Siemens SINUMERIK 810D Programming Manual

SINUMERIK SINUMERIK 840D sl/840D/840Di sl/840Di/810D Measuring cycles

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Preface

General 1

Parameter description 2

Measuring cycle help

programs 3

Measuring in JOG 4

Measuring Cycles for Milling

and Machining Centers 5

Measuring Cycles for

Turning Machines 6

Miscellaneous functions 7

Hardware/software 8

Data description 9

Start-up (hardware) 10

Alarm, error, and system

messages 11

Adaptation of the Measuring

Cycles to Previous Software

Versions

12

Appendix A

List of abbreviations B

Parameter C

SINUMERIK

840D sl/840D/840Di sl/840Di/810D

Measuring cycles

Programming Manual

Release 04/2006

6FC5398-4BP10-0BA0

Valid for

Control

SINUMERIK 840D sl/840DE sl

SINUMERIK 840Di sl/840DiE sl

SINUMERIK 840D powerline/840DE powerline

SINUMERIK 840Di powerline/840DiE powerline

SINUMERIK 810D powerline/810DE powerline

Software Version

NCU system software for 840D sl/840DE sl 1.3

Measuring cycles for 840D/840DE 7.4

Measuring cycles for 840Di/840DiE 3.3

Measurin

g

c

y

cles for 810D/810DE 7.4

Safety Guidelines

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent

damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert

symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are

graded according to the degree of danger.

Danger

indicates that death or severe personal injury will result if proper precautions are not taken.

Warning

indicates that death or severe personal injury may result if proper precautions are not taken.

Caution

with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.

Caution

without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

Notice

indicates that an unintended result or situation can occur if the corresponding information is not taken into

account.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will

be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to

property damage.

Qualified Personnel

The device/system may only be set up and used in conjunction with this documentation. Commissioning and

operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes

in this documentation qualified persons are defined as persons who are authorized to commission, ground and

label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage

Note the following:

Warning

This device may only be used for the applications described in the catalog or the technical description and only in

connection with devices or components from other manufacturers which have been approved or recommended by

Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly

as well as careful operation and maintenance.

Trademarks

All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this

publication may be trademarks whose use by third parties for their own purposes could violate the rights of the

owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software

described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the

information in this publication is reviewed regularly and any necessary corrections are included in subsequent

editions.

Siemens AG

Automation and Drives

Postfach 48 48

90437 NÜRNBERG

GERMANY

Order No.: 6FC5398-4BP10-0BA0

Edition 05/2006

Technical data subject to change

Measuring cycles

Programming Manual, Release 04/2006, 6FC5398-4BP10-0BA0 iii

Preface

Structure of the documentation

The SINUMERIK documentation is organized in 3 parts:

• General Documentation

• User documentation

• Manufacturer/service documentation

A list of documents, updated on a monthly basis and indicating the available languages, is

available on the Internet at:

http://www.siemens.com/motioncontrol

Select "Support" → "Technical Documentation" → "Overview of Documents".

The Internet version of the DOConCD (DOConWEB) is available at:

http://automation.siemens.com/doconweb

Information on the range of training courses and FAQs (frequently asked questions) are

available in the Internet under:

http://www.siemens.com/motioncontrol and there under the menu item "Support"

Target group

This Manual is intended for machine-tool programmers.

Benefits

With the user manual, the target group can develop, write, test, and debug programs.

Standard scope

The functionality of the standard scope (measuring cycle release SW 6.3) is described in this

programming manual. The machinery construction OEM documents supplements or

changes that he makes (the machinery construction OEM).

Other functions not described in this documentation might be executable in the control.

However, no claim can be made regarding the availability of these functions when the

equipment is first supplied or in the event of servicing.

For the sake of simplicity, this documentation does not contain all detailed information about

all types of the product and cannot cover every conceivable case of installation, operation, or

maintenance.

Preface

Measuring cycles

iv Programming Manual, Release 04/2006, 6FC5398-4BP10-0BA0

Technical Support

If you have any questions, please contact our Hotline:

Europe and Africa time zone

A&D Technical Support

Tel.: +49 (0) 180 / 5050 - 222

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Internet:

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A&D Technical Support

Tel.: +86 1064 719 990

Fax: +86 1064 747 474

Internet:

Email: mailto:[email protected]

America time zone

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Tel.: +1 423 262 2522

Fax: +1 423 262 2289

Internet:

Email: mailto:[email protected]

Note

Country telephone numbers for technical support are provided under the following Internet

address:

http://www.siemens.com/automation/service&support

Questions on the manual

If you have any queries (suggestions, corrections) in relation to this documentation, please

fax or e-mail us:

Fax: +49 (0) 9131 / 98 - 63315

Email: mailto:motioncontrol.docu@siemens.com

Fax form: See the reply form at the end of this publication

SINUMERIK Internet address

http://www.siemens.com/sinumerik

Preface

Measuring cycles

Programming Manual, Release 04/2006, 6FC5398-4BP10-0BA0 v

Validity

This User's Guide is valid for the following controls:

Measuring cycles, version 6.3.

Software versions stated in the programming manual refer to the 840D and their 810D

equivalent, e.g. SW 5 (840D) corresponds to SW 3 (810D).

Structure of descriptions

All cycles and programming options have been described according to the same internal

structure, as far as this is meaningful and practicable. The various levels of information have

been organized such that you can selectively access the information you need for the task in

hand.

Supplementary devices

The applications of SIEMENS controls can be expanded for specific purposes through the

addition of special add-on devices, equipment and expansions supplied by SIEMENS.

Preface

Measuring cycles

vi Programming Manual, Release 04/2006, 6FC5398-4BP10-0BA0

Measuring cycles

Programming Manual, Release 04/2006, 6FC5398-4BP10-0BA0 vii

Table of contents

Preface ......................................................................................................................................................iii

1 General................................................................................................................................................... 1-1

1.1 Basics......................................................................................................................................... 1-1

1.2 General prerequisites................................................................................................................. 1-2

1.3 Behavior on block search, dry run, program testing, simulation................................................ 1-3

1.4 Reference points on the machine and workpiece...................................................................... 1-5

1.5 Definition of the planes, tool types............................................................................................. 1-7

1.6 Probes that can be used .......................................................................................................... 1-11

1.7 Probe, calibration body, calibration tool................................................................................... 1-13

1.7.1 Measuring workpieces on milling machines, machining centers............................................. 1-13

1.7.2 Measuring tools on milling machines, machining centers ....................................................... 1-14

1.7.3 Measuring workpieces at the turning machines....................................................................... 1-15

1.7.4 Measuring tools at lathes ......................................................................................................... 1-18

1.8 Measurement principle............................................................................................................. 1-20

1.9 Measuring strategy for measuring workpieces with tool offset................................................ 1-24

1.10 Parameters for checking the measurement result and offset.................................................. 1-27

1.11 Effect of empirical value, mean value, and tolerance parameters........................................... 1-32

1.12 Overview of measuring cycle functions for milling technology ................................................ 1-33

1.12.1 Tool measurement on milling machines, machining centers................................................... 1-33

1.12.2 Calibrating workpiece probes................................................................................................... 1-34

1.12.3 Workpiece measurement at one point ..................................................................................... 1-34

1.12.4 Measuring the workpiece parallel to the axis........................................................................... 1-35

1.12.5 Measuring a workpiece at an angle ......................................................................................... 1-38

1.12.6 Measuring a surface at an angle.............................................................................................. 1-39

1.12.7 Measuring spheres .................................................................................................................. 1-40

1.12.8 Workpiece measurement: Setting-up a corner ........................................................................ 1-41

1.13 Overview of measuring cycle functions for turning technology................................................ 1-42

1.13.1 Measuring tools at lathes ......................................................................................................... 1-42

1.13.2 Calibrating workpiece probes................................................................................................... 1-43

1.13.3 Measuring workpieces at lathes: 1-point measurement .......................................................... 1-44

1.13.4 Measuring workpieces at lathes: 2-point measurement .......................................................... 1-45

2 Parameter description............................................................................................................................. 2-1

2.1 Parameter concept of the measuring cycles.............................................................................. 2-1

2.2 Parameter overview ................................................................................................................... 2-2

2.2.1 Defining parameters................................................................................................................... 2-2

2.2.2 Result parameters...................................................................................................................... 2-4

2.3 Description of the most important defining parameters ............................................................. 2-5

2.3.1 Measurement variant: _MVAR................................................................................................... 2-5

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2.3.2 Number of the measuring axis: _MA.......................................................................................... 2-5

2.3.3 Tool number and tool name: _TNUM and _TNAME .................................................................. 2-6

2.3.4 Offset number: _KNUM .............................................................................................................. 2-7

2.3.5 Offset number _KNUM extended for tool offset: up to 9 digits................................................. 2-10

2.3.6 Correcting setup and additive offset in workpiece measurement: _DLNUM ........................... 2-11

2.3.7 Correcting the tool of a stored tool environment: _TENV ........................................................ 2-12

2.3.8 Example of automatic tool offset with and without saved tool environment in workpiece

measuring cycles ..................................................................................................................... 2-12

2.3.9 Variable measuring velocity: _VMS ......................................................................................... 2-14

2.3.10 Offset angle position: _CORA .................................................................................................. 2-14

2.3.11 Tolerance parameters: _TZL, _TMV, _TUL, _TLL, _TDIF and _TSA....................................... 2-15

2.3.12 Measurement path: _FA........................................................................................................... 2-16

2.3.13 Probe type, probe number: _PRNUM ...................................................................................... 2-17

2.3.14 Empirical value, mean value: _EVNUM ................................................................................... 2-18

2.3.15 Multiple measurement at the same location: _NMSP .............................................................. 2-19

2.3.16 Weighting factor for mean value calculation: _K...................................................................... 2-19

3 Measuring cycle help programs .............................................................................................................. 3-1

3.1 Measuring cycle subroutines...................................................................................................... 3-1

3.1.1 Overview .................................................................................................................................... 3-1

3.1.2 CYCLE116: Calculation of center point and radius of a circle................................................... 3-2

3.2 Measuring cycle user programs................................................................................................. 3-4

3.2.1 General information.................................................................................................................... 3-4

3.2.2 CYCLE198: User program before undertaking measurement................................................... 3-4

3.2.3 CYCLE199: User program after undertaking measurement...................................................... 3-4

3.3 Package structure of the measuring cycles ............................................................................... 3-5

4 Measuring in JOG................................................................................................................................... 4-1

4.1 Overview .................................................................................................................................... 4-1

4.2 Workpiece measurement ........................................................................................................... 4-5

4.2.1 Overview .................................................................................................................................... 4-5

4.2.1.1 General information.................................................................................................................... 4-5

4.2.1.2 Operational sequence................................................................................................................ 4-5

4.2.1.3 "Function interface of the measuring point softkeys (P1...P4)", in the PLC............................... 4-7

4.2.1.4 Measuring in JOG with active TRAORI...................................................................................... 4-8

4.2.2 Calibrating the workpiece probe ................................................................................................ 4-9

4.2.2.1 General information.................................................................................................................... 4-9

4.2.2.2 Calibrating probe length........................................................................................................... 4-10

4.2.2.3 Calibrating probe radius........................................................................................................... 4-11

4.2.3 Measure edge .......................................................................................................................... 4-12

4.2.3.1 General information.................................................................................................................. 4-12

4.2.3.2 Setting the edge ....................................................................................................................... 4-14

4.2.3.3 Orienting the edge.................................................................................................................... 4-15

4.2.3.4 Distance 2 edges ..................................................................................................................... 4-17

4.2.4 Measuring corner ..................................................................................................................... 4-19

4.2.4.1 General information.................................................................................................................. 4-19

4.2.4.2 Right-angled corner.................................................................................................................. 4-20

4.2.4.3 Any corner................................................................................................................................ 4-22

4.2.5 Measuring pocket, hole or spigot ............................................................................................. 4-23

4.2.5.1 General information.................................................................................................................. 4-23

4.2.5.2 Rectangular pocket or 1 hole or 1 spigot ................................................................................. 4-24

4.2.5.3 2 holes or 2 circular spigots ..................................................................................................... 4-27

4.2.5.4 3 holes or 3 circular spigots ..................................................................................................... 4-29

4.2.5.5 4 holes or 4 circular spigots ..................................................................................................... 4-31

4.2.6 Align plane ............................................................................................................................... 4-33

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4.2.6.1 General information ................................................................................................................. 4-33

4.2.6.2 Measuring a plane that is oblique in space.............................................................................. 4-34

4.2.7 Rejection, repetition, end of measurement.............................................................................. 4-35

4.2.7.1 Rejection and repetition of measurements .............................................................................. 4-35

4.2.7.2 Terminating the measurement................................................................................................. 4-35

4.2.8 Cascaded measurement.......................................................................................................... 4-37

4.2.9 Support of set-up in JOG - after measurement........................................................................ 4-38

4.2.9.1 General information ................................................................................................................. 4-38

4.2.9.2 Example 1 ................................................................................................................................ 4-39

4.2.9.3 Example 2 ................................................................................................................................ 4-40

4.3 Measuring the tool ................................................................................................................... 4-42

4.3.1 Overview of function and sequence......................................................................................... 4-42

4.3.2 Calibrating the tool probe......................................................................................................... 4-42

4.3.3 Measuring milling or drilling tools............................................................................................. 4-44

5 Measuring Cycles for Milling and Machining Centers ............................................................................. 5-1

5.1 General prerequisites................................................................................................................. 5-1

5.1.1 General information ................................................................................................................... 5-1

5.1.2 Overview of measuring cycles ................................................................................................... 5-1

5.1.3 Overview of the auxiliary programs required ............................................................................. 5-2

5.1.4 Call and return conditions .......................................................................................................... 5-2

5.2 CYCLE971 tool: Measuring milling tools, drills.......................................................................... 5-4

5.2.1 Function overview ...................................................................................................................... 5-4

5.2.2 Measurement and correction strategy ....................................................................................... 5-6

5.2.2.1 Measuring strategy .................................................................................................................... 5-6

5.2.2.2 Compensation strategy .............................................................................................................. 5-7

5.2.2.3 Compensation with correction table when measuring with rotating spindle .............................. 5-8

5.2.3 Calibrating tool probes ............................................................................................................. 5-10

5.2.3.1 Calibration................................................................................................................................ 5-10

5.2.3.2 Programming example 1.......................................................................................................... 5-12

5.2.3.3 Programming example 2.......................................................................................................... 5-13

5.2.3.4 Operational sequence.............................................................................................................. 5-15

5.2.4 Calibrating tool probes automatically....................................................................................... 5-17

5.2.4.1 Automatic calibration................................................................................................................ 5-17

5.2.4.2 Programming example............................................................................................................. 5-18

5.2.4.3 Operational sequence.............................................................................................................. 5-19

5.2.5 Measuring tool.......................................................................................................................... 5-21

5.2.5.1 Measurement ........................................................................................................................... 5-21

5.2.5.2 Programming examples 1 ........................................................................................................ 5-25

5.2.5.3 Programming example 2.......................................................................................................... 5-27

5.2.5.4 Operational sequence.............................................................................................................. 5-28

5.3 CYCLE976 calibrate workpiece probe..................................................................................... 5-29

5.3.1 Function overview .................................................................................................................... 5-29

5.3.2 Calibrating a workpiece probe in a hole of known hole center point ....................................... 5-33

5.3.2.1 General information ................................................................................................................. 5-33

5.3.2.2 Programming example............................................................................................................. 5-34

5.3.2.3 Operational sequence.............................................................................................................. 5-36

5.3.3 Calibrating a workpiece probe in a hole of unknown hole center point ................................... 5-37

5.3.3.1 General information ................................................................................................................. 5-37

5.3.3.2 Programming example............................................................................................................. 5-38

5.3.3.3 Operational sequence.............................................................................................................. 5-40

5.3.4 Calibration of a workpiece probe on a surface ........................................................................ 5-41

5.3.4.1 General information ................................................................................................................. 5-41

5.3.4.2 Programming example............................................................................................................. 5-43

5.3.4.3 Operational sequence.............................................................................................................. 5-44

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5.3.5 Calibrating a workpiece probe in the applicate determining probe length............................... 5-44

5.3.5.1 General information.................................................................................................................. 5-44

5.3.5.2 Programming example ............................................................................................................. 5-46

5.3.5.3 Operational sequence.............................................................................................................. 5-47

5.4 CYCLE977 workpiece: Measure hole/shaft/groove/web/rectangle parallel to axes ................ 5-48

5.4.1 Function overview .................................................................................................................... 5-48

5.4.2 Measuring contour elements.................................................................................................... 5-52

5.4.2.1 General information.................................................................................................................. 5-52

5.4.2.2 Programming example ............................................................................................................. 5-55

5.4.2.3 Operational sequence.............................................................................................................. 5-57

5.4.3 Measuring and tool offset......................................................................................................... 5-61

5.4.3.1 General information.................................................................................................................. 5-61

5.4.3.2 Programming example ............................................................................................................. 5-63

5.4.4 Measurement and ZO determination ....................................................................................... 5-65

5.4.4.1 General information.................................................................................................................. 5-65

5.4.4.2 Programming example ............................................................................................................. 5-67

5.5 CYCLE978 workpiece: Measuring a surface parallel to the axis............................................. 5-69

5.5.1 Function overview .................................................................................................................... 5-69

5.5.2 Measuring the surface.............................................................................................................. 5-71

5.5.3 Measurement and ZO determination ....................................................................................... 5-73

5.5.3.1 General information.................................................................................................................. 5-73

5.5.3.2 Programming example ............................................................................................................. 5-74

5.5.4 Measuring and tool offset......................................................................................................... 5-76

5.5.4.1 General information.................................................................................................................. 5-76

5.5.4.2 Programming example ............................................................................................................. 5-78

5.6 CYCLE979 workpiece: Measure hole/shaft/groove/rib at an angle ......................................... 5-80

5.6.1 Function overview .................................................................................................................... 5-80

5.6.2 Measure shaft, groove, web..................................................................................................... 5-83

5.6.2.1 General information.................................................................................................................. 5-83

5.6.2.2 Operational sequence.............................................................................................................. 5-85

5.6.3 Measuring and tool offset......................................................................................................... 5-88

5.6.3.1 General information.................................................................................................................. 5-88

5.6.3.2 Programming example ............................................................................................................. 5-90

5.6.4 Measurement and ZO determination ....................................................................................... 5-92

5.6.4.1 General information.................................................................................................................. 5-92

5.6.4.2 Programming example ............................................................................................................. 5-94

5.7 CYCLE998 workpiece: Angle measurement and ZO determination........................................ 5-95

5.7.1 Function overview .................................................................................................................... 5-95

5.7.2 1-angle measurement .............................................................................................................. 5-98

5.7.2.1 General information.................................................................................................................. 5-98

5.7.2.2 Programming example ........................................................................................................... 5-100

5.7.2.3 Operational sequence............................................................................................................ 5-102

5.7.3 2-angle measurement ............................................................................................................ 5-107

5.7.3.1 General information................................................................................................................ 5-107

5.7.3.2 Programming example 1........................................................................................................ 5-108

5.7.3.3 Programming example 2........................................................................................................ 5-110

5.7.3.4 Operational sequence............................................................................................................ 5-113

5.8 CYCLE961 workpiece: Setup inside and outside corner ....................................................... 5-114

5.8.1 Function overview .................................................................................................................. 5-114

5.8.2 Setting up a corner with definition of distances and angles................................................... 5-117

5.8.2.1 General information................................................................................................................ 5-117

5.8.2.2 Programming example ........................................................................................................... 5-119

5.8.2.3 Operational sequence............................................................................................................ 5-120

5.8.3 Setting up a corner with 4 points............................................................................................ 5-122

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5.8.3.1 General information ............................................................................................................... 5-122

5.8.3.2 Programming example........................................................................................................... 5-123

5.8.3.3 Operational sequence............................................................................................................ 5-125

5.9 CYCLE997 workpiece: Measuring a sphere and ZO determination...................................... 5-127

5.9.1 Function overview .................................................................................................................. 5-127

5.9.2 Measurement and ZO determination ..................................................................................... 5-132

5.9.2.1 General information ............................................................................................................... 5-132

5.9.2.2 Operational sequence............................................................................................................ 5-135

5.9.3 Programming example CYCLE997........................................................................................ 5-137

5.9.4 CYCLE119: Arithmetic cycle for determining position in space............................................. 5-139

5.9.4.1 General information ............................................................................................................... 5-139

5.9.4.2 Programming example........................................................................................................... 5-141

6 Measuring Cycles for Turning Machines................................................................................................. 6-1

6.1 General prerequisites................................................................................................................. 6-1

6.1.1 General information ................................................................................................................... 6-1

6.1.2 Overview of measuring cycles ................................................................................................... 6-1

6.1.3 Overview of the auxiliary programs required ............................................................................. 6-1

6.1.4 Call and return conditions .......................................................................................................... 6-2

6.2 CYCLE982, CYCLE972 Tool: Measure turning tools ................................................................ 6-4

6.2.1 Function overview ...................................................................................................................... 6-4

6.2.2 Calibrate tool probe (machine-related) ...................................................................................... 6-7

6.2.2.1 General information ................................................................................................................... 6-7

6.2.2.2 Programming example............................................................................................................... 6-9

6.2.2.3 Operational sequence.............................................................................................................. 6-10

6.2.3 Determining dimensions of calibration..................................................................................... 6-11

6.2.4 Measure turning tool (machine-related)................................................................................... 6-12

6.2.4.1 General information ................................................................................................................. 6-12

6.2.4.2 Programming example............................................................................................................. 6-14

6.2.4.3 Operational sequence.............................................................................................................. 6-17

6.3 CYCLE982 tool: Measure turning and milling tools ................................................................. 6-18

6.3.1 Function overview .................................................................................................................... 6-18

6.3.1.1 General information ................................................................................................................. 6-18

6.3.1.2 Special aspects with milling tools............................................................................................. 6-21

6.3.1.3 Measuring variants................................................................................................................... 6-22

6.3.1.4 Result parameters.................................................................................................................... 6-23

6.3.2 Calibrating tool probes ............................................................................................................. 6-25

6.3.2.1 General information ................................................................................................................. 6-25

6.3.2.2 Programming example............................................................................................................. 6-26

6.3.3 Measuring tool.......................................................................................................................... 6-28

6.3.3.1 General information ................................................................................................................. 6-28

6.3.3.2 Programming example............................................................................................................. 6-30

6.3.3.3 Operational sequence.............................................................................................................. 6-31

6.3.4 Automatic tool measurement ................................................................................................... 6-37

6.3.4.1 General information ................................................................................................................. 6-37

6.3.4.2 Operational sequence.............................................................................................................. 6-39

6.3.5 Incremental calibration............................................................................................................. 6-44

6.3.5.1 General information ................................................................................................................. 6-44

6.3.5.2 Programming example............................................................................................................. 6-45

6.3.5.3 Operational sequence.............................................................................................................. 6-46

6.3.6 Incremental measurement ....................................................................................................... 6-48

6.3.6.1 General information ................................................................................................................. 6-48

6.3.6.2 Programming example............................................................................................................. 6-50

6.3.6.3 Operational sequence.............................................................................................................. 6-51

6.3.7 Milling tool: Suppression of start angle positioning _STA1...................................................... 6-54

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6.3.8 Measuring drills – special applications (from measuring cycles SW 6.3) ................................ 6-55

6.4 CYCLE973 Calibrating workpiece probes................................................................................ 6-56

6.4.1 Function overview .................................................................................................................... 6-56

6.4.2 Calibrating in the reference groove.......................................................................................... 6-59

6.4.2.1 General information.................................................................................................................. 6-59

6.4.2.2 Programming example ............................................................................................................. 6-61

6.4.2.3 Operational sequence.............................................................................................................. 6-62

6.4.3 Calibration on surface .............................................................................................................. 6-62

6.4.3.1 General information.................................................................................................................. 6-62

6.4.3.2 Programming example ............................................................................................................. 6-64

6.4.3.3 Operational sequence.............................................................................................................. 6-65

6.5 CYCLE974 workpiece: 1-point measurement.......................................................................... 6-66

6.5.1 Function overview .................................................................................................................... 6-66

6.5.2 1-point measurement and ZO determination ........................................................................... 6-69

6.5.2.1 General information.................................................................................................................. 6-69

6.5.2.2 Programming example ............................................................................................................. 6-70

6.5.2.3 Operational sequence.............................................................................................................. 6-71

6.5.3 1-point measurement and tool offset ....................................................................................... 6-71

6.5.3.1 General information.................................................................................................................. 6-71

6.5.3.2 Programming example ............................................................................................................. 6-73

6.5.3.3 Operational sequence.............................................................................................................. 6-75

6.5.4 1-point measurement with reversal and tool offset .................................................................. 6-75

6.5.4.1 General information.................................................................................................................. 6-75

6.5.4.2 Programming example ............................................................................................................. 6-77

6.6 CYCLE994 workpiece: 2-point measurement.......................................................................... 6-79

6.6.1 Function overview .................................................................................................................... 6-79

6.6.1.1 General information.................................................................................................................. 6-79

6.6.1.2 Programming example ............................................................................................................. 6-83

6.6.1.3 Operational sequence.............................................................................................................. 6-86

6.7 Complex example for tool measurement ................................................................................. 6-88

7 Miscellaneous functions.......................................................................................................................... 7-1

7.1 Log measurement results........................................................................................................... 7-1

7.1.1 Overview of the logging cycles................................................................................................... 7-1

7.1.2 Log file........................................................................................................................................ 7-1

7.1.3 Handling the log cycles .............................................................................................................. 7-2

7.1.3.1 General information.................................................................................................................... 7-2

7.1.3.2 CYCLE100 Logging ON............................................................................................................. 7-2

7.1.3.3 CYCLE101 Logging OFF ........................................................................................................... 7-2

7.1.3.4 CYCLE105(PAR1) Creating log content....................................................................................7-3

7.1.3.5 CYCLE106(PAR1) Logging sequence control........................................................................... 7-3

7.1.3.6 CYCLE113(PAR1,PAR2) Read system date and time.............................................................. 7-3

7.1.3.7 CYCLE118(PAR1,PAR2,PAR3,PAR4,PAR5)............................................................................ 7-3

7.1.3.8 Programming example for formatting a single number.............................................................. 7-4

7.1.3.9 Programming example for formatting three numbers ................................................................ 7-4

7.1.4 Variables when logging.............................................................................................................. 7-5

7.1.5 Selection of the log content........................................................................................................ 7-6

7.1.6 Log format .................................................................................................................................. 7-7

7.1.7 Log header ................................................................................................................................. 7-8

7.1.8 Example: Creating a measurement result log............................................................................ 7-9

7.2 Measuring cycle support in the program editor (up to measuring cycles SW 5.4) .................. 7-12

7.2.1 Measuring cycle support files................................................................................................... 7-12

7.2.2 Load the measuring cycle support ........................................................................................... 7-13

7.2.3 Assigning calls and measuring cycles ..................................................................................... 7-13

Table of contents

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7.2.4 Description of the parameterizing cycles ................................................................................. 7-14

7.2.4.1 General information ................................................................................................................. 7-14

7.2.4.2 Setting additional parameters - CYCLE_PARA ....................................................................... 7-14

7.2.4.3 Calibrate tool probe - CYCLE_CAL_TOOLSETTER................................................................ 7-15

7.2.4.4 Calibration on surface - CYCLE_CAL_PROBE ....................................................................... 7-15

7.2.4.5 Calibration in groove - CYCLE_973......................................................................................... 7-16

7.2.4.6 Calibration in hole - CYCLE_976 ............................................................................................. 7-16

7.2.4.7 Measuring milling tools - CYCLE_971 ..................................................................................... 7-17

7.2.4.8 Measuring turning tools - CYCLE_972 .................................................................................... 7-17

7.2.4.9 Hole, measure shaft – CYCLE_977_979A............................................................................... 7-18

7.2.4.10 Groove, measure web – CYCLE_977_979B............................................................................ 7-18

7.2.4.11 Measure rectangle - CYCLE_977_979C.................................................................................. 7-19

7.2.4.12 Single-point measurement - CYCLE_978................................................................................ 7-20

7.2.4.13 Angle measurement - CYCLE_998.......................................................................................... 7-20

7.2.4.14 Corner measurement with specification of angles - CYCLE_961_W....................................... 7-20

7.2.4.15 Corner measurement with specification of points - CYCLE_961_P......................................... 7-21

7.2.4.16 Single-point measurement - CYCLE_974................................................................................ 7-22

7.2.4.17 Two-point measurement - CYCLE_994 ................................................................................... 7-23

7.3 Measuring cycle support in the program editor (from measuring cycles SW 6.2)................... 7-24

7.3.1 Menus, explanation of the cycles............................................................................................. 7-24

7.3.1.1 General information ................................................................................................................. 7-24

7.3.1.2 Softkey bars for turning............................................................................................................ 7-25

7.3.1.3 Softkey bars for milling............................................................................................................. 7-27

7.3.1.4 Programming example............................................................................................................. 7-30

7.3.2 Pre-setting of the measuring cycle support ............................................................................. 7-31

7.4 Measuring result screens......................................................................................................... 7-34

8 Hardware/software.................................................................................................................................. 8-1

8.1 Hardware requirements ............................................................................................................. 8-1

8.1.1 General hardware prerequisites................................................................................................. 8-1

8.1.2 Measuring probe connection...................................................................................................... 8-1

8.1.2.1 General information ................................................................................................................... 8-1

8.1.2.2 SINUMERIK 810D, 840D powerline, 840Di............................................................................... 8-1

8.1.2.3 SINUMERIK 840D sl (solution line) probe connection to X122, NCU 7x0 ................................ 8-6

8.1.3 Measuring in JOG ...................................................................................................................... 8-7

8.2 Software requirements............................................................................................................... 8-7

8.2.1 How the measuring cycles are supplied ....................................................................................8-7

8.2.2 Software versions NC and MMC/HMI........................................................................................ 8-7

8.2.3 Options....................................................................................................................................... 8-7

8.3 Function test............................................................................................................................... 8-8

9 Data description...................................................................................................................................... 9-1

9.1 Machine data for machine cycle runs ........................................................................................9-1

9.1.1 Machine data that configure the memory .................................................................................. 9-1

9.1.1.1 General information ................................................................................................................... 9-1

9.1.1.2 Memory configuring machine data, SRAM ................................................................................ 9-2

9.1.1.3 Memory configuring machine data, DRAM ................................................................................ 9-5

9.1.2 Other machine data ................................................................................................................... 9-6

9.2 Cycle data .................................................................................................................................. 9-8

9.2.1 Data blocks for measuring cycles .............................................................................................. 9-8

9.2.1.1 General information ................................................................................................................... 9-8

9.2.1.2 Data block GUD5.DEF............................................................................................................... 9-8

9.2.1.3 Data block GUD6.DEF............................................................................................................... 9-8

9.2.2 Data adjustment to a specific machine .................................................................................... 9-13

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xiv Programming Manual, Release 04/2006, 6FC5398-4BP10-0BA0

9.2.3 Central values .......................................................................................................................... 9-15

9.2.4 Central bits ............................................................................................................................... 9-22

9.2.4.1 In data block GUD6.DEF.......................................................................................................... 9-22

9.2.4.2 Detailed description.................................................................................................................. 9-23

9.2.5 Central strings .......................................................................................................................... 9-26

9.2.6 Channel-oriented values .......................................................................................................... 9-27

9.2.7 Channel-oriented bits............................................................................................................... 9-31

9.2.7.1 In data block GUD6.DEF.......................................................................................................... 9-31

9.2.7.2 Detailed description.................................................................................................................. 9-33

9.3 Data for measuring in JOG ...................................................................................................... 9-39

9.3.1 Machine data for ensuring operability...................................................................................... 9-39

9.3.2 Modifying the GUD7 data block ............................................................................................... 9-41

9.3.3 Settings in data block GUD6.................................................................................................... 9-46

9.3.4 Loading files for measuring in JOG.......................................................................................... 9-47

10 Start-up (hardware)............................................................................................................................... 10-1

10.1 Commissioning measuring cycles for the first time.................................................................. 10-1

10.1.1 Requirements........................................................................................................................... 10-1

10.1.2 Overview of diskette in delivery form ....................................................................................... 10-1

10.2 Steps for commissioning measuring cycles for the first time ................................................... 10-3

10.2.1 General information.................................................................................................................. 10-3

10.2.2 Step 0.1 – set up memory configuring machine data............................................................... 10-3

10.2.3 Step 0.2 – set up other machine data ...................................................................................... 10-3

10.2.4 Step 0.3 - set up machine data for measuring in JOG............................................................. 10-4

10.3 Commissioning measuring cycles for HMI-Advanced PCU50 powerline up to SW 06.03.18

and/or SW 06.04.08 ................................................................................................................. 10-5

10.3.1 Requirements........................................................................................................................... 10-5

10.3.2 Step 1 – load definition files ..................................................................................................... 10-5

10.3.2.1 General..................................................................................................................................... 10-5

10.3.2.2 Only for measuring in JOG up to measuring cycle release SW 6.02.16 ................................. 10-6

10.3.3 Step 2 – load cycle programs................................................................................................... 10-7

10.3.4 Step 3 – load measuring cycle text files................................................................................... 10-8

10.3.5 Step 4 – load files for measurement result display .................................................................. 10-8

10.3.6 Step 5 – load measuring cycle support.................................................................................... 10-8

10.3.7 Step 6 – activate measuring cycle support, configure ............................................................. 10-9

10.3.8 Step 7 - load and activate measuring in JOG .......................................................................... 10-9

10.3.9 Step 8 – set measuring cycle data ......................................................................................... 10-10

10.4 Commissioning measuring cycles for HMI-Advanced PCU50 powerline as of SW 06.03.19.

and/or

SW 06.04.10 and HMI-Advanced PCU50 Solutionline.......................................................... 10-11

10.4.1 Requirements......................................................................................................................... 10-11

10.4.2 Step 1 – load definition files ................................................................................................... 10-11

10.4.3 Step 2 – load other archive .................................................................................................... 10-12

10.4.4 Step 3 - activate entry softkeys "Measure turning" and "Measure milling" for measuring cycle

support ................................................................................................................................... 10-13

10.4.5 Step 4 - activate softkey "Measuring cycles" in the "Commissioning" area........................... 10-13

10.4.6 Step 5 - activate entry softkeys "Measure workpiece" and "Measure tool" for measuring in JOG

in the machine's "JOG" area .................................................................................................. 10-13

10.4.7 Step 6 – set measuring cycle data ......................................................................................... 10-14

10.5 Commissioning measuring cycles for HMI-Embedded PCU20 powerline............................. 10-15

10.5.1 Requirements......................................................................................................................... 10-15

10.5.2 Step 1 – load definition files ................................................................................................... 10-15

10.5.3 Step 2 – load cycle programs................................................................................................. 10-15

10.5.4 Step 3 – set measuring cycle data ......................................................................................... 10-15

Table of contents

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Programming Manual, Release 04/2006, 6FC5398-4BP10-0BA0 xv

10.5.5 Step 4 – menu tree for extending measuring cycles.............................................................. 10-15

10.5.6 Step 5 – configure measuring cycle support.......................................................................... 10-16

10.5.7 Step 6 – incorporate text files................................................................................................. 10-16

10.5.8 Step 7 – incorporate files for measurement result display..................................................... 10-17

10.5.9 Step 8 – incorporate measuring cycle support....................................................................... 10-17

10.5.10 Step 9 – incorporate displays for measuring cycle support ................................................... 10-18

10.5.11 Step 10 - produce image file and program on a Flash card .................................................. 10-18

10.6 Commissioning measuring cycles, HMI-Embedded TCU solution line SW 1.x..................... 10-19

10.6.1 Requirements......................................................................................................................... 10-19

10.6.2 Step 1 – load archive ............................................................................................................. 10-19

10.6.3 Step 2 – activate definition files.............................................................................................. 10-20

10.6.4 Step 3 - activate entry softkeys "Measure turning" and "Measure milling" for measuring cycle

support ................................................................................................................................... 10-20

10.6.5 Step 4 - activate softkey "Measuring cycles" in the "Commissioning" area........................... 10-20

10.6.6 Step 5 – set measuring cycle data......................................................................................... 10-20

10.7 Upgrading measuring cycles.................................................................................................. 10-21

10.7.1 General information ............................................................................................................... 10-21

10.7.2 Upgrading measuring cycles for HMI-Advanced PCU50 powerline up to SW 06.03.18 and/or

SW 06.04.08 .......................................................................................................................... 10-21

10.7.3 Upgrading measuring cycles for HMI-Advanced PCU50 powerline as of SW 06.03.19. and/or as

of SW 06.04.10 and HMI-Advanced PCU50 solution line ..................................................... 10-22

10.7.3.1 Requirements......................................................................................................................... 10-22

10.7.3.2 Step 1 – load definition files ................................................................................................... 10-23

10.7.3.3 Step 2 – load other archive .................................................................................................... 10-23

10.7.3.4 Step 3 – update Bitmaps........................................................................................................ 10-24

10.7.4 Upgrading measuring cycles for HMI-Embedded PCU20 powerline..................................... 10-24

10.8 Sequence for probe installation ............................................................................................. 10-25

10.9 Example of calculating the repeat accuracy .......................................................................... 10-27

11 Alarm, error, and system messages ..................................................................................................... 11-1

11.1 General notes........................................................................................................................... 11-1

11.2 Error rectification in the measuring cycles ............................................................................... 11-1

11.3 Overview of measuring cycle alarms ....................................................................................... 11-1

12 Adaptation of the Measuring Cycles to Previous Software Versions..................................................... 12-1

12.1 General information ................................................................................................................. 12-1

12.2 Measuring cycle subroutines ................................................................................................... 12-1

A Appendix.................................................................................................................................................A-1

A.1 Overview of measuring cycle parameters..................................................................................A-1

B List of abbreviations................................................................................................................................B-1

C Parameter...............................................................................................................................................C-1

Glossary ..................................................................................................................................... Glossary-1

Index................................................................................................................................................ Index-1

Table of contents

Measuring cycles

xvi Programming Manual, Release 04/2006, 6FC5398-4BP10-0BA0

Measuring cycles

Programming Manual, Release 04/2006, 6FC5398-4BP10-0BA0 1-1

General 1

1.1 1.1 Basics

General information

Measuring cycles are general subroutines designed to solve specific measurement tasks.

They can be adapted to specific problems via parameter settings.

When taking general measurements, a distinction is made between

• tool measurements and

• workpiece measurements.

Workpiece measurements

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In workpiece measurement, a measuring probe is moved up to the clamped workpiece in the

same way as a tool and the measured values are acquired. The flexibility of measuring

cycles makes it possible to perform nearly all measurements required on a milling or turning

machine.

An automatic tool offset or ZO correction can be applied to the workpiece measurement

result.

General

1.2 General prerequisites

Measuring cycles

1-2 Programming Manual, Release 04/2006, 6FC5398-4BP10-0BA0

Tool measurements

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In tool measurement, the selected tool is moved up to the probe and the measured values

are acquired. The probe is either in a fixed in position or is swung into the working area with

a mechanism. The tool geometry measured is entered in the appropriate tool offset data set.

1.2 1.2 General prerequisites

Certain preconditions must be met before measuring cycles can be used.

These are detailed in Part 2 Description of Functions (Chapter 8 ff.).

The following checklist is useful for checking which preconditions have been met:

Machine

• All machine axes are designed in accordance with DIN 66217.

• Machine data have been adapted.

Existence of cycles, data blocks

The following have been loaded into the control and activated:

• The data blocks into the "Definitions" directory:

– GUD5.DEF

– GUD6.DEF and

– GUD7.DEF (for measuring in JOG)

• The measuring cycles into the standard cycle directory.

Starting position

• The reference points have been approached.

• The starting position can be reached by linear interpolation without collision.

General

1.3 Behavior on block search, dry run, program testing, simulation

Measuring cycles

Programming Manual, Release 04/2006, 6FC5398-4BP10-0BA0 1-3

Display functions of the measuring cycles

An HMI/PCU is required for showing the measuring result displays and measuring cycle

support.

Please observe the following when programming:

• Tool radius compensation is deselected before it is called (G40).

• All parameters for the cycle call have been defined beforehand.

• The cycle is called no later than at the 5th program level.

• The system of units allows measuring in the programmed unit system that deviates from

the basic system with switchable technology data.

– For metric dimension system with active G70, G700.

– For inch-based dimension system with active G71, G710.

1.3 1.3 Behavior on block search, dry run, program testing, simulation

Function

The measuring cycles are skipped during execution if one of the following execution modes

is active:

• "Trial run" ($P_DRYRUN=1)

• "Program test" ($P_ISTEST=1)

• "Block search" ($P_SEARCH=1), only if $A_PROTO=0.

Simulation

• On HMI Advanced ($P_SIM=1)

The measuring cycle programs are executed on selection of "Simulation" on the HMI.

• On Jobshop products ($P_SEARCH=1 and $A_PROTO=1)

The measurements are simulated. No selected tool or zero offset is applied. Active functions

such as "measuring result display", "travel with collision monitoring", "measuring cycle

logging" are not executed.

Suppression of simulation execution

Execution of the measuring cycles in simulation can be suppressed in simulation by resetting

the variable _MC_SIMSIM=0 in data block GUD6. The measuring cycles are then skipped.

Specifying differences for simulation

The variable _MC_SIMDIFF of data type REAL permits specification of simulated

measurement deviations at measuring points. The value is a dimension in the basic system

of the control.

General

1.3 Behavior on block search, dry run, program testing, simulation

Measuring cycles

1-4 Programming Manual, Release 04/2006, 6FC5398-4BP10-0BA0

Excessive values of _MC_SIMDIFF with corresponding value assignment of the defining

parameters cause cycle alarms to be output.

Note

It is not ensured that the correction value contains the correct sign of _MC_SIMDIFF. This

depends on the measurement or calibration task and the direction of measurement. The sign

is influenced in such a way that the overall result makes sense (e.g. "Measure hole").

Changing the sign always causes the sign of the result to change.

Demo program for simulation on HMI Advanced

The measuring cycle software supplied includes programs for demonstrating how the

measuring cycles work when simulating on HMI Advanced. The programs are divided into

turning technology and milling technology. When a program is loaded, the "workpieces" are

created whose directory contains all data and settings required for simulation.

Example 1: Measure hole (TESIM_977BO with CYCLE977, milling technology)

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