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

Description of functions

8.6 Several tools at a magazine location (multitool)

FC6: TM_TRANS2 - transfer block for tool management and multitool (Page 153)

FC8: TM_TRANS - transfer block for tool management (Page 157)

8.6.4

Tool change and tool number for multitools

Tx - Tx programmed: Configuration of the tool selection

$MC_TOOL_MANAGEMENT_MASK, bit 11 makes it possible to adjust the behavior when

repeatedly programming Tx - Tx. The setting is valid for the tool to be selected and also for the

MT itself.

Example:

Tool selection with T, tool change with M code. The following is programmed:

T="TOOL5"

The second tool preparation command is a "superfluous" command, which as default setting

does not result in a command being output to the PLC. If "Tool5" is a tool belonging to a multitool,

then with the command, generally

• a) a transport task of the MT "from magazine to tool holder" is generated

• b) a positioning command of the MT location with the programmed tool.

If "Tool5" is in an MT, then two basic situations can exist for the MT:

1. The MT is already located on the tool holder.

1.1 The programmed tool has already been positioned.

–

1.2 The programmed tool is a different tool than the tool that was positioned.

2. The MT is not yet located on the tool holder.

For case 1.1, the data is

• a) "MT from tool holder to tool holder"

• b) "Position at the location of the tool "Tool5" that has already been positioned

For case 1.2, the data is

• a) "MT from tool holder to tool holder"

• b) "Position to the location of the tool that has still not been positioned "Tool5""

For case 2, the data is

• a) "MT from magazine to tool holder"

• b) "Position to the location of the tool "Tool5""

The general criterion as to whether the second program command is a "superfluous" command

is whether the generated command data for the PLC is identical to that of the first command. The

second command is then not output to the PLC.

This command output can be forced using the bit value 1 of bit 11 from

$MC_TOOL_MANAGEMENT_MASK.

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Description of functions

8.6 Several tools at a magazine location (multitool)

Tool change command canceled before the final acknowledgement

If, within the scope of a tool change, the MT has already been mechanically loaded, but the MT

has not been positioned, and the operation is interrupted in this state (fault, RESET, EMERGENCY

STOP, power off, power failure...), then before continuing, the PLC must ensure that the

previously pending MT positioning is carried out. The PLC must then make sure that the NC is

informed about the MT change (e.g. using an asynchronous transfer with acknowledgement

status 4 or 5. In so doing, the NC synchronizes the MT position with the command data from the

PLC). With an asynchronous transfer, the PLC can also communicate the MT position to the NC.

Note

Init blocks for START and/or RESET

Especially if init blocks for START and/or RESET are generated via MD settings, with the property

"activate the tool on the tool holder", and the tool on the tool holder is an MT, then the PLC must

ensure that the MT is correctly positioned on the tool holder before the NC makes the correction

selection (i.e. before the RESET command is sent to the NC, the MT must have been positioned).

T0 - tool deselection and return transport of the multitool into the magazine

T0 deselects the tool and loads the associated MT back into the magazine.

A T0 is output at the PLC user interface. The "tool carrier" must be removed from the tool holder.

It does not make any difference as to whether it involves an individual tool or a multitool.

DB72.DBB(n+1), bit 7 is not set, as there is no relevant data.

M06 ; generates the PLC command = 3.

If a tool from this multitool that has just been exchanged is again selected/loaded, then the

multitool is again loaded onto the tool holder.

It is not possible to program a T0 with the meaning to deselect the active tool, and at the same

time to keep the MT on the tool holder. T0 M06 D0 means, that after successful execution

- the correction is deselected

- there is no active tool

- there is no tool or MT on the tool holder.

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Description of functions

8.6 Several tools at a magazine location (multitool)

PLC acknowledgement status 2 and 7 in the FC6

The PLC acknowledgement status numbers 2 and 7 (FC6 (Page 153) and FC8 (Page 157)) refer

to the respective tool within the multitool. This means that the tool is rejected, not the multitool.

If the newly selected tool is in another multitool, then the transport task data for the multitool

as well as for the newly selected tool contained in it, are newly determined and output to the PLC.

The following apply:

• Status=2:

The tool cannot be made available. The NC locks this tool and tries to repeat the tool

preparation with another tool. This status is permissible only in conjunction with a

preparation command.

• Status=7:

Analogous to status 2 - with the property that no tool is disabled (i.e. the same tool can be

selected again).

Tool change with "T=magazine location number" programming ("T=location")

With a multitool, there are three variants of T=location programming:

1. Specification of multitool location and magazine location, e.g. N100 MTL=2 T4

2. With MD20274 $MC_MULTITOOLLOC_DEFAULT

The magazine location is programmed, e.g. T4

The tool at the multitool location specified in the machine data is selected.

3. Via the current multitool position

The magazine location is programmed, e.g. T6

The tool at the multitool location specified in the multitool parameter $TC_MTP_POS is

selected.

In these three options, variant 1 has the highest priority and variant 3 the lowest.

The following examples illustrate this.

Example 1:

$MC_TOOL_CHANGE_MODE=0 applies (tool change only with the T command, i.e. the T

programming results in the output of command number 4 to the PLC).

Multitool with distance coding, location number, $TC_MTP_KD[500]=1, is in turret 1, location 4

and has the MT no. = 500; $TC_MPP6[1, 4] = 500. The MT position is

$TC_MTP_POS[500]=2.

The tool at magazine location 1/1 is loaded onto tool holder 9998/1. The MT on magazine

location 4 has 3 locations.

The following tools are loaded in the multitool:

"tool_1": $TC_MTPP6[500, 1] =11 MT distance $TC_MTPPA[500, 1] = 1

"tool_2": $TC_MTPP6[500, 1] =22 MT distance $TC_MTPPA[500, 2] = 2

- $TC_MTPP6[500, 1] =0 MT distance $TC_MTPPA[500, 3] = 3

There is no tool at location 3 of the multitool. $MC_MULTITOOLLOC_DEFAULT=0 applies.

Tool selection and tool change are programmed with T. The "T=magazine location number"

function is used.

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Description of functions

8.6 Several tools at a magazine location (multitool)

The following command is then programmed:

;MT-Position $TC_MTP_POS[500]=2

;MT position $TC_MTP_POS[500] = 2

;at magazine location 4, in the multitool loaded there, select the tool,

;which is loaded at MT location 2 of the multitool and load the MT - if it is not disabled

- and

;activate the tool.

;If the tool at MT location 2 of the multitool is disabled, then a search is made for

;another matching tool with the name "tool_2", which under certain circumstances -

;depending on the tool -;search strategy, tool equipping -is at some location ;of

another multitool ;or which is contained as individual tool on another

;turret location.

The resulting command to the PLC is as follows:

T4 programming with the result "Multitool 500 is at the programmed magazine location and at

the MT location selected (via the MT position), there is tool "tool_2" with the T no.=22" - supplies

the following (essential) data to the PLC.

No tool on MT location

For "T=magazine location" and "No tool on the magazine location", it is defined that a regular tool

change command to the PLC is output with the special property "T number of the new tool = 0".

Similarly for "T=magazine location" and

"An MT is on the magazine location" and

"No tool is on the selected MT location"

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Description of functions

8.6 Several tools at a magazine location (multitool)

it is defined that a regular tool change command to the PLC is output with the special property:

• a) MT is in the magazine

T number of the tool that is to be moved on the tool holder is the MT number of the MT that

is on the magazine location and the T number of the new tool in the MT = 0.

With the information of the PLC command, the PLC can decide what is to be done in this

situation: Either position the MT on the empty MT location or issue an alarm "There is no tool

on the MT location".

- Example 2:

If $MC_MULTITOOLLOC_DEFAULT =3 applies, then the result in example 1 - the

multitool position is 2 ($TC_MTP_POS[500]=2), there is no tool on MT location 3 - is

that T0 is programmed with the programming T4 based on the effect (no new tool is

available, but the request to dispose of the old tool is issued nevertheless.

• b) MT is on the tool holder

T number of the tool that is to be moved on the tool holder is the MT number of the MT that

is already on the tool holder. The transport request "From → to" for the MT is "From tool holder

→ tool holder" and the

T number of the new tool in the MT = 0.

With the information of the PLC command, the PLC can decide what is to be done in this

situation: Either position the MT on the empty MT location or issue an alarm "There is no tool

on the MT location".

- Example 3:

The preconditions are the same as in example 2 with the condition that the MT from

location 4 is already on the tool holder. Programming T4 has the same effect as if T0 were

programmed (a new tool is not available, but the request for the offset deselection is still

issued; the old tool transport data is 0/0 → 0/0), the MT remains on the tool holder.

Tool change with "T=magazine location number MTL=MT location" programming

As an alternative to the programming described in the section above, the MT location can be

programmed with MTL=p in the multitool (p=location number).

The following applies for the programming:

• MTL is non-modal.

• MTL must be programmed in the NC block before the T command.

• The programmed value for MTL must correspond to an existing location number in the

multitool to be selected. Otherwise, an alarm is output.

MD $MC_MULTITOOLLOC_DEFAULT can be used to define the MT location number which is used

when MTL is not programmed. The MTL programming replaces the default defined with

$MC_MULTITOOLLOC_DEFAULT.

Example 4:

If $MC_MULTITOOLLOC_DEFAULT =3 applies, this results in example 2 of the section above -

the multitool position is 2 ($TC_MTP_POS[500]=2), there is no tool on MT location 3 - that, with

the following programming, the value of $MC_MULTITOOLLOC_DEFAULT=3 and the current MT

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Description of functions

8.6 Several tools at a magazine location (multitool)

position 2 are ignored, because MTL is explicitly programmed. This selects "tool_1" with the tool

number 11.

MTL=1 T4

;affects precisely T4 in this block,

;which is programmed subsequently in the block.

Example 5:

If $MC_MULTITOOLLOC_DEFAULT =3 applies, this results in example 2 of the section above -

the multitool position is 2 ($TC_MTP_POS[500]=2), there is no tool on MT location 3 - that, with

the following programming, the programmed value MTL=1 remains without effect and the

value of $MC_MULTITOOLLOC_DEFAULT=3 is used. There is no tool at MT location 3 and

MTL=1

;does not affect following block T4 because this is non-modal

;the setting of the MD takes effect

Example 6:

If $MC_MULTITOOLLOC_DEFAULT =0 applies, this results in example 2 of the section above -

the multitool position is 2 ($TC_MTP_POS[500]=2), there is no tool on MT location 3 - that, with

the following programming, the programmed value MTL=1 remains without effect and the

value of $MC_MULTITOOLLOC_DEFAULT=0 is used; i.e. the value of the MT position = 2. The tool

with tool number=22 is on the MT location 2.

MTL=1

;does not affect following block T4 because this is non-modal

;the setting of the MD takes effect - that is now MT position=2

$C_MTL - transfer of the MTL_value to the replacement cycle

The programmed value for MTL can be read in an existing replacement cycle for T with $C_MTL.

$C_MTL_PROG - MTL is programmed

If MTL has been programmed in the NC block, then this can be determined in an existing

replacement cycle for T with $C_MTL_PROG. $C_MTL_PROG==1 means that MTL has been

programmed. The programmed value can be queried with $C_MTL.

Example:

The multitool function and the function T=location have been configured.

N10 MTL=3 T=8

Then the replacement cycle contains T code of the type for the command:

N140 IF $C_T_PROG == 1

N142

IF $C_MTL_PROG == 1

N144

MTL=$C_MTL T[$C_TE]=$C_T

N146

ELSE

N148

T[$C_TE]=$C_T

N150

ENDIF

N152 ENDIF

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Description of functions

8.6 Several tools at a magazine location (multitool)

Load/move multitool on tool holder and init block

If a multitool is loaded onto a tool holder other than through a tool change (loading operation,

movement command) and for the init block handling (if it is appropriately configured), the active

tool must be subsequently determined, then the following applies:

• If necessary: After loading/moving, set the MT position so that the requested tool can be

activated - or so that the MT position matches the mechanical MT position

• Always issue a tool change command to the PLC which contains the MT position of the tool

to be activated.

• Take the MT which is located on the master tool holder.

• Take the tool which is at the MT location with MT location number = "MT position" (=

$TC_MTP_POS), and select it.

• Activate the D offset of this tool with the lowest D number.

Irrespective of the value of bit 12 (bit value==1 corresponds to ’H1000’) of the MD

$MC_TOOL_MANAGEMENT_MASK, a command is output to the PLC if the activated tool is

not on the MT location which was output last for this tool holder or was contained in the

acknowledged tool change command.

Note

The MT position of the multitool on the tool holder must be synchronized to the mechanical

position of the multitool on the machine. If the MT position when loading does not already

match the MT loading position, then under certain circumstances the PLC can initiate this

synchronization with an asynchronous transfer before the RESET command to the NC (that

generates the init block).

Example

The init block generation is activated ($MC_TOOL_MANAGEMENT_MASK, bit 14 (bit value==1

corresponds to ’H4000’)).

The part program is exited. The MT remains on the tool holder. The last tool change in the part

program was performed with regard to MT position = 3. The PLC acknowledged the MT tool

change command with MT position = 3.

The init block generated with the operator panel RESET determines the MT on the tool holder,

the tool on the MT location with the number of the MT position. The compensation of the

smallest D number is activated.

Positioning is now performed on a different location with the OPI PI _N_POSMT_. A tool

command with the number = 1 (move/position) is output to the PLC and acknowledged

accordingly. The MT now has a different position than at the time of the previous end of the

program. With the operator panel reset, the tool on this MT location is determined and the

compensation activated accordingly. There is no tool change command output to the PLC.

Only the data of the MT position is now changed (e.g. by a write command with $TC_MTP_POS).

Machine and NC data are now asynchronous. With the operator panel reset, the tool on this MT

location is determined and the compensation activated accordingly. A tool change command is

output to the PLC irrespective of the setting of bit 12 of $MC_TOOL_MANAGEMENT_MASK. After

correct positioning, the machine and the NC data are synchronous again.

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Description of functions

8.6 Several tools at a magazine location (multitool)

Not possible to move the tool from or to the MT location

A tool cannot be transported to or from a multitool location. The PI service as well as the NC

command or asynchronous transfer are rejected with an error.

The multitool is considered to be an entity in its own right that is manually equipped, and which

is loaded, unloaded or transported as a whole. Movement of tools in the multitool have not been

realized.

Tool change - tool search

The tool search strategies are described in Section "Search for tool (Page 480)". They are

essentially also applied to the multitool.

NC identifier

Description

Format

Preassignment

$TC_MAMP"

Type of search strategy

INT

$TC_MAP10

Bit 0 - 7 tool search strategy

Regarding tools in the multitool, the individual tool search strategies behave as follows:

Bit 0 = 1: Select the "active" tool.

If there is more than one suitable tool in the multitool with the "active" state, then the first

checked tool of these tools is selected.

Bit 1 = 1: Select the tool that can be reached over the shortest distance.

Within the multitool there is no "shortest distance" search. With shortest distance, the "shortest

distance within the magazine" is always meant. It does not make any difference whether a tool

or a multitool is at the particular magazine location.

Bit 2 = 1: Select the "active" tool. If there is no active tool available, then select the replacement

tool with the lowest number contained in $TC_TP10.

If there is more than one suitable tool in the multitool with the "active" state, then the first

checked tool of these tools is selected.

Bit 3 = 1: Lowest actual value (residual value) of the monitoring functions.

If there is more than one suitable tool with "lowest actual value" in the multitool, then the first

checked tool of these tools is selected.

Bit 4 = 1: Highest actual value (residual value ) of the monitoring functions.

If there is more than one suitable tool with "highest actual value" in the multitool, then the first

checked tool of these tools is selected.

Note

Further, the tool search is tool-oriented, i.e. the tool of a tool group is checked as to whether it

can be used corresponding to the actual configuration and search strategy.

The MT with suitable tool is already on the tool holder.

If an MT with a tool suitable for the programmed tool change command is already on the

programmed tool holder, then - irrespective of the defined tool search strategy - this tool is

selected or loaded.

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Description of functions

8.6 Several tools at a magazine location (multitool)

Example:

The MT with number = 22 is on the tool holder / spindle with number = 1. The tool with T no. =

7 is active and is disabled. This tool is loaded to MT location = 1. A tool with the same name

"Tool_1" and the T no. = 8 is on MT location = 2. The tool change command with the tool name

of the tool that is disabled now selects the tool with T no. = 8:

Extract from NC program:

N600 T="Tool_1" M06 ; T no. = 7 is loaded

... ; tool is disabled (e.g. because of tool monitoring)

N700 T="Tool_1" M06 ; T no. = 8 is loaded

The MT itself remains at its location (from->to addresses are 9998/1 -> 9998/1. Only a new MT

position must be assumed (MTPos value 1 -> 2)

Wear group and multitool

All tools within a multitool belong to the wear group of the multitool itself. The locations within

a multitool have the "wear group" property.

Manual tool and multitool

The "manual tool" function is also available for multitools. As far as this function is concerned,

the MT itself is the manual tool and not the programmed tool. If a tool is programmed which is

in an MT, but this MT is not loaded, then the MT is treated just like a manual tool.

Example:

The name of the multitool is "MT1", the name of the tool - programmed for tool holder 1 - is

"Tool4" with duplo number 5.

The following is programmed

T="Tool4" M06 D1.

This is then followed by the request to load with alarm 17212 "Load manual tool "Tool4", duplo

no. 5 to spindle / tool holder 1".

T0 M06 D0

then correspondingly generates alarm 17214 "Unload manual tool "Tool4" from spindle /tool

holder 1"

and correspondingly requests that the manual tool (that is an MT or is located in an MT) is again

removed from the tool holder.

Suppressing alarms 17212, 17214, 17215, 17216

The manual tool change request alarms can be suppressed using bit 16 in MD

$MN_SUPPRESS_ALARM_MASK_2. Then, using the tool change command data, the PLC must

correctly load and remove the manual tool.

Empty location search strategy - "replace old tool by new tool" and multitool

Just like tools, for an empty location search, multitools can use the search strategy - "replace old

tool by new tool" (1:1 exchange). The MT has the necessary defined data required for this

purpose - such as location type, tool size.

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Description of functions

8.7 Using manual tools

8.7

Using manual tools

8.7.1

Manual tools (adding tools during machining)

Manual tools are tools whose data is completely available in the NC, but are not loaded into the

magazine. The function is set with MD22562 $MC_TOOL_CHANGE_ERROR_MODE, bit 1=1. The

automatically selected tool must be inserted in the machine manually and removed again

manually after machining.

Responsibility of the operator

The user must ensure that

• the data record of the tool positioned on the spindle is actually in the NC and

• that he places the tool that corresponds to the data record in the NC on the spindle.

Tools which are loaded manually during machining are referred to as "manual tools".

Note

The responsibility is on the users themselves to comply with the safety regulations via the PLC

program.

Unique identification of manual tools

Manual tools are characterized by the fact that they are not loaded in a magazine and the status

is set via $TC_TP8 Bit 15 =1.

This is then used to derive as to whether (within the scope of a change) it is loaded or removed

from the virtual magazine location 9999/1.

This also means that a tool which, for example, was loaded onto the spindle as a result of an

operator action at the HMI, is a manual tool. As a consequence, it cannot be placed in the

magazine using T0/M06.

The fact that a tool loses its owner location when being transported can be a legal state. This

means that it is no longer possible to reliably identify a manual tool.

If this state is set, a search is not made for an empty location in a magazine for the tool - and this

(old) tool is directly transported to the virtual magazine location 9999/1 when the tool is

changed. By moving this tool between the locations of the buffer magazine, independent of the

motion command that initiated this, the "manual tool" state no longer changes. (Exception: see

Section, resetting the "manual tool" state)

Note

As a consequence, a tool that was loaded onto the spindle, e.g. via SINUMERIK Operate, is now

not a manual tool. As a consequence, it is placed in the magazine using T0/M06.

Setting the "manual tool" state

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8.7 Using manual tools

The "manual tool" state of a tool is set if the following condition are fulfilled:

• machine data $MC_TOOL_CHANGE_ERROR_MODE, bit1 is set

• as part of a tool change, an unloaded tool was selected. As a result, $TC_TP8 Bit 15 = 1 is

automatically set.

• Alternatively, the status can be explicitly set with $TC_TP8 Bit 15 = 1.

Resetting the "manual tool" state

The "manual tool" state of a tool is reset if the following occurs:

• The tool is unloaded, i.e. the tool no longer has a current magazine location.

This can especially occur as a result of:

- Unloading the old tool as part of the tool change

- Transporting a manual tool to a loading position (unloading as a result of an HMI operator

action)

- Writing $TC_MPP6[m,p]=0 to the location of the buffer magazine where the manual tool

is currently located. (m=magazine no., p=location no.)

• The command to select or load a manual tool was interrupted and the tool was still not moved

to a magazine location.

• An owner location is assigned to the tool. For example, this can be realized with the extended

NC language command "GETFREELOC" with a reservation of the location (withReserv).

• The tool was brought to a location in a real magazine or the loading magazine.

• The identification as a manual tool is reset via $TC_TP8 Bit 15 = 0.

Boundary conditions for writing the status "Manual tool"

It is not possible to set the "manual tool" tool state, if

• machine data $MC_TOOL_CHANGE_ERROR_MODE, bit1 is not set. Otherwise, Alarm 17242

( "Channel %1, block %2, manual tool cannot be set as the function is not active") is issued.

• It is not possible to set the "manual tool" tool state, if the tool is located

- in a real magazine location,

- in a loading magazine,

- in a buffer magazine location and has an owner location.

If this is set, it is rejected with Alarm 17218 ("Channel %1, block %2, tool %3 cannot become

a manual tool").

If a tool, which is located in a magazine location, is to become a manual tool, then it must be

transported into the buffer or loading magazine (using asynchronous transfer, PI service or

MVTOOL language command). Then, using the NC language command "DELMLOWNER", the

reservation and the owner location can be deleted. Only then can the "manual tool" state be

set.

If the tool state "manual tool" is explicitly reset, then initially an empty location search is not

made for the tool and no reservation is made. It is also not allocated an owner location. Only in

subsequent operations can an empty location search be made - and real magazine locations

reserved.

The state "manual tool" can also be set and reset via the OPI interface (block T/TD, column 8).

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Description of functions

8.7 Using manual tools

Properties of the "manual tool" state

For a manual tool, when the tool is being changed, a search is not made for an empty location,

an owner location is not allocated and a reservation is not made. Also for other tool transport

types and search operations, for a manual tool, an empty location is not searched for - exception,

explicit reservation using the NC language command "GETFREELOC".

The command data set, which the NC sends to the PLC when a tool is being changed, always

contains as target address for a manual tool as old tool, the virtual magazine location 9999/1.

For manual tools, the empty location search strategy "1:1 replacement" is not effective, as the

"manual tool" property has priority, i.e.

• if the new tool is a manual tool and the old tool comes from a location in a real magazine, then

the transport task sent by the NC to the PLC is as follows: Old tool back into the real magazine,

new tool from virtual magazine location 9999/1.

• And vice versa: If the old tool is a manual tool and the new tool comes from a location in a real

magazine, then the transport task sent by the NC to the PLC is as follows: Old tool to virtual

magazine location 9999/1, new tool from the location of the real magazine.

The "manual tool" state is effective via a POWER ON.

When unloading a tool to the virtual magazine address 9999/1, the settings of MD

$MN_TOOL_UNLOAD_MASK are not effective, i.e. the corresponding tool states are kept.

Note

Using the NC language command "GETFREELOC" or for the PI service "_N_TMFDPL" or

"_N_TMFPBP", a check is not made as to whether a manual tool is involved. If the NC command

"GETFREELOC" is parameterized in such a way that a buffer location is also reserved, the tool

loses its "manual tool" status.

Note

At POWER ON, the "manual tool" state for tools is reset, which

• are at a real magazine location or the loading magazine, or

• are at a buffer magazine location and have an owner location, or

• are not at any magazine location.

Note

If, when writing to $TC_MPP6[m,p] a manual tool is set at a magazine location, the "manual tool"

state is deleted, if

• "m" addresses a real magazine or the loading magazine, or

• "m" addresses the buffer magazine and the tool has an owner location.

Note

If a manual tool should come to the unloading point magazine location 9999/1 for unloading

using an asynchronous transfer, the NC language command "MVTOOL" or the PI service

"_N_TMMVTL", then this location must be defined and also free. On the other hand, for

unloading operations for a manual tool, magazine location 9999/1 does not have to be defined

and does not have to be free.

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8.7 Using manual tools

Behavior, NC language commands "TCA", "TCI" and return transport for manual tools

If the language command TCA programs a specific tool, which is not located at a magazine

location (also not at an internal magazine location), then this tool is selected and changed in as

manual tool.

If the language command TCI is applied to a buffer location where there is a manual tool, then

the target location for the movement is the virtual magazine location 9999/1 (this means that

the TCI instruction does not bring the manual tool into a real magazine corresponding to the

definition of TCI for other tools). Alarm 17215 "Channel %1 tool management: Remove manual

tool %3 from buffer %2" is issued. This alarm is acknowledged by the tool change

acknowledgement from the PLC.

Users must themselves ensure that the safety regulations are maintained through their PLC

programs, such as when loading a manual tool.

The tool state "BACKTRANSFER" for a manual tool is evaluated in the form so that the virtual

magazine location 9999/1 is specified in the PLC command for the manual tool.

Alarm 17215 "Channel %1 tool management: Unload manual tool %3 from buffer location %3."

is issued. This alarm is acknowledged by the tool change acknowledgement from the PLC.

Users must themselves ensure that the safety regulations are maintained through their PLC

programs, such as when loading a manual tool.

Suppressing alarms 17212, 17214, 17215, 17216

The manual tool change request alarms can be suppressed using bit 12 in MD

$MN_SUPPRESS_ALARM_MASK_2. Then, using the tool change command data, the PLC must

correctly load and remove the manual tool.

Example 1

(milling machine, $MC_TOOL_CHANGE_MODE=1, 1 x spindle, 1 x chain-type magazine, double

gripper)

T=MILLER_120"

Task to PLC:

new tool from 9999/1 to 9998/1

old tool from 9998/1 to 1/10

"Manual tool" identifier is set

M06

Information alarm 17212 "...manual tool "MILLER_120"

Duplo number 00001 load onto spindle / tool holder 1"

The information alarm is acknowledged with the final acknowledgment from M06

Task to PLC:

new tool from 0/0 to 0/0

old tool from 9998/1 to 9999/1

M06

Information alarm 17212 "...manual tool "MILLER_120"

Duplo number 00001 take from spindle / tool holder 1"

With the final acknowledgment from M06

a. The information alarm is acknowledged

b. The identifier "manual tool" is deleted

Example 2

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8.7 Using manual tools

(milling machine, $MC_TOOL_CHANGE_MODE=1, 1 x spindle, 1 x chain-type magazine, double

gripper)

The "FACE MILLER_120" tool is loaded directly onto the spindle (e.g. using an HMI operator

command) and is then loaded into the magazine using T0/M06.

Task to PLC:

new tool from 9999/1 to 9998/1

Identifier "manual tool" is not set, no information alarm

Task to PLC:

new tool from 0/0 to 0/0

old tool from 9998/1 to 1/x

As this does not involve a manual tool, the NC performs an empty location search and

places the tool in the magazine.

M06

No information alarm, as it does not involve a manual tool.

Supplementary conditions

In conjunction with tool selection, tool change and offset selection, only problems associated

with the offset block technique can be rectified that have arisen because of programming errors

or incorrectly defined data in the NC.

8.7.2

Tool change with manual tools

Tool change sequence

If a tool change is initiated, the NC searches for the selected tool and detects that no suitable tool

is available in the magazine. After a suitable tool is not found in the magazine, then a search is

made in the other tools that are not loaded. The tool with the status "active" is selected from

these. If an active tool does not exist, a replacement tool - corresponding to the selected search

strategy - is selected.

If a suitable tool is found, then the manual tool can be loaded.

The following cases are possible during a tool change, for example:

• The manual tool is manually removed from the spindle and the new tool is manually

reinserted.

• The manual tool is manually removed from the spindle and the new tool is manually loaded

into the spindle via the magazine.

The manual tool change from the spindle to the spindle then proceeds as follows:

1. The "Perform change" request is issued.

2. The old manual tool is removed from spindle 1.

3. The new manual tool is inserted into spindle 1

4. The "Perform change" request is acknowledged.

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8.7 Using manual tools

Note

If the manual tool is loaded, alarm 17212: "Channel %1, Manual tool %3, Duplo No. %2, load to

tool holder %4" is output. The alarm is confirmed by the tool-change acknowledgement from the

PLC.

The information alarms can be hidden ($MN_SUPPRESS_ALARM_MASK_2).

Note

It is not permissible that the PLC rejects a manual tool preselected from the NC (tool rejection,

also refer to MD20310 $TC_TOOL_MANAGEMENT_MASK).

The tool state "CHANGEACTIVE" is taken into account corresponding to the setting in

"$MC_TOOL_MANAGEMENT_MASK".

A manual tool is always inserted via the spindle change position in DB72, also for the setting

$MC_TOOL_CHANGE_MODE = 0.

Magazine location 9999/1 for manual tools

For manual tools, magazine location 1 in Magazine 9999 has a special significance.

Typically, as a result of the magazine configuration that is created on the HMI, the magazine with

number 9999 is defined as loading magazine and has at least one magazine location, which has

the number 1. As a consequence, in most cases magazine 9999 has a magazine location 1 with

the property "loading point".

For the preparation and change command from the NC or its acknowledgment, normally only

locations associated with real magazines and tool holders are involved. However, if magazine

location 1 of magazine 9999 is specified as source location of the tool to be loaded or as target

location of a tool to be changed out, then it involves a "virtual magazine location address", which

under certain circumstances, has nothing to do with the actually available magazine location 1

in magazine 9999. This can then be identified in so much that

• a tool can be loaded into the actual magazine location without an error message being

output and

• a tool at magazine location 9999/1 - assuming that magazine 9999 is defined as a loading

magazine - is not found when selecting a tool.

Block search, program test

In a block search, there is no difference to a normal tool change. However, the corresponding

alarms are not generated.

No change commands are output to the PLC during the block search. If a manual tool needs to

be loaded when the NC is first started, then this can be achieved using magazine location 1 in

magazine 9999 and output of the corresponding alarm.

The data for the tools and magazines has to remain unchanged in the NC during the program-

test mode. A manual tool that has been loaded during program-test selection is therefore

removed in terms of its data from the tool holder and saved internally. The stored manual tool

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Description of functions

8.7 Using manual tools

is loaded back into the tool holder in response to PLC task "Return manual tool from magazine

9999, location 1".

Note

Several tool holders and manual tools can exist in the program test mode because of the

technology used for the internal storing.

Manual tools for circular magazines (change with T command)

Manual tools are loaded and removed via the spindle interface in the DB72 - with the exception

of a special case. The interface number is the number of the spindle / tool holder that was

assigned to the turret. The special case occurs if the tool in the spindle is a manual tool. A new

tool, which is located in the turret, is programmed. In this case, the command in DB73 is output

in the corresponding turret interface. In this case, the manual tool must first be removed. The

tool be loaded into the turret must be swiveled into the machining position. The command then

has to be acknowledged.

8.7.3

Role of the PLC for manual tools

Changing manual tools

The manual tools are identified in the interface to the PLC by the Magazine location no. 1 in

the magazine 9999. As a consequence, the basic PLC program interprets this as involving a

manual tool and sets the interface signals DB72.DBx(n) bit 5 and bit 6 "Replace or load manual

tool". The PLC user program must ensure that a safe state exists in order that the user can

perform the manual tool change.

The following bytes in DB72 (Page 130) are filled during a tool change:

• DBB0.0; The interface defines the loading point. Interface 1 with loading point 1 is assigned

to the spindle.

• DBW(n+24); Number of the source magazine.

• DBW(n+26); Location number in the source magazine.

• DBW(n+28); Number of the target magazine.

• DBW(n+30); Location number

These target addresses are communicated to FC8/FC6 via the following parameters:

• "NewToolMag" contains DB72.DBW(n+20)

• "NewToolLoc" contains DB72.DBW(n+26)

• "OldToolMag" contains DB72.DBW(n+28)

• "OldToolLoc" contains DB72.DBW(n+30)

• "Status (Page 161)" conveys whether the tool change has been successfully completed.

The interface is then filled as follows (n = 4 for spindle 1)

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8.7 Using manual tools

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Change manual tool DB72

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Description of functions

8.7 Using manual tools

PLC sample programs

The following sample programs (description of DB150 (Page 122)) show the acknowledgement

of loading via interface 1. To this end, the network is programmed in an FC150 user block.

Sample program "Load magazine"

NETWORK TITLE =Carry out acknowledgement of change

E 87.7;

//Signal for the acknowledgement

DB72.DBX 0.0; //Interface 1 active

DB72.DBX 4.1; //Change active

DB72.DBX 4.2;

M 156.1;

SPBN

M690;

DB150.DBB 0; //DB72

DB150.DBB 1; //Interface 1

DB72.DBW 24;

W#16#0;

SPN

M694; //T0? No->

DB150.DBW 2;

DB150.DBW 4;

SPA

M693;

M694:

DB72.DBW 20;

DB150.DBW 2; //Source magazine of new tool

DB72.DBW 22;

DB150.DBW

4; //Source location of new tool

M693:

DB72.DBW 28;

DB150.DBW 6; //Target magazine for old tool

DB72.DBW 30;

DB150.DBW 8; //Target location for old tool

DB150.DBW 10; //Status 1

DB72.DBX 5.7;

SPB

M692;

L -1;

DB150.DBW 12;

SPA

M691;

M692:

DB1072.DBW 10;

DB150.DBW 12; //Multitool location

M691:

SET ;

DB150.DBX 16.0; //Start FC6

M690:

NOP 0;

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8.7 Using manual tools

Example of a transfer with FC6

NETWORK

TITLE =Tool management status transfer

CALL

FC 6 (//Tool management transfer block

Start

:= DB150.DBX 16.0,//Start

TaskID

:= DB150.DBB 0,

TaskIDNo

:= DB150.DBB 1,

NewToolMag

:= DB150.DBW 2,//Pos new tool

NewToolLoc

:= DB150.DBW 4,

OldToolMag

:= DB150.DBW 6,//Pos old tool

OldToolLoc

:= DB150.DBW 8,

Status

:= DB150.DBW 10,//Status

MultitoolLoc

:= DB150.DBW 12,

Ready

:= DB150.DBX 16.1,

Error

:= DB150.DBW 14);

DB150.DBX

16.1; //Prompt ready

DB150.DBX

16.0; //Reset start

DB150.DBW

14; //Error information

<>I

;

//Evaluate error

DB150.DBX

16.0; //Reset start

Old tool manual tool, new tool magazine tool

The old tool can be removed from the spindle by hand and the new tool can be loaded into the

spindle from a real magazine. A tool change could go as follows:

1. "Execute change" job.

2. Remove tool from the spindle (interim acknowledgement spindle -> loading point)

3. New tool from magazine to gripper 1 (interim acknowledgement magazine -> gripper 1)

4. New tool from gripper 1 to spindle (interim acknowledgement gripper 1 -> spindle)

5. Acknowledge "Execute change" job.

In accordance with the individual steps, the DB72 and the individual interim acknowledgements

must be programmed in the user program via FC6/FC8.

See also

FC8: TM_TRANS - transfer block for tool management (Page 157)

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Description of functions

8.8 Search for tool

8.8

Search for tool

8.8.1

Strategies for tool searches

The tool search is initiated by the preparation command (T selection). The search begins for a

tool to load in the spindle.

In the default setting, tool searches are always performed on a magazine-specific basis, i.e. with

this setting for the search strategy, the search is performed in the magazine from which the last

change was carried out.

Tool group

The tools with the same identifier (name or Ident) but different duplo numbers are combined to

form one tool group. The tool identifier is programmed in the part program with the NC address,

i.e. only the tool group is specified during preparation.

Tool search

In order to move a tool from a physical magazine to a spindle it must have the following

characteristics:

• Tool status must be "enabled"

• Tool status must not be "disabled" (exceptions: NC command TCA as well as PLC interface

signal "Tool disable inactive")

• Tool status may not be "currently being changed"

• Tool must not already be used by a spindle other than the requesting spindle.

• Tool must be present in the magazine location (except for manual tools)

• This magazine must be linked to the requesting spindle via a distance relationship

($TC_MDP2)

• This magazine must not have the status "disabled".

The explicit tool is requested at the time of the tool call. The request is made for a special spindle

(general tool holder); this is the number of the address extension of T. At this point in time, user

interface DB72 is written for the relevant spindle and must be evaluated by the PLC user program.

The tool search strategy is defined using the system variable $TC_MAMP2 for the TO area, with

the system variable $TC_MAP10[Mag_No] magazine-specific. With bit 0 to bit 1, a search is

made according to the criteria active tool and lowest duplo number. The "search criterion" for

tool wear uses bit 3 to bit 4. Bit 7 is used to set whether the tool search is made on a magazine-

for-magazine basis or across all linked magazines.

Setting bit 7=1 means that the search strategies defined using bits 0, 1, 2 start with the search

from the 1st magazine of the distance table. (The sequence in the distance table is defined using

the programming sequence of $TC_MDP2.) The standard setting is bit 7=0. The search starts in

the magazine from which the previous tool that was loaded was taken.

Setting bit 6 means that a search is first made in the magazine currently being considered. This

is only effective in conjunction with bit 7=1. The strategies, where the search always starts in the

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8.8 Search for tool

first magazine of the distance table are described in Section "Magazine blocks $TC_MAMP

(Page 199)".

Note

Bit 3 = 1 and bit 4 = 1 (search criterion "tool wear") are only significant when the monitoring

function is active (defined by $TC_TP9). Otherwise they have no effect on the suitability check.

The monitoring functions are essentially cutting edge-specific. This means that the wear values

of all cutting edges of the tool are regarded. Application of this search strategy is generally not

practical for multi-edge tools.

Note

The tool search strategies apply equally for all magazine types (chain, box-type and circular) but

not for the buffer magazine.

Search strategies for tool search ($TC_MAMP2 or $TC_MAP10)

$TC_MAMP2/$TC_M

Search strategies

Meaning

AP10

Bit0=0

Search sequence

Take the first available tool found in the tool group. The search starts in

the magazine from which the last change took place (default setting).

Bit0=1

Active tool in the magazine

Select the "active" tool in the magazine of the previously changed tool,

otherwise search for replacement tool with lowest duplo number. If no

tool is found in this magazine, the search is continued in the other

associated magazines.

Bit1

Next tool

Search for the next replacement tool at the shortest possible distance

from the current magazine position.

Bit2

Active tool

Select the "active" tool, otherwise the replacement tool with the low-

est number contained in $TC_TP10 is searched for.

Bit3

Lowest actual value

Search for tool in the group with the lowest actual value for the moni-

tored quantity.

Bit4

Highest actual value

Search for tool in the group with the highest actual value for the

monitored quantity.

Bit5

Reserved

Bit6

Search current magazine

First searches in the magazine currently being considered (this is only

effective in conjunction with bit 7=1)

Bit7=0

Starting point of the tool search

The tool search starts in the magazine from which the last changed

tool came.

Bit7=1

Starting point of the tool search

The tool search always starts in the 1st magazine in the distance table.

Note

Bit7=1 + bit0=1 or bit2=1, if an "active tool" is not found in the magazine, then - if available - the

active tool is selected from another magazine linked to the tool holder.

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Description of functions

8.8 Search for tool

Tool in disabled magazine location

Tools that are located in a disabled magazine location ($TC_MPP4, Bit 0=1) cannot, after a tool

change, be returned to the original magazine because that location is now disabled. With

machine data MD22562 $MC_TOOL_CHANGE_ERROR_MODE, you can set whether tools

located in disabled magazine locations will be included in the search:

• $MC_TOOL_CHANGE_ERROR_MODE Bit 8=0: Tools in disabled magazine locations are not

included in the search (factory setting).

• $MC_TOOL_CHANGE_ERROR_MODE Bit 8=1: Tools in disabled magazine locations are

included in the search. With $TC_TP8 Bit 17=1, you can mark tools so that they can also be

placed in a disabled magazine location or adjacent location with $TC_MPP6, see also Tool-

related data $TC_TP (Page 179).

Tool with the status "to be unloaded"

The machine data MD22562 $MC_TOOL_CHANGE_ERROR_MODE is used to set whether tools

with this status are to be taken into consideration during the tool search:

• $MC_TOOL_CHANGE_ERROR_MODE, Bit 9 = 0: A tool that has the status "to be unloaded"

($TC_TP8, Bit 10 = 1) continues to be considered during the tool search. That is the active

default setting.

• $MC_TOOL_CHANGE_ERROR_MODE, Bit 9 = 1: A tool that has the status "to be unloaded"

($TC_TP8, Bit 10 = 1) is treated like a disabled tool, i.e. it is no longer taken into consideration

during a tool search and can no longer be selected within the scope of T programming.

Example, tool search routine

A tool change at a spindle shall take place.

The search sequence for the correct tool is as follows:

1. The control checks whether the tool which is called is already located on the spindle.

2. If buffer locations are linked to the spindle (see $TC_MSLR), the control checks whether a

suitable tool is already located in one of these.

3. The tool search starts in the 1st magazine of the distance table ($TC_MDP2) according to the

selected search strategy.

(Applies only if bit 7 of $TC_MAMP2 = 1; otherwise, the search starts in the magazine from

which the last loaded tool was fetched.)

4. If no tool is found in the first magazine, the search is repeated in the next magazine of the

distance table.

5. If all the magazines that are linked to the spindle have been searched and no suitable tool

found, the search is terminated with an alarm (22069 or 22068).

6. If the function "manual tool" is active, after an unsuccessful search in the magazines - a search

is made in the TO unit for an unloaded tool, but a tool that can also be used. If none is found,

the search is terminated with an alarm.

Any suitable tool with the programmed identifier found (not disabled) in one of the stages

described above will be used.

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8.9 Empty location search

8.9

Empty location search

8.9.1

Empty location search for a tool - from spindle to magazine

With the T preparation command, a matching empty location is automatically searched for the

spindle tool. The location in which the new tool is stored is still occupied at this time and cannot

therefore be identified as an empty location, the 1:1 interchange is the exception.

Note

Generally, a search is made for an empty location in that magazine from which the current tool

in the toolholder was taken.

Fixed location coding

When searching for an empty location for fixed-location coded tools its previous location in the

magazine is usually retained.

If the search for an empty location for a fixed-location-coded tool is started with a specific

magazine number, that number is ignored. The old tool location is defined as an empty location.

If this number is however an internal magazine number (for a loading or buffer magazine), then

the number is explicitly taken into consideration and the fixed location coding is ignored. This

case arises when loading/unloading tools.

If a location search for a fixed location coded tool is initiated using a specific magazine number

and magazine location number, the fixed location coding is ignored and the specified location

checked as a suitable location for the tool. This is used in the HMI function "Relocating".

Variable location coding

Initially, the procedure for an empty location search is the same as that for a fixed location-coded

tool. If this check fails, the search for a free location is continued. The search is performed

according to the selected search strategy ($TC_MAMP2 / $TC_MAP10). If the search cannot find

an available location with the specified location type in this magazine, a new search operation

based on the location type hierarchy is started in the magazine. A location is only then

considered as a suitable type of location when it applies that "Location type of the location" is

larger than "Location type of the tool", whereby the "larger than" relationship is defined by the

location-type hierarchy. If no free location is found in this magazine, the search is continued in

the next magazine (search strategy).

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Description of functions

8.9 Empty location search

8.9.2

Search strategy for empty locations

Search strategy

The strategy can be defined with the magazine configuration according to which the search is

made in magazines of TO units for an empty location. If it involves a box-type magazine, then the

search is executed according to the default strategy (forwards search starting at the first location

number).

Possible strategies are listed in the table.

$TC_MAMP2

Search strategies

Meaning

Bit 8 = 1

Forwards search

The search takes place from location No. 1 in ascending

order.

256

Bit 9 = 1

Forwards search

The search takes place from the current location at the

change position in ascending order.

512

Bit 10 =1

Backwards search

The search takes place backwards starting from the last

location No.

1024

Bit 11 = 1

Backwards search

The search takes place from the current location at the

change position backwards.

2048

Bit 12 = 1

Symmetrical search

The search starts at the current location number at the

change position (1st location left, 1st location right,

4096

2nd location left, 2nd location right, etc.).

Bit 13 = 1

1:1 exchange

If the location type and size of the old and new tool are the

same, the magazine location of the "new" tool to be loa-

ded is transferred to the "old" tool to be unloaded - and

vice versa.

The 1:1 interchange acts in addition to other selected

search strategies. If possible, the 1:1 exchange is treated

as a priority.

Bit 14

Magazine search strategy

First search the magazine with a search run across the

location types of the hierarchy of the tool type. If no lo-

cation is found, then a search run is performed across the

magazines.

Search the location type of the tool in the magazine. If

nothing is found, search run across the magazines. If a

location is still not found, then a search run is repeated

across all magazines with the next location type from the

type hierarchy.

See also Search strategy across magazines (Page 496).

Note

The empty location search strategy is set TO-specific using $TC_MAMP2, magazine-specific using

$TC_MAP10. If the magazine-specific search is not set, when the NC boots, it copies the value

from MAMP2 to MAP10.

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8.9 Empty location search

Definition of the current magazine position

The current magazine position at the change location is stored in magazine parameter (system

variable) $TC_MAP8. The value is automatically updated by the PLC acknowledgement of a

command, if the new tool is moved. If the magazine or tool is moved without a task from the NC,

the user must correct the actual position. An NC cycle or also the PLC can write to parameter

$TC_MAP8. Either by writing the OPI variable (selected with NCVAR selector block TM; variable

magNrPaces) or with the FC 8/FC 6 (with the parameters TaskIdent=4 TaslIdentNo=channel

number, status=5, OldToolMag=9998,OldToolLoc=1). The current position is parameterized

(referred to spindle) in NewToolMag and NewToolLocspindle.

8.9.3

Search procedure for empty locations

The following apply as criteria for the empty location search:

• Location type must coincide with location type of tool. A hierarchy is taken into account.

• Check the tool size.

• Location must have the status "free".

• Location must not be "disabled".

• Magazine must not be "disabled".

The essential search criterion for the empty location search is the magazine location type. The

magazine location type must match the magazine location type entered in the tool-specific data

($TC_TP). The magazine is searched. Each location is checked. If a suitable location is found the

search is terminated.

If a matching location is not found, then a check is made whether there is a magazine location

type hierarchy for the magazine-location type that is entered in the tool. If there is none, the next

magazine is taken if there are further magazines available. If there is a defined hierarchy, then

the search routine is repeated starting at the magazine that has just been searched. If this search

is also unsuccessful, the search moves to the next magazine, assuming another one is available.

Note

With oversized tools, the location types of the adjacent location are not considered.

8.9.4

Search strategy, 1:1 exchange (old for new)

With this search option, the magazine location of the "new" tool (tool to be loaded) is made

available as the empty location for the ’old’ tool (tool to be unloaded).

It is not assumed that the "new" tool is stored in the magazine location. It only needs to have

been loaded (it may be located on a gripper, for example). If the location in question is not

suitable for the "old" tool, then another appropriate empty location is sought.

Description of function

The new search strategy for an empty location is preset in the already existing bit-coded system

variable $TC_MAMP2 with bit 13.

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Description of functions

8.9 Empty location search

If 2 tools (new and old tool) are exchanged 1:1, then the two tools are marked. For this purpose,

bit 14 = 1 is set in tool status ($TC_TP8).

Boundary conditions

With this empty-location search strategy, the NC checks a magazine location that at the point of

time of making the check is normally identified as still occupied by the "new" tool or is still

"reserved for tool from buffer location". This location is defined as an empty location for the "old"

tool if the check gives a positive result.

If the new or old tool is coded as a fixed location tool or the tool size or the location type are not

identical, then the strategy is not used.

Note

The PLC program has to execute the tool transportation operations in the correct sequence for

the tool change:

Remove "new" tool from the magazine location.

Bring the "old" tool to the magazine location.

Otherwise damage may occur to the machine or tool.

The 1:1 exchange can be set as the only search strategy for the buffer magazine (9998).

The empty location search strategy is only effective within tool changes programmed in the part

program. PI services or language commands for an empty location search cannot use this.

Example

This strategy is especially suitable for use with double grippers and tools of the same type (same

size and same location type).

The already defined system variable $TC_MAMP2 includes an additional setting option for the

new empty-location search strategy.

Bit

Value

Meaning

Tool search strategy

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8.9 Empty location search

Search strategy for empty location

The magazine location for the "new" tool to be loaded is transferred to the "old"

tool to be replaced and vice versa.

Precondition is that the tool sizes and location types of the tools match or are

compatible in terms of location hierarchy.

The location of the "new" tool is detected as empty location for the "old" tool even

if the "new" tool is still positioned at this location at the time the check is per-

formed.

The tool transport must be designed so that the "new" tool is first removed from

the magazine location before the "old" tool is taken to it.

Otherwise, depending on the sequence of the mechanical tool transport opera-

tions, the machine could be damaged.

The type of empty location search is determined via the bits 8 through 12.

It is not possible for tool change to take place if the "old" tool does not have a

magazine location assigned to it. The tool search strategy is then determined via

bits 8 to 12.

8.9.5

Tool search in wear group

Overview

If "Wear group" function is used:

In the case of existing tool-search strategies, the search refers only to the active wear group,

i.e. only those tools are considered during a search within a tool group that are at magazine

locations of the active wear group.

Tools in magazine locations with wear group number 0 are also checked for suitability.

If there are no spare tools available, then all $TC_MPP5 parameters of the current groups are

negated and all locations are individually disabled by this. $TC_MAP9 is also negated (wear

group disabled). All active tools are reset if this response has been configured via $TC_MAMP3

(bit 1 = 1).

The next wear group is called ($TC_MAP9 is assigned the number of the next wear group that

can be activated).

If no further groups are available the search is terminated with an alarm. In such a case, the

disabled tools should be replaced, if necessary. In order to enable the wear groups again, the

wear group numbers of the magazine locations must be again set to values > 0.

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8.9 Empty location search

Search strategies

There are two search strategies for finding the next available wear group that can be activated:

• Starting from the lowest magazine location number, the replacement tools are searched

through location by location according to the way they are sorted internally (time-optimized

search).

The wear group that is the subject of the search is found by searching for the first tool that is

assigned to a wear group that can be activated.

• A search is made for the wear group with the lowest enabled wear group number (the first

that can be activated).

Search in several magazines

The magazine definition for a machine defines whether the search is to be performed in one or

several magazines.

If the search is conducted in several magazines while several wear groups are being used, always

make sure that a wear group can only ever be assigned to one magazine.

The search is conducted according to the following priorities:

1. The search is performed in a magazine according to the configuration and strategy.

2. The search is performed in the active wear group.

3. The set tool-search strategy is taken into consideration.

Activation

In order to work with wear groups, the magazine locations must be assigned to wear groups via

system variable $TC_MPP5 and the function must be activated via the machine data.

In addition, the number of the wear group with which machining is to commence must be

assigned to system variable $TC_MAP9 of the magazine to be selected (value > 0).

For the configuration of the machine, it is defined by $TC_MAMP3 how the tool status shall

change when switching from one wear group to the next (defaulted is an unchanged tool

status).

Note

The PLC signal "tool selection from disabled tools" has no effect when resetting the tool state.

Example: Tool search in wear group

$TC_MAMP3 = 3 - change "active" status of tools

Target

• The tools must be set to "active" when a wear group is activated.

• When a wear group is disabled all the tools contained in that wear group should also be

deactivated.

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8.9 Empty location search

Specifications

• Circular magazine number 1 (6 locations)

• The circular magazine is to be divided into two parts:

Locations 2 and 3 form wear group 1.

Locations 4, 5, 6 and 1 form wear group 2.

• $TC_MAP9 = 1 (wear group 1 is "active")

Assignment to the wear group is achieved by:

$TC_MPP5[1,2] = 1

TC_MPP5[1,3] = 1

$TC_MPP5[1,4] = 2

$TC_MPP5[1,5] = 2

$TC_MPP5[1,6] = 2

$TC_MPP5[1,1] = 2

The tools with T=10 and T=11 are assigned to wear group 1. As wear group 1 was activated, tools

T=10, 11 were therefore also set to "active" (via $TC_MAMP3, bit 0=1).

Note

NC command SETTA (see Section "SETTA - Activate tool from wear group (Page 261)") can also

be used to set these tools to active.

Tool assignment:

$TC_MPP6[1,2] = 10

;T=10 has identifier "Tool1"/duplo no.=1 tool state "ac-

tive"

$TC_MPP6[1,3] = 11

;T=11 has identifier "Tool2"/duplo no.=1 tool state "ac-

tive"

$TC_MPP6[1,4] = 12

;T=12 has identifier "Tool1"/duplo no.=2

$TC_MPP6[1,5] = 13

;T=13 has identifier "Tool2"/duplo no.=2

$TC_MPP6[1,6] = 14

;T=14 has identifier "Tool1"/duplo no.=3

$TC_MPP6[1,1] = 15

;T=15 has identifier "Tool2"/duplo no.=3

$TC_MAMP2 = 1

The active tool is to be searched for. If none is available, the next possible tool is to be located.

This tool search strategy includes a check for the number of the active wear group. That is, only

those tools are considered during the search for a tool with the status "active" that are at

magazine locations and that have the number of the currently activated wear group.

T="Tool2"

Tool group "Tool2" consists of tools

T=11, 13, 15.

T=11 is positioned in a location of the active wear group (No. 1) and is "active". The result of the

tool search is T=11.

Machining is continued. T=11 is "disabled" during machining.

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Description of functions

8.9 Empty location search

T="Tool1"

Wear group 1 is still active. T=10 is identified as active and suitable for use.

T="Tool2"

The tool group of identifier "Tool2" now has no active tool (has been disabled) and a new tool has

not yet been set to "active". This step is not taken until "Tool2" is reprogrammed. The tools of the

group are examined. In the locations of wear group 1, which is still active, there is no tool with

identifier "Tool2" or any other suitable tool.

This condition causes the next wear group (2) to be activated. Wear group 1 is now no longer the

active wear group. The status of the tools in wear group 1 has been reset (not "active"), as

configured by $TC_MAMP3, bit 1=1.

The tool search is now performed exclusively in wear group 2. Its tools were set to "active" when

the wear group was activated (one tool from each tool group in the wear group because setting

of $TC_MAMP3, bit 0=1).

The turret is now assigned as follows:

$TC_MPP6[1,2]=10

T=10 has identifier "Tool1"/duplo no.=1 ;tool state "not active"

$TC_MPP6[1,3]=11

T=11 has identifier "Tool2"/duplo no.=1 ;tool state "disabled"

$TC_MPP6[1,4]=12

T=12 has identifier "Tool1"/duplo no.=2 ;tool state "active"

$TC_MPP6[1,5]=13

T=13 has identifier "Tool1"/duplo no.=2 ;tool state "active"

$TC_MPP6[1,6]=14

T=14 has identifier "Tool1"/duplo No.=3

$TC_MPP6[1,1]=15

T=15 has identifier "Tool2"/duplo No.=3

In the example T=13 is now taken as the next available tool "Tool2".

Note

The tool search only then generates an alarm when no further spare tool available in the tool

group with the given identifier is found and no further wear group can be activated.

Control system response

Control behavior at Power On, mode group change, reset, block search and Repos is described

below.

Configuration $TC_MAMP3, bit 0=1 (activate internally)

At Power On, the NC checks whether the value of $TC_MAP9 > 0, i.e. whether a wear group has

been selected. In this case the tools of that wear group are checked again and the value for

$TC_MPP5 of each location in question is set to positive. In addition, the status of the tool in the

location is set to "active".

Configuration $TC_MAMP3, bit 1=1 (disable internally)

At Power On, the NC checks whether $TC_MAP9 is negative, i.e. a wear group has been disabled.

In this case the tools of the disabled wear group are checked again and the value for $TC_MPP5

of the location in question is set to negative. The "active" status of the tool in the location is reset.

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8.10 Location type hierarchies

8.10

Location type hierarchies

8.10.1

Hierarchies of location types in magazines

Hierarchies of location types

If a tool is to be loaded into a real magazine, the location type of the tool decides which locations

are available in the magazines. The system variables $TC_TP7 and $TC_MPP2 must be defined

and match, i.e. $TC_MPP2 is of type 'match all'. The tools of any type fit into those locations.

To optimize the assignment of locations in a magazine, hierarchies can be defined for the

magazine locations. The hierarchy level of the location type of the tool decides which locations

in a real magazine will be available for the tool.

Application example:

For example, by using location type hierarchies, you can ensure that heavy tools are stored at the

center of the magazine, but that the preferred storage location for light tools is in the outer

region of the magazine. If there are no vacant magazine locations in the outer region, magazine

locations at the center of the magazine can also be occupied by lighter tools. Several "weight

classes" can be defined, which are mapped onto the hierarchy levels.

When a tool search is started, a suitable magazine location is searched for, from the highest to

the lowest hierarchy level. The highest hierarchy level is equal to the location type of the tool

conducting the search and the lowest hierarchy level is equal to the location type "match all". The

next free location type with the highest hierarchy level is then selected.

It is possible to define several hierarchies. The valid hierarchy is then determined by the

magazine location type of the tool conducting the search.

Setting important machine data

When hierarchies are defined, the number of possible hierarchies and the number of entries in

a magazine location hierarchy must be defined.

Machine data

Description

MD18078 MM_MAX_NUM_OF_HI-

In this machine data, you define the maximum possible number of hierarchies (up to 32)

ERARCHIES

in MM_MAX_NUM_OF_HIERARCHIES. "0" means that the magazine location type hierar-

chy is not available.

MD18079 MM_MAX_HIERAR-

In this machine data, you define the maximum possible number of location types in a

CHY_ENTRIES

magazine location type hierarchy (up to 32) in MM_MAX_HIERARCHY_ENTRIES.

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Description of functions

8.10 Location type hierarchies

Defining a hierarchy

The location types of a tool and magazine locations are specified by numbers. Accordingly, the

hierarchies are also specified by numbers, which are defined in system variable $TC_MPTH:

System variable $TC_MPTH

$TC_MPTH[hierarchyNo - 1, hierarchyLevel - 1]

hierarchyNo

Number of the hierarchy if several hierarchies are defined

0 < hierarchy-no ≤ $MN_MM_MAX_NUM_OF_HIERARCHIES

hierarchyLevel

Hierarchy level within a hierarchy

0 < hierarchy-level ≤ $MN_MM_MAX_HIERARCHY_ENTRIES

For examples of hierarchy definitions, see also Magazine location type hierarchy $TC_MPTH

(Page 195).

Hierarchy types

Two hierarchy types are implemented. With system variable $TC_MAMP2, you define how a

matching location type will be searched for:

• $TC_MAMP2, Bit15=0: Conventional location type hierarchy

• $TC_MAMP2, Bit15=1: Alternative location type hierarchy

Note

Hierarchy will be deleted

If you move from one location type hierarchy to the other, alarm 17255 is output warning you

that all hierarchy definitions will be deleted ($TC_MPTH[x,y]=9999).

Definitions

• $TC_MPTH = “9999” is the default setting of the system variables and designates a non-

defined location type. If this value is contained in a hierarchy, it will be interpreted as non-

existent and the search will move to the next lowest hierarchy level.

• $TC_MPTH = “0” defines the location type "match all". This value must not be included in a

hierarchy table ($TC_MPTH) because it is always placed at the end as the lowest hierarchy

level.

• Tools with location type "0" can only be loaded into magazine locations with location type

"match all".

• The location types of locations in internal magazines must also match the tool.

• Tools with a location type to which no hierarchy is assigned, are checked against a "mini

hierarchy". This mini hierarchy only consists of the highest hierarchy level (= location type of

the tool conducting the search) and the lowest hierarchy level (= location type "match all").

• The definition of the location type hierarchy always applies to one TO unit. This means that

the hierarchies and how they are selected are always defined with the cross-magazine system

variable $TC_MAMP2 and not with the magazine-specific system variable $TC_MAP10. The

relevant bits in $TC_MAP10 are defined by the corresponding bits in $TC_MAMP2.

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8.10 Location type hierarchies

System variables

You can request information about the configured magazine location type hierarchies with the

following system variables:

• $P_MAGNH / $P_MAGNHLT / $P_MAGHLT - Location type hierarchies (Page 317)

8.10.2

Conventional location type hierarchy $TC_MAMP2, Bit15=0

Conventional location type hierarchy

For this hierarchy type, the location type of the tool conducting the search is searched for in the

table of system variable $TC_MPTH[m,n]. If the location type is found, this hierarchy is used and

evaluated from this level right to the end.

Example:

Example: Search for an empty location for a tool with location type "21".

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Figure 8-40

Conventional location type hierarchy

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Description of functions

8.10 Location type hierarchies

Location type "21" is found in hierarchy "3". The search for a free magazine location in hierarchy

"3" is performed according to the following scheme:

1. Search for location type "21", no hits?

2. Search for location type "3", no hits?

3. Search for location type "45", no hits?

4. Search for location type "match all" (="0")

The following applies to conventional location type hierarchies:

• In the system variable array $TC_MPTH, each location type must only exist once.

• The number of the hierarchy is not relevant to the hierarchy selection. This means:

hierarchies can be swapped and empty hierarchies (= all values of a hierarchy are "9999")

have no meaning.

8.10.3

Alternative location type hierarchy $TC_MAMP2, Bit15=1

Alternative location type hierarchy

In an alternative location type hierarchy, the location type of the tool for which a location is being

searched for directly determines the hierarchy in system variable $TC_MPTH[m,n].

First, a free magazine location of the relevant location type is searched for (basic level of the

hierarchy). If the search fails, the hierarchy with the number of the location type is searched.

Finally, a location of location type "match all" (= "0") is searched for.

Example:

An empty location for a tool with location type "2" is searched for.

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8.10 Location type hierarchies

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Figure 8-41

Alternative location type hierarchy

A free magazine location is searched for as follows:

1. Search for a free magazine location of location type "2" if the search fails:

2. Search acc. to hierarchy 2:

- Search for a free magazine location of location type "55", no match?

- Search for a free magazine location of location type "808", no match?

- Search for a free magazine location of location type "45", again no match?

3. Search for a free magazine location of location type "match all" (= "0").

It thus follows that:

• the array of system variables $TC_MPTH can contain location types more than once (see

location type "808" in the above example).

• Hierarchies must not be swapped

• For tools with location type > $MN_MM_MAX_NUM_OF_HIERARCHIES, the search is

performed with the "mini hierarchy".

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Description of functions

8.10 Location type hierarchies

8.10.4

Search strategy across magazines

Search strategy

The search within a magazine or across magazine boundaries can be defined as a search

strategy. The search strategy is set with Bit14 of system variable $TC_MAMP2.

The set search strategy also applies to the "mini hierarchy", which consists only of the location

type of the tool and the general location type "match all".

Example magazines:

Hierarchy is defined as follows: 87 - 21 - 3 - 9999 - 62 - 0

Magazine 1

$TC_MPP2[1,1]=0

$TC_MPP2[1,2]=62

$TC_MPP2[1,3]=9999

$TC_MPP2[1,4]=521

$TC_MPP2[1,5]=3

$TC_MPP2[1,6]=21

$TC_MPP2[1,7]=87

$TC_MPP2[1,8]=21

$TC_MPP2[1,9]=62

$TC_MPP2[1,10]=3

$TC_MPP2[1,11]=0

Magazine 2

$TC_MPP2[2,1]=0

$TC_MPP2[2,2]=62

$TC_MPP2[2,3]=9999

$TC_MPP2[2,4]=521

$TC_MPP2[2,5]=3

$TC_MPP2[2,6]=21

$TC_MPP2[2,7]=87

Search within a magazine has priority

An empty location for a tool is first searched for within one magazine before the search is

continued in the next magazine. This search method is performed with the

setting $TC_MAMP2, Bit14=0. See also Strategies for tool searches (Page 480).

A tool of location type "21" is searched for.

∎

Magazine 1

Magazine 2

∎

① = hierarchy level

② = Other magazine location types (9999)

The search for an empty location is initially performed within magazine 1. If there were no empty

location in magazine 1, the search would continue in magazine 2. The numbers express the

priority of the matches.

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8.10 Location type hierarchies

Search with priority to hierarchy

An empty location search for a tool starts with the search for a free magazine location with the

highest hierarchy level across all suitable magazines. Then the search is continued with the next

lowest hierarchy level, again across all suitable magazines.

This type of search is performed with the setting $TC_MAMP2, Bit14=1.

A tool of location type "21" is searched for.

∎

Magazine 1

Magazine 2

∎

① = hierarchy level

② = Other magazine location types (9999)

The empty location search starts in magazine 1 with the highest hierarchy. The search for an

empty location then continues within the hierarchy from magazine to magazine.

8.10.5

Mini hierarchies

Properties of mini hierarchies

A mini hierarchy is created for a location type that does not belong to any hierarchy. It consists

only of the location type itself and location type "match all" (="0").

The following example shows a magazine with a mini hierarchy of location types "0" and "521".

An empty location is searched for a tool with location type "521".

Hierarchy level

Magazine

521

Other

Search strategy "priority in magazine" in this case yields an empty location of location type "521"

at magazine location "4". In subsequent empty location searches, locations "2" and "3" are found

under location type "0".

Revoking a mini hierarchy

For compatibility reasons, it is possible to revoke a mini hierarchy with $TC_MAMP2 Bit16=1. The

empty location search then no longer differentiates between the general location type,

e.g."521", and location type "0" = match all. The search yields the next suitable location.

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8.11 Tool monitoring (workpiece count, tool life, wear)

8.11

Tool monitoring (workpiece count, tool life, wear)

8.11.1

Monitoring types

Quantity

The quantity monitoring, initiated by the NC command SETPIECE (Page 237), considers the

cutting edges of all of the tools that have been used. In this case, it must be observed that there

can be several spindles.

Service life

Tool life monitoring is only performed on the tool edge that is currently in use. As soon as the

path axes are moved (with the exception of G00), then monitoring time of the active cutting

edge is decremented. If the tool life for a cutting edge expires during machining, the tool is

disabled as a whole.

Wear

As is the case for the time and workpiece count (quantity) monitoring, the prerequisite for using

the wear monitoring function is that tool monitoring is enabled. In addition, wear monitoring

must be enabled using machine data (MM_TOOL_MANAGEMENT_MASK; Bit 5=1). The wear

parameters of the cutting edge correspond to the local offsets (additive offset parameters), see

Section "Location of use-dependent offsets fine (additive offsets) $TC_SCP (Page 176)".

Service life, quantity

The monitoring value runs from a value greater than 0 to 0. The monitoring setpoint has no

affect on the monitoring, this value is only evaluated when reactivating a tool.

Tool life, workpiece count and wear

The monitoring type for the tools is generally set when creating or loading. You can change the

monitoring type at any time by changing the setting for system variable MD $TC_TP9.

The tool management monitors a tool for tool life, workpiece count, tool wear state or additive

offset with prewarning limit.

The monitoring counter triggering the tool status change depends on the system variable

$TC_TP9 (= type of monitoring):

• $TC_TP9 = 0 → No monitoring

• $TC_TP9 = 1 → Time-monitored tool

• $TC_TP9 = 2 → Workpiece count-monitored tool

• $TC_TP9 = 4 → Wear-monitored tool

• $TC_TP9 = 8 → Additive offset

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8.11 Tool monitoring (workpiece count, tool life, wear)

Several monitoring types can be activated simultaneously for one tool. Of the monitoring types,

only wear monitoring and additive offset monitoring are mutually exclusive.

If the monitoring criterion (tool life/workpiece count and wear) for a tool that is currently located

in the spindle expires, it remains in use. Machining is not automatically interrupted to replace the

tool with a replacement tool. The tool is not disabled until the next time it is selected. Since it is

no longer "available", a search is made for a replacement tool and the replacement tool is then

loaded into the spindle. The tool change has to be organized by the PLC or come from the NC

cycle.

Prewarning limit

The prewarning limits are defined via the following system variables:

• $TC_MOP1 - prewarning limit for tool life

• TC_MOP3 - prewarning limit for workpiece count

• $TC_MOP5 - prewarning limit wear

The monitoring counters count from a set setpoint > 0 down to zero. If a cutting edge has

reached its prewarning limit, then the whole tool is set to the status "Prewarning limit reached"

($TC_TP8[i]=4).

At the same time a message is output that a replacement tool may be required.

Monitoring threshold

The monitoring counters count from a set setpoint > 0 down to zero. When a tool's cutting edge

(one of up to 12 cutting edges) has reached its limit value, the whole tool is set to status

"monitoring threshold reached".

The setpoints are defined via system variables:

• $TC_MOP11 - tool life setpoint

• $TC_MOP13 - workpiece count setpoint

• $TC_MOP15 - wear setpoint

In wear or additive offset monitoring, the actual values of the monitoring counters are compared

with a maximum value. If the values of one cutting edge exceed its particular monitoring limit

values, the whole tool is set to status "disabled" = SUSPENDED.

Resetting a status

Once the prewarning limit or monitoring limit is reached, a tool is set to the status

LIMITWARNING or status SUSPENDED.

The states are reset by the following operations (manufacturer cycle, PLC, user):

• Monitoring counter is set to a value > 0.

• Monitoring counter is set to a value > prewarning limit.

• A new initial value for the monitoring counter is set.

• Reactivate the tool (HMI user interface or NC command) (RESETMON - NC command for

setpoint activation (Page 265))

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8.11 Tool monitoring (workpiece count, tool life, wear)

The monitoring counters are the corresponding actual values:

• $TC_MOP2 - tool life - actual value

• $TC_MOP4 - workpiece count - actual value

• $TC_MOP6 - wear - actual value

The tool status changes automatically when the data changes. This means that the set status is

removed again when a limit is reached.

If the tool has several cutting edges, all of the cutting edges must be beyond the monitoring

limits.

Tool monitoring alarms

When the prewarning limit or the monitoring limit of a tool is reached, one of the alarms 6010,

6011, 6012, 6013 (cancel clear delete condition) is output for information purposes.

Note

Suppressing alarms

Alarms can be suppressed with machine data $MN_SUPPRESS_ALARM_MASK and

$MN_SUPPRESS_ALARM_MASK2.

With the NC command SETPIECE(...) or PI command _N_TMPCIT (= other workpiece counters) it

is possible for several tools to reach a limit value and therefore result in multiple alarms being

issued.

No alarm is output if a limit value is reached as the result of changing data via variable service

(OPI).

Check monitoring status

A check can be made during program execution by issuing the programmed tool change

command (e.g. "M06" for milling) without a T call to see whether a monitoring function has

responded. If it has, tool life management will search for a replacement tool and a request for

a tool change issued.

Enable memory and function

In general, in machine data

• MD18080 $MN_MM_TOOL_MANAGEMENT_MASK and

• MD20310 $MC_TOOL_MANAGEMENT_MASK

at least bits 0 and 1 must be set. This prepares the memory for the monitoring data and enables

the function.

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8.11 Tool monitoring (workpiece count, tool life, wear)

Enabling tool life monitoring

For the tool life monitoring, in addition, in the channel-specific MD20320

$MC_TOOL_TIME_MONITOR_MASK, the spindle (the tool holder) or the spindles must be

specified, for which a tool life check should be performed. This machine data is bit-coded.

Example: MD20320 $MC_TOOL_TIME_MONITOR_MASK

• Value = 1, only spindle number 1

• Value = 2, only spindle number 2

• Value = 3, spindle numbers 1 and 2

8.11.2

Tool life monitoring

Monitoring of tool cutting edge

Tool life monitoring is only performed on the tool edge that is currently in use. The spindle (tool

holder) must have been activated beforehand (MD20320 $MC_TOOL_TIME_MONITOR_MASK =

spindle no.).

If MD20124 $MC_TOOL_MANAGEMENT_TOOLHOLDER is > 0, then for MD 20320, the tool

holder number is selected and not the spindle number.

Service life

Counting or monitoring is performed in milliseconds.

Disabled

If the remaining tool life is less than or equal to 0, the tool is set to "disabled".

After the next tool change it is no longer used.

Monitoring from the

The residual tool life is decreased whenever one of the 3 path axes is traversed

at machining feedrate (e.g. G01). G00 traversing blocks are not "counted".

Monitoring from PLC

You can start and stop time monitoring with PLC signal "Time monitoring active"

DB21-DB30 (channel). Machine data 20310 is used to select whether this con-

trol type is active.

Prewarning limit

Entered during loading or via part program. When the prewarning limit has been

reached, the tool is assigned the status "Prewarning limit reached" (display in the

magazine list).

Special case, limit

The tool life of a tool expires while it is in use. A check is made as to whether this

values

disabled tool is re-programmed by a change operation (e.g. M06 without T

word), and whether the monitoring time has already elapsed. If yes, a replace-

ment tool is located.

$A-MONIFACT factor

By entering a channel-specific factor which is set before a tool is used for the first time, it is

possible to monitor the different degrees of tool wear resulting from machining different types

of workpiece material. The value by which the time value of the cutting edge is decremented is

multiplied by the current time measurement (from $A_MONIFACT). The write operation is

performed synchronously with the main run.

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8.11 Tool monitoring (workpiece count, tool life, wear)

Start and stop the tool life decrementation

Tool life monitoring runs when geometry axes are not traversed with G00 (default setting).

The user can start and stop the time monitoring using PLC signal "Time monitoring active" (DB21

DBX1.3).

Which type of control is active is set via MD20310 $MC_TOOL_MANAGEMENT_MASK, bit 17.

The default setting (bit 17=0) is standard; i.e. traversing blocks not equal to G00 will increment

the time counter. PLC signal "Time monitoring active" is activated with bit 17 = 1.

Time monitoring hierarchy

The combination of system variable $A_MONIFACT and function "Program test active" produces

the following nested time monitoring structure:

Machine data MD20310 $MC_TOOL_MANAGEMENT_MASK defines the monitoring control via

G00 or via a PLC signal. Tools on spindles that are activated by machine data MD20320

$MC_TOOL_TIME_MONITOR_MASK, are time-monitored.

The VDI signal "Program test active" switches the momentarily valid time monitoring on or off;

i.e. "Program test active" has a higher priority than the actual time monitoring.

When time monitoring is active, the service life reduction (as defined by the internal clock) is

multiplied by the factor $A_MONIFACT and the result is subtracted from the current time count

of a tool edge mounted on the spindle.

8.11.3

Workpiece count monitoring

Changing the number of workpieces

The number of workpieces can be changed by:

• Operator action at the HMI

• With a part program command (SETPIECE)

• PI service (TMPCIT) by PLC or HMI-OEM

Workpiece counter per spindle

Every spindle has a "memory" for the cutting edges used on it. With program command SETPIECE

(1) the workpiece counter for the cutting edges that are used on the main spindle is

decremented by 1. The workpiece counter of each spindle can be addressed individually.

The workpiece counter must count all the tools that are used to produce a workpiece. Take into

account that the machine may have several spindles and that different tools can be used

simultaneously.

The cutting edge of a tool is only counted once per spindle.

The part program programmer who programmed SETPIECE can program the parameter as a

function of the material.

SETPIECE (factor * no. of workpieces)

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8.11 Tool monitoring (workpiece count, tool life, wear)

Like the factor for time monitoring, this function allows a workpiece count that depends on the

process, the workpiece material or other factors.

Workpiece count can be deactivated via the channel DB.DBX29.5.

Monitoring from the NC

The workpiece counter is decremented each time that SETPIECE is pro-

grammed. When the prewarning limit is reached, an information alarm

is output. When the counter reaches the value=0, the tool is disabled

and an alarm is output. The next time the tool is called, the replacement

tool is loaded at change.

Set workpiece counter

Entered when creating or loading the tool or via the part program with

e.g. $TC_MOP4=500.

Decrement number of work-

The number of workpieces must be decremented at the relevant point

pieces

in the part program with the NC language command SETPIECE (x, y)

(e.g. SETPIECE(1) → workpiece counter for main spindle tools is decre-

mented by 1).

The function for decrementing the workpiece count is activated from

die PLC program using a PI command (TMPCIT).

Disabled

When the workpiece count has reached zero, the tool is disabled

Prewarning limit

Entered when creating or loading the tool or via the part program with

e.g. $TC_MOP3=50. When the prewarning limit has been reached, the

tool is assigned the status "Prewarning limit reached".

Special case, limit values

It is not possible to realize a workpiece count for any number of cutting

edges simultaneously! If the monitoring function has been enabled and

activated by machine data, then all spindles can be monitored together

at a time = "Number of cutting edges in the TO area" (= MD) for the

number of cutting edges.

An edge of a tool is only counted once per spindle.

8.11.4

Wear monitoring

The wear monitoring function is only available if the "Tool monitoring" system has been enabled

via machine data.

In addition, wear monitoring must be enabled using machine data (MD18080

$MN_MM_TOOL_MANAGEMENT_MASK, bit 5).

Definition

$TC_TP9 = 4; Wear monitoring is active for the tool.

$TC_TP9 = 8 can be set to select the "Additive offset" monitoring function if this is required.

$TC_TP9 = 4

The wear parameters for a tool edge are defined with system variables $TC_DP12, ..., $TC_DP20.

These are assigned directly to the edge geometry values TC_DP3, ...,$TC_DP11.

$TC_DP10 and $TC_DP11 describe "angles". The other parameters stand for the tool edge

lengths and radii.

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Only these values are included in the monitoring, i.e. wear parameters $TC_DP19 and

$TC_DP20, which are analogous to system variables $TC_DP10 and $TC_DP11, are not taken

into account.

Note

Wear monitoring is performed automatically by the NC when the user changes the cutting edge

offsets.

Note

Wear monitoring does not monitor every single value but rather only the largest absolute value

of each of these maximum seven wear parameters ($TC_DP12, ..., $TC_DP18).

$TC_TP9 = 8

Wear parameters (system variables) of the cutting edge can be found in the additive offset

parameters.

Analog to wear, the following system variables are monitored for the additional location-specific

offsets of the cutting edge:

• $TC_SCP12, ... $TC_SCP18

First additive offset for the cutting edge (if defined)

• $TC_SCP22, ... $TC_SCP28

Second additive offset for the cutting edge (if defined) etc. for the other additive offsets for

the cutting edge

Note

Wear monitoring does not monitor every single value but rather only the high contribution

of each of these maximum seven additive offset parameters * number of defined additive

offsets for the cutting edge ($TC_SCP12, …, $TC_SCP18, $TC_SCP22, …, $TC_SCP28, …).

Most tool geometries are described by a subset of the named data records.

If a parameter is changed (written), the NC then checks whether the new value is higher than

any of the other parameters and, if necessary, this value is subtracted from the wear setpoint.

The result is the new actual value for the wear.

Analogous to other monitoring variables, the actual wear runs from the positive setpoint

towards zero.

Monitoring parameters (system variables)

$TC_MOP15

Wear setpoint or additive offset value

$TC_MOP5

Wear pre-warning limit or additive offset pre-warning limit

$TC_MOP6

Wear value or additive-offset setpoint

The physical quantity of the new monitoring parameters is "Length". The unit is the same as for

the wear values.

Wear monitoring can be deactivated via the channel DB.DBX29.6.

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The signal only acts on changes in wear data that occur during execution of the NC program. The

PLC signal is suppressed if this data is changed via the OPI (e.g. during HMI operation).

Reset to setpoints

Resetting the actual values of wear and additive offset "fine" means that all the parameters for

wear offset and additive offset used for monitoring are set to zero.

Example

For the tool with T No.=3, the wear monitoring is active and it is

$TC_MOP5[3,1]=0.002

;= Wear prewarning limit

$TC_MOP6[3,1]=0.003

;= Wear actual value

$TC_MOP15[3,1]=0.007

;= Wear setpoint

It was already set.

$TC_DP12[3,1]=0.004

;= Wear component 1

$TC_DP13[3,1] =+0.00

;= Wear component 2

Wear component 3 is now set.

$TC_DP14[3,1] := -0.006.

Thus the maximum absolute value is given for the wear components = 0.006.

The resulting new actual value is

$TC_MOP15[3,1] - 0.006 = 0.001 = $TC_MOP6[3,1].

The prewarning limit has been reached.

Note: The wear components can be negative or positive - or a mixture of each.

Note

The VDI signal "Activate program test" has no effect on wear monitoring since new wear values

are only entered during machining and not during the program test (provided that wear was not

changed by the machining program itself).

8.11.5

Signals to and from the PLC

Overview

Previously, an alarm message was output as soon as the prewarning limit or limit value was

reached. Alarms 6410 and 6411 are output when the prewarning limit is reached and 6412

and 6413 when the limit value is reached. Alarms 6410 and 6412 are triggered via the OP

interface and alarms 6411 and 6413 via the NC program. The alarm texts identify the affected

tool via the tool ID, duplo number and D number.

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The following information is returned to the channel interface for one OB1 cycle (internal T

numbers):

• Prewarning limit reached

• Limit reached

A strobe signal is set for one PLC cycle (DB channel.DBB344) which indicates that new data is

available.

VDI signal "Warning limit reached" channel DB.DBD348

If a tool reaches its prewarning limit with tool life, workpiece count or wear monitoring, the

internal T No. of the tool is entered here and the associated strobe signal is set.

VDI signal "Limit value reached" channel DB.DBD352

If the tool life, workpiece count or wear value has expired for a monitored tool, the internal T No.

of the tool is entered and the associated strobe signal is set.

Note

If machining is being performed with tools that are monitored for their workpiece count, it is

possible for several tools to reach their prewarning limit or limit value simultaneously (SETPIECE

is programmed at the end of program).

In this case, only the T No. of the tool that was last programmed is output.

VDI signal "T number of new replacement tool" - channel DB.DBD356

The transition to a new replacement tool is initiated by the tool status "was in use". This means

that when searching for a tool in the NC, if a (usable) tool was found that had still not been used,

then it is evaluated as being the first selection and the interface signal set.

This process state change is output to the PLC via the T number of the replacement tool.

The action of the operator changing the tool status does not cause any change to the signal.

VDI signal "Last replacement tool in the tool group" - channel DB.DBD360

If, during the tool change when searching for a tool in the NC a tool is found, and at this point

in time there are no further replacement tools available for the programmed spindle / tool

holder, then this is evaluated as the "Last replacement tool found in the tool group".

If there is only one tool (i.e. there is no replacement tool) it is also a tool group. When this tool

is programmed, the interface signal is set immediately.

This process state change is output to the PLC via the T number of the replacement tool.

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8.11 Tool monitoring (workpiece count, tool life, wear)

The action of the operator changing the tool status does not cause any change to the signal.

Note

For tool groups containing many tools, the function increases the time required in the NC for the

main run when the tool is selected.

The function must be enabled MD20310 $MC_TOOL_MANAGEMENT_MASK, bit 18=1.

Disable monitored tools - PLC-controlled by the VDI signal

In earlier versions, a tool assumed the status "disabled" as soon as the actual value of the active

monitoring function reached the value zero. A tool being used for machining that is set to

"disabled" remains operational until the next tool change takes place. After that the tool can no

longer be used.

The PLC can also determine when a disabled tool can no longer be used, i.e. when the "disabled"

status is taken into account in the tool search.

• With the VDI signal "Tool disable not active" = 1

(channel DB.DBX29.7 = 1) the NC does not take the tool status "disabled" into account during

the tool search.

• With the VDI signal "Tool disable not active" = 0

(channel DB.DBX29.7 = 0) the NC takes the tool status "disabled" into account during the tool

search.

The bit is channel-specific.

"Search for active tool" strategy

This search strategy can ensure, for example, that a machining operation is not performed with

different tools from the same tool group.

When the tool is disabled, a monitoring function and the set VDI signal "Tool disable not active"

mean that the status "active" is not canceled.

This tool is therefore assigned the status "active" and "disabled".

If the required machining operation is terminated without a tool change, the status of all

disabled tools must be checked. A PI service (_N_TMRASS, in PLC TMRASS) is provided for this.

This service can be used to cancel the status "active" for all tools that have been disabled (e.g. by

the PLC program at the end of the program).

The other tool-search strategies

A disabled tool can still be used with the other tool-search strategies when the VDI signal "Tool

disable not active" (channel DB.DBX29.7 = 1) is set. The tool selected solely depends on the

search strategy.

The search strategy therefore takes precedence over the VDI signal "Tool disable not active".

Both the last tool to be disabled or any other disabled tool can be selected.

Another tool which is not disabled might also exist, but is not selected because of the search

strategy!

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8.12 Tool monitoring without active tool management

8.12

Tool monitoring without active tool management

8.12.1

Tool monitoring overview

General

The tool monitoring without active tool management is activated via the following machine

data:

• MD18080 $MN_MMTOOL_MANAGEMENT_MASK, bit 1=1

• MD20310 $MC_TOOL_MANAGEMENT_MASK, bit 1=1

Note

The function "Monitoring without active tool management" (WZMO) is set by default.

The tool monitoring without active tool management function allows the following monitoring

types of the active cutting edge of the active tool:

• Monitoring the tool life

• Monitoring the workpiece count

• Monitoring the wear

• Monitoring the additive offset

The function allows tool identifiers to be used and it is also possible to use replacement tools.

Monitoring counter

Monitoring counters exist for each monitoring type. These count from a set value > 0 down to

zero. When a counter has decremented to a value of ≤0, the limit value is reached. A

corresponding alarm is issued. The same applies if a cutting edge of a tool has reached its set

prewarning limit.

State and type of tool monitoring

System parameter $TC_TP8 can be used to determine the state for the particular tool, $TC_TP9

to determine the monitoring function type.

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8.12 Tool monitoring without active tool management

Contrary to the magazine management (see Section "Magazines (Page 345)"), in the tool

monitoring function without active tool management, only the following states are of

significance:

• $TC_TP8[t] - State of the tool with the number t

Bit 0 = 1: Tool is active

Bit 0 = 0: Tool is not active

Bit 1 = 1: Tool is enabled

Bit 0 = 0: Tool is not enabled

Bit 2 = 1 Tool is disabled

Bit 2 = 0: Tool is not disabled

Bit 3: Reserved

Bit 4 = 1: Prewarning limit reached

Bit 4 = 0: Prewarning limit not reached

• $TC_TP9[t] - Type of the monitoring function for the tool with the number t

= 0: No monitoring

= 1: Time-monitored tool

= 2: Workpiece count-monitored tool

= 4: Wear-monitored tool

= 8: Additive offset

Several monitoring types are possible for a tool. Wear and additive offset monitoring cannot be

simultaneously selected (only alternatively).

System variables for active tool

The active cutting edge of the active tool can be determined using an existing system/OPI

variable:

• $P_TOOL / actDNumber: Active tool offset D

• $P_TOOLNO / actTNumber: Active tool number T

8.12.2

Tool life monitoring

Overview

Tool life monitoring is done for the tool cutting edge that is currently in use (active cutting edge

D of the active tool T).

As soon as the path axes traverse (G1, G2, G3, ... but not for G00), the residual tool life

($TC_MOP2[t,d]) of this tool cutting edge is updated. If the remaining tool lifetime of a tool

cutting edge expires during a machining operation, an alarm is output. The tool changes to the

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8.12 Tool monitoring without active tool management

"disabled" condition and cannot be programmed as long as the "disabled" condition is present.

The operator must intervene and ensure that an operational tool for machining is provided.

Note

As standard, the time is counted if the geometry axes are traversed - but not equal to G00. As an

alternative, using MD $MC_TOOL_MANAGEMENT_MASK, bit 17, the time monitoring can be

started and stopped from the PLC.

The channel-specific system parameter $A_MONIFACT allows the clock to be either run slower

or faster.

Time monitoring and reference to the spindle or to the tool holder

For MD $MC_T_M_ADDRESS_EXT_IS_SPINO = TRUE, only the time for the active tool is counted

whose programmed spindle number has a value that is set is by selecting the bit in MD

$MC_TOOL_TIME_MONITOR_MASK.

The value of MD $MC_TOOL_TIME_MONITOR_MASK has no significance, if MD

$MC_T_M_ADDRESS_EXT_IS_SPINO = FALSE. In this case, the time is counted and monitored for

each active cutting edge.

8.12.3

Workpiece count monitoring

General

The active cutting edge of the tool that has been loaded at change is monitored for the

workpiece count without reference to the spindle number (standard).

Monitoring the workpiece count registers all the tool edges that are used to produce a

workpiece. If the workpiece count is changed by an operator input, the monitoring data of all the

cutting edges that have become active since the last workpiece count is adjusted.

The workpiece count can be updated by the PLC, using the PI command _N_TMPCIT or from the

NC program using the language command SETPIECE.

Workpiece count monitoring and reference to the spindle or to the tool holder

If MD $MC_T_M_ADDRESS_EXT_IS_SPINO = TRUE is used, the address extension of T is

interpreted as spindle number. The workpiece counter monitoring is then realized separately for

the spindles; further, the SETPIECE command requires the "spindle number" parameter.

If MD $MC_T_M_ADDRESS_EXT_IS_SPINO = FALSE is used, the parameter "spindle number" in

SETPIECE and/or the analog PI service is ignored.

The workpiece count monitoring can be activated and deactivated by the PLC using an interface

signal.

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8.12 Tool monitoring without active tool management

8.12.4

Wear monitoring

The wear monitoring must be enabled using MD $MN_MM_TOOL_MANAGEMENT_MASK, bit 5.

As default, the function is not activated.

The wear parameters for a cutting edge are defined with system variables $TC_DP12 ...20. The

highest value of parameter $TC_DP12 ...18 - responsible for the lengths and radii of the cutting

edge - is monitored.

The wear monitoring can be activated and deactivated by the PLC using an interface signal.

8.12.5

Monitoring the additive offset

When using the "additive offset" function, using $TC_TP9=8 for the wear monitoring, additive

offset monitoring can be selected. Instead of wear parameters $TC_DP12 ... 18, the additive

offset parameters $TC_SCP12 ...18 are monitored. This corresponds to a defined 1st additive

offset of the cutting edge. In turn, only the highest value of the additive offset parameter of all

defined additive offsets is monitored.

8.12.6

Working with replacement tools

If replacement tools are used, it is necessary to define the rules relating to the transition to the

replacement tool.

When changing a tool, only the name of the tool group is specified in the part program. This

comprises several tools, that differ by their duplo number. The NC selects, if available, the tool

with the "active" state. If there is no tool with the "active" state, the next tool that can be used

is selected whose value of the system variable $TC_TP10 regarding the other tools in the tool

group is the lowest. The user allocates the parameter values so that tools are used in the required

sequence. If values are not allocated, then the NC automatically selects some sort of suitable

tool.

8.12.7

Examples

Requirement

Specified setting:

MD18080 $MN_MM_TOOL_MANAGEMENT_MASK = 0x02

MD20310 $MC_TOOL_MANAGEMENT_MASK = 0x02

Service life monitoring for tool 2, cutting edge 1 in the NC program

$TC_TP9[2,1]=1

;Activation of the service life monitoring

$TC_MOP1[2,1]=100

;Prewarning limit in minutes

$TC_MOP2[2,1]=245

;Residual tool life in minutes

$TC_MOP11[2,1]=800

; Reference service life in minutes

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8.12 Tool monitoring without active tool management

Service life monitoring for the active tool with active D number in the NC program

$TC_TP9[$P_TOOLNO]=1

;Activation of the service life monitoring

$TC_MOP1[$P_TOOLNO, $P_TOOL]=200

;Prewarning limit in minutes

$TC_MOP2[$P_TOOLNO, $P_TOOL]=602

;Residual tool life in minutes

$TC_MOP11[$P_TOOLNO, $P_TOOL]=700

; Reference service life in minutes

8.12.8

NC language commands

General

The NC language commands, which apply for tool monitoring without tool management, are

only listed here. A detailed description is provided in this documentation under the appropriate

index entry.

• SETPIECE

Decrement workpiece counter.

• RESETMON

Language command for setpoint activation

• $A_MONIFACT

Read factor for tool life monitoring.

• NEWT

Create new tool.

• DELT

Delete tool.

• GETT

Read T number

• GETACTT

Read the active internal T No.

The associated PI commands can also be used:

• _N_TMCRTO

• _N_TMCRTC

• _N_TMGETT

• _N_TRESMO

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8.13 Variants of D-number assignments

8.13

Variants of D-number assignments

8.13.1

Free selection of D numbers for every T

D numbers can be freely assigned to tool edge numbers in systems with and without tool

management. A maximum of 12 cutting edges are possible for each tool "T". The upper limit for

the D numbers used is limited by the machine data.

This assignment option is an extension of the process to relative D numbers.

With this setting ($MN_MM_MAX_CUTTING_EDGE_NO >

$MN_MM_MAX_CUTTING_EDGE_PER_TOOL) additional program commands can be used that

make a check for unambiguous assignment of D numbers to T numbers or identifiers possible.

With this setting, the cutting edge number $TC_DPCE[T-No,D-No] is also created.

The same D numbers shall be assigned in each case for the cutting edges for duplo tools (same

identifiers).

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Figure 8-42

Structure of the tool offset memory

Note

Uniform system support is not available for this function.

Machine data for user (unique) assignment of D numbers

$MN_MAX_CUTTING_EDGE_NO = Maximum permissible D number

Example:

$MN_MAX_CUTTING_EDGE_NO=1

A maximum of 1 offset (D1) can be defined per

tool.

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$MN_MAX_CUTTING_EDGE_NO=9999

Tools can be assigned unique D numbers as

follows:

T1 with D1, D2, D3

T2 with D10, D20, D30

T3 with D100, D200, D300

$MN_MAX_CUTTING_EDGE_PER_TOOL =Assignment of tool edges per tool

Example:

$MN_MAX_CUTTING_EDGE_PER_TOOL=1

Only tools used with 1 cutting edge

$MN_MAX_CUTTING_EDGE_PER_TOOL=12

Up to 12 cutting edges per tool.

Check for uniqueness (CHKDNO)

The NC language command CHKDNO checks the D numbers assigned within the NC for

uniqueness. The D numbers of all tools defined within a TO unit may not occur more than once.

No allowance is made for replacement tools.

Check within the magazine (CHKDM)

Exactly like CHKNO, the NC language command CHKDM checks the D numbers assigned within

the NC for an activated tool management for uniqueness. This check function can be restricted

to individual magazines.

D number to T number (GETACTTD)

Using the NC language command GETACTTD if tool management is active, the T number in

which the D number occurs can be searched for.

Precondition for this is that the D numbers have been uniquely assigned in the TO unit being

considered.

GETDNO, SETDNO when re-equipping

The NC language commands GETDNO and SETDNO permit reading and writing the offset

number D for a specified cutting-edge number CE.

GETDNO (T, CE): Read the D number for the cutting edge CE of the tool T

SETDNO (T, CE, D): Set the D number for the cutting edge CE of the tool T

$TC_DPCE[T, D]=...: Assignment of tool edge number CE to offset number D

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8.13 Variants of D-number assignments

Example:

Rename cutting edge CE=3 from D2 to D17

• With initial situation:

Internal T number 1

D number: 2

Tool 1 cutting edge with:

$TC_DP2[1, 2]=120 ;tool radius T1, D2: 120 mm

$TC_DP3[1, 2]=5.5 ;tool radius T1, D2: 5.5 mm

$TC_DPCE[1, 2]=3 ;cutting edge number T1, D2: 3

(programming: T1,...D2)

• Using variable definition:

DEF INT DNoOld, DNoNew=17

DnOld=GETDNO (1, 3) ;value 2 is read in DnOld

SETDNO (1, 3, DNoNew) ;the new D no. is assigned to the cutting edge

• The new D value 17 is assigned to cutting edge CE=3

$TC_DP2[1,17]=120

$TC_DP3[1, 17]=5.5

$TC_DPCE[1, 17]=3

8.13.2

Location-dependent offsets (additive offsets)

Overview

Location-dependent offsets are a generalized form of wear. They are part of the cutting edge

data. The parameters of the additive offset refer to the geometrical data of a cutting edge.

Location-dependent offset can in general be used, i.e. with active/inactive tool management;

with flat D-number function.

To meet the requirements of special machine operating modes, the location-dependent offsets

can be subdivided into the following categories by setting the appropriate machine data:

• Location-dependent offset, fine

• Location-dependent offsets, coarse = setting-up offset

The purpose of the setting-up offset is to allow the operator to set values prior to the machining

operation. These values are stored in their own memory in the NC, the operator can access the

location-dependent fine offsets via the HMI. Location-dependent offsets "fine" and location-

dependent offsets "coarse" are added NC-internally and then act like the additive offset itself.

Several location-dependent offsets can be defined per D number. Machine data define the

absolute number of location-dependent offsets, the maximum number of location-dependent

offsets per cutting edge and specify which additive offsets are active after the end of program or

when the Reset key is pressed.

Applicable only when tool management is active:

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Description of functions

8.13 Variants of D-number assignments

MD18112 $MN_MM_KIND_OF_SUMCOR can be set to define which additive offset must be

operative if a tool is assigned the "active" status in the part program in the coarse of a

programmed tool change:

• Additive offset values "fine" of the tool cutting edges remain unchanged or

• Additive offset values "fine" of the tool cutting edges are set to the value 0

The function is enabled by setting bit 8 = 1 in machine data

$MN_MM_TOOL_MANAGEMENT_MASK.

DL - programming the additive/setting-up offset

Programming the additive offset is always relative to the active D number and is executed using

the command

DL ="n"

The additive offset with the relative number "n" with respect to the active D number is activated

by this. This means that the additive offset "n" is added to the wear of the active D number.

The additive offset is deselected with the command

DL = 0

Configuration of additive/setting-up offset

$MN_MM_KIND_OF_SUMCORR, bit 4=0

Corresponds to the default setting; only one data record of additive offset available per DL

number. In this case, the term "additive offset" merely refers to the data represented by

$TC_SCPx.

$GGLWLYH RIIVHW

7&B6&3

' RIIVHW

7&B6&3

7&B'3 >W

7&B'3

$GGLWLYH RIIVHW

7&B6&3

7&B'3

7&B'3&(>W

7&B6&3

Figure 8-43

$MN_MM_KIND_OF_SUMCORR, bit 4=0

The data in the diagram is used when programming (the tool with T=t is active):

;Cutting edge offsets

;i.e. $TC_DP3,...$TC_DP11 + wear ($TC_DP12,...$DP29) + adapter dimen-

sion

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8.13 Variants of D-number assignments

DL=1

;Additive offset 1 is added to the existing offsets of D2

;i.e. $TC_SCP13,...$TC_SCP21

DL=2

;Additive offset 1 is no longer added to offset D2, but additive off-

set 2 instead

;i.e. $TC_SCP23,...$TC_SCP31

DL=0

;Deselection of additive offset; only the data of D2 is still effec-

tive

$MN_MM_KIND_OF_SUMCORR, bit 4=1

Setting-up offsets are available. The general term "additive offset" refers to a combination of the

"fine" additive offset, represented by $TC_SCPx, and the additive offset, represented by

$TC_ECPx. There are two data records for one DL number. The additive offset equals the product

of the corresponding components $TC_SCPx + $TC_ECPx.

$GGLWLYH RIIVHW ILQH

6HWXS RIIVHW

7&B(&3

7&B6&3

7&B(&3

7&B6&3

' RIIVHW

7&B'3 >W

$GGLWLYH RIIVHW ILQH

7&B'3

6HWXS RIIVHW

7&B(&3

7&B'3

7&B6&3

7&B'3&(>W

7&B(&3

7&B6&3

Figure 8-44

$MN_MM_KIND_OF_SUMCORR, bit 4=1

The data in the diagram is used when programming (the tool with T=t is active):

;Cutting edge offsets

;i.e. $TC_DP3,...$TC_DP11 + wear ($TC_DP12,...$DP29) + adapter dimen-

sion

DL=1

;Additive offset 1 is added to the existing offsets of D2

;i.e. $TC_ECP13 + $TC_SCP13 ,...$TC_ECP21 + $TC_SCP21

DL=2

;Additive offset 1 is no longer added to offset D2, but additive off-

set 2 instead

;i.e. $TC_ECP23 + $TC_SCP23,... $TC_ECP31 + $TC_SCP31

DL=0

;Deselection of additive offset; only the data of D2 is still effec-

tive

The new NC language command DELDL can be used to delete location-dependent offsets from

cutting edges.

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Description of functions

8.14 Tool adapter

8.14

Tool adapter

8.14.1

Machine data for setting adapters of type 1 and type 2

Setting machine data

To use angle head adapters of types 1 and 2, the following machine data must be set:

• Tool management with magazine management (TMMG)

- $MN_MM_TOOL_MANAGEMENT_MASK, Bit0=1

- $MC_TOOL_MANAGEMENT_MASK, Bit0=1

• "Adapter" function

- $MN_MM_TOOL_MANAGEMENT_MASK, Bit7=1

• "Multitool" function (adapter type 2)

- $MN_MM_TOOL_MANAGEMENT_MASK, Bit10=1

• Number of angle head adapters specified

- $MN_MM_NUM_TOOL_ADAPTER_TYP2 >= 0

8.14.2

Creating/deleting adapters

Two types of tool adapters are supported:

• Type 1 (Page 522) defines conventional adapters. These adapters can be assigned to any

location in the magazine.

• Type 2 (Page 534) defines angle head adapters in which the tool base position is angled. This

type is assigned to a multitool location.

Create adapter

An adapter is created by using the system variable $TC_ADPT_TYPE[n] to assign an adapter type

to an adapter with the number "n".

The data is saved in system variables for the two available types of adapters. The adapter types

are defined via the system variable $TC_ADPT_TYPE[n]:

•

0: No adapter with the number "n" is defined.

•

1: An adapter with the number "n" is of type 1 (conventional adapter)

•

2: An adapter with the number "n" is of type 2 (angle head adapter)

If the data of an adapter that was not set is written, then the command is declined with an alert.

Example:

$TC_ADPT_TYPE[1] = 2 creates an adapter of type 2.

See also $TC_ADPTx - adapter description (Page 308).

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Description of functions

8.14 Tool adapter

Number of possible adapters

The number of possible adapters is set via the machine

data $MN_MM_NUM_TOOL_ADAPTER_TYPE2 (Page 520).

Delete adapter

Adapters can be deleted via the system variable $TC_ADPT_TYPE[n] using the following

commands:

• $TC_ADPT_TYPE[n] = 0; the adapter with the number "n" is deleted.

• $TC_ADPT_TYPE[0] = 0; all adapters are deleted.

Note

Only adapters that are not assigned to a magazine location can be deleted.

Adapters of type "1" can be deleted using the command $TC_ADPTT[n]=-1 with n>0. This

command is not available for adapters of type "2".

With the NC language instruction "$TC_MAP1[0]=0", all of the magazine data of the TOA unit of

the channel is deleted and consequently all of the adapters as well. The exception to the rule are

adapters that are already assigned to a multitool.

8.14.3

Constraints for adapters

Constraints

Please note the following constraints:

• The option for "Angle head adapter" is set.

• The "Multitool" option is set for adapter type 2.

• The "Tool and magazine management" and "Adapters" functions are set.

• Adapter type 1 can only be assigned to a magazine location.

• Adapter type 2 (angle head) can only be assigned to a multitool location. The multitool has

only one magazine location.

• Adapters on a magazine location and multitool location cannot be cascaded.

- Exception: The adapter type 1 on the magazine location only has default values

$TC_ADPT1-3 =0 and $TC_ADPTT=1.

Note

Available tool types for adapter type 2

Only the tool types <400 and >=600 are possible, i.e. no turning or grinding tools.

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Description of functions

8.14 Tool adapter

Note

Observe multitool rules for type 2 adapters

Since the adapter type 2 is only permitted on multitool locations, the rules for multitools must

be observed, e.g. handling in the PLC, determination of the T no. of the spindle tool.

8.14.4

Managing adapter data

8.14.4.1

Managing adapter data for type 1 and type 2

Number of possible adapters

The number of possible angle head adapters is set via the machine data MD

$MN_MM_NUM_TOOL_ADAPTER_TYPE2.

Managing the adapter data from the NC program

The following properties can be determined from this via system variables from the NC program.

System variable

Description

$P_MAGNA

Number of created adapters of type 1 and type 2 in total in the TO unit of the channel.

$P_MAGNA1

Number of created adapters of type 1 in the TO unit of the channel.

$P_MAGNA2

Number of created adapters of type 2 in the TO unit of the channel.

$P_MAGNA[i]

i-th adapter number that is defined. The adapter numbers are sorted in ascending order.

8.14.5

Adapter type 1

8.14.5.1

Overview

Purpose

The standard dataset for the tool offsets gives you, via the system variables $TC_DP21,

$TC_DP22 and $TC_DP23, the capability of entering the dimensions (Length1, Length2 and

Length3) of an adapter.

If tool management is active the additional adapter data can also be assigned to specific

magazine locations.

This function is used for adapters that are fixed to a magazine location for a long period and used

by different types of tool.

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8.14 Tool adapter

In individual cases, it is also possible to use identical adapters on several magazine locations. To

do this it makes sense to define and store the adapter data records separately from the magazine

locations.

'HIDXOW JHRPHWU\

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7UDQVIRUPHG WRRO

JHRPHWU\

7XUUHW ORFDWLRQ ZLWK

DGDSWHU

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&XWWLQJ HGJH SRVLWLRQ

Figure 8-45

Adapter transformation

Adapter data "adapter transformation" allows fixed orientation of the tool on the adapter or

orientation of the adapter including its tool with reference to the machine.

If adapter data are used, system variables $TC_DP21, $TC_DP22 and $TC_DP23 have a different

reference and are therefore only formally part of the cutting edge data record in the NC.

8.14.5.2

Description of function

The adapter data function must be enabled via machine data (MD18104:

$MN_MN_MM_NUM_TOOL_ADAPTER).

In order to activate the setting, bit 7 must be set in MD18080 MM_TOOL_MANAGEMENT_MASK.

Definitions

The machine data can be used to set two definition types of adapter data:

• One adapter data record is assigned to each magazine location as standard.

• Adapter data records can be defined independently of magazine locations. The magazine

locations are then assigned as an additional step.

The magazine location is the reference point for adapter and tool. Both are assigned to the

magazine location.

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Description of functions

8.14 Tool adapter

The following points are realized when programming the D numbers in the part program:

• The offset is assigned to a real tool.

• The tool is assigned to a magazine location

• It is possible to assign an adapter to the magazine location, for which a transformation

(orientation) of the tool it contains can be defined.

Thus, the working offset can be clearly computed and the tool path accordingly adjusted.

If an additive offset is programmed, then its value refers to the active D offset.

8.14.5.3

Activation

Requirements

• In order to be able to use magazine location oriented adapter data, machine data MD18104

$MN_MM_NUM_TOOL_ADAPTER must have a value that is not equal to zero.

• Adapter data records must be defined.

• If the values of the machine data are > 0, the adapters must be linked to the magazine

locations or assigned to them (can be automated via the HMI or using a cycle).

As a result, the adapter data including the defined transformations are always taken into account

for the tool located on the magazine location in question. The working offset is calculated

including the transformation and the adapter data.

The offset data can then be displayed as follows:

• Geometrical data for the tool (system variable $TC_DP3,...DP11); designated as neutral

default geometry

• Non-transformed working offset (sum of the values from tool geometry, wear, additive

offset, tool base dimension or adapter)

• Non-transformed working offset (transformation of the sum of the values from tool

geometry, wear, additive offset) and tool base dimension of the adapter.

Machine data and setting data are used to define the sizes the transformation affects. The mode

of transformation of the additive offset can be set.

Magazine-location-related adapter data records

Create new

MD18104 $MN_MM_NUM_TOOL_ADAPTER = -1:

One magazine location and one adapter data record are created. Default values are stored in the

adapter data record which is automatically linked to the magazine location.

It is not possible to create a new free adapter at this point. The adapter numbers are assigned

automatically (1 ... max. number of available magazine locations).

Delete

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8.14 Tool adapter

If an adapter data record is linked to a magazine location (MM_NUM_TOOL_ADAPTER = -1), it

cannot be deleted.

Note

Only the setting $MN_MM_NUM_TOOL_ADAPTER = -1 is currently supported by HMI Operate.

With this setting, freely creating adapter data sets and freely assigning them is not possible.

It is not permissible to change the automatic assignment and numbering of the adapter.

Free adapter data records

Create new

MD18104 $MN_MM_NUM_TOOL_ADAPTER > 0:

The adapter data can be created freely. Adapter data can be created by the user with a write

operation to a non-existent data record.

$TC_ADPTi[n] = value; i = T, 1 2, 3, ..., n (number of the adapter)

If data record n does not yet exist and the maximum number of adapter data records that have

already been defined is less than the value of MD18104 $MN_MM_NUM_TOOL_ADAPTER, a

new adapter data record is created and assigned specific values.

The value "value" is assigned to parameter i. The following applies, 0 < n ≤ 3 2000. The index

value 0 is reserved.

Note

The adapters must be assigned explicitly to the magazine locations for

MM_NUM_TOOL_ADAPTER > 0.

- OR -

An adapter is created by using the system variable $TC_ADPT_TYPE[n] to assign an adapter type

to an adapter with the number "n". Example: $TC_ADPT_TYPE[1] = 1

Deleting an adapter of type 1

If, MD18104 MM_NUM_TOOL_ADAPTER has the value > 0, then the adapter data can be deleted

as required provided it is not assigned to a magazine location.

$TC_ADPTT[n] = -1

Adapter data record n is deleted and the memory becomes free again.

- OR -

$TC_ADPT_TYPE[n] = 0; the adapter with the number "n" is deleted.

Deleting an assigned adapter data record:

The assignment to the magazine location must be undone first. You can only do this if the

magazine location is empty. An alarm is issued if deletion fails.

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Description of functions

8.14 Tool adapter

Please proceed as follows:

• Remove the tool from the magazine location

(unload, relocate).

• Remove the adapter from the magazine location.

• Delete the adapter data record (with $TC_ADPTTi[n] = -1).

Adapter data record n is deleted and the memory becomes free again.

Deleting all adapter data records

For MM_NUM_TOOL_ADAPTER > 0, you can delete the adapter data if it is not assigned to a

magazine location:

$TC_ADPTT[0] = -1

All non-assigned adapter data of the TO units is deleted. If you want to delete assigned adapters,

you must first undo the assignment of those adapters to magazine locations. An alarm is issued

if deletion fails.

- OR -

$TC_ADPT_TYPE[0] = 0; all adapters are deleted.

Read/write adapter parameters

You can modify adapter data at any time even if an adapter is assigned to a magazine location

and/or a tool is located in the magazine location with the adapter.

Magazine location assignment/release

For MM_NUM_TOOL_ADAPTER > 0, an adapter record must be assigned to a magazine location

explicitly:

$TC_MPP7[m,p] = "adapter no."

Adapter number "adapter no." is assigned to magazine location p of magazine m. For "adapter

no." = 0 any previous assignment is removed.

Note

An assignment can only be established or released if no tool is assigned to the magazine location.

Determination of the adapter

When determining the relevant adapter, a distinction is made between a turret and the other

magazines.

The following applies for a turret:

The adapter is used on the owner location (i.e. the source location, whereby the tool only leaves

the magazine location in the data) of the selected tool.

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8.14 Tool adapter

The following applies for chain and box-type magazines:

The adapter of the current magazine location containing the tool (usually the spindle) is used.

Example:

A tool magazine is changed from Magazine_1/Location_1 into the spindle. The adapter from

Magazine_location_1 is not read now, but rather from the spindle location. This means that in

the change cycle, the adapter data from the magazine location must be copied to the spindle

location.

Example of an adapter transformation

A turning tool with lengths L and Q is described below.

]

LGHQWLW\

[

Figure 8-46

The 8 defined transformations (T = 1...8) for the adapter with G 18 and for a turning tool.

The assignments of tool lengths I1, I2, I3 are shown on the geometry axes x, y, z.

Transformations for numbers 1 to 8 are defined. Number 1 is the identity: no transformation of

input data.

Other transformations can be implemented. The available transformations are designed initially

for turning tools. These are typically defined by Q=I₁=$TC_DP3 and L=I₂=$TC_DP4.

The transformation numbers correspond to the transformations shown in the table. In general:

Length1_t, length2_t, length3_t = f(length1, length2, length3) = f(l₁,l₂,l₃) = f(Q,L,l₃)

Transformation

GEO

number

Turning tool with G18 transformation

+L1

+L3

+L2

+L1

-L3

-L2

ROT X 180

-L1

-L3

+L2

ROT Z 180

-L1

+L3

-L2

ROT X 180 Z 180

+L2

-L3

+L1

ROT Y 90 Z 180

-L2

+L3

+L1

ROT Y -90

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Description of functions

8.14 Tool adapter

+L2

+L3

-L1

ROT Y 90

-L2

-L3

-L1

ROT Y -90 Z 180

L1, L2 and L3 are working offsets of the tool prior to transformation with or without adapter

(depending on machine data settings). They are assigned to the geometry axes during

compensation.

Note

In turning, L and Q are also used to describe a tool. In the above table, l₁corresponds, for

example, to variable Q (or x direction) and l₂ to variable L (or z direction), assuming the plane

G18 is selected (default setting for turning machines).

As standard, activation of an offset is calculated as follows:

Offset = D offset + x_i(e.g. wear, additive offset)

Length1

$TC_DP3 + x_i

Length2

$TC_DP4 + x_i+1

Length3

$TC_DP5 + x_i+2

Length4

$TC_DP6 + x_i+3

The adapter transformation then acts on the transformed tool offset values and is added to the

transformed offset values.

The transformation number of the adapter causes a transformation of the tool (the cutting

edges) located in this adapter (orientation according to the transformation number).

Working offset = f(offset) + adapter dimension of the magazine location

aLength1

Length1_t + $TC_ADPT1

aLength2

Length2_t+ $TC_ADPT2

aLength3

Length3_t + $TC_ADPT3

ARadius1

Radius1

Depending on the programmed plane selection G17, G18, G19, these values are added to the

geometry axes.

G17, G18, G19 - plane selection (declarations)

The following agreements (different for machining and milling tools) apply for assigning tool-

length parameters of the tools to the geometry axes:

Machining plane

System variables for tool length description

$TC_DP3(I₁)

$TC_DP4(I₂)

$TC_DP5(I₃)

G17 Milling

Turning

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8.14 Tool adapter

G18 Milling

Turning

G19 Milling

Turning

Transformation of cutting edge position

The cutting edge position described by system variable $TC_DP2 is also transformed.

Transformations for the cutting edge position are performed as shown in the table below:

Transformation number

Cutting edge position

7&B'3

, RU 4

7&B'3

5DGLXV

7XUQLQJ

0LOOLQJ

Figure 8-47

Turning and milling tools - relationship between cutting edge position and radius

compensation

Turning tool geometries (I₁, I₃ or L, Q) are described in terms of P, the point of approach at the

workpiece. However, the center point of cutting edge S with reference to the tool nose radius

must be known for radius compensation.

This center point can only be accurately calculated if the cutting edge position is known. Point

S can then be derived from point P.

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SINUMERIK 840D sl. Service - Functions. Manual (2018-2020) - page 88