized with

$A_DBB[x+13]

the value of Bit_12 of

• Bit 0 = 0: POS mode

MD 62508.

• Bit 0 = 1: GAIN mode

Bit_4 of $A_DBB[x

• Bit_4 = 1: causes the CLC velocity limit to use the

+13] remains un-

value set in MD $MC_CLC_SENSOR_VELO_LIM-

changed after a reset

IT[1].

CLC_RT_TRACE_FLAG

SynAct variable

Variable to start and stop the integrated CLCX trace.

Unchanged

$A_DBB[x+68]

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5.6 Programming

5.6.3

Synact variables for diagnostics

Available synchronized actions variables for diagnostics

Table 5-8

Diagnostics variables

Name of the

Type and byte

Description

SynAct variable

offset

CLC_RTD_SENSOR_VOLT

$A_DBR[x+28]

Shows the currently applied input voltage in Volts. Allows you to set the

correct normalization factor and update/check the voltage clearance tables.

The sensor voltage is displayed even if CLC is not active.

CLC_RTD_SENSOR_DIST

$A_DBR[x+32]

Shows the distance that the sensor is currently measuring.

This value results from the actual sensor voltage and the currently selected

voltage clearance table.

The table is evaluated even if CLC is actually deactivated. The last selected

table number remains active after RESET.

The distance is always displayed in mm, regardless of any inch/metric set-

tings.

CLC_RTD_PROG_DIST

$A_DBR[x+36]

Displays the clearance setpoint resulting from the programmed modal NC

command CLC_DIST=<value> and the real-time offset set with the SynAct

variable CLC_RT_DIST_OFFSET.

The clearance setpoint is always displayed in mm, regardless of all inch/

metric settings.

CLC_RTD_LOWER_LIMIT

$A_DBR[x+40]

Shows the effective lower limit of the CLC motion.

The value refers to the position at which the CLC was switched on.

With 3D-CLC, the limitation can be additionally restricted if the programmed

TCP motion approaches the software limit of an axis.

This value is always displayed in mm, regardless of any inch/metric settings.

CLC_RTD_UPPER_LIMIT

$A_DBR[x+44]

Shows the effective upper limit of CLC motion.

The value refers to the position at which the CLC was switched on.

With 3D-CLC, the limitation can be additionally restricted if the programmed

TCP motion approaches the software limit of an axis.

This value is always displayed in mm, regardless of any inch/metric settings.

CLC_RTD_ACT_POS

$A_DBR[x+48]

The current set position of the CLC motion.

The zero point to which this coordinate refers is the position at which the

CLC was switched on.

The set position is always displayed in mm, regardless of any inch/metric

settings.

CLC_RTD_ACT_POS_ABS

$A_DBR[x+52]

The current set position of the CLC motion in MCS coordinates.

This position is always displayed in mm, regardless of any inch/metric set-

tings.

In the 3D case, this variable shows the same position as CLC_RTD_ACT_POS.

CLC_RTD_ACT_VEL

$A_DBR[x+56]

The current speed setpoint of the CLC motion.

This speed is always displayed in mm/min, regardless of any inch/metric

settings.

CLC_RTD_STATE

$A_DBB[x+60]

Displays the current status of the CLC motion. See Diagnosis of the CLCX

state (Page 61).

CLC_RTD_TECH_MODE

$A_DBB[x+61]

Shows the state that resulted from the last given TECH command.

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5.6 Programming

Name of the

Type and byte

Description

SynAct variable

offset

CLC_RTD_DYN_LIM

$A_DBB[x+62]

The bits indicate the various dynamic limits currently acting on the input

variable of the CLC interpolator and limiter.

If all bits are zero, the sensor's motion specification is currently not limited.

CLC_RTD_FREE_DIR_ANGLE

$A_DBB[x+72]

Angle (in degrees) between the orientation generated by "free direction

programming" and the current tool orientation of the 5-axis transformation.

5.6.4

Available technology commands

Technology commands available for synchronized action

The following table lists the technology commands that can be programmed in synchronized

actions while the CLC is active. The right column shows the corresponding mode that is output

by the variable CLC_RTD_TECH_MODE.

Table 5-9

Technology commands

CLC_RT_

Description

CLC_RTD_ TECH_MODE

TECH_CMD

0

This command cancels any other currently active command and moves the

0 ... 5

CLC axis sensor-controlled up to the programmed distance

CLC_RTD_PROG_DIST above the plate.

10

jump_up_rel: Starting from the current position, the CLC axis moves with

10

the maximum permissible dynamic response by the distance specified in

the variable CLC_RT_MOVE_POS_REL.

11

jump_up_abs: The CLC axis moves with the maximum permissible dynam-

11

ic response up to the MCS position specified in the variable

CLC_RT_MOVE_POS_ABS.

Note: In the 3D case, the target position of the jump is specified absolutely

in relation to the CLC coordinate system. For the reference to the regular

MCS, the specification of three coordinates would be necessary.

20

freeze_both_dirs: Locks the CLC axis at its current position

20

21

freeze_down_pos: Prevents the CLC axis from moving lower than its cur-

21

rent position.

The axis can still be moved upward (sensor-controlled) and can also be

moved back again to the frozen position.

22

freeze_down_dir: Prevents the CLC axis from moving further down. The

22

sensor can only move the axis upwards to higher positions.

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5.6 Programming

CLC_RT_

Description

CLC_RTD_ TECH_MODE

TECH_CMD

30

This number reports a "tip-touch" event if tip-touch monitoring has been

30

activated with the switch-on command CLC(2) or CLC(4):

Either the external tip-touch signal or the internal tip-touch evaluation has

triggered a motion of the CLC axis by the distance specified in the variable

CLC_RT_MOVE_POS_REL.

This state cannot be actively programmed. However, the tip-touch state

can be canceled and the sensor-controlled motion can be continued by

overwriting the pending command code 30 with 0 or another valid com-

mand code in CLC_RT_TECH_CMD.

99

Switches on the sine-wave generator to determine the sensor delay

99

The GUD CLC_SIN_GEN_AMP determines the amplitude (in mm) of the

generator and CLC_SIN_GEN_FREQ the frequency (in Hz).

Executing a technology command in the IPO task

In principle, all CLC_RT_TECH_CMD commands that are not equal to "0" must be repeated within

each IPO cycle as long as the command is to be executed. If you do not repeat the command in

an IPO cycle, CLCX receives the command "CLC_RT_TECH_CMD=0" and terminates the current

technology actions (Auto-Cancelling).

Example:

For example, if you want to cross a hole already cut in the sheet metal with the cutting head

raised by 5 mm, you can program the following instruction:

Programming example

CLC_RT_MOVE_REL_POS=5.0 ; prepares a relative jump-up of 5 mm

whenever TRUE do CLC_RT_TECH_CMD=10 ; keeps the jump_up_rel command active during the next

executable block

The Auto-Cancelling property of CLC_RT_TECH_CMD makes the programming of synchronized

actions more user-friendly in many cases because you do not need an additional command to

terminate the action.

On the other hand, this setting prevents the corresponding commands from being entered into

the $A_DBB variable by the PLC or manually via the variable view of the SINUMERIK Operate,

since with both methods the input cannot be repeated in every IPO cycle.

Executing a technology command with "AUTO-HOLD"

To nevertheless use the technology commands from the PLC or from the variable view of the

SINUMERIK Operate, you can optionally select the Auto Hold mode which can be applied for each

technology command not equal to zero. You must increase the respective command value by

100 for this purpose.

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5.6 Programming

Example:

Set the technology command CLC_RT_TECH_CMD = 10 (jump_up_rel) with auto hold mode in

a synchronized action:

Programming example

When TRUE do CLC_RT_TECH_CMD=110 ; in the first cycle of the next executable block, the

jump_up_rel command becomes active in AUTO-HOLD

A technology command issued in Auto-Hold mode remains active until you explicitly cancel it by

executing CLC_RT_TECH_CMD=0 or another technology command.

As long as no technology command greater than zero is active, CLCX controls the axis in sensor-

controlled mode.

CLC_RTD_TECH_MODE

As long as no technology command is issued, the CLC moves the axes in sensor-driven control

mode. The variable CLC_RTD_TECH_MODE reports back details of the active control mode

according to the following table:

CLC_RTD_TECH_MODE

Description

0

The CLC function is switched off

1

The CLC motion is driven by the sensor. It approaches the sheet metal, but

the sensor is still outside its sensitive range.

2

The "POS mode" is active (CLC_RT_CTRL_MODE=0)

The CLC motion is driven by the sensor, which is now in its sensitive range.

3

The "GAIN mode" is active (CLC_RT_CTRL_MODE=1)

The CLC motion is driven by the sensor, which is now in its sensitive range.

4

Like mode 2, but the internal JERK filter is still activated. In sensor-driven

mode, the jerk filter is switched off as quickly as possible.

5

Like mode 3, but the internal JERK filter is still activated. In sensor-driven

mode, the jerk filter is switched off as quickly as possible.

5.6.5

Diagnosis of the CLCX state

Motion state of CLCX

The synchronized action variable CLC_RTD_STATE shows the detailed motion status of the CLCX

axis:

Table 5-10

Synchronization variable CLC_RTD_STATE

CLC_RTD_STATE

Description

0

CLC is deactivated.

1

CLC axis is moving.

2

CLC motion is at a standstill according to the period set in MD 62520 and the

position tolerance set in MD 62521 [0].

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5.7 3D clearance control

CLC_RTD_STATE

Description

3

CLC stopped at lower motion limit.

4

CLC stopped at upper motion limit.

5

CLC motion is at standstill and at the same time the current sensor position is

within the tolerance window to the programmed clearance setpoint specified in

MD 62521 [1].

10

CLC stops:

Identifies the IPO cycles required by the CLC to decelerate the axis motion to a

standstill after an off command is received

11

CLC moves back:

Appears while the axis is moving back to the last IPO position if the deactivation

was programmed with CLC(-1).

12

CLC has reached the stop state:

Marks the IPO cycle in which the CLC motion is stopped after state 10.

CLCX limiter/interpolator

The synchronized action variable CLC_DIAG_RTD_DYN_LIM shows the detailed state of the CLCX

interpolator/dynamic limiter.

As long as this variable shows a value of zero, the motion specified by the sensor or internally can

be executed without being limited by the dynamic response of the CLC axis.

Table 5-11

Display CLCX interpolator with CLC_DIAG_DYN_LIM

CLC_RTD_DYN_LIM

Description

bit_0

Brakes with predictable overshoot

bit_1

Braking to a fixed target position

bit_2

Current negative acceleration limit reached

bit_3

Current positive acceleration limit reached

bit_4

Current negative velocity limit reached

bit_5

Current positive velocity limit reached

bit_6

Lower position limit reached

bit_7

Upper position limit reached

5.7

3D clearance control

5.7.1

3D clearance control - overview

4 and 5-axis transformation

A prerequisite for the application of the 3D clearance control is that a 4 or 5-axis transformation

has been defined via TRAORI.

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5.7 3D clearance control

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). The clearance control only affects the linear axes. Two

options are available for the direction of the sensor-guided control motion in space ("the 3D

control direction"):

• in the direction of the vector of the programmed tool orientation (standard case)

• in any direction, which must be programmed by three additional vector components within

each traversing block

Note

The 3D clearance control can only be used on Cartesian machines with generic 4 or 5-axis

transformation.

The 3D CLC cannot be used on robots or other non-Cartesian kinematics. There, the TOFF

function, which operates in the IPO cycle, can be used.

5.7.2

3D control direction

Standard 3D control direction

In the standard case, the control direction of the clearance control and the vector of the tool

orientation are identical. Consequently, the compensation movement of the clearance control

is normally always in the direction of the tool orientation.

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The programmed TCP corresponds to the ideal machining point.

Figure 5-6

Clearance control with standard control direction

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 thus also the control direction is perpendicular to the

workpiece surface, no geometric offset of the machining point on the surface of the workpiece

surface results from the correction movements of the clearance control.

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Clearance control (CLC/CLCX)

5.7 3D clearance control

If, for technological reasons, a setting angle of the beam is required so that the tool orientation

is no longer perpendicular to the workpiece surface, correction movements of the clearance

control of the standard control direction result in a geometric offset of the machining point on

the workpiece surface.

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Standard 3D control direction

The reason for the offset of the machining point is the vector component (KX) of the control

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

is shifted by this amount.

Programmable control direction

When using the software option "freely programmable control direction", the correction

movements of the clearance control can be made in the direction of the programmed vector, i.e.

it is no longer bound to the beam orientation (= tool orientation).

If the programmed orientation is perpendicular to the workpiece surface, a geometric offset due

to the 3D correction motion of the CLCX can be avoided.

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Clearance control (CLC/CLCX)

5.7 3D clearance control

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Programmable 3D control direction

5.7.3

Parameterization of the programmable control direction

Reference coordinate system

Three vector components to be programmed as additional axis positions are used to specify the

direction in which the sensor-guided correction movement of the clearance control takes place.

The vector components refer to the basic coordinate system. Programmed frames that act on the

contour and, if applicable, the tool orientation are not taken into account when calculating the

control direction.

Axis positions for setting the vector of the control direction

The following conditions must be met for the specification of the vector components of the

control direction via programmed axis positions:

1. The three axes used should be simulated NC axes:

- MD30240 $MA_ENC_TYPE[x]=0

- MD30130 $MA_CTRLOUT_TYPE[x]=0

2. The axes must be channel axes of the channel in which the clearance control is activated.

3. The axes must be linear axes. +-1.0mm is recommended as maximum programmed position

range of each vector component to avoid interpolation of long axis distances. The length of

the programmed vector need not be standardized to 1.0.

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65

Clearance control (CLC/CLCX)

5.7 3D clearance control

Orientation of the control direction perpendicular to a semicircular workpiece surface. The

programming of the traversing motion is not considered.

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Interpolation of the vector of the control direction

Before the part program block N100, the control direction vector has been oriented to [1, 0, 0]

by programming the direction axes. In part program block N100, the end position of the control

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

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

the part program block:

• Geometry and orientation axes for the movement of the machining head

• The three component axes for rotating the vector of the control direction.

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

an antiparallel orientation of the control direction 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 vector, and the orientation of the

control direction vector would remain unchanged.

Antiparallel orientation of the vector of the control direction

If in a part program block an antiparallel orientation of the free control direction with respect to

the previous direction is programmed, the following alarm will be displayed:

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

Note

Interpolation of the vector

As described above, the interpolation of the vector of the control direction is not a true vector

interpolation, but is the result of the component-wise interpolation of the three simulation

axes involved.

Rotation of the workpiece coordinate system

The programming of the three vector components of the control direction always refers to the

basic coordinate system, as described above. If a rotating or mirroring frame is used for

machining the workpiece, so that the coordinate axes of the programming coordinate system

(WCS) and those of the basic coordinate system are no longer parallel and of the same

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5.8 Multiple CLCX instances in different channels

orientation, a corresponding conversion must also be made for the components of the control

direction.

CAUTION

Not of the same orientation

If the workpiece coordinate system is rotated or mirrored in such a way that the coordinate axes

of the basic and workpiece coordinate systems are no longer parallel and of the same

orientation, the user is responsible for the corresponding transformation of the freely

programmed control direction.

5.8

Multiple CLCX instances in different channels

5.8.1

Multiple CLCX instances in one channel

CLCX instance

Via a CLCX instance, the functionality of clearance control is applied to an axis or (for 3D CLC) to

the Cartesian axes of a 4 or 5-axis transformation. Up to four instances can be configured within

one NCU. All four instances can be used in one channel ("multi-head machine") or freely

distributed to several channels of a control system. For example, two instances can run in the

first channel and one instance each in the second channel and fourth channel.

Since a channel represents a machining context in which only exactly one 5-axis transformation

can run, CLCX configurations with several instances per channel only make sense with the single-

axis version.

Assigning CLCX instances to channels

As with other compile cycles, the following machine data determines the channels in which the

CLCX function is to be used:

$MN_CC_ACTIVE_IN_CHAN_CLCX[0] = 'Hxxx':

• 'Hxxx' is a bit mask in hexadecimal format, which is used to select the channels in which at

least one CLCX instance should be available.

Activating an instance in a channel

$MN_CC_ACTIVE_IN_CHAN_CLCX[0] = 'H1'

With this command you activate a CLCX instance in channel 1.

Activating one instance in several channels each

$MN_CC_ACTIVE_IN_CHAN_CLCX[0] = 'H5'

With this command you activate one instance in channel 1 and one instance in channel 3 (H5 =

binary 0101).

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Clearance control (CLC/CLCX)

5.8 Multiple CLCX instances in different channels

During the NC restart, the CLCX calls this function internally. In this way, the additional

characteristics can be used without having to explicitly repeat the call of this NC function at each

NCK restart.

In any case, the GUD variable CLCX_TAB_STATUS reflects the status of the last transmission and

must be checked to detect errors within the current GUD definition. Such errors do not set the

alarm 75001 with error ID: -1 or -2 as invalid characteristic curves entered via machine data do.

Display CLCX_TAB_STATUS

If CLCX_TAB_STATUS shows one of the following negative values, none of the additional

characteristics defined via GUD can be used. You must first fix the specified problem.

Table 5-12

Status displays

-1

CLCX_PREP_DATA was called while CLC is active and one of the GUD tables is in use.

-2

CLCX_PREP_DATA was called with an argument unequal to "SENSOR_GUD_TAB".

-3

CLCX_PREP_DATA internal READ_ERROR when reading the argument.

-10

Expected GUD names CLCX_TAB_V, CLCX_TAB_D not found.

-11

The GUD data definition must be global: "DEF NCK REAL ..."

-12

The GUD data definition must be of data type REAL: "DEF NCK REAL ..."

-13

CLCX_TAB_D and CLCX_TAB_V: The size of the first array dimension must be at least 2.

-14

CLCX_TAB_V: The size of the second array dimension must be at least 2.

-16

Internal READ_ERROR when reading a GUD

-20

CLCX_TAB_V: The order of the entries does not increase or decrease monotonously.

-21

CCC_TAB_D: Order of entries does not increase monotonously.

-25

CLC_TAB_D: The first entry in the clearance table is not equal to zero.

If there was no problem in any of the table definitions during the transmission of the GUD values,

the number of successfully transmitted voltage values is reported back as a positive number.

If, for example, 11 tables with 16 valid entries each have been defined, the following value is set

in the status variable:

CLCX_TAB_STATUS = 176

If CLCX_TAB_STATUS shows that the additional internal sensor characteristics have been

successfully updated from the GUD arrays, any instance of the CLCX function in any channel can

use these characteristics by programming CLC_SEL(10) through CLC_SEL(20).

• CLC_SEL(10) uses the measured voltages CLCX_TAB_V[0, 0...15]

• CLC_SEL(11) uses the measured voltages from CLCX_TAB_V [1, 0...15]

• ...

• CLC_SEL(20) uses the measured voltages from CLCX_TAB_V[10, 0 ...15]

If a characteristic is programmed in CLC_SEL() that is currently not defined, CLCX sets the

following alarm:

75002 Channel %1 NC block %2 CC_CLCX programming error, error code: 5

Error code 5: CLC_SEL(1x) programs without valid GUD characteristics set

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Clearance control (CLC/CLCX)

5.9 Function-specific display data

5.9

Function-specific display data

The "Clearance control" technology function provides specific display data for supporting setup

and for service purposes.

Possible applications

Possible applications of the display data include, for example:

• Determination of the form deviations and control errors occurring for a short time via the

variables for the maximum and minimum position offset or the sensor input voltage.

• Determination of the voltage noise detected by the A/D converter using the variables for the

maximum and minimum sensor input voltage. Prerequisites are a constant distance of the

clearance sensor from the workpiece surface with blocked clearance control (e.g. with

CLC__RT_GAIN_FACTOR = 0.0).

The minimum and maximum values are acquired in the position controller cycle.

Types of variables

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

a synchronized action variable (Page 61). The min/max values are only available in the GUD.

5.9.1

Channel-specific GUD variables

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

variables for SINUMERIK Operate:

Table 5-13

Channel-specific GUD variables

GUD variable

Designation

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 technology function has been set up, the GUD variables listed are not displayed

automatically on the HMI interface.

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5.10 Function-specific alarm texts

SINUMERIK Operate

Proceed as follows to create and display the GUD variables for SINUMERIK Operate.

1. Set password

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

2. If no MGUD.DEF file exists yet:

Operating area switchover > Commissioning > System data > Open NC data directory:

Move the cursor to Definitions > New...

• Name: MGUD

• Type: DEF

Confirm with OK.

This opens the file in the editor.

1. Edit the GUD variable definitions

DEF CHAN REAL CLC_DISTANCE[3] ; Array of real, 3 elements

DEF CHAN REAL CLC_VOLTAGE[3] ; Array of real, 3 elements

M30

2. Save the file and close the editor

3. Activate the file MGUD.DEF

The GUD variables for clearance control are now displayed under:

Operating area switchover >Parameters > User variables > Channel GUD

SINUMERIK NC

The newly created and already displayed GUD variables are only recognized and supplied with

current values by the clearance control after an NC POWER ON-RESET.

Note

After creating the GUD variables, an NC POWER ON-RESET must be triggered so that the

clearance control updates the GUD variables.

5.10

Function-specific alarm texts

For the procedure for creating function-specific alarm texts, see Creating alarm texts (Page 23).

The following table shows the alarm numbers of CLCX:

CLCX alarm number

CLC alarm number

75001

CLCX wrong MD configuration, error code: %2

75002

CLCX NC block %2 programming error, error code: %3

75003

CLCX NC block %2 invalid limits prog. in CLCX_LIM

75004

CLCX NC block %2 switched off with active tool radius compensation

75006

CLCX NC block %2 abrupt change of orientation

75007

CLCX NC block %2 sensor tip touched at pos. %3 mm

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Clearance control (CLC/CLCX)

5.11 Supplementary conditions

CLCX alarm number

CLC alarm number

75008

CLCX NC block %2 position offset at lower limit %3

75009

CLCX NC block %2 position offset at upper limit %3

75011

CLCX NC block %2 prog. clearance exceeds %3 mm

75013

CLCX NC block %2 freely prog. direction error code %3

75014

CLCX NC block %2 freely prog. Direction real-time error code %3

5.11

Supplementary conditions

5.11.1

I/O modules

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

the NC via an I/O module with an analog input.

Connection options

With a SINUMERIK NCU, the SIMATIC ET 200S I/O is connected via PROFINET IO. The clearance

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

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Suitable I/O modules

As the A/D conversion time directly affects the dead time of the clearance control loop, only one

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

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5.12 Data lists

Programming: Rotations around the Z axis

Since the Z axis is no longer a geometry axis in this configuration, its name can no longer be used

for rotary frames. Therefore, for rotations around the Z axis, the predefined procedure CRPL()

must be used instead of the predefined function CROT():

CROT(Z,<angle>) → CRPL(1,<angle>)

5.12

Data lists

5.12.1

Machine data

5.12.1.1

NC-specific machine data

Number

Identifier: $MN_

Description

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

5.12.1.2

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

Clearance control

62500

CLC_AXNO

Assignment of a channel axis or transformation number

62502

CLC_ANALOG_IN

Assignment of an analog input

62503

CLC_ANALOG_IN_HW_NORM_FACT

Normalization of the internal voltage representation to the input

voltage

62504

CLC_SENSOR_TOUCHED_INPUT

Assignment of an input for the external "tip-touch" signal

62505

CLC_SENSOR_LOWER_LIMIT

Lower motion limit of clearance control

62506

CLC_SENSOR_UPPER_LIMIT

Upper motion limit of clearance control

62507

CLC_A_DB_RT_VAR_START_INDEX

Start index of the used variable area $A_DBx

62508

CLC_SPECIAL_FEATURE_MASK

Special functions and operating modes of the clearance control

62509

CLC_DISTANCE_SETPOINT

Default clearance that is used after reset as long as no clearance has

been programmed.

62510

CLC_SENSOR_VOLTABE_TABLE_1

First voltage table for linearization of the sensor characteristic curve

62511

CLC_SENSOR_DIST_TABLE_1 [0... 15 ]

First clearance table for linearization of the sensor characteristic

curve

62512

CLC_SENSOR_VOLTABE_TABLE_2

Second voltage table for linearization of the sensor characteristic

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5.12 Data lists

Number

Identifier: $MC_

Description

62513

CLC_SENSOR_DIST_TABLE_2 [ 0... 15 ]

Second clearance table for linearization of the sensor characteristic

curve

62514

CLC_DISTANCE_CTRL_GAIN

GAIN factor in "GAIN mode"

62515

CLC_PLUS_DIR_GAIN_FACTOR

Increase the gain factor if the sensor is below the clearance setpoint.

62516

CLC_SENSOR_VELO_LIMIT

Limit of the velocity of the clearance control movement

62517

CLC_SENSOR_ACCEL_LIMIT

Limit of the acceleration of the clearance control movement

62518

CLC_SENSOR_JERK_TIME

Jerk filter for smoothing the non-sensor-controlled CLCX motion.

62519

CLC_SENSOR_DELAY_COMP_TIME

Compensates the delay time of the sensor signal with respect to the

encoder position.

62520

CLC_SENSOR_STOP_POS_TOL

Position tolerance for status message "Clearance control zero speed"

62521

CLC_SENSOR_STOP_DWELL_TIME

Wait time for "CLC standstill"

62525

CLC_SENSOR_FILTER_TIME

Time constant of the mean value filter for the sensor signal and

internal tip-touch monitoring

62526

CLC_TIP_TOUCH_DISTANCE

Trigger distance of the internal tip-touch monitoring

62527

CLC_MODE_SWITCH_DIST_ERROR

Activation and threshold specification for automatic switchover

from POS mode to GAIN mode and vice versa

62528

CLC_PROG_ORI_AX_MASK

Axis mask for selecting the vector components for the freely pro-

grammable 3D control direction

62529

CLC_PROG_ORI_MAX_ANGLE

Maximum difference angle between the freely programmable con-

trol direction and the tool orientation.

5.12.1.3

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

32410

AX_JERK_TIME

Time constant for axial jerk filter. Do not use for CLCX axes if possible.

32610

VELO_FFW_WEIGHT Feedforward control factor for velocity feedforward control

36000

STOP_LIM-

Exact stop coarse

IT_COARSE

36010

STOP_LIMIT_FINE

Exact stop fine

36040

STANDSTILL_DE-

Delay time zero-speed monitoring

LAY_TIME

36060

STANDSTILL_VE-

Axis/spindle velocity stopped

LO_TOL

36100

POS_LIMIT_MINUS

1st software limit switch in minus direction. Must be set for CLC axes

36110

POS_LIMIT_PLUS

1st software limit switch in plus direction. Must be set for CLC axes

36120

POS_LIMIT_MINUS2 2nd software limit switch in minus direction. Must be set for CLC axes

36130

POS_LIMIT_PLUS2

2nd software limit switch in plus direction. Must be set for CLC axes

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Speed/torque coupling, master-slave

6

6.1

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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Technologies

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Speed/torque coupling, master-slave

6.2 Coupling diagram

6.2

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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Technologies

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Speed/torque coupling, master-slave

6.3 Configuring a coupling

6.3

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 92)")

Dynamic assignment

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 ma-

chine data:

MD37252 $MA_MS_ASSIGN_MASTER_TORQUE_CTR<slave axis> = <axis>

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Speed/torque coupling, master-slave

6.3 Configuring a coupling

(See Section "Tension torque (Page 92)")

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

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

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 95)").

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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Alternating assignment of the slave axis

Technologies

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6.4 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.

6.4

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.

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Speed/torque coupling, master-slave

6.4 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

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Speed/torque coupling, master-slave

6.5 Tension torque

6.5

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 89)"), 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

A minimum tension torque must be greater than the stiction, so that the edges are applied

reliably. Otherwise an edge change will not be permitted:

• If this is the case, the acceleration (+const. forces) must be limited accordingly so that the

forces are less than the tension torque.

• If the acceleration is greater, the result is a torque difference (no longer an opposite sign).

However, this is always adhered to with a 50% division.

Reducing motor heating

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

temperature rise.

Example 1: Static coupling and establishing a tension in pairs

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

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

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6.5 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 speed setpoint

Reference axis of the torque

Input of the torque equalization

coupling

equalization 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

Leading axis, AX1

1

Leading axis, AX1

0

Master and slave

AX3

1

Leading axis, AX1

0

No reference axis

3

No input

AX4

1

Leading axis, AX1

3

2nd slave axis, AX3

0

Master and slave

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Figure 6-3

Example 1: Torque equalization control in pairs

Example 2: 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 leading axis specified when defining the coupling (MASLDEF) is, as

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

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Speed/torque coupling, master-slave

6.5 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 speed setpoint

Reference axis of the torque

Input of the torque equalization

coupling

equalization 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: "1x4 axes" activated

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 MASLDEF-defined

;

leading axis

NEWCONF

STOPRE

MASLDEF(AX2, AX1)

;

Define assignment for 1st "2x2 axes"

MASLDEF(AX4, AX3)

;

Define assignment for 2nd "2x2 axes"

MASLON(AX2, AX4)

;

Switch on couplings

MASL_ACTIVE=2 MASL_REQUEST=0

;

Feedback: "2x2 axes" switched on

ENDIF

RET

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6.6 Closing/opening a coupling

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Example 2: alternating coupling with 1x4 and 2x2 axes

6.6

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.

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Speed/torque coupling, master-slave

6.7 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 97)").

6.7

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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Activation procedure

When switching on the coupling using the program command MASLON, the system waits until

the coupling is closed before the block is changed. The "Master-slave switchover active" message

will be displayed on the user interface during this time.

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Speed/torque coupling, master-slave

6.7 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.

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.

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6.8 Supplementary conditions

Coupling characteristics

The behavior regarding the program commands MASLON, MASLOF, MASLOFS, MASLDEL 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 standstill.

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 automati-

cally.

6.8

Supplementary conditions

6.8.1

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.

• When the coupling is switched-in (closed) via the slave axis, the master axis is braked

automatically, if the channel axis is in the same channel: ⇒ asymmetrical behavior when

opening and closing the coupling:

- Activate: the leading axis is automatically braked

- Deactivating: no automatic braking of the leading axis

• The setpoint position of a coupled slave axis corresponds to its actual position.

• For axes and spindles in the positioning mode, the coupling is only switched-in (closed) and

switched-out (opened) at standstill (zero speed).

• The leading-following coupling must be deactivated prior to a gear change or a star-delta

switchover.

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Speed/torque coupling, master-slave

6.8 Supplementary conditions

Axis container

If a coupled slave axis is configured as a container axis, alarm "4025 Switch axis container %3 not

permitted: Master-slave active channel %1 Axis %2" is displayed for an axis container rotation.

Axis containers with changing master can be used to make the relevant spindle the master

spindle following a rotation of the axis container. Both master and slave spindles can be

container spindles.

For a coupling to be closed after axis container rotation using a different spindle in each case, the

old coupling must be separated before the rotation, the configuration deleted and the new

coupling configured and closed after the rotation.

Example of a cyclic coupling sequence (position = 3 / container = CT1)

Program code

Comment

MASLDEF(AUX,SPI(3))

; S3 master for AUX

MASLON(AUX)

; Coupling in for AUX

M3=3 S3=4000

; Machining ...

MASLDEL(AUX)

; Delete configuration and release coupling

AXCTSWE(CT1)

; Axis container rotation

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

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

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6.9 Examples

6.9.2

Close coupling via the PLC

This application allows you to close or separate a master-slave coupling between the machine

axes AX1=Master axis and AX2=Slave axis during operation.

Preconditions

• One configured master axis

MD37250 $MA_MS_ASSIGN_MASTER_SPEED_CMD ≠ 0

• Activation of a master-slave coupling via

MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE=0

• The coupling is open.

Typical sequence of operations

Action

Effect/comment

• Approach coupling position

Each axis moves to the coupling position.

• Close coupling mechanically

Both axes are mechanically coupled to one another.

• Request to close the coupling

PLC interface signal "Master/slave on" DB32, ...

DBX24.7 is set.

• Read back coupling state

When the axis is at a standstill, the coupled slave

axis sets PLC interface signal "Master/slave active"

DB32, ... DBX96.7 and clears "Position controller

active" DB32, ... DBX61.5.

Wait for checkback signal.

• Moving the master-slave group

The master axis is moved.

6.9.3

Close/separate coupling via part program

This application allows you to close or separate a master-slave coupling between the machine

axes AX1=Master axis and AX2=Slave via the part program.

Preconditions

• A configured master axis MD37250 0 0.

• Not a static master-slave coupling:

MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE= 0

• The coupling is open.

Parts program

Program code

Comment

N10 G0 AX1=0 AX2=0

; Approach the coupling position on an axis-for-axis basis

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6.9 Examples

Program code

Comment

N20 MASLON (AX2)

; (mechanically connect the axes)

; Close the coupling.

N30 AX1=100

; Move the master-slave group using the master axis.

N40 MASLOF (AX2)

; Open the coupling.

; (Mechanically separate the axes)

N50 AX1=200 AX2=200

; Move the axes separately.

N60 M30

6.9.4

Release the mechanical brake

This application allows implementation of a brake control for machine axes AX1=Master axis and

AX2=Slave axis in a master-slave coupling.

Preconditions

• Master-slave coupling is configured.

• Axes are stationary.

• No servo enable signals.

Typical sequence of operations

Action

Effect/comment

• Request to close the coupling

The following PLC interface signal is set:

DB31, ... DBX24.7 (Master/Slave ON)

• Set controller enable

PLC interface signal "Servo enable" DB31, ...

DBX2.1 is set for both axes.

• Interpreting the feedback

Link PLC interface signals of the master axis using

AND:

DB31, ... DBX61.7 (current controller active)

DB31, ... DBX61.6 (speed controller active)

DB31, ... DBX61.5 (position controller active)

Link PLC interface signals of the saster axis using

AND:

DB31, ... DBX61.7 (current controller active)

DB31, ... DBX61.6 (speed controller active)

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

• Release brakes

If the result of the AND operations on the master

and slave axes is ≠ 0, the brake may be released.

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Speed/torque coupling, master-slave

6.10 Data lists

6.10

Data lists

6.10.1

Machine data

6.10.1.1

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

37250

MS_ASSIGN_MASTER_SPEED_CMD

Leading axis for speed setpoint coupling

37252

MS_ASSIGN_MASTER_TORQUE_CTR

Leading axis for torque distribution

37254

MS_TORQUE_CTRL_MODE

Connection of torque control output

37255

MS_TORQUE_CTRL_ACTIVATION

Activate torque compensatory control

37256

MS_TORQUE_CTRL_P_GAIN

Gain factor of torque compensatory controller

37258

MS_TORQUE_CTRL_I_TIME

Reset time for torque compensatory controller

37260

MS_MAX_CTRL_VELO

Limitation of torque compensatory control

37262

MS_COUPLING_ALWAYS_ACTIVE

Permanent master-slave coupling

37263

MS_SPIND_COUPLING_MODE

Coupling characteristics of a spindle

37264

MS_TENSION_TORQUE

Master-slave tension torque

37268

MS_TORQUE_WEIGHT_SLAVE

Torque weighting of the slave axis

37270

MS_VELO_TOL_COARSE

Master-slave velocity tolerance "coarse"

37272

MS_VELO_TOL_FINE

Master-slave velocity tolerance "fine"

37274

MS_MOTION_DIR_REVERSE

Invert master-slave direction of travel

6.10.2

System variables

After a block search, the coupling status and associated axis positions can be adjusted

subsequently by means of a system ASUB (asynchronous subroutine) "PROGEVENT.SPF". System

variables $P_SEARCH_MASL_C, $P_SEARCH_MASL_D and $AA_MASL_STAT are available for this

purpose; they can be used to alter the positional offset between the coupled axes and the

coupling status:

Identifier

Meaning

$P_SEARCH_MASLC[following axis name]

This variable registers a change in the coupling state during the

SERUPRO block search.

$P_SEARCH_MASLD[following axis name]

This variable indicates the positional offset between the slave and

master axes at the instant the coupling was closed.

$AA_MASL_STAT[following axis name]

This variable indicates the current coupling state.

Value ≠ 0: "Master-slave coupling active"

In this case, it contains the current machine number of the master

axis and, if the NCU link is active (several operating panel fronts and

NCUs), also the NCU No. at the hundreds position.

Example: 201 for Axis 1 on NCU2.

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