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SINUMERIK 840D sl. Service - Functions. Manual (2018-2020) - page 93

Tool offset

3.5 2D tool radius compensation

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Figure 3-16

Overshoot with DISC depending on contour angle

G451 (intersection)

If the G451 G command is active, the position (intersection) resulting from the path lines

(straight line, circle or helix only) located at a distance of the tool radius to the programmed

contour (center-point path of the tool) is approached. Splines and polynomials are never

extended.

Tools

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Tool offset

3.5 2D tool radius compensation

Very pointed outside corners

Where outside corners are very pointed, G451 can result in excessive idle paths. Therefore, the

system switches automatically from G451 (intersection) to G450 (transition circle, with DISC

where appropriate) when outside corners are very pointed.

The threshold angle (contour angle) for this automatic switchover (intersection point →

transition circle) can be specified in the machine data:

MD20210 $MC_CUTCOM_CORNER_LIMIT (Max. angle for compensation blocks with tool radius

compensation).

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Figure 3-17

Example of automatic switchover to transition circle

Very flat outside corners

Where outside corners are very flat, the response with G450 (transition circle) and G451

(intersection) becomes increasingly similar. In this case, it is no longer advisable to insert a

transition circle. One reason why it is not permitted to insert a transition circle at these outside

corners with 5-axis machining is that this would impose restrictions on speed in contouring

mode (G64). Therefore, the system switches automatically from G450 (transition circle,

with DISC where appropriate) to G451 (intersection) when outside corners are very flat.

The threshold angle (contour angle) for this automatic switchover (transition circle →

intersection point) can be specified in the machine data:

MD20230 $MC_CUTCOM_CURVE_INSERT_LIMIT (Max. angle for intersection calculation with

tool radius compensation).

Tools

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Tool offset

3.5 2D tool radius compensation

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Example of automatic switchover to intersection

3.5.7

Compensation and inner corners

Point of intersection

If two consecutive blocks form an inside corner, an attempt is made to find a point at which the

two equidistant paths intersect. If an intersection is found, the programmed contour is

shortened to the intersection:

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Point of intersection

① First block shortened at end.

② Second block shortened at beginning.

Figure 3-19

Programmed contour is shortened

Tools

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Tool offset

3.5 2D tool radius compensation

No intersection

For inside corners, it is possible that no intersection is found between two consecutive blocks.

In this case, the control automatically checks the next block and attempts to find an intersection

with the equidistant paths of this block:

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Point of intersection

Figure 3-20

Predictive contour calculation

This automatic check of the next blocks, predictive contour calculation, is always performed

until a number of blocks defined via machine data has been reached:

MD20240 $MC_CUTCOM_MAXNUM_CHECK_BLOCKS (blocks for predictive contour calculation

for TRC)

If no intersection is found within the number of blocks defined for the looking ahead, program

execution is interrupted and an alarm is output.

Tools

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Tool offset

3.5 2D tool radius compensation

Multiple intersections

With inside corners it is also possible that predictive contour calculation finds multiple

intersections of the equidistant paths in several consecutive blocks. In this case, the last

intersection is always used as the valid intersection. The previous intersection points are not

approached:

6

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Figure 3-21

In this example, the pocket is machined only as much as is possible without causing a

contour violation.

For further information, see also Chapter "Collision monitoring ("bottleneck detection")

(Page 73)".

Special features

Where multiple intersections with the next block are found, the intersection nearest the start of

the next block applies.

3.5.8

Collision monitoring ("bottleneck detection")

3.5.8.1

Function

If tool radius compensation is active, collision monitoring ("bottleneck detection") checks by

predictive contour calculation across a certain number of blocks whether the equidistant paths

of non-consecutive blocks intersect. This look-ahead function allows possible collisions to be

detected in advance and permits the control to actively avoid them.

The maximum number of blocks that are looked at in advance can be set by channel-specific

machine data (see "Parameterization (Page 74)").

If an intersection is detected, the motions programmed between these blocks on the

compensation plane are not executed. Alarm 10763 "The path component of the block in the

compensation plane will become zero" is displayed. This alarm does not interrupt the NC

program, it is only displayed as a warning. The bottleneck is bypassed. All other motions and

executable instructions (M commands, traversal of positioning axes, etc.) contained in the

omitted blocks are executed at the position of the last intersection found in the sequence in

which they are programmed in the NC program.

Tools

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Tool offset

3.5 2D tool radius compensation

Example:

1

1

1

1

When collision monitoring is active with a predictive contour calculation ≥ 8 blocks, blocks

N3 to N10 are not executed, only alarm 10763 "The path component of the block in the

compensation plane will become zero" is displayed. The control system only runs through blocks

N1, N2 and N11.

Activation / deactivation

The function is activated / deactivated in the NC program with commands of G Group 23.

See "Programming (Page 75)".

3.5.8.2

Parameterization

Maximum number of blocks for predictive contour calculation

The maximum number of blocks to be predictively checked is set in:

MD20240 $MC_CUTCOM_MAXNUM_CHECK_BLOCKS (blocks for predictive contour calculation

for TRC)

Alarm 10763 "The path component of the block in the compensation plane will become zero"

Suppressing an alarm

The display of alarm 10763 "The path component of the block in the correction plane will

become zero" (Page 73) can be suppressed by the following setting:

MD11410 $MN_SUPPRES_ALARM_MASK (mask for support of special alarm outputs), bit 1 = 1

Outputting an alarm and stopping machining

Machining can be stopped by the following setting when alarm 10763 "The path component of

the block in the correction plane will become zero" is output:

Tools

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Tool offset

3.5 2D tool radius compensation

MD11411 $MN_ENABLE_ALARM_MASK (mask for activation of warnings), bit 16 = 1

Stopping the machining has the advantage that the user must actively confirm the skipping of

blocks by NC Start and thus knows that parts of the machining process may not be processed due

to a detected risk of collision.

3.5.8.3

Programming

Collision monitoring ("bottleneck detection") with active tool radius compensation is activated

or deactivated in the NC program with the commands of G group 23.

Syntax

G41/G42 CDON

CDOF/CDOF2

Meaning

CDON:

Activating collision detection ("bottleneck detection")

With CDON it is possible to check over an adjustable (MD20240 (Page 74)) number of

blocks whether the tool paths of non-adjacent or non-sequential blocks intersect. This look-

ahead function allows possible collisions to be detected in advance and permits the control

to actively avoid them.

CDOF:

Deactivating collision detection ("bottleneck detection")

With CDOF, a search is made in the previous traversing block (at inside corners) for a

common intersection for the current block; if necessary the search is extended to even

earlier blocks. If an intersection is found, no further blocks are examined. With outside

corners, an intersection is always found between two consecutive blocks.

Note:

CDOF can be used to avoid the faulty detection of bottlenecks which may occur due to lack

of information in the NC program, for example.

CDOF2:

Deactivating collision detection for 3D circumferential milling

The tool offset direction is determined from adjacent block parts with CDOF2. CDOF2 is only

effective for 3D circumferential milling (CUT3Dx) and has the same meaning as CDOF for all

other types of machining (e.g. CUT2D or CUT3DFD).

3.5.8.4

Supplementary conditions

Program test

To avoid program stops, the tool with the largest radius from the range of used tools should

always be used during the program test.

"Bottleneck detection" due to overhangs at outside corners

When the intersections of non-consecutive blocks are checked, not the programmed original

contours are examined, but the associated calculated equidistant paths. This can result in a

"bottleneck" being falsely detected at outside corners. The reason for this is that the calculated

tool path does not run equidistant to the programmed original contour when DISC > 0.

Tools

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Tool offset

3.5 2D tool radius compensation

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Example

Effect of collision detection using an example

The NC program describes the center point path of a standard tool. The contour for a tool that

is actually used results in undersize, which is shown unrealistically large to demonstrate the

geometric relationships in the following figure.

The control also only has an overview of three blocks in the example:

MD20240 $MC_CUTCOM_MAXNUM_CHECK_BLOCKS = 3

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Since an intersection exists only between the offset curves of the two blocks N10 and N40, the

two blocks N20 and N30 would have to be omitted. In the example, the control does not know

in block N40 if N10 has to be completely processed. Only a single block can therefore be omitted.

With active CDOF2, the compensation motion shown in the figure is executed and not stopped.

In this situation, an active CDOF or CDON would result in an alarm.

Tools

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Tool offset

3.5 2D tool radius compensation

3.5.9

Slot shape recognition (option)

If tool radius correction is active and collision monitoring (Page 73) is switched on, a

programmed slot with a width smaller than the tool diameter is detected as a possible contour

violation and it is omitted from machining. In certain technology-dependent application cases

(e.g. manufacturing deflection lines with a laser cutting machine), however, it is necessary to

machine the slots when the radius of the tool (laser beam) is somewhat larger than the

programmed width of the slot would allow. To give the user this option, the tool radius

correction has been expanded to include the function "slot shape recognition".

Note

The "slot shape recognition" function is an option for SINUMERIK 840D sl that requires a license.

Article number: 6FC5800-0AS18-0YB0

Function

If the "slot shape recognition" function is active, slots that have a predefined shape are

automatically identified and their machining is ensured.

The following are detected:

• I-slot

• T-slot

If the slot width is greater than or equal to the tool diameter, the slot will be traversed as

programmed. If the slot width is smaller than the tool diameter, the equidistant path is

calculated in such a way that the tool traverses along the center of the programmed slot:

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Tool offset

3.5 2D tool radius compensation

Program code

Comment

N13 G03 X0.100 Y-0.100 I0.100

N14 G01 X49.700

N15 G02 X0.200 Y-0.200 J-0.200

; Rounding at the end of the deflec-

tion line contour.

N16 G01 Y-24.500

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If slot shape recognition is inactive (SD42977 $SC_SLOT_FORM_RECOGN = 0), the tool radius

correction will detect and omit the programmed deflection line as an impermissible contour for

the tool used (laser beam) because the slot width is 0.3 mm but the tool has radius 0.2 mm. On

the other hand, if the slot shape recognition is active (SD42977 $SC_SLOT_FORM_RECOGN = 1),

the tool radius correction will detect the programmed deflection line as an I-slot and the laser

beam will cut the deflection line along the center of the programmed slot.

Because, in this example, the slot comprises seven contour elements (4 arcs, 3 straight lines),

the following minimum value must be set in MD28620 $MC_MM_NUM_FEATURE_BLOCK:

MD28620 $MC_MM_NUM_FEATURE_BLOCK ≥ 7

3.5.10

Blocks with variable compensation value

Supplementary conditions

A variable compensation value is permissible for all types of interpolation (including circular and

spine interpolation).

It is also permitted to change the sign (and, therefore, the compensation side).

Tools

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Tool offset

3.5 2D tool radius compensation

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Figure 3-22

Tool radius compensation with variable compensation value

Calculation of intersection

When the intersections in blocks with variable compensation value are calculated, the

intersection of the offset curves (tool paths) is always calculated based on the assumption that

the compensation value is constant.

If the block with the variable compensation value is the first of the two blocks to be examined

in the direction of travel, then the compensation value at the block end is used for the

calculation; the compensation value at the block start is used otherwise.

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Figure 3-23

Intersection calculation with variable compensation value

Restrictions

If during machining on the inside of the circle the compensation radius becomes geater than the

programmed circle radius, then the machining is rejected with the following alarm:

Alarm 10758 "Curvature radius with variable compensation value too small"

Tools

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Tool offset

3.5 2D tool radius compensation

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Figure 3-24

Retraction behavior with G460

The last block with active tool radius compensation (N20) is so short that an intersection no

longer exists between the offset curve and the preceding block (or a previous block) for the

current tool radius. An intersection between the offset curves of the following and preceding

blocks is therefore sought, i.e. between N10 and N30 in this example. The curve used for the

retraction block is not a real offset curve, but a straight line from the offset point at the end of

block N20 to the programmed end point of N30. The intersection is approached if one is found.

The colored area in the figure is not machined, although the tool used would be capable of this.

G460

With G460, the approach/retraction strategy is the same as before.

G461

If no intersection is possible between the last TRC block and a preceding block, the offset curve

of this block is extended with a circle whose center point lies at the end point of the uncorrected

block and whose radius is equal to the tool radius.

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Retraction behavior with G461

Tools

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Tool offset

3.5 2D tool radius compensation

The control attempts to cut this circle with one of the preceding blocks. If CDOF is active, the

search is terminated when an intersection is found, i.e. the system does not check for more

intersections with even earlier blocks.

If CDON is active, the search for more intersections continues after the first intersection is found.

An intersection point, which is found in this way, is the new end point of a preceding block and

the start point of the deactivation block. The inserted circle is used exclusively to calculate the

intersection and does not produce a traversing movement.

Note

If no intersection is found, the following alarm is output:

Alarm "10751 Collision danger"

G462

If no intersection is possible between the last TRC block and a preceding block, a straight line is

inserted, on retraction with G462 (basic setting), at the end point of the last block with tool

radius compensation (the block is extended by its end tangent).

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Retraction behavior with G462

The search for the intersection is then identical to the procedure for G461.

With G462, the corner generated by N10 and N20 in the sample program is not machined to the

full extent actually possible with the tool used. However, this behavior may be necessary if the

part contour (as distinct from the programmed contour), to the left of N20 in the example, is not

permitted to be violated even with y values greater than 10 mm.

If KONT is active (travel round contour at start or end point), behavior will differ according to

whether the end point is in front of or behind the contour.

Tools

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Tool offset

3.6 2 1/2 D tool radius compensation

3.5.14

Tools with a relevant tool point direction

The following must be observed for tools with relevant cutting edge position:

• The straight line between the tool edge center points at the block start and block end is used

to calculate intersection points with the approach and retraction block. The difference

between the tool edge reference point and the tool edge center point is superimposed on this

movement.

For approach and/or retraction with KONT, the movement is superimposed in the linear

subblock of the approach or retraction movement. Therefore, the geometric conditions for

tools with or without relevant cutting edge position are identical.

• In circle blocks and in motion blocks containing rational polynomials with a denominator

degree > 4, it is not permitted to change a tool with active tool radius compensation in cases

where the distance between the tool edge center point and the tool edge reference point

changes. With other types of interpolation, it is now possible to change when a

transformation is active (e.g. TRANSMIT).

• For tool radius compensation with variable tool orientation, the transformation from the tool

edge reference point to the tool edge center point can no longer be performed by means of

a simple zero offset. Tools with a relevant cutting edge position are therefore not permitted

for 3D peripheral milling (an alarm is output).

Note

The subject is irrelevant with respect to face milling as only defined tool types without

relevant cutting edge position are permitted for this operation anyway. (A tool with a type,

which has not been explicitly approved, is treated as a ball end mill with the specified radius.

A cutting edge position parameter is ignored).

3.6

2 1/2 D tool radius compensation

The 2½ D tool radius compensation should be used if, when machining inclined surfaces,

the workpiece is to be rotated, and not the tool alignment. This function is activated using

commands CUT2D, CUT2DD, CUT2DF oder CUT2DFD.

Tool length offset

The tool length compensation is always taken into account referred to the machining plane that

is not rotated and is fixed in space.

2½ D tool radius compensation for contour tools

2½ D tool radius compensation for contour tools is activated, if, together with CUT2D, CUT2DD,

CUT2DF or CUT2DFD, one of the two commands G41 (tool radius compensation left of the

contour) or G42 (tool radius compensation right of the contour) is programmed. It is used for

automatic cutting-edge selection in the case of non-axially symmetrical tools that can be used

for piece-by-piece machining of individual contour segments.

Note

If 2½ D tool radius compensation is not activated, a contour tool behaves like a standard tool,

which only has the first cutting edge.

Tools

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Tool offset

3.6 2 1/2 D tool radius compensation

2½ tool radius compensation referred to a differential tool

2½ D tool radius compensation, referred to a differential tool, is activated using theCUT2DD or

CUT2DFD commands. It should be applied if the programmed contour refers to the center point

path of a differential tool, and a tool other than a differential tool is used for machining. When

calculating the 2½ D tool radius compensation, only the wear of the radius of the active tool

($TC_DP_15) and the possibly programmed tool offsetOFFN and TOFFR are taken into account.

The basic radius ($TC_DP6) of the active tool is not taken into account.

Syntax

CUT2D

CUT2DD

CUT2DF

CUT2DFD

Meaning

CUT2D:

Activating the 2½ D radius compensation

CUT2DD:

Activating the 2½ D radius compensation referred to a differential tool

CUT2DF:

Activating 2½ D radius compensation, tool radius compensation relative to the current

frame and/or inclined plane

CUT2DFD:

Activating 2½ D radius compensation, tool radius compensation relative to the current

frame and/or inclined plane

Further information

Contour tools

• Enabling

Tool radius compensation for contour tools is enabled on a channel-specific basis using:

MD28290 $MC_MM_SHAPED_TOOLS_ENABLE

• Tool type

Contour tool types are defined on a channel-specific basis using:

MD20370 $MC_SHAPED_TOOL_TYPE_NO

• Cutting edge

A number of cutting edges (D numbers) can be assigned to each contour tool in any

sequence. The maximum number of cutting edges per tool is parameterized using:

MD18106 $MN_MM_MAX_CUTTING_EDGE_PERTOOL

The first cutting edge of a contour tool is the cutting edge, which is selected when activating

the tool. If, e.g. in a program, using the commands T3 D5, the fifth cutting edge (D5) of the

third tool (T3) is activated, then D5 and the following cutting edges define with one part, or

altogether, the contour tool. The cutting edges located before D5 are ignored.

2½ D tool radius compensation without rotating the correction plane (CUT2D, CUT2DD)

If a frame that contains a rotation is programmed, then for CUT2D or CUT2DD, the plane in which

the tool radius compensation (correction plane) takes place is not rotated at the same time.

The tool radius compensation is taken into account, referred to the non rotated machining

plane (G17, G18, G19). The tool length compensation acts relative to the correction plane.

Tools

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Tool offset

3.6 2 1/2 D tool radius compensation

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For machining inclined surfaces, the tool offsets must be appropriately defined or calculated

based on the functions for "Tool length compensation for tools that can be orientated".

2½ D tool radius compensation with rotation of the compensation plane (CUT2DF,

CUT2DFD)

If a frame is programmed that contains a rotation, then for CUT2DF or CUT2DFD, the plane in

which the tool radius compensation takes place (correction plane) is also rotated. The tool

radius compensation is taken into account, referred to the rotated machining plane (G17, G18,

G19). However, the tool length compensation still acts relative to the non-rotated machining

plane.

Requirement: At the machine, the tool orientation must be able to be adjusted perpendicular

to the rotated machining plane, and set for machining.

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Tools

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Tool offset

3.7 Keep tool radius compensation constant

block is inserted between the end point of the previous block, i.e. the last programmed

traversing block with active CUTCONON, and this point.

Circular blocks, for which the circle plane is perpendicular to the compensation plane (vertical

circles), are treated as though they had CUTCONON programmed. This implicit activation of

compensation suppression is automatically canceled in the first traversing block that contains a

traversing motion in the compensation plane and is not such a circle. Vertical circle in this sense

can only occur during circumferential milling.

Example:

N10

; Definition of tool d1

N20 $TC_DP1[1,1] = 110

; Type

N30 $TC_DP6[1,1]=

; Radius

N40

N50 X0 Y0 Z0 G1 G17 T1 D1 F10000

N60

N70 X20 G42 NORM

N80 X30

N90 Y20

N100 X10 CUTCONON

; Activation of the compensation suppression

N110 Y30 KONT

; On deactivation of contour suppression,

insert bypass circle, if necessary

N120 X-10 CUTCONOF

N130 Y20 NORM

; No bypass circle when deactivating the TRC

N140 X0 Y0 G40

N150 M30

Tools

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Tool offset

3.7 Keep tool radius compensation constant

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Sample program for contour suppression

Special cases

• If tool radius compensation is not active (G40), CUTCONON has no effect. No alarm is

produced. The G command remains active, however.

This is significant if tool radius compensation is to be activated in a later block with G41 or

G42.

• A change from the G command to the 7th G group (tool radius compensation; G40 / G41 /

G42) with active CUTCONON is permissible. A change to G40 is active immediately.

The offset used for traversing the previous blocks is traveled.

• If CUTCONON or CUTCONOF is programmed in a block without traversing in the active

compensation plane, activation is delayed until the next block that has such a traversing

motion.

• If CUTCONON is programmed with active tool radius compensation and not canceled before

the end of the program, the traversing blocks are traversed with the last valid offset.

The same applies for reprogramming of G41 or G42 in the last traversing block of a program.

• If tool radius compensation is activated with G41 or G42 and CUTCONON is also already

active, activation of compensation is delayed until the next traversing block with CUTCONOF.

• When repositioning with CUTCONOF, the 17th G group (approach and retraction behavior

with tool offset; NORM / KONT) is evaluated, i.e. a bypass circle is inserted if necessary for

KONT. A bypass circle is inserted under the same conditions as for activation of tool radius

compensation with G41 or G42.

• The number of blocks with suppressed tool radius compensation is restricted:

MD20252 $MC_CUTCOM_MAXNUM_SUPPR_BLOCKS (Maximum number of blocks with

compensation suppression)

If it is exceeded, machining is aborted and an error message issued.

The restriction is necessary because the internal block processing in the last block before

CUTCONON must be resumed when repositioning.

Tools

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Tool offset

3.8 Tool carriers with orientation capability

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Cardan tool carrier with two axes

Prerequisites

The following data must be available so that the control can take tool offsets for orientable tool

carriers into account:

• Tool data (geometry, wear, etc.)

• Tool carrier data (data for the geometry of the tool carrier with orientation capability)

Tool carrier selection

The tool carrier is selected by programming the address TCARR in the NC program:

TCARR=<m>

<m>: Number of the tool carrier

The tool carrier has an associated tool carrier data block that describes its geometry.

Selection and activation of the tool carrier and its data block has an immediate effect, i.e. starting

with the next traversing block.

Tools

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Tool offset

3.8 Tool carriers with orientation capability

Storing angles in the tool carrier data

In virtually any case where ambiguities may arise, it is necessary to store the approximate angle

expected from the frame in the tool carrier data.

Parameter sets

A complete parameter set for a tool carrier with orientation capability consists of 33 values,

which are stored in the following system variables:

• $TC_CARR1 to $TC_CARR33

In addition, there are system variables at the free disposal of the user and for fine offsets:

• $TC_CARR34 to $TC_CARR65

The significance of the individual parameters is distinguished as follows.

Machine kinematics

$TC_CARR1 to $TC_CARR20 and $TC_CARR23

$TC_CARR18 to $TC_CARR20 define a further vector l₄, which is needed to describe the machine

with extended kinematics (both tool and workpiece can be rotated).

$TC_CARR21 and $TC_CARR22 contain the channel-axis names of the rotary axes, the positions

of which can be used to determine the orientation of the tool carrier with orientation capability,

if necessary.

Kinematic type

$TC_CARR23 = <kinematic type>

<Kinematic type>

Meaning

T

Only the (Tool) can be rotated (basic value).

P

Only the workpiece (Part) can be rotated.

M

Both tool and workpiece can be rotated (Mixed mode).

Parameterization of the axes of rotation

$TC_CARR24 to $TC_CARR33

The system variables in $TC_CARR24 to $TC_CARR33 can be used to define offsets, angle

compensations, Hirth tooth system and axis limits.

Components and presetting of the chain/data block

The values $TC_CARR1 to $TC_CARR20 and $TC_CARR24 to $TC_CARR33 in the tool carrier data

block are of NC language format type REAL..

The values $TC_CARR21 and $TC_CARR22 for the axis name of the first rotary axis (v₁) and the

second rotary axis (v₂) are of NC language format type AXIS.

They are all preset to zero.

The value $TC_CARR23 is initialized with the uppercase letter "T" (only tool can be rotated).

$TC_CARR[0]= 0 has a special significance.

Tools

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Tool offset

3.8 Tool carriers with orientation capability

System variables for tool carriers with orientation capability

$TC_CARR<n>[<m>]

<n>: Parameters 1 ... 33

<m>: Number of the orientable tool carrier

Value range:

1 ... MD18088 $MN_MM_NUM_TOOL_CARRIER (maximum number of

definable tool carriers)

NC variable

Meaning

Data type

Default setting

$TC_CARR1

x component of offset vector l₁

REAL

0

$TC_CARR2

y component of offset vector l₁

REAL

0

$TC_CARR3

z component of offset vector l₁

REAL

0

$TC_CARR4

x component of offset vector l₂

REAL

0

$TC_CARR5

y component of offset vector l₂

REAL

0

$TC_CARR6

z component of offset vector l₂

REAL

0

$TC_CARR7

x component of rotary axis v₁

REAL

0

$TC_CARR8

y component of rotary axis v₁

REAL

0

$TC_CARR9

z component of rotary axis v₁

REAL

0

$TC_CARR10

x component of rotary axis v₂

REAL

0

$TC_CARR11

y component of rotary axis v₂

REAL

0

$TC_CARR12

z component of rotary axis v₂

REAL

0

$TC_CARR13

Angle of rotation α1 (in degrees)

REAL

0

$TC_CARR14

Angle of rotation α₂ (in degrees)

REAL

0

$TC_CARR15

x component of offset vector l₃

REAL

0

$TC_CARR16

y component of offset vector l₃

REAL

0

$TC_CARR17

z component of offset vector l₃

REAL

0

$TC_CARR18

x component of offset vector l₄

REAL

0

$TC_CARR19

y component of offset vector l₄

REAL

0

$TC_CARR20

z component of offset vector l₄

REAL

0

$TC_CARR21

Tool carrier of the rotary axis v₁

AXIS

0

$TC_CARR22

Axis name of the rotary axis v₂

AXIS

0

$TC_CARR23

Kinematic type

CHAR

T

$TC_CARR24

Offset of rotary axis v₁

REAL

0

$TC_CARR25

Offset of rotary axis v₂

REAL

0

$TC_CARR26

Angle offset of rotary axis v₁ (Hirth tooth)

REAL

0

$TC_CARR27

Angle offset of rotary axis v₂ (Hirth tooth)

REAL

0

$TC_CARR28

Angle increment of rotary axis v₁ (Hirth tooth)

REAL

0

$TC_CARR29

Angle increment of rotary axis v₂ (Hirth tooth)

REAL

0

$TC_CARR30

Minimum position of rotary axis v₁ (SW limit)

REAL

0

$TC_CARR31

Minimum position of rotary axis v₂ (SW limit)

REAL

0

$TC_CARR32

Maximum position of rotary axis v₁ (SW limit)

REAL

0

$TC_CARR33

Maximum position of rotary axis v₂ (SW limit)

REAL

0

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Tool offset

3.8 Tool carriers with orientation capability

System variables for the user and for fine offsets

• $TC_CARR34 to $TC_CARR40

Contain parameters, which are freely available to the user.

• $TC_CARR41 to $TC_CARR65

Contain fine offset parameters that can be added to the values in the basic parameters. The

fine offset value assigned to a basic parameter is obtained when the value 40 is added to the

parameter number.

• $TC_CARR47 to $TC_CARR54 and $TC_CARR61 to $TC_CARR63

Not defined and produce an alarm if read or write access is attempted.

NC variable

Meaning

Data type

Default setting

$TC_CARR34

Tool carrier name

STRING[32]

""

$TC_CARR35 *⁾

Axis name 1

STRING[32]

""

$TC_CARR36 *⁾

Axis name 2

STRING[32]

""

$TC_CARR37 *⁾

Identifier

INT

0

$TC_CARR38 *⁾

Position component X

REAL

0

$TC_CARR39 *⁾

Position component Y

REAL

0

$TC_CARR40 *⁾

Position component Z

REAL

0

$TC_CARR41

x comp. fine offset of offset vector l₁

REAL

0

$TC_CARR42

y comp. fine offset of offset vector l₁

REAL

0

$TC_CARR43

z comp. fine offset of offset vector l₁

REAL

0

$TC_CARR44

x comp. fine offset of offset vector l₂

REAL

0

$TC_CARR45

y comp. fine offset of offset vector l₂

REAL

0

$TC_CARR46

z comp. fine offset of offset vector l₂

REAL

0

$TC_CARR55

x comp. fine offset of offset vector l₃

REAL

0

$TC_CARR56

y comp. fine offset of offset vector l₃

REAL

0

$TC_CARR57

z comp. fine offset of offset vector l₃

REAL

0

$TC_CARR58

x comp. fine offset of offset vector l₄

REAL

0

$TC_CARR59

y comp. fine offset of offset vector l₄

REAL

0

$TC_CARR60

z comp. fine offset of offset vector l₄

REAL

0

$TC_CARR64

Offset of fine offset of rotary axis v₁

REAL

0

$TC_CARR65

Offset of fine offset of rotary axis v₂

REAL

0

*)

The system variables $TC_CARR35 to $TC_CARR40 are used in the measuring cycles as well as ShopMill

and ShopTurn.

3.8.2

Kinematic interaction and machine design

Representation of the kinematic chain

The concept of the kinematic chain is used to describe the kinematic interaction between a

reference point and the tool tip.

Tools

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Tool offset

3.8 Tool carriers with orientation capability

Kinematics data expansions

• Possibility of direct access to existing machine axes in order to define the setting of the tool

carriers via the rotary axis positions.

• Extension of the kinematics with rotary workpiece and on kinematics with rotary tool and

rotary workpiece.

• Possibility to permit only discrete values in a grid for the rotary axis positions (Hirth joints).

The extensions are compatible with earlier software versions and encompass the kinematic data

sets from $TC_CARR18 to $TC_CARR23.

Machine with rotary tool

On machines with rotary tool there is no change in the definition of the kinematics compared to

older software versions. The newly introduced vector l₄, in particular, has no significance. Should

the contents of l₄ not be zero, this is ignored.

The term "Toolholder with orientation capability" is actually no longer really appropriate for the

new kinematic types, with which the table can also be rotated, either alone or additionally to the

tool. However, it has been kept for reasons of compatibility.

The kinematic chains used to describe the machine with rotary tool (general case) are shown in

the figure below:

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Kinematic chain to describe a tool with orientation

Vectors which describe offsets in the rotary head are positive in the direction from the tool tip to

the reference point of the tool carrier.

The following kinematic type is defined for machines with a rotary tool:

Tools

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Tool offset

3.8 Tool carriers with orientation capability

$TC_CARR23 using letter T

Machine with rotary workpiece

On machines with rotary workpiece, the vector l₁ has no significance. If it contains a value other

than zero, this is ignored.

The kinematic chain for machines with rotary workpiece is shown in the figure below.

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Kinematic chain to describe a rotary table

Vectors, which describe offsets in the rotary table, are positive in the direction from the machine

reference point to the table.

The following kinematic type is defined for machines with a rotary workpiece:

$TC_CARR23 using letter P

Note

On machines with rotatable workpiece, it is generally useful if the selected machine reference

point and the reference point of the table are identical. Selecting the reference points in this way

has the advantage that the position of the workpiece zero in the initial state (i.e. with rotary axes

not turned) does not change when the rotary table is activated. The (open) kinematic chain (see

figure) is then closed.

In this special case, therefore, the following formula applies: l₂ = - (l₃ + l₄)

Machines with extended kinematics

On machines with extended kinematics (both tool and workpiece are rotary), it is only possible

to turn each of the components with one axis.

The kinematic of the rotary tool is described with the first axis of rotation (v₁) and the two vectors

l₁ and l₂, that of the rotary table with the second axis of rotation (v₂) and the two vectors l₃ and

l₄. The two kinematic chain components for machines with rotary tool and rotary workpiece are

shown in the figure below.

Tools

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Tool offset

3.8 Tool carriers with orientation capability

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Kinematic sequence with extended kinematics

The following kinematic type is defined for machines with a rotary tool and rotary workpiece:

$TC_CARR23 using letter M (extended kinematics)

Note

On machines with extended kinematics it is generally useful, as with machines where only the

table can be rotated, for the machine reference point and the reference point of the table to be

identical. The (open) chain component to describe the table (see figure) is then closed.

In this special case, the following formula applies: l₃ = - l₄

Rotary tool types T and M

For machine kinematics with a rotary tool (types T and M), the tool carrier component with

orientation capability, which describes the tool or head component (as opposed to the table

component), acts, in conjunction with the active tool, as a new overall tool.

Fine offset

The offset vectors l₁ to l₄ and the offsets of the axes of rotation v₁ and v₂ can be represented as the

sum of a basic value and a fine offset. The fine offset parameters assigned to the basic values are

achieved by adding a value of 40 to the index of the basic value.

Example:

Tools

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Tool offset

3.8 Tool carriers with orientation capability

The parameter $TC_CARR5 is assigned to the fine offset $TC_CARR45.

Note

For the significance of the system variables $TC_CARR41 to $TC_CARR65 available for the fine

offset see:

Further information

Programming Manual Advanced; Tool offsets

Activation

The following setting adds the fine offset values to the basic values:

SD42974 $SC_TOCARR_FINE_CORRECTION = 1 (fine offset TCARR on/off)

Constraints

The amount is limited to the permissible fine offset.

The maximum permissible value is defined:

Components

Machine data

• Components of vectors l₁ to l₄:

MD20188 $MC_TOCARR_FINE_LIM_LIN

• Offsets of the two axes of rotation v₁ and v₂:

MD20190 $MC_TOCARR_FINE_LIM_ROT

An impermissible fine offset value is only detected upon occurrence of the following conditions:

• A tool carrier capable of orientation which has such a value is activated

• The following setting data is applied at the same time:

SD42974 $SC_TOCARR_FINE_CORRECTION

Description of a rotation

A data set for describing a rotation comprises one vector v₁ /v₂ to describe the direction of

rotation of the axis of rotation in its initial state and an angle α1/α2. The angle of rotation is

counted positively for clockwise rotation facing the direction of the rotation vector.

The two tool carrier angles α1 and α2 are determined using a frame, independent of the active

plane currently selected (G17 - G19).

The tool orientation in the initial state (both angles α1 and α2 are zero) is (as in the default case):

• G17: Parallel to Z.

• G18: Parallel to Y.

• G19: Parallel to X.

Assigning data to the tool carrier

Example of a machine with rotary tool carrier

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103

Tool offset

3.8 Tool carriers with orientation capability

The following settings are obtained at the mill head shown for a machine with tool carrier with

orientation capability of kinematic type T:

Component of the offset vector l₁ =

(-200, 0, 0)

Component of the offset vector l₂ =

(0, 0, 0)

Component of the offset vector l₃ =

(-100, 0, 0)

Component of axis of rotation v₁ =

(1, 0, 0)

Component of axis of rotation v₂ =

(-1, 0, 1)

Tool base dimension of tool reference point

(0, 0, 250)

Note

The tool reference point for the tool base dimension is defined by the reference point at the

machine.

For further information regarding the reference points in the working area, see Function Manual

"Basic Functions", Chapter "Axes, coordinate systems, frames".

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Assignment of the tool carrier data

Tools

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Tool offset

3.8 Tool carriers with orientation capability

Suitable assumptions were made for the following values in the data set:

• The two axes of rotation intersect at one point.

All components of l₂ are therefore zero.

• The first axis of rotation lies in the x/z plane, the second rotary axis is parallel to the x axis.

These conditions define the directions of v₁ and v₂ (the lengths are irrelevant, provided that

they are not equal to zero).

• The reference point of the tool carrier lies 200 mm in the negative x direction viewed from

the intersection of the two rotary axes.

This condition defines l₁ .

Specify associated data set values

The following associated data set values are specified for the tool carrier shown on a machine

with rotary tool carrier:

Description

NC variable

Value

x component of offset vector l₁

$TC_CARR1

-200

y component of offset vector l₁

$TC_CARR2

0

z component of offset vector l₁

$TC_CARR3

0

x component of offset vector l₂

$TC_CARR4

0

y component of offset vector l₂

$TC_CARR5

0

z component of offset vector l₂

$TC_CARR6

0

x component of axis of rotation v₁

$TC_CARR7

1

y component of axis of rotation v₁

$TC_CARR8

0

z component of axis of rotation v₁

$TC_CARR9

0

x component of axis of rotation v₂

$TC_CARR10

-1

y component of axis of rotation v₂

$TC_CARR11

0

z component of axis of rotation v₂

$TC_CARR12

1

Angle of rotation α1 (in degrees)

$TC_CARR13

0

Angle of rotation α2 (in degrees)

$TC_CARR14

0

x component of offset vector l₃

$TC_CARR15

-100

y component of offset vector l₃

$TC_CARR16

0

z component of offset vector l₃

$TC_CARR17

0

Explanations

The tool carrier kinematic chosen in the example is such that the two axes of rotation form an

angle of 45 degrees, which means that the orientation cannot take just any value. In concrete

terms, this example does not permit the display of orientations with negative X components.

x component of the tool base dimension:

0

y component of the tool base dimension:

0

z component of the tool base dimension:

250

Tools

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Tool offset

3.8 Tool carriers with orientation capability

Example for a rotatable tool

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Blue:

Kinematic chain of the machine

Figure 3-33

Tool carrier with rotatable tool

Example of a rotatable workpiece

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Kinematic chain of the tool carrier

Blue:

Kinematic chain of the machine

Figure 3-34

Tool carrier with rotatable workpiece

Tools

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107

Tool offset

3.8 Tool carriers with orientation capability

Example of mixed kinematics

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I₁ and I₂

Offset of the tool chain of the tool carrier

v₁

Rotary axis of the tool chain

I₃ and I₄

Offset of the workpiece chain of the tool carrier

v₂

Rotary axis of the tool chain

Figure 3-35

Mixed kinematics

The kinematics of the tool carrier is defined together with the machine kinematics.

Definition of the tool carrier:

• Definition of the characteristics of tool carrier with $TC_CARR_KIN_CNTRL:

- Close tool carrier via kinematic chain, tool chain, and table chain of the tool carrier.

• The starting point of the kinematic chain of the tool carrier is set via system variables

$TC_CARR_KIN_TOOL_START and $TC_CARR_KIN_PART_START (chain element name).

• Definition of the rotary axes of the tool carrier with $TC_CARR21 (Page 92) and $TC_CARR22

• Definition of the tool carrier type with $TC_CARR23 (T, P, or M)

Tools

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3.8 Tool carriers with orientation capability

$TC_CARR_KIN_CNTRL

$TC_CARR_KIN_CNTRL specifies whether the geometry data of a tool carrier are read from

kinematic chain elements or from conventional tool carrier data ($TC_CARRxx). The system

variable is bit-coded.

Syntax

Description

$TC_CARR_KIN_CNTRL[n]

Controls transfer of the geometry data of a machine model defined with kinematic chains to

parameterize a tool carrier. If Bit0 = 1, the data from $TC_CARRxx are ignored but data are taken

from the kinematic chains. It may furthermore be set how the kinematic chain is closed.

Data type: INT

n

Index of the tool carrier; the maximum number of tool carriers can be defined in machine data

MM_NUM_TOOL_CARRIER.

Bit0=1

The tool carrier is parameterized from the kinematic chain elements. The following data of the tool

carrier, including the fine offset, are replaced with geometry data from the kinematic chain ele-

ments:

Conventional tool carrier

Kinematic chain

$TC_CARR1 - TC_CARR3 (offset vector l₁)

X, Y, and Z component of the offset vector I₁

$TC_CARR4 - TC_CARR6 (offset vector l₂)

X, Y, and Z component of the offset vector I₂

$TC_CARR7 - TC_CARR9 (axis of rotation direc-

X, Y, and Z component of the axis of rotation v₁

tion v₁)

$TC_CARR10 - TC_CARR12 (axis of rotation di-

X, Y, and Z component of the axis of rotation v₂

rection v₂)

$TC_CARR15 - TC_CARR17 (offset vector l₃);

X, Y, and Z component of the offset vector I₃

$TC_CARR18 - TC_CARR20 (offset vector l₄)

X, Y, and Z component of the offset vector I₄

$TC_CARR24 - TC_CARR25 (rotary axis offsets)

Bit0=0

The tool carrier parameters are assigned with the data from $TC_CARRxx.

Bit1=1

The content of offset vector I₁ is changed in such a way that the end point of the tool chain coincides

with the zero point of the world coordinate system (chain is closed).

Bit2=1

The content of offset vector I₄ is changed in such a way that the end point of the workpiece chain

coincides with the zero point of the world coordinate system (chain is closed).

$TC_CARR_KIN_TOOL_START and $TC_CARR_KIN_PART_START

System variables $TC_CARR_KIN_TOOL_START and $TC_CARR_KIN_PART_START define the

starting points of the kinematic chains that are used to parameterize the tool or workpiece part

of a tool carrier. If the system variables are empty, the starting point of each kinematic chain is

the root element of the kinematic description.

The option of parameterizing only part of the kinematic chain that does not start with the root

element makes particular sense and indeed is necessary if the tool carrier is to be deployed in its

Tools

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Tool offset

3.8 Tool carriers with orientation capability

original function as a "tool extension" and not for the static modeling of the complete

transformation kinematics of a machine tool.

Syntax

Description

$TC_CARR_KIN_TOOL_START[n] =

Defines the name of the starting elements of the tool or workpiece chain.

<name>

Data type: STRING

$TC_CARR_KIN_PART_START[n] =

<name>

n

Index of the tool carrier; the maximum number of tool carriers can be defined in ma-

chine data MM_NUM_TOOL_CARRIER.

$TC_CARR_KIN_TOOL_END and $TC_CARR_KIN_PART_END

System variables $TC_CARR_KIN_TOOL_END and $TC_CARR_KIN_PART_END define the end

points of the kinematic chains that are used to parameterize the tool or workpiece part of a tool

carrier. At least one of these two names must be not equal to the null string.

Syntax

Description

$TC_CARR_KIN_TOOL_END[n] =

Defines the name of the end elements of the tool or workpiece chain.

<name>

Data type: STRING

$TC_CARR_KIN_PART_END[n] =

<name>

n

Index of the tool carrier; the maximum number of tool carriers can be defined in ma-

chine data MM_NUM_TOOL_CARRIER.

Simulation with tool carriers capable of orientation (kinematic chain)

Note

Setting machine data for simulation and recording

To ensure that simulation and recording is implemented correctly, set the machine data MD

51226 $MNS_FUNCTION_MASK_SIM Bit 22.

Constraints and notes

• If the system data of the tool carrier (TC_CARRxx) are replaced with data from kinematic chain

elements, the content of system variable $TC_CARRxx is not changed.

• Tool carriers and transformations that were defined with kinematic chains can be active at

the same time. It does not matter how the tool carrier is parametrized (directly from the

system data TC_CARR… or from kinematic chains).

• It must be possible to map the kinematic chains that will be used to parameterize a tool carrier

onto a tool carrier configuration. If this condition is not met, alarm 14149 is triggered.

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Tool offset

3.8 Tool carriers with orientation capability

Measuring tool carriers from kinematic chains

When measuring the kinematics of a tool carrier and the subsequent offset, the effective offset

vectors have to be modified. Because such an offset vector can in principle be formed from any

number of partial vectors of the kinematic chain supplying the parameter settings, the chain

element to be corrected is not automatically identifiable.

Syntax

Description

$TC_CARR_CORR_ELEM[n, m] = <string>

Name of the next element in the kinematic chain from which the tool carrier

data are to be read. The element is used as the correction element for the

offset vector with index m.

Data type: STRING

n

Index of the tool carrier; the maximum number of tool carriers can be de-

fined in machine data MM_NUM_TOOL_CARRIER.

m

Index of the correction vector (value range 0...3)

These chain elements can be uniquely identified with system variable

$TC_CARR_CORR_ELEM[m, n]. where m is the index of the tool carrier data set and n is the index

of the correction vector (n = 0...3]).

Read out length and direction of the vectors of TCARR

The currently active offset vectors, rotary axis vectors, and rotary axis offsets can be read out via

system variables $PC_TCARR_OFFSET, $PC_TCARR_AX_VECT, and $PC_TCARR_AX_OFFSET. For

more detailed information about offset vectors, see General information (Page 92).

Syntax

Description

$PC_TCARR_OFFSET[m,n] = <value>

Current value of the n-th vector component of offset I_m of an active tool

carrier. Maximum 4 offset vectors (l1 to l4) are defined for an active tool

carrier. Vector components can be read out with this system variable.

Data type: DOUBLE

m

Offset vector[m] (where m = 1...4) of the active tool carrier.

n

Vector component n (where 0 ≤ n ≤ 2) of the vector that was selected with

field index m.

Syntax

Description

$PC_TCARR_AX_VECT[m,n] = <value>

Current value of the n-th vector component of rotary axis v_m of an active tool

carrier. A maximum of 2 rotation axes (v1 to v2) are defined for an active tool

carrier. Vector components can be read out with this system variable.

Data type: DOUBLE

m

Axis of rotation direction v1, v2, where m = 1...2 of the active tool carrier.

n

Vector component n (where 0 ≤ n ≤ 3) of the vector that was selected with

m.

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3.8 Tool carriers with orientation capability

Syntax

Description

$PC_TCARR_AX_OFFSET[m] = <value>

Current value of the rotational offset of rotation axes 1 and 2. Maximum 2

rotation axes are defined for an active tool carrier. The positions of the rotary

axes in their initial state can be read out with this system variable.

Data type: DOUBLE

m

Rotary offset where m = 1...2 of the active tool carrier.

Tool carrier with more than two rotary axes

For tool carriers that are defined with more than two rotary axes, the third axis is ignored. It

describes a constant angle (knee-point) between the two axes of rotation. Axis v₂ in the example

is not taken into account. Instead, offset I₂ is formed.

The relevant rotary axes are defined with the system variable $TC_CARR_KIN_ROTAX_NAME in

the sequence in which they occur in the chain. Up to two rotary axes may be defined.

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Figure 3-36

Tool carriers with orientation capability with 3 axes of rotation

The rotary axes are not orientation axes, as used for the 5-axis-transformation.

Defining rotation axes (more than two rotary axes)

If a tool carrier comprises more than two rotation axes, this is defined via the relevant axes using

the system variable $TC_CARR_KIN_ROTAX_NAME. The name of the chain element is entered in

the system variable in this regard. The maximum two rotary axes are defined in the sequence in

which they are defined in the kinematic chain. The entries must begin with the index "0".

Syntax

Description

$TC_CARR_KIN_ROTAX_NAME[n, m] =

Name of the element in the kinematic chain which is to be

<String>

defined as the rotary axis.

Data type: STRING

n

Index of the tool carrier; the maximum number of tool carriers

can be defined in machine data MM_NUM_TOOL_CARRIER.

m

Index of rotary axes (value range 0...1)

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Tool offset

3.8 Tool carriers with orientation capability

Example

You will find a part program for a tool carrier via a kinematic chain under: Example: Tool carrier

with orientation capability via kinematic chain (Page 127).

3.8.4

Programming

3.8.4.1

Tool length compensation for orientable toolholders (TCARR, TCOABS, TCOFR,

TCOFRX, TCOFRY, TCOFRZ)

As the spatial orientation of the tool carrier and thus of the tool changes, its tool length

components also change:

=

7

,

;

T

Tool carrier reference point

I₁, I₂

Tool length components

After a reset, e.g. through manual setting or change of the tool carrier with a fixed spatial

orientation, the tool length components also have to be determined again. The commands of G

group 42 "tool carrier" are used for this purpose.

Syntax

TCARR=<m>

TCOABS

TCOFR

TCOFRZ/TCOFRY/TCOFRX

Meaning

Element

Type

Meaning

TCARR=<m>

Address

Request tool carrier

<m>

Number of the tool carrier

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3.8 Tool carriers with orientation capability

Element

Type

Meaning

TCOABS

G com-

Determine tool length components from the orientation of

mand

the current tool carrier

TCOFR

G com-

Determine tool length components from the orientation of

mand

the active frame

TCOFRZ/TCOFRY/

G com-

The TCOFRX/TCOFRY/TCOFRZ command assumes a tool orien-

TCOFRX

mand

ted in the corresponding direction (X/Y/Z) and calculates the

setting angles of the orientable tool carrier so that the tool in

the active frame is oriented in the same direction.

TCOFRZ

The tool oriented in the Z direction is aligned so

that it is also oriented in the Z direction in the

active frame.

TCOFRY

The tool oriented in the Y direction is aligned so

that it is also oriented in the Y direction in the

active frame.

TCOFRX

The tool oriented in the X direction is aligned so

that it is also oriented in the X direction in the

active frame.

Further information

Tool carrier selection (TCARR)

A tool carrier data block is connected to the tool carrier which describes its geometry. If a tool is

active at the time of tool carrier selection, it is assigned to the newly selected tool carrier and the

geometry data of the tool carrier take effect immediately. It is not necessary to change or re-

program the active tool. When a new tool is activated, it is treated as if it was mounted on the

active tool carrier.

With TCARR=0, the active tool carrier is deselected.

Note

The current geometry data of the tool carrier can also be defined in the NC program via the

corresponding system variables (see "Access to tool carrier data blocks").

Note

From the point of view of the control, tool carrier numbers <m> and tool numbers <n> can be

freely combined. In the real application, however, certain combinations can be ruled out for

machining or mechanical reasons. The control does not check whether the combinations make

sense.

Access to tool carrier data blocks

The current geometry data of a tool carrier can be accessed from the NC program as follows:

• Write:

$TC_CARR<n>[<m>]=<Value>

• Read:

<Value>=$TC_CARR<n>[<m>]

(<Value> must be a variable of data type REAL)

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Tool offset

3.8 Tool carriers with orientation capability

Frame change

The user can change the frame after selecting the tool. This does not have any effect on the tool

length compensation components.

The rotation angles stored in the tool carrier data are not affected by the rotation angles defined

with frames. When changing from TCOFR to TCOABS, the original (programmed) angles of

rotation in the tool carrier data is reactivated.

Recalculation of the tool length compensation

To recalculate the tool length compensation after a frame change, the tool must be selected

again. When the tool length compensation is calculated, the angle of rotation of the tool carrier

is calculated in an intermediate step. Since tool carriers with two axes of rotation generally have

two rotation angle pairs with which the tool orientation can be adapted to the active frame, the

rotation angle values stored in the tool carrier data must at least approximately correspond to

the mechanically set rotation angles.

Note

In virtually any case where ambiguities may arise, it is necessary to store the approximate angle

expected from the frame in the tool carrier data.

Note

The tool orientation must be manually adapted to the active frame.

Note

The control system cannot check the angles of rotation calculated via the frame orientation for

adjustability on the machine. If the machine is designed in such a way that the axes of rotation

of the tool carrier cannot reach the tool orientation calculated by the frame orientation, an alarm

is output.

Note

The combination of tool precision compensation and the functions for tool length offset on

movable tool carriers is not permissible. If both functions are called simultaneously, an error

message is issued.

Note

With TOFRAME it is possible to define a frame based on the orientation direction of the selected

tool carrier.

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Tool offset

3.8 Tool carriers with orientation capability

Note

When orientation transformation is active (3, 4 or 5-axis transformation), it is possible to select

a tool carrier with an orientation deviating from the zero position without causing output of an

alarm.

Note

With an active frame without rotation, orientation with TCOFRX/TCOFRY/TCOFRZ leads to a trivial

solution, since the tool orientation already points in the X/Y/Z direction.

Orientation in the Z direction (TOFRAME)

With the TOFRAME command of the G group 53 (tool-related frame rotation), it is possible to

define a frame whose Z direction is aligned in parallel to the orientation direction of the selected

tool carrier.

If no tool carrier or a tool carrier without orientation change is active, then the Z direction in the

new frame is as follows:

• The same as the old Z direction with G17.

• The same as the old Y direction with G18.

• The same as the old X direction with G19.

Transfer parameter from standard and measuring cycles

For the transfer parameter of standard and measuring cycles, the following defined value ranges

apply.

For angle values, the following value ranges are defined:

Rotation around ...

Value range

1st geometry axis

-180° ≤ angle ≤ +180°

2nd geometry axis

-90° ≤ angle ≤ +90°

3rd geometry axis

-180° ≤ angle ≤ +180°

Note

When transferring angular values to a standard or measuring cycle, the following should be

carefully observed:

Values smaller than the computational accuracy of the NC must be rounded to zero!

The calculation resolution of the NC for angular positions is defined in the machine data:

MD10210 $MN_INT_INCR_PER_DEG

3.8.4.2

Modifying the orientable tool carrier according to the machine measurement

(CORRTC)

Measured kinematic chain elements of a tool carrier can be written to special correction

elements with the CORRTC function.

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3.8 Tool carriers with orientation capability

Note

The correction values written with the CORRTC function are not immediately effective in the tool

carrier. The correction values only become active after deselecting the tool carrier, NEWCONF

and selecting the tool carrier.

Syntax

<_Corr_Status> = CORRTC(<_Corr_Vect>, <_Corr_Index>, <_Corr_Mode>,

[ <_No_Alarm>])

Meaning

CORRTC:

Function call

<_Corr_Status>:

Function return value

Data type:

INT

Values:

0

The function was executed without an error.

1

No tool carrier is active.

2

The active tool carrier was not defined with kinematic chains.

10

The <_Corr_Index> call parameter is negative.

11

The <_Corr_Mode> call parameter is negative.

12

Invalid reference to a section of a subchain (_CORR_INDEX).

13

No correction element has been defined in the section referred to by the

_CORR_INDEX parameter ($TC_CARR_CORR_ELEM).

20

The hundreds position of <_CORR_MODE> is invalid. Only the values 0 and 1

are permissible.

21

The thousands position of <_CORR_MODE> is invalid. Only the values 0 and

1 are permissible.

30

For the correction of an offset vector, the deviation from the current value in

at least one coordinate is greater than the maximum value specified by the

setting data SD41612 $SN_CORR_TRAFO_LIN_MAX.

31

The attempt to write a system variable was rejected because of missing write

rights.

<_Corr_Vect>:

Correction vector

The content of the correction vector is defined by the following parameters <_Corr_Index>

and <_Corr_Mode>.

If <_Corr_Status> = 30, the content of the vector is overwritten (see above).

Data type:

REAL

<_Corr_Index>:

Designates the section for which the direction vector of the correction element is to be corrected.

Data type:

INT

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Tool offset

3.8 Tool carriers with orientation capability

<_Corr_Mode>:

Correction mode

Data type:

INT

The <Corr_Index> parameter is decimal coded (unit to thousands position):

Unit

Reserved

position:

Tens

Specifies how the correction element to which the content of <_Corr_Index>

position:

refers, is to be modified.

xx0x

The correction vector is written immediately to the correction element.

This variant can be used to immediately write the correction element

without the index <n> of the relevant system data

($NK_OFF_DIR[<n>, ...]) having to be known.

xx1x

As 0, but with the difference that the transferred correction value is in-

terpreted in world coordinates.

A difference between variants 0 and 1 can always occur when the kine-

matic chain in the initial state (positions of all rotary axes equal to 0)

contains other rotations.

xx2x

As 1, but with the difference that the correction value refers to the entire

section, i.e. a value is entered in the correction element so that the entire

section reaches the length defined by the correction value.

Hundreds

Specifies how the content of the <_Corr_Vect> parameter is to be interpreted.

position:

x0xx

The transferred correction vector <_Corr_Vect> contains the entire

new length of the correction element or the section to which

the <_Corr_Index> in conjunction with the tens position

of <_Corr_Mode> refers (absolute correction).

x1xx

The transferred correction vector <_Corr_Vect> only contains the dif-

ference compared to the current length of the correction element or the

section to which the <_Corr_Index> in conjunction with the tens po-

sition of <_Corr_Mode> refers (incremental correction).

Thousands

Determines whether or not the maximum permissible correction is to be limited by

position:

the setting data $SN_ CORR_TOCARR_LIN_MAX.

0xxx

Threshold value monitoring is active.

1xxx

The threshold value monitoring is suppressed.

<_No_Alarm>:

Response in the event of an error (return value > 0) (optional)

Data type:

BOOL

Value:

FALSE (de-

In the event of an error, the program execution is stopped and an

fault)

alarm displayed.

TRUE

In the event of an error, the program processing is not stopped and no

alarm is displayed.

Application: User-specific response corresponding to the return value

Further information about CORRTC

The kinematic structure of a tool carrier is described by one (type T and type P) or two (type M)

kinematic chains (subchains), which start from the associated reference point, machine zero or

tool carrier reference point). One of the two chains, the tool chain, ends at the reference point

of the tool, the other chain, the workpiece chain ends in the zero point of the basic coordinate

system.

Tools

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3.8 Tool carriers with orientation capability

The CORRTC function writes axis directions for machines with tool carriers in special correction

elements. A kinematic chain is described, for example, with elements of the type OFFSET, which

are defined via $ NK_TYPE.

CORRTC works with sections

The two subchains can each be divided into a maximum of four sections:

• Section 1 begins at the starting point of the chain and ends at the first rotary axis.

• Section 2 is the section between rotary axis 1 and rotary axis 2.

• Section 3 is the section between rotary axis 2 and the end of the chain.

The following figure shows an orientable tool carrier with 2 rotary axes.

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CORRTC example

The sections are clearly defined: If the kinematic subchain is executed from its starting point to

its end point, then the first section has the index 1, next has index 2, and so on.

Correction elements

A reference can be made to a constant kinematic chain element (chain element of the type

$NK_TYPE[<n>] = "OFFSET") in each of these sections with the $TC_CARR_CORR_ELEM [, 0 ... 3]

system variables. The correction values determined during the machine measurement are

written to the so designated elements with the CORRTC function.

The sequence of references in $TC_CARR_CORR_ELEM[m, 0 ... 3] must correspond to the

sections described above, that is there can only be one chain element in

$TC_CARR_CORR_ELEM[m, 0] which belongs to the offset vector l1, etc.

The reference value is always the corresponding value effective in the tool carrier active when

CORRTC is called. After selection of the tool carrier, changed contents of the stored kinematic

data have no effect on the method of operation of the CORRTC function.

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Tool offset

3.8 Tool carriers with orientation capability

In N360, solid angles are used to define a plane whose intersecting lines in the XZ and in the YZ

plane each form an angle of +45 degrees or -45 degrees with the X or Y axis. The plane defined

in such a way therefore has the following position: The surface normal points towards the solid

diagonals.

N370 traverses to the position X20 Y0 Z0 in the new coordinate system. Since the tool is

deselected with D0 at the same time, there is no longer an additional offset in Z. Since the new

X axis lies in the old X-Z plane, this block reaches the machine position X14.142 Y0 Z-14.142.

N380 only traverses on the Y axis in the rotated coordinate system. This leads to a motion of all

three machine axes. The machine position is X5.977 Y16.330 Z-22.307.

N390 approaches a point on the new Z axis. Relative to the machine axes this is thus on the solid

diagonal. All three axes thus reach the position 11.547.

3.8.5.3

Calculation of compensation values on a location-specific and workpiece-specific

basis

Tool with adapter

A tool with adapter and tool carrier with orientation capability is defined in the following

program example. To simplify the overview, only length L1 is different from zero for the additive

and insert offsets and for the adapter in case of the tool itself. The offset vectors of the tool carrier

with orientation capability are all zero.

Program code

Comment

N10 $TC_TP2[1]="MillingTool"

; Name of identifier

N20 $TC_TP7[1]=9

; Location type

N30 $TC_TP8[1]=2

; Status: Enabled and not

blocked

; D corr. D=1

N40 $TC_DP1[1,1]=120

; Tool type - milling

N50 $TC_DP3[1,1]=

; Length offset vector

N60 $TC_DP12[1,1]=

; Wear

N70 $TC_SCP13[1,1]=0.1

; Sum offset DL=1

N80 $TC_ECP13[1,1]=0.01

; Insert offset DL=1

N90 $TC_ADPTT[1]=5

; Adapter transformation

N100 $TC_ADPT1[1]=0.001

; Adapter dimension

; Magazine data

N110 $TC_MAP1[1]=3

; Magazine type: Turret

N120 $TC_MAP2[1]="Turret"

; Name of a magazine

N130 $TC_MAP3[1]=17

; Status of magazine

N140 $TC_MAP6[1]=1

; Dimension - line

N150 $TC_MAP7[1]=2

; Dimension - column -> 2

positions

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Tool offset

3.8 Tool carriers with orientation capability

Program code

Comment

N160 $TC_MPP1[1,1]=1

; Location type

N170 $TC_MPP2[1,1]=9

; Location type

N180 $TC_MPP4[1,1]=2

; Location status

N190 $TC_MPP7[1,1]=1

; Bring adapter into position

N200 $TC_MPP6[1,1]=1

; T number "MillingTool"

N210 $TC_MAP1[9999]= 7

; Magazine type: Buffer

N220 $TC_MAP2[9999]="Buffer"

; Name of a magazine

N230 $TC_MAP3[9999]=17

; Status of magazine

N240 $TC_MAP6[9999]=1

; Dimension - line

N250 $TC_MAP7[9999]=1

; Dimension - column -> 1

position

N260 $TC_MPP1[9999,1]=2

; Location type

N270 $TC_MPP2[9999,1]=9

; Location type

N280 $TC_MPP4[9999,1]=2

; Location status

N290 $TC_MPP5[9999,1]=1

; Spindle no. 1

N300 $TC_MDP2[1,1]=0

; Distance from spindle to mag.

1

; Definition of tool carrier 1

N310 $TC_CARR10[1]=1

; Component 2. Axis of rotation

in the X direction

N320 $TC_CARR14[1]=45

; Angle of rotation of 2nd axis

N330 $TC_CARR23[1]="T"

; Tool mode

N340 Stopre

N350 $SC_WEAR_TRANSFORM='B101'

N360 T0 D0 DL=0

N370 ROT X30

N380 G90 G1 G17 F10000 X0 Y0 Z0

N390 T="MillingTool" X0 Y0 Z0 TOWSTD

; X 0.000 Y11.110 Z 0.001

N400 T="MillingTool" X0 Y0 Z0 TOWMCS

; X 0.000 Y10.100 Z 1.011

N410 T="MillingTool" X0 Y0 Z0 TOWWCS

; X 0.000 Y 9.595 Z 0.876

N420 TCARR=1 X0 Y0 Z0

; X 0.000 Y 6.636 Z 8.017

N430 G18 X0 Y0 Z0

; X10.100 Y-0.504 Z 0.876

N440 M30

Explanations regarding the example above

Starting at block N390, various methods are used to approach position X0 Y0 Z0. The machine

positions reached are specified in the blocks in comments. After the program a description is

given of how the positions were reached.

N390: The adapter transformation 5 (block N90) transforms length L1 into length L2. Only the

actual adapter dimension is not subject to this transformation. The Y value (L2 with G17) results

from the sum of the tool length (10), tool wear (1), sum offset (0.1), and insert offset (0.01). The

adapter dimension (0.001) is in Z (L1).

Tools

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Tool offset

3.8 Tool carriers with orientation capability

TCOFR/TCOABS frame rotation

A frame rotation does not take place on activation and a rotation which is already active is not

changed. As in case T (only the tool can be rotated), the position of the rotary axes used for the

calculation is dependent on the G command TCOFR/TCOABS and determined from the rotation

component of an active frame or from the entries $TC_CARRn.

Activation of a frame changes the position in the workpiece coordinate system accordingly,

without compensating motion by the machine itself. The ratios are shown in the figure below:

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Figure 3-38

Work offset on activation of a rotary table with TCARR

Example

On the machine in the figure, the axis of rotation of the table is pointing in the positive Y

direction. The table is rotated by +45 degrees. PAROT defines a frame, which similarly describes

a rotation of 45 degrees about the Y axis. The coordinate system is not rotated relative to the

actual environment (marked in the figure with "Position of the coordinate system after TCARR"),

but is rotated by -45 degrees relative to the defined coordinate system (position after PAROT).

If this coordinate system is defined with ROT Y-45, for example, and if the tool carrier is then

selected with active TCOFR, an angle of +45 degrees will be determined for the axis of rotation

of the tool carrier.

Rotary table

With rotary tables (kinematic types P and M), activation with TCARR similarly does not lead to

an immediate rotation of the coordinate system (see figure), i.e. even though the zero point of

the coordinate system is offset relative to the machine, while remaining fixed relative to the zero

point of the workpiece, the orientation remains unchanged in space.

Activation of kinematic types P and M

With kinematics of type P and M the selection of a tool carrier activates an additive frame (table

offset of the tool carrier with orientation capability), which takes into account the zero point

offset as a result of the rotation of the table.

The work offset can be written to a dedicated system frame $P_PARTFR. For this, the bit 2 must

be set in the machine data:

MD28082 $MC_MM_SYSTEM_FRAME_MASK (system frames (SRAM))

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Tool offset

3.8 Tool carriers with orientation capability

3.8.8

Procedure when using toolholders with orientation capability

Creating a tool carrier

Setting the number of available tool carrier data sets

The number of available tool carrier data sets in the control system is defined with machine data:

MD18088 $MN_MM_NUM_TOOL_CARRIER (maximum number of definable tool carriers)

The number must be set according to the following rule:

MD18088 $MN_NUM_TOOL_CARRIER =

<highest number of tool carriers required in one channel> *

<number of parameterized channels>

The number of tool carriers parameterized in the machine data is then distributed equally across

the parameterized channels and TO units.

<available number of tool carriers per channel or TO unit> =

MD18088 $MN_NUM_TOOL_CARRIER /

<number of parameterized channels>

Note

For further explanations on definition and assignment of a TO unit to a channel with machine

data MD28085 by machine data $MC_MM_LINK_TOA_UNIT, see:

Further information

Function Manual Basic Functions; Memory configurations

Zero setting of tool carrier data:

You can use the command $TC_CARR1[0] = 0 to zero all values of all data sets.

Individual tool carrier data sets can be deleted selectively with the NC command DELTC or the

PI service _N_DELTCAR.

Accessing the data of a tool carrier:

• Part program

- Write: $TC_CARR<n>[<m>] = <value>

Value <value> is written to parameter <n> of tool carrier <m> .

- Read: <value> = $TC_CARR<n>[<m>]

Parameter <n> of tool carrier <m> is read. If the referenced tool carrier is not defined, an

alarm is displayed.

• OPI interface

The parameters of a tool carrier with orientation capability can be read and written with the

system variables $P_TCANG[<n>].

Data backup

The system variables specified above are saved as part of the general NC data backup.

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