Preface

Fundamental safety
instructions 1

F2: Multi-axis transformations 2

SINUMERIK
G1: Gantry axes 3
SINUMERIK 840D sl / 828D
Special functions
K6: Contour tunnel monitoring 4
K7: Kinematic chain - only
840D sl 5
Function Manual
K8: Geometric machine
modeling - only 840D sl 6
K9: Collision avoidance - only
840D sl 7

M3: Coupled axes 8

R3: Extended stop and retract 9

S9: Setpoint exchange -
840D sl only 10
T3: Tangential control - 840D
sl only 11
T4: Automatic post
optimization with AST 12
(option) - only 840D sl
Valid for
TE01: Installation and
Control
SINUMERIK 840D sl / 840DE sl
activation of loadable 13
SINUMERIK 828D compile cycles

Software version TE02: Simulation of Compile

CNC software 4.7 SP2 Cycles (only HMI Advanced) 14
TE1: Clearance control -
10/2015 840D sl only 15
6FC5397-2BP40-5BA3

Continued on next page

Siemens AG Order number: 6FC5397-2BP40-5BA3 Copyright © Siemens AG 1995 - 2015.
Division Digital Factory Ⓟ 11/2015 Subject to change All rights reserved
Postfach 48 48
90026 NÜRNBERG
GERMANY
 Continuation

TE3: Speed/torque coupling,

master-slave 16
TE4: Handling transformation
package - 840D sl only 17
TE6: MCS coupling - 840D sl
only 18
SINUMERIK 840D sl / 828D
Special functions TE7: Continue machining at
the contour (retrace support) 19
- 840D sl only

Function Manual TE8: Cycle-independent

path-synchronous switching 20
signal output - 840D sl only

TE9: Axis pair collision

protection 21

V2: Preprocessing 22
W5: 3D tool radius
compensation - 840D sl only 23
W6: Path length evaluation -
840D sl only 24

Z3: NC/PLC interface signals 25

Appendix A
Legal information
Warning notice system
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
indicates that minor personal injury can result if proper precautions are not taken.

NOTICE
indicates that property damage can result if proper precautions are not taken.
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 product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified
personnel are those who, based on their training and experience, are capable of identifying risks and avoiding
potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:

WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks
All names identified by ® are registered trademarks of 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 Order number: 6FC5397-2BP40-5BA3 Copyright © Siemens AG 1995 - 2015.

Division Digital Factory Ⓟ 11/2015 Subject to change All rights reserved
Postfach 48 48
90026 NÜRNBERG
GERMANY
Preface

SINUMERIK documentation
The SINUMERIK documentation is organized in the following categories:
● General documentation
● User documentation
● Manufacturer/service documentation

Additional information
You can find information on the following topics at www.siemens.com/motioncontrol/docu:
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (find and search in manuals/information)
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following address:
[email protected]

My Documentation Manager (MDM)

Under the following link you will find information to individually compile OEM-specific machine
documentation based on the Siemens content:
www.siemens.com/mdm

Training
For information about the range of training courses, refer under:
● www.siemens.com/sitrain
SITRAIN - Siemens training for products, systems and solutions in automation technology
● www.siemens.com/sinutrain
SinuTrain - training software for SINUMERIK

FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support. http://support.automation.siemens.com

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 5
Preface

SINUMERIK
You can find information on SINUMERIK under the following link:
www.siemens.com/sinumerik

Target group
This publication is intended for:
● Project engineers
● Technologists (from machine manufacturers)
● System startup engineers (Systems/Machines)
● Programmers

Benefits
The function manual describes the functions so that the target group knows them and can
select them. It provides the target group with the information required to implement the
functions.

Standard version
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine tool manufacturer are documented by the machine tool
manufacturer.
Other functions not described in this documentation might be executable in the control. This
does not, however, represent an obligation to supply such functions with a new control or when
servicing.
Further, 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.

Technical Support
You will find telephone numbers for other countries for technical support in the Internet under
http://www.siemens.com/automation/service&support

Structure_FB1+2

Structure
This Function Manual is structured as follows:
● Inner title (page 3) with the title of the Function Manual, the SINUMERIK controls as well
as the software and the version for which this version of the Function Manual is applicable
and the overview of the individual functional descriptions.
● Description of the functions in alphabetical order (e.g. A2, A3, B1, etc.)

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6 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 Preface

● Appendix with:
– List of abbreviations
– Documentation overview
● Index of terms

Note
For detailed descriptions of data and alarms see:
● For machine and setting data:
Detailed description of machine data (only electronically on DOConCD or DOConWEB)
● For NC/PLC interface signals:
– Function Manual, Basic Functions; NC/PLC Interface Signals (Z1)
– Function Manual, Extension Functions; NC/PLC Interface Signals (Z2)
– Function Manual, Special Functions; NC/PLC Interface Signals (Z3)
● For alarms:
Diagnostics Manual

Notation of system data

The following notation is applicable for system data in this documentation:

Signal/Data Notation Example

NC/PLC interface ... NC/PLC interface signal: When the new gear stage is engaged, the following NC/PLC
signals <signal address> (<signal name>) interface signals are set by the PLC program:
DB31, ... DBX16.0-2 (actual gear stage A to C)
DB31, ... DBX16.3 (gear is changed)
Machine data ... machine data: Master spindle is the spindle stored in the machine data:
<Type><Number> <Complete Des‐ MD20090 $MC_SPIND_DEF_MASTER_SPIND (position of de‐
ignator> (<Meaning>) letion of the master spindle in the channel)
Setting data ... setting data: The logical master spindle is contained in the setting data:
<Type><Number> <Complete Des‐ SD42800 $SC_SPIND_ASSIGN_TAB[0] (spindle number con‐
ignator> (<Meaning>) verter)

Note
Signal address
The description of functions include as <signal address> of an NC/PLC interface signal, only
the address valid for SINUMERIK 840D sl. The signal address for SINUMERIK 828D should
be taken from the data lists "Signals to/from ..." at the end of the particular description of
functions.

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 7
Preface

Quantity structure
Explanations concerning the NC/PLC interface are based on the absolute maximum number
of the following components:
● Mode groups (DB11)
● Channels (DB21, etc.)
● Axes/spindles (DB31, etc.)

Data types
The control provides the following data types that can be used for programming in part
programs:

Type Meaning Value range

INT Signed integers -2,147,483,648 ... +2,147,483,647
REAL Numbers with decimal point ≈ ±5.0*10-324 … ≈ ±1.7*10+308
BOOL Boolean values TRUE (≠0) , FALSE (0)
CHAR ASCII characters and bytes 0 ... 255 or -128 ... 127
STRING Character string, null-terminated Maximum of 400 characters + /0
(no special characters)
AXIS Axis names All axis names available in the control
system
FRAME Geometrical parameters for moving, rotating, scaling, and ---
mirroring

Arrays
Arrays can only be formed from similar elementary data types. Up to 3-dimensional arrays are
possible.
Example: DEF INT ARRAY[2, 3, 4]

Number systems
The following number systems are available:
● Decimal: DEF INT number = 1234 or DEF REAL number = 1234.56
● Hexadecimal: DEF INT number = 'H123ABC'
● Binary: DEF INT number = 'B10001010010'

Querying REAL variables

We recommend that querying REAL or DOUBLE variables in NC programs and synchronized
actions is programmed as limit value evaluation.
Example: Querying the actual value of an axis for a specific value

DEF REAL AXPOS = 123.456

IF ($VA_IM[<axis>] - 1ex-6) <= AXPOS <= ($VA_IM[<axis>] + 1ex-6) ; actual position
... == AXPOS

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8 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 Preface

ELSE
... <> AXPOS
ENDIF

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 9
Preface

Special functions
10 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
Table of contents

Preface.........................................................................................................................................................5
1 Fundamental safety instructions.................................................................................................................31
1.1 General safety instructions.....................................................................................................31
1.2 Industrial security...................................................................................................................31
2 F2: Multi-axis transformations....................................................................................................................33
2.1 Brief description.....................................................................................................................33
2.1.1 5-axis Transformation............................................................................................................33
2.1.2 3-axis and 4-axis transformation............................................................................................35
2.1.3 Orientation transformation with a swiveling linear axis..........................................................36
2.1.4 Universal milling head............................................................................................................38
2.1.5 Orientation axes.....................................................................................................................39
2.1.6 Cartesian manual travel.........................................................................................................40
2.1.7 Cartesian PTP travel..............................................................................................................40
2.1.8 Generic 5-axis transformation................................................................................................40
2.1.9 Online tool length offset.........................................................................................................40
2.1.10 Activation via parts/program/softkey......................................................................................41
2.1.11 Orientation compression........................................................................................................41
2.2 5-axis transformation..............................................................................................................41
2.2.1 Kinematic transformation.......................................................................................................41
2.2.2 Machine types for 5-axis transformation................................................................................42
2.2.3 Configuration of a machine for 5-axis transformation............................................................43
2.2.4 Tool orientation......................................................................................................................48
2.2.5 Singular positions and handling.............................................................................................52
2.3 3-axis and 4-axis transformations..........................................................................................55
2.4 Transformation with swiveled linear axis................................................................................56
2.5 Cardan milling head...............................................................................................................62
2.5.1 Fundamentals of cardan milling head....................................................................................62
2.5.2 Parameterization....................................................................................................................64
2.5.3 Traverse of the cardan milling head in JOG mode.................................................................65
2.6 Programming of the 3- to 5-axis transformation.....................................................................66
2.7 Generic 5-axis transformation and variants...........................................................................67
2.7.1 Functionality...........................................................................................................................67
2.7.2 Description of machine kinematics.........................................................................................68
2.7.3 Generic orientation transformation variants...........................................................................69
2.7.4 Parameterization of orientable toolholder data......................................................................71
2.7.5 Extension of the generic transformation to six axes - 840D sl only........................................75
2.7.6 Extension of the generic transformation to seven axes - 840D sl only..................................78
2.7.7 Cartesian manual travel with generic transformation.............................................................82
2.8 Restrictions for kinematics and interpolation..........................................................................84
2.8.1 Singularities of orientation......................................................................................................85

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Table of contents

2.9 Orientation..............................................................................................................................87
2.9.1 Basic orientation.....................................................................................................................87
2.9.2 Orientation movements with axis limits..................................................................................89
2.9.3 Orientation compression........................................................................................................90
2.9.4 Smoothing of the orientation characteristic............................................................................95
2.9.4.1 Function.................................................................................................................................95
2.9.4.2 Commissioning.......................................................................................................................95
2.9.4.3 Programming..........................................................................................................................96
2.9.5 Orientation relative to the path...............................................................................................97
2.9.6 Programming of orientation polynominals............................................................................101
2.9.7 System variable for tool orientation......................................................................................104
2.10 Orientation axes...................................................................................................................106
2.10.1 JOG mode............................................................................................................................108
2.10.2 Programming for orientation transformation.........................................................................109
2.10.3 Programmable offset for orientation axes............................................................................111
2.10.4 Orientation transformation and orientable tool holders........................................................112
2.10.5 Modulo display of orientation axes.......................................................................................112
2.11 Orientation vectors...............................................................................................................113
2.11.1 Polynomial interpolation of orientation vectors.....................................................................113
2.11.2 Rotations of orientation vector.............................................................................................117
2.11.3 Extended interpolation of orientation axes...........................................................................121
2.12 Online tool length offset.......................................................................................................125
2.13 Examples.............................................................................................................................129
2.13.1 Example of a 5-axis transformation......................................................................................129
2.13.2 Example of a 3-axis and 4-axis transformation....................................................................132
2.13.2.1 Example of a 3-axis transformation......................................................................................132
2.13.2.2 Example of a 4-axis transformation......................................................................................132
2.13.3 Example of a universal milling head.....................................................................................132
2.13.4 Example for orientation axes................................................................................................134
2.13.5 Examples for orientation vectors..........................................................................................136
2.13.5.1 Example for polynomial interpretation of orientation vectors...............................................136
2.13.5.2 Example of rotations of orientation vector............................................................................137
2.13.6 Examples for generic axis transformations..........................................................................137
2.13.6.1 Example of a generic 6-axis transformation.........................................................................139
2.13.6.2 Example of a generic 7-axis transformation.........................................................................140
2.13.6.3 Example for the modification of rotary axis motion..............................................................141
2.14 Data lists..............................................................................................................................141
2.14.1 Machine data........................................................................................................................141
2.14.1.1 General machine data..........................................................................................................141
2.14.1.2 Channelspecific machine data.............................................................................................142
2.14.2 Setting data..........................................................................................................................145
2.14.2.1 General setting data.............................................................................................................145
2.14.2.2 Channelspecific setting data................................................................................................146
2.14.3 Signals.................................................................................................................................146
2.14.3.1 Signals from channel............................................................................................................146
3 G1: Gantry axes.......................................................................................................................................147
3.1 Brief description...................................................................................................................147
3.2 "Gantry axes" function..........................................................................................................148

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3.2.1 Definition of a gantry grouping.............................................................................................148

3.2.2 Monitoring the synchronism difference................................................................................149
3.2.3 Extended monitoring of the synchronism difference............................................................150
3.2.4 Referencing and synchronization of gantry axes.................................................................150
3.2.5 Control dynamics.................................................................................................................151
3.2.6 Opening the gantry grouping................................................................................................151
3.3 Referencing and synchronization of gantry axes.................................................................152
3.3.1 Introduction..........................................................................................................................152
3.3.2 Automatic synchronization...................................................................................................158
3.3.3 Points to note.......................................................................................................................159
3.4 Start-up of gantry axes.........................................................................................................162
3.5 Parameter assignment: Response to faults.........................................................................166
3.6 PLC interface signals for gantry axes..................................................................................167
3.7 Miscellaneous points regarding gantry axes........................................................................169
3.8 Examples.............................................................................................................................171
3.8.1 Creating a gantry grouping...................................................................................................171
3.8.2 Setting of NCK PLC interface...............................................................................................173
3.8.3 Commencing start-up...........................................................................................................173
3.8.4 Setting warning and trip limits..............................................................................................175
3.9 Data lists..............................................................................................................................176
3.9.1 Machine data........................................................................................................................176
3.9.1.1 Axis/spindlespecific machine data.......................................................................................176
3.9.2 Signals.................................................................................................................................177
3.9.2.1 Signals from mode group.....................................................................................................177
3.9.2.2 Signals from channel............................................................................................................177
3.9.2.3 Signals to axis/spindle..........................................................................................................178
3.9.2.4 Signals from axis/spindle.....................................................................................................178
4 K6: Contour tunnel monitoring..................................................................................................................179
4.1 Brief description...................................................................................................................179
4.1.1 Contour tunnel monitoring - 840D sl only.............................................................................179
4.1.2 Programmable contour accuracy.........................................................................................180
4.2 Contour tunnel monitoring - 840D sl only.............................................................................181
4.3 Programmable contour accuracy.........................................................................................182
4.4 Constraints...........................................................................................................................185
4.5 Data lists..............................................................................................................................186
4.5.1 Machine data........................................................................................................................186
4.5.1.1 Channelspecific machine data.............................................................................................186
4.5.1.2 Axis/spindlespecific machine data.......................................................................................186
4.5.2 Setting data..........................................................................................................................186
4.5.2.1 Channelspecific setting data................................................................................................186
5 K7: Kinematic chain - only 840D sl...........................................................................................................187
5.1 Function description.............................................................................................................187
5.1.1 Characteristics.....................................................................................................................187
5.2 Commissioning.....................................................................................................................191

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5.2.1 General................................................................................................................................191
5.2.1.1 Overview..............................................................................................................................191
5.2.1.2 Structure of the system variables.........................................................................................192
5.2.2 Machine data........................................................................................................................193
5.2.2.1 Maximum number of elements.............................................................................................193
5.2.2.2 Root element........................................................................................................................193
5.2.2.3 Maximum number of switches..............................................................................................193
5.2.3 System variables, all transformations types.........................................................................194
5.2.3.1 Overview..............................................................................................................................194
5.2.3.2 $NK_NAME..........................................................................................................................195
5.2.3.3 $NK_NEXT...........................................................................................................................196
5.2.3.4 $NK_PARALLEL..................................................................................................................196
5.2.3.5 $NK_TYPE...........................................................................................................................197
5.2.3.6 Type-dependent variables for $NK_TYPE = "AXIS_LIN".....................................................198
5.2.3.7 Type-dependent variables for $NK_TYPE = "AXIS_ROT"...................................................201
5.2.3.8 Type-dependent variables for $NK_TYPE = "ROT_CONST"...............................................205
5.2.3.9 Type-dependent variables for $NK_TYPE = "OFFSET"......................................................207
5.2.3.10 Type-dependent variables for $NK_TYPE = "SWITCH"......................................................208
5.2.3.11 $NK_SWITCH......................................................................................................................210
5.2.4 System variables, additive for orientation transformations...................................................211
5.2.4.1 Overview..............................................................................................................................211
5.2.5 System variables, additive for face transformation (TRANSMIT).........................................212
5.2.5.1 Overview..............................................................................................................................212
5.3 Programming........................................................................................................................213
5.3.1 Deletion of components (DELOBJ)......................................................................................213
5.3.2 Index determination by means of names (NAMETOINT).....................................................216
5.4 Example...............................................................................................................................217
5.4.1 Specifications.......................................................................................................................217
5.4.2 Part program of the machine model.....................................................................................219
5.5 Data lists..............................................................................................................................222
5.5.1 Machine data........................................................................................................................222
5.5.1.1 NC-specific machine data....................................................................................................222
5.5.2 System variables..................................................................................................................222
6 K8: Geometric machine modeling - only 840D sl.....................................................................................223
6.1 Function description.............................................................................................................223
6.1.1 Features...............................................................................................................................223
6.1.2 Automatic tool protection areas............................................................................................226
6.2 Commissioning.....................................................................................................................229
6.2.1 General................................................................................................................................229
6.2.1.1 Overview..............................................................................................................................229
6.2.1.2 Structure of the system variables.........................................................................................229
6.2.1.3 Color chart............................................................................................................................231
6.2.2 Machine data........................................................................................................................232
6.2.2.1 Maximum number of protection areas..................................................................................232
6.2.2.2 Maximum number of protection area elements for machine protection areas.....................232
6.2.2.3 Maximum number of protection area elements for automatic tool protection areas............232
6.2.2.4 Maximum number of NC/PLC interface signals for the preactivation of protection areas....232
6.2.2.5 Maximum number of triangles for machine protection areas...............................................232
6.2.2.6 Maximum number of triangles for automatic tool protection areas......................................232

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6.2.2.7 Creation mode for automatic tool protection areas..............................................................233

6.2.3 System variables: Protection areas......................................................................................233
6.2.3.1 Overview..............................................................................................................................233
6.2.3.2 $NP_PROT_NAME..............................................................................................................234
6.2.3.3 $NP_CHAIN_ELEM..............................................................................................................235
6.2.3.4 $NP_PROT_TYPE...............................................................................................................236
6.2.3.5 $NP_1ST_PROT..................................................................................................................237
6.2.3.6 $NP_PROT_COLOR............................................................................................................238
6.2.3.7 $NP_PROT_D_LEVEL.........................................................................................................239
6.2.3.8 $NP_BIT_NO........................................................................................................................240
6.2.3.9 $NP_INIT_STAT...................................................................................................................242
6.2.3.10 $NP_INDEX.........................................................................................................................243
6.2.4 System variables: Protection area elements for machine protection areas.........................244
6.2.4.1 Overview..............................................................................................................................244
6.2.4.2 $NP_NAME..........................................................................................................................245
6.2.4.3 $NP_NEXT...........................................................................................................................246
6.2.4.4 $NP_NEXTP........................................................................................................................247
6.2.4.5 $NP_COLOR........................................................................................................................249
6.2.4.6 $NP_D_LEVEL.....................................................................................................................250
6.2.4.7 $NP_USAGE........................................................................................................................251
6.2.4.8 $NP_TYPE...........................................................................................................................252
6.2.4.9 $NP_FILENAME..................................................................................................................255
6.2.4.10 $NP_PARA...........................................................................................................................257
6.2.4.11 $NP_OFF.............................................................................................................................258
6.2.4.12 $NP_DIR..............................................................................................................................259
6.2.4.13 $NP_ANG.............................................................................................................................261
6.2.5 System variables: Protection area elements for automatic tool protection areas................262
6.2.6 Boundary conditions.............................................................................................................263
6.3 Data lists..............................................................................................................................264
6.3.1 Machine data........................................................................................................................264
6.3.1.1 NC-specific machine data....................................................................................................264
6.3.2 System variables..................................................................................................................264
7 K9: Collision avoidance - only 840D sl.....................................................................................................267
7.1 Function description.............................................................................................................267
7.1.1 Characteristics.....................................................................................................................267
7.1.2 Reaction of the control to a risk of collision..........................................................................269
7.1.3 State diagram: Protection area............................................................................................272
7.1.4 Tools....................................................................................................................................273
7.1.5 Boundary conditions.............................................................................................................275
7.2 Commissioning.....................................................................................................................277
7.2.1 General................................................................................................................................277
7.2.1.1 Overview..............................................................................................................................277
7.2.1.2 Structure of the system variables.........................................................................................277
7.2.2 Machine data........................................................................................................................278
7.2.2.1 Enable..................................................................................................................................278
7.2.2.2 Collision tolerance................................................................................................................279
7.2.2.3 Safety clearance..................................................................................................................279
7.2.2.4 Maximum memory space.....................................................................................................280
7.2.2.5 Maximum number of collision pairs......................................................................................280
7.2.2.6 Protection levels for collision avoidance On/Off...................................................................281

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7.2.3 System variables..................................................................................................................281

7.2.3.1 Overview..............................................................................................................................281
7.2.3.2 $NP_COLL_PAIR.................................................................................................................282
7.2.3.3 $NP_SAFETY_DIST............................................................................................................283
7.2.4 Extend system variables......................................................................................................285
7.2.4.1 Overview..............................................................................................................................285
7.2.4.2 State data.............................................................................................................................285
7.2.4.3 Memory requirement............................................................................................................286
7.2.4.4 Braking distance estimations...............................................................................................286
7.3 Programming........................................................................................................................287
7.3.1 Check for collision pair (COLLPAIR)....................................................................................287
7.3.2 Request recalculation of the machine model of the collision avoidance (PROTA)..............289
7.3.3 Setting the protection area state (PROTS)..........................................................................290
7.3.4 Determining the clearance of two protection areas (PROTD)..............................................290
7.4 Example...............................................................................................................................292
7.4.1 Specifications.......................................................................................................................292
7.4.2 Part program of the machine model.....................................................................................296
7.5 Data lists..............................................................................................................................304
7.5.1 Machine data........................................................................................................................304
7.5.1.1 NC-specific machine data....................................................................................................304
7.5.2 System variables..................................................................................................................304
7.5.3 Signals.................................................................................................................................305
7.5.3.1 Signals to NC.......................................................................................................................305
7.5.3.2 Signals from NC...................................................................................................................305
7.5.3.3 Signals from channel............................................................................................................306
7.5.3.4 Signals from axis..................................................................................................................306
8 M3: Coupled axes.....................................................................................................................................307
8.1 Coupled motion....................................................................................................................307
8.1.1 Brief description...................................................................................................................307
8.1.1.1 Function...............................................................................................................................307
8.1.1.2 Preconditions.......................................................................................................................307
8.1.2 General functionality............................................................................................................308
8.1.3 Programming........................................................................................................................312
8.1.3.1 Definition and switch on of a coupled axis grouping (TRAILON).........................................312
8.1.3.2 Switch off (TRAILOF)...........................................................................................................312
8.1.4 Effectiveness of PLC interface signals.................................................................................313
8.1.5 Status of coupling.................................................................................................................314
8.1.6 Dynamics limit......................................................................................................................315
8.1.7 Supplementary conditions....................................................................................................316
8.1.8 Examples.............................................................................................................................316
8.2 Curve tables - 840D sl only..................................................................................................317
8.2.1 Product brief.........................................................................................................................317
8.2.1.1 Function...............................................................................................................................317
8.2.1.2 Preconditions.......................................................................................................................318
8.2.2 General functionality............................................................................................................318
8.2.3 Memory organization............................................................................................................319
8.2.4 Commissioning.....................................................................................................................321
8.2.4.1 Memory configuration...........................................................................................................321
8.2.4.2 Tool radius compensation....................................................................................................322

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8.2.4.3 Specification of memory type...............................................................................................322

8.2.5 Programming........................................................................................................................323
8.2.6 Access to table positions and table segments.....................................................................329
8.2.7 Activation/deactivation.........................................................................................................333
8.2.8 Modulo-leading axis special case........................................................................................334
8.2.9 Behavior in AUTOMATIC, MDA and JOG modes................................................................334
8.2.10 Effectiveness of PLC interface signals.................................................................................335
8.2.11 Diagnosing and optimizing utilization of resources..............................................................335
8.2.12 Supplementary conditions....................................................................................................339
8.2.13 Examples.............................................................................................................................339
8.3 Master value coupling - 840D sl only...................................................................................341
8.3.1 Product brief.........................................................................................................................341
8.3.1.1 Function...............................................................................................................................341
8.3.1.2 Preconditions.......................................................................................................................341
8.3.2 General functionality............................................................................................................341
8.3.3 Programming........................................................................................................................345
8.3.4 Behavior in AUTOMATIC, MDA and JOG modes................................................................349
8.3.5 Effectiveness of PLC interface signals.................................................................................351
8.3.6 Special characteristics of the axis master value coupling function......................................351
8.3.7 Supplementary conditions....................................................................................................352
8.4 Electronic gear (EG).............................................................................................................352
8.4.1 Product brief.........................................................................................................................352
8.4.1.1 Function...............................................................................................................................352
8.4.1.2 Preconditions.......................................................................................................................353
8.4.2 Definition of an EG axis group.............................................................................................361
8.4.3 Activating an EG axis group.................................................................................................362
8.4.4 Deactivating an EG axis group.............................................................................................367
8.4.5 Deleting an EG axis group...................................................................................................367
8.4.6 Interaction between rotation feedrate (G95) and electronic gearbox...................................368
8.4.7 Response to POWER ON, RESET, operating mode change, block search........................368
8.4.8 System variables for electronic gearbox..............................................................................369
8.4.9 Examples.............................................................................................................................370
8.4.9.1 Example using linear couplings............................................................................................370
8.4.9.2 Extended example with non-linear components..................................................................374
8.5 Generic coupling..................................................................................................................380
8.5.1 Brief description...................................................................................................................380
8.5.1.1 Function...............................................................................................................................380
8.5.1.2 Requirements.......................................................................................................................380
8.5.2 Fundamentals......................................................................................................................384
8.5.2.1 Coupling module..................................................................................................................384
8.5.2.2 Keywords and coupling characteristics................................................................................385
8.5.2.3 System variables..................................................................................................................388
8.5.3 Creating/deleting coupling modules.....................................................................................388
8.5.3.1 Creating a coupling module (CPDEF)..................................................................................388
8.5.3.2 Delete coupling module (CPDEL)........................................................................................389
8.5.3.3 Defining leading axes (CPLDEF or CPDEF+CPLA)............................................................390
8.5.3.4 Delete leading axes (CPLDEL or CPDEL+CPLA)................................................................391
8.5.4 Switching coupling on/off.....................................................................................................393
8.5.4.1 Switching on a coupling module (CPON).............................................................................393
8.5.4.2 Switch off coupling module (CPOF).....................................................................................393
8.5.4.3 Switching on leading axes of a coupling module (CPLON)..................................................394

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8.5.4.4 Switching off leading axes of a coupling module (CPLOF)..................................................395

8.5.4.5 Implicit creation and deletion of coupling modules...............................................................396
8.5.5 Programming coupling characteristics.................................................................................396
8.5.5.1 Coupling rule (CPLNUM, CPLDEN, CPLCTID)...................................................................396
8.5.5.2 Coupling relationship (CPLSETVAL)...................................................................................398
8.5.5.3 Co-ordinate reference (CPFRS):..........................................................................................399
8.5.5.4 Block change behavior (CPBC)...........................................................................................400
8.5.5.5 Synchronized position of the following axis when switching on (CPFPOS+CPON).............402
8.5.5.6 Synchronized position of the leading axis when switching on (CPLPOS)............................403
8.5.5.7 Synchronization mode (CPFMSON)....................................................................................404
8.5.5.8 Behavior of the following axis at switch-on (CPFMON).......................................................406
8.5.5.9 Behavior of the following axis at switch-off (CPFMOF)........................................................407
8.5.5.10 Position of the following axis when switching off (CPFPOS+CPOF)...................................408
8.5.5.11 Condition at RESET (CPMRESET)......................................................................................408
8.5.5.12 Condition at parts program start (CPMSTART)...................................................................410
8.5.5.13 Status during part program start in search run via program test (CPMPRT).......................411
8.5.5.14 Offset / scaling (CPLINTR, CPLINSC, CPLOUTTR, CPLOUTSC)......................................412
8.5.5.15 Synchronism monitoring stage 1 (CPSYNCOP, CPSYNFIP, CPSYNCOV, CPSYNFIV) ....415
8.5.5.16 Synchronous operation monitoring stage 2 (CPSYNCOP2, CPSYNFIP2)..........................419
8.5.5.17 Reaction to stop signals and commands (CPMBRAKE)......................................................423
8.5.5.18 Response to certain NC/PLC interface signals (CPMVDI) ..................................................424
8.5.5.19 Alarm suppression (CPMALARM)........................................................................................428
8.5.6 Coupling cascading..............................................................................................................429
8.5.7 Compatibility.........................................................................................................................430
8.5.7.1 Adaptive cycles....................................................................................................................430
8.5.7.2 Coupling types (CPSETTYPE).............................................................................................431
8.5.7.3 Projected coupling (CPRES)................................................................................................436
8.5.8 Cross-channel coupling, axis replacement..........................................................................437
8.5.9 Behavior with rotary axes.....................................................................................................437
8.5.10 Behavior during POWER ON, .............................................................................................439
8.5.11 CP SW limit monitoring........................................................................................................440
8.5.11.1 Function...............................................................................................................................440
8.5.11.2 Parameterization..................................................................................................................442
8.5.11.3 Programming........................................................................................................................443
8.5.11.4 Boundary conditions.............................................................................................................443
8.5.11.5 Examples.............................................................................................................................444
8.5.12 Disturbance characteristic....................................................................................................445
8.5.12.1 Rapid stop............................................................................................................................445
8.5.13 Tracking the deviation from synchronism.............................................................................446
8.5.13.1 Fundamentals......................................................................................................................446
8.5.13.2 Measuring the deviation from synchronism..........................................................................447
8.5.13.3 Entering the deviation from synchronism directly.................................................................450
8.5.13.4 Synchronism correction........................................................................................................450
8.5.13.5 Diagnostics for synchronism correction...............................................................................451
8.5.13.6 Resetting synchronism correction........................................................................................452
8.5.13.7 Limitations and constraints...................................................................................................453
8.5.14 Examples.............................................................................................................................455
8.5.14.1 Programming examples.......................................................................................................455
8.5.14.2 Adapt adaptive cycle............................................................................................................456
8.6 Dynamic response of following axis.....................................................................................457
8.6.1 Parameterized dynamic limits..............................................................................................457
8.6.2 Programmed dynamic limits.................................................................................................458

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8.6.2.1 Programming (VELOLIMA, ACCLIMA)................................................................................458

8.6.2.2 Examples.............................................................................................................................460
8.6.2.3 System variables..................................................................................................................461
8.7 General supplementary conditions.......................................................................................461
8.8 Data lists..............................................................................................................................462
8.8.1 Machine data........................................................................................................................462
8.8.1.1 NC-specific machine data....................................................................................................462
8.8.1.2 Channelspecific machine data.............................................................................................462
8.8.1.3 Axis/spindlespecific machine data.......................................................................................463
8.8.2 Setting data..........................................................................................................................463
8.8.2.1 Axis/spindle-specific setting data.........................................................................................463
8.8.3 System variables..................................................................................................................463
8.8.4 Signals.................................................................................................................................466
8.8.4.1 Signals to axis/spindle..........................................................................................................466
8.8.4.2 Signals from axis/spindle.....................................................................................................467
9 R3: Extended stop and retract..................................................................................................................469
9.1 Brief description...................................................................................................................469
9.2 Control-managed ESR - 840D sl only..................................................................................469
9.2.1 Extended stop and retract (ESR).........................................................................................469
9.2.2 Drive-independent reactions................................................................................................471
9.2.3 Power failure detection and bridging....................................................................................471
9.2.4 NC-controlled extended stop................................................................................................472
9.2.5 Retract..................................................................................................................................474
9.2.6 Trigger sources....................................................................................................................479
9.2.7 Logic gating functions: Source and reaction linking.............................................................480
9.2.8 Activation..............................................................................................................................481
9.2.9 Configuring aids for ESR......................................................................................................481
9.2.10 Control system response.....................................................................................................484
9.2.10.1 Axis behavior depending on the enable signals...................................................................484
9.2.10.2 POWER OFF/POWER ON..................................................................................................486
9.2.10.3 Operating mode change, NC Stop, reset.............................................................................486
9.2.10.4 Part program start, NC start.................................................................................................487
9.2.10.5 Alarm behavior.....................................................................................................................487
9.2.10.6 Block search, REPOS..........................................................................................................488
9.3 ESR executed autonomously in the drive............................................................................488
9.3.1 Fundamentals......................................................................................................................488
9.3.2 Configuring stopping in the drive..........................................................................................489
9.3.3 Configuring retraction in the drive........................................................................................491
9.3.4 Configuring generator operation in the drive........................................................................492
9.3.5 ESR is enabled via system variable.....................................................................................494
9.3.6 Triggering ESR via system variable.....................................................................................494
9.3.7 Feedback of the ESR status................................................................................................494
9.3.8 Acknowledge ESR reactions................................................................................................495
9.3.9 Configuring ESR in the part program...................................................................................496
9.3.9.1 Stopping (ESRS)..................................................................................................................497
9.3.9.2 Retraction (ESRR)...............................................................................................................497
9.3.9.3 Boundary conditions.............................................................................................................499
9.3.10 ESR and Safety Integrated (840D sl)...................................................................................500
9.3.11 ESR and Safety Integrated (828D)......................................................................................501

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9.4 Boundary conditions.............................................................................................................502

9.5 Examples.............................................................................................................................503
9.5.1 NC-controlled reactions........................................................................................................503
9.5.2 Retraction while thread cutting.............................................................................................504
9.5.3 Rapid lift using ASUB and fast input....................................................................................505
9.5.4 Rapid lift, absolute and incremental.....................................................................................505
9.5.5 Lift fast with linear relation of axes.......................................................................................506
9.6 Data lists..............................................................................................................................506
9.6.1 Machine data........................................................................................................................506
9.6.1.1 Channelspecific machine data.............................................................................................506
9.6.1.2 Axis/spindlespecific machine data.......................................................................................507
9.6.2 System variables..................................................................................................................507
9.6.3 Signals.................................................................................................................................507
9.6.3.1 Signals to channel................................................................................................................507
9.6.3.2 Signals to axis/spindle..........................................................................................................507
9.6.3.3 Signals from axis/spindle.....................................................................................................508
10 S9: Setpoint exchange - 840D sl only......................................................................................................509
10.1 Brief description...................................................................................................................509
10.2 Startup..................................................................................................................................509
10.3 Interface signals...................................................................................................................512
10.4 Interrupts..............................................................................................................................515
10.5 Position control loop.............................................................................................................515
10.6 Reference points..................................................................................................................515
10.7 Supplementary conditions....................................................................................................515
10.8 Data lists..............................................................................................................................516
10.8.1 Machine data........................................................................................................................516
10.8.1.1 Axis/spindlespecific machine data.......................................................................................516
11 T3: Tangential control - 840D sl only........................................................................................................517
11.1 Commissioning.....................................................................................................................518
11.2 Programming........................................................................................................................519
11.2.1 Defining coupling (TANG)....................................................................................................519
11.2.2 Activating intermediate block generation (TLIFT)................................................................521
11.2.3 Activating the coupling (TANGON)......................................................................................522
11.2.4 Deactivating the coupling (TANGOF)...................................................................................523
11.2.5 Deleting a coupling (TANGDEL)..........................................................................................524
11.3 Limit angle............................................................................................................................525
11.4 Supplementary conditions....................................................................................................526
11.5 Examples.............................................................................................................................526
11.6 Data lists..............................................................................................................................529
11.6.1 Machine data........................................................................................................................529
11.6.1.1 NC-specific machine data....................................................................................................529
11.6.1.2 Axis/spindlespecific machine data.......................................................................................529
11.6.2 Setting data..........................................................................................................................530

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11.6.2.1 Channel-specific setting data...............................................................................................530

11.6.3 System variables..................................................................................................................530
12 T4: Automatic post optimization with AST (option) - only 840D sl............................................................531
12.1 Function...............................................................................................................................531
12.2 Commissioning.....................................................................................................................533
12.3 Programming........................................................................................................................534
12.3.1 Overview..............................................................................................................................534
12.3.2 CYCLE751 - Open/execute/close optimization session.......................................................535
12.3.3 CYCLE752 - Add axis to an optimization session................................................................536
12.3.4 CYCLE753 - Select optimization mode................................................................................539
12.3.5 CYCLE754 - Add/remove data set.......................................................................................540
12.3.6 CYCLE755 - Backup/restore data........................................................................................541
12.3.7 CYCLE756 - Activate optimization results...........................................................................542
12.3.8 CYCLE757 - Save optimization data....................................................................................543
12.3.9 CYCLE758 - Change a parameter value.............................................................................547
12.3.10 CYCLE759 - Read parameter value....................................................................................548
12.3.11 List of the parameters for the automatic servo optimization.................................................549
12.4 Diagnostics...........................................................................................................................554
12.5 Supplementary conditions....................................................................................................555
12.6 Examples.............................................................................................................................555
12.6.1 Example 1: Measuring an axis with AST default settings....................................................555
12.6.2 Example 2: Reoptimize the speed controller of an axis.......................................................557
12.6.3 Example 3: Reoptimize the speed controller and the position controller of an axis.............560
12.6.4 Example 4: Reoptimization of the path interpolation............................................................564
12.6.5 Example 5: Reoptimize the speed control loop to eliminate known periodic disturbance
frequencies...........................................................................................................................568
12.6.6 Example 6: Measuring an axis without optimization............................................................570
13 TE01: Installation and activation of loadable compile cycles....................................................................573
13.1 Loading compile cycles........................................................................................................574
13.1.1 Loading a compile cycle with SINUMERIK Operate............................................................574
13.1.2 Loading a compile cycle with HMI Advanced.......................................................................575
13.1.3 Loading a compile cycle from an external computer with WinSCP3....................................576
13.2 Interface version compatibility..............................................................................................576
13.3 Software version of a compile cycle.....................................................................................578
13.4 Activating the technological functions in the NCK................................................................578
13.5 Function-specific startup......................................................................................................579
13.6 Creating alarm texts.............................................................................................................579
13.6.1 Creating alarm texts with SINUMERIK Operate...................................................................579
13.6.2 Creating alarm texts with HMI Advanced.............................................................................580
13.7 Upgrading a compile cycle...................................................................................................581
13.8 Deleting a compile cycle......................................................................................................582
13.9 Data lists..............................................................................................................................583
13.9.1 Machine data........................................................................................................................583
13.9.1.1 NC-specific machine data....................................................................................................583

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14 TE02: Simulation of Compile Cycles (only HMI Advanced)......................................................................585

14.1 Brief description...................................................................................................................585
14.1.1 Function...............................................................................................................................585
14.2 OEM transformations...........................................................................................................585
15 TE1: Clearance control - 840D sl only......................................................................................................587
15.1 Brief description...................................................................................................................587
15.1.1 General information..............................................................................................................587
15.1.2 Function description.............................................................................................................588
15.2 Clearance control.................................................................................................................589
15.2.1 Control dynamics.................................................................................................................589
15.2.2 Velocity feedforward control.................................................................................................591
15.2.3 Control loop structure...........................................................................................................592
15.2.4 Compensation vector...........................................................................................................593
15.3 Technological features of clearance control.........................................................................596
15.4 Sensor collision monitoring..................................................................................................597
15.5 Startup..................................................................................................................................598
15.5.1 Activating the technological function....................................................................................598
15.5.2 Configuring the memory.......................................................................................................598
15.5.3 Parameter settings for input signals (840D sl).....................................................................598
15.5.4 Parameters of the programmable compensation vector......................................................599
15.5.5 Parameter settings for clearance control.............................................................................601
15.5.6 Starting up clearance control...............................................................................................602
15.6 Programming........................................................................................................................604
15.6.1 Activating and deactivating clearance control (CLC)...........................................................604
15.6.2 Closed-loop control gain (CLC_GAIN).................................................................................609
15.6.3 Limiting the control range (CLC_LIM)..................................................................................611
15.6.4 Direction-dependent traversing motion disable....................................................................613
15.6.5 Voltage offset, can be set on a block-specific basis (CLC_VOFF).......................................615
15.6.6 Voltage offset definable by synchronized action..................................................................615
15.6.7 Selection of the active sensor characteristic (CLC_SEL).....................................................616
15.7 Function-specific display data..............................................................................................617
15.7.1 Channel-specific GUD variables..........................................................................................618
15.7.2 OPI variable.........................................................................................................................620
15.8 Function-specific alarm texts................................................................................................621
15.9 Supplementary conditions....................................................................................................621
15.9.1 I/O modules..........................................................................................................................621
15.9.1.1 External smoothing filters.....................................................................................................622
15.9.2 Function-specific supplementary conditions........................................................................622
15.10 Data lists..............................................................................................................................625
15.10.1 Machine data........................................................................................................................625
15.10.1.1 NC-specific machine data....................................................................................................625
15.10.1.2 Channelspecific machine data.............................................................................................625
15.10.1.3 Axis/spindlespecific machine data.......................................................................................626
15.10.2 Drive parameters (SINAMICS S120)...................................................................................626
15.10.3 Signals.................................................................................................................................627

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15.10.3.1 Signals to channel................................................................................................................627

15.10.3.2 Signals from channel............................................................................................................627
16 TE3: Speed/torque coupling, master-slave..............................................................................................629
16.1 Brief description...................................................................................................................629
16.2 Coupling diagram.................................................................................................................630
16.3 Configuring a coupling.........................................................................................................631
16.4 Torque compensatory controller..........................................................................................633
16.5 Tension torque.....................................................................................................................635
16.6 Closing/opening a coupling..................................................................................................639
16.7 Response on activation/deactivation....................................................................................641
16.8 Supplementary conditions....................................................................................................645
16.8.1 Functional boundary conditions...........................................................................................645
16.8.2 Axial NC/PLC interface signals............................................................................................647
16.8.3 Interaction with other functions............................................................................................648
16.9 Examples.............................................................................................................................654
16.9.1 Master-slave coupling between AX1=Master and AX2=Slave.............................................654
16.9.2 Close coupling via the PLC..................................................................................................654
16.9.3 Closing/separating the coupling via the part program for the SINUMERIK 840D sl............655
16.9.4 Release the mechanical brake.............................................................................................656
16.10 Data lists..............................................................................................................................657
16.10.1 Machine data........................................................................................................................657
16.10.1.1 Axis/spindlespecific machine data.......................................................................................657
16.10.2 System variables..................................................................................................................657
16.10.3 Signals.................................................................................................................................658
16.10.3.1 Signals to axis/spindle..........................................................................................................658
16.10.3.2 Signals from axis/spindle.....................................................................................................658
17 TE4: Handling transformation package - 840D sl only.............................................................................659
17.1 Brief description...................................................................................................................659
17.2 Kinematic transformation.....................................................................................................660
17.3 Definition of terms................................................................................................................660
17.3.1 Units and directions..............................................................................................................660
17.3.2 Definition of positions and orientations using frames...........................................................661
17.3.3 Definition of a joint................................................................................................................662
17.4 Configuration of a kinematic transformation.........................................................................663
17.4.1 General machine data..........................................................................................................664
17.4.2 Parameterization using geometry data................................................................................665
17.5 Descriptions of kinematics...................................................................................................677
17.5.1 3-axis kinematics..................................................................................................................677
17.5.2 4-axis kinematics..................................................................................................................684
17.5.3 5-axis kinematics..................................................................................................................690
17.5.4 6-axis kinematics..................................................................................................................694
17.5.5 Special kinematics...............................................................................................................695
17.6 Tool orientation....................................................................................................................699

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17.6.1 Orientation programming for 4-axis kinematics....................................................................701

17.6.2 Orientation programming for 5-axis kinematics....................................................................702
17.7 Singular positions and how they are handled......................................................................703
17.8 Call and application of the transformation............................................................................704
17.9 Actual value display.............................................................................................................705
17.10 Tool programming................................................................................................................706
17.11 Cartesian PTP travel with handling transformation package...............................................707
17.12 Startup..................................................................................................................................707
17.12.1 General commissioning........................................................................................................707
17.12.2 Function-specific commissioning.........................................................................................707
17.13 Supplementary conditions....................................................................................................709
17.14 Data lists..............................................................................................................................710
17.14.1 Machine data........................................................................................................................710
17.14.1.1 General machine data..........................................................................................................710
17.14.1.2 Channelspecific machine data.............................................................................................710
17.14.1.3 Channel-specific machine data for compile cycles..............................................................710
17.14.2 Signals.................................................................................................................................712
17.14.2.1 Signals from channel............................................................................................................712
18 TE6: MCS coupling - 840D sl only............................................................................................................713
18.1 Brief description...................................................................................................................713
18.2 Description of MCS coupling functions................................................................................714
18.2.1 Defining coupling pairs.........................................................................................................714
18.2.2 Switching the coupling ON/OFF...........................................................................................715
18.2.3 Tolerance window................................................................................................................716
18.2.4 Memory configuration: Block memory..................................................................................716
18.3 Description of collision protection.........................................................................................717
18.3.1 Defining protection pairs......................................................................................................717
18.3.2 Switching collision protection ON / OFF...............................................................................717
18.3.3 Configuring example............................................................................................................718
18.4 User-specific configurations.................................................................................................719
18.5 Special operating states.......................................................................................................720
18.6 Boundary conditions.............................................................................................................721
18.7 Data lists..............................................................................................................................721
18.7.1 Machine data........................................................................................................................721
18.7.1.1 Channelspecific machine data.............................................................................................721
18.7.1.2 Axis/spindlespecific machine data.......................................................................................722
19 TE7: Continue machining at the contour (retrace support) - 840D sl only ...............................................723
19.1 Brief description...................................................................................................................723
19.2 Function description.............................................................................................................724
19.2.1 Function...............................................................................................................................724
19.2.2 Definition of terms................................................................................................................726
19.2.3 Functional sequence (principle)...........................................................................................726
19.2.4 Maximum retraceable contour area.....................................................................................729

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19.3 Startup..................................................................................................................................730
19.3.1 Activation..............................................................................................................................730
19.3.2 Definition of the RESU working plane..................................................................................730
19.3.3 Memory configuration: Block memory..................................................................................730
19.3.4 Memory configuration: Heap memory..................................................................................731
19.3.5 RESU main program memory area......................................................................................732
19.3.6 Storage of the RESU subroutines........................................................................................733
19.3.7 ASUB enable........................................................................................................................733
19.3.8 PLC user program................................................................................................................734
19.4 Programming........................................................................................................................735
19.4.1 RESU Start/Stop/Reset (CC_PREPRE)...............................................................................735
19.5 RESU-specific part programs...............................................................................................736
19.5.1 Overview..............................................................................................................................736
19.5.2 Main program (CC_RESU.MPF)..........................................................................................737
19.5.3 INI program (CC_RESU_INI.SPF).......................................................................................738
19.5.4 END program (CC_RESU_END.SPF).................................................................................740
19.5.5 Retrace support ASUB (CC_RESU_BS_ASUP.SPF)..........................................................740
19.5.6 RESU ASUB (CC_RESU_ASUP.SPF)................................................................................741
19.6 Retrace support....................................................................................................................742
19.6.1 General information..............................................................................................................742
19.6.2 Block search with calculation on contour.............................................................................742
19.6.3 Reposition............................................................................................................................743
19.6.4 Temporal conditions concerning NC start............................................................................744
19.6.5 Block search from last main block........................................................................................745
19.7 Function-specific display data..............................................................................................746
19.7.1 Channel-specific GUD variables..........................................................................................746
19.8 Function-specific alarm texts................................................................................................747
19.9 Boundary conditions.............................................................................................................747
19.9.1 Function-specific supplementary conditions........................................................................747
19.9.1.1 Continue machining within subprograms.............................................................................747
19.9.1.2 Continue machining within program loops...........................................................................748
19.9.1.3 Machining continuation on full circles...................................................................................748
19.9.1.4 Automatically generated contour elements..........................................................................748
19.9.2 Supplementary conditions for standard functions................................................................749
19.9.2.1 Axis replacement..................................................................................................................749
19.9.2.2 Traversing movements of the channel axes........................................................................749
19.9.2.3 Block numbers.....................................................................................................................749
19.9.2.4 Block search.........................................................................................................................750
19.9.2.5 Transformations...................................................................................................................750
19.9.2.6 Compensations....................................................................................................................750
19.9.2.7 Frames.................................................................................................................................751
19.9.2.8 Tool offsets...........................................................................................................................751
19.10 Data lists..............................................................................................................................752
19.10.1 Machine data........................................................................................................................752
19.10.1.1 General machine data..........................................................................................................752
19.10.1.2 Channelspecific machine data.............................................................................................752

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20 TE8: Cycle-independent path-synchronous switching signal output - 840D sl only ................................753

20.1 Brief description...................................................................................................................753
20.2 Functional description..........................................................................................................754
20.2.1 General information..............................................................................................................754
20.2.2 Calculating the switching positions......................................................................................754
20.2.2.1 Block-related switching signal output...................................................................................754
20.2.2.2 Path length-related switching signal output..........................................................................756
20.2.3 Calculating the switching instants........................................................................................757
20.2.4 Switching frequency and switching position distance..........................................................757
20.2.5 Approaching switching position............................................................................................758
20.2.6 Programmed switching position offset.................................................................................759
20.2.7 Response to part program interruption................................................................................759
20.3 Startup..................................................................................................................................760
20.3.1 Activation..............................................................................................................................760
20.3.2 Memory configuration...........................................................................................................760
20.3.3 Parameterizing the digital on-board outputs........................................................................760
20.3.4 Parameterizing the switching signal.....................................................................................761
20.3.5 Parameterization of the geometry axes...............................................................................761
20.4 Programming........................................................................................................................762
20.4.1 Activating the block-related switching signal output (CC_FASTON)....................................762
20.4.2 Activating the path length-related switching signal output (CC_FASTON_CONT)..............763
20.4.3 Deactivation (CC_FASTOFF)...............................................................................................764
20.5 Function-specific alarm texts................................................................................................764
20.6 Supplementary conditions....................................................................................................765
20.6.1 Block search.........................................................................................................................765
20.6.2 Transformations...................................................................................................................766
20.6.3 Compensations....................................................................................................................767
20.6.4 Tool radius compensation (TRC).........................................................................................767
20.6.5 Continuous-path mode.........................................................................................................767
20.6.6 Software cams.....................................................................................................................768
20.7 Data lists..............................................................................................................................768
20.7.1 Machine data........................................................................................................................768
20.7.1.1 General machine data..........................................................................................................768
20.7.1.2 Channelspecific machine data.............................................................................................768
21 TE9: Axis pair collision protection.............................................................................................................769
21.1 Brief description...................................................................................................................769
21.1.1 Brief description...................................................................................................................769
21.2 Functional description..........................................................................................................769
21.3 Startup..................................................................................................................................770
21.3.1 Enabling the technology function (option)............................................................................770
21.3.2 Activating the technology function........................................................................................770
21.3.3 Definition of an axis pair.......................................................................................................771
21.3.4 Retraction direction..............................................................................................................772
21.3.5 Offset for the machine coordinate systems..........................................................................772
21.3.6 Protection window................................................................................................................773
21.3.7 Orientation............................................................................................................................773

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 Table of contents

21.3.8 Protection window extension................................................................................................774

21.3.9 Activating the protection function.........................................................................................774
21.3.10 Axis-specific acceleration.....................................................................................................774
21.3.11 Monitoring status (GUD)......................................................................................................775
21.3.12 PLC interface for axis-specific braking operations...............................................................775
21.4 Limitations and constraints...................................................................................................776
21.4.1 Precedence of function-specific acceleration.......................................................................776
21.4.2 Axis container.......................................................................................................................776
21.4.3 Interpolatory couplings.........................................................................................................778
21.5 Examples.............................................................................................................................778
21.5.1 Collision protection...............................................................................................................778
21.5.2 Collision protection and distance limiter...............................................................................780
21.6 Data lists..............................................................................................................................781
21.6.1 Option data...........................................................................................................................781
21.6.2 Machine data........................................................................................................................782
21.6.2.1 NC-specific machine data....................................................................................................782
21.6.2.2 Axis/Spindle-specific machine data......................................................................................782
21.6.3 User data..............................................................................................................................782
21.6.3.1 Global user data (GUD).......................................................................................................782
22 V2: Preprocessing....................................................................................................................................783
22.1 Brief description...................................................................................................................783
22.2 Program handling.................................................................................................................785
22.3 Program call.........................................................................................................................788
22.4 Constraints...........................................................................................................................790
22.5 Examples.............................................................................................................................791
22.5.1 Preprocessing individual files...............................................................................................791
22.5.2 Preprocessing in the dynamic NC memory..........................................................................793
22.6 Data lists..............................................................................................................................793
22.6.1 Machine data........................................................................................................................793
22.6.1.1 General machine data..........................................................................................................793
22.6.1.2 Channelspecific machine data.............................................................................................794
23 W5: 3D tool radius compensation - 840D sl only......................................................................................795
23.1 Brief description...................................................................................................................795
23.1.1 General information..............................................................................................................795
23.1.2 Machining modes.................................................................................................................797
23.2 Circumferential milling..........................................................................................................798
23.2.1 Corners for circumferential milling........................................................................................799
23.2.2 Behavior at outer corners.....................................................................................................800
23.2.3 Behavior at inside corners....................................................................................................804
23.3 Face milling..........................................................................................................................809
23.3.1 Cutter shapes.......................................................................................................................809
23.3.2 Orientation............................................................................................................................811
23.3.3 Compensation on path.........................................................................................................812
23.3.4 Corners for face milling........................................................................................................813
23.3.5 Behavior at outer corners.....................................................................................................814

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Function Manual, 10/2015, 6FC5397-2BP40-5BA3 27
Table of contents

23.3.6 Behavior at inside corners....................................................................................................815

23.3.7 Monitoring of path curvature................................................................................................817
23.4 Selection/deselection of 3D TRC.........................................................................................817
23.4.1 Selection of 3D TRC............................................................................................................818
23.4.2 Deselection of 3D TRC........................................................................................................819
23.5 Constraints...........................................................................................................................819
23.6 Examples.............................................................................................................................820
23.7 Data lists..............................................................................................................................821
23.7.1 General machine data..........................................................................................................821
23.7.2 Channelspecific machine data.............................................................................................822
24 W6: Path length evaluation - 840D sl only................................................................................................823
24.1 Brief description...................................................................................................................823
24.2 Data......................................................................................................................................824
24.3 Parameterization..................................................................................................................824
24.3.1 General activation................................................................................................................824
24.3.2 Data groups..........................................................................................................................824
24.4 Examples.............................................................................................................................825
24.4.1 Traversal per part program..................................................................................................825
24.5 Data lists..............................................................................................................................826
24.5.1 Machine data........................................................................................................................826
24.5.1.1 NC-specific machine data....................................................................................................826
24.5.1.2 Axis/spindlespecific machine data.......................................................................................826
25 Z3: NC/PLC interface signals...................................................................................................................827
25.1 F2: 3 to 5-axis transformation..............................................................................................827
25.1.1 Signals from channel (DB21, ...)..........................................................................................827
25.2 G1: Gantry axes...................................................................................................................829
25.2.1 Signals to axis/spindle (DB31, ...)........................................................................................829
25.2.2 Signals from axis/spindle (DB31, ...)....................................................................................830
25.3 K9: Collision avoidance........................................................................................................833
25.3.1 Signals from PLC to NC (DB10)...........................................................................................833
25.3.2 Signals from the NC to the PLC (DB10)...............................................................................834
25.3.3 Signals from channel (DB21)...............................................................................................835
25.3.4 Signals from axis (DB31).....................................................................................................835
25.4 M3: Axis couplings...............................................................................................................836
25.4.1 Signals to axis (DB31, ...).....................................................................................................836
25.4.2 Signals from axis (DB31, ...)................................................................................................836
25.5 R3: Extended stop and retract.............................................................................................837
25.5.1 Signals from axis/spindle (DB31, ...)....................................................................................837
25.6 S9: Setpoint changeover......................................................................................................838
25.6.1 Signals to axis/spindle (DB31, ...)........................................................................................838
25.6.2 Signals from axis/spindle (DB31, ...)....................................................................................839
25.7 T3: Tangential control..........................................................................................................839
25.7.1 Special response to signals.................................................................................................839

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28 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 Table of contents

25.8 TE1: Clearance control........................................................................................................839

25.8.1 Signals to channel (DB21, ...)..............................................................................................839
25.8.2 Signals from channel (DB21, ...)..........................................................................................840
25.9 TE3: Speed/torque coupling, master-slave..........................................................................842
25.9.1 Signals to axis/spindle (DB31, ...)........................................................................................842
25.9.2 Signals from axis/spindle (DB31, ...)....................................................................................842
25.10 TE4: Transformation package, handling..............................................................................843
25.10.1 Signals from channel (DB21, ...)..........................................................................................843
25.11 TE6: MCS coupling..............................................................................................................844
25.11.1 Signals to axis/spindle (DB31, ...)........................................................................................844
25.11.2 Signals from axis/spindle (DB31, ...)....................................................................................845
25.12 TE7: Continue machining at the contour – retrace support..................................................846
25.12.1 Signals to channel................................................................................................................846
25.12.2 Signals from channel............................................................................................................847
A Appendix...................................................................................................................................................849
A.1 List of abbreviations.............................................................................................................849
A.2 Overview..............................................................................................................................858
Glossary...................................................................................................................................................859
Index.........................................................................................................................................................881

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Function Manual, 10/2015, 6FC5397-2BP40-5BA3 29
Table of contents

Special functions
30 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
Fundamental safety instructions 1
1.1 General safety instructions

WARNING
Risk of death if the safety instructions and remaining risks are not carefully observed
If the safety instructions and residual risks are not observed in the associated hardware
documentation, accidents involving severe injuries or death can occur.
● Observe the safety instructions given in the hardware documentation.
● Consider the residual risks for the risk evaluation.

WARNING
Danger to life or malfunctions of the machine as a result of incorrect or changed
parameterization
As a result of incorrect or changed parameterization, machines can malfunction, which in turn
can lead to injuries or death.
● Protect the parameterization (parameter assignments) against unauthorized access.
● Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY
STOP or EMERGENCY OFF).

1.2 Industrial security

Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, solutions, machines, equipment and/or networks. They are
important components in a holistic industrial security concept. With this in mind, Siemens’
products and solutions undergo continuous development. Siemens recommends strongly that
you regularly check for product updates.
For the secure operation of Siemens products and solutions, it is necessary to take suitable
preventive action (e.g. cell protection concept) and integrate each component into a holistic,
state-of-the-art industrial security concept. Third-party products that may be in use should also
be considered. For more information about industrial security, visit this address (http://
www.siemens.com/industrialsecurity).
To stay informed about product updates as they occur, sign up for a product-specific
newsletter. For more information, visit this address (http://support.automation.siemens.com).

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 31
Fundamental safety instructions
1.2 Industrial security

WARNING
Danger as a result of unsafe operating states resulting from software manipulation
Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe
operating states to develop in your installation which can result in death, severe injuries and/
or material damage.
● Keep the software up to date.
You will find relevant information and newsletters at this address (http://
support.automation.siemens.com).
● Incorporate the automation and drive components into a holistic, state-of-the-art industrial
security concept for the installation or machine.
You will find further information at this address (http://www.siemens.com/
industrialsecurity).
● Make sure that you include all installed products into the holistic industrial security concept.

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32 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
F2: Multi-axis transformations 2
2.1 Brief description

Note
The transformations described below require that individual names are assigned to machine
axes, channels and geometry axes when the transformation is active. Compare macchine data:
MD10000 $MN_AXCONF_MACHAX_NAME_TAB (machine axis name)
MD20080 $MC_AXCONF_CHANAX_NAME_TAB (name of the channel axis in the channel)
MD20060 $MC_AXCONF_GEOAX_NAME_TAB (name of the geometry axis in the channel)
Besides this no unambiguous assignments are present.

2.1.1 5-axis Transformation

Function
The "5-Axis Transformation" machining package is designed for machining sculptured
surfaces that have two rotary axes in addition to the three linear axes X, Y, and Z. This package
thus allows an axially symmetrical tool (milling cutter, laser beam) to be oriented in any desired
relation to the workpiece in the machining space.
The path and path velocity are programmed in the same way as for 3-axis tools. The tool
orientation is programmed additionally in the traversing blocks.
The real-time transformation performs the calculation of the resulting motion of all 5 axes. The
generated machining programs are therefore not machine specific. Kinematic-specific post-
processors are not used for the 5-axis machining operation.
A selection of various transformations is available for adapting the control to various machine
kinematics. Part program commands can be issued in operation to switch over between two
transformations parameterized during start-up.
This package therefore covers the three possible basic machine configurations which differ in
terms of tool and workpiece orientation:
● Orientation of tool with two-axis swivel head (machine type 1)
● Orientation of workpiece with two-axis rotary table (machine type 2)
● Orientation of workpiece and tool with single-axis rotary table and swivel head (machine
type 3)
The calculation also includes tool length compensation.
Since the orientation in relation to the workpiece surface is stored in a separate FRAME, a tool
retraction operation with vertical orientation to the workpiece is also possible.

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Function Manual, 10/2015, 6FC5397-2BP40-5BA3 33
F2: Multi-axis transformations
2.1 Brief description

Tool orientation
Tool orientation can be specified in two ways:
● Machine-related orientation
The machine-related orientation is dependent on the machine kinematics.
● Workpiece-related orientation
The workpiece-related orientation is not dependent on the machine kinematics.
It is programmed by means of:
– Euler angles
– RPY angles
– Vector components
The direction of the tool is described in the workpiece coordinate system with the part
orientation. It is possible to program a specific component of the tool in its orientation to
the workpiece. In most cases, this will be a longitudinal axis of the tool with the tool tip (Tool
Center Point, TCP), which is also referred to as TCP-programming.

System variables for orientation

Part programs and synchronized actions can access the system variables that provide
information on the following, in read only mode:
● End orientation of block (run-in value)
● Setpoint orientation
● Actual value orientation
● Switching between setpoint and actual value orientation
● Status for variables of actual value orientation

Special cases of 5-Axis transformation

The following transformations are to be entered as special cases of the general 5-Axis
transformation:
● 3-axis and 4-axis transformation
There are 2 or 3 linear axes and a rotary axis.
● Swivelling linear axis
One of the rotary axis rotates the 3rd linear axis.
● Universal milling head
The two rotary axes are positioned at a projectable angle in relation to one another.
Knowledge of the general 5-axis transformation is a prerequisite for all of these transformations.

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34 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.1 Brief description

2.1.2 3-axis and 4-axis transformation

Function
The 3- and 4-Axis transformations are distinguished by the following characteristics:

Transformation Features
3-axis Transformation 2 linear axes
1 rotary axis
4-Axis transformation 3 linear axes
1 rotary axis

Both types of transformation belong to the orientation transformations. Orientation of the tool
must be programmed explicitly. The orientation of the tool is executed in a plane perpendicular
to the rotary axis.

] ]

% %
= =

< <

[
[

; ;

Figure 2-1 Schematic diagram of 3-axis transformation

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Function Manual, 10/2015, 6FC5397-2BP40-5BA3 35
F2: Multi-axis transformations
2.1 Brief description

]
=

<

Figure 2-2 Schematic diagram of a 4-axis transformation with moveable workpiece

2.1.3 Orientation transformation with a swiveling linear axis.

Function
The orientation transformation with swiveling linear axis is similar to the 5-axis transformation
of Machine Type 3, though the 3rd linear axis is not always perpendicular to the plane defined
by the other two linear axes.

Features of kinematics
● Kinematics with three linear axes and two orthogonal rotary axes.
● Rotary axes are parallel to two of the three linear axes.
● The first rotary axis is moved by two Cartesian linear axes. It rotates the third linear axis,
which moves the tool. The tool is aligned parallel to the third linear axis.
● The second rotary axis rotates the workpiece.
● The kinematics comprise a moved workpiece and a moved tool.
The following figure shows the interrelations for one of the possible axis sequences, for which
transformation is possible.

Special functions
36 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.1 Brief description

6ZLYHOLQJOLQHDUD[LV


=


5RWDU\D[LV

ZRUNSLHFH

/LQHDUD[LV

5RWDU\D[LV

; 


< 


 %

/LQHDUD[LV
0DFKLQH]HUR

Figure 2-3 Schematic diagram of a machine with swiveling linear axis

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Function Manual, 10/2015, 6FC5397-2BP40-5BA3 37
F2: Multi-axis transformations
2.1 Brief description

2.1.4 Universal milling head

Function
A machine tool with a universal milling head has got at least 5 axes:
● 3 linear axes
– for linear movement [X, Y, Z]
– move the machining point to any random position in the working area
● 2 rotary swivelling axes
– are arranged under a configurable angle (mostly 45 Degree)
– enable the tool to define orientations in space
(are limited to a hemisphere in a 45 degree arrangement)

$D[LV

&D[LV

7RROD[LV

Figure 2-4 Schematic diagram of a machine tool with universal milling head

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38 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.1 Brief description

2.1.5 Orientation axes

Model for describing change in orientation

There is no such simple correlation between axis motion and change in orientation in case of
robots, hexapodes or nutator kinamatics, as in the case of conventional 5-axes machines.
For this reason, the change in orientation is defined by a model that is created independently
of the actual machine. This model defines three virtual orientation axes which can be visualized
as rotations about the coordinate axes of a rectangular coordinate system.
For the purpose of 6-axis transformation, a third degree of freedom for orientation, describing
the rotation of the tool about itself, has been introduced.

Real-time transformation
The Cartesian coordinates are converted from basic to machine coordinate system by means
of a real-time transformation process.
These Cartesian coordinates comprise:
● Geometry axes
Geometry axes describe the machining point.
● Orientation axes
Orientation axes describe the orientation of a tool in space.

Tool orientation
You can define the orientation of the tool in space as follows using linear interpolation, large
circle interpolation and by means of orientation vectors:
● Direct programming of rotary axis positions A, B, C
5-axis transformation by programming:
– The Euler- or RPY angle in degrees through A2,B2,C2
or
– The direction vector over A3,B3,C3
● Programming using lead angle LEAD and tilt angle TILT

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Function Manual, 10/2015, 6FC5397-2BP40-5BA3 39
F2: Multi-axis transformations
2.1 Brief description

2.1.6 Cartesian manual travel

Function
The "Cartesian Manual Operation" function can be used to set one of the following coordinate
systems as reference system for JOG motion to be selected separately for translation and
orientation as:
● Basic coordinate system (BCS)
● Workpiece coordinate system (WCS)
● Tool coordinate System (TCS)

2.1.7 Cartesian PTP travel

Function
The "Cartesian PTP Travel" [PTP = Point-to-point movement (Point to Point)] function can be
used to program a position in a cartesian coordinate system (workpiece coordinate system).
The machine however moves in its machine coordinates.
The function can be used, for example, to traverse a singularity. Cartesian positions, supplied
by a CAD system, need not been converted to machine axis values.
It must also be noted that axes take longer to traverse in the Cartesian coordinate system with
active transformation and programmed feedrate than when they are traversed directly.

2.1.8 Generic 5-axis transformation

Function
The generic 5-axis transformation function differs from earlier 5-axis transformation versions
insofar as it is no longer restricted with respect to the directions of rotary axes.
The basic orientation of the tool is no longer predefined in machine data as was the case in
earlier versions of orientation transformations, but can now be programmed freely.

2.1.9 Online tool length offset

Function
The system variable $AA_TOFF[ ] can be used to overlay the effective tool lengths in 3-D in
runtime. For an active orientation transformation (TRAORI) or for an active tool carrier that can
be oriented, these offsets are effective in the particular tool axes.

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40 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.2 5-axis transformation

If the tool orientation changes, the tool length offsets that apply are rotated so that the pivot
point for the orientation movement always refers to the corrected tool tip.

2.1.10 Activation via parts/program/softkey

The machine data relevant to the kinematic transformation has thus far been activated mostly
through POWER ON.
Transformations MDs can also be activated via the part program / softkey and it is not
necessary to boot the control system.
References:
Function Manual, Extended Functions; Kinematic Transformations (M1),
Section: Cartesian PTP travel

2.1.11 Orientation compression

During the execution of NC programs containing blocks with relatively short traverse paths,
the interpolator clock cycle can lead to a reduction in tool path velocity and a corresponding
increase in machining time.

COMPON, COMPCURV, COMPCAD

You can run NC programs with short traverse paths without reducing the tool path velocity by
activating "compressors" COMPON, COMPCURV or COMPCAD. The compressor also
smoothes the programmed movements and consequently tool path velocity.

Programming of direction vectors

Programming of tool orientation that is independent of the kinematics, can be achieved through
programming of direction vectors. NC programs with such direction vectors can be executed
with compressors COMPON, COMPCURV and COMPCAD.

2.2 5-axis transformation

2.2.1 Kinematic transformation

Task of orientation transformation

The task of orientation transformation is to compensate movements of the tool nose, which
result from changes in orientation, by means of appropriate compensating movements of the
geometry axes. The orientation movement is therefore decoupled from the movement on the
workpiece contour. Various machine kinematics each require their own orientation
transformation.

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Function Manual, 10/2015, 6FC5397-2BP40-5BA3 41
F2: Multi-axis transformations
2.2 5-axis transformation

Fields of application
The "5-axis transformation" machining package is provided for machine tools, which have two
additional rotary axes (rotation about the linear axes) in addition to three linear axes X, Y and
Z: This package thus allows an axially symmetrical tool (milling cutter, laser beam) to be
oriented in any desired relation to the workpiece in every point of the machining space.
The workpiece is always programmed in the rectangular workpiece coordinate system; any
programmed or set frames rotate and shift this system in relation to the basic system. The
kinematic transformation then converts this information into motion commands of the real
machine axes.
The kinematic transformation requires information about the design (kinematics) of the
machine, which are stored in machine data.
The kinematic transformation does not act on positioning axes.

2.2.2 Machine types for 5-axis transformation

Kinematics of machines for 5-axis transformation

5-axis machines are generally equipped with three linear and two rotary axes: the latter may
be implemented as a two-axis swivel head, a two-axis rotary table or as a combination of single-
axis rotary table and swivel head. These types of machine are characterized by:
1. Three linear axes form a right-handed, Cartesian coordinate system.
2. Rotary axes are parallel to the traversing direction of one of the linear axes.
Example:
– A parallel to X
– B parallel to Y
– C parallel to Z
3. Rotary axes are positioned vertically one above the other.
4. Rotary axes turn
– Tool with two-axis swivel head (machine type 1)
– Workpiece with two-axis rotary table (machine type 2)
– Tool and workpiece with single-axis rotary table and swivel head (machine type 3)
5. The following applies to machine types 1 and 2:
– Rotary axis 1 is treated as the 4th machine axis of the transformation.
– Motion of 1st rotary axis changes the orientation of the 2nd rotary axis.
– Rotary axis 2 is treated as the 5th machine axis of the transformation.
– Motion of 2nd rotary axis does not change the orientation of the 1st rotary axis.

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42 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.2 5-axis transformation

6. The following applies to machine type 3:

– 1. Rotary axis (4th machine axis of transformation) turns the tool.
– 2. Rotary axis (5th machine axis of transformation) turns the tool.
7. Initial tool position:
– in negative Z direction.

6ZLYHOKHDGFDQ = 6ZLYHOKHDGFDQEH 6ZLYHOKHDG

EHURWDWHGDERXW; URWDWHGDERXW<D[LV IL[HG
D[LVDQG=D[LV
&
<

2
; 7RROWDEOHFDQEH 7RROWDEOHFDQEH
URWDWHGDERXW= URWDWHGDERXW;D[LV
= D[LV = DQG=D[LV
& & <

7RROWDEOHIL[HG 2
;

URWDWHGWRRO URWDWHGWRRO URWDWHGZRUNSLHFH

URWDWHGZRUNSLHFH

0DFKLQHW\SH 0DFKLQHW\SH 0DFKLQHW\SH

7ZRD[LVVZLYHOKHDG 6LQJOHD[LVVZLYHOKHDG 7ZRD[LVURWDU\WDEOH
ZLWKWKHD[LVDUUDQJHPHQW&$ DQGVLQJOHD[LVURWDU\WDEOH ZLWKWKHD[LVDUUDQJHPHQW$&
ZLWKWKHD[LVDUUDQJHPHQW%&

Figure 2-5 Machine types for 5-axis transformation

Note
Transformations that do not fulfill all the conditions mentioned here (3 and 4-axis
transformations, orientation transformation with swivelling linear axes, universal milling
head) are described in separate sub chapters.

2.2.3 Configuration of a machine for 5-axis transformation

To ensure that the 5-axis transformation can convert the programmed values to axis motions,
certain information about the mechanical design of the machine is required; this information
is stored in machine data:
● Machine type
● Axis assignment
● Geometry information
● Assignment of direction of rotation

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Function Manual, 10/2015, 6FC5397-2BP40-5BA3 43
F2: Multi-axis transformations
2.2 5-axis transformation

Machine type
The machine types have been designated above as types 1 to 3 and are stored in the following
machine data as a two-digit number:
MD24100 $MC_TRAFO_TYPE_1 (definition of channel transformation 1)
...
MD24480 $MC_TRAFO_TYPE_10 (definition of channel transformation 10)
The following table contains a list of machine types, which are suitable for 5-axis transformation.

axis se‐ Machine type 1 Machine type 2 Machine type 3

quence with swivelling / rotary tool with swivelling / rotary work‐ with swivelling / rotary tool/
piece workpiece
AB 16 32 48
AC x 33 49

BA 18 34 50
BC x 35 51

CA 20 x x
CB 21 x x

Combinations that are not meaningful, whose C-axis corresponds to a rotation of the tool about its
longitudinal axis (symmetry axis), are marked by x.

Identification of axis sequence

The axis sequence is identified in the following way:
● AB means: A is 4th axis, B is 5th axis of transformation
● For machine type 3, the swivel axis of the tool is the 4th axis of the transformation and the
rotary axis of the workpiece is the 5th axis of the transformation.

Axis assignment
The axis assignment at the start of the 5-axis transformation defines the axis that will be
mapped by the transformation internally onto a channel axis. Thus, the following is defined in
the machine data below:
MD24110 $MC_TRAFO_AXES_IN_1 (Axis assignment for transformation 1)
...
MD24482 $MC_TRAFO_AXES_IN_10 (Axis assignment for transformation 10)

Geometry information
Information concerning machine geometry is required so that the 5-axis transformation can
calculate axis values: This information is stored in the machine data (in this case, for the first
transformation in the channel):

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44 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.2 5-axis transformation

MD24500 $MC_TRAFO5_PART_OFFSET_1 (workpiece-oriented offset)

● for machine type 1 (two-axis swivel head)
Vector from machine reference point to table zero point (zero vector)
● for machine type 2 (two-axis rotary table)
Vector from last table swivel joint to zero point of table

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Figure 2-6 Machine data MD24500 $MC_TRAFO5_PART_OFFSET_1 for machine type 2

● for machine type 3 (single-axis swivel head and single-axis rotary table)
Vector from joint of table to zero point of table
MD24560 $MC_TRAFO5_JOINT_OFFSET_1 (vector of the kinematic offset of 5-axis
transformation 1)
Vector from the first to the second swivel joint (machine type 1 and 2)
Vector from machine zero point to the swivel joint of the table (machine type 3)
MD24510 $MC_TRAFO5_ROT_AX_OFFSET_1 (position offset of rotary axes 1/2/3 5-axis
transformation 1) angle offset of the first or second rotary axis

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 45
F2: Multi-axis transformations
2.2 5-axis transformation

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po $MC_TRAFO5_PART_OFFSET_n[0 ..2]
x Vector of programmed position in BCS
t Tool correction vector
to $MC_TRAFO5_BASE_TOOL_n[0 .. 2]
jo $MC_TRAFO5_JOINT_OFFSET_n[0 .. 2]

Figure 2-7 Schematic diagram of CA kinematics, moved tool

Special functions
46 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.2 5-axis transformation

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Figure 2-8 Schematic diagram of CB kinematics, moved workpiece

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Figure 2-9 Schematic diagram of AC kinematics, moved tool, moved workpiece

Assignment of direction of rotation

The sign interpretation setting for a rotary axis is stored in the sign machine data for 5-axis
transformation.

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 47
F2: Multi-axis transformations
2.2 5-axis transformation

MD24520 $MC_TRAFO5_ROT_SIGN_IS_PLUS_1[n] (sign of rotary axis 1/2/3 for 5-axis

transformation 1)
MD24620 $MC_TRAFO5_ROT_SIGN_IS_PLUS_2[n] (sign of rotary axis 1/2/3 for 5-axis
transformation 2)

Transformation types
Ten transformation types per channel can be configured in the following machine data:
MD24100 $MC_TRAFO_TYPE_1 ...MD24480 $MC_TRAFO_TYPE_10 (definition of
transformation 1 in channel … definition of transformation 10 in channel)
Of these eight types, a maximum of two may be 5-axis transformations.

Activation
Activation of the 5-axis transformation is described in the section "Activation and Application
of 3- to 5-axis Transformation".

2.2.4 Tool orientation

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Figure 2-10 Machining of workpieces with 5-axis transformation

Special functions
48 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.2 5-axis transformation

Programming
The orientation of the tool can be programmed in a block directly by specifying the rotary axes
or indirectly by specifying the Euler angle, RPY angle and direction vector. The following
options are available:
● directly as rotary axes A, B, C
● indirectly for 5-axis transformation:
via Euler or RPY angles in degrees via A2, B2, C2
● Indirectly for 5-axis transformation via direction vector A3, B3, C3
The identifiers for Euler angles and direction vectors can be set in machine data:
Euler angles via:
MD10620 $MN_EULER_ANGLE_NAME_TAB (name of Euler angles)
Direction vector via:
MD10640 $MN_DIR_VECTOR_NAME_TAB (name of direction vectors)
The tool orientation can be located in any block. Above all, it can be programmed alone in a
block, resulting in a change of orientation in relation to the tool tip which is fixed in its
relationship to the workpiece.

Euler or RPY
The following machine data can be used to switch between Euler and RPY angles:
MD21100 $MC_ORIENTATION_IS_EULER (angle definition for orientation programming)

Orientation reference
A tool orientation at the start of a block can be transferred to the block end in two different
ways:
● in the workpiece coordinate system with command ORIWKS
● in the machine coordinate system with command ORIMKS

ORIWKS command
The tool orientation is programmed in the workpiece coordinate system (WCS) and is thus not
dependent on the machine kinematics.
In the case of a change in orientation with the tool tip at a fixed point in space, the tool moves
along a large arc on the plane stretching from the start vector to the end vector.

ORIMKS command
The tool orientation is programmed in the machine coordinate system and is thus dependent
on the machine kinematics.
In the case of a change in orientation of a tool tip at a fixed point in space, linear interpolation
takes place between the rotary axis positions.

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 49
F2: Multi-axis transformations
2.2 5-axis transformation

The orientation is selected via NC language commands ORIWKS and ORIMKS.

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Figure 2-11 Change in cutter orientation while machining inclined edges

Special functions
50 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.2 5-axis transformation

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Figure 2-12 Change in orientation while machining inclined edges

ORIMKS constitutes the basic setting

The basic setting can be changed via the following machine data:
MD20150 MC_GCODE_RESET_VALUES (RESET position of G groups)
MD20150 $MC_GCODE_RESET_VALUES [24] = 1 ⇒ ORIWKS is basic setting
MD20150 $MC_GCODE_RESET_VALUES [24] = 2 ⇒ ORIWKS is basic setting

Illegal tool orientation

If tool position is programmed in relation to the following functions, alarm 12130 "Illegal tool
orientation" is output when Euler angles and direction vectors are selected and the NC program
then stops (this alarm can also occur in connection with G331, G332 and G63).
● G04: Dwell time
● G33: Thread cutting with constant lead
● G74: Approaching a reference point
● G75: Approaching a fixed point
● REPOSL: Repositioning to the contour
● REPOSQ: Repositioning to the contour
● REPOSH: Repositioning to the contour
To remedy this situation, tool orientation can be programmed with axis end values.

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Function Manual, 10/2015, 6FC5397-2BP40-5BA3 51
F2: Multi-axis transformations
2.2 5-axis transformation

Alarm 17630 or 17620 is output for G74 and G75 if a transformation is active and the axes to
be traversed are involved in the transformation. This applies irrespective of orientation
programming.
If the start and end vectors are inverse parallel when ORIWKS is active, then no unique plane
is defined for the orientation programming, resulting in the output of alarm 14120.
If a transformation switch (switch On, switch Off or change transformation) is undertaken, alarm
14400 will be generated.
In the reverse situation, i.e. a tool radius offset is selected or deselected when a transformation
is active, no alarm message is output.

Multiple input of tool orientation

According to DIN 66025, only one tool orientation may be programmed in a block, e.g. with
direction vectors:

N50 A3=1 B3=1 C3=1

If tool orientation is entered multiply, i.e. with direction vectors and with Euler angles, error
message 12240 "Channel X block Y tool orientation xx defined more than once" is displayed
and the NC part program stops.

N60 A3=1 B3=1 C3=1 A2=0 B2=1 C2=3

Tool orientation using orientation vectors

Polynomials can also be programmed for the modification of the orientation vector.
This method produces an extremely smooth change in speed and acceleration at the block
changes for rotary axes when the tool orientation has to be programmed over several blocks.
The interpolation of orientation vectors can be programmed with polynomials up to the 5th
degree. Polynomial interpolation of orientation vectors is described in the "Polynomial
Interpolation of Orientation Vectors" section.

Note
Further explanations of tool orientation using orientation vectors and their handling in machines
are given in:
Reference:
Function Manual, Basic Machine; Tool Offset; Orientable Toolholders (W1)

2.2.5 Singular positions and handling

Extreme velocity increase

If the path runs in close vicinity to a pole (singularity), one or several axes may traverse at a
very high velocity.

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52 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.2 5-axis transformation

Alarm 10910 "Irregular velocity run in a path axis" is then triggered. The programmed velocity
is then reduced to a value, which does not exceed the maximum axis velocity.

Behavior at pole
Unwanted behavior of fast compensating movements can be controlled by making an
appropriate selection of the following machine data (see following Figure):
● MD24530 $MC_TRAFO5_NON_POLE_LIMIT_1 (definition of pole area for 5-axis
transformation 1)
● MD24630 $MC_ TRAFO5_NON_POLE_LIMIT_2 (definition of pole area for 5-axis
transformation 2)
● MD24540 $MC_TRAFO5_POLE_LIMIT_1 (closing angle tolerance for interpolation by pole
for 5-axis transformation)
● MD24640 $MC_TRAFO5_POLE_LIMIT_2 (closing angle tolerance for interpolation by pole
for 5-axis transformation)
Note
Singularities are dealt with differently in SW 5.2 and higher: Only one relevant machine
data item exists, $MC_TRAFO5_POLE_LIMIT (see Section "Singularities of orientation
(Page 85)" or "Programming Manual, Production Planning).

Definition of the pole range for 5-axis transformation

This machine data identifies a limit angle of the 5th axis of the first MD24530
$MC_TRAFO5_NON_POLE_LIMIT_1 or the second MD24630
$MC_TRAFO5_NON_POLE_LIMIT_2 5-axis transformation with the following properties:
If the path runs past the pole at an angle lower than the value set here, it crosses through the
pole.
With the 5-axis transformation, a coordinate system consisting of circles of longitude and
latitude is spanned over a spherical surface by the two orientation axes of the tool.
If, as a result of orientation programming (i.e. the orientation vector is positioned on one plane),
the path passes so close to the pole that the angle is less than the value defined in this machine
data, then a deviation from the specified interpolation is made so that the interpolation passes
through the pole.

End angle tolerance for interpolation by pole for 5-axis transformation

This machine data identifies a limit angle for the 5th axis of the first MD24540
$MC_TRAFO5_NON_POLE_LIMIT_1 or the second MD24640
$MC_TRAFO5_NON_POLE_LIMIT_2 5-axis transformation with the following properties:
With interpolation through the pole point, only the fifth axis moves; the fourth axis remains in
its start position. If a movement is programmed which does not pass exactly through the pole
point, but is to pass within the tolerance defined by the following machine data in the vicinity

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Function Manual, 10/2015, 6FC5397-2BP40-5BA3 53
F2: Multi-axis transformations
2.2 5-axis transformation

of the pole, a deviation is made from the specified path because the interpolation runs exactly
through the pole point.
● MD24530 $MC_TRAFO5_NON_POLE_LIMIT_1
● MD24630 $MC_TRAFO5_NON_POLE_LIMIT_2
As a result, the position at the end point of the fourth axis (pole axis) deviates from the
programmed value.
This machine data specifies the angle by which the pole axis may deviate from the programmed
value with a 5-axis transformation if a switchover is made from the programmed interpolation
to interpolation through the pole point. In the case of a greater deviation, an error message is
output and the interpolation is not executed.

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Figure 2-13 5-axis transformation; orientation path in pole vicinity. Example for machine type 1: 2-axis
swivel head with rotary axis RA 1 (4th axis of transformation) and rotary axis RA 2 (5th
axis of transformation)

Behavior during large circle interpolation at pole position

The following machine data can be used to set the response for large circle interpolation in
pole position as follows:
MD21108 $MC_POLE_ORI_MODE

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54 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.3 3-axis and 4-axis transformations

Does not define the treatment of changes in orientation during large circle interpolation unless
the starting orientation is equal to the pole orientation or approximates to it and the end
orientation of the block is outside the tolerance circle defined in the following machine data.
● MD24530 $MC_TRAFO5_NON_POLE_LIMIT_1
● MD24630 $MC_TRAFO5_NON_POLE_LIMIT_2
The position of the polar axis is arbitrary in the polar position. For the large circle interpolation,
however, a specified orientation is required for this axis.
The following machine data is coded decimally.
MD21108 $MC_POLE_ORI_MODE
The units define the behavior if start orientation coincides with pole position and the decade
the behavior if start orientation is within the tolerances defined by the following machine data:
● MD24530 $MC_TRAFO5_NON_POLE_LIMIT_1
● MD24630 $MC_TRAFO5_NON_POLE_LIMIT_2
All setting values are described in "Channel-specific Machine Data".

2.3 3-axis and 4-axis transformations

Introduction
3-axis and 4-axis transformations are special types of the 5-axis transformation initially
described. Orientation of the tool is possible only in the plane perpendicular to the rotary axis.
The transformation supports machine types with movable tool and movable workpiece.

Kinematics variants
The variants specified in the following table apply both for 3-axis and 4-axis transformations.

Variants of 3-axis and 4-axis transformations

Machine type swiveling/ rotary axis is orientation plane $MC_TRA‐ Tool orientation in
rotary parallel FO_TYPE_n zero position
1 Tool X Y-Z 16 Z
Y X-Z 18
Z X-Y 20 Y
Z X-Y 21 X
any any * 24 Any
2 workpiece X Y-Z 32, 33 Z
Y X-Z 34, 35
Any any * 40 Any
*
Note: on types 24 and 40 *
In the case of transformation types 24 and 40, the axis of rotation and tool orientation can be
set so that the change in orientation takes place at the outside of a taper and not in a plane.

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 55
F2: Multi-axis transformations
2.4 Transformation with swiveled linear axis

Zero position
Tool orientation at zero position is the position of the tool with G17 as the active working plane
and position of the rotary axis at 0 degrees.

Axis assignments
The three translatory axes included in the transformation are assigned to any channel axes
via machine data $MC_TRAFO_GEOAX_ASSIGN_TAB_n[0..2] and
$MC_TRAFO_AXES_IN_n[0..2]. The following must apply for the assignment of channel axes
to geometry axes for the transformation:
$MC_TRAFO_GEOAX_ASSIGN_TAB_n[0] = $MC_TRAFO_AXES_IN_n[0]
$MC_TRAFO_GEOAX_ASSIGN_TAB_n[1] = $MC_TRAFO_AXES_IN_n[1]
$MC_TRAFO_GEOAX_ASSIGN_TAB_n[2] = $MC_TRAFO_AXES_IN_n[2]
The axes with corresponding index must be assigned to each other.

Parameter assignment procedure

● Enter the type of transformation according to the previous table as machine data:
$MC_TRAFO_TYPE_n
● Assign channel axes to the geometry axes of the transformation.
● For a 3-axis transformation, set the values for the axis, which is not required:
– $MC_TRAFO_GEOAX_ASSIGN_TAB_n[geoax] = 0
– $MC_TRAFO_AXES_IN_n[geoax] = 0
$MC_TRAFO_AXES_IN_n[4] = 0; → there is no 2nd rotary axis
● For a 4-axis transformation, set the following for the 3 linear axes
– $MC_TRAFO_GEOAX_ASSIGN_TAB_n[geoax] = ...
– $MC_TRAFO_AXES_IN_n[geoax] = ...
$MC_TRAFO_AXES_IN_n[4] = 0; → there is no 2nd rotary axis
Complete examples of a 3-axis and 4-axis transformation can be found in "Example for 3- and
4-axis Transformation" section.

2.4 Transformation with swiveled linear axis

General information
The "transformation with swiveling linear axis forms" a transformation group of its own. It can
be used when a kinematic as described in the Section "Orientation transformation with a
swiveling linear axis. (Page 36)" is present:
● Three Cartesian linear axes (X, Y, Z) and two orthogonal rotary axes (A, B).
● The rotary axes are parallel to two of the three linear axes.

Special functions
56 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.4 Transformation with swiveled linear axis

● The first rotary axis (A) is moved by two Cartesian linear axes. It rotates the third linear axis
(Z) that moves the tool.
● The tool is aligned parallel to the third linear axis (Z).
● The second rotary axis (B) rotates the workpiece.
Additional requirement:
● The first rotary axis (A) may only sweep a very small swivel range (swivel range << ± 90°).
Note
All the axis values used in the text relate to the designations of the example machine in the
following figure "Machine with swiveling linear axis Z"

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Figure 2-14 Example: Machine with swiveling linear axis Z

Pole
The transformation with swiveling linear axis has a pole for a tool orientation parallel to the
second rotary axis (B). Singularity occurs in the pole position because the third linear axis (Z)
is parallel to the plane of the first two linear axes (X, Y), thus excluding the possibility of
compensating movements perpendicular to this plane.

Parameterization

Kinematic variants
The kinematic variant of the machine is set in the machine data:

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 57
F2: Multi-axis transformations
2.4 Transformation with swiveled linear axis

MD24100, ... MD25190 $MC_TRAFO_TYP_n = <type>, with n = 1, 2, 3, ...

Kinematics <type>
1. Rotary axis 2. rotary axis swiveled linear axis Bits 6 - 0
A B Z 10,00 000
A C Y 10,00 001
B A Z 10,00 010
B C X 10,00 011
C A Y 10,00 100
C B X 10,00 101

Machine kinematics
The machine kinematics is set for the 1st ($MC_TRAFO5 ... _1) and/or 2nd ($MC_TRAFO5 ...
_2) 5-axis transformation in the channel set with the following machine data:
● Vector (po, see following figure) from the second rotary axis to workpiece table zero:
– MD24500 $MC_TRAFO5_PART_OFFSET_1
– MD24600 $MC_TRAFO5_PART_OFFSET_2
● Axis positions of the two rotary axes at the initial position of the machine:
– MD24510 $MC_TRAFO5_ROT_AX_OFFSET_1
– MD24610 $MC_TRAFO5_ROT_AX_OFFSET_2
● Sign with which the rotary axis positions are included in the transformation:
– MD24520 $MC_TRAFO5_ROT_SIGN_IS_PLUS_1
– MD24620 $MC_TRAFO5_ROT_SIGN_IS_PLUS_2
● Vector (jo) from machine zero to the second rotary axis:
– MD24560 $MC_TRAFO5_JOINT_OFFSET_1
– MD24660 $MC_TRAFO5_JOINT_OFFSET_2
● Vector (to) from the toolholder (flange) to the first rotary axis (measured at machine initial
position):
– MD24550 $MC_TRAFO5_BASE_TOOL_1
– MD24650 $MC_TRAFO5_BASE_TOOL_2
● Vector (ro) from machine zero to the first rotary axis (measured at the machine initial
position):
– MD24562 $MC_TRAFO5_TOOL_ROT_AX_OFFSET_1
– MD24662 $MC_TRAFO5_TOOL_ROT_AX_OFFSET_2

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58 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.4 Transformation with swiveled linear axis

Determining the machine data values

As an aid for determining the values for the above-mentioned machine data, the following two
sketches clarify the relationships between the vectors.

Note
Requirement
The machine has been traversed so that the toolholding flange aligns with the table zero (*).
Is this is technically not possible, vector to must be corrected by the deviations.

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Figure 2-15 Projections of the vectors to be set in the machine data

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 59
F2: Multi-axis transformations
2.4 Transformation with swiveled linear axis

Note
A physically identical point on the 1st rotary axis (e.g. point of intersection between the tool
axis and the 1st rotary axis) must be assumed for both views.

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Figure 2-16 Machine in the zero position

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Figure 2-17 Front view: Vectors for machine in the zero position

Special functions
60 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.4 Transformation with swiveled linear axis

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Figure 2-18 Top view: Vectors for machine in the zero position

Determination of the machine data values

Perform the following operation:
1. Determine, as shown in the lower part for vector jo in the "Vectors for machine in zero
position" figure, the X and Y components for all vectors.
2. As shown in the upper part for vector ro in the "Vectors for machine in zero position" figure,
determine the Z component for all vectors.
3. Enter the X, Y and Z components of the vectors (po, jo, to, ro) in the relevant machine data.
The procedure can be used all settable kinematic variants.

Note
For the appropriate machine geometry or position of the machine zero, both individual
components as well as complete vectors can become zero.

Programming
The switch on/off of the transformation in the part program or synchronized action is described
in Section "Programming of the 3- to 5-axis transformation (Page 66)".

Tool orientation
For a transformation with swiveling linear axis, the same statements as for the 5-axis
transformation with regard to the tool orientation apply similarly (see Section "Tool
orientation (Page 48)").

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 61
F2: Multi-axis transformations
2.5 Cardan milling head

2.5 Cardan milling head

2.5.1 Fundamentals of cardan milling head

Note
The following description of the cardan milling head transformation has been formulated on
the assumption that the reader has already read and understood the general 5-axis
transformation described in Section "5-axis transformation (Page 41)". Please note that where
no specific statements relating to the cardan milling head are made in the following section,
the statements relating to general 5-axis transformation apply.

Applications
A cardan milling head is used for machining contours of sculptured parts at high feedrates. An
excellent degree of machining accuracy is achieved thanks to the rigidity of the head.

C
ϕ

A’

C A’

z
y
tool tool

Figure 2-19 Schematic representation of the cardan milling head versions

Configuring the nutator angle φ

The angle of the inclined axis can be configured in a machine data:
$MC_TRAFO5_NUTATOR_AX_ANGLE_1: for the first orientation transformation
$MC_TRAFO5_NUTATOR_AX_ANGLE_2: for the second orientation transformation
The angle must lie within the range of 0 degrees to +89 degrees.

Special functions
62 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 F2: Multi-axis transformations
2.5 Cardan milling head

Tool orientation
Tool orientation at zero position can be specified as follows:
● parallel to the first rotary axis or
● perpendicular to it, and in the plane of the specified axis sequence

Types of kinematics
The axis sequence of the rotary axes and the orientation direction of the tool at zero position
are set for the different types of kinematics using the following machine data:
$MC_TRAFO_TYPE_1 ... $MC_TRAFO_TYPE_10

Axis designation scheme

As for the other 5-axis transformations, the following applies:
the rotary axis ...
...A is parallel to X: A' is below the angle φ to the X axis
...B is parallel to Y: B' is below angle φ to the Y axis
...C is parallel to Z: C' is below angle φ to the Z axis

Angle definition

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=
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Figure 2-20 Position of axis A'

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 63
F2: Multi-axis transformations
2.5 Cardan milling head

Axis A' is positioned in the plane spanned by the rectangular axes of the designated axis
sequence. If, for example, the axis sequence is CA', then axis A' is positioned in plane Z-X.
The angle φ then is the angle between axis A' and the X axis.

2.5.2 Parameterization

Setting the type of transformation

The transformation type is set with the machine data of the corresponding transformation data
block:
MD24100, ... MD25190 $MC_TRAFO_TYP_n, with n = 1, 2, 3, ...

Bit <value> Description

7 1 Activation of the transformation for cardan milling head
6-5 Moving component
00 Movable tool
01 Movingworkpiece
10 movable tool and workpiece
4-3 Direction of orientation of tool in position zero
00 X direction
01 Y direction
10 Z direction
2-0 Axis sequence
000 AB' or A'B
001 AC' or A'C
010 BA' or B'A
011 BC' or B'C
100 CA' or C'A
101 CB' or C'B

The following transformation types can be set:

Axis se‐ Moving component: Bits 6 - 5

quence: Tool Workpiece Tool/workpiece
Bits 0 - 2 00 01 10
Zero position 1) Zero position 1) Zero position 1)
X Y Z X Y Z X Y Z
00 01 10 00 01 10 00 01 10
AB' / A'B x x - - - - - - -
000
AC' / A'C x - x - - - - - -
001
BA' / B'A x x - - - - x x
010

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2.5 Cardan milling head

Axis se‐ Moving component: Bits 6 - 5

quence: Tool Workpiece Tool/workpiece
Bits 0 - 2 00 01 10
Zero position 1) Zero position 1) Zero position 1)
X Y Z X Y Z X Y Z
00 01 10 00 01 10 00 01 10

BC' / B'C - x x - x x - - -
011
CA' / C'A x - x - - - - - -
100
CB' / C'B - x x - - - - - -
101
1) Orientation of the tool in the zero position: Bits 3 - 4
x: Transformation type can be set
-: Transformation type cannot be set

Active machining plane

The tool orientation at the zero position can be set not only in the Z direction. For this reason,
ensure that the active working plane is set so that the tool length compensation acts in the tool
orientation direction.
The active machining plane should always be the plane according to which the tool orientation
is set in position zero.

Other settings
The geometry information used by the cardan milling head transformation for calculation of
the axis values is set in the same way as that of the other 5-axis transformations.

2.5.3 Traverse of the cardan milling head in JOG mode

JOG
In JOG mode, the linear axes can be traversed normally. It is, however, difficult to set the
orientation correctly by traversing these axes.

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2.6 Programming of the 3- to 5-axis transformation

2.6 Programming of the 3- to 5-axis transformation

Switch on
The 3- to 5-axis transformations, including the transformations with swiveled linear axis and
cardan milling head, are enabled with the TRAORI(<transformation-no.>) command.
The enable of the transformation sets the NC/PLC interface signal:
DB21, ... DBX33.6 = 1 (transformation active)

Deactivation
With the TRAFOOF command disables the currently active 3- to 5-axis transformation. The
disable of the transformation resets the NC/PLC interface signal:
DB21, ... DBX33.6 = 0 (transformation inactive)

Switch-over
If a transformation is already active in the channel, the TRAORI(<transformation-no.>)
with a new transformation number command can be used to switch to another transformation.

Reset / program end

The control behavior after startup, program end or NC reset is set in the machine data:
MD20110 $MC_RESET_MODE_MASK, bit 7 = <value>

<value> Meaning
0 Initial setting for active transformation after reset / program end according to $MC_TRA‐
FO_RESET_VALUE
1 The active transformation remains active over reset / program end

Option
The "5-axis transformation" function, together with its special forms, is an option.

References
A detailed description of the machine data can be found in:
Parameter Manual, Detailed Machine Data Description

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2.7 Generic 5-axis transformation and variants

2.7.1 Functionality

Scope of functions
The scope of functions of generic 5-axis transformation covers implemented 5-axis
transformations (see Section "5-axis transformation (Page 41)") for perpendicular rotary axes
as well as transformations for the cardan milling head (one rotary axis parallel to a linear axis,
the second rotary axis at any angle to it, see Section "Cardan milling head (Page 62)").

Applications
In certain cases, it may not be possible to compensate the conventional transformation
machine accuracy, e.g. if:
● the rotary axes are not exactly mutually perpendicular or
● one of the two rotary axes is not positioned exactly parallel to the linear axes
In such cases, generic 5-axis transformation can produce better results.
Programming example
for generic 5-axis transformation is shown in Section "Example for Generic 5-axis
Transformation".

Activation
Generic 5-axis transformation can also be activated like any other orientation transformation
using the TRAORI() or TRAORI(n) command (where n is the number of the transformation).
Furthermore, the basic transformation can be transferred in the call in three other parameters,
e.g. TRAORI(1, 1.1, 1.5, 8.9).
A transformation can be deselected implicitly by selecting another transformation or explicitly
with TRAFOOF.

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2.7.2 Description of machine kinematics

Machine types
Like the existing 5-axis transformations, there are three different variants of generic 5-axis
transformation:
1. Machine type: Rotatable tool
Both rotary axes change the orientation of the workpiece. The orientation of the workpiece
is fixed.
2. Machine type: Rotatable workpiece
Both rotary axes change the orientation of the workpiece. The orientation of the tool is fixed.
3. Machine type: Rotatable tool and rotatable workpiece - one rotary axis changes the tool
orientation and the other the workpiece orientation.

Configurations
As previously, the machine configurations are defined in the following machine data (see
Section "Configuration of a machine for 5-axis transformation (Page 43)"):
$MC_TRAFO_TYPE_1, ..., _8
Additional types have been introduced for generic 5-axis transformation:

Table 2-1 Overview of machine types for the generic 5-axis transformation

Machine type 1 2 3
Swivel/rotatable: tool workpiece Tool/workpiece
Transformation types 24 40 56

Rotary axis direction

The direction of the rotary axis is defined by the following machine data:
$MC_TRAFO5_AXIS1_n (1st rotary axis) and
$MC_TRAFO5_AXIS2_n (2nd rotary axis)
where n is 1 or 2 for the first or second 5-axis transformation in the system respectively. The
machine data specified above are fields with three values, which describe that axis direction
vectorially (similar to the description of rotary axes for orientable toolholder). The absolute
value of the vectors is insignificant; only the defined direction is relevant.
Example:
1. A-axis is the rotary axis (parallel to the x direction):
MD24570 $MC_TRAFO5_AXIS1_1[0] = 1.0 (direction first rotary axis)
MD24570 $MC_TRAFO5_AXIS1_1[1] = 0.0
MD24570 $MC_TRAFO5_AXIS1_1[2] = 0.0
2. B-axis is the rotary axis (parallel to the y direction):

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MD24572 $MC_TRAFO5_AXIS2_1[0] = 0.0 (direction 2nd rotary axis)

MD24572 $MC_TRAFO5_AXIS2_1[1] = 1.0
MD24572 $MC_TRAFO5_AXIS2_1[2] = 0,0

2.7.3 Generic orientation transformation variants

Extension
Generic orientation transformation for 5-axis transformation has been extended with the
following variants for 3-and 4-axis transformation:

Variant 1
4-axis transformations
A 4-axis transformation is characterized by the exclusive use of the first rotary axis as an entry
axis of the transformation. The following applies:
MD24110 $MC_TRAFO_AXES_IN_1[4] = 0 (axis assignment for transformation 1) or
MD24210 $MC_TRAFO_AXES_IN_2[4] = 0 (axis assignment for transformation 2)

Variant 2
3-axis transformations
In a 3-axis transformation, one of the geometry axes is not present, by entering a zero in the
field:
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1[n] (assignment between geometry axis
and channel axis for transformation 1)
MD24220 $MC_TRAFO_GEOAX_ASSIGN_TAB_2[n] (assignment between geometry axis
and channel axis for transformation 2)

Transformation types
Both variants of generic 3- or 4-axis transformation are described by the following
transformation types:
● 3- or 4-axis transformation with rotatable tool
$MC_TRAFO_TYPE_n = 24
● 3- or 4-axis transformation with rotatable workpiece
$MC_TRAFO_TYPE_n = 40
In conventional 3-axis or 4-axis transformations, the transformation type also defined the basic
tool orientation in addition to the position of the rotary axis, which could then no longer be
influenced.

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Effects on orientations
Generic 3-axis or 4-axis transformation has the following effect on the various orientations:
The resulting tool orientation is defined according to the hierarchy specified for generic 5-axis
transformation.
Priority:
● high: programmed orientation,
● medium: tool orientation and
● low: basic orientation
Allowance is made, in particular, for the following orientations:
● A programmed tool orientation
● A basic tool orientation, modified by orientable toolholders.
Note
Further information on programmable tool orientation and on basic tool orientation can be
found in:
Reference:
Function Manual, Basic Machine; Tool Offset; Orientable Toolholders (W1)
Programming Manual, Fundamentals

Comparison
Besides the 3- and 4-axis transformations mentioned in Section "3- and 4-axis
Transformations", the following differences should be noted:
● Position of the rotary axis:
– can be arbitrary
– need not be parallel to a linear axis
● Direction of the rotary axis
– Must be defined by the following machine data:
MD24570 $MC_TRAFO5_AXIS1_1[n] (direction first rotary axis) or
MD24670 $MC_TRAFO5_AXIS1_2[n] (direction first rotary axis)
● Basic tool orientation
– Must be defined by the following machine data:
MD24574 $MC_TRAFO5_BASE_ORIENT_1[n] (workpiece orientation) or
MD24674 $MC_TRAFO5_BASE_ORIENT_2[n] (workpiece orientation)
● Selection of a generic 3-/4-axis transformation
– Optional tool orientation can be transferred as in the case of a generic 5-axis
transformation.

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2.7.4 Parameterization of orientable toolholder data

Application
Machine types for which the table or tool can be rotated, can either be operated as true 5-axis
machines or as conventional machines with orientable toolholders. In both cases, machine
kinematics is determined by the same data, which, due to different parameters, previously had
to be entered twice - for toolholder via system variables and for transformations via machine
data. The new transformation type 72 can be used to specify that these two machine types
access identical data.

Transformation type 72
The following machine data can be used to define a generic 5-axis transformation for
transformation type 72 with kinematic data read from the data for an orientable toolholder.
MD24100 $MC_TRAFO_TYPE_1 (definition of transformation 1 in the channel) or
MD24200 $MC_TRAFO_TYPE_2 (definition of transformation 2 in the channel)
From this number data is made available via machine data MD24582
$MC_TRAFO5_TCARR_NO_1 (TCARR-Number for the first 5-axis transformation) for the first
or MD24682 $MC_TRAFO5_TCARR_NO_2 (TCARR-Number for the second 5-axis
transformation) for the second orientation transformation. The corresponding transformation
type can then be derived from the content of kinematic type with parameter $TC_CARR23 -
see following table.

Table 2-2 Machine types for generic 5-axis transformation

Machine type 1 2 3 4
Swivel/ tool workpiece Tool/workpiece Type 3 or orienta‐
rotatable: ble toolholder
Kinematic type: T P M T, P, M
Transformation 24 40 56 72 from content of
type: $TC_CARR23

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Note
The transformation only takes place if the orientable toolholder concerned is available and the
value of $TC_CARR23 contains a valid entry for type M, P or T kinematics in lower or upper
case.
Transformation machine data for the first orientation transformation listed in the tables below
are equally valid for the second orientation transformation. All other machine data that may
affect the transformation characteristics and do not appear in the tables below, remain valid
and effective:
MD24110/MD24210 $MC_TRAFO_AXES_IN_1/2 (axis assignment for transformation) or
MD24574/MD24674 $MC_TRAFO5_BASE_ORIENT_1/2 (basic tool orientation)
If in the tables below a second additive parameter appears in brackets for the parameters of
the orientable toolholder (e.g. $TC_CARR24 (+ $TC_TCARR64)), the sum of both values will
only be effective if the fine offset specified in setting data is active when the data is transferred
from the orientable toolholder.
SD42974 $SC_TOCARR_FINE_CORRECTION = TRUE (fine offset TCARR on/off)

Activation
The most significant parameter values of an orientable toolholder for a transformation can be
activated in the part program with NEWCONFIG. Alternatively, the machine data concerned
for transformation type 72 can be activated via the HMI user interface.

Assignment for all types of transformation

The assignments between the toolholder data for writing the linear offsets and the
corresponding machine data for kinematic transformations are determined by the
transformation type. The following assignment of all other parameters is identical for all three
possible types of transformation:

Assignment for all types of transformation together identical

MD24100 $MC_TRAFO_TYPE_1 (definition of transfor‐ 24 $TC_CARR23 = T
mation 1 in the channel) 40 P
56 M
MD24570 $MC_TRAFO5_AXIS1_1[0] (direction first rotary axis) $TC_CARR7
MD24570 $MC_TRAFO5_AXIS1_1[1] $TC_CARR8
MD24570 $MC_TRAFO5_AXIS1_1[2] $TC_CARR9
MD24572 $MC_TRAFO5_AXIS2_1[0] (direction second rotary ax‐ $TC_CARR10
is)
MD24572 $MC_TRAFO5_AXIS2_1[1] $TC_CARR11
MD24572 $MC_TRAFO5_AXIS2_1[2] $TC_CARR12
MD24510 $MC_TRAFO5_ROT_AX_OFFSET_1[0] (position offset $TC_CARR24 (+
of rotary axes 1/2/3 for 5-axis transformation) 1) $TC_TCARR64)

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Assignment for all types of transformation together identical

MD24510 $MC_TRAFO5_ROT_AX_OFFSET_1[1] $TC_CARR25 (+
$TC_TCARR65)
MD24520 $MC_TRAFO5_ROT_SIGN_IS_PLUS_1[0] (sign of rotary TRUE*
axis 1/2/3 for 5-axis transformation 1)
MD24520 $MC_TRAFO5_ROT_SIGN_IS_PLUS_1[1] TRUE*

*) Machine data MD24520/MD24620 $MC_TRAFO5_ROT_SIGN_IS_PLUS_1/2 are

redundant. They are used to invert the direction of rotation of the assigned rotary axis.
However, this can also be achieved by inverting the direction of axis vector
$MC_TRAFO5_AXIS1/2_1/2. It is for this reason that there is no corresponding parameter for
the orientable toolholder. For the purpose of absolute clarity, the following machine data must
be ignored:
MD24520/MD24620 TRAFO5_ROT_SIGN_IS_PLUS_1/2

Assignments for transformation type 24

Toolholder data assignments dependent on transformation type 24

Transformation type "T" (in accordance with MD24100 $MC_TRAFO_TYPE_1 = 24)

MD24500 $MC_TRAFO5_PART_OFFSET_1[0] $TC_CARR1 (+$TC_TCARR41)
(translation vector of 5-axis transformation 1)
MD24500 $MC_TRAFO5_PART_OFFSET_1[1] $TC_CARR2 (+$TC_TCARR42)
MD24500 $MC_TRAFO5_PART_OFFSET_1[2] $TC_CARR3 (+$TC_TCARR43)

MD24560 $MC_TRAFO5_JOINT_OFFSET_1[0] (vec‐ $TC_CARR4 (+$TC_TCARR44)

tor of the kinematic offset of 5-axis transformation 1)
MD24560 $MC_TRAFO5_JOINT_OFFSET_1[1] $TC_CARR5 (+$TC_TCARR45)
MD24560 $MC_TRAFO5_JOINT_OFFSET_1[2] $TC_CARR6 (+$TC_TCARR46)

MD24550 $MC_TRAFO5_BASE_TOOL_1[0] (vector $TC_CARR15 (+$TC_TCARR55)

of basic tool when 5-axis transformation is active) 1)
MD24550 $MC_TRAFO5_BASE_TOOL_1[1] $TC_CARR16 (+$TC_TCARR56)
MD24550 $MC TRAFO5_BASE_TOOL_1[2] $TC_CARR17 (+$TC_TCARR57)

Assignments for transformation type 40

Toolholder data assignments dependent on transformation type 40

Transformation type "P" (in accordance with MD24100 $MC_TRAFO_TYPE_1 = 40)

MD24550 $MC_TRAFO5_BASE_TOOL_1[0] $TC_CARR4 (+$TC_TCARR44)
MD24550 $MC_TRAFO5_BASE_TOOL_1[1] $TC_CARR5 (+$TC_TCARR45)
MD24550 $MC_TRAFO5_BASE_TOOL_1[2] $TC_CARR6 (+$TC_TCARR46)

MD24560 $MC_TRAFO5_JOINT_OFFSET_1[0] $TC_CARR15 (+$TC_TCARR55)

MD24560 $MC_TRAFO5_JOINT_OFFSET_1[1] $TC_CARR16 (+$TC_TCARR56)
MD24560 $MC_TRAFO5_JOINT_OFFSET_1[2] $TC_CARR17 (+$TC_TCARR57)

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Transformation type "P" (in accordance with MD24100 $MC_TRAFO_TYPE_1 = 40)

MD24500 $MC_TRAFO5_PART_OFFSET_1[0] $TC_CARR18 (+$TC_TCARR58)

MD24500 $MC_TRAFO5_PART_OFFSET_1[1] $TC_CARR19 (+$TC_TCARR59)
MD24500 $MC_TRAFO5_PART_OFFSET_1[2] $TC_CARR20 (+$TC_TCARR60)

Assignments for transformation type 56

Toolholder data assignments dependent on transformation type 56

Transformation type "M" (in accordance with MD24100 $MC_TRAFO_TYPE_1 = 56)

MD24560 $MC_TRAFO5_JOINT_OFFSET_1[0] (vector $TC_CARR1 (+$TC_TCARR41)
of the kinematic offset of 5-axis transformation 1)
MD24560 $MC_TRAFO5_JOINT_OFFSET_1[1] $TC_CARR2 (+$TC_TCARR42)
MD24560: TRAFO5_JOINT_OFFSET_1[2] $TC_CARR3 (+$TC_TCARR43)

MD24550 $MC_TRAFO5_BASE_TOOL_1[0] $TC_CARR4 (+$TC_TCARR44)

MD24550 $MC_TRAFO5_BASE_TOOL_1[1] $TC_CARR5 (+$TC_TCARR45)
MD24550 $MC_TRAFO5_BASE_TOOL_1[2] $TC_CARR6 (+$TC_TCARR46)

MD24558 $MC_TRAFO5_JOINT_OFFSET_PART_1[0] $TC_CARR15 (+$TC_TCARR55)

MD24558 $MC_TRAFO5_JOINT_OFFSET_PART_1[1] $TC_CARR16 (+$TC_TCARR56)
MD24558 $MC_TRAFO5_JOINT_OFFSET_PART_1[2] $TC_CARR17 (+$TC_TCARR57)

MD24500 $MC_TRAFO5_PART_OFFSET_1[0] $TC_CARR18 (+$TC_TCARR58)

MD24500 $MC_TRAFO5_PART_OFFSET_1[1] $TC_CARR19 (+$TC_TCARR59)
MD24500 $MC_TRAFO5_PART_OFFSET_1[2] $TC_CARR20 (+$TC_TCARR60)

Example of parameterization
The first 5-axis transformation is to obtain its data from machine data and the second, in
contrast, is to be parameterized using the data from the 3rd orientable toolholder.

MD24100 $MC_TRAFO_TYPE_1 = 24 ; first 5-axis transformation

MD24200 $MC_TRAFO_TYPE_2 = 72 ; second 5-axis transformation
MD24682 $MC_TRAFO5_TCARR_NO_2 = ; parameterize data of the third orientable
3; ; toolholder

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2.7.5 Extension of the generic transformation to six axes - 840D sl only

Application
With the maximum 3 linear axes and 2 rotary axes, the motion and direction of the tool in space
can be completely described with the generic 5-axis transformation. Rotations of the tool
around itself, as is important for a tool that is not rotation-symmetric or robots, require an
additional rotary axis. The previous generic 5-axis transformation will therefore be extended
by a 3rd rotary axis and further functions added.
● Extension to 3 linear axes and 3 rotary axes, i.e. 6 axes.
● General use of the generic orientation transformation with unchanged parameterization of
machine data.
● Cartesian manual travel also for the generic transformation.

Kinematics for the 6-axis transformation

The 6-axis transformation is based on the generic 5-axis transformation and is extended by
transformation type 57. Therefore, four different machine kinematics exist that are
differentiated through the specification of the transformation type in the following machine data:
MD24100 $MC_TRAFO_TYPE_1 = transformation type (definition of transformation 1 in the
channel)

Table 2-3 Overview of machine types for the generic 6-axis transformation

Machine type 1 2 3 4
swivel/rotatable tool workpiece Tool/ Tool/
workpiece workpiece
Transformation 24 40 56 57
types
Orientation in space, Unchanged. Unchanged. Tool by 2 axes, Tool by
rotation of the axes All three axes rotate All three axes rotate workpiece by one ro‐ one axis,
the tool the workpiece tary axis workpiece
by two ro‐
tary axes

In all four cases, the first rotary axis is the one which closest to the workpiece and the third
rotary axis the one which closest to the tool in the kinematic chain.

Note
The four specified transformation types only cover those kinematics in which the three linear
axes form a rectangular Cartesian coordinate system, i.e. no kinematics are covered in which
at least one rotary axis lies between two linear axes in the kinematic chain.
Dedicated machine data exist for each general transformation or for each orientation
transformation that are differentiated by the suffixes _1, _2 etc. (e.g. MD24100
$MC_TRAFO_TYPE_1, MD24200 $MC_TRAFO_TYPE_2 etc.). In the following, only the
names for the first transformation are specified, i.e. those with the suffix _1. If a transformation
other than the first is parameterized, the correspondingly modified names must be used.

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Configuration
For configuration of a 6-axis transformation the extensions of the following machine data are
required:
● The channel axis index of the 3rd rotary axis must be entered in the following machine data:
MD24110 $MC_TRAFO_AXES_IN_1[5] (axis assignment for transformation)
● The direction of the 3rd rotary axis must be specified in the following machine data:
MD24573 $MC_TRAFO5_AXIS3_1[0..2] (direction 3rd rotary axis)
● An orientation normal vector with a length not equal to zero and which is not parallel or anti-
parallel to the orientation vector defined in machine data MD24574
$MC_TRAFO5_BASE_ORIENT_1[0..2] (basic tool orientation), must be specified in
machine data MD24576 $MC_TRAFO6_BASE_ORIENT_NORMAL_1[0..2] (tool normal
vector).
The previous offsets (vector):
● MD24550 $MC_TRAFO5_BASE_TOOL_1[0..2]
(vector of the basic tool with activation of the 5-axis transformation) 1)
● MD24560 $MC_TRAFO5_JOINT_OFFSET_1[0..2]
(vector of the kinematic offset of 5-axis transformation 1)
● MD24558 $MC_TRAFO5_JOINT_OFFSET_PART_1[0..2]
(vector of kinematic offset in table)
● MD24500 $MC_TRAFO5_PART_OFFSET_1[0..2]
(translation vector 5-axis transformation 1)
The following machine data is added as new offset (vector), describing the offset between the
second and third rotary axis:
● MD24561 $MC_TRAFO6_JOINT_OFFSET_2_3_1[0..2]
(vector of kinematic offset)
Note
Existing machine data blocks are compatible for transfer, without any changes having to
be made in the machine data. The new machine data therefore do not have to be specified
for a 3-/4-/5-axis transformation.

Programming of orientation
With the extension of the generic orientation transformation to 6 axes, all three degrees of
freedom of the orientation can be freely selected. They can be uniquely defined through the
position of a rectangular Cartesian coordinate system. One axis direction, that of the third axis,
(typically in the Z direction) defines the orientation.
Two degrees of freedom are required for the specification of this direction. The third degree
of freedom is defined via a rotation around this direction, e.g. through the specification of an
angle THETA or a direction vector for one of the two other axes of the coordinate system, see
Section "Rotations of orientation vector (Page 117)").
The new addresses AN3, BN3, CN3 define the direction of the second axis, of the coordinate
system (typically the Y axis) of the orientation normal vector. The programmed orientation

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normal vector should be perpendicular to the orientation and is only possible when both
programmed vectors are not parallel or anti-parallel. Otherwise, alarm 4342 is output.
The direction of the first axis, the X axis, is then uniquely defined.

Default setting of the orientation normal vector

The default setting of the orientation normal vector in the transformation can also be defined
as for the default setting of the orientation in one of three ways:
Specification for the activation of the transformation
1. Vector components are transferred as parameters 8 to 10:
Parameter 1: Transformation No.
Parameter 2 - 4: Orientation vector,
Parameter 5 - 7: Rotary axis offsets
2. If no orientation normal vector has been specified and a tool is active, the vector is taken
from the tool data.
3. If no orientation normal vector has been specified and also no tool is active, the vector
defined in the following machine data is used.
MD24567 $MC_TRAFO6_BASE_ORIENT_NORMAL_1[0..2] (tool normal vector)
The position of the orientation coordinate system of a standard tool depends on the active
plane G17, G18, G19 according to the following table:

Table 2-4 Position of the orientation coordinate system

G17 G18 G19

Direction of the orientation vector Z Y X
Direction of the orientation normal vector Y X Z

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Note
The orientation vector of a tool can also be defined via system the variables $TC_DPV or
$TC_DPV3 - $TC_DPV5 in tool data - see Function Manual Basic Machine, Tool Corrections
(W1), Section: Sum and setup offsets.
This option is expanded in order to specify the orientation normal vector, using system
variables $TC_DPVN3 - $TC_DPVN5. The meaning of the vector components is similar to the
meaning of the components of the tool orientation:
$TC_DPVN3 is the component in the direction of tool length L1,
$TC_DPVN4 is the component in the direction of tool length L2,
$TC_DPVN5 is the component in the direction of tool length L3,
The following machine data must have the value 3 in order to allow the new tool parameters
to be used:
MD18114 $MN_MM_ENABLE_TOOL_ORIENT (assign orientation to tool cutting)
The coordinate system is not rotated through the programming of a rotation of the tool with
AN3, BN3, CN3 or THETA.

Programming example
See Section "Example of a generic 6-axis transformation (Page 139)".

2.7.6 Extension of the generic transformation to seven axes - 840D sl only

Application
The generic 5-/6-axis transformation with transformation type 24 is extended by a 7th or 6th
axis, which rotates the workpiece. The work space of the transformation can be expanded in
this way.

Requirement
For generic 7-axis transformation there must be at least 6 or 7 axes.

Function
Another 7th axis is required in connection with the generic 6-axis transformation which rotates
the workpiece. This 7th axis is considered only along with transformation type 24 (generic 6-
axis transformation having 3 rotary axes that move the tool ).
The position of the 7th axis is specified according to a strategy of the CAD system and settled
with the Cartesian position (X, Y, Z) by the generic transformation in such a way that the axes
always approach the TCP position programmed with reference to the workpiece, independently
of the position of the 7th axis. If ORIWKS is active, the end orientation programmed with

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reference to the workpiece is also rotated by the 7th axis. This way it is possible to program
the orientation in relation to the workpiece.
The transformation uses the 7th axis as the observed input variable.
To configure the 7th axis, the channel machine data of the 5-/6-axis transformation is extended
by one field containing the 3 components of the direction vector of the 7th axis and an axis
offset.
This gives the following advantages:
● The contour and the orientation at the workpiece can be programmed in relation to the
workpiece.
● The programmed feed is maintained in the contour, even if the 7th axis also moves.
● All the contour-related control functions can be used.
● The displayed WCS position corresponds to the programmed position.
● The transformation is configured as in generic 6-axis transformation. One can switch
between a 6-axis and a 7-axis transformation smoothly.
● In case of large radius circular interpolation, the release of singularities incorporating the
7th axis.

Notations
Dedicated machine data exist for each general transformation and for each orientation
transformation that are differentiated by the suffixes _1, _2 etc. (e.g. $MC_TRAFO_TYPE_1,
$MC_TRAFO_TYPE_2 etc.). In the following, only the names for the first transformation are
specified, i.e. those with the suffix _1. If a transformation other than the first is parameterized,
the correspondingly modified names must be used.

Description of the kinematics

The 7-axis transformation builds on the generic 5-/6-axis transformation.

Note
The 7-axis transformation also covers kinematics in which the 6th axis is not available. In the
following pages, we speak exclusively about a 7th axis or about a 7-axis transformation, even
when it is actually the 6th axis in connection with a 5-axis kinematics.
The 7-axis transformation types only cover those kinematics in which the three linear axes
form a rectangular Cartesian coordinate system, i.e. no kinematics are covered in which at
least one rotary axis lies between two linear axes in the kinematic chain.

There is only one machine kinematics for which a 7th axis can be configured. It is designated
by the Transformation Type 24:
$MC_TRAFO_TYPE_1 = 24 Rotary tool: Three (or two) axes rotate the tool; the 7th axis rotates
the workpiece.

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2.7 Generic 5-axis transformation and variants

The extensions of the following machine data are required to configure a generic 7-axis
transformation:

Machine data extension

$MC_TRAFO_AXES_IN_1[9] The channel axis index of the 4th rotary axis is recor‐
ded here.
$MC_TRAFO_AXES_IN_1[10] and $MC_TRA‐ This machine data is to be assigned with default val‐
FO_AXES_IN_1[11] ue of 0. (default setting)
$MC_TRAFO_AXES_IN_1[6..8] This machine data is not evaluated by the generic 7-
axis transformation.
$MC_TRAFO7_EXT_AXIS1_1[0..2] The direction of the 4th rotary axis is specified here.
$MC_TRAFO7_EXT_AX_OFFSET_1[0..2] A position offset of the 4th rotary axis is recorded
here.

MR
$
&
MR

&

PR
WR

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0DFKLQH]HUR

mo: Position vector in MCS

po: $MC_TRAFO5_PART_OFFSET_n[0..2]
x. Vector of programmed position in the WCS
t: Tool correction vector
to: $MC_TRAFO5_BASE_TOOL_n[0..2]
jo: $MC_TRAFO5_JOINT_OFFSET_n[0..2]
jo23: $MC_TRAFO6_JOINT_OFFSET_2_3_n[0..2]

Figure 2-21 Schematic diagram of 7-axis kinematics

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 F2: Multi-axis transformations
2.7 Generic 5-axis transformation and variants

Programming
1. Programming the Cartesian position
The position of the 7th axis must be programmed in the workpiece coordination system in
addition to the Cartesian position. The Cartesian position is thus programmed in relation
to the constant workpiece. The 7-axis transformation converts the WCS position via the
rotation of the 7th axis in the basic coordinate system. Possibly programmed or set frames
are normally settled before the 7-axis transformation.
2. Programming of orientation
All programming options of the generic 5-/6-axis transformation are available while
programming the orientation. The 7th axis must always be programmed additionally.
Two different response types can be set in this context via the G code.
– The position of the 7th axis does not influence the programmed orientation.
– The programmed end-orientation is rotated with the 7th axis.

Orientation
1. Orientation with axis interpolation
If the 7th axis should have no influence on the programmed orientation, the G codes of
Groups 25 and 51 must be set accordingly:
G code group 25: ORIMKS
G code group 51: ORIAXES (if MD21104 $MC_ORI_IPO_WITH_G_CODE = 1 is set).
The programmed positions of the rotary axes are not changed by the position of the 7th
axis in this case, but approached directly. The orientation is programmed in relation to the
machine.
Example

Program code
TRAORI(1)
ORIAXES
ORIMKS
G1 X500 Y300 Z800 C15 A5 C1=10 E1=120

1. Orientation and large circle interpolation

If traversing is to be done with large radius circular interpolation, the end orientation is
rotated with the 7th axis.
G code group 25: ORIWKS
G code group 51: ORIVECT (if MD21104 $MC_ORI_IPO_WITH_G_CODE = 1 is set).
In this case the orientation must be programmed in relation to the workpiece. The
programmed orientation is thus related to the fixed workpiece. The position of the 7th axis
is thus not contained in the programmed orientation.
Example

Program code
TRAORI(1)
ORIVECT
ORIWKS
G1 X500 Y800 Z100 A3=0 B3=1 C3=0 AN3=0 BN3=0 CN3=–1 E1=–90

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2.7 Generic 5-axis transformation and variants

Frames
The basic coordinate system sits on the 7th axis. It is also rotated when the 7th axis rotates.
This way the workpiece coordinate system (WCS) does not remain stationary when the
workpiece is rotated over the 7th axis. A workpiece position rotated to the zero position of the
7th axis can be compensated by an axial frame offset of the 7th axis.

Traversing with the 7th axis in the JOG mode

Only the compensatory movements for the linear axes are created if the 7th axis is traversed
in the JOG mode with active 7-axis transformation. The position at the workpiece is kept
constant in this way. As the rotary axes go into the transformation only as input axes, they are
not influenced by the 7th axis during the JOG travel. The orientation at the workpiece is thus
kept variable.

2.7.7 Cartesian manual travel with generic transformation

Note
The use of the "Handling transformation package" option is necessary for the "Cartesian
manual travel" function.

Functionality
The "Cartesian manual travel" function, as a reference system for JOG mode, allows axes to
be set independently of each other in Cartesian coordinate systems:
● Basic coordinate system (BCS)
● Workpiece coordinate system (WCS)
● Tool coordinate system (TCS)
The following machine data not only activates the function, but also sets the permitted
coordinate systems.
MD21106 $MC_CART_JOG_SYSTEM (coordinate systems for Cartesian JOG)
For JOG motion, one of the three reference systems can be set not only for the translation/
movement of the geometry axes, but also for tool orientation/movement of the orientation axes
via the setting data SD42650 $SC_CART_JOG_MODE (coordinate systems for Cartesian
manual traverse) independently from one another.

Activation
The following machine data not only activates the function, but also sets the permitted
coordinate systems.
MD21106 $MC_CART_JOG_SYSTEM (coordinate systems for Cartesian JOG)
The following setting data sets the virtual kinematics used for traversing motion of the
orientation:

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2.7 Generic 5-axis transformation and variants

SD42660 $SC_ORI_JOG_MODE (definition of virtual kinematics for JOG)

As opposed to the generic 5-/6-axis transformation, only kinematics can be set in which the
rotary axes are perpendicular to one another.
The traversing of the geometry and orientation axes is performed via the VDI interface signals
of the geometry or orientation axes.

Translations
A translatory movement can be used to move the tool tip (TCP) 3-dimensionally in parallel to
the axes of the set reference system. Traversing is performed via the VDI interface signals of
the geometry axes.

Note
For further information about the representation of the translations for the Cartesian manual
travel in the corresponding coordinate systems, see:
References:
Function Manual Extension Functions; Kinematic Transformation (M1)

Tool orientation
The tool can be aligned to the workpiece surface via an orientation movement. The motions
of the orientation axes are triggered by the PLC via the VDI interface signals of the orientation
axes. The virtual orientation axes execute rotations around the fixed directions of the relevant
reference system. Virtual kinematics is defined by the following setting data via the active
transformation:
SD42660 $SC_ORI_JOG_MODE = 0

Rotations of the orientations

Rotation of the orientation axes is defined by additional settings of the following setting data:
SD42660_$MC_ORI_JOG_MODE
The options are as follows:

Rotations with JOG

With JOG, the rotations around the specified directions of the respective reference system can
be performed with Euler angle or RPY angle.
SD42660 $SC_ORI_JOG_MODE = 1: When jogging, Euler angles are traversed, i.e.:
the first axis rotates around the z direction,
the second axis rotates around the x direction,
the third axis (if present) rotates around the new z direction.
SD42660 $SC_ORI_JOG_MODE = 2: When jogging, RPY angles are traversed with rotation
sequence XYZ, i.e.:

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2.8 Restrictions for kinematics and interpolation

the first axis rotates around the x direction,

the second axis rotates around the y direction,
the third axis (if present) rotates around the new z direction.
SD42660 $SC_ORI_JOG_MODE = 3: When jogging, RPY angles are traversed with rotation
sequence ZYX, i.e.:
the first axis rotates around the z direction,
the second axis rotates around the y direction,
the third axis (if present) rotates around the new x direction.

Rotation sequence of the rotary axes

Rotation sequence of the rotary axes is set via the following setting data:
● SD42660 $SC_ORI_JOG_MODE = 4:
via machine data MD21120 $MC_ORIAX_TURN_TAB_1 (definition of reference axes for
ORI axes)
● SD42660 $SC_ORI_JOG_MODE = 5:
via machine data MD21130 $MC_ORIAX_TURN_TAB_2 (definition of reference axes for
ORI axes)
For further explanations of the orientation movements (see Section "Orientation (Page 87)"
and "Orientation axes (Page 106)").

Note
For further information about the programming of rotations please refer to:
References:
Programming Manual, Job Planning; Section: "Transformations"

2.8 Restrictions for kinematics and interpolation

For systems where there are less than six axes available for transformation, the following
restrictions must be taken into account.

5-axis kinematics
For 5-axis kinematics there are two degrees of freedom for orientation. The assignment of
orientation axes and tool vector direction must be selected so that there is no rotation around
the tool vector. As a result, only two orientation angles are required to describe the orientation.
If the axis is traversed using ORIVECT, the tool vector performs pure swiveling motion.

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2.8 Restrictions for kinematics and interpolation

3-and 4-axis kinematics

For 3- and 4-axis kinematics, only one degree of freedom is available for orientation. The
respective transformation determines the relevant orientation angle. In this case, it only makes
sense to traverse the orientation axis using ORIAXES. In this case, the orientation axis is
directly and linearly interpolated.

Interpolation of the tool orientation over several blocks by means of orientation vectors
If the orientation of a tool is programmed over several consecutive part program blocks by
directly entering the appropriate rotary axis positions, then undesirable discontinuous changes
of the orientation vector are obtained at the block transitions. This results in discontinuous
velocity and acceleration changes of the rotary axes. This means that no continuous velocity
and acceleration of the orientation axes over several blocks can be achieved using large circle
interpolation.
Continuous block transitions
As long as only linear blocks (G1) are programmed, then the orientation axes also behave just
like linear axes. In this case, motion with continuous acceleration is achieved through
polynomial interpolation. Significantly better results can be achieved by programming the
orientation in space using orientation vectors (see Section "Polynomial interpolation of
orientation vectors (Page 113)").

2.8.1 Singularities of orientation

Description of problem
As described in Section "Singularities and how to treat them", singularities (poles) are
constellations in which the tool is orientated becomes parallel to the first rotary axis. If the
orientation is changed when the tool is in or close to a singularity (as is the case with large-
circle interpolation ORIWKS ), the rotary axis positions must change by large amounts to
achieve small changes in orientation. In extreme cases, a jump in the rotary axis position would
be needed.
Such a situation would be treated as follows:
There is only one relevant machine data, which circles the pole as usual:
MD24540 $MC_TRAFO5_POLE_LIMIT_1 (closing angle tolerance for interpolation by pole for
5-axis transformation)
or
MD24640 $MC_TRAFO5_POLE_LIMIT_2 (closing angle tolerance for interpolation by pole for
5-xis transformation)
For further information about the handling of singular positions, see:
References:
Programming Manual, Job Planning, Transformations; Section: Cartesian PTP travel

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F2: Multi-axis transformations
2.8 Restrictions for kinematics and interpolation

Example for machine type 1

Rotatable tool
Both rotary axes change the orientation of the workpiece. The orientation of the workpiece is
fixed.
2-axis swivel head with rotary axis RA 1 (4th transformation axis) and rotary axis RA 2 (5th
transformation axis)

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Figure 2-22 Generic 5-axis transformation; end point of orientation inside tolerance circle.

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2.9 Orientation

End point within the circle

If the end point is within the circle, the first axis comes to a standstill and the second axis moves
until the difference between target and actual orientation is minimal. However, since the first
rotary axis does not move, the orientation will generally deviate from the programmed value
(see previous figure). However, the programmed orientation can at least be reached exactly
if the first rotary axis happens to be positioned correctly.

Note
In the previous Figure the resulting path is a straight line because the position of the first rotary
axis is constant on that path. This representation is always correct, irrespective of the angle
between the two rotary axes. The orientation vector only moves in a plane, however, if the two
rotary axes and the basic orientation are all mutually perpendicular. In all other cases, the
orientation vector describes the outside of a cone.

End point outside the circle

If the orientation interpolation describes a path through the circle, while the end point is outside
the circle, the end point is approached with axis interpolation. This applies in particular if the
interpolation starting point is located inside the circle. Path deviations from the programmed
setpoint orientation are thus unavoidable.

2.9 Orientation

2.9.1 Basic orientation

Differences to the previous 5-axis transformations

In the 5-axis transformations implemented to date, basic orientation of the tool was defined by
the type of transformation.
Generic 5-axis transformation can be used to enable any basic tool orientation, i.e. space
orientation of the tool is arbitrary, with axes in their initial positions.
If an orientation is programmed by means of Euler angles, RPY angles (A2, B2, C2) or vectors
(A3, B3, C3), basic orientation is taken into consideration, i.e. the rotary axes are positioned
so that a tool positioned in basic orientation is traversed to the programmed orientation.
If the rotary axes are programmed directly, basic orientation has no effect.

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2.9 Orientation

Definition
The basic orientation can be defined in three different ways:
● Definition by calling the transformation
● Definition by the orientation of the active tool
● Definition using a machine data

Definition by calling the transformation

When the transformation is called, the direction vector of the basic orientation can be specified
in the call, e.g. TRAORI(0, 0., 1., 5.). The direction vector is defined by parameters 2
to 4. This is the reason that in the example it has the value (0., 1., 5.).
The first parameter specifies the transformation number. The number can be omitted if the first
transformation is to be activated. To enable the parameters to be identified correctly when
specifying an orientation, a blank space has to be inserted instead of the transformation
number, e.g. TRAORI(, 0., 1., 5.).

Note
The orientation data is absolute. It is not modified by a frame that is possibly active.
The absolute value of the vector is insignificant, only the direction is relevant. Non-programmed
vector elements can be set to zero.

Please note that if all three vector components are zero (because they have been set explicitly
so or not specified at all), the basic orientation is not defined by data in the TRAORI(...) call,
but by one of the two other options.
If a basic orientation is defined by calling the transformation, it cannot be altered while a
transformation is active. The orientation can be changed only by selecting the transformation
again.

Definition by the orientation of the active tool

The basic orientation is determined by the tool, if:
● it has not been defined by specifying a direction vector in the transformation call
and
● a tool is already active.
The orientation of a tool is dependent on the selected plane. It is parallel to Z at G17, parallel
to Y at G18 and parallel to X at G19.
It can be modified arbitrarily by orientable toolholders, see:
Reference:
Function Manual, Basic Functions; Tool Offset (W1), Chapter: "Orientable tool carrier"
If the tool is changed when a transformation is active, the basic orientation is also updated.
The same applies if the orientation of a tool changes as the result of a change in plane (plane
changes are equivalent to tool changes, as they also alter the assignment between tool length
components and individual axes).

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2.9 Orientation

If the tool is de-selected, thereby canceling the definition of tool orientation, the basic
orientation programmed in machine data becomes operative.

Definition using a machine data

If the basic orientation is not defined by either of the two variants described above, it is specified
with reference to the following machine data:
$MC_TRAFO5_BASE_ORIENT_n (basic tool orientation)
This machine data must not be set to a zero vector or else an alarm will be generated during
control run-up when a transformation is active.
If a basic orientation is programmed in machine data $MC_TRAFO5_BASE_ORIENT_n when
a transformation is active and a tool is subsequently activated, the basic orientation is re-
defined by the tool.

Note
The range of settable orientations depends on the directions of the rotary axes involved and
the basic orientation. The rotary axes must be mutually perpendicular if all possible orientations
are to be used. If this condition is not met, "dead" ranges will occur.

Examples:
1. Extreme example: A machine with rotatable tool has a C axis as its first rotary axis and an
A axis as its second. If the basic orientation is defined in parallel to the A axis, the orientation
can only be changed in the X-Y plane (when the C axis is rotating), i.e. orientation with a
Z component unequal to zero is not possible in this instance. The orientation does not
change when the A axis rotates.
2. Realistic example: A machine with nutator kinematics (cardan head) with an axis inclined
at less than 45o in a basic orientation parallel to the Z axis can only assume orientations
within a semi-circle: The top semi-circle with basic orientation towards +Z and the bottom
with basic orientation towards -Z.

2.9.2 Orientation movements with axis limits

Calculate rotary axis position

If the final orientation in a 5-axis transformation is programmed indirectly in an NC block by
means of a Euler, RPY angle or direction vector, it is necessary to calculate the rotary axis
positions that produce the desired orientation. This calculation has no unique result.
There are always at least two essentially different solutions. In addition, any number of
solutions can result from a modification to the rotary axis positions by any multiple of 360
degrees.
The control system chooses the solution which represents the shortest distance from the
current starting point, allowing for the programmed interpolation type.

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2.9 Orientation

Determining permissible axis limits

The control system attempts to define another permissible solution if the axis limits are violated,
by approaching the desired axis position along the shortest path. The second solution is then
verified, and if this solution also violates the axis limits, the axis positions for both solutions
are modified by multiples of 360 until a valid position is found.
The following conditions must be met in order to monitor the axis limits of a rotary axis and
modify the calculated end positions:
● A generic 5-axis transformation of type 24, 40 or 56 must be active.
● The axis must be referenced.
● The axis must not be a modulo rotary axis.
● The following machine data may not be equal to zero:
MD21180 $MC_ROT_AX_SWL_CHECK_MODE (check software limits for orientation axes)
MD21180 $MC_ROT_AX_SWL_CHECK_MODE specifies the conditions under which the
rotary axis positions may be modified:

Value Meaning
0 No modification permitted (default, equivalent to previous behavior).
1 Modification is only permitted if axis interpolation is active (ORIAXES or ORIMKS).
2 Modification is always permitted, even if vector interpolation (large circle interpolation, conical
interpolation, etc.) was active originally.

Switch-over to axis interpolation

If the axis positions have to be changed from the originally determined value, the system
switches to rotary axis interpolation because the original interpolation path, e.g. large circle
interpolation or conical interpolation, can no longer be maintained.

Example
An example for modifying the rotary axis motion of a 5-axis machine with a rotatable tool is
shown in Chapter "Examples for generic axis transformations (Page 137)".

2.9.3 Orientation compression

Function
Using compressor functions COMPON, COMPCURV, COMPCAD and COMPSURF, also NC
programs, in which the orientation is programmed using direction vectors, can be compressed,
but still maintaining a specifiable tolerance.

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2.9 Orientation

The orientation movement is compressed in the following cases:

● Active orientation transformation (TRAORI)
● Active large radius circular interpolation (i.e. tool orientation is changed in the plane which
is determined by start and end orientation).
Large circle interpolation is performed under the following conditions:
– MD21104 $MC_ORI_IPO_WITH_G_CODE = 0
+ ORIWKS is active
+ orientation is programmed using vectors (with A3, B3, C3 or A2, B2, C2).
– MD21104 $MC_ORI_IPO_WITH_G_CODE = 1
+ ORIVECT or ORIPLANE is active.
The tool orientation can be programmed either as a direction vector or with rotary axis
positions. No large radius circle interpolation is performed, if one of the G commands
ORICONxx or ORICURVE is active, or if polynomials for orientation angle (PO[PHI] and
PO[PSI]) are programmed.

Parameterization
NC blocks can only be compressed if deviations are allowed between the programmed contour
and interpolated contour or between the programmed orientation and interpolated orientation.
Compression tolerances can be used to set the maximum permissible deviation. The higher
the tolerances, the more blocks can be compressed. However, the higher the tolerances, the
more the interpolated contour or orientation can deviate from the programmed values.
Axis accuracy
For each axis, the compressor creates a spline curve which deviates from the programmed
end points of each axis by a maximum of the value set with the following machine data:
MD33100 $MA_COMPRESS_POS_TOL (maximum permitted axis-specific path deviation for
compression)
Contour accuracy
The maximum contour deviations (geo axes) and tool orientation are specified via the following
setting data:
SD42475 $SC_COMPRESS_CONTUR_TOL (maximum permissible contour deviation with
compression)
SD42476 $SC_COMPRESS_ORI_TOL (maximum deviation of the tool orientation for
compression)
SD42477 $SC_COMPRESS_ORI_ROT_TOL (maximum angular deviation of the tool rotation
for compression) (only available for 6-axis machines!)

Note
A maximum deviation of tool orientation can only be specified if an orientation transformation
is active (TRAORI).

Compression mode

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2.9 Orientation

The manner in which the tolerances are to be considered is set via the unit position in the
machine data:
MD20482 $MC_COMPRESSOR_MODE (mode of compression)

Value Meaning
0 The tolerances specified with MD33100 $MA_COMPRESS_POS_TOL are observed for all
the axes (geo and orientation axes).
1 The contour tolerance specified with SD42475 $SC_COMPRESS_CONTUR_TOL is effec‐
tive for the geometry axes.
The axis-specific tolerances MD33100 $MA_COMPRESS_POS_TOL are effective for the
orientation axes.
2 The axis-specific tolerances MD33100 $MA_COMPRESS_POS_TOL are effective for the
geometry axes.
The maximum angular deviations SD42476 $SC_COMPRESS_ORI_TOL or
SD42477 $SC_COMPRESS_ORI_ROT_TOL are effective for the orientation axes.
3 The contour tolerance specified with SD42475 $SC_COMPRESS_CONTUR_TOL is effec‐
tive for the geometry axes.
The maximum angular deviations SD42476 $SC_COMPRESS_ORI_TOL or
SD42477 $SC_COMPRESS_ORI_ROT_TOL are effective for the orientation axes.

With the tens digit of MD20482 you set whether blocks with programmed tool orientation and/
or value assignments (for example, X=100 ...) are to be compressed or not:

Value Meaning
x0x All blocks with programmed tool orientation and/or value assignments will be compressed
(default setting).
Notice: This behavior is incompatible with earlier SW versions!
x1x Only the blocks with programmed tool orientation will be compressed. The blocks with value
assignments will not be compressed.
x2x Only the blocks with value assignments will be compressed. The blocks with programmed
tool orientation will not be compressed.
x3x All blocks with programmed tool orientation and/or value assignments will not be com‐
pressed.
This setting provides a behavior that is fully compatible with earlier SW versions.

The hundreds position of MD20482 is used to select which blocks outside the linear blocks
(G1) should be compressed.

Value Meaning
0xx Circular blocks and G0 blocks are not compressed. This is compatible with earlier SW
versions.
1xx Circular blocks will be linearized and compressed by COMPCAD.
Advantage:
The compressor function works more accurate and therefore creates normally better surfa‐
ces.
Disadvantage:
The compressor function is more sensitive to bugs in the NC programs. For reasons of
compatibility it might therefore be necessary to keep the setting 0xx.

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2.9 Orientation

Value Meaning
2xx G0 blocks are compressed - it is possible that a different tolerance becomes effective (see
MD20560 $MC_G0_TOLERANCE_FACTOR or NC command STOLF).
Advantage:
As a result that the tolerance has been set higher and the compression of G0 infeed motion,
these can be more quickly and more fluidly executed.
3xx Combination of the two previous options: Circular blocks as well as G0 blocks are com‐
pressed.

The thousands digit of MD20482 optimizes the compressor for different machining types.

Value Meaning
0xxx Optimization to achieve a good surface quality for tool and mold making.
1xxx Optimization for soft and fast traversing in special applications (e.g. tape laying)

Programming
Tool orientation
If orientation transformation (TRAORI) is active, for 5-axis machines, tool orientation can be
programmed in the following way (independent of the kinematics):
● Programming of the direction vectors via:
A3=<...> B3=<...> C3=<...>
● Programming of the Eulerangles or RPY-angles via:
A2=<...> B2=<...> C2=<...>

Rotation of the tool

For 6-axis machines you can program the tool rotation in addition to the tool orientation.
The angle of rotation is programmed with:
THETA=<...>

Note
NC blocks, in which rotation is also programmed, can only be compressed if the angle of
rotation changes linearly. This means that it is not permissible that a polynomial with
PO[THT]=(...) for the angle of rotation is programmed.

General structure of an NC block that be compressed

The general structure of an NC block that can be compressed can therefore look like this:
N... X=<...> Y=<...> Z=<...> A3=<...> B3=<...> C3=<...> THETA=<...> F=<...>
or
N... X=<...> Y=<...> Z=<...> A2=<...> B2=<...> C2=<...> THETA=<...> F=<...>

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2.9 Orientation

Programming tool orientation using rotary axis positions

Tool orientation can be also specified using rotary axis positions, e.g. with the following
structure:
N... X=<...> Y=<...> Z=<...> A=<...> B=<...> C=<...> THETA=<...> F=<...>
In this case, compression is executed in two different ways, depending on whether large radius
circular interpolation is executed. If no large radius circular interpolation takes place, then the
compressed change in orientation is represented in the usual way by axial polynomials for the
rotary axes.

Activation/deactivation
Compressor functions are activated by modal G commands COMPON, COMPCURV, COMPCAD
or COMPSURF.
COMPOF terminates the compressor function.

Example
In the example program below, a circle approximated by a polygon definition is compressed.
The tool orientation moves on the outside of the taper at the same time. Although the
programmed orientation changes are executed one after the other, but discontinuously, the
compressor function generates a smooth motion of the orientation.

Program code Comment

DEF INT NUMBER=60
DEF REAL RADIUS=20
DEF INT COUNTER
DEF REAL ANGLE
N10 G1 X0 Y0 F5000 G64 //sort match
rate lower first

$SC_COMPRESS_CONTUR_TOL=0.05 ; Maximum deviation of the contour = 0.05 mm

$SC_COMPRESS_ORI_TOL=5 ; Maximum deviation of the orientation
= 5 degrees

TRAORI
COMPCURV
; The movement describes a circle generated
from polygons. The orientation moves on a
taper around the Z axis with an opening an-
gle of 45 degrees.
N100 X0 Y0 A3=0 B3=-1 C3=1
N110 FOR COUNTER=0 TO NUMBER
N120 ANGLE=360*COUNTER/NUMBER
N130 X=RADIUS*cos(angle) Y=RADIUS*sin(angle)
A3=sin(angle) B3=-cos(angle) C3=1
N140 ENDFOR

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References
Function Manual, Basic Functions; Chapter "B1: Continuous-path mode, Exact stop, Look
Ahead" > "Compressor functions"

2.9.4 Smoothing of the orientation characteristic

2.9.4.1 Function
With many of the NC programs for 5-axis machining created with CAD/CAM systems it
happens that although the contour characteristic is sufficiently smooth in accordance with the
underlying geometry the orientation characteristic contains fluctuations it to one extent or the
other. These fluctuations in orientation result in very unsmooth running of the orientation axes
with permanent acceleration and braking. The compensating motion that the linear axes then
have to carry out requires that they also have to be continually accelerated and braked. Due
to this unnecessary acceleration, the possible path velocity is significantly limited and
consequently the machining time unnecessarily lengthened.
The "Smoothing the orientation characteristic" function can be used to smooth oscillations
affecting orientation over several blocks. The aim is to achieve a smooth characteristic for both
the orientation and the contour.

Preconditions
The following preconditions apply when using the function:
● The function is only available in systems with 5/6-axis transformation.
● It can only be used in conjunction with the COMPCAD compressor function.

2.9.4.2 Commissioning

Parameterization
Number of blocks
Smoothing of the orientation characteristic is carried out by means of an adjustable number
of blocks:
MD28590 $MC_MM_ORISON_BLOCKS = <value>
For most applications, 10 blocks should be sufficient. The minimum value that should be
entered is 4.

Note
If smoothing of the orientation characteristic is activated without sufficient block memory having
been configured for it (MD28590 < 4), an alarm message will be output and the function cannot
be executed.

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Maximum block path length

The orientation characteristic is only smoothed in blocks whose traversing distance is shorter
than the settable maximum block path length:
MD20178 $MC_ORISON_BLOCK_PATH_LIMIT
Blocks with longer traversing distances interrupt smoothing and are traversed as programmed.
Maximum tolerance
Smoothing of the orientation characteristic is carried out with the specified maximum tolerance
being observed (maximum angular displacement of tool orientation in degrees):
SD42678 $SC_ORISON_TOL
Maximum path distance
The maximum distance over which smoothing is carried is the specified path distance:
SD42680 $SC_ORISON_DIST

2.9.4.3 Programming
The "Smoothing of the orientation characteristic" is activated/deactivated in the part program
using the commands of G group 61. The commands are modal.

Preconditions
● System with 5/6-axis transformation.
● Compressor function COMPCAD is active.

Syntax
ORISON
...
ORISOF

Meaning

ORISON: Activating the orientation characteristic smoothing

ORISOF: Deactivating the orientation characteristic smoothing

Example
Program code Comment
...
TRAORI() ; Activation of orientation transformation.
COMPCAD ; Activating the COMPCAD compressor function.
ORISON ; Activating orientation smoothing.

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Program code Comment

$SC_ORISON_TOL=1.0 ; Maximum angular deviation of the tool orientation
= 1.0 degrees.
G91
X10 A3=1 B3=0 C3=1
X10 A3=–1 B3=0 C3=1
X10 A3=1 B3=0 C3=1
X10 A3=–1 B3=0 C3=1
X10 A3=1 B3=0 C3=1
X10 A3=–1 B3=0 C3=1
X10 A3=1 B3=0 C3=1
X10 A3=–1 B3=0 C3=1
X10 A3=1 B3=0 C3=1
X10 A3=–1 B3=0 C3=1
...
ORISOF ; Deactivation of orientation smoothing.
...

The orientation is pivoted through 90 degrees on the XZ plane from -45 to +45 degrees. Due
to the smoothing of the orientation characteristic the orientation is no longer able to reach the
maximum angle values of -45 or +45 degrees.

2.9.5 Orientation relative to the path

Functionality
Irrespective of certain technological applications, the previous programming of tool orientation
is improved in that the programmed relative orientation in relation to the total path is maintained.
The required deviations from the ideal orientation path can be specified if, for example, a corner
occurs in the contour.
Tool orientation can be modified not only via configurable machine data, but also via new
language commands in the part program. In this way, it is possible to maintain the relative

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2.9 Orientation

orientation not only at the block end, but also throughout the entire trajectory. The desired
orientation is achieved:
● By settable orientation methods with ORIPATH, specifying how interpolation is to be
performed relative to the path.
● Whether the tool orientation should either always run continuously with specifiable
deviations from the orientation relative to the path at a block transition, or whether the
orientation jump should be smoothed in a dedicated, inserted intermediate block. In this
case, path motion is stopped in the contour corner.
● There are two options of 6-axis transformations:
– Like tool rotation, tool orientation is interpolated relative to the path using ORIPATH,
ORIPATHS.
– The orientation vector is programmed and interpolated in the usual manner. The rotation
of the orientation vector is initiated relative to the path tangent using ORIROTC.
Note
Orientation relative to the path interpolation with ORIPATH or ORIPATHS and
ORIROTC, can not be used in conjunction with the function "Orientation smoothing". For
this OSOF must be active in the part program. Otherwise alarm 10980 "Orientation
smoothing not possible" is generated.

Activate orientation relative to the path

The extended function "Orientation relative to the path" is activated with the following machine
data:
MD21094 $MC_ORIPATH_MODE > 0 (setting for path relative orientation ORIPATH)
The tool orientation relative to the path is activated in the part program by programming
ORIPATH. A kink in the orientation path, e.g. as can occur at a corner in the contour, can be
smoothed with ORIPATH.

Orientation at block transition

In case of the following machine data, tool orientation is always continuous at a block transition:
MD21094 $MC_ORIPATH_MODE = 0
With the following machine data a jump in tool orientation can occur at a block transition:
MD21094 $MC_ORIPATH_MODE > 0
A jump in orientation always occurs when either the path tangent or the surface normal vector
does not change smoothly at a block transition.

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Deviation from the desired orientation

During the interpolation of the block, the orientation may deviate more or less from the desired
relative orientation. The orientation achieved in the previous block is transferred to the
programmed end orientation using large circular interpolation. The resulting deviation from the
desired relative orientation has two main causes:
1. The end orientation of the previous block refers to the tangent and the normal vector at the
end of the previous block. Both can differ from this at the start of the current block. Therefore,
the start orientation in the current block does not have the same alignment with respect to
the tangent and the normal vector as at the end of the previous block.
2. Not only the tangent, but also the normal vector can change throughout the entire block.
This is the case, when circles, splines or polynomials are programmed for the geometry
axes, or when not only a start, but also an end value is programmed for the normal vector.
In this case, the tool orientation must change accordingly during the interpolation of the
block, in order to have the same reference to the path tangent and to the surface normal
vector in each path point.

Set orientation relative to the path

The following machine data is used to set in which way the orientation relative to the path is
to be interpolated.
MD21094 $MC_ORIPATH_MODE (setting for path relative orientation ORIPATH)
With ORIPATH the behavior of tool orientation interpolation relative to the path can be activated
for various functions:

Meaning of units activate proper orientation relative to the path

0: The tool orientation only has the reference to the path tangent and to the normal vector
programmed with LEAD and TILT at the end of the block, whereas, during the block, the
orientation does not follow the path tangent (previous behavior).
1: Reference of the tool orientation to the path tangent and to the surface normal vector
programmed with LEAD/TILT is maintained throughout the entire block.

Meaning of decades Interpretation of the turning angle TILT

0: LEAD = rotation about the direction perpendicular to the tangent and normal vector (forward
angle)
TILT = rotation of orientation around the normal vector
1: LEAD = rotation about the direction perpendicular to the tangent and normal vector (forward
angle)
TILT = rotation of orientation around the direction of path tangent (sideways angle)

Meaning of centuries Retracting movement with re-orientation

0: There is no retracting movement
There is a retracting movement in the tool coordinate system, i.e. the direction programmed
by the retracting vector is interpreted in a coordinate system, which is specified in the following
way:

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1: Current tool direction (z coordinate) and orientation change (x coordinate)

2: Active plane (z coordinate is normal vector to the active plane) and orientation change (x
coordinate)

Smoothing of the orientation jump ORIPATHS

Smoothing of the orientation jump is done within the setting data SD42670
$SC_ORIPATH_SMOOTH_DIST (path distance to smoothing orientation) of the specified
path. The programmed reference of the orientation to the path tangent and normal vector is
then no longer maintained within this distance. If this distance is set too small, the path velocity
may have to be reduced significantly.
A velocity jump of the orientation axes can also be smoothed. In the case where the orientation
path does not perform a jump, but whose first derivation is not smooth, the resulting velocity
jump can be smoothed. The setting data SD42672 $SC_ORIPATH_SMOOTH_TOL > 0
(tolerance for smoothing the orientation) is used to specify how much the orientation may
deviate from the "tangential" alignment. This orientation smoothing is only performed if G code
ORIPATHS ORIPATHS is active and setting data SD42672 SC_ORIPATH_SMOOTH_TOL >
0.
Insertion of intermediate blocks for the smoothing of the orientation path
If the following setting data is set, a separate intermediate block is inserted for the smoothing
of the orientation path:
SD42670 $SC_ORIPATH_SMOOTH_DIST = 0.0 (path distance for smoothing the orientation)
This means that the path motion then stops at the corner of the contour and only then the jump
in the tool orientation is executed. The orientation change is then only performed with with
continuous acceleration when ORIPATHS is active. Otherwise the orientation is transferred
from the start orientation to the end orientation by means of linear large circle interpolation.

Execute tool retracting movement

A tool retracting movement can be performed during this re-orientation. The direction and path
length of the retracting movement is programmed via the vector using the components A8=x,
B8=y and C8=z. If the length of this vector is exactly zero, no retracting movement is executed.
In which coordinate system the tool retracting vector is interpreted, depends on the value of
the following machine data:
MD21094 $MC_ORIPATH_MODE (setting for path relative orientation ORIPATH)
This specifies in which coordinate system the retracting vector is interpreted.
1. Tool coordinate system: z coordinate defined by current tool direction.
2. Workpiece coordinate system: z coordinate defined by active plane.
Normally the retracting movement is performed simultaneously to the orientation change. A
factor can be programmed with the identifier ORIPLF = r , which defines a "safety clearance".
In this way, tool orientation only changes when the tool has retracted by r * retraction path.
The programmed retraction factor must be in the interval 0 = r 1, in order to avoid alarm 14126.

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Path relative interpolation of the rotation ORIROTC

With 6-axis transformations, in addition to the complete interpolation of the tool orientation
relative to the path and the rotation of the tool, there is also the option that only the rotation of
the tool relative to the path tangent is interpolated. The tool orientation can be programmed
and interpolated independently of this. This is activate by the G-code ORIROTC in the 54th G-
code group. Tool orientation direction can be programmed as usual with direction vectors,
Euler or RPY angle. Their interpolation method can be specified as usual with the G codes
ORIVECT, ORIAXES, ORICONxx, ORICURVE , see Section "Rotations of orientation vector
(Page 117)").

2.9.6 Programming of orientation polynominals

Function
Orientation polynomials and even axis polynomials can be programmed with different types
of polynomials regardless of the type of polynomial interpolation currently active. This can be
applied to:
● Linear interpolation with G command G01
● Polynomial interpolation with G command TERMINAL
● Circular interpolation with G command G02, G03 or CIP
● Involute interpolation with G command INVCW or INVCCW
This enables a number of polynomials to be programmed for one contour at the same time.

Note
For additional information about programming axis polynomials with PO[X], PO[Y], PO[Z] and
orientation polynomials such as PO[PHI], PO[PSI], PO[THT] and PO[XH], PO[YH], PO[ZH],
see:
Reference:
Programming Manual Production Planning

Two different types of orientation polynomials are defined:

● Polynomials for angles with reference to the plane defined by the start and end orientation
(type 1 orientation polynomials)
● Polynomials for coordinates in space of a reference point on the tool (type 2 orientation
polynomials).

Type 1 polynomials
Orientation polynomials of type 1 are polynomials for angles

PO[PHI]: Angle in the plane between start and end orientation

PO[PSI]: Angle describing the tilt of the orientation from the plane between start and end
orientation

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Type 2 polynomials
Orientation polynomials of type 2 are polynomials for coordinates

PO[XH]: x coordinate of the reference point on the tool

PO[YH]: y coordinate of the reference point on the tool
PO[ZH]: z coordinate of the reference point on the tool

Polynomials for angle of rotation and rotation vectors

For 6-axis transformations, the rotation of the tool around itself can be programmed for tool
orientation. This rotation of a third rotary axis is described either by an angle of rotation or by
a rotation vector, which is perpendicular to the tool direction in the plane.
In addition, a polynomial for rotation with PO[THT} of the orientation vector can be programmed
in these three cases. This is always possible if the kinematic transformation applied, supports
rotary angles.

Angle of rotation with ORIPATH and ORIPATHS

With orientation interpolation relative to the path with ORIPATH or ORIPATHS, the additional
rotation can be programmed with the angle THETA=<...>. In addition, for this angle of
rotation, with PO[THT]=(...) as a maximum, a 5th degree polynomial angles.
The 3 possible angles, i.e. lead angle, tilt angle and angle of rotation, have the following
meaning with respect to the rotation effect:

LEAD: Angle relative to the surface normal vector in the plane put up by the path tangent and
the surface normal vector.
TILT: Rotation of orientation in the z direction or rotation about the path tangent.
THETA: Rotation around the tool direction. This is only possible when the tool orientation has
a total of 3 degrees of freedom (see Section "Extension of the generic transformation
to six axes - 840D sl only (Page 75)").
How the angles LEAD and TILT are to be interpreted, can be set with the following machine
data:
MD21094 $MC_ORIPATH_MODE (setting for path relative orientation ORIPATH)
In addition to the constant angles programmed with LEAD and TILT, polynomials can be
programmed for lead angle and tilt angle. The polynomials are programmed using the angles
PHI and PSI:

PO[PHI]=(a2,a3,a4 Polynomial for the LEAD angle

,a5):
PO[PSI]=(b2,b3,b4 Polynomial for the TILT angle
,b5):
For both angles, as a maximum, 5th degree polynomial angles can be programmed. The angle
values at the block end are programmed with the NC addresses LEAD=<...> or
TILT=<...>.
The higher polynomial coefficients, which are zero, can be omitted when programming. For
eexample PO[PHI] = (a2) programs a parabola for the lead angle LEAD.

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Rotations of rotation vectors with ORIROTC

The rotation vector is interpolated relative to the path tangent with an offset that can be
programmed using the THETA angle.
For the offset angle, with PO[THT]=(c2,c3,c4,c5), as a maximum, a 5th degree
polynomial angle can be programmed.

Note
If ORIAXES is active, i.e. the tool orientation is interpolated via axis interpolation, the orientation
of the rotation vector relative to the path is only fulfilled at the end of the block.
For further information about programming, see:
References:
Programming Manual Production Planning; Transformations, Interpolation type (ORIPATH,
ORIPATHS)

Boundary conditions
It is only useful to program orientation polynomials for specific interpolation types, which affect
both contour and orientation. A number of supplementary conditions must be met to avoid
illegal programming settings:
Orientation polynomials cannot be programmed,
● if ASPLINE, BSPLINE, CSPLINE spline interpolations are active.
Polynomials for type 1 orientation anglesare possible for every type of interpolation except
spline interpolation, i.e.linear interpolation with rapid traverse G00 or with feedrate G01 and
polynomial POLY and circular/involute interpolation G02, G03, CIP, CT, INVCW and
INVCCW.
In contrast, type 2 orientation polynomials are only possible iflinear interpolation with rapid
traverse G00 or with feedrate G01 or polynomial interpolation POLY is active.
● if the orientation is interpolated using ORIAXES axis interpolation.
In this case, polynomials can be programmed directly with PO[A] and PO[B] for orientation
axes A and B.
If ORICURVE is active, the Cartesian components of the orientation vector are interpolated
and only type 2 orientation polynomials are possible. However, type 1 orientation polynomials
are not permitted.
Only type 1 orientation polynomials are possible for large circle interpolation and taper
interpolation with ORIVECT, ORIPLANE, ORICONxxx. However, type 2 orientation
polynomials are not permitted.

Alarms
An illegally programmed polynomial is signaled with the following alarms:

Alarm 14136: Oreintation polynomial is generally not allowed.

Alarm 14137: Polynomials PO[PHI] and PO[PSI] are not permitted.
Alarm 14138: Polynomials PO[XH], PO[YH], PO[ZH] are not permitted.
Alarm 14139: Polynomial for angle of rotation PO[THT] is not permitted.

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2.9.7 System variable for tool orientation

The tool orientation can be read in various coordinate systems (BCS, WCS, SZS) via system
variables as well as also via OPI variables.

Tool orientation in BCS

System variable Meaning

$AC_TOOLO_ACT[<i>] ; <i> = 1, 2, 3 i-th component of the vector of the actual reference
orientation
$AC_TOOLO_END[<i>] ; <i> = 1, 2, 3 i-th component of the vector of the end orientation
of the actual block
$AC_TOOLO_DIFF Residual angle in degrees, i.e. this is the angle be‐
tween vectors $AC_TOOLO_END[<i>] and
$AC_TOOLO_ACT[<i>]
$VC_TOOLO[<i>] ; <i> = 1, 2, 3 i-th component of the vector of the actual orientation
$VC_TOOLO_DIFF Angle in degrees between reference and actual val‐
ue orientation
$VC_TOOLO_STAT Status variable for actual orientation
Indicates whether the actual orientation can be cal‐
culated. The following values are possible:
0 Actual orientation can be calculated.
-1 Actual orientation cannot be calculated, as the
presently active transformation cannot calcu‐
late these values in real time.

These system variables can always be read by the part program as well as in synchronized
actions. Write access operations are not permitted.

Note
The components of vectors $AC_TOOLO_ACT[<i>], $AC_TOOLO_END[<i>] and
$VC_TOOLO[<i>] of the orientation are scaled so that the orientation vector has the absolute
value of 1.

Rotation vector in the BCS

For a 6-axis kinematics, in addition to the orientation of the tool, there is also a rotation of the
tool, which can be changed.

System variable Meaning

$P_TOOLROT[<i>] ; <i> = 1, 2, 3 i-th component of the actual rotation vector in the
NC program
$AC_TOOLR_ACT[<i>] ; <i> = 1, 2, 3 i-th component of the vector of the actual setpoint
of the orientation rotation
$AC_TOOLR_END[<i>] ; <i> = 1, 2, 3 i-th component of the vector of the setpoint of the
rotation at the end of the actual block

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System variable Meaning

$AC_TOOLR_DIFF Residual angle in degrees, i.e. this is the angle be‐
tween vectors $AC_TOOLR_END[<i>] and
$AC_TOOLR_ACT[<i>]
$VC_TOOLR[<i>] ; <i> = 1, 2, 3 i-th component of the vector of the actual value of
the orientation rotation
$VC_TOOLR_DIFF Angle in degrees between the setpoint and actual
value of the orientation rotation
$VC_TOOLR_STAT Status variable for the actual value of the rotation
vector
Indicates whether the actual value of the rotation
vector can be calculated. The following values are
possible:
0 The actual value of the rotation vector can be
calculated.
-1 Actual value of the rotation vector cannot be
calculated, as the presently active transforma‐
tion cannot calculate these values in real time.

Orientation and rotation of the tool in the various coordinate systems (BCS, WCS, SZS)

Tool orientation

System variable Meaning

$P_TOOL_O[<i>,<j>] ; <i> =1, 2, 3 i-th component of the actual orientation vector in the
; <j> = 0, 1, 2 NC program in the coordinate system <j>
<j> = 0: BCS
<j> = 1: WCS
<j> = 2: SZS
$AC_TOOL_O_ACT[<i>,< j>] ; <i> =1, 2, 3 i-th component of the actual orientation vector in the
; <j> = 0, 1, 2 coordinate system <j>
$AC_TOOL_O_END[<i>,< j>] ; <i> =1, 2, 3 i-th component of the end orientation of the actual
; <j> = 0, 1, 2 block in the coordinate system <j>
$AC_TOOL_O_DIFF[<j>] ; <j> = 0, 1, 2 Residual angle of the orientation vector in degrees
in various coordinate systems <j>
$VC_TOOL_O[<i>,<j>] ; <i> =1, 2, 3 i-th component of the vector of the actual orientation
; <j> = 0, 1, 2 in various coordinate systems <j>
$VC_TOOL_O_DIFF[<j>] ; <j> = 0, 1, 2 Angle in degrees between reference and actual val‐
ue orientation in various coordinate systems <j>

Rotation vector (only for 6-axis kinematics)

System variable
$P_TOOL_R[<i>,<j>] ; <i> =1, 2, 3 i-th component of the actual rotation vector in the
; <j> = 0, 1, 2 NC program in the coordinate system <j>
<j> = 0: BCS
<j> = 1: WCS
<j> = 2: SZS

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System variable
$AC_TOOL_R_ACT[<i>,<j>] ; <i> =1, 2, 3 i-th component of the actual rotation vector in the
; <j> = 0, 1, 2 coordinate system <j>
$AC_TOOL_R_END[<i>,<j>] ; <i> =1, 2, 3 i-th component of the rotation vector at the end of
; <j> = 0, 1, 2 the actual block in the coordinate system <j>
$AC_TOOL_R_DIFF[<j>] ; <j> = 0, 1, 2 Residual angle of the rotation vector in degrees in
various coordinate systems <j>
$VC_TOOL_R[<i>,<j>] ; <i> =1, 2, 3 i-th component of the actual value of the rotation
; <j> = 0, 1, 2 vector in various coordinate systems <j>
$VC_TOOL_R_DIFF[<j>] ; <j> = 0, 1, 2 Angle in degrees between reference and actual val‐
ue of the rotation vector in various coordinate sys‐
tems <j>

Boundary conditions
Not all transformations provide the actual value of the tool orientation in real time. In this case,
variables $VC_TOOLO[<i>] or VC_TOOL_O[<i>] and $VC_TOOLO_DIFF or
$VC_TOOL_O_DIFF cannot be calculated. The components of $VC_TOOLO[<i>] or
$VC_TOOL_O[<i>] are all zero, and status variable $VC_TOOLO_STAT supplies the value
"-1". The same is true for the actual values of the rotation vector $VC_TOOLR[<i>] or
$VC_TOOL_R[<i>,<j>].

2.10 Orientation axes

Direction
The directions around which axes are rotated are defined by the axes of the reference system.
In turn, the reference system is defined by ORIMKS and ORIWKS commands:
● ORIMKS : Reference system = Basic coordinate system
● ORIWKS: Reference system = Workpiece coordinate system

Order of rotation
The order of rotation for the orientation axes is defined by the following machine data:
MD21120 $MC_ORIAX_TURN_TAB_1[0..2] (definition of reference axes for ORI axes)
1. First rotation around the axis of the reference system, defined in the following machine data:
MD21120 $MC_ORIAX_TURN_TAB_1[0]
2. Second rotation around the axis of the reference system, defined in the following machine
data:
MD21120 $MC_ORIAX_TURN_TAB_1[1]
3. Third rotation around the axis of the reference system, defined in the following machine
data:
MD21120 $MC_ORIAX_TURN_TAB_1[2]

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Direction of the tool vector

The direction of the tool vector in the initial machine setting is defined in the following machine
data:
MD24580 $MC_TRAFO5_TOOL_VECTOR_1 (orientation vector direction) or
MD24680 $MC_TRAFO5_TOOL_VECTOR_2 (orientation vector direction)

Assignment to channel axes

Machine data MD24585 $MC_TRAFO5_ORIAX_ASSIGN_TAB_1[0..2] (ORI/channel
assignment Transformation 1) are used to assign up to a total of 3 virtual orientation axes to
the channel, which are set as input variables in machine data $MC_TRAFO_AXES_IN_n[4..6]
(axis assignment for Transformation n).
For assigning channel axes to orientation axes, the following applies:
● $MC_TRAFO5_ORIAX_ASSIGN_TAB_n[0] = $MC_TRAFO_AXES_IN_n[4]
● $MC_TRAFO5_ORIAX_ASSIGN_TAB_n[1] = $MC_TRAFO_AXES_IN_n[5]
● $MC_TRAFO5_ORIAX_ASSIGN_TAB_n[2] = $MC_TRAFO_AXES_IN_n[6]

Orientation transformation 1:
MD24585 $MC_TRAFO5_ORIAX_ASSIGN_TAB_1[n] n = channel axis [0..2]
Orientation transformation 2:
MD24685 $MC_TRAFO5_ORIAX_ASSIGN_TAB_2[n] n = channel axis [0..2]
transformation [1..4]
MD24110 $MC_TRAFO5_AXES_IN_1[n] (axis assignment n = channel axis [0..7]
for transformation)
to
MD24410 $MC_TRAFO5_AXES_IN_4[n] (axis assignment
for transformation 4)
transformation [5..8]
MD24432 $MC_TRAFO5_AXES_IN_5[n] (axis assignment n = channel axis [0..7]
for transformation 5)
to
MD24462 MC_TRAFO5_AXES_IN_8[n] (axis assignment
for transformation 8)

Example
For orientation axes, see Section "Example for orientation axes (Page 134)".

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2.10 Orientation axes

2.10.1 JOG mode

It is not possible to traverse orientation axes in JOG mode until the following conditions are
fulfilled:
● The orientation axis must be defined as such, that is, a value must be set in the following
machine data:
MD24585 $MC_TRAFO5_ORIAX_ASSIGN_TAB (ORI/channel axis assignment
Transformation 1)
● A transformation must be active (TRAORIcommand)

Axis traversal using traverse keys

When using the traverse keys to move an axis continuously (momentary-trigger mode) or
incrementally, it must be noted that only one orientation axis can be moved at a time.
If more than one orientation axis is moved, alarm 20062 "Channel 1 axis 2 already active" is
generated.

Traversal using handwheels

More than one orientation axis can be moved simultaneously via the handwheels.

Feedrate in JOG
When orientation axes are traversed manually, the channel-specific feedrate override switch
or the rapid traverse override switch in rapid traverse override is applied.
Until now, velocities for traversal in JOG mode have always been derived from the machine
axis velocities. However, geometry and orientation axes are not always assigned directly to a
machine axis.
For this reason, new machine data have been introduced for geometry and orientation axes,
allowing separate velocities to be programmed for these axis types:
● MD21150 $MC_JOG_VELO_RAPID_ORI[n]
(conventional fast traverse for ORI axes)
● MD21155 $MC_JOG_VELO_ORI[n]
(conventional ORI axis speed)
● MD21160 $MC_JOG_VELO_RAPID_GEO[n]
(conventional fast traverse for GEO axes)
● MD21165 $MC_JOG_VELO_GEO[n]
(conventional GEO axis speed)
Appropriate speed values for the axes must be programmed in these data.

Acceleration
Acceleration for the orientation axes can be set by means of the following machine data:
MD21170 $MC_ACCEL_ORI[n] (ascceleration for orientation axes)

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2.10 Orientation axes

2.10.2 Programming for orientation transformation

The values can only be programmed in conjunction with an orientation transformation.

Programming of orientation
Orientation axes are programmed by means of axis names A2, B2 and C2.
Euler and RPY values are distinguished on the basis of G-group 50:
● ORIEULER:
Orientation programming on the basis of Euler angles (default)
● ORIRPY:
Orientation programming via RPY angles
● ORIVIRT1:
Orientation programming on the basis of virtual orientation axes (definition 1)
● ORIVIRT2:
Orientation programming on the basis of virtual orientation axes (definition 2)
The type of interpolation is distinguished on the basis of G-group 51:
● ORIAXES:
Orientation programming of linear interpolation of orientation axes or machine axes
● ORIVECT:
Orientation programming of large circle interpolation of orientation axes (interpolation of
the orientation vector)
Machine data MD21102 $MC_ORI_DEF_WITH_G_CODE (definition of ORI axes via G-code)
is used to specify whether MD21100 $MC_ORIENTATION_IS_EULER (angle definition for
orientation programming) is active (default) or G-group 50.
The following four variants are available for programming orientation:
1. A, B, C:
Machine axis parameter designation
2. A2, B2, C2:
Angle programming of virtual axes
3. A3, B3, C3:
Vector component designation
4. LEAD, TILT:
Specification of lead and side angles with reference to path and surface

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F2: Multi-axis transformations
2.10 Orientation axes

References:
Programming Manual Fundamentals

Note
The four variants of orientation programming are mutually exclusive. If mixed values are
programmed, alarm 14130 or alarm 14131 is generated.
Exception:
For 6-axis kinematics with a 3rd degree of freedom for orientation, C2 may also be programmed
for variants 3 and 4. C2 in this case describes the rotation of the orientation vector about its
own axis.

Example
For orientation axes for kinematics with 6 or 5 transformed axes, see Section "Example for
orientation axes (Page 134)".

Interpolation type
The following machine data is used to specify which interpolation type is used:
MD21104 $MC_ORI_IPO_WITH_G_CODE (G-code for orientation interpolation):
● ORIMKS or ORIWKS (for description, see Section "Tool orientation (Page 48)")
● G-code group 51 with the commands ORIAXES or ORIVECT
– ORIAXES:
Linear interpolation of machine axes or orientation axes.
– ORIVECT:
Orientation is controlled by the orientation vector being swivelled in the plane spanned
by the start and end vectors (large circle interpolation). With 6 transformation axes a
rotation around the orientation vector is excuted in addition to the swivel movement.
With ORIVECT the orientation axes are always traversed on the shortest possible path.

Range of values
Value range for orientation axes:
● 180 degrees < A2 < 180 degrees
● 90 degrees < B2 < 90 degrees
● 180 degrees < C2 < 180 degrees
All possible rotations can be represented with this value range. Values outside the range are
normalized by the control system to within the range specified above.

Feedrate when programming ORIAXES

Feedrate for an orientation axis can be limited via the FL[ ] instruction (feed limit).

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 F2: Multi-axis transformations
2.10 Orientation axes

2.10.3 Programmable offset for orientation axes

How the programmable offset works

The additional programmable offset for orientation axes acts in addition to the existing offset
and is specified when transformation is activated. Once transformation has been activated, it
is no longer possible to change this additive offset and no zero offset will be applied to the
orientation axes in the event of an orientation transformation.
The programmable offset can be specified in two ways.
1. Direct programming of the offset with TRAORI() when transformation is activated.
2. Automatic transfer of the offset from the zero offset active for the orientation axes when
transformation is activated. This automatic transfer is configured via machine data.

Programming offset directly

When transformation is activated, the offset can be programmed directly as TRAORI(n, x, y,
z, a, b) TRAORI(n, x, y, z, a, b) . The following parameters are available as an option:

n: Number of transformation n = 1 or 2
x, y, z Components of the vector for the basic orientation of thetool (generic 5-axis
transformation only).
a, b: Offset for rotary axes
These optional parameters can be omitted. However, if they are used for programming
purposes, the correct sequence must be observed. If for example only one rotary axis offset
is to be entered, TRAORI(,,,, a, b) is to be programmed.
For further information about programming, please see:
Reference:
Programming Manual, Production Planning; Transformations

Programming offset automatically

As the offset is transferred automatically from the currently active zero offset on the orientation
axes, the effects of zero offset on rotary axes are always the same, both with and without active
transformation. Automatic take-over of offset from zero offset is possible via machine data
MD24590 $MC_TRAFO5_ROT_OFFSET_FROM_FR_1 = TRUE (Offset of rotary
transformation axes from NPV) for the first machine data, or MD24690
$MC_TRAFO5_ROT_OFFSET_FROM_FR_2 = TRUE (Offset of rotary transformation axes
from NPV) for the second transformation in the channel.

Note
There is no difference between a zero offset on the orientation axes programmed during active
transformation and the previous offset.
If automatic transfer of offset has been activated and a rotary axis offset is programmed at the
same time, the programmed offset value takes priority.

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F2: Multi-axis transformations
2.10 Orientation axes

Orientable toolholder with additive offset

On an orientable toolholder, the offset for both rotary axes can be programmed with the system
variables $TC_CARR24 and $TC_CARR25. This rotary axis offset can be transferred
automatically from the zero offset effective at the time the orientable toolholder was activated.
Automatic transfer of offset from zero offset is made possible via the following machine data:
MD21186 $MC_TOCARR_ROT_OFFSET_FROM_FR = TRUE (offset of TOCARR rotary axes
from NPV)

Note
For more information about orientable toolholders, please see:
Reference:
Function Manual, Basic Machine; Tool Offset (W1)

2.10.4 Orientation transformation and orientable tool holders

Note
Orientation transformation and orientable tool holders can becombined.
The resulting orientation of the tool is produced by linking the orientation transformation and
the orientable tool holder.

2.10.5 Modulo display of orientation axes

Function
The positions of orientation axes can be displayed for the BCS and WCS display in a settable
modulo area. Whether the concerned machine axes are linear or rotary is not relevant in this
context, i.e. this display option can be enabled even for normal generic 5-/6-axis
transformation.

Requirements
● Orientation axes must be available. This is the case if an orientation transformation is active
(e.g. generic 5-/6-axis transformation).
● The following machine data must also be set for OEM transformations:
MD24585 $MC_TRAFO5_ORIAX_ASSIGN_TAB_1[0..2]

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2.11 Orientation vectors

Parameterization
The modulo display of orientation axes is activated as follows:
MD21132 $MC_ORI_DISP_IS_MODULO[0...2] = TRUE
The modulo range is defined with the help of the following machine data:
● MD21134 $MC_ORI_MODULO_RANGE[0...2]
(Size of the modulo range for the display of the orientation axes)
● MD21136 $MC_ORI_MODULO_RANGE_START[0...2]
(Starting position of the modulo range for the display of the orientation axes)
Please note the following:
● The machine data becomes effective with NewConfig.
● The machine data does not have any influence or effects on:
– any axis positions that can be programmed for these axes.
– The traversing movements of these axes.
– The display of the MCS values of these axes

2.11 Orientation vectors

2.11.1 Polynomial interpolation of orientation vectors

Programming of polynomials for axis motions

The rotary axes are normally subjected to linear interpolation in case of orientation changes
with the help of rotary axis interpolation. However, it is also possible to program the polynomials
as usual for the rotary axes. This allows a generally more homogeneous axis motion to be
produced.

Note
Further information about programming polynomial interpolation with POLY and on
interpolation of orientation vectors is given in:
Reference:
Programming Manual; Production Planning

A block with POLY is used to program polynomial interpolation. Whether the programmed
polynomials are then interpolated as polynomial, depends on whether the G-code POLY is
active or not:
● The G-code ist not active: The programmed axis end points are traversed linearly.
● The G-code is active: The programmed polynomials are interpolated as polynomials.

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F2: Multi-axis transformations
2.11 Orientation vectors

MD10674
Using machine data MD10674 $MN_PO_WITHOUT_POLY = FALSE
(polynomial can be programmed without G command POLY), it can be set as to whether the
following programming is possible:
● PO[...] or PO(...) is possible only if POLY is active, or
● PO[ ] or PO( ) polynomials are also possible without active G-code POLY.
As default, MD10674: PO_WITHOUT_POLY = FALSE set and with MD10674
$MN_PO_WITHOUT_POLY = TRUE the following programming is always possible:
● PO[...] = (...), regardless of whether POLY is active or not.
Orientation polynomials can be programmed in conjunction with different interpolation types
and are described in Section "Programming of Orientation Polynomials".

POLYPATH:
In addition to the modal G command POLY, with the predefined subprogram
POLYPATH(argument), polynomial interpolation can be selectively activated for various axis
groups. The following arguments are allowed for the activation of polynomial interpolation

("AXES"): For all path axes and supplementary axes

("VECT"): For orientation axes
("AXES", "VECT"): For path axes, supplementary axes and orientation axes
(without argument): deactivates polynomial interpolation for all axis groups
Normally, the polynomial interpolation is activated for all axis groups.

Programming of orientation vectors

An orientation vector can be programmed in each block. If polynomials are programmed for
the orientation, the interpolated orientation vector is generally turned not in the plane between
start and end vector, but it can be rotated at random from this plane.
Orientation vectors can be programmed as follows:
1. Programming of rotary axis positions with A, B and C or with the actual rotary axis names.
2. Programming in Euler angle or RPY angle via A2, B2, C2.
3. Programming of the direction vector via A3, B3, C3.
4. Programming using lead angle LEAD and tilt angle TILT.

Selection of type of interpolation

The type of interpolation of orientation axes is selected with G-code of group 51 and is
independent of the programming type of the end vector:
● ORIAXES: Linear interpolation of the machine axes or using polynomials for active POLY
or
● ORIVECT: Interpolation of the orientation vector using large circle interpolation

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 F2: Multi-axis transformations
2.11 Orientation vectors

If ORIAXES is active, the interpolation of the rotary axis can also take place using polynomials
like polynomial interpolation of axes with POLY .
On the other hand, if ORIVECT is active, "normal" large circle interpolation is carried out
through linear interpolation of the angle of the orientation vector in the plane that is defined by
the start and end vector.

Polynomials for 2 angles

Additional programming of polynomials for 2 angles that span the start vector and end vector
can also be programmed as complex changes in orientation with ORIVECT .
The two PHI and PSI angles are specified in degrees.

POLY Activation of polynomial interpolation for all axis groups.

POLYPATH ( ) Activation of polynomial interpolation for all axis groups. "AXES" and
"VECT" are possible groups.
The coefficients an and bn are specified in degrees.
PO[PHI]=(a2, a3, a4, The angle PHI is interpolated according to PHI(u) = a0 + a1*u + a2*u2 +
a5) a3*u3+ a4*u4 + a5*u5.
PO[PSI]=(b2, b3, b4, The angle PHI is interpolated according to PSI(u) = b0 + b1*u + b2*u2 +
b5) b3*u3+ b4*u4 + b5*u5.
PL Length of the parameter interval where polynomials are defined. The
interval always starts at 0.
Theoretical value range for PL: 0.0001 ... 99999.9999
The PL value applies to the block that contains it. PL = 1 is applied if no
PL value is programmed.

Rotation of the orientation vector

Changes in orientation are possible with ORIVECT independent of the type of end vector
programming. The following situations apply:
Example 1: Components of end vectors are programmed directly.
N... POLY A3=a B3=b C3=c PO[PHI] = (a2, a3, a4, a5) PO[PSI] = (b2, b3, b4, b5)
Example 2: The end vector is determined by the position of the rotary axes.
N... POLY Aa Bb Cc PO[PHI] = (a2, a3, a4, a5) PO[PSI] = (b2, b3, b4, b5)
The angle PHI describes the rotation of the orientation vector in the plane between start and
end vectors (large circle interpolation, see figure below). The orientation is interpolated exactly
as in Example 1.

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F2: Multi-axis transformations
2.11 Orientation vectors

3+,
6WDUWYHFWRU
(QGYHFWRU

Figure 2-23 Rotation of the orientation vector in the plane between start and end vector

PHI and PSI angle

Programming of polynomials for the two angles PO[PHI] and PO[PSI] is always possible.
Whether the programmed polynomials are actually interpolated for PHI and PSI depends on:
● POLYPATH("VECT") and ORIVECT are active, then the polynomials will be interpolated.
● If POLYPATH("VECT") and ORIVECT are not active, the programmed orientation vectors
are traversed at the end of the block by a "normal" large circle interpolation. This means
that the polynomials for the two angles PHI and PSI are ignored in this case.

6WDUW (QG
3+,

36,

Figure 2-24 Movement of the orientation vector in plan view

The angle PSI can be used to generate movements of the orientation vector perpendicular to
large circle interpolation plane (see previous figure).

As a maximum, a 5th degree polynomial is permissible

As a maximum, 5th degree polynomials can be programmed for the PHI and PSI angles. Here
the constants and linear coefficient are defined by the initial value or end value of the orientation
vector.
Higher degree coefficients can be omitted from the coefficient list (..., ....) if these are all equal
to zero.
The length of the parameter interval in which the polynomials are defined can also be
programmed with PL.

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 F2: Multi-axis transformations
2.11 Orientation vectors

Special situations
If no polynomial for angle PSI is programmed, the orientation vector is always interpolated in
the plane defined by the start and end vector.
The PHI angle in this plane is interpolated according to the programmed polynomial for PHI.
As a result the orientation vector moves through a "normal" large circle interpolation in the
plane between the start and end vector and the movement is more or less irregular depending
on the programmed polynomial.
In this way, the velocity and acceleration curve of the orientation axes can be influenced within
a block, for example.

Note
Further information on polynomial interpolation for axis motion and general programming is
given in:
Reference:
Programming Manual; Production Planning

Boundary conditions
Polynomial interpolation of orientation vectors is only possible for control variants in which the
following functions are included in the functional scope:
● Orientation transformation
● Polynomial interpolation

2.11.2 Rotations of orientation vector

Functionality
Changes in tool orientation are programmed by specifying an orientation vector in each block,
which is to be reached at the end of the block. The end orientation of each block can be
programmed in the following way:
1. programming the vector directly, or
2. programming the rotary axis positions.
The second option depends on machine kinematics. Interpolation of the orientation vector
between the start and end values can also be modified by programming polynomials.

Programming of orientation directions

The following options are available for programming tool orientation:
1. Direct programming of rotary axis positions (the orientation vector is derived from machine
kinematics).
2. Programming in Euler angles via A2, B2, C2 (angle C2 is irrelevant).

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F2: Multi-axis transformations
2.11 Orientation vectors

3. Programming in RPY angles via A2, B2, C2.

4. Programming the direction vector via A3, B3, C3 (the length of the vector is irrelevant).
Switching between Euler and RPY angle programming can be selected via the following
machine data or via the G-codes ORIEULER and ORIRPY :
MD21100 $MC_ORIENTATION_IS_EULER (angle definition for orientation programming)

Programming of orientation direction and rotation

While the direction of rotation is already defined when you program the orientation with RPY
angles, additional parameters are needed to specify the direction of rotation for the other
orientations:
1. Direct programming of the rotary axes
A supplementary rotary axis for direction of rotation has to be defined.
2. Programming in Euler angles via A2, B2, C2
Angle C2 must be programmed additionally. The complete orientation is thus defined,
including tool rotation.
3. Programming in RPY angles via A2, B2, C2
Additional settings are not required.
4. Programming of the direction vector via A3, B3, C3
The rotation angle is programmed with THETA=<value>.
Note
The following cases do not allow for a programmed rotation:
Multiple programming of the direction of rotation is not allowed and results in an alarm. If
the Euler angle C2 and the angle of rotation THETA are programmed simultaneously, the
programmed rotation is not executed.
If machine kinematics are such that the tool cannot be rotated, any programmed rotation
is ignored. This is the case with a normal 5-axis machine, for example.

Rotation of the orientation vector

The following options are available for interpolating rotation of the orientation vector by
programming the vector directly:
● Linear interpolation, i.e. the angle between the current rotation vector and the start vector
is a linear function of the path parameter.
● Non-linear due to additional programming of a polynomial for the angle of rotationq of 5th
degree maximum, in the format:
PO[THT] = (d2, d3, d4, d5)

Interpolation of the angle of rotation

Higher degree coefficients can be omitted from the coefficient list (..., ....) if these are all equal
to zero.

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 F2: Multi-axis transformations
2.11 Orientation vectors

In such cases, the end value of the angleand the constant and linear coefficient dn of the
polynomial cannot be programmed directly.
The linear coefficient dn is defined by means of the end angle qe in degrees.
The end angle qe is derived from programming of the rotation vector.
The start angle qs is derived from the start value of the rotation vector, resulting from the end
value of the previous block. The constant coefficient of the polynomial is defined by the starting
angle of the polynomial.
The rotation vector is always perpendicular to the current tool orientation and forms the angle
THETAin conjunction with the basic rotation vector.

Note
During machine configuration, the direction in which the rotation vector points at a specific
angle of rotation can be defined, when the tool is in the basic orientation.

Formula
In general, the angle of rotation is interpolated with a 5th degree polynomial:

θu=θs+d1u+d2u2+d3u3+d4u4+d5u5 (14)
For the parameter interval 0 ... 1, this produces the following values for linear coefficients:

d1=θe −θs −d2−d3−d4−d5 (15)

Interpolation of the rotation vector

The programmed rotation vector can be interpolated in the following way, using modal G-
codes:
● ORIROTA (orientation rotation absolute):
The angle of rotation THETA is interpreted with reference to an absolute direction in space.
The basic direction of rotation is defined by machine data.
● ORIROTR (orientation rotation relative):
The angle of rotation THETA is interpreted relative to the plane defined by the start and end
orientation.
● ORIROTT (orientation rotation tangential):
The angle of rotation THETA is interpreted relative to the change in orientation. That means
the rotation vector interpolation is tangential to the change in orientation for THETA=0.
This is different to ORIROTR, only if the change in orientation does not take place in one
plane. This is the case if at least one polynomial was programmed for the "tilt angle" PSI
for the orientation. An additional angle of rotation THETA can then be used to interpolate
the rotation vector such that it always produces a specific angle referred to the change in
orientation.

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F2: Multi-axis transformations
2.11 Orientation vectors

Activation of rotation
A rotation of the orientation vector is programmed with the identifier THETA. The following
options are available for programming:

THETA=<value> Programming of an angle of rotation at the end of the block.

THETA = qe Programmed angles qe can be interpreted as absolute (G90 is active)
or as relative (G91 is active incremental).
THETA = AC(...) Switch over to absolute dimensions per block
THETA = IC(...) Switch over to incremental dimensions per block
PO[THT] = (...) Programming of a polynomial for rotation angle THETA.
The angle THETA is programmed in degrees.
Interpolation of the rotation vector is defined by modal G-codes:
ORIROTA Angle of rotation to an absolute direction of rotation
ORIROTR Angle of rotation relative to the plane between the start and end
orientation
ORIROTT Angle of rotation relative to the change of the tangential rotationvec‐
tor of the orientation vector to the orientation change
ORIROTC Angle of rotation relative to the change of the tangential rotationvec‐
tor of the orientation vector to the path tangent
PL Length of the parameter interval where polynomials are defined. The
interval always starts at 0. If no PL has been programmed, PL = 1
will be applied.
These G-codes define the reference direction of the angle of rotation. The meaning of the
programmed angle of rotation changes accordingly.

Boundary conditions
The angle of rotation or rotation vector can only be programmed in all four modes if the
interpolation type ORIROTA is active.
1. Rotary axis positions
2. Euler angles via A2, B2, C2
3. RPY angles via A2, B2, C2
4. Direction vector via A3, B3, C3
If ORIROTR or ORIROTT is active, the angle of rotation can only be programmed directly with
THETA.
The other programming options must be excluded in this case, since the definition of an
absolute direction of rotation conflicts with the interpretation of the angle of rotation in these
cases. Possible programming combinations are monitored and an alarm is output if applicable.
A rotation can also be programmed in a separate block without an orientation change taking
place. In this case ORIROTR and ORIROTT are irrelevant. In this case the angle of rotation is
always interpreted with reference to the absolute direction (ORIROTA).
A programmable rotation of the orientation vector is only possible when an orientation
transformation (TRAORI) is active.

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 F2: Multi-axis transformations
2.11 Orientation vectors

A programmed orientation rotation is only interpolated if the machine kinematics allow rotation
of the tool orientation (e.g. 6-axis machines).

2.11.3 Extended interpolation of orientation axes

Functionality
To execute a change in orientation along the peripheral surface of a cone located in space, it
is necessary to perform an extended interpolation of the orientation vector. The vector around
which the tool orientation is to be rotated must be known. The start and end orientation must
also be specified. The start orientation is given by the previous block and the en orientation
must either be programmed or defined by other conditions.

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Figure 2-25 Change in orientation of the peripheral surface of a cone located in space

Required definitions
Generally, the following data is required:
● The start orientation is defined by the end orientation of the previous block.
● The end orientation is defined either by specifying the vector (with A3, B3, C3), the Euler
angles or RPY angles (with A2, B2, C2) or by programming the positions of the rotary axis
(with A, B, C).
● The rotary axis of the taper is programmed as a (normalized) vector with A6, B6, C6.

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F2: Multi-axis transformations
2.11 Orientation vectors

● The opening angle of the cone is programmed degrees with the identifier (nutation angle).
The value range of this angle is limited to the interval between 0 degrees and 180 degrees.
The values 0 degrees and 180 degrees must not be programmed. If an angle is
programmed outside the valid interval, an alarm is generated.
In the special case where NUT = 90 degrees, the orientation vector in the plane is
interpolated perpendicular to the direction vector (large circle interpolation).
The sign of the programmed opening angle specifies whether the traversing angle is to be
greater or less than 180 degrees.
In order to define the cone, the direction vector or its opening angle must be programmed.
Both may not be specified at the same time.
● A further option is to program an intermediate orientation that lies between the start and
end orientation.

Programming

ORIPLANE orientation interpolation in a plane: Interpolation in a plane

(large circle interpolation)
ORICONCW orientation interpolation on a cone clockwise: Interpolation on
the peripheral surface of a cone in the clockwise direction
ORICONCCW orientation interpolation on a cone counter clockwise: Interpo‐
lation on the peripheral surface of a cone in the counter-clock‐
wise direction.
Programming of the direction vector is carried out using the identifiers A6, B6, C6 and is
specified as a (normalized) vector.

Note
Programming of an end orientation is not absolutely necessary. If no end orientation is
specified, a full outside cone with 360 degrees is interpolated.

The opening angle of the taper is programmed with NUT= <angle>, where the angle is specified
in degrees.

Note
An end orientation must be specified. A complete outside cone with 360 degrees cannot be
interpolated in this way. The sign of the opening angle defines whether the traversing angle is
to be greater or less than 180 degrees.

The identifiers have the following meanings:

NUT = +... Traverse angle smaller than or equal to 180 degrees

NUT = -... Traverse angle greater than or equal to 180 degrees
A positive sign can be omitted when programming.

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 F2: Multi-axis transformations
2.11 Orientation vectors

Settings for intermediate orientation

ORICONIO orientation interpolation on a cone with intermediate orienta‐

tion: Interpolation on a conical peripheral surface with inter‐
mediate orientation setting
If this G-code is active, it is necessary to specify an intermediate orientation with A7, B7, C7
which is specified as a (normalized) vector.

Note
Programming of the end orientation is absolutely necessary in this case.

The change in orientation and the direction of rotation is defined uniquely by the three vectors
Start, End and Intermediate orientation.
All three vectors must be different from each other. If the programmed intermediate orientation
is parallel to the start or end orientation, a linear large circle interpolation of the orientation is
executed in the plane that is defined by the start and end vector.

Angle of rotation and opening angle

The following may be programmed additionally for the angle of the cone:

PHI angle of rotation for orientation about the direction axis

PSI Opening angle of the cone
Besides this polynomials of the 5th degree (max.) can be programmed as follows:

PO[PHI] = (a2, a3, a4, a5) Constant and linear coefficients are defined by start and end ori‐
PO[PSI] = (b2, b3, b4, b5) entation respectively.

Further interpolation options

It is possible to interpolate the oreintation on a cone which connects tangentially to the previous
change of orientation. This orientation interpolation is achieved by programming the G-codes
ORICONTO.

ORICONTO orientation interpolation on a cone with tangential orientation:

Interpolation on a peripheral surface of the cone with tangential
transition
A further option for orientation interpolation is to describe the change in orientation through
the path of a 2nd contact point on the tool.

ORICURVE orientation interpolation with a second curve: Interpolation of

orientation with specification of motion of two contact points of
the tool.
The coordinates for movement of the 2nd contact point of the tool must be specified. This
additional curve in space is programmed with XH, YH, ZH.
Besides the two end values, additional polynomials can be programmed in the following form:

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2.11 Orientation vectors

PO[XH] = (xe, x2, x3, x4, x5): (xe, ye, ze) the end point of the curve, and
PO[YH] = (ye, y2, y3, y4, y5): xi, yi, zi the coefficients of the polynomials
PO[ZH] = (ze, z2, z3, z4, z5): of the 5th degree maximum.
This type of interpolation can be used to program points (G1) or polynomials (POLY) for the
two curves in space.

Note
Circles or involutes are specificaly not allowed. It is also possible to activate a spindle
interpolation with BSPLINE. The programmed end points of both curves in space are then
interpreted as nodes.
Other types of splines (ASPLINE and CSPLINE) and the activation of a compressor
(COMPON, COMPCURV, COMPCAD) are not permitted here.

Supplementary conditions
The extended interpolation of orientations requires that all necessary orientation
transformations be considered, since these belong to the functional scope.

Activation
A change in orientation on any peripheral surface of a cone in space is activated with the G-
code of group 51 through extended interpolation of the orientation vector, using the following
commands:

ORIPLANE Interpolation in a plane with specification of the end orientation

(same as ORIVECT)
ORICONCW Interpolation on a peripheral surface of a taper in clockwise
directionwith specification of the end orientation and taper di‐
rection or opening angle of the cone.
ORICONCCW Interpolation on the peripheral surface of a cone in the counter-
clockwise direction. Specification of the end orientation andt
cone direction or opening angle of the taper.
ORICONIO Interpolation on a peripheral surface of a cone with specifica‐
tion of end orientation and an intermediate orientation.
ORICONTO Interpolation on a peripheral surface of a cone with tangential
transition and specification of end orientation.
ORICURVE Interpolation of orientation with specification of motion of two
contact points of the tool.
ORIPATH Tool orientation in relation to the path
ORIPATHS Tool orientation in relation to the path, when, for example, a
kink in the orientation path, e.g. at a corner in the contour, is
to be smoothed, see Section "Orientation relative to the path
(Page 97)").

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2.12 Online tool length offset

Examples
Various changes in orientation are programmed in the following program example:

Program code Comment

...
N10 G1 X0 Y0 F5000
N20 TRAORI ; Orientation transformation active.
N30 ORIVECT ; Interpolate tool orientation as a vector
N40 ORIPLANE ; Select large circle interpolation
N50 A3=0 B3=0 C3=1
N60 A3=0 B3=1 C3=1 ; Orientation in the Y/Z plane by 45
; Degrees rotated, at the block end the
; orientation (0, 1 / (√2),
; 1 / (√2) is reached.
N70 ORICONCW ; The orientation vector is on a
; Outside of the taper with the direction
N80 A6=0 B6=0 C6=1 A3=1 B3=0 C3=1; (0, 0, 1) to the orientation
; (1 / √2), 0, 1 / (√2)
; Interpolated clockwise,
; The rotation angle is 270 degrees.
; The tool orientation traverses a complete
N90 A6=0 B6=0 C6=1 ; rotation on the same outside surface of the cone
...

2.12 Online tool length offset

Functionality
Effective tool length can be changed in real time so that the length changes are also considered
for changes in orientation of the tool. The system variable $AA_TOFF[<geometry axis name>]
includes tool length compensations in 3-D according to the three tool directions.
None of the tool parameters are changed. The actual compensation is performed internally by
means of transformations using an orientable tool length compensation.
The number of active compensation directions must be the same as the number of active
geometry axes. All offsets can be active at the same time.

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2.12 Online tool length offset

Application
The online tool length compensation function can be used for:
● Orientation transformations (TRAORI)
● Orientable tool carriers (TCARR)
Note
The online tool length offset is an option. This function is only practical in conjunction with
an active orientation transformation or an active orientable toolholder.
Reference:
Function Manual, Basic Functions; Tool Offset, Section: Orientable toolholders (W1)

Block preparation
In the case of block preparation in run-in, the tool length offset currently active in the main run
is considered. In order to utilize the maximum permissible axis velocities as far as possible, it
is necessary to halt the block preparation with a stop preprocessing command (STOPRE) while
a tool offset is being generated.
The tool offset is always known at the time of run-in when the tool length offsets are not changed
after program start or if more blocks have been processed after changing the tool length offsets
than the IPO buffer can accommodate between run-in and main run. This ensures that correct
axis velocities are applied quickly.
The dimension for the difference between the currently active compensation in the interpolator
and the compensation that was active at the time of block preparation can be polled in the
system variable $AA_TOFF_PREP_DIFF[ ].

Note
Changing the effective tool length using online tool length offset produces changes in the
compensatory movements of the axes involved in the transformation in the event of changes
in orientation. The resulting velocities can be higher or lower depending on machine kinematics
and the current axis position.

MD21190 $MC_TOFF_MODE (operation of tool offset)

The following machine data can be used to set whether the content of the synchronization
variable $AA_TOFF[ ] is to be approached as an absolute value or whether an integrating
behavior is to take place:
MD21190 $MC_TOFF_MODE
The integrating behavior of $AA_TOFF[ ] allows 3D remote control. The integrated value is
available via the system variable $AA_TOFF_VAL[ ].

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2.12 Online tool length offset

The following machine data and setting data are available for configuring online tool length
compensation:

Machine data / setting data Meaning for online tool length offset
MD21190 $MC_TOFF_MODE The contents of $AA_TOFF[ ] are traversed as an
absolute value or integrated
MD21194 $MC_TOFF_VELO (speed online tool Speed of online tool length offset
offset)
MD21194 $MC_TOFF_ACCEL (acceleration on‐ Acceleration of online tool length offset
line tool offset)
SD42970 $SC_TOFF_LIMIT (upper limit of off‐ Upper limit of tool length offset value
set value $AA_TOFF)

With the acceleration margin, 20% is reserved for the overlaid movement of online tool length
offset, which can be changed via the following machine data:
MD20610 $MC_ADD_MOVE_ACCEL_RESERVE(acceleration margin for overlaid
movements)

Activation
The TOFFON instruction can be used to activate online tool length offset from the part program
for at least one tool direction, if the option is available. During activation an offset value can
be specified for the relevant direction of compensation and this is immediately traversed.
Example: TOFFON(Z, 25).
Repeated programming of the instruction TOFFON( ) with an offset causes the new offset to
be applied. The offset value is added to variables $AA_TOFF[ ] as an absolute value.

Note
For further information about programming plus programming examples, please see:
Reference:
Programming Manual, Job Planning; Transformations

As long as online tool length offset is active, the VDI signal on the NCK → PLC interface in the
following interface signal is set to 1:
DB21, ... DBX318.2 (TOFF active)
While a correction movement is active, the VDI → signal in the following interface signal is set
to 1:
DB21, ... DBX318.3 (TOFF movement active)

Reset
Compensation values can be reset with the TOFFOF( ) command. This instruction triggers a
preprocessing stop.
Accumulated tool length compensations are cleared and incorporated in the basic coordinate
system. The run-in is synchronized with the current position in main run. Since no axes can
be traversed here, the values of $AA_IM[ ] do not change. Only the values of the variables

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2.12 Online tool length offset

$AA_IW[ ] and $AA_IB[ ] are changed. These variables now contain the deselected share of
tool length compensation.
Once "Online tool length offset" has been deselected for a tool direction, the value of system
variable $AA_TOFF[ ] or $AA_TOFF_VAL[ ] is zero for this tool direction. The following interface
signal is set to 0:
DB21, ... DBX318.2 (TOFF active)

Alarm 21670
An existing tool length offset must be deleted via TOFFOF( ) so that alarm 21670 "Channel
%1 block %2, illegal change of tool direction active due to $AA_TOFF active" is suppressed:
● When the transformation is deactivated with TRAFOOF
● On switch-over from CP to PTP travel.
● If a tool length offset exists in the direction of the geometry axis during geometry
replacement.
● If a tool length offset is present during change of plane.
● When changing from axis-specific manual travel in JOG mode to PTP as long as a tool
length compensation is active. There is no switchover to PTP.

Mode change
Tool length compensation remains active even if the mode is changed and can be executed
in any mode.
If a tool length compensation is interpolated on account of $AA_TOFF[ ] during mode change,
the mode change cannot take place until the interpolation of the tool length compensation has
been completed. Alarm 16907 "Channel %1 action %2 ALNX possible only in stop state" is
issued.

Behavior with REF and block search

Tool length offset is not considered during reference point approach REF in JOG mode.
The instructions TOFFON( ) and TOFFOF( ) are not collected and output in an action block
during block search.

System variable
In the case of online tool length offset, the following system variables are available to the user:

System variable Meaning for online tool length offset

$AA_TOFF[ ] Position offset in the tool coordinate system
$AA_TOFF_VAL[ ] Integrated position offset in the WCS
$AA_TOFF_LIMIT[ ] Query whether the tool length offset value is close to the limit
$AA_TOFF_PREP_DIFF[ ] Magnitude of the difference between the currently active value of
$AA_TOFF[ ] and the value prepared as the current motion block.

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2.13 Examples

Reference:
Parameter Manual, System Variables

Boundary conditions
The online tool length offset function is an option and is available during "generic 5-axis
transformation" by default and for "orientable toolholders".
If the tool is not perpendicular to the workpiece surface during machining or the contour
contains curvatures whose radius is smaller than the compensation dimension, deviations
compared to the actual offset surface are produced. It is not possible to produce exact offset
surfaces with one tool length compensation alone.

2.13 Examples

2.13.1 Example of a 5-axis transformation

CHANDATA(1)

$MA_IS_ROT_AX[AX5] = TRUE
$MA_SPIND_ASSIGN_TO_MACHAX[AX5] = 0
$MA_ROT_IS_MODULO[AX5]=0

;-----------------------------------------------------------------------------------------------------
; general 5-axis transformation
;
; kinematics: 1. rotary axis is parallel to Z
; 2. rotary axis is parallel to X
; Movable tool
;-----------------------------------------------------------------------------------------------------

$MC_TRAFO_TYPE_1 = 20

$MC_ORIENTATION_IS_EULER = TRUE

$MC_TRAFO_AXES_IN_1[0] = 1
$MC_TRAFO_AXES_IN_1[1] = 2
$MC_TRAFO_AXES_IN_1[2] = 3
$MC_TRAFO_AXES_IN_1[3] = 4
$MC_TRAFO_AXES_IN_1[4] = 5

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2.13 Examples

$MC_TRAFO_GEOAX_ASSIGN_TAB_1[0]=1
$MC_TRAFO_GEOAX_ASSIGN_TAB_1[1]=2
$MC_TRAFO_GEOAX_ASSIGN_TAB_1[2]=3

$MC_TRAFO5_PART_OFFSET_1[0] = 0
$MC_TRAFO5_PART_OFFSET_1[1] = 0
$MC_TRAFO5_PART_OFFSET_1[2] = 0
$MC_TRAFO5_ROT_AX_OFFSET_1[0] = 0
$MC_TRAFO5_ROT_AX_OFFSET_1[1] = 0

$MC_TRAFO5_ROT_SIGN_IS_PLUS_1[0] = TRUE

$MC_TRAFO5_ROT_SIGN_IS_PLUS_1[1] = TRUE
$MC_TRAFO5_NON_POLE_LIMIT_1 = 2.0

$MC_TRAFO5_POLE_LIMIT_1 = 2.0
$MC_TRAFO5_BASE_TOOL_1[0] = 0.0
$MC_TRAFO5_BASE_TOOL_1[1] = 0.0
$MC_TRAFO5_BASE_TOOL_1[2] = 5,0

$MC_TRAFO5_JOINT_OFFSET_1[0] = 0.0
$MC_TRAFO5_JOINT_OFFSET_1[1] = 0.0
$MC_TRAFO5_JOINT_OFFSET_1[2] = 0.0

CHANDATA(1)
M17
Program example for general 5-axis transformation:

Program code Comment

; Definition of tool T1
$TC_DP1[1,1] = 10 ; Type
$TC_DP2[1,1] = 0
$TC_DP3[1,1] = ;z length compensation vector G17
$TC_DP4[1,1] = 0. ; y
$TC_DP5[1,1] = 0. ; x
$TC_DP6[1,1] = 0. ; Radius
$TC_DP7[1,1] = 0
$TC_DP8[1,1] = 0
$TC_DP9[1,1] = 0
$TC_DP10[1,1] = 0
$TC_DP11[1,1] = 0
$TC_DP12[1,1] = 0

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2.13 Examples

Approach initial position:

N100 G1 x1 y0 z0 a0 b0 F20000 G90 G64 T1 D1 G17 ADIS=.5 ADISPOS=3

Orientation vector programming:

N110 TRAORI(1)
N120 ORIWKS
N130 G1 G90
N140 a3 = 0 b3 = 0 c3 = 1 x0
N150 a3 = 0 b3 =-1 c3 = 0
N160 a3 = 1 b3 = 0 c3 = 0
N170 a3 = 1 b3 = 0 c3 = 1
N180 a3 = 0 b3 = 1 c3 = 0
N190 a3 = 0 b3 = 0 c3 = 1

Euler angles program:

N200 ORIMKS
N210 G1 G90
N220 a2 = 0 b2 = 0 x0
N230 a2 = 0 b2 = 90
N240 a2 = 90 b2 = 90
N250 a2 = 90 b2 = 45
N260 a2 = 0 b2 =-90
N270 a2 = 0 b2 = 0

Axis programming:

N300 a0 b0 x0
N310 a45
N320 b30

TOFRAME:

N400 G0 a90 b90 x0 G90

N410 TOFRAME
N420 z5
N430 x3 y5
N440 G0 a0 b0 x1 y0 z0 G90

N500 TRAFOOF
m30

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F2: Multi-axis transformations
2.13 Examples

2.13.2 Example of a 3-axis and 4-axis transformation

2.13.2.1 Example of a 3-axis transformation

Example: For the schematically represented machine (see "Figure 2-1 Schematic diagram of
3-axis transformation (Page 35)"), the 3-axis transformation can be projected as follows:

Program code Comment

$MC_TRAFO_TYPE_n = 18
$MC_TRAFO_GEOAX_ASSIGN_TAB_n[0] = 1 ; Assignment of channel axes to geometry
axes
$MC_TRAFO_GEOAX_ASSIGN_TAB_n[1] = 0
$MC_TRAFO_GEOAX_ASSIGN_TAB_n[2] = 3
$MC_TRAFO_AXES_IN_n[0] = 1 ; X axis is channel axis 1
$MC_TRAFO_AXES_IN_n[1] = 0 ; Y axis is not used
$MC_TRAFO_AXES_IN_n[2] = 3 ; Z axis is channel axis 3
$MC_TRAFO_AXES_IN_n[4] = 0 ; There is no second rotary axis

2.13.2.2 Example of a 4-axis transformation

Example: For the schematically represented machine (see "Figure 2-2 Schematic diagram of
a 4-axis transformation with moveable workpiece (Page 36)"), however, with an additional axis
(Y), the 4-axis transformation can be configured as follows:

Program code Comment

$MC_TRAFO_TYPE_n = 18

$MC_TRAFO_GEOAX_ASSIGN_TAB_n[0] = 1
$MC_TRAFO_GEOAX_ASSIGN_TAB_n[1] = 2
$MC_TRAFO_GEOAX_ASSIGN_TAB_n[2] = 3

$MC_TRAFO_AXES_IN_n[0] = 1 ; X axis is channel axis 1

$MC_TRAFO_AXES_IN_n[1] = 2 ; Y axis is channel axis 2
$MC_TRAFO_AXES_IN_n[2] = 3 ; Z axis is channel axis 3

$MC_TRAFO_AXES_IN_n[4] = 0 ; There is no second rotary axis

2.13.3 Example of a universal milling head

General
The following two subsections show the main steps which need to be taken in order to activate
a transformation for the universal milling head.

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 F2: Multi-axis transformations
2.13 Examples

Machine data
; machine kinematics CA' with tool orientation in zero position in the z direction
$MC_TRAFO_TYPE_1 = 148

$MC_TRAFO_GEOAX_ASSIGN_TAB_1[0]=1
$MC_TRAFO_GEOAX_ASSIGN_TAB_1[1]=2
$MC_TRAFO_GEOAX_ASSIGN_TAB_1[2]=3

; angle of second rotary axis

$MC_TRAFO5_NUTATOR_AX_ANGLE_1 = 45

Program
Program code Comment
; Definition of tool T1
$TC_DP1[1,1] = 120 ; Type
$TC_DP2[1,1] = 0 ;
$TC_DP3[1,1] = 20 ; Z length offset vector G17
$TC_DP4[1,1] = 8. ; Y
$TC_DP5[1,1] = 5. ; X

TRAORI(1) ; Activation of transformation

ORIMKS ; Orientation reference to MCS
G0 X1 Y0 Z0 A0 B0 F20000 G90 G64 T1 D1 G17
; Programming of direction vector
G1 G90
a3 = 0 b3 = 1 c3 = 0
; Programming in Euler angles
G1 G90
a2 = 0 b2 = 0 X0

; Programming of rotary axis motion

G1 X10 Y5 Z20 A90 C90

m30

References:
Programming Manual, Fundamentals

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F2: Multi-axis transformations
2.13 Examples

2.13.4 Example for orientation axes

Example 1:
3 orientation axes for the 1st orientation transformation for kinematics with 6 transformed axes.
Rotation must be done in the following sequence:
● firstly about the Z axis.
● then about the Y axis and
● finally about the Z axis again.
The tool vector must point in the X direction.

Program code Comment

CHANDATA(1)

$MC_TRAFO5_TOOL_VECTOR_1=0 ; Tool vector in X direction

$MC_TRAFO5_ORIAX_ASSIGN_TAB_1[0]=4 ; Channel index of first orientation axis
$MC_TRAFO5_ORIAX_ASSIGN_TAB_1[1]=5 ; Channel index of second orientation ax-
is
$MC_TRAFO5_ORIAX_ASSIGN_TAB_1[2]=6 ; Channel index of third orientation axis
$MC_ORIAX_TURN_TAB_1[0]=3 ; Z direction
$MC_ORIAX_TURN_TAB_1[1]=2 ; Y direction
$MC_ORIAX_TURN_TAB_1[2]=3 ; Z direction

CHANDATA(1)
M17

= =


 =

 $

<


&
%
& <
 <


%
$
<
;VWDUW

$ ;WDUJHW
;
% &
;
 ;


;

Figure 2-26 3 orientation axes for the 1st orientation transformation for kinematics with 6 transformed
axes

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 F2: Multi-axis transformations
2.13 Examples

Example 2:
3 orientation axes for the 2nd orientation transformation for kinematics with 5 transformed
axes. Rotation must be done in the following sequence:
● firstly about the X axis.
● then about the Y axis and
● finally about the Z axis.
The tool vector must point in the Z direction.

Program code Comment

CHANDATA(1)
$MC_TRAFO5_TOOL_VECTOR_2=2 ; Tool vector in Z direction
$MC_TRAFO5_ORIAX_ASSIGN_TAB_1[0]=4 ; Channel index of first orientation axis
$MC_TRAFO5_ORIAX_ASSIGN_TAB_1[1]=5 ; Channel index of second orientation axis
$MC_TRAFO5_ORIAX_ASSIGN_TAB_1[2]=0 ; Channel index of third orientation axis
$MC_ORIAX_TURN_TAB_1[0]=1 ; X direction
$MC_ORIAX_TURN_TAB_1[1]=2 ; Y direction
$MC_ORIAX_TURN_TAB_1[2]=3 ; Z direction

CHANDATA(1)
M17

=
=

&
$
% <
<

%
$

<
%

$
;
;

Figure 2-27 3 orientation axes for the 2nd orientation transformation for kinematics with 5 transformed
axes

The rotation through angle C2 about the Z" axis is omitted in this case, because the tool vector
orientation can be determined solely from angles A2 and B2 and no further degree of freedom
is available on the machine.

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F2: Multi-axis transformations
2.13 Examples

References:
Programming Manual, Production Planning

2.13.5 Examples for orientation vectors

2.13.5.1 Example for polynomial interpretation of orientation vectors

Orientation vector in Z-X plane

The orientation vector is programmed directly in the examples below. The resulting movements
of the rotary axes depend on the particular kinematics of the machine.

Program code Comment

N10 TRAORI
N20 POLY ; Polynomial interpolation is possible.
N30 A3=0 B3=0 C3=1 ; Orientation in +Z direction (start vector)
N40 A3=1 B3=0 C3=0 ; Orientation in +X direction (end vector)

In N40, the orientation vector is rotated in the Z-X plane which is spanned by the start and end
vector. Here, the PHI angle is interpolated in a line in this plane between the values 0 and 90
degrees (large circle interpolation).
The additional specification of the polynomials for the two angles PHI and PSI means that the
interpolated orientation vector can lies anywhere between the start and end vector.

PHI angle using polynomial PHI

In contrast to the example above, the PHI angle is interpolated using the polynomial PHI(u) =
(90-10)u + 10*u2 between the values 0 and 90 degrees.
The angle PSI is not equal to zero and is interpolated according to the following polynomial:
PSI(u) = -10*u + 10*u2
The maximum "tilt" of the orientation vector from the plane between the start and end vector
is obtained in the middle of the block (u = 1/2).

Program code Comment

N10 TRAORI
N20 POLY ; Polynomial interpolation is possible.
N30 A3=0 B3=0 C3=1 ; Orientation in +Z direction (start vector)
N40 A3=1 B3=0 C3=0 PO[PHI]=(10) ; in +X direction (end vector)
PO[PSI]=(10)

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2.13 Examples

2.13.5.2 Example of rotations of orientation vector

Rotations with angle of rotation THETA

In the following example, the angle of rotation is interpolated in linear fashion from starting
value 0 degrees to end value 90 degrees. The angle of rotation changes according to a
parabola or a rotation can be executed without a change in orientation. tool orientation is
rotated from the Y direction to the X direction.

Program code Comment

N10 TRAORI ; Activation of orientation transformation
N20 G1 X0 Y0 Z0 F5000 ;
; Tool orientation
N30 A3=0 B3=0 C3=1 THETA=0 ; In Z direction with angle of rotation 0
N40 A3=1 B3=0 C3=0 THETA=90 ; In X direction and rotation
; By 90 degrees
N50 A3=0 B3=1 C3=0 PO[THT]=(180,90) ; In Y direction and rotation
; To 180 degrees
N60 A3=0 B3=1 C3=0 THETA=IC(-90) ; Remains constant and rotation
; To 90 degrees
N70 ORIROTT ; Angle of rotation relative to
; change in orientation.
N80 A3=1 B3=0 C3=0 THETA=30 ; Rotation vector in angle
; 30 degrees to X-Y plane.

N40 Linear interpolation of angle of rotation from starting value 0 degrees to end value 90
degrees.
N50 The angle of rotation changes from 90 degrees to 180 degrees in accordance with the
parabola.
θ(u) = 90 + u2
N60 A rotation can also be programmed without a change in orientation taking place.
N80 Tool orientation is rotated from the Y direction to the X direction. The change in orientation
takes place in the X-Y plane and the rotation vector describes an angle of 30 degrees to this
plane.

2.13.6 Examples for generic axis transformations

The following example is based on a machine with rotatable tool on which the first rotary axis
is a C axis and the second a B axis (CB kinematics). The basic orientation defined in the
machine data is the bisecting line between the X and Z axes.
Relevant machine data is as follows:

CHANDATA(1)
$MC_TRAFO_TYPE_1 = 24 ; General 5-axis transformation

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2.13 Examples

; Rotatable tool
$MC_TRAFO5_AXIS1_1[0] = 0.0
$MC_TRAFO5_AXIS1_1[1] = 0.0
$MC_TRAFO5_AXIS1_1[2] = 1,0 ; 1. Rotary axis is parallel to Z.
$MC_TRAFO5_AXIS2_1[0] = 0.0
$MC_TRAFO5_AXIS2_1[1] = 1,0
$MC_TRAFO5_AXIS2_1[2] = 0.0 ; 2. Rotary axis is parallel to Y.
$MC_TRAFO5_BASE_ORIENT_1[0] = 1.0
$MC_TRAFO5_BASE_ORIENT_1[1] = 0,0
$MC_TRAFO5_BASE_ORIENT_1[2] = 1.0
M30
Example program:

Program code Comment

N10 $TC_DP1[1,1] = 120 ; End mill
N20 $TC_DP3[1,1]= 0 ; Length offset vector
N30
N40 ; Definition of tool carrier
N50 $TC_CARR7[1] = 1 ; Component of the 1st rotary axis
; In the X direction
N60 $TC_CARR11[1] = 1 ; Component of the 2nd rotary axis
; In the Y direction
N70 $TC_CARR13[1] = -45 ; Angle of rotation of 1st axis
N80 $TC_CARR14[1] = 0 ; Angle of rotation of 2nd axis
N90
N100 X0 Y0 Z0 B0 C0 F10000 ORIWKS G17
N110 TRAORI() ; Selection of basic transformation orientation
; from the machine data
N120 C3=1 ; Orientation parallel to Z
; Set → B-45 C0
N130 T1 D1 ; Basic orientation is now parallel to Z
N140 C3=1 ; Orientation parallel to Z
; Set → B0 C0
N150 G19 ; Basic orientation is now parallel to X
N160 C3=1 ; Orientation parallel to Z
; Set → B-90 C0
N170 G17 TCARR=1 TCOABS ; Basic orientation is now angle-
; halving Y-Z
N180 A3=1 ; Orientation parallel to X
; Set → B-90 C-135
N190 B3=1 C3=1 ; Orientation parallel to
; basic orientation → B0 C0
N200 TRAORI(,2.0, 3.0, 6.0) ; Pass basic orientation in call
N210 A3=2 B3=3 C3=6 ; Orientation parallel to

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 F2: Multi-axis transformations
2.13 Examples

Program code Comment

; basic orientation → B0 C0
N220 TOFRAME ; Z axis points in the direction
; of the orientation
N230 G91 Z7 ; 7 mm in new Z direction
; Traverse → X2 Y3 Z6
N240 C3=1 ; Orientation parallel to
; New Z axis → B0 C0
N250 M30

2.13.6.1 Example of a generic 6-axis transformation

Activation of a 6-axis transformation with subsequent orientation changes and traversing:

Program code Comment

N10 A0 B0 X0 Y0 Z0 ;
N20 TRAORI(1, ,,, 0,0,0, 0,1,0) ; Transfer the orientation vector
; and the orientation normal vector,
; transformation selection
N30 T1 D1 X10 Y20 Z30 A3=0.5 ; Change of orientation, rotation
C3=1 BN3=1 ORIPLANE ORIWKS ; and traversing motion
N40 B3=0.5 C3=1 AN3=-1 ; Rotation programmed,
; Orientation constantly
N50 M30

A tool, of which the orientation differs from the default, is defined in the following example.
With G17, the orientation vector is in the X-Z plane and its inclination to the Z axis is 26.565
degrees because of tan(26.565) = 0.5 = $TC_DPV3[2,2] / $TC_DPV5[2,2].
The orientation normal vector is also specified. As only $TC_DPVN4[2,2] is not equal to zero,
it points in the Y direction. Orientation vector and orientation normal vector are perpendicular
to one another.
An orthogonalization is therefore not necessary, and therefore the programmed orientation
normal vector is not modified.

Program code Comment

N100 $TC_DP1[2,2] = 120 ; End mill
N110 $TC_DP3[2,2]= 20 ; Length offset vector
N120 $TC_DPV [2,2] = 0 ; Tool cutting edge orientation
N130 $TC_DPV3[2,2] = 1 ; X component tool cutting edge orientation
N140 $TC_DPV4[2,2] = 0 ; Y component tool cutting edge orientation
N150 $TC_DPV5[2,2]= 0.5 ; Z component tool cutting edge orientation
N160 $TC_DPVN3[2,2]= 0 ; X component orientation normal vector
N170 $TC_DPVN4[2,2]= 1 ; Y component orientation normal vector
N180 $TC_DPVN5[2,2]= 0 ; Z component orientation normal vector
N200 TRAORI() ; Pass basic orientation in call
N210 A3=5 C3=10 BN3=1 ; Place rotary axes in initial state

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F2: Multi-axis transformations
2.13 Examples

Program code Comment

N220 C3=1 ; Orientation in the Z direction → tool
; rotated by 26.565 degrees
N230 THETA=IC(90) ; Orientation normal vector
; Incremental by 90 degrees
; rotate Vector points in negative
; X direction
N240 M30

2.13.6.2 Example of a generic 7-axis transformation

Example of a generic 7-axis transformation

Activation of a 7-axis transformation with subsequent orientation changes and traversing:

Program Comment
N10 TRAFOOF
N20 a0 b0 c0 x0 y0 z0 e=0
N30 $MC_TRAFO5_AXIS1_1[2] = 1 ; 1. Rotary axis shows in Z direction
N40 $MC_TRAFO5_AXIS1_2[0] = 1 ; 2. Rotary axis shows in X direction
N50 $MC_TRAFO5_AXIS1_3[2] = 1 ; 3. Rotary axis shows in Z direction
N60 $MC_TRAFO7_EXT_AXIS1_1[0] = 1 ; 7. Axis shows in X direction
N70 $MC_TRAFO_BASE_ORIENT_1[2] = 1 ; Orientation vector
N80 $MC_TRAFO_BASE_ORIENT_NORMAL_1[1] = 1 ; Orientation normal vector
N90 NEWCONF
N100 traori()
N110 G1 t1 d1 x10 y0 z50 c3=1 an3=1 bn3=1
orivect oriwks G19 F10000
N120 G2 y50 z0 b3=1 e=DC(90) CR=50 ; 1. Quadrant
N130 G2 y0 z–50 c3=–1 e=DC(180) CR=50 ; 2. Quadrant
N140 G2 y–50 z0 b3=–1 e=DC(270) CR=50 ; 3. Quadrant
N150 G2 y0 z50 c3=1 e=DC(0) CR=50 ; 4. Quadrant
N200 M30

Note
While traversing the quadrant in the example, only the 7th axis turns by 360 degrees. The
machine remains in the fixed position.

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 F2: Multi-axis transformations
2.14 Data lists

2.13.6.3 Example for the modification of rotary axis motion

The machine is a 5-axis machine of machine type 1 (two-axis swivel head with CA kinematics)
on which both rotary axes rotate the tool (transformation type 24). The first rotary axis is a
modulo axis parallel to Z (C axis); the second rotary axis is parallel to Y (B axis) and has a
traversing range from -5 degrees to +185 degrees.
To allow modification at any time, the following machine data has the value 2:
MD21180 $MC_ROT_AX_SWL_CHECK_MODE (check software limits for orientation axes)

N10 X0 Y0 Z0 B0 C0
N20 TRAORI( ) ; basic orientation 5-axis transformation
N30 B-1 C10 ; Rotary axis positions B-1 and C10
N40 A3=-1 C3=1 ORIWKS ; large circle interpolation in WCS
N50 M30

At the start of block N40 in the example program, the machine is positioned at rotary axis
positions B-1 C10. The programmed end orientation can be achieved with either of the axis
positions B-45 C0 (1st solution) or B45 C180 (2nd solution).
The first solution is selected initially, because it is nearest to the starting orientation and, unlike
the second solution, can be achieved using large circle interpolation (ORIWKS). However, this
position cannot be reached because of the axis limits of the B axis.
The second solution is therefore used instead, i.e. the end position is B45 C180. The end
orientation is achieved by axis interpolation. The programmed orientation path cannot be
followed.

2.14 Data lists

2.14.1 Machine data

2.14.1.1 General machine data

Number Identifier: $MN_ Description

10620 EULER_ANGLE_NAME_TAB Name of Euler angles or names of orientation axes
10630 NORMAL_VECTOR_NAME_TAB Name of normal vectors
10640 DIR_VECTOR_NAME_TAB Name of direction vectors
10642 ROT_VECTOR_NAME_TAB Name of rotation vectors
10644 INTER_VECTOR_NAME_TAB Name of intermediate vector components
10646 ORIENTATION_NAME_TAB Identifier for programming a 2nd orientation path
10648 NUTATION_ANGLE_NAME Name of orientation angle
10670 STAT_NAME Name of position information

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F2: Multi-axis transformations
2.14 Data lists

Number Identifier: $MN_ Description

10672 TU_NAME Name of position information of the axes
10674 PO_WITHOUT_POLY Permits programming of PO[ ] without POLY having to
be active

2.14.1.2 Channelspecific machine data

Number Identifier: $MC_ Description

20150 GCODE_RESET_VALUES[n] Reset G groups
20152 GCODE_RESET_MODE[n] Setting after RESET/end of part program
20482 COMPRESS_MODE Mode of the compressor
20621 HANDWH_ORIAX_MAX_INCR_SIZE Limitation of handwheel increment
20623 HANDWH_ORIAX_MAX_INCR_VSIZE Orientation velocity overlay
21094 ORIPATH_MODE Setting for path relative orientation
21100 ORIENTATION_IS_EULER Angle definition for orientation programming
21102 ORI_DEF_WITH_G_CODE Definition of orientation angles A2, B2, C2
21104 ORI_IPO_WITH_G_CODE Definition of interpolation type for orientation
21106 CART_JOG_SYSTEM Coordinate system for Cartesian JOG
21108 POLE_ORI_MODE Behavior during large circle interpolation at pole position
21120 ORIAX_TURN_TAB_1[n] Assignment of rotation of orientation axes about the ref‐
erence axes, definition 1 [n = 0..2]
21130 ORIAX_TURN_TAB_2[n] Assignment of rotation of orientation axes about the ref‐
erence axes, definition 2 [n = 0..2]
21132 ORI_DISP_IS_MODULO[n] Modulo display of the orientation axes positions [n = 0..2]
21134 ORI_DISP_MODULO_RANGE Size of the module range for the display of the orienta‐
tion axes
21136 ORI_DISP_MODULO_RANGE_START Starting position of the module range for the display of
the orientation axes
21150 JOG_VELO_RAPID_ORI[n] Rapid traverse in jog mode for orientation axes in the
channel [n = 0..2]
21155 JOG_VELO_ORI[n] Orientation axis velocity in jog mode [n = 0..2]
21160 JOG_VELO_RAPID_GEO[n] Rapid traverse in jog mode for geometry axes in the
channel [n = 0..2]
21165 JOG_VELO_GEO[n] Geometry axis velocity in jog mode [n = 0..2]
21170 ACCEL_ORI[n] Acceleration for orientation axes [n = 0..2]
21180 ROT_AX_SWL_CHECK_MODE Check software limits for orientation axes
21186 TOCARR_ROT_OFFSET_FROM_FR Offset of TOCARR rotary axes
21190 TOFF_MODE Operation of online offset in tool direction
21194 TOFF_VELO Speed of online offset in tool direction
21196 TOFF_ACCEL Acceleration of online offset in tool direction
24100 TRAFO_TYPE_1 Definition of transformation 1 in channel
24110 TRAFO_AXES_IN_1[n] Axis assignment for transformation 1 [axis index]

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2.14 Data lists

Number Identifier: $MC_ Description

24120 TRAFO_GEOAX_ASSIGN_TAB_1[n] Assignment geometry axis to channel axis for transfor‐
mation 1 [geometry no.]
24200 TRAFO_TYPE_2 Definition of transformation 2 in channel
24210 TRAFO_AXES_IN_2[n] Axis assignment for transformation 2 [axis index]
24220 TRAFO_GEOAX_ASSIGN_TAB_2[n] Assignment geometry axis to channel axis for transfor‐
mation 2 [geometry no.]
24300 TRAFO_TYPE_3 Definition of transformation 3 in channel
24310 TRAFO_AXES_IN_3[n] Axis assignment for transformation 3 [axis index]
24320 TRAFO_GEOAX_ASSIGN_TAB_3[n] Assignment geometry axis to channel axis for transfor‐
mation 3 [geometry no.]
24400 TRAFO_TYPE_4 Definition of transformation 4 in channel
24410 TRAFO_AXES_IN_4[n] Axis assignment for transformation 4 [axis index]
24420 TRAFO_GEOAX_ASSIGN_TAB_4[n] Assignment geometry axis to channel axis for transfor‐
mation 4 [geometry no.]
24430 TRAFO_TYPE_5 Definition of transformation 5 in channel
24432 TRAFO_AXES_IN_5[n] Axis assignment for transformation 5 [axis index]
24434 TRAFO_GEOAX_ASSIGN_TAB_5[n] Assignment geometry axis to channel axis for transfor‐
mation 5 [geometry no.]
24440 TRAFO_TYPE_6 Definition of transformation 6 in channel
24442 TRAFO_AXES_IN_6[n] Axis assignment for transformation 6 [axis index]
24444 TRAFO_GEOAX_ASSIGN_TAB_6[n] Assignment geometry axis to channel axis for transfor‐
mation 6 [geometry no.]
24450 TRAFO_TYPE_7 Definition of transformation 7 in channel
24452 TRAFO_AXES_IN_7[n] Axis assignment for transformation 7 [axis index]
24454 TRAFO_GEOAX_ASSIGN_TAB_7[n] Assignment geometry axis to channel axis for transfor‐
mation 7 [geometry no.]
24460 TRAFO_TYPE_8 Definition of transformation 8 in channel
24462 TRAFO_AXES_IN_8[n] Axis assignment for transformation 8 [axis index]
24464 TRAFO_GEOAX_ASSIGN_TAB_8[n] Assignment geometry axis to channel axis for transfor‐
mation 8 [geometry no.]
24470 TRAFO_TYPE_9 Definition of transformation 9 in channel
24472 TRAFO_AXES_IN_9[n] Axis assignment for transformation 9 [axis index]
24474 TRAFO_GEOAX_ASSIGN_TAB_9[n] Assignment geometry axis to channel axis for transfor‐
mation 9 [geometry no.]
24480 TRAFO_TYPE_10 Definition of transformation 10 in channel
24482 TRAFO_AXES_IN_10[n] Axis assignment for transformation 10 [axis index]
24484 TRAFO_GEOAX_ASSIGN_TAB_10[n] Assignment geometry axis to channel axis for transfor‐
mation 10 [geometry no.]
24500 TRAFO5_PART_OFFSET_1[n] Offset vector for 5-axis transformation 1 [n = 0.. 2]
24510 TRAFO5_ROT_AX_OFFSET_1[n] Position offset of rotary axis 1/2 for 5-axis transformation
1 [axis no.]
24520 TRAFO5_ROT_SIGN_IS_PLUS_1[n] Sign of rotary axis 1/2 for 5-axis transformation 1 [axis
no.]
24530 TRAFO5_NON_POLE_LIMIT_1 Definition of pole range for 5-axis transformation 1

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F2: Multi-axis transformations
2.14 Data lists

Number Identifier: $MC_ Description

24540 TRAFO5_POLE_LIMIT_1 End angle tolerance with interpolation through pole for
5-axis transformation 1
24550 TRAFO5_BASE_TOOL_1[n] Vector of base tool for activation of 5-axis transformation
1 [n = 0.. 2]
24558 TRAFO5_JOINT_OFFSET_PART_1[n] Vector of kinematic offset in table for 5-axis transforma‐
tion 1 [n = 0.. 2]
24560 TRAFO5_JOINT_OFFSET_1[n] Vector of kinematic offset for 5-axis transformation 1 [n
= 0.. 2]
24561 TRAFO6_JOINT_OFFSET_2_3_1[n] Vector of kinematic offset for 6-axis transformation
2_3_1
24562 TRAFO5_TOOL_ROT_AX_OFFSET_1[n] Offset of focus of 1st 5-axis transformation with swiveled
linear axis.
24564 TRAFO5_NUTATOR_AX_ANGLE_1 Angle of 2nd rotary axis for the universal milling head
24570 TRAFO5_AXIS1_1[n] Vector for the first rotary axis and the first orientation
transformation. [n = 0.. 2]
24572 TRAFO5_AXIS2_1[n] Vector for the second rotary axis and the first transfor‐
mation [n = 0.. 2]
24673 TRAFO5_AXIS3_1[n] Direction of third rotary axis for general 6-axis transfor‐
mation
(Transformer type 24, 40, 56, 57)
24574 TRAFO5_BASE_ORIENT_1[n] Basic orientation for the first transformation [n = 0.. 2]
24576 TRAFO6_BASE_ORIENT_NORMAL_1[n] Tool normal vector for the first transformation [n = 0.. 2]
24580 TRAFO5_TOOL_VECTOR_1 Tool vector direction for the first 5-axis transformation 1
24582 TRAFO5_TCARR_NO_1 TCARR number for the first 5-axis transformation 1
24585 TRAFO5_ORIAX_ASSIGN_TAB_1[n] Assignment of orientation axes to channel axes for ori‐
entation transformation 1 [n = 0.. 2]
24590 TRAFO5_ROT_OFFSET_FROM_FR_2 Offset of transf. rotary axes from WO
24594 TRAFO7_EXT_ROT_AX_OFFSET_1 Angle offset of the 1st external rotary axis
24595 TRAFO7_EXT_AXIS1_1 Direction of the 1st external rotary axis
24600 TRAFO5_PART_OFFSET_2[n] Offset vector for 5-axis transformation 2 [n = 0.. 2]
24610 TRAFO5_ROT_AX_OFFSET_2[n] Position offset of rotary axis 1/2 for 5-axis transformation
2 [axis no.]
24620 TRAFO5_ROT_SIGN_IS_PLUS_2[n] Sign of rotary axis 1/2 for 5-axis transformation 2 [axis
no.]
24630 TRAFO5_NON_POLE_LIMIT_2 Definition of pole range for 5-axis transformation 2
24640 TRAFO5_POLE_LIMIT_2 End angle tolerance with interpolation through pole for
5-axis transformation 2
24650 TRAFO5_BASE_TOOL_2[n] Vector of base tool with activation of 5-axis transforma‐
tion 2 [n = 0.. 2]
24658 TRAFO5_JOINT_OFFSET_PART_2[n] Vector of kinematic offset in table for 5-axis transforma‐
tion 2 [n = 0.. 2]
24660 TRAFO5_JOINT_OFFSET_2[n] Vector of kinematic offset for 5-axis transformation 2 [n
= 0.. 2]
24661 TRAFO6_JOINT_OFFSET_2_3_2[n] Vector of kinematic offset for 6-axis transformation
2_3_2

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 F2: Multi-axis transformations
2.14 Data lists

Number Identifier: $MC_ Description

24662 TRAFO5_TOOL_ROT_AX_OFFSET_2[n] Offset of focus of 2nd 5-axis transformation with swiv‐
eled linear axis.
24664 TRAFO5_NUTATOR_AX_ANGLE_2 Angle of the 2nd rotating axis for the universal milling
head
24670 TRAFO5_AXIS1_2[n] Vector for the first rotary axis and the second orientation
transformation [n = 0.. 2]
24672 TRAFO5_AXIS2_2[n] Vector for the second rotary axis and the first transfor‐
mation [n = 0.. 2]
24673 TRAFO5_AXIS3_2[n] Direction of third rotary axis for generic 6-axis transfor‐
mation (type 24, 40, 56, 57)
24674 TRAFO5_BASE_ORIENT_2[n] Basic orientation for the second transformation [n = 0..
2]
24676 TRAFO6_BASE_ORIENT_NORMAL_2[n] Tool normal vector for the second transformation [n = 0..
2]
24680 TRAFO5_TOOL_VECTOR_2 Tool vector direction for the second 5-axis transforma‐
tion 2
24682 TRAFO5_TCARR_NO_2 TCARR number for the second 5-axis transformation 2
24685 TRAFO5_ORIAX_ASSIGN_TAB_2[n] Assignment of orientation axes to channel axes for ori‐
entation transformation 2 [n = 0.. 2]
24694 TRAFO7_EXT_ROT_AX_OFFSET_2 Angle offset of the 2nd external rotary axis
24695 TRAFO7_EXT_AXIS1_2 Direction of the 2nd external rotary axis
25294 TRAFO7_EXT_ROT_AX_OFFSET_3 Angle offset of the 3rd external rotary axis
25295 TRAFO7_EXT_AXIS1_3 Direction of the 3rd external rotary axis
25394 TRAFO7_EXT_ROT_AX_OFFSET_4 Angle offset of the 4th external rotary axis
25395 TRAFO7_EXT_AXIS1_4 Direction of the 4th external rotary axis
28580 MM_ORIPATH_CONFIG Configuration for path relative orientation ORIPATH

2.14.2 Setting data

2.14.2.1 General setting data

Number Identifier: $SN_ Description

41110 JOG_SET_VELO Geometry axes
41130 JOG_ROT_AX_SET_VELO Orientation axes

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F2: Multi-axis transformations
2.14 Data lists

2.14.2.2 Channelspecific setting data

Number Identifier: $SC_ Description

42475 COMPRESS_CONTOUR_TOL Max. contour deviation for compressor
42476 COMPRESS_ORI_TOL Max. angular displacement of tool orientation for the
compressor
42477 COMPRESS_ORI_ROT_TOL Max. angular displacement of tool rotation for the com‐
pressor
42650 CART_JOG_MODE Coordinate system for Cartesian manual travel
42660 ORI_JOG_MODE Definition of virtual kinematics for JOG
42670 ORIPATH_SMOOTH_DIST Smoothing path of the orientation
42672 ORIPATH_SMOOTH_TOL Smoothing tolerance of the orientation
42970 TOFF_LIMIT Upper limit for offset value $AA_TOFF

2.14.3 Signals

2.14.3.1 Signals from channel

Signal name SINUMERIK 840D sl SINUMERIK 828D

Activate PTP traversal DB21, ... DBX29.4 -
Transformation active DB21, ... DBX33.6 -
Number of active G function of DB21, ... DBB232 -
G function group 25
PTP traversal active DB21, ... DBX317.6 -
Activate online tool length offset DB21, ... DBX318.2 -
Activate offset motion DB21, ... DBX318.3 -

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G1: Gantry axes 3
3.1 Brief description
For gantry machines, each of various machine elements, such as the gantry and the transverse
beams, are moved by several axes that operate in parallel. The axes that together move a
machine part, are designated as gantry axes or gantry grouping. Because of the mechanical
structure, the gantry axes are rigidly connected with each other and so must always be
traversed synchronously by the control.

=
==
< = JDQWU\JURXSLQJ&URVVEHDPV

=
;

; < ;;
JDQWU\JURXSLQJ*DQWU\
;

Figure 3-1 Example: Gantry-type milling machine with gantry and transverse beams

Guide axis
The guide axis of the gantry grouping is the axis that represents the gantry grouping. Only this
axis is programmed to perform the traversing movements of the gantry grouping.

Synchronous axes
The synchronous axes of the gantry grouping are the axes that because of their coupling with
the guide axis are also automatically traversed by the control. A guide axis can be assigned
any number of synchronous axes.

Synchronization difference
The synchronous operation difference is the deviation of the axial actual value of a
synchronous axis from its ideal position referred to the actual value of the guide axis. The
control continually monitors the synchronous operation difference. A message is displayed if
the alarm limit is exceeded. The complete gantry grouping is stopped when the alarm limit is
exceeded. The limit values can be parameterized as machine data.

Special functions
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G1: Gantry axes
3.2 "Gantry axes" function

3.2 "Gantry axes" function

3.2.1 Definition of a gantry grouping

Definition
The axes of a gantry grouping are specified via the following axial machine data:

MD37100 $MA_GANTRY_AXIS_TYPE[AX1] = xy
x Tens decimal place: Type of gantry axis (guide or synchronous axis)
y Ones decimal place: ID of the gantry grouping

A maximum of eight gantry groupings (gantry grouping ID: 1 - 8) can be defined. The gantry
grouping ID must be unique in all channels or in all NCUs in accordance with the assigned
axis.
In principle, a gantry grouping can be assigned any number of synchronous axes.

Example
Definition of a gantry grouping with ID=1, guide axis AX1 and synchronous axis AX2
● MD37100 $MA_GANTRY_AXIS_TYPE[AX1] = 01 (guide axis)
● MD37100 $MA_GANTRY_AXIS_TYPE[AX2] = 11 (synchronous axis)

Supplementary conditions
The following supplementary conditions apply to a gantry grouping:
● A gantry grouping must not contain a spindle.
● A synchronous axis must not be a concurrent POS axis.
● A synchronous axis must not belong to a transformation.
● A synchronous axis must not be a following axis of another axis coupling.
● A synchronous axis must not be a guide axis of another axis coupling.
● All axes of a gantry grouping must be of the same axis type, linear or rotary: MD30300
$MA_IS_ROT_AX (rotary axis/spindle)
Note
Drive optimization
At a SINAMICS S120 drive unit, a maximum of three drives can be optimized or measured
at the same time (speed controller optimization / function generator). Therefore, for a
coupling with more than three coupled drives at the same time, we recommend that these
are distributed over several drive units.

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 G1: Gantry axes
3.2 "Gantry axes" function

3.2.2 Monitoring the synchronism difference

Limit values for monitoring

2 limit values can be specified for the synchronism difference.

Gantry warning limit

The gantry warning limit is set using the following machine data:
MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit)
The "Alarm limit exceeded" message is displayed if the synchronism difference exceeds the
gantry warning limit. In addition, the NC/PLC-interface signal is set:
DB31, ... DBX101.3 = 1 (gantry warning limit exceeded)
After the alarm limit has been fallen below, the message and interface signal are automatically
reset.

Note
Gantry warning limit
If the "Alarm limit exceeded" message is not to be displayed, then a value of 0 should be
entered into MD37110.

Gantry trip limit

The gantry trip limit is set using the following machine data:
● for the synchronized gantry grouping:
MD37120 $MA_GANTRY_POS_TOL_ERROR
● for the non-synchronized gantry grouping:
MD37130 $MA_GANTRY_POS_TOL_REF
Alarm 10653 "Error limit exceeded" is displayed if the synchronism difference exceeds the
gantry trip limit. In addition, the NC/PLC-interface signal is set:
DB31, ... DBX101.2 = 1 (gantry trip limit exceeded)

*DQWU\WULSOLPLW
6\QFKURQRXVJURXSLQJ0'0$B*$175<B326B72/B(5525
1RQV\QFKURQRXVJURXSLQJ0'0$B*$175<B326B72/B5()

*DQWU\ZDUQLQJOLPLW
0'0$B*$175<B326B72/B:$51,1*

The alarm is also displayed if the gantry grouping is jammed (no controller enable, gantry
grouping in the "Hold" state).

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G1: Gantry axes
3.2 "Gantry axes" function

3.2.3 Extended monitoring of the synchronism difference

Activation of the extended monitoring

An extended monitoring of the synchronism difference can be activated using the following
machine data:
MD37150 $MA_GANTRY_FUNCTION_MASK, Bit 0 = 1
For the extended monitoring, a synchronism difference between the leading and synchronous
axis, obtained when tracking or when the gantry grouping is opened, is taken into account.
The extended monitoring becomes active after the NC boots after the first referencing
(incremental encoder) or synchronization (absolute encoder).

Exceeding the gantry trip limit

If, when the extended monitoring is active, the trip limit of the synchronism difference is
exceeded, Alarm 10653 "Error limit exceeded" is displayed.
In order to be able to reset the alarm, proceed as follows:
1. Deactivating extended monitoring:
MD37150 $MA_GANTRY_FUNCTION_MASK, Bit 0 = 0
2. Deleting the synchronism difference displayed in the machine data:
MD37135 $GANTRY_ACT_POS_TOL_ERROR = 0
3. Cancel alarm
4. Re-reference or re-synchronize the axes of the gantry grouping
5. Reactivating extended monitoring:
MD37150 $MA_GANTRY_FUNCTION_MASK, Bit 0 = 1

3.2.4 Referencing and synchronization of gantry axes

Use case
In cases where an incremental measuring system is being used for the leading or the
synchronous axis, after the NC boots, the measuring systems must be referenced, maintaining
the axis coupling.
After every axis in the gantry grouping has approached its reference point, any misalignment
that may exist between the axes must be eliminated (gantry synchronization process). Once
this has been performed, the NC/PLC interface signal is set:
DB31, ... DBX101.5 = 1 (gantry grouping is synchronized)
For the sequence when referencing or synchronizing gantry axes, see Section Referencing
and synchronization of gantry axes (Page 152).

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 G1: Gantry axes
3.2 "Gantry axes" function

3.2.5 Control dynamics

Use case
From the user perspective, a gantry grouping is exclusively traversed via the leading axis. The
NC generates the setpoints of the synchronous axes directly from the setpoints of the leading
axis in time synchronism and outputs these to them. To minimize the synchronous operation
differences, the control system dynamics of all axes of a gantry grouping must be set identical
(see Section "Start-up of gantry axes (Page 162)").

Note
Identical control dynamics must be set for all axes of a gantry grouping.

Disturbance characteristic
If faults occur, which cause an axis of the gantry to be stopped, then the complete gantry
grouping is always stopped.

3.2.6 Opening the gantry grouping

Description
The axis coupling within a gantry grouping can be opened (dissolved) using the following
machine data:
MD37140 $MA_GANTRY_BREAK_UP = 1 (invalidate gantry grouping)

CAUTION
No synchronous operation
If the gantry axes remain mechanically coupled, there is a risk of damage to the machine
when the leading or synchronous axes are traversed in this operating state!

When the setting becomes active, the axes of the gantry grouping can be individually traversed
in the JOG, AUTOMATIC and MDA modes.
The monitoring functions of the synchronism difference and/or the alarm and trip limits are not
active.
The NC/PLC interface signal "Gantry grouping is synchronized" is reset:
DB31, ... DBX101.5 = 0

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3.3 Referencing and synchronization of gantry axes

3.3 Referencing and synchronization of gantry axes

3.3.1 Introduction

Misalignment after starting

Immediately after the machine is switched on, the leading and synchronous axes may not be
ideally positioned in relation to one another (e.g. misalignment of a gantry). Generally speaking,
this misalignment is relatively small so that the gantry axes can still be referenced.
In special cases (e.g. gantry axes were stopped owing to a disturbance, power failure or
EMERGENCY STOP), the dimensional offset must be checked for permissible tolerance
values and a compensatory motion executed if necessary before the axes are traversed.
To execute this compensatory motion, the gantry grouping must be invalidated by means of
the following machine data:
MD37140 $MA_GANTRY_BREAK_UP (invalidate gantry grouping)

Gantry synchronization process

All gantry axes must first be referenced and then synchronized after the control system is
switched on. During gantry synchronization, all gantry axes approach the reference position
of the gantry grouping in the decoupled state. The reference position of the gantry grouping
for referencing the gantry axes corresponds to the reference position of the leading axis:
MD34100 $MA_REFP_SET_POS (reference point value/destination point for distancecoded
system)
Otherwise, the reference position is the current actual position of the leading axis.
These operations for referencing and synchronizing the gantry axes are executed
automatically in accordance with a special flowchart.

Referencing process
The flowchart for referencing gantry axes using an incremental measuring system is as follows:
Section 1:
Referencing of the leading axis
The axis-specific referencing of the gantry axis will be started by the active machine function
REF upon the leading axis' interface signal from the PLC user program:
DB31, ... DBX4.7/4.6 (traversing key plus/minus)
The leading axis approaches the reference point (operational sequence as for reference point
approach).
References:
Function Manual Basic Functions; Reference Point Approach (R1)

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3.3 Referencing and synchronization of gantry axes

The appropriate synchronous axes traverse in synchronism with the leading axis. Interface
signal "Referenced/synchronized" of the leading axis is output to indicate that the reference
point has been reached.
Section 2:
Referencing of the synchronous axes
As soon as the leading axis has approached its reference point, the synchronous axis is
automatically referenced (as for reference point approach).
References:
Function Manual Basic Functions; Reference Point Approach (R1)
The dependency between the leading axis and synchronous axis is inverted in the control for
this phase so that the leading axis now traverses in synchronism with the synchronous axis.
IS "Referenced/synchronized" of the synchronous axis is output to indicate that the reference
point has been reached. The gantry axis dependency then reverts to its previous status. If a
further synchronous axis is defined in the grouping, then this is also referenced in the way
described above.
Section 3:
Gantry synchronization process
Once all axes in the gantry grouping have been referenced, they must be synchronized with
the defined reference position. The actual position of each gantry axis is first compared to the
defined reference position of the leading axis.

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3.3 Referencing and synchronization of gantry axes

The next step in the operating sequence depends on the difference calculated between the
actual values of the leading and synchronous axes:
● difference is smaller than the gantry warning limit:
MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit)
The gantry synchronization process is started automatically. The message
"Synchronization in progress gantry grouping x" is output during this process.
The message "Synchronization running gantry grouping x" can be suppressed with:
MD37150 $MA_GANTRY_FUNCTION_MASK Bit 2 = 1
All gantry axes traverse at a specific position value in the decoupled state at the velocity
set in the machine data:
MD34040 $MA_REFP_VELO_SEARCH_MARKER (creep velocity)
The position value is defined by the leading axis:
MD34100 $MA_REFP_SET_POS (reference point/destination point for distance‐
coordinated system)
The absolute encoders and distanced-coded encoders of the leading axis will be set to the
current actual position of the leading axis or to the reference point by the following machine
data:
MD34330 $MA_REFP_STOP_AT_ABS_MARKER (Distancecoded linear measuring
system without destination point)
For this operation, the axes traverse at the same velocity as set for reference point
approach:
MD34070 $MA_REFP_VELO_POS (reference point positioning velocity)
As soon as all gantry axes have reached their target position (ideal position), IS "Gantry
grouping is synchronized" is set to "1" followed by re-activation of the gantry axis coupling.
The position actual value of all axes in the gantry grouping must now be identical. The
gantry synchronization process is now complete.
● Difference is higher than the gantry warning limit for at least one synchronous axis:
IS "Gantry synchronization read to start" is set to "1" and the message "Wait for
synchronization start of gantry grouping x" is output. The gantry synchronization process
is not started automatically in this case, but must be started explicitly by the operator or
from the PLC user program. The process is initiated by IS "Start gantry synchronization"
on the leading axis. The signal is set on the leading axis. The operational sequence is then
the same as that described above.
The following flowchart illustrates the referencing and synchronization processes.

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3.3 Referencing and synchronization of gantry axes

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G1: Gantry axes
3.3 Referencing and synchronization of gantry axes

Figure 3-2 Flowchart for referencing and synchronization of gantry axes

Synchronization process
A synchronization process is always required in the following cases:
● after the reference point approach of all axes included in a grouping,
● if the axes become de-synchronized (s below).

Operational sequence failure

If the referencing process described above is interrupted as a result of disturbances or a
RESET, proceed as follows:
● Abort within section 1 or 2:
Restart reference point with leading axis (see section 1)
● Abort in section 3:
In cases where the gantry axes have not yet been referenced (IS "Referenced/
Synchronized" = 1), the gantry synchronization process can be started again with IS
"Synchronize gantry grouping".

Restart gantry synchronization

Synchronization of the gantry axes can be started with IS "Start gantry synchronization" under
the following conditions only:
● JOG/REF mode must be active. The following interface signal must be set:
DB11, ... DBX5.2 = 1 (active machine function REF)
● DB31, ... DBX 101.5 = 0 (gantry grouping is synchronized)
● All grouping axes operate within the tolerance windows:
DB31, ... DBX 101.4 = 1(gantry synchronization process ready to start)
● Axes are not referenced in the relevant NC channel
DB21, ... DBX33.0 = 0 (referencing active)
If the gantry synchronization process is not started from the referencing process by means of
IS "Start gantry synchronization process", then the reference position is not specified as target
position for the synchronous axes:
MD34100 $MA_REFP_SET_POS (reference point value/destination point for distancecoded
system)

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3.3 Referencing and synchronization of gantry axes

Instead, the actual position of the leading axis is specified as the target position and is
approached in the uncoupled state.

Note
For the leading axis, automatic synchronization can be locked using the following NC/PLC
interface signal:
DB31, ... DBX29.5 = 1 (no automatic synchronization process)
This always makes sense if no axis enabling signal has yet been issued for the axes. In this
case, the synchronization process should also be started explicitly with the NC/PLC interface
signal:
DB31, ... DBX29.4 = 1 (start gantry synchronization process)

Loss of synchronization
The gantry grouping becomes desynchronized as a result of:
● "Tracking" the gantry axes
● Loss of the reference position of a gantry axis, e.g. by "Parking" (no measuring system
active)
● Re-referencing of gantry axis
● The gantry grouping is opened (dissolved) by:
MD37140 $MA_GANTRY_BREAK_UP = 0 (invalidate gantry axis grouping)
The corresponding NC/PLC interface signal is reset:
● DB31, ... DBX60.4 or DBX60.5 == 0 (referenced/synchronized 1 or 2 respectively)
● DB31, ... DBX 101.5 == 0 (gantry grouping is synchronized)

If, in operation, gantry grouping synchronization is lost due to a fault, then synchronization can
be restarted using the NC/PLC interface signal:
DB31, ... DBX29.4 == 1 (start gantry synchronization process)
Requirement is that the following applies to all axes of the gantry grouping:
DB31, ... DBX60.4 or DBX60.5 = 1 (referenced/synchronized 1 or 2 respectively)
In this case, the synchronizing axes traverse the current actual position of the leading axis in
the decoupled state.

If, when the gantry grouping is traversing, the signal "Emergency Stop" (DB10, DBX56.2) is
set and again reset, and the gantry axes have drifted apart less than the standstill tolerance
of the synchronous axes, then these are automatically resynchronized. Automatic
synchronization can be suppressed using the NC/PLC interface signal for the leading axis:
DB31, ... DBX29.5 = 1 (no automatic synchronization process)

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3.3 Referencing and synchronization of gantry axes

Selecting the reference point

To ensure that the shortest possible paths are traversed when the gantry axes are referenced,
the reference point values from leading and synchronous axes should be the same in the
machine data:
MD34100 $MA_REFP_SET_POS (reference point value/destination point for distancecoded
system)
Allowance for deviations in distance between the zero mark and the reference point must be
made for specific axes via the machine data:
MD34080 $MA_REFP_MOVE_DIST (reference point distance)
MD34090 $MA_REFP_MOVE_DIST_CORR (reference point offset/absolute offset)

Referencing direction selection

The zero mark search direction of the synchronous axis can be defined via the machine data:
MD37150 $MA_GANTRY_FUNCTION_MASK, Bit 1

Bit Value Meaning

1 0 Zero mark search direction of the synchronous axis analog to machine data:
MD34010 $MA_REFP_CAM_DIR_IS_MINUS
1 Zero mark search direction of the synchronous axis the same as the leading axis

During referencing, the reference point value of the leading axis is specified as the target
position for all axes in the grouping for the synchronization compensatory motion. This position
is then approached without axis coupling. The absolute encoders and distanced-coded
encoders of the leading axis will be set to the current actual position of the leading axis or to
the reference point by the following machine data:
MD34330 $MA_REFP_STOP_AT_ABS_MARKER (Distancecoded linear measuring system
without destination point)
If only one reference cam is used for the leading and synchronous axes, then this must be
taken into account in the PLC user program.

3.3.2 Automatic synchronization

Automatic synchronization can take place:
● In referencing mode (see Section "Introduction (Page 152)")
● in other modes, as described below:
If a gantry grouping is switched to follow-up mode, monitoring of the actual values between
the leading and synchronized axes is disabled. The grouping is no longer synchronized as a
result. Independent of axes positions, the following interface signal will be set to 0 (from leading
axis)
DB31, ... DBX101.5 (gantry grouping is synchronous)
If the gantry grouping is switched from follow-up mode to position control mode, axis
synchronism is automatically restored provided the actual-value monitor does not detect a

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3.3 Referencing and synchronization of gantry axes

difference between the positions of the leading and synchronized axes greater than the setting
in the machine data:
MD36030 $MA_STANDSTILL_POS_TOL (standstill tolerance)
In this case, a new setpoint is specified for the synchronized axis (axes) without interpolation.
The positional difference detected earlier is then corrected by the position controller. The
correction causes only the synchronized axis (axes) to move.
The motional sequence of the synchronized axis (axes) is analogous to the situation in which
the grouping switches from the "Hold" state to position control mode. In this case, the position
specified by the position controller before the grouping is halted is set again on condition that
the zero speed monitor has not activated alarm 25040 (with follow-up as alarm reaction) in the
meantime.
The same tolerance window is used for this mode of automatic synchronization as for the zero
speed monitoring function:
MD36030 $MA_STANDSTILL_POS_TOL (standstill tolerance)
Parameter rate dependence loads with machine data:
MD36012 $MA_STOP_LIMIT_FACTOR (exact stop coarse/fine and standstill factor)

Note
The following interface signal blocks automatic synchronization in all modes except referencing
mode:
DB31, ... DBX29.5 (no automatic synchronization)
Should the automatic synchronization be activated at this point, then the following interface
signal must be reset:
DB31, ... DBX29.5 = 0 (no automatic synchronization)
Then switch one of the axes in the gantry grouping from follow-up mode to position-controlled
mode. This is achieved with the interface signals:
DB31, ... DBX1.4 = 1 (follow-up mode)
DB31, ... DBX2.1 = 1 (servo enable)

3.3.3 Points to note

2. Position measuring systems per gantry axis

Different types of position measuring systems can be mounted on the gantry axes of a
grouping. Furthermore, each gantry axis is capable of processing two position measuring
systems, it being possible to switch over from one system to the other at any time:
DB31, ... DBX1.5 (position measuring system 1)
DB31, ... DBX1.6 (position measuring system 2)
The maximum tolerance for position actual value switchover should be set to a lower value
than the gantry warning limit:

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MD36500 $MA_ENC_CHANGE_TOL (Max. tolerance for position actual value switchover)

The two position measuring systems must, however, have been referenced beforehand. The
relevant measuring system must be selected before referencing is initiated. The operational
sequence is then the same as that described above.

Channelspecific referencing
Gantry axes can also be referenced by channel with the following interface signal:
DB21, ... DBX1.0 (activate referencing)
The value of the leading axis' machine data is used for the axis sequence for channel-specific
referencing:
MD34110 $MA_REFP_CYCLE_NR (Axis sequence for channel-specific referencing)
After the reference point of the leading axis has been reached, the synchronized axes are
referenced first as described above.

Referencing from part program with G74

The referencing and synchronization process for gantry axes can also be initiated from the
part program by means of command G74. In this case, only the axis name of the leading axis
may be programmed. The operational sequence is analogous to that described for axis-specific
referencing.

Position measuring system with distancecoded reference marks

In order that return traverses do not have to be made over large distances, it is possible to use
a position measuring system with distance-coded reference marks as a sole or second
measuring system for gantry axes. In this way the measuring system is referenced after
traversal of a short path (e.g. 20 mm). The procedure for referencing the gantry axes is the
same as that described for the normal incremental measuring system.
References:
Function Manual Basic Functions; Reference Point Travel (R1)

Absolute encoder
During the course of the synchronization compensatory motion, all axes in the gantry axis
grouping traverse to the reference point value of the leading axis defined in the machine data:
MD34100 $MA_REFP_SET_POS (reference point value/destination point for distancecoded
system)
The absolute encoders and distanced-coded encoders of the leading axis will be set to the
current actual position of the leading axis or to the reference point by the following machine
data:
MD34330 $MA_REFP_STOP_AT_ABS_MARKER (Distancecoded linear measuring system
without destination point)

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Activation of axis compensations

Compensation functions can be activated for both the leading axis and the synchronized axes.
Compensation values are applied separately for each individual gantry axis. These values
must therefore be defined and entered for the leading axis and the synchronized axes during
start-up.
The compensations do not become operative internally in the control until the axis is referenced
or the gantry grouping synchronized. The following applies:

Compensation type Takes effect when PLC interface signal

Backlash compensation Axis is referenced "Referenced/Synchronized"
LEC Axis is referenced "Referenced/synchronized"
Sag compensation Gantry grouping is synchron‐ "Gantry grouping is synchronized"
ized
Temperature compensation Gantry grouping is synchron‐ "Gantry grouping is synchronized"
ized

If a movement by the synchronized axis (axes) is caused by an active compensation, a travel

command is displayed for the synchronized axis (axes) independently of the leading axis.

Monitoring functions effective

Analogous to normal NC axes, the following monitoring functions do not take effect for gantry
axes until the reference point is reached (IS "Referenced/Synchronized"):
● Working area limits
● Software limit switch
● Protection zones
The axial machine data values are used as monitoring limit values for the synchronized axes
as well.

Multi-channel block search

The cross-channel block search in Program Test mode (SERUPRO "Search Run by Program
test") can be used to simulate the traversal of gantry axis groupings.

Note
Further information regarding multi-channel block search SERUPRO can be found under:
References:
Function Manual, Basic Functions; Mode Group, Channel, Program Mode (K1),
Section: Program test

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3.4 Start-up of gantry axes

3.4 Start-up of gantry axes

General
Owing to the forced coupling which is normally present between guide and synchronous gantry
axes, the gantry grouping must be started up as if it were an axis unit. For this reason, the
axial machine data for the guide and synchronous axes must always be defined and entered
jointly.
If the synchronous axis is overloaded due to a weaker dynamic response than the guide axis,
alarm 10656 is displayed.
Special points to be noted with regard to starting up gantry axes are described below.

Traversing direction
As part of the start-up procedure, a check must be made to ensure that the direction of rotation
of the motor corresponds to the desired traversing direction of the axis. Correct with the
following axial machine data:
MD32100 $MA_AX_MOTION_DIR (traversing direction)

Entering gantry trip limits

For the monitoring of the actual position values of the synchronous axis in relation to the actual
position of the guide axis, the limit values for termination, as well as for the guide and
synchronous axes, should be entered corresponding to the specifications of the machine
manufacturer:
● MD37120 $MA_GANTRY_POS_TOL_ERROR (gantry trip limit)
● MD37130 $MA_GANTRY_POS_TOL_REF (gantry trip limit for referencing)
Note
The control must then be switched off and then on again because the gantry axis definition
and the trip limit values only take effect after power ON.

Response to setpoint changes and disturbances

Since digital drives respond well to disturbances and setpoint changes, there is no need for a
compensatory control between the gantry axes. However, the gantry axes can only operate
in exact synchronism if the parameters for the control circuits of the guide and synchronous
axes are set to the same dynamic response value.
To ensure the best possible synchronism, the guide axis and synchronous axis must be
capable of the same dynamic response to setpoint changes. The axial control loops (position,
speed and current controllers) should each be set to the optimum value so that disturbances
can be eliminated as quickly and efficiently as possible. The dynamic response adaptation
function in the setpoint branch is provided to allow differing dynamic responses of axes to be
matched without loss of control quality.

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3.4 Start-up of gantry axes

Axial optimization
The following control parameters must be set to the optimum axial value for both the guide
axis and the synchronous axis:
● MD32200 $MA_POSCTRL_GAIN (servo gain factor)
● MD32620 $MA_FFW_MODE (feedforward control parameter)
● MD32610 $MA_VELO_FFW_WEIGHT (feedforward control factor for acceleration/speed)
● MD32650 $MA_AX_INERTIA (inertia for torque feedforward control)
● MD32800 $MA_EQUIV_CURRCTRL_TIME (equivalent time constant current control loop
for feedforward control)
● MD32810 $MA_EQUIV_SPEEDCTRL_TIME (equivalent time constant speed control loop
for feedforward control)

References
Extended Functions Function Manual; Compensations (K3)

Same settings
The following control parameters must be set to the same value for the guide axis and
synchronous axis:
● MD33000 $MA_FIPO_TYPE (fine interpolator type)
● MD32400 $MA_AX_JERK_ENABLE (axial jerk limitation)
● MD32410 $MA_AX_JERK_TIME (time constant for the axial jerk filter)
● MD32420 $MA_JOG_AND_POS_JERK_ENABLE (basic position of axial jerk limitation)
● MD32430 $MA_JOG_AND_POS_MAX_JERK (axial jerk)

References
Basic Functions Function Manual; Velocities, Setpoint / Actual Value Systems, Closed-Loop
Control (G2)

Dynamics matching
The guide axis and the coupled synchronous axis must be capable of the same dynamic
response to setpoint changes. The same dynamic response means: The following errors are
equal in magnitude when the axes are operating at the same speed.
The dynamic response adaptation function in the setpoint branch makes it possible to obtain
an excellent match in the response to setpoint changes between axes which have different
dynamic characteristics (control loops). The difference in equivalent time constants between
the dynamically "weakest" axis and the other axis in each case must be specified as the
dynamic response adaptation time constant.

Example
When the speed feedforward control is active, the dynamic response is primarily determined
by the equivalent time constant of the "slowest" speed control loop.

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3.4 Start-up of gantry axes

Guide axis
MD32810 $MA_EQUIV_SPEEDCTRL_TIME [n] = 5 ms (equivalent time constant speed
control loop for feedforward control)

Synchronous axis
MD32810 $MA_EQUIV_SPEEDCTRL_TIME [n] = 3 ms
● Time constant of dynamic response adaptation for synchronous axis:
MD32910 $MA_DYN_MATCH_TIME [n] = 5 ms - 3 ms = 2 ms (time constant of dynamic
response adaptation)
The dynamic response adaptation must be activated axially with the machine data:
MD32900 $MA_DYN_MATCH_ENABLE (dynamic response adaptation)

Check of dynamic response adaptation:

The following errors of the guide and synchronous axes must be equal in magnitude when the
axes are operating at the same speed!
For the purpose of fine tuning, it may be necessary to adjust servo gain factors or feedforward
control parameters slightly to achieve an optimum result.

Referencing gantry axes

The positions of the guide and synchronous axes reference points must first be set to almost
identical values.
To ensure that the synchronization compensatory motion of the gantry axes is not started
automatically, the gantry warning limit must be set to 0 at the first start-up before referencing:
MD37100 $MA_GANTRY_POS_TOL (gantry axis definition)
This will prevent a warning message being output during traversing motion.
In cases where an excessively high additional torque is acting on the drives due to
misalignment between the guide and synchronous axes, the gantry grouping must be aligned
before the axes are traversed. After this, the gantry axes must be referenced. For further
details, see:
● Section "Referencing and synchronization of gantry axes (Page 152)"
● References: Basic Functions Function Manual; Reference Point Approach (R1)
After the guide and synchronous axes have been referenced, the difference between them
must be determined by comparing the actual position value (HMI: Operating area "Diagnostics"
> "Service axes") and taken into account as the reference point offset:
● MD34080 $MA_REFP_MOVE_DIST (reference point distance)
● MD34090 $MA_REFP_MOVE_DIST_CORR (reference point offset / absolute offset)
The differences in distance between the zero mark and reference point must also be calculated
for each gantry axis and adjusted. They are to be customized, via the following machine data,
in such a way that the actual position values of the guide and synchronous axes are identical
after execution of the compensatory motion:
● MD34080 $MA_REFP_MOVE_DIST (reference point distance)
● MD34090 $MA_REFP_MOVE_DIST_CORR (reference point offset / absolute offset)

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3.4 Start-up of gantry axes

Synchronizing gantry axes

The gantry synchronization is activated via the NC/PLC interface signal (see Section
"Referencing and synchronization of gantry axes (Page 150)"):
DB31, ... DBX29.4 = 1 (start synchronization of gantry)
The completion of the synchronization is displayed via the NC/PLC interface signal:
DB31, ... DBX101.5 == 1 (gantry grouping is synchronous)
Once the axes have been synchronized, check that the dimensional offset between the guide
and the synchronous axes is 0. If required, make corrections in the machine data mentioned
above.

Input of gantry warning limit

Once the reference point values for the guide and synchronous axes have been optimized so
that the gantry axes are perfectly aligned with one another after synchronization, the warning
limit values for all axes must be entered in the following machine data:
MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit)
To do this, the value must be increased incrementally until it is just below the alarm (limit
exceeded) response limit. It is particularly important to check the acceleration phases.
This limit value also determines the position deviation value at which gantry synchronization
is automatically started in the control.

Calculating and activating compensations

In cases where the gantry axes require compensation (backlash, sag, temperature or
leadscrew error), the compensation values for the guide axis and the synchronous axis must
be calculated and entered in the appropriate parameters or tables.

References
Extended Functions Function Manual; Compensations (K3)

Function generator / measuring function

The activation of the function generator and measuring function for a synchronous axis is
aborted with an error message. If an activation of the synchronous axis is absolutely necessary,
e.g. to measure the machine, the guide and the synchronous axes must be temporarily
interchanged.

Special cases
If individual axes have to be activated, the gantry groups must be temporarily canceled. As
the second axis no longer travels in synchronism with the first axis, the activated axis must not
be allowed to traverse beyond the positional tolerance.

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3.5 Parameter assignment: Response to faults

If the gantry grouping is canceled, the following points must be noted:

● Always activate the traversing range limits and set them to the lowest possible values
(position tolerance).
● Synchronize the gantry grouping first if possible and then execute a POWER-ON-RESET
without referencing the axes again. This ensures that the traversing range limits always
refer to the same position (i.e. that which was valid on power ON).
● Avoid using the step-change function. Position step changes are only permissible if they
stay within the permitted tolerance.
● Always use an offset of 0 for the function generator and measuring function in contrast to
the recommendations for normal axes.
● Set the amplitudes for function generator and measuring function to such low values that
the activated axis traverses a shorter distance than the position tolerance allows. Always
activate the traversing range limits as a check (see above).

References
Drive Functions Function Manual; Speed Control Loop (DD2)

Start-up support for gantry groupings

The start-up functions of the function generator and measuring are parameterized via the PI
service. The traversing movement starts for all parameterized axes with NC start in JOG mode.
A window is displayed in the "Measuring function and function generator in gantry grouping"
user interface. Two amplitude values, each with an offset and bandwidth, must be entered in
this window. The first amplitude value applies to the measuring axis and the second to the
other coupled axes.

3.5 Parameter assignment: Response to faults

Pulse suppression
The behavior of the gantry grouping with regard to faults that trigger pulse suppression can
be set with the following axis-specific machine data:

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3.6 PLC interface signals for gantry axes

MD30455 $MA_MISC_FUNCTION_MASK, bit 9 = <value>

<value> Meaning
0 When a fault occurs that triggers the pulse suppression (e.g. measuring-circuit fault), the
pulses in all other axes of the gantry grouping will also be suppressed.
Result: Coast down of all axes of the gantry grouping.
1 When a fault occurs that triggers the pulse suppression (e.g. measuring-circuit fault), the
pulses for only this axis will be suppressed. The other axes of the gantry grouping will be
stopped. The pulses for these axes are also then suppressed. To ensure that the pulses
these axes are not suppressed in advance, especially for axes to be held at the standstill
position (vertical axes), the following drive parameters must be taken into account:
● p1135[0...n] OFF3 ramp-down time
● p1217 holding brake application time
● p1227 zero speed detection monitoring time
● p1228 pulse suppression, delay time
For a detailed description of drive parameters, refer to:
References:
SINAMICS S120/S150 Parameter Manual

3.6 PLC interface signals for gantry axes

Special IS for gantry axes

The special NC/PLC interface signals of the coupled gantry axes are taken via the axial NC/
PLC interface of the leading or synchronized axes. The table below shows all special gantry
NC/PLC interface signals along with their codes and indicates whether the IS is evaluated on
the leading axis or the synchronized axis.

NC/PLC interface signal Direction of transfer DB31, ... Leading axis Synchronous axis
DBX...
Start gantry synchronization PLC → NCK 29.4 X
No automatic synchronization PLC → NCK 29.5 X
Gantry axis NCK → PLC 101.7 1 1
Gantry leading axis NCK → PLC 101.6 1 0
Gantry grouping is synchronized NCK → PLC 101.5 X
Gantry synchronization ready to NCK → PLC 101.4 X
start
Gantry warning limit exceeded NCK → PLC 101.3 X
Gantry trip limit exceeded NCK → PLC 101.2 X

Effect of axial interface signals on gantry axes

a) Axial interface signals from PLC to axis (PLC → NCK)
The axial interface signals from the PLC to the axis are always referred to all gantry axes in
the grouping. In this case, all gantry axes (leading and synchronized axis) have equal priority.

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3.6 PLC interface signals for gantry axes

For example, all axes in the gantry groupings will be simultaneously shut down when the
following interface signal is set to "0" from the leading axis:
DB31, ... DBX2.1 (servo enable)
The following table shows the effect of individual interface signals (from PLC to axis) on gantry
axes:

NC/PLC interface signal DB31, ... DBX ... Effect on

Leading axis Synchronous axis
Axis/spindle disable 1.3 On all axes in gantry No effect
grouping
Position measuring system 1/2 1.5 and 1.6 Axial 1) Axial 1)
Controller enable 2.1 On all axes in gantry grouping 2)
Delete distance to go (axial) 2.2 Axial No effect
Clamping in progress 2.3 Axial Axial
Reference point value 1-4 2.4 - 2.7 Axial Axial
Feed stop 4.3 On all axes in gantry grouping
Hardware limit switch plus/minus 12.0 and 12.1 Axial alarm: Brake request on all axes in gantry
grouping
2. Hardware limit switch plus / minus 12.2 and 12.3 Axial Axial
Ramp-function generator fast stop (RFGFS) 20.1 On all axes in gantry grouping
Select drive parameter set 21.0 - 21.2 Axial Axial
Enable Pulses 21.7 Axial Axial
1)
DB31, ... DBX1.5 and 1.6 (position measuring system 1/2)
The switchover between position measuring systems 1 and 2 applies individually for each gantry axis. However, deactivation
of both position measuring systems (known as the parking position) applies as a common signal for all gantry axes.
2)
DB31, ... DBX2.1 (controller enable)
If the servo enable signal on one gantry axis is canceled, all axes in the gantry grouping are shut down simultaneously. The
method by which shutdown is implemented (e.g. with fast stop) is identical for all gantry axes.

Either the "Follow-up" state (IS of one gantry axis = 1) or the "Stop" state (IS of all gantry axes
= 0) is activated for all gantry axes, depending on interface signal:
DB31, ... DBX1.4 (follow-up mode)
b) Axial interface signals from axis to PLC (NCK → PLC)
Each of the axial, axis-to-PLC interface signals for the synchronized axis and the leading axis
is always set on an axis-specific basis and output to the PLC.
Example:
DB31, ... DBX60.4 resp. 60.5 (referenced/synchronized 1/2).
Exception:
When the leading axis is traversed, the interface signal will also be set for the synchronizing
axis:
DB31, ... DBX64.6 and 64.7 (traverse command plus resp. minus)

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3.7 Miscellaneous points regarding gantry axes

3.7 Miscellaneous points regarding gantry axes

Manual travel
It is not possible to traverse a synchronized axis directly by hand in JOG mode. Traverse
commands entered via the traversing keys of the synchronized axis are ignored internally in
the control. Rotation of the handwheel for the synchronized axis has no effect either.

Handwheel override
An overriding motion by means of the handwheel can only be applied to the leading axis in
coupled axis mode. In this case, the synchronized axes traverse in synchronism with the
leading axis.

DRF offset
A DRF offset can only be applied to the leading axis. In this case, the synchronized axes
traverse in synchronism with the leading axis.

Programming in part program

Only the leading axis of a gantry axis grouping may be programmed in the part program. An
alarm is generated while programming a synchronized axis, even when a gantry axis grouping
is released (MD37140 $MA_GANTRY_BREAK_UP = 1).

PLC or command axes

Only the leading axis of the gantry grouping can be traversed by the PLC using FC 18 or as
a command axis by means of synchronized actions.
References:
● Function Manual, Basic Functions, Basic PLC Program (P3)
● Function Manual, Synchronized Actions

PRESET
The PRESET function can only be applied to the leading axis. All axes in the gantry grouping
are reevaluated internally in the control when PRESET is activated. The gantry axis then lose
their reference and synchronization:
DB31, ... DBX101.5 (gantry grouping is synchronized) = 0

Channel assignment of the gantry axes

Please ensure that for a gantry grouping whose leading axis is known in several channels, its
synchronized axes in these channels are also known. If this is not the case, Alarm 10651 is
output with reason 60XX (XX is the objectionable gantry grouping).

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3.7 Miscellaneous points regarding gantry axes

Axis replacement
All axes in the gantry grouping are released automatically in response to a RELEASE
command (leading axis).
A replacement of the leading axis of a closed gantry grouping is only possible, if all axes of
the grouping are known in the channel in which they are to be transferred, otherwise alarm
10658 is signaled.
No automatic axis change and no automatic adjustment of the gantry axis conditions are
undertaken while trying to reconnect a gantry grouping is released with
MD37140 $MA_GANTRY_BREAK_UP = 1. The user is responsible for this. A check of the
axis conditions is conducted after the break up and if necessary, a corresponding alarm 10658
is output.

Note
If a gantry grouping is to be closed again, the user must ensure that all axes of the grouping
are in a channel with a corresponding axis condition.

Default for RESET

In an active gantry grouping, the following machine data parameterization is ignored for the
synchronized axes:
MD30450 $MA_IS_CONCURRENT_POS_AX = 1 (Reset default: neutral axis/channel axis)
The state of the leading axis is assumed. The user is informed about the inappropriate
configuration with display alarm 4300.

Display data
The position actual value display shows the actual values of both the leading axis and the
synchronized axes. The same applies to the service display values in the "Diagnosis" operating
area.

software limit switch

The SW limit switch monitor is processed for the leading axis only. If the leading axis crosses
the limit switch, all axes in the gantry grouping are braked to a standstill.

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3.8 Examples

Differences in comparison with the "Coupled motion" function

The main differences between the "gantry axes" and "coupled motion" functions are listed
below:
● The axis coupling between the gantry axes must always be active. Separation of the axis
coupling via part program is therefore not possible for gantry axes. In contrast, the coupled
axis grouping can be separated by means of the part program and the axes then traversed
individually.
● In the "Gantry Axes" function, the difference of the actual position values from the leading
and synchronized axis is monitored continuously and the traversing motion is shut down if
there are impermissible deviations. There is no monitoring for the "Coupled motion" function.
● Gantry axes must remain coupled even during referencing. For this reason, special
procedures are applied for the reference point approach of gantry axes. In contrast, coupled-
motion axes are referenced as individual axes.
● For the gantry axes to traverse without mechanical offset, the synchronized axes must be
set like the leading axes from the control dynamics perspective. In contrast, the "coupled
motion" function permits axes with different dynamic control response characteristics to be
coupled.
References:
Function Manual, Basic Functions, Reference Point Approach (M3)

Block search with active coupling

Note
For an active coupling, it is recommended to only use block search type 5, "Block search via
program test" (SERUPRO) for a block search.

3.8 Examples

3.8.1 Creating a gantry grouping

Introduction
The gantry grouping, the referencing of its axes, the orientation of possible offsets and, finally,
the synchronization of the axes involved are complicated procedures. The individual steps
involved in the process are explained below by an example constellation.

Constellation
Machine axis 1 = gantry leading axis, incremental measuring system
Machine axis 3 = gantry synchronized axis, incremental measuring system

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3.8 Examples

Machine data
The following machine data describes the original values at the beginning of the procedure.
Individual settings must be corrected or added later according to the information below.
Gantry machine data
Axis 1
MD37100 $MA_GANTRY_AXIS_TYPE = 1 (gantry axis definition)
MD37110 $MA_GANTRY_POS_TOL_WARNING =0 (gantry warning limit)
MD37120 $MA_GANTRY_POS_TOL_ERROR = e.g. 1 (gantry trip limit)
MD37130 $MA_GANTRY_POS_TOL_REF = e.g. 100 mm (max. misalignment) (gantry trip
limit for referencing)
MD37140 $MA_GANTRY_BREAK_UP = 0 (invalidate gantry axis grouping)
Axis 3
MD37100 $MA_GANTRY_AXIS_TYPE= 11
MD37110 $MA_GANTRY_POS_TOL_WARNING = 0
MD37120 $MA_GANTRY_POS_TOL_ERROR = e.g. 1 mm
MD37130 $MA_GANTRY_POS_TOL_REF = e.g. 100 mm (max. misalignment)
MD37140 $MA_GANTRY_BREAK_UP = 0
Reference point machine data (for first encoder each)
Axis 1
MD34000 $MA_REFP_CAM_IS_ACTIVE = TRUE
MD34010 $MA_REFP_CAM_DIR_IS_MINUS = e.g. FALSE
MD34020 $MA_REFP_VELO_SEARCH_CAM =
MD34030 $MA_REFP_MAX_CAM_DIST = corresponds to max. distance traversed
MD34040 $MA_REFP_VELO_SEARCH_MARKER =
MD34050 $MA_REFP_SEARCH_MARKER_REVERSE = e.g. FALSE
MD34060 $MA_REFP_MAX_MARKER_DIST = Difference betw. cam edge and 0 mark
MD34070 $MA_REFP_VELO_POS =
MD34080 $MA_REFP_MOVE_DIST = 0
MD34090 $MA_REFP_MOVE_DIST_CORR = 0
MD34092 $MA_REFP_CAM_SHIFT = 0
MD34100 $MA_REFP_SET_POS = 0
MD34200 $MA_ENC_REFP_MODE = 1
The reference point machine data (for the first encoder) of axis 3 must be specified analogously.

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3.8 Examples

3.8.2 Setting of NCK PLC interface

Introduction
An automatic synchronization process during axis referencing must be disabled initially so as
to prevent any damage to grouping axes that are misaligned.

Disabling of automatic synchronization

The PLC user program sets the following for the axis data block of axis 1:
DB31, ... DBX29.4 = 0 (do not start gantry synchronization)
DB31, ... DBX29.5 = 1 (no automatic synchronization process)

The NCK sets the following as a confirmation in the axis block of axis 1:
DB31, ... DBB101.4 = 0 (synchronization process not ready to start)
DB31, ... DBB101.6 = 1 (leading axis LA)
DB31, ... DBB101.7 = 1 (gantry axis)

The PLC user program sets for the axis data block of axis 3:
DB31, ... DBX29.4 = 0 (do not start gantry synchronization)

The NCK sets the following as a confirmation in the axis block of axis 3:
DB31, ... DBB101.4 = 0 (synchronization process not ready to start)
DB31, ... DBB101.6 = 0 (synchronized axis GA)
DB31, ... DBB101.7 = 1 (gantry axis)

3.8.3 Commencing start-up

Referencing
The following steps must be taken:
● Select "REF" operating mode
● Start referencing for axis 1 (master axis)
● Wait until message "10654 Channel 1 Waiting for synchronization start" appears.
At this point in time, the NCK has prepared axis 1 for synchronization and registers this to the
interface signal:
DB31 DB31, ... DBB101.4 = 1 (synchronization process ready to start)
DB31, ... DBB101.6 = 1 (leading axis LA)

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3.8 Examples

DB31, ... DBB101.7 = 1 (gantry axis)

In addition, the following steps must be taken:

● RESET
● Read off values in machine coordinate system:
e.g.
X = 0.941
Y = 0.000
XF = 0.000
● Enter the X value of master axis 1 with inverted sign in the machine data of slave axis 3:
MD34090 $MA_REFP_MOVE_DIST_CORR = - 0.941 (reference point offset/absolute
offset)
Note
This machine data is effective after power ON. To avoid having to perform a power ON
now, the value can also be entered in the following machine data:
MD34080 $MA_REFP_MOVE_DIST (reference point distance)
This machine data is then valid after a RESET.

● Start referencing again for axis 1 (master axis) with the modified machine data
● Wait until message "10654 Channel 1 Waiting for synchronization start" appears
● At this point in time, the NCK has prepared axis 1 for synchronization and registers this to
the interface signal:
DB31 DB31, ... DBB101.4 = 1 (synchronization process ready to start)
DB31, ... DBB101.6 = 1 (leading axis LA)
DB31, ... DBB101.7 = 1 (gantry axis)

● Examine actual positions of machine. Case A or B might apply:

$ $ $ $

!  !

GLII



5
! !5
&DVH$ &DVH%

Figure 3-3 Possible results after referencing of axis 1 (master axis)

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3.8 Examples

If Case A applies, the synchronization process can be started immediately (see "start
synchronization process" step). If Case B applies, the offset "diff" must be calculated and taken
into account:
● Measuring of diff
● By using two appropriate, right-angled reference points R' and R" in the machine bed (right
in picture), the difference in position in JOG can be traversed. The diff offset can then be
read as the difference in the position display. The diff offset must be entered in the machine
data of axis 3 (synchronized axis):
MD34100 $MA_REFP_SET_POS
Continue with Step 1 (see above).
● Start gantry synchronization. PLC sets:
DB31, ... DBX29.4 = 1 (start synchronization of gantry)

3.8.4 Setting warning and trip limits

If the gantry grouping is set and synchronized, the following machine data must then be set:
MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit)
MD37120 $MA_GANTRY_POS_TOL_ERROR (gantry trip limit)

Proceed as follows
● Set the machine data for all axes with a large value to begin with:
MD37120 $MA_GANTRY_POS_TOL_ERROR (gantry trip limit)
● Set a very small value in the machine data:
MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit)
When you put a heavy, dynamic strain on the axes, the self-canceling alarm "10652 channel
%1 axis %2 gantry warning limit exceeded" will be output repeatedly.
● Now increase the following machine data:
MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit)
Repeat this until the alarm no longer appears. The interface indicates the status:
DB31, ... DBB102.2 = 0 (trip limit not exceeded)
DB31, ... DBB102.3 = 0 (warning limit not exceeded)
DB31, ... DBB102.4 = 0 (synchronization process not ready to start)
DB31, ... DBB102.5 = 1 (gantry grouping is synchronous)
DB31, ... DBB102.6 = 1 (leading axis LA)
DB31, ... DBB102.7 = 1 (gantry axis)
If the monitoring still only triggers very sporadically, it is possible to program a edge memory
bit in the PLC user program.
● Enter the value calculated for the warning limit + a small safety provision in the following
machine data:
MD37120 $MA_GANTRY_POS_TOL_ERROR (gantry trip limit)

Error limit values

Values are entered in the following machine data:

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3.9 Data lists

MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit)

MD37120 $MA_GANTRY_POS_TOL_ERROR (gantry trip limit)
MD37130 $MA_GANTRY_POS_TOL_REF (gantry trip limit for referencing)
These should have the following scales of magnitude at the end of the customizing process:

0'0$B*$175<B326B72/B:$51,1*
0'0$B*$175<B326B72/B(5525
0'0$B*$175<B326B72/B5()

Note
The same procedure must be followed when starting up a gantry grouping in which the coupled
axes are driven by linear motors and associated measuring systems.
The error limits entered into machine data MD37110 and MD37120 are considered as
additional tolerance values of the actual-value difference of the master and following axis if
the IS "Gantry is synchronous" is not present (e.g. to be resynchronized after canceling alarms
without gantry).

3.9 Data lists

3.9.1 Machine data

3.9.1.1 Axis/spindlespecific machine data

Number Identifier: $MA_ Description

30300 IS_ROT_AX Rotary axis
32200 POSCTRL_GAIN KV factor
32400 AX_JERK_ENABLE Axial jerk limitation
32410 AX_JERK_TIME Time constant for axis jerk filter
32420 JOG_AND_POS_JERK_ENABLE Initial setting for axial jerk limitation
32430 JOG_AND_POS_MAX_JERK Axial jerk
32610 VELO_FFW_WEIGHT Feedforward control factor for speed feedforward control
32620 FFW_MODE Feedforward control mode

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3.9 Data lists

Number Identifier: $MA_ Description

32650 AX_INERTIA Moment of inertia for torque feedforward control
32800 EQUIV_CURRCTRL_TIME Equivalent time constant, current control loop for feed‐
forward control
32810 EQUIV_SPEEDCTRL_TIME Equivalent time constant, speed control loop for feedfor‐
ward control
32900 DYN_MATCH_ENABLE Dynamic response adaptation
32910 DYN_MATCH_TIME Time constant for dynamic response adaptation
33000 FIPO_TYPE Fine interpolator type
34040 REFP_VELO_SEARCH_MARKER Creep velocity
34070 REFP_VELO_POS Reference point start velocity
34080 REFP_MOVE_DIST Reference point approach distance
34090 REFP_MOVE_DIST_CORR Home position offset
34100 REFP_SET_POS Reference point value
34110 REFP_CYCLE_NR Axis sequence for channel-specific referencing
34330 REFP_STOP_AT_ABS_MARKER Distancecoded linear measuring system without desti‐
nation point
36012 STOP_LIMIT_FACTOR Exact stop coarse/fine factor and zero speed
36030 STANDSTILL_POS_TOL Zero speed tolerance
36500 ENC_CHANGE_TOL Maximum tolerance for position actual value switchover
37100 GANTRY_AXIS_TYPE Gantry axis definition
37110 GANTRY_POS_TOL_WARNING Gantry warning limit
37120 GANTRY_POS_TOL_ERROR Gantry trip limit
37130 GANTRY_POS_TOL_REF Gantry trip limit for referencing
37140 GANTRY_BREAK_UP Invalidate gantry axis grouping

3.9.2 Signals

3.9.2.1 Signals from mode group

Signal name SINUMERIK 840D sl SINUMERIK 828D

Active machine function REF DB11 DBX5.2 DB3100.DBX1.2

3.9.2.2 Signals from channel

Signal name SINUMERIK 840D sl SINUMERIK 828D

Referencing active DB21, ... DBX33.0 DB330x.DBX1.0

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3.9 Data lists

3.9.2.3 Signals to axis/spindle

Signal name SINUMERIK 840D sl SINUMERIK 828D

Start gantry synchronization DB31, ... DBX29.4 DB380x.DBX5005.4
No automatic synchronization DB31, ... DBX29.5 DB380x.DBX5005.5

3.9.2.4 Signals from axis/spindle

Signal name SINUMERIK 840D sl SINUMERIK 828D

Referenced/synchronized 1, referenced/synchronized 2 DB31, ... DBX60.4/5 DB390x.DBX0.4/5
Gantry trip limit exceeded DB31, ... DBX101.2 DB390x.DBX5005.2
Gantry warning limit exceeded DB31, ... DBX101.3 DB390x.DBX5005.3
Gantry synchronization ready to start DB31, ... DBX101.4 DB390x.DBX5005.4
Gantry grouping is synchronized DB31, ... DBX101.5 DB390x.DBX5005.5
Gantry guide axis DB31, ... DBX101.6 DB390x.DBX5005.6
Gantry axis DB31, ... DBX101.7 DB390x.DBX5005.7

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K6: Contour tunnel monitoring 4
4.1 Brief description

4.1.1 Contour tunnel monitoring - 840D sl only

Function
The absolute movement of the tool tip in space is monitored. The function operates channel
specific.

Model
A round tunnel with a definable diameter is defined around the programmed path of a
machining operation. Axis movements are stopped as an option if the path deviation of the
tool tip is greater than the defined tunnel as the result of axis errors.

Response
In the event of a recognized deviation, the system reacts as quick as possible. However, at
least one interpolator clock cycle will pass, before one of the following reactions will occur:
● An alarm is triggered when the tunnel is violated and the axes continue to traverse.
● Violation of the tunnel triggers an alarm and the axis movements are decelerated.

Braking methods
If the monitoring tunnel is violated, one of the following methods can be used to decelerate:
● Deceleration ramp
● Speed setpoint zero and follow-up mode

Use
The function can be used for 2D and 3D paths. For 2D the monitoring surface is defined by
parallel lines to the programmed path. The monitoring area is defined by 2 or 3 geometry axis.
Monitoring of synchronized axes, positioning axes, etc. that are not geometry axes is
performed directly on the machine axis plane with the "Contour monitoring".

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K6: Contour tunnel monitoring
4.1 Brief description

Example
The following figure is a diagram of the monitoring area shown by way of a simple example.

=
&RQWRXU7RROWLSSDWK

3HUPLWWHGWROHUDQFH
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ಱ7XQQHOಯDURXQGWKHFRQWRXU
WROHUDQFHEDQG
;

Figure 4-1 Position of the contour tunnel around the programmed path

As long as the calculated actual position of the tool tip remains inside the sketched tunnel,
motion continues in the normal way. If the calculated actual position violates the tunnel, an
alarm is triggered (in the default setting) and the axes are stopped by "Ramp Stop". This
response to the violation of the tunnel can be disabled (alarm triggered but movement
continued) or intensified (rapid stop) by means of a machine data setting.

Analysis
The calculated distance between the programmed path and the actual values can be routed
to an analog output to analyze the progression of the contour errors during normal operation
(quality control).

4.1.2 Programmable contour accuracy

Function
As an alternative to the function described in "Contour tunnel monitoring", i.e. monitoring of
the machining accuracy and stopping machining if excessive deviations occur, another function
is offered. With this function, the selected accuracy is always achieved with the path velocity
being reduced if necessary. Detailed information about this function can be found under the
subject "Programmable contour accuracy".

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4.2 Contour tunnel monitoring - 840D sl only

4.2 Contour tunnel monitoring - 840D sl only

Aim of the monitoring function

The aim of the monitoring function is to stop the movement of the axes if axis deviation causes
the distance between the tool tip (actual value) and the programmed path (setpoint) to exceed
a defined value (tunnel radius).

Tunnel size
The radius of the contour tunnel being monitored around the programmed path must be defined
to implement the monitoring function:
MD21050 $MC_CONTOUR_TUNNEL_TOL (Response threshold for Contour tunnel
monitoring)
If the machine data is set to 0.0, monitoring is not performed. The value of the machine data
is transferred to the control for new configurations.

Parameterizable deceleration behavior

The deceleration behavior for the monitoring response can be set via the following machine
data:
MD21060 $MC_CONTOUR_TUNNEL_REACTION (Reaction upon response of contour
tunnel monitoring)

Value Meaning
0 Display alarm and continue machining
1 Deceleration according to the deceleration ramps (default setting)
2 Rapid stop (speed setpoint = 0)

Encoder switchover
Switching between two encoder systems usually causes a sudden change in the actual position
of the tool tip. This change resulting from encoder switchover must not be so large as to cause
the tool tip to violate the monitoring tunnel. The radius defined in MD21050 must be higher
than the allowed tolerance on actual value switchover:
MD36500 $MA_ENC_CHANGE_TOL (Max. tolerance for position actual value switchover)

Activation
The monitoring will only become active if the following conditions are met:
● MD21050 is higher than 0.0.
● At least two geometry axes have been defined.

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4.3 Programmable contour accuracy

Shutting down
Monitoring can be stopped by enabling the machine data setting:
MD21050 = 0.0.

Analysis output
The values of deviation of the actual value of the tool tip from the programmed path can – for
analysis purposes – be output on a fast analog output (accuracy monitoring).
The assignment of an analog output to output the contour error is programmed in machine
data:
MD21070 $MC_CONTOUR_ASSIGN_FASTOUT

Value Meaning
0 No output (default setting)
1 Output to output 1
2 Output to output 2
… …
8 Output to output 8

Scale
The tunnel radius set in MD21050 corresponds to a voltage of 10 V at the output.

4.3 Programmable contour accuracy

Function
The function "Programmable contour accuracy" limits the contour errors caused by control
behavior and jerk filter to a specified value by reducing the path velocity on curved contours
by the necessary amount. It allows the user to set a compromise between accuracy and
productivity of a machining.

Note
The "LookAhead" function ensures that the velocity necessary for maintaining the required
contour accuracy is not exceeded at any point along the path.

Configuration
The mode of operation and parameterization of the function is determined by the machine data:

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4.3 Programmable contour accuracy

MD20470 $MC_CPREC_WITH_FFW (programmable contour accuracy)

Value Meaning
0 The "Programmable contour accuracy" function has no effect when feedforward control is also
active.
1 The "Programmable contour accuracy" function also acts for feedforward control.
With active feedforward control, the reduction of the path velocity is calculated on the basis of
the effective KV factor with feedforward control.
2 Like 1, the function, however, is parameterized with MD32415 $MA_EQUIV_CPREC_TIME
(time constant for the programmable contour accuracy).
The jerk filter is correctly taken into account. The SD42450 $SC_CONTPREC setting data
determines the permissible contour errors (see "Parameterization").
3 Like for 2, but any contour accuracy programmed with CTOL has priority over SD42450
$SC_CONTPREC.
The jerk filter is correctly taken into account. The programmed CTOL contour tolerance deter‐
mines the permissible contour errors (see "Parameterization"). $SC_CONTPREC is relevant
only if CTOL has not be programmed.

For the MD20470 = 2 or 3 functional versions, the control assumes that there is a jerk filter
time constant (MD32410 $MA_AX_JERK_TIME) for which the setting of the control section
with feedforward control generates a negligible contour error. This value must be entered in
the machine data MD32415 $MA_EQUIV_CPREC_TIME (see "Parameterization").
To calculate the contour error based on the set jerk filter type (MD32402
$MA_AX_JERK_MODE), the following value is used:
● For active feedforward control, the difference:
MD32410 $MA_AX_JERK_TIME - MD32415 $MA_$MA_EQUIV_CPREC_TIME
● Without feedforward control, the complete value from MD32410 $MA_AX_JERK_TIME
This procedure allows the commissioning engineer to first change from an initially precise, but
possibly excessively hard, setting by increasing the jerk filter time constants to a softer setting
with a controlled loss of accuracy.
Supplementary conditions:
● The function does not use the "belt stop" jerk filter type (MD32412 $MA_AX_JERK_MODE
= 3).
● The MD20470 = 2 or 3 functional versions are primarily intended for use with feedforward
control. If one of the two functional versions is active for switched off feedforward control,
a contour error that results from the Kv factor is added. This reduces the path velocity
significantly faster.

Note
The MD20470 = 0 or 1 functional versions are no longer recommended. They only provide
compatibility with older software versions.

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4.3 Programmable contour accuracy

Parameterization

Contour accuracy
The maximum contour error for the path of the geometry axes on curved contours is determined
by:
● For MD20470 $MC_CPREC_WITH_FFW = 2 with the setting data:
SD42450 $SC_CONTPREC (contour accuracy)
● For MD20470 $MC_CPREC_WITH_FFW = 3 with the contour tolerance programmed with
CTOL.
The smaller the value and the lower the Kv factor of the geometry axes, the greater the path
feedrate on curved contours is lowered.

Minimum path feedrate

The user can use the following setting data to specify a minimum path feedrate for the
"Programmable contour accuracy" function:
SD42460 $SC_MINFEED (minimum path feed with CPRECON)
The feedrate will not limited below this value, unless a lower F value has been programmed
or the dynamic limitations of the axes force a lower path velocity.

Time constant for the programmable contour accuracy

The equivalent time constant for the MD20470 = 2 or 3 functional versions (see "Configuration")
is entered in the machine data:
MD32415 $MA_EQUIV_CPREC_TIME (time constant for the programmable contour
accuracy)
MD32415 must contain that jerk filter time constant (MD32410 $MA_AX_JERK_TIME) for
which the contour error for active feedforward control is negligibly small.

Programming
The "programmable contour accuracy" can be activated and deactivated in the part program
with the CPRECON and CPRECOF modal G functions.
Example:

Program code Comment

N10 G0 X0 Y0
N20 CPRECON ; Activate the "programmable contour accuracy".
N30 G1 G64 X100 F10000 ; Machining with10 m/min in the continuous-path mode.
N40 G3 Y20 J10 ; Automatic feed limitation in circular block
N50 G1 X0 ; Feedrate again without limitation (10 m/min).
...
N100 CPRECOF ; Deactivate the "programmable contour accuracy".
N110 G0 ...

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4.4 Constraints

The two CPRECON and CPRECOF modal G functions form the G function group 39
(programmable contour accuracy).

Behavior for part program start and after reset / part program end
For part program start and after reset / part program end, the configured control initial setting
acts for the G function group 39:
MD20110 $MC_RESET_MODE_MASK (definition of initial control settings after RESET / TP
End)
MD20112 $MC_START_MODE_MASK (definition of the basic setting of the control after part
program start)

Supplementary conditions

Positioning axes
The function considers only the geometry axes of the path. It does not have any effect of the
velocities for the positioning axes.

References
Information about MD32402 $MA_AX_JERK_MODE (filter type for axial jerk limitation) and
MD32410 $MA_AX_JERK_TIME (time constant for the axial jerk filter), see:
Function Manual, Basic Functions; Acceleration (B2), Section: "Functions" > "Jerk filter (axis-
specific)"
Information about CTOL, see:
Function Manual, Basic Functions; Continuous-Path Mode, Exact Stop, Look Ahead (B1),
Section: "Contour/orientation tolerance"

4.4 Constraints

Availability of the "Contour tunnel monitoring" function

The function is an option ("Contour monitoring with tunnel function"), which must be assigned
to the hardware via the license management.

Coupled motion
If coupled motion between two geometry axes is programmed with contour tunnel monitoring,
this always results in activation of the contour tunnel monitoring. In this case, the contour tunnel
monitoring must be switched off before programming the coupled motion:
MD21050 $MC_CONTOUR_TUNNEL_TOL = 0.0

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4.5 Data lists

4.5 Data lists

4.5.1 Machine data

4.5.1.1 Channelspecific machine data

Number Identifier: $MC_ Description

20110 RESET_MODE_MASK Determination of basic control settings after Reset / TP
End
20112 START_MODE_MASK Definition of the initial control settings after part program
start
20470 CPREC_WITH_FFW Programmable contour accuracy
21050 CONTOUR_TUNNEL_TOL Response threshold for contour tunnel monitoring
21060 CONTOUR_TUNNEL_REACTION Reaction to response of contour tunnel monitoring
21070 CONTOUR_ASSIGN_FASTOUT Assignment of an analog output for output of the contour
error

4.5.1.2 Axis/spindlespecific machine data

Number Identifier: $MA_ Description

32402 AX_JERK_MODE Filter type for axial jerk limitation
32410 AX_JERK_TIME Time constant for axial jerk filter
32415 EQUIV_CPREC_TIME Time constant for the programmable contour accuracy
36500 ENC_CHANGE_TOL Maximum tolerance for position actual value switchover

4.5.2 Setting data

4.5.2.1 Channelspecific setting data

Number Identifier: $SC_ Description

42450 CONTPREC Contour accuracy
42460 MINFEED Minimum path feed for CPRECON

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5.1 Function description

5.1.1 Characteristics
In the following chapter it is described how, for NC functions such as "Collision avoidance" or
"Kinematic transformation", the kinematic structure of a machine can be mapped using a
kinematic chain, and parameterized in the control system using system variables.
The system variables are retentatively saved in the NC and can be archived and/or read as
"NC data" via SINUMERIK Operate using the commissioning archive.
For functions such as "collision avoidance" which also require a description of the machine
geometry, see section "K8: Geometric machine modeling - only 840D sl (Page 223)".

Note
Graphic editor
As an alternative to writing the system variables in a part program, the machine can be modeled
from the SINUMERIK Operate user interface:
Operating area: "Commissioning" > "NC" > "Machine model"
Changes to the machine model
The direct changes to the machine model at the system variables only become visible at the
user interface after explicitly requesting that the machine model is recalculated by calling the
PROTA() (Page 289) or PROTS() (Page 290) function.
Changes to the machine model made at the user interface are immediately adopted in the
system variables of the NC. The changes only become active after explicitly requesting that
the machine model is recalculated by calling the PROTA() (Page 289) or PROTS()
(Page 290) function.

Kinematic structure
The kinematic structure of a machine comprises the following:
● Number and type of the machine axes: Linear or rotary axes
● Arrangement of the machine axes: Position and orientation
● Dependencies of the machine axes to one another: Which machine axis traverses with
which other machine axis.

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5.1 Function description

Kinematic chain
A kinematic structure of a machine is described using a kinematic chain with the following
properties:
● A kinematic chain consists of an arbitrary number of interconnected elements.
● Parallel subchains can branch off from a kinematic chain.
● Only one active kinematic chain is available in the control.
● The active kinematic chain starts with the root element.
● If parameterized kinematic elements are not connected to the active kinematic chain, they
remain inactive.
● A kinematic chain is defined in the spatially-fixed coordinates of the world coordinate
system.

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Element
An element of a kinematic chain basically describes the transformation with which the local
coordinate system of the previous element is mapped in the local coordinate system of the
current element:
Kn-1 ⇒ Tn ⇒ Kn

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The following constant transformations are possible:

● Offset (type: OFFSET (Page 207))
● Rotation (type: ROT_CONST (Page 205))

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5.1 Function description

The following changing transformations, based on the current position values of the machine
axis assigned to the element (linear axis / rotary axis), are possible:
● Offset (type: AXIS_LIN (Page 198))
● Rotation (type: AXIS_ROT (Page 201))
A position or orientation change in an element, e.g. through a position change of the associated
machine axis, affects all the following elements of the chain or parallel subchains.
The maximum number of possible elements can be parameterized using machine data
(Page 193).

Parallel subchains
If a parallel subchain branches off from an element en, then for the kinematics, the branch is
always before the element. For this reason, a change in element en, e.g. a position change of
the associated machine axis, does not affect the subchain branch.

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Figure 5-3 Parallel subchains branching off from elements en and en+2

Switch
A switch is a special element that is not kinematically active (type: SWITCH (Page 208)) in a
kinematic chain, which can assume the CLOSED and OPEN states.
In the OPEN state, the connection from the previous to the following element is interrupted.

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Figure 5-4 OPEN state

In the CLOSED state, the previous element is connected to the following element.

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5.1 Function description

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The switch does not influence the connection to a parallel element.

The maximum number of possible switches can be parameterized usingmachine data
(Page 193).

Note
Local coordinate system
The local coordinate system of a switch is not rotated with respect to the world coordinate
system.

World coordinate system

In order to uniquely describe the kinematic stricture of a machine, all elements of the kinematic
chain - as well as the orientation and offset vectors of the machine axis and the constant
rotation/offsets - are referred to the world coordinate system.
Elements with linear axes do not change the orientation of the following elements. The
orientation and offset vectors of the following elements can therefore refer to the world
coordinate system without further supplementary conditions.

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Elements with rotary axes change the orientation of the following elements. This is the reason
that the orientation and offset vectors of the following elements, for a defined initial position of
the previous orientation changing elements, must be referred to the world coordinate system.

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5.2 Commissioning

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Origin and orientation of the world coordinate system can be freely selected. The following
arrangement is recommended:
● Origin of the world coordinate system at the machine zero point
● Orientation of the world coordinate system so that the coordinate axes are arranged in the
positive traversing direction of the machine linear main axes

Direction vectors
Within a kinematic chain, the direction vectors, which are used to specify the alignment of the
machine axes, are always specified in absolute terms, i.e. referred to the world coordinate
system.

5.2 Commissioning

5.2.1 General

5.2.1.1 Overview
The commissioning of the "Kinematic chain" function is performed using:
● Machine data
– Specification of the quantity structure
– Specification of the first element in the kinematic chain
● System variables
– Specification of the kinematic properties of an element
– Connection of the element to the kinematic chain

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5.2 Commissioning

5.2.1.2 Structure of the system variables

The system variables are structured according to the following scheme:
● $NK_<Name>[<Index_1>]
● $NK_<Name>[<Index_1>, <Index_2>]

General
The system variables to describe the elements of kinematic chains have the following
properties:
● The prefix for all system variables of the kinematic chain is $NK_, (N for NC, K for kinematic).
● The system variables can be read and written via NC programs.
● The system variables can be stored in archives and loaded to the NC again.

Data type

STRING
All system variables of the STRING data type have the following properties:
● Maximum string length: 31 characters
● No distinction is made between upper and lower case
Example: "Axis1" is identical to "AXIS1"
● Spaces and special characters are permitted
Example: "Axis1" is not identical to "Axis 1"
● Names that start with two underscores "__" are reserved for system purposes and must
not be used for user-defined names.
Note
Leading space
Since spaces are valid and distinct characters, names that start with a space followed by two
underscores "__" can, in principle, be used for user-defined names. However, because they
can be easily mistaken for system names, this procedure is not recommended.

Index_1
The individual elements are addressed via index_1. Index 0 → 1. Element, index 1 → 2.
Element, ... n → (n+1) element, with n = ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)
All system variables of an element have the same index.

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5.2 Commissioning

Index_2
For system variables that contain a vector, the coordinates of the vector are addressed via
index_2.
● 0 → X axis
● 1 → Y axis
● 2 → Z axis

5.2.2 Machine data

5.2.2.1 Maximum number of elements

The maximum number of elements for kinematic chains is set using machine data.
MD18880 $MN_MM_MAXNUM_KIN_CHAIN_ELEM = <number>

5.2.2.2 Root element

The following machine data is used to specify the root element, i.e. the first element of the
currently active kinematic chain.
MD16800 $MN_ROOT_KIN_ELEM_NAME = "<element_name>"
All parameterized elements and subchains that are connected to the root element in such a
way that the connection starts at the root element, are part of the currently active kinematic
chain.
Parameterized elements or subchains that are not connected to the root element or whose
connection points towards the root element, are not part of the currently active kinematic chain.

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5.2.2.3 Maximum number of switches

The maximum number of switches for kinematic chains is set using machine data
MD18882 $MN_MM_MAX_NUM_KIN_SWITCHES = <Number>

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5.2.3 System variables, all transformations types

5.2.3.1 Overview

System variables independent of any element

System variable Meaning

$NK_SWITCH Switch variable to open and close the switch

Element-specific system variables

Element-specific system variables are subdivided into variables that are independent of the
type and dependent on the type:
● Variables independent of the type

System variable Meaning

$NK_NAME Name of the current element en
$NK_NEXT Name of the next element en+1
$NK_PARALLEL Name of a branching parallel element ep before the current element
en
$NK_TYPE Type of the element

● Variables dependent on the type

System variable Meaning

$NK_OFF_DIR Offset or direction vector
$NK_AXIS Machine axis or object name
$NK_A_OFF Work offset for linear axis or rotary axis
$NK_SWITCH_INDEX Switch index
$NK_SWITCH_POS Switch position "CLOSED"
For the following types, variables dependent on the type are evaluated:

System variable Type

OFFSET AXIS_LIN AXIS_ROT ROT_CON SWITCH
ST
$NK_OFF_DIR x x x x -
$NK_AXIS - x x - -
$NK_A_OFF - x x x -
$NK_SWITCH_INDEX - - - - x
$NK_SWITCH_POS - - - - x

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The system variables are described in detail in the following sections.

Note
Establish a defined initial state
It is recommended that a defined initial state be generated before parameterizing the kinematic
chain. To do this, the system variables of the kinematic chain should be set to their default
value using function DELOBJ() (Page 213).
Change system variable values
If the value of one of the system variables listed above is changed, then the change becomes
immediately visible on the user interface, e.g. SINUMERIK Operate. The machine model of
the NC is only updated after explicitly requesting that the machine model is recalculated by
calling the PROTA() (Page 289) or PROTS() (Page 290) function.

5.2.3.2 $NK_NAME

Function
Enter the NC-wide unique element name in the system variable. The element is referenced
via this name, e.g. within kinematic chains. The name is also displayed in the graphical editor
of SINUMERIK Operate.

Syntax
$NK_NAME[<n>] = "<name>"

Meaning

$NK_NAME: Name of the element

Data type: STRING
Default value: "" (empty string)
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)
<name>: Element name, max. string length: 31 characters
Data type: STRING

Example
The 9th kinematic element is assigned the name "B axis":

Program code Comment

N100 $NK_NAME[8] = "B axis" ; 9th kinematic element,
; name = "B axis"

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5.2.3.3 $NK_NEXT

Function
If the element is part of a kinematic chain, the name of the following element should be entered
in the system variable.

Syntax
$NK_NEXT[<n>] = "<name>"

Meaning

NK_NEXT: Name of the following element

Data type: STRING
Range of values: All names contained in $NK_NAME (Page 195)
Default value: "" "" (empty string)
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)
<name>: Element name, max. string length: 31 characters
Data type: STRING

Example
The 9th kinematic element does not have a following element:

Program code Comment

N100 $NK_NEXT[8] = "" ; 9. kin. element,
; following element = ""

5.2.3.4 $NK_PARALLEL

Function
The name of the element that branches off before the current element should be entered in
the system variable. The branching element is parallel to the current element. Changes to the
current element, e.g. position changes of the assigned machine axis, have no effect on the
parallel element.

Syntax
$NK_PARALLEL[<n>] = "<name>"

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Meaning

$NK_PARALLEL: Name of the parallel element

Data type: STRING
Range of values: All names contained in $NK_NAME (Page 195)
Default value: "" "" (empty string)
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)
<name>: Element name, max. string length: 31 characters
Data type: STRING

Example
The "Offset to the rotary table" element is arranged parallel to the 9th kinematic element:

Program code Comment

N100 $NK_PARALLEL[8] = "Offset to the rotary ; Parallel to the 9th kin. element,
table" ; name = "Offset to the rotary table"

5.2.3.5 $NK_TYPE

Function
The element type should be entered in the system variable:

Type Description
AXIS_LIN The element describes a linear machine axis (linear axis) with direction vector
(Page 198) $NK_OFF_DIR and work offset $NK_A_OFF.
AXIS_ROT The element describes a rotary machine axis (rotary axis) with direction vector
(Page 201) $NK_OFF_DIR and work offset $NK_A_OFF or a spindle.
Note
The position of a spindle is considered differently depending on the function used by
the kinematic chain:
● Collision avoidance: Indeterminate position
● Kinematic transformation: Depending on the setting in $NT_CNTRL, bit 1-3, the
position corresponding to $NK_A_OFF or the speed setpoint is taken into
consideration
ROT_CONST The element describes a constant rotation around direction vector $NK_OFF_DIR
(Page 205) and angle $NK_A_OFF.
OFFSET The element describes a constant linear offset with the offset vector $NK_OFF_DIR.
(Page 207)
SWITCH The element defines a switch, which is switched using system variable
(Page 208) $NK_SWITCH (Page 210).

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Syntax
$NK_TYPE[<n>] = "<Typ>"

Meaning

$NK_TYPE: Type of the element

Data type: STRING
Default value: "" (empty string)
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)
<Typ>: Element name, max. string length: 31 characters
Data type: STRING
Range of values: "AXIS_LIN", "AXIS_ROT", "ROT_CONST", "OFFSET",
"SWITCH"

Example
The 9th kinematic element is a rotary axis:

Program code Comment

N100 $NK_TYPE[8] = "AXIS_ROT" ; 9th kin. element
; type = rotary axis

5.2.3.6 Type-dependent variables for $NK_TYPE = "AXIS_LIN"

$NK_OFF_DIR

Function
The direction vector along which the linear axis $NK_AXIS assigned to the element moves,
should be entered in the system variable. The output coordinate system therefore results from
the input coordinate system, offset by the current position value of the linear axis and the work
offset specified in $NK_A_OFF.
Supplementary conditions:
● The direction vector must be specified as an absolute value, i.e. in relation to the world
coordinate system.
● The direction vector must be specified so that it points in the positive traversing direction
of the machine axis.
● The absolute value of the direction vector must be greater than 1*10-6.

Syntax
$NK_OFF_DIR[<n>,<k>] = <value>

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Meaning

$NK_OFF_DIR: Direction vector (X; Y; Z)

Data type: REAL
Range of values: Direction vector: 1*10-6 < |Vector | ≤ max. REAL value
Default value: (0.0, 0.0, 0.0)
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)
<k>: Coordinate index
Data type: INT
Range of values: 0: X coordinate (abscissa)
1: Y coordinate (ordinate)
2: Z coordinate (applicate)
<value>: Coordinate value
Data type: REAL
Range of values: - max. REAL value ≤ x ≤ + max. REAL value

Example
; The linear axis of the 9th element moves along the direction vector. The direction vector is
the unit vector (1; 0; 0), rotated around Z with γ=90° in the X/Y plane, and around X with
α=10° in the Y/Z plane referred to the world coordinate system. The following values result
from this for the individual components (x, y, z) of the direction vector:
● x = cos(γ) * cos(α) = cos(90) * cos(10) = 0.0
● y = sin(γ) * cos(α) = sin(90) * cos(10) ≈ 0.985
● z = sin(α) = sin(10) ≈ 0.174

))B ',5
 1 . B2
˞ _Y_ 
<

ˠ ]
[

; \

Figure 5-6 Direction vector, general

Program code Comment

; 9th kinematic element
N100 $NK_OFF_DIR[8,0] = COS(90)*COS(10) ; 0 = X component
N110 $NK_OFF_DIR[8,1] = SIN(90)*COS(10) ; 1 = Y component
N120 $NK_OFF_DIR[8,2] = SIN(10) ; 2 = Z component

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$NK_AXIS

Function
The name of the machine axis (MD10000 $MN_AXCONF_MACHAX_NAME_TAB) that is to
be assigned to the element should be entered in the system variable.
The output coordinate system of the element results from the input coordinate system offset
by the current position setpoint of the machine axis in the MCS and the offset specified in
$NK_A_OFF. The position setpoint of the machine axis contains all the active work offsets and
corrections.
In accordance with the AXIS_LIN type entered in $NK_TYPE, the machine axis must be a
linear axis:
MD30300 $MA_IS_ROT_AX = 0

Syntax
$NK_AXIS[<n>] = <name>

Meaning

$NK_AXIS: Machine axis name

Data type: STRING
Range of values: Machine axis name
Default value: "" (empty string)
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)
<value>: Machine axis name
Data type: STRING
Range of values: Machine axis names

Example
The 9th kinematic element is assigned the machine axis with the name V1 as linear axis.

Program code Comment

N100 $NK_AXIS[8] = "V1" ; 9th kin. element
; axis = machine axis V1

$NK_A_OFF

Function
An additional work offset can be entered in the system variable for the assigned machine axis
($NK_AXIS). This work offset is only effective within the kinematic chain.

Syntax
$NK_A_OFF[<n>] = <value>

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Meaning

$NK_A_OFF: Work offset

Data type: REAL
Range of values: - max. REAL value ≤ x ≤ ± max. REAL value
Default value: 0.0
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)
<value>: Offset value
Data type: REAL
Range of values: - max. REAL value ≤ x ≤ ± max. REAL value

Example
The linear axis zero point of the 9th kinematic element is moved by 30.0 mm compared to the
modelled kinematics.
The unit in which the numerical value is interpreted depends on the current input system (inch/
metric).

Program code Comment

N100 $NK_A_OFF[8] = 30.0 ; 9th kin. element
; Work offset = 30.0 mm

5.2.3.7 Type-dependent variables for $NK_TYPE = "AXIS_ROT"

$NK_OFF_DIR

Function
The direction vector around which the rotary axis $NK_AXIS assigned to the element rotates,
should be entered in the system variable. The output coordinate system is therefore calculated
from the input coordinate system, rotated by the current position value of the rotary axis and
the offset specified in $NK_A_OFF around the direction vector $NK_OFF_DIR.
Supplementary conditions:
● The direction vector must be specified as an absolute value, i.e. in relation to the world
coordinate system.
● The direction vector must be specified so that, in accordance with the "right-hand rule", the
thumb points in the direction of the vector when the rotary axis turns in the positive direction.
● The absolute value of the direction vector must be greater than 1*10-6.

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Note
Spindle
If the assigned machine axis is a spindle, its position is taken into account in different ways
specific to the function:
● Collision avoidance: Indeterminate position
● Kinematic transformation: depending on the setting in $NT_CNTRL, bit 1-3
– Bit x == 0 → indeterminate position
– Bit x == 1 → current position value + $NK_A_OFF,

Syntax
$NK_OFF_DIR[<n>,<k>] = <value>

Meaning

$NK_OFF_DIR: Direction vector (X; Y; Z)

Data type: REAL
Range of values: Direction vector: 1*10-6 < |Vector | ≤ max. REAL value
Default value: (0.0, 0.0, 0.0)
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)
<k>: Coordinate index
Data type: INT
Range of values: 0: X coordinate (abscissa)
1: Y coordinate (ordinate)
2: Z coordinate (applicate)
<value>: Coordinate value
Data type: REAL
Range of values: - max. REAL value ≤ x ≤ + max. REAL value

Example
The rotary axis of the 9th element rotates around the direction vector. The direction vector is
the unit vector (1; 0; 0), rotated around Z with γ=90° in the X/Y plane, and around X with
α=10° in the Y/Z plane referred to the world coordinate system. The following values result
from this for the individual components (x, y, z) of the direction vector:
● x = cos(γ) * cos(α) = cos(90) * cos(10) = 0.0
● y = sin(γ) * cos(α) = sin(90) * cos(10) ≈ 0.985
● z = sin(α) = sin(10) ≈ 0.174

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))B ',5
 1 . B2
˞ _Y_ 
<

ˠ ]
[

; \

Figure 5-7 Direction vector, general

Program code Comment

; 9th kinematic element
N100 $NK_OFF_DIR[8,0] = COS(90)*COS(10) ; 0 = X component
N110 $NK_OFF_DIR[8,1] = SIN(90)*COS(10) ; 1 = Y component
N120 $NK_OFF_DIR[8,2] = SIN(10) ; 2 = Z component

$NK_AXIS

Function
The name of the machine axis (MD10000 $MN_AXCONF_MACHAX_NAME_TAB) that is to
be assigned to the element should be entered in the system variable.
The output coordinate system of the element results from the input coordinate system rotated
through the current position setpoint of the machine axis in the MCS and the offset specified
in $NK_A_OFF. The position setpoint of the machine axis contains all the active work offsets
and corrections.
The machine axis type must correspond to the type entered in $NK_TYPE:
In accordance with the AXIS_ROT type entered in $NK_TYPE, the machine axis must be a
rotary axis:
MD30300 $MA_IS_ROT_AX = 1

Syntax
$NK_AXIS[<n>] = <name>

Meaning

$NK_AXIS: Machine axis name

Data type: STRING
Range of values: Machine axis name
Default value: "" (empty string)
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)

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<value>: Machine axis name

Data type: STRING
Range of values: Machine axis names

Example
The 9th kinematic element is assigned the machine axis with the name B1 as rotary axis.

Program code Comment

N100 $NK_AXIS[8] = "B1" ; 9th kin. element
; axis = machine axis B1

$NK_A_OFF

Function
An additional work offset can be entered in the system variable for the assigned machine axis
($NK_AXIS). This work offset is only effective within the kinematic chain.

Syntax
$NK_A_OFF[<n>] = <value>

Meaning

$NK_A_OFF: Work offset

Data type: REAL
Range of values: - max. REAL value ≤ x ≤ ± max. REAL value
Default value: 0.0
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)
<value>: Offset value
Data type: REAL
Range of values: - max. REAL value ≤ x ≤ ± max. REAL value

Example
The rotary axis zero point of the 9th kinematic elements is moved through 30.0° compared to
the modelled kinematics.

Program code Comment

N100 $NK_A_OFF[8] = 30.0 ; 9th kin. element
; Work offset = 30.0°

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5.2.3.8 Type-dependent variables for $NK_TYPE = "ROT_CONST"

$NK_OFF_DIR

Function
The direction vector around which the constant rotation is performed should be entered in the
system variable. The output coordinate system is therefore calculated from the input coordinate
system, rotated through the angle specified in $NK_A_OFF around the direction vector
$NK_OFF_DIR.
Supplementary conditions:
● The direction vector must be specified as an absolute value, i.e. in relation to the world
coordinate system.
● The direction vector must be specified so that, in accordance with the "right-hand rule", the
thumb points in the direction of the vector when the rotary axis turns in the positive direction.
● The absolute value of the direction vector must be greater than 1*10-6.

Syntax
$NK_OFF_DIR[<n>,<k>] = <value>

Meaning

$NK_OFF_DIR: Direction vector (X; Y; Z)

Data type: REAL
Range of values: Direction vector: 1*10-6 < |Vector | ≤ max. REAL value
Default value: (0.0, 0.0, 0.0)
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)
<k>: Coordinate index
Data type: INT
Range of values: 0: X coordinate (abscissa)
1: Y coordinate (ordinate)
2: Z coordinate (applicate)
<value>: Coordinate value
Data type: REAL
Range of values: - max. REAL value ≤ x ≤ + max. REAL value

Example
The output coordinate system of the 9th Elements therefore arises from the input coordinate
system, rotated through the angle specified in $NK_A_OFF around the direction vector. The
direction vector is the unit vector (1; 0; 0), rotated around Z with γ=90° in the X/Y plane, and

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around X with α=10° in the Y/Z plane referred to the world coordinate system. The following
values result from this for the individual components (x, y, z) of the direction vector:
● x = cos(γ) * cos(α) = cos(90) * cos(10) = 0.0
● y = sin(γ) * cos(α) = sin(90) * cos(10) ≈ 0.985
● z = sin(α) = sin(10) ≈ 0.174

))B ',5
˞  1 . B2
<
)
$ B2 )
ˠ ] 1. B
[

; \

Figure 5-8 ROT_CONST

Program code Comment

; 9th kinematic element
N100 $NK_OFF_DIR[8,0] = COS(90)*COS(10) ; 0 = X component
N110 $NK_OFF_DIR[8,1] = SIN(90)*COS(10) ; 1 = Y component
N120 $NK_OFF_DIR[8,2] = SIN(10) ; 2 = Z component

$NK_A_OFF

Function
The angle through which the output coordinate system is rotated compared with the input
coordinate system around the direction vector $NK_OFF_DIR should be entered in the system
variable.

Syntax
$NK_A_OFF[<n>] = <value>

Meaning

$NK_A_OFF: Angle of rotation

Data type: REAL
Range of values: - max. REAL value ≤ x ≤ + max. REAL value
Default value: 0.0
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)

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<value>: Angle
Data type: REAL
Range of values: - max. REAL value ≤ x ≤ + max. REAL value

Example
The angle of rotation of the 9th kinematic element is 30.0°.

Program code Comment

N100 $NK_A_OFF[8] = 30.0 ; 9th kin. element
; Angle of rotation = 30.0°

5.2.3.9 Type-dependent variables for $NK_TYPE = "OFFSET"

$NK_OFF_DIR

Function
The offset vector by which the output coordinate system is moved compared to the input
coordinate system should be entered in the system variable.
The offset vector must be specified as an absolute value, i.e. in relation to the world coordinate
system.

Syntax
$NK_OFF_DIR[<n>,<k>] = <value>

Meaning

$NK_OFF_DIR: Offset vector (X; Y; Z)

Data type: REAL
Range of values: Offset vector: 0 ≤ vector ≤ (± max. REAL value)
Default value: (0.0, 0.0, 0.0)
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)
<k>: Coordinate index
Data type: INT
Range of values: 0: X coordinate (abscissa)
1: Y coordinate (ordinate)
2: Z coordinate (applicate)
<value>: Coordinate value
Data type: REAL
Range of values: - max. REAL value ≤ x ≤ + max. REAL value

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Example
The output coordinate system of the 9th Elements are obtained from the input coordinate
system, offset through offset vector (x, y, z) - with the following coordinates referred to the
world coordinate system:
● x = 10.0
● y = 20.0
● z = 30.0

=
))B ',5
 1 . B2
<
]
[

; \

Figure 5-9 Offset vector

Program code Comment

; 9th kinematic element
N100 $NK_OFF_DIR[8,0] = 10.0 ; 0 = X component
N110 $NK_OFF_DIR[8,1] = 20.0 ; 1 = Y component
N120 $NK_OFF_DIR[8,2] = 30.0 ; 2 = Z component

5.2.3.10 Type-dependent variables for $NK_TYPE = "SWITCH"

$NK_SWITCH_INDEX

Function
The switch is emulated using system variables $NK_SWITCH_INDEX and
$NK_SWITCH_POS (see the following paragraph)
Index i must be entered in $NK_SWITCH_INDEX, with which the switch is closed and opened
via system variable $NK_SWITCH[<i>].

Syntax
$NK_SWITCH_INDEX[<n>] = <i>

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Meaning

$NK_SWITCH_ Index i, via which the switch is addressed using system variable
INDEX: $NK_SWITCH[<i>]
Data type: INT
Range of values: -1, 0, 1, 2, ... ($MN_MAXNUM_NK_SWITCHES (Page 193) - 1)
-1: The state of the switch is always CLOSED
Default value: -1
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM
(Page 193) - 1)
<i>: Index value
Data type: INT

Example
The 9th element of the kinematic chain is a switch, which is activated by system variable
$NK_SWITCH[ 2 ].

Program code Comment

; 9th element
N100 $NK_SWITCH_INDEX[8] = 2 ; Index 2

$NK_SWITCH_POS

Function
A switch is emulated by system variables $NK_SWITCH_INDEX (see the previous paragraph)
and $NK_SWITCH_POS.
In $NK_SWITCH_POS, value p (close value) should be entered, where the switch is brought
into the CLOSED position by system variable $NK_SWITCH[<i>].
Independent of $NK_SWITCH[<i>], the switch has the following states:
● CLOSED: The close value p of the switch, specified in $NK_SWITCH_POS is the same as
the actual value of $NK_SWITCH[<i>].
$NK_SWITCH_POS[<n>] == $NK_SWITCH[<i>]
The previous element of the kinematic chain is connected with the output, i.e. the following
element of the switch specified in $NK_NEXT.
● OPEN: The close value of the switch, specified in $NK_SWITCH_POS, is not the same as
the actual value of $NK_SWITCH[<i>].
$NK_SWITCH_POS[<n>] ≠ $NK_SWITCH[<i>]
The previous element of the kinematic chain is notconnected with the output, i.e. the
following element of the switch specified in $NK_NEXT.

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The close value can be freely selected.

Note
Parallel element $NK_PARALLEL
The connection to a parallel element specified in $NK_PARALLEL is not influenced by the
switch. This means that the previous element is always connected to the element in the branch
parallel with the switch.

Syntax
$NK_SWITCH_POS[<n>] = <p>

Meaning

$NK_SWITCH_ Close value

POS: Data type: INT
Range of values: 0 ≤ x ≤ positive max. INT value
Default value: 0
<n>: System variable or element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_KIN_CHAIN_ELEM - 1)
<p>: Value for switch position CLOSED
Data type: INT

Example
The 9th element of the kinetic chain is a switch, which is closed if $NK_SWITCH[ 3 ] == 1

Program code Comment

; 9th element
N110 $NK_SWITCH_POS[8] = 1 ; switch position = 1

See also
$NK_SWITCH (Page 210)

5.2.3.11 $NK_SWITCH

Function
The switch variable comprises an array of switch positions i. The actual switch positions p
should be entered in this array.

Function
To parameterize (Page 208) a switchi in a kinematic chain, switchiwith index i must be
connected to the switch variable and its switch position p for the CLOSED state assigned to it.
$NK_SWITCH_INDEX[<n>] = <i>

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$NK_SWITCH_POS[<n>] = <p>
Switchi can then be closed and opened via index i of the switch variable:
Close: $NK_SWITCH[<i>] = <p>
Open: $NK_SWITCH[<i>] ≠ <p>
As many switches as required can be connected with an index of the switch variable.

Syntax
$NK_SWITCH[<i>] = <p>

Meaning

$NK_SWITCH<i>: Switch variable with switch positions i

Data type: INT
Value range: -1 ≤x ≤ positive max. INT value
Note
-1: Initial state OPEN
<i>: Switch index
Data type: INT
Range of values: 0, 1, 2, ... (MD18882 $MN_MM_MAX_NUM_KIN_SWITCHES
- 1)
<p>: Switch setting
Data type: INT
Value range: -1 ≤x ≤ positive max. INT value
-1: Initial state OPEN

Example
The 9th kinematic element is assigned the name "B axis":

Program code Comment

N100 $NK_SWITCH[3] = 1 ; actual switch position
; for switch [3] = 1

5.2.4 System variables, additive for orientation transformations

5.2.4.1 Overview

System variable Meaning

$NT_BASE_ORIENT Basic tool orientation
$NT_BASE_ORIENT_NORMAL Normal vector of the orientation

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System variable Meaning

$NT_ROT_AX_POS Axis positions of the orientation axes, which are parameterized as
constant rotations
$NT_POLE_LIMIT End angle tolerance with interpolation through pole
$NT_POLE_TOL End angle tolerance for pole interpolation
$NT_IGNORE_TOOL_ORIENT Always take tool orientation from $NT_BASE_ORIENT /
$NT_BASE_ORIENT_NORMAL.
$NT_CORR_ELEM Name of the chain elements that can be written to by the CORR‐
TRAFO(...) function.

The system variables are described in detail in the following sections.

Note
Element names
The system does not monitor as to whether the element names of the kinematic chain, which
are referenced to parameterize transformation, were allocated a multiple number of times. If
names such as these are available a multiple number of times, then the system data of the
transformation always refer to the corresponding element with the lowest index.
Establish a defined initial state
It is recommended that a defined initial state be generated before parameterizing the kinematic
chain. To do this, the system variables of the kinematic chain should be set to their default
value using function DELOBJ() (Page 213).
Change system variable values
Changes to system variable values of the transformation data $NT_... only become effective
when the NEWCONF machine data becomes effective. This can be done using the softkey
on the user interface in the operating area "Commissioning" > "Machine data " > "Set MD
active", in a program using the NEWCONF command or using a program end reset, channel
reset or a warm or cold restart.

5.2.5 System variables, additive for face transformation (TRANSMIT)

5.2.5.1 Overview

System variable Meaning

$NT_POLE_SIDE_FIX Limitation of the working area before and after the pole

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The system variables are described in detail in the following sections.

Note
Element names
The system does not monitor as to whether the element names of the kinematic chain, which
are referenced to parameterize transformation, were allocated a multiple number of times. If
names such as these are available a multiple number of times, then the system data of the
transformation always refer to the corresponding element with the lowest index.
Establish a defined initial state
It is recommended that a defined initial state be generated before parameterizing the kinematic
chain. To do this, the system variables of the kinematic chain should be set to their default
value using function DELOBJ() (Page 213).
Change system variable values
Changes to system variable values of the transformation data $NT_... only become effective
when the NEWCONF machine data becomes effective. This can be done using the softkey
on the user interface in the operating area "Commissioning" > "Machine data " > "Set MD
active", in a program using the NEWCONF command or using a program end reset, channel
reset or a warm or cold restart.

5.3 Programming

5.3.1 Deletion of components (DELOBJ)

The DELOBJ() function "deletes" components by resetting the assigned system variables to
their default values:
● Elements from kinematic chains
● Protection areas, protection area elements and collision pairs
● Transformation data

Syntax
[<RetVal>=] DELOBJ(<CompType>[,,,<NoAlarm>)])
[<RetVal>=] DELOBJ(<CompType>,<Index1>[,,<NoAlarm>])
[<RetVal>=] DELOBJ(<CompType>[,<Index1>][,<Index2>][,<NoAlarm>])

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Meaning

DELOBJ: Deletion of elements from kinematic chains, protection areas, protection area ele‐
ments, collision pairs and transformation data
<CompType>: Component type to be deleted
Data type: STRING
Value: "KIN_CHAIN_ELEM"
Meaning: System variables of all kinematic elements: $NK_...
Value: "KIN_CHAIN_SWITCH"
Meaning: System variable $NK_SWITCH[<i>]
Value: "KIN_CHAIN_ALL"
Meaning: All kinematic elements and switches.
Is the same as the successive call of DELOBJ with "KIN_CHAIN_ELEM" and
"KIN_CHAIN_SWITCH"
Value: "PROT_AREA"
Meaning: System variables of the protection areas:
● $NP_PROT_NAME
● $NP_CHAIN_NAME
● $NP_CHAIN_ELEM
● $NP_1ST_PROT
Value: "PROT_AREA_ELEM"
Meaning: System variables of the protection area elements of machine protection
areas and/or automatic tool protection areas:
● $NP_NAME
● $NP_NEXT
● $NP_NEXTP
● $NP_COLOR
● $NP_D_LEVEL
● $NP_USAGE
● $NP_TYPE
● $NP_FILENAME
● $NP_PARA
● $NP_OFF
● $NP_DIR
● $NP_ANG
Value: "PROT_AREA_COLL_PAIRS"
Meaning: System variables of the collision pairs:
● $NP_COLL_PAIR
● $NP_SAFETY_DIST
Value: "PROT_AREA_ALL"
Meaning: All protection areas, protection area elements and collision pairs (system
variable $NP_... )
Is the same as the successive call of DELOBJ with "PROT_AREA,"
"PROT_AREA_ELEM," and "PROT_AREA_COLL_PAIRS"
Value: "TRAFO_DATA"
Meaning: System variables of all transformations $NT_...

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<Index1>: Index of the first component to be deleted (optional)

Data type: INT
Default value: -1
Range of val‐ -1 ≤ x ≤ (maximum number of configured components -1)
ues:
Value Meaning
0, 1, 2, .... Index of the component to be deleted.
-1 All components of the specified type are deleted. <Index2> is not
evaluated.
<Index2>: Index of the last components to be deleted (optional)
If <Index2> is not programmed, only the system variables of the component refer‐
enced in <Index1> are deleted.
Data type: INT
Default value: Only the system variables of the component referenced in <In‐
dex1> are deleted.
Range of val‐ <Index1> < x ≤ (max. number of configured components -1)
ues:
<NoAlarm>: Alarm suppression (optional)
Data type: BOOL
Default value: FALSE
Value Meaning
FALSE In the event of an error (<RetVal> < 0), program processing is
stopped and an alarm displayed.
TRUE In the event of an error, the program processing is not stopped
and no alarm displayed.
Application: User-specific reaction corresponding to the return
value
<RetVal>: Function return value
Data type: INT
Range of val‐ 0, -1, -2, ... -7
ues:
Value Meaning
0 No error occurred.
-1 Call of the function without parameters. At least parameter
<CompType> must be specified.
-2 <CompType> identifies an unknown component
-3 <Index1> is less than -1
-4 <Index1> is greater than the configured number of components
-5 <Index1> has a value not equal to -1 when deleting a component
group
-6 <Index2> is less than <Index1>
-7 <Index2> is greater than the configured number of components

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5.3 Programming

5.3.2 Index determination by means of names (NAMETOINT)

User-specific names are entered in the system variable arrays of type STRING. Based on the
identifier of the system variables and the name, the NAMETOINT() function determines the
index value belonging to the name under which it is stored in the system variable array.

Syntax
<RetVal> = NAMETOINT(<SysVar>,<Name>[,<NoAlarm>])

Meaning

NAMETOINT: Determining the system variable index

<SysVar>: Name of the system variable array of typeSTRING
Data type: STRING
Range of val‐ Name of all NC system variable arrays of type STRING
ues:
<Name>: Character string or name for which the system variable index is to be determined.
Data type: STRING
<NoAlarm>: Alarm suppression (optional)
Data type: BOOL
Default value: FALSE
Value Meaning
TRUE In the event of an error, the program processing is not stopped
and no alarm displayed.
Application: User-specific reaction corresponding to the return
value
FALSE In the event of an error (<RetVal> < 0), program processing is
stopped and an alarm displayed.

<RetVal>: System variable index or error message

Data type: INT
Range of val‐ -1 ≤ x ≤ (max. number of configured components -1)
ues:
Value Meaning
≥0 The sought name has been found under the specified system
variable index.
-1 The sought name has not been found or an error has occurred.

Example
Program code Comment
DEF INT INDEX
$NP_PROT_NAME[27]="Cover"
...
INDEX = NAMETOINT("$NP_PROT_NAME","Cover") ; INDEX == 27

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5.4 Example

5.4 Example

5.4.1 Specifications

General Information
The principle approach when parameterizing a kinematic chain with three switches using a
part program is shown using as example a 5-axis machine with three different tool heads,
which are used alternating. All of the system variables, relevant for kinematic chain, are written
to the part program:
● Kinematic chain $NK_...

Option and machine data

The following option and machine data must be set for the example:

No. Option data: $ON_ Value

MD19830 COLLISION_MASK 1

No. Machine data: $MN_ Value

MD18880 MM_MAXNUM_KIN_CHAIN_ELEM 15

Kinematic chain

Schematic representation of the machine kinematics

 &$$;,6
2))6(7
$$;,6



&$;,6
&$;,62))6(7

722/5()



 
=$;,6







6+($'



6
;,
$
<

6+($'
;$;,6
6+($'

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5.4 Example

Elements of the kinematic chain

The kinematic chain (see next diagram) starts with an "Offset" type element. When completely
parameterizing the collision avoidance, these are assigned to all static protection areas of the
machine
The offset element is followed by the kinematic elements of the linear machine axes X, Y and
Z - as well as the offset and kinematic elements of rotary axes C and A.
The offset element for the reference point of the tool heads is followed by three switches to
switch on and switch off the tool heads. As a result of $NK_INDEX = 3 all three switches refer
to the same switch variable $NK_SWITCH[ 3 ]. As a result of the different switch positions (1,
2, 3), only the subchain of the active tool head is active.

5RRW ;$;,6 <$;,6 =$;,6 &$;,6 &$;,6

2))6(7 $;,6B/,1 $;,6B/,1 $;,6B/,1 2)) $;,6B527
 2))6(7


'2&.B3B +($'
6:,7&+ 2))6(7
 

'2&.B3B +($'
6:,7&+ 2))6(7
 

&$$;,6 $$;,6 722/5() '2&.B3B +($'

2)) $;,6B527 2))6(7 6:,7&+ 2))6(7
2))6(7   


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5.4 Example

5.4.2 Part program of the machine model

Program code
;===========================================================
; Definitions
;===========================================================
N10 DEF INT KIE_CNTR ; COUNTER FOR ELEMENTS OF THE KIN. CHAINS
N20 DEF INT RETVAL
;
;===========================================================
; Initialization of collision data
;===========================================================
; Reset all parameters to their initial values:
N30 RETVAL = DELOBJ("KIN_CHAIN_ELEM")
N40 KIE_CNTR = 0
;
;===========================================================
; Kinematic chain
;===========================================================
; KE1: OFFSET: Root
; ----------------------------------------------------------
N50 $NK_TYPE[KIE_CNTR] = "OFFSET"
N60 $NK_NAME[KIE_CNTR] = "ROOT"
N70 $NK_NEXT[KIE_CNTR] = "X-AXIS"
N80 KIE_CNTR = KIE_CNTR + 1
;
; ----------------------------------------------------------
; Kinematic element: LINEAR AXIS: X axis
; ----------------------------------------------------------
N90 $NK_TYPE[KIE_CNTR] = "AXIS_LIN"
N100 $NK_NAME[KIE_CNTR] = "X-AXIS"
N110 $NK_NEXT[KIE_CNTR] = "Y-AXIS"
N120 $NK_AXIS[KIE_CNTR] = "X1"
;
N130 $NK_OFF_DIR[KIE_CNTR,0] = 1.0 ; X
N140 KIE_CNTR = KIE_CNTR + 1
;
; ----------------------------------------------------------
; Kinematic element: LINEAR AXIS: Y axis
; ----------------------------------------------------------
N150 $NK_TYPE[KIE_CNTR] = "AXIS_LIN"
N160 $NK_NAME[KIE_CNTR] = "Y-AXIS"
N170 $NK_NEXT[KIE_CNTR] = "Z-AXIS"
N180 $NK_AXIS[KIE_CNTR] = "Y1"
;
N190 $NK_OFF_DIR[KIE_CNTR,1] = 1.0 ; Y
N200 KIE_CNTR = KIE_CNTR + 1
;
; ----------------------------------------------------------
; Kinematic element: LINEAR AXIS: Z axis
; ----------------------------------------------------------
N210 $NK_TYPE[KIE_CNTR] = "AXIS_LIN"
N220 $NK_NAME[KIE_CNTR] = "Z-AXIS"
N230 $NK_NEXT[KIE_CNTR] = "C-AXIS-OFFSET"
N240 $NK_AXIS[KIE_CNTR] = "Z1"
;

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5.4 Example

Program code
N250 $NK_OFF_DIR[KIE_CNTR,2] = 1.0 ; Z
N260 KIE_CNTR = KIE_CNTR + 1
;
; ----------------------------------------------------------
; Kinematic element: OFFSET: C axis
; ----------------------------------------------------------
N270 $NK_TYPE[KIE_CNTR] = "OFFSET"
N280 $NK_NAME[KIE_CNTR] = "C-AXIS-OFFSET"
N290 $NK_NEXT[KIE_CNTR] = "C-AXIS"
;
N300 $NK_OFF_DIR[KIE_CNTR,2] = 600.0 ; Z direction
N310 KIE_CNTR = KIE_CNTR + 1 ;
;
; ----------------------------------------------------------
; Kinematic element: ROTARY AXIS: C axis
; ----------------------------------------------------------
N320 $NK_TYPE[KIE_CNTR] = "AXIS_ROT"
N330 $NK_NAME[KIE_CNTR] = "C-AXIS"
N340 $NK_NEXT[KIE_CNTR] = "C-A-OFFSET"
N350 $NK_AXIS[KIE_CNTR] = "C1"
;
N360 $NK_OFF_DIR[KIE_CNTR,2] = 1.0 ; Z direction
N370 KIE_CNTR = KIE_CNTR + 1
;
; ----------------------------------------------------------
; Kinematic element: OFFSET: C-A axis
; ----------------------------------------------------------
N380 $NK_TYPE[KIE_CNTR] = "OFFSET"
N390 $NK_NAME[KIE_CNTR] = "C-A-OFFSET"
N400 $NK_NEXT[KIE_CNTR] = "A-AXIS"
;
N410 $NK_OFF_DIR[KIE_CNTR,0] = 20.0 ; X direction
N420 $NK_OFF_DIR[KIE_CNTR,1] = -5.0 ; Y direction
N430 KIE_CNTR = KIE_CNTR + 1
;
; ----------------------------------------------------------
; Kinematic element: ROTARY AXIS: A axis
; ----------------------------------------------------------
N440 $NK_TYPE[KIE_CNTR] = "AXIS_ROT"
N450 $NK_NAME[KIE_CNTR] = "A-AXIS"
N460 $NK_NEXT[KIE_CNTR] = "TOOL-REF"
N470 $NK_AXIS[KIE_CNTR] = "A1"
;
N480 $NK_OFF_DIR[KIE_CNTR,0] = 1.0 ; X direction
N490 KIE_CNTR = KIE_CNTR + 1
;
; ----------------------------------------------------------
; Kinematic element: OFFSET: Tool reference
; ----------------------------------------------------------
N500 $NK_TYPE[KIE_CNTR] = "OFFSET"
N510 $NK_NAME[KIE_CNTR] = "TOOL-REF"
N520 $NK_NEXT[KIE_CNTR] = "DOCKING_POINT 1"
;
N530 $NK_OFF_DIR[KIE_CNTR,2] = -200.0 ; Z direction
N540 KIE_CNTR = KIE_CNTR + 1
;

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Program code
; ----------------------------------------------------------
; Kinematic element: Switch 3/1
; ----------------------------------------------------------
N550 $NK_TYPE[KIE_CNTR] = "SWITCH"
N560 $NK_NAME[KIE_CNTR] = "DOCKING_POINT 1"
N570 $NK_NEXT[KIE_CNTR] = "HEAD 1"
N580 $NK_PARALLE[KIE_CNTR] = "DOCKING_POINT 2"
;
N590 $NK_SWITCH_INDEX[KIE_CNTR] = 3 ; Index 3
N600 $NK_SWITCH_POS[KIE_CNTR] = 1 ; switch position 1
N610 KIE_CNTR = KIE_CNTR + 1
;
; ----------------------------------------------------------
; Kinematic element: Switch 3/2
; ----------------------------------------------------------
N620 $NK_TYPE[KIE_CNTR] = "SWITCH"
N630 $NK_NAME[KIE_CNTR] = "DOCKING_POINT 2"
N640 $NK_NEXT[KIE_CNTR] = "HEAD 2"
N650 $NK_PARALLE[KIE_CNTR] = "DOCKING_POINT 3"
;
N660 $NK_SWITCH_INDEX[KIE_CNTR] = 3 ; Index 3
N670 $NK_SWITCH_POS[KIE_CNTR] = 2 ; switch position 2
N680 KIE_CNTR = KIE_CNTR + 1
;
; ----------------------------------------------------------
; Kinematic element: Switch 3/3
; ----------------------------------------------------------
N690 $NK_TYPE[KIE_CNTR] = "SWITCH"
N700 $NK_NAME[KIE_CNTR] = "DOCKING_POINT 3"
N710 $NK_NEXT[KIE_CNTR] = "HEAD 3"
N720 $NK_PARALLE[KIE_CNTR] = ""
N730 $NK_SWITCH_INDEX[KIE_CNTR] = 3 ; Index 3
N740 $NK_SWITCH_POS[KIE_CNTR] = 3 ; switch position 3
N750 KIE_CNTR = KIE_CNTR + 1
;
; ----------------------------------------------------------
; Kinematic element: OFFSET: HEAD 1
; ----------------------------------------------------------
N760 $NK_TYPE[KIE_CNTR] = "OFFSET"
N770 $NK_NAME[KIE_CNTR] = "HEAD 1"
N780 $NK_NEXT[KIE_CNTR] = ""
;
N790 $NK_OFF_DIR[KIE_CNTR,0] = 100 ; X direction
N800 $NK_OFF_DIR[KIE_CNTR,1] = -30 ; Y direction
N810 KIE_CNTR = KIE_CNTR + 1
;
; ----------------------------------------------------------
; Kinematic element: OFFSET: HEAD 2
; ----------------------------------------------------------
N820 $NK_TYPE[KIE_CNTR] = "OFFSET"
N830 $NK_NAME[KIE_CNTR] = "HEAD 2"
N840 $NK_NEXT[KIE_CNTR] = ""
;
N850 $NK_OFF_DIR[KIE_CNTR,2] = -230 ; Z direction
N860 KIE_CNTR = KIE_CNTR + 1
;

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5.5 Data lists

Program code
; ----------------------------------------------------------
; Kinematic element: OFFSET: HEAD 3
; ----------------------------------------------------------
N870 $NK_TYPE[KIE_CNTR] = "OFFSET"
N880 $NK_NAME[KIE_CNTR] = "HEAD 3"
N890 $NK_NEXT[KIE_CNTR] = ""
;
N900 $NK_OFF_DIR[KIE_CNTR,0] = 50 ; X direction
N910 $NK_OFF_DIR[KIE_CNTR,1] = -20 ; Y direction
N920 $NK_OFF_DIR[KIE_CNTR,2] = -90 ; Z direction
N930 KIE_CNTR = KIE_CNTR + 1
End

5.5 Data lists

5.5.1 Machine data

5.5.1.1 NC-specific machine data

Number Identifier: $MN_ Description

16800 ROOT_KIN_ELEM_NAME Name of the first element in the kinematic chain
18880 MM_MAXNUM_KIN_CHAIN_ELEM Maximum number of elements for kinematic chains

5.5.2 System variables

Identifier Description
$NK_NAME Name of the kinematic element
$NK_NEXT Name of the next element in the kinematic chain
$NK_PARALLEL Name of the first element of a parallel branching kinematic chain before the
element
$NK_TYPE Type of the kinematic element
$NK_OFF_DIR Depends on $NK_TYPE: Offset or direction vector
$NK_AXIS Name of the assigned machine axis or object name
$NK_A_OFF Work offset in the element for linear or rotary axes
$NK_SWITCH_INDEX Index i, via which the switch is addressed using system variable
$NK_SWITCH[<i>]
$NK_SWITCH_POS Switch position CLOSED
$NK_SWITCH Switch variable

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6.1 Function description

6.1.1 Features
This section describes how the geometry of machine parts can be mapped based on protection
areas and parameterized in the control using system variables for NC functions such as
"collision avoidance".
The system variables are retentatively saved in the NC and can be archived and/or read as
"NC data" via SINUMERIK Operate using the commissioning archive.
By assigning a protective area to an element of the kinematic chain (Page 187) described in
the previous section, the position and motion of the machine part can be clearly described
within the machine space.

Note
Graphic editor
As an alternative to writing the system variables in a part program, the machine can be modeled
from the SINUMERIK Operate user interface:
Operating area: "Commissioning" > "NC" > "Machine model"
Changes to the machine model
The direct changes to the machine model at the system variables only become visible at the
user interface after activating with PROTA or PROTS . Changes to the machine model made at
the user interface are immediately adopted in the system variables.

Protection area
The protection areas are the central element when geometrically modeling a machine. The
geometric dimensions of a machine part, its reference to the kinematic chain and additional
general features are described by a protection area.
A protection area has the following parameters:
● Name of the protection area
● Name of the kinematic element to which the protection area is assigned
● Type of the protection area
● Name of the first protection area element
● Color and transparency of the protection area
● Detail level for the protection area
● Number of NC/PLC interface bits of the protection area

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6.1 Function description

● Initialization status of the protection area

● Address of the geometric data of the machine element to the protected
(only relevant for automatic protection areas)
Each parameter is mapped by a system variable. The individual parameters and/or system
variables are described in detail in Chapter "System variables: Protection areas (Page 233)".

Kinematic chain
The corresponding protection area is assigned to an element of the kinematic chain in order
to map the position and motion of a machine part. The geometric data of the protection area
relates then to the local coordinate system of this kinematic element.

Type of the protection area

The following types of protection areas are available:
● Machine protection areas (type: "MACHINE")
Machine protection areas are used for general machine modeling. They are used to map
stationary and moving machine parts whose geometry is defined once upon commissioning
and no longer changes when the machine is in operation.
● Automatic tool protection areas (type: "TOOL")
Automatic machine protection areas are used to map tools. The geometry of the tool is not
provided directly with this but is produced automatically by the control when the tool is
activated.
See section "Automatic tool protection areas (Page 226)".

Protection area element

Using a protection area element, the geometrical element used is described regarding its
geometrical and general properties.
A protection area element has the following parameters:
● Name of the protection area element
● Name of the following protection area element
● Name of the following protection area element parallel to $NP_NEXT
● Color and transparency of the protection area element
● Detail level for the protection area element
● Use of the protection area element
● Type of the protection area element
● File name of the STL file that contains the geometric data of the protection area element
(only relevant for type "FILE")
● Geometrical parameters of the protection area body
(only relevant for types, "BOX", "SPHERE" or "CYLINDER")
● Offset vector of the protection area element local coordinate system
● Direction vector for the rotation of the protection area element local coordinate system
● Angle for the rotation of the protection area element local coordinate system

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6.1 Function description

Each parameter is mapped by a system variable. The individual parameters or system

variables are described in detail in:
● Chapter "System variables: Protection area elements for machine protection areas
(Page 244)"
● Chapter "System variables: Protection area elements for automatic tool protection areas
(Page 262)"

Protection area, protection area elements and kinematic chain

Using an example of a protection area with two protection area elements, the following diagram
shows the interrelationship between the protection area, its protection area elements and the
assignment to an element of the kinematic chain.

VH 
.LQHPDWLFFKDLQ ]
V
H H \

VH 
] [
V
Y

VH \
[

VH VH 
=
VH

*HRPHWULFPDFKLQHPRGHOLQJ 
<
; H H
0DFKLQHFRRUGLQDWHV\VWHP

:RUOGFRRUGLQDWHV\VWHP

e1 Kinematic element 1, type "OFFSET", continuous offset

e2 Kinematic element 2, type "AXIS_LIN", machine axis AX1
s1 Protection area
se1 Protection area element 1, type "FRAME", offset
se2 Protection area element 2, type "BOX"
se3 Protection area element 3, type "CYLINDER"

Figure 6-1 Protection area, protection area elements and kinematic chain

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6.1 Function description

6.1.2 Automatic tool protection areas

Unlike machine protection areas whose geometry is defined once during the machine modeling
and then no longer changes, the geometry of a tool protection area can change with every tool
change. As a result the geometry of an automatic tool protection area is not described directly
when the machine model is created, and instead the address (magazine number, magazine
location, etc.) is provided under which the tool data is stored. The following actions are then
carried out automatically by the control.
1. The tool modeling (see "Tool modeling" section below) produces an STL file.
2. A protection area element of the "FILE" type is produced and assigns the STL file.
3. The protection area element is assigned to the protection area (type "TOOL").

Tool definition independent of the tool mounting position

Normally the parameter "$NP_1ST_PROT (Page 237)" remains empty for the definition of a
tool protection area. The name of the protection area element is only entered when the tool is
activated by the control (see above).
In order for there to be a tool definition independently of the tool mounting position, a protection
area element of the "FRAME (Page 252)" type can be assigned via the parameter
"$NP_1ST_PROT" (transformation element). The transformations to align the tool can be
carried out via this additional element. When a tool is activated the name of the internal
protection area element is entered in the parameter "$NP_NEXT (Page 246)" of the
transformation element by the control.
The following rules must be observed:
● The transformation element may only be of the "FRAME" type.
● Only one transformation element may be used for each tool protection area.
● The parameter "$NP_NEXTP" of the transformation element is not evaluated.

Tool reference point

The position of the tool reference point in the machine model is determined by the kinematic
element to which the tool protection area is assigned. In addition the tool reference point can
be offset within the tool protection area by an optional transformation element.

Kinematic transformations
The tool reference point may only be determined via the kinematic chain when defining a
kinematic transformation. Offsets by the transformation element of the tool protection area are
not taken into account.

NOTICE
Determination of the tool reference point for kinematic transformations
Offsets of the tool reference point by the transformation element of the tool protection area
are not taken into account by kinematic transformations.

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6.1 Function description

Tool modeling
The model of a tool is created by the control heuristically from the tool data. The tool data used
for this (L1, L2, L3, R) is always the the overall dimensions resulting from the individual
components, e.g. length plus wear, as is also entered in the program processing for tool offset.

Programmable tool offsets

Programmable tool offsets such as OFFN (offset to the programmed contour) are not taken
into account as they may change in any block, even without a tool change.

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6.1 Function description

Tool type-dependent model generation

The following tool types are distinguished for the model generation:
● Milling tool and all other tools that are neither turning tools or grinding tools
– Modeling
The tool is modeled by a cylinder with the height L1 and radius R. If the length L1 is
negative the absolute value of L1 is used for the cylinder height. The sign L1 is taken
into account when positioning the cylinder in the machine model. The cylinder axis is
parallel to L1.
Tool type 110 (ball end mill cutter) and 111 (face cutter) are modeled using half a sphere
or sphere segments.
If the radius is negative the absolute value of the radius is used. If the value for the radius
is less than 1/3 mm, a radius of 1/3 mm is used.
– Positioning
The cylinder is positioned in the machine model using the tool length components L2
and L3.
For milling tools (tool type 100 ... 199) and drilling tools (tool type 200 ... 299) on turning
machines the cylinder is positioned using the cutting edge position.
Precondition: Cutting edge position == 5 ... 8
● Grinding tools
– Modeling
Grinding tools (grinding wheel, tool type 400 ... 499) are modeled by a cylinder with the
tool length as the radius and double the tool radius as the height.
– Positioning
The cylinder is positioned in the machine model using the tool lengths L1, L2 and L3.
● Turning tools
In the case of turning tools only the cutting tips are taken into account in the machine model
but not their connection to the tool reference point.
The following data is taken into account when modeling a cutting tip:
– Tool type
– Cutting edge position
– Cutting edge radius
– Clearance angle
– Holder angle
– Cutting tip length
– Cutting tip width
– Tip thickness (assumption: tip thickness = 10% tip length)

Tool model
A tool is modeled as standard with an accuracy of one third of the collision tolerance
(Page 279). The geometric data of the modeled tool is stored in an internal file in STL format:
● Directory: _N_PROT3D_DIR/_N_TOOL_DIR
● Identifiers: Name of the associated protection area with prefix _N_ and ending with _STL

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6.2 Commissioning

The coordinate system of the geometric data always has its origin at the point from which the
tool length offsets point to the tip of the tool.

System variable
All parameters for an automatic tool protection area can be read via System variable
(Page 244).

6.2 Commissioning

6.2.1 General

6.2.1.1 Overview
The commissioning of the "Collision avoidance" function is performed using:
● Machine data
– Specifications for the quantity structure of protection areas, protection area elements,
NC/PLC interface signals, triangles for the geometry modelling
– Creation mode of the machine model
– Creation mode for automatic tool protection areas
● System variables
– Parameterization of the protection areas
– Parameterization of the protection area elements of a protection area

6.2.1.2 Structure of the system variables

The system variables are structured according to the following scheme:
● $NP_<name>[<index_1>]
● $NP_<name>[<index_1>, <index_2>]

General
The system variables to describe the protection areas or protection area elements have the
following properties:
● Prefix: $NP_, (N for NC, P for protection).
● They can be read and written via NC programs.
● They can be stored in archives and loaded to the NC again.

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6.2 Commissioning

Data type

STRING
All system variables of the STRING data type have the following properties:
● Maximum string length: 31 characters
● No distinction is made between upper and lower case
Example: "Axis1" is identical to "AXIS1"
● Spaces and special characters are permitted
Example: "Axis1" is not identical to "Axis 1"
● Names that start with two underscores "__" are reserved for system purposes and must
not be used for user-defined names.
Note
Leading space
Since spaces are valid and distinct characters, names that start with a space followed by two
underscores "__" can, in principle, be used for user-defined names. However, because they
can be easily mistaken for system names, this procedure is not recommended.

Index_1

System variables for protection areas

The individual protection areas are addressed via index_1. Index 0 → 1st protection area, index
1 → 2nd protection area, ... m → (m+1) protection area, where m =
($MN_MM_MAXNUM_3D_PROT_AREAS - 1)
All system variables of a protection area have the same index.

System variables for protection areas elements

The individual protection area elements are addressed via index_1. Index 0 → 1st protection
area element, index 1 → 2nd protection area element, ... n → (n+1)th protection area element,
where n = ($MN_MM_MAXNUM_3D_PROT_AREA_ELEM - 1)
All system variables of a protection area element have the same index.

Index_2
Depending on the respective system variables, index_2 has different meanings.

See also
Deletion of components (DELOBJ) (Page 213)

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6.2 Commissioning

6.2.1.3 Color chart

The following color chart provides an overview of the RGB color values and the associated
colors. A RGB color value comprises three bytes. One byte per color:

3rd byte 2nd byte 1st byte

Color value for red Color value for green Color value for blue
0 - 255D or 0 - FFH 0 - 255D or 0 - FFH 0 - 255D or 0 - FFH

    && )) )) &&     )) )) )) )) ))&& ))))

    && )) )) &&     )) )) )) )) ))&& ))))

    && )) )) &&     )) )) )) )) ))&& ))))

    && )) )) &&     )) )) )) )) ))&& ))))

&& && && && &&& ))&& ))&& &&& && && && && ))&& ))&& ))&& ))&& ))&&&& ))))&&

)) )) )) )) &&)) )))) )))) &&)) )) )) )) )) )))) )))) )))) )))) ))&&)) ))))))

)) )) )) )) &&)) )))) )))) &&)) )) )) )) )) &&)) &&)) &&)) &&)) &&&&)) &&))))

&& && && && &&& ))&& ))&& &&&& && && && && &&&& &&&& &&&& &&&& &&&&&& &&))&&

    && )) )) &&     && && && && &&&& &&))

    && )) )) &&     && && && && &&&& &&))

    && )) )) &&     && && && && &&&& &&))

    && )) )) &&     && && && && &&&& &&))

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6.2 Commissioning

6.2.2 Machine data

6.2.2.1 Maximum number of protection areas

The maximum number of all types of parameterizable protection areas (Page 236) is specified
with the machine data.
MD18890 $MN_MM_MAXNUM_3D_PROT_AREAS = <number>

6.2.2.2 Maximum number of protection area elements for machine protection areas
The maximum number of parameterizable protection area elements for machine protection
areas is specified using machine data ($NP_PROT_TYPE == "MACHINE" (Page 236)).
MD18892 $MN_MM_MAXNUM_3D_PROT_AREA_ELEM = <number>

6.2.2.3 Maximum number of protection area elements for automatic tool protection areas
The maximum number of protection area elements for automatic tool protection areas is
specified with the machine data. For each automatic tool protection area the control precisely
creates one protection area element. As a consequence, using the value parameterized here,
the maximum possible number of parameterizable automatic tool protection areas
($NP_PROT_TYPE == "TOOL" (Page 236)) is also simultaneously defined.
MD18893 $MN_MM_MAXNUM_3D_T_PROT_ELEM = <number>

6.2.2.4 Maximum number of NC/PLC interface signals for the preactivation of protection areas
The control is informed of the maximum number of used NC/PLC interface signals of interface
DB10, DBX234.0 - DBX241.7 (Page 833) (collision avoidance: activate protection area) with
the machine data. The number of interface signals used increases the memory space required
for each part program block. Counting the number of used NC/PLC interface signal starts at
DB10, DBX234.0
MD18897 $MN_MM_MAXNUM_3D_INTERFACE_IN = <number>

6.2.2.5 Maximum number of triangles for machine protection areas

With the machine data, the maximum number of triangles for protection area bodies
($NP_TYPE == "FILE" (Page 252)) of machine protection areas ($NP_PROT_TYPE ==
"MACHINE" (Page 236)) to be provided by the control is defined.
MD18895 $MN_MM_MAXNUM_3D_FACETS = <number>

6.2.2.6 Maximum number of triangles for automatic tool protection areas

With the machine data, the maximum number of triangles for protection area bodies of
automatic tool protection areas to be provided by the control is defined.
MD18894 $MN_MM_MAXNUM_3D_FACETS_INTERN = <number>

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The control system automatically models the protection area bodies based on the geometric
data of the tool active at the time of creation. The number of triangles correspondingly
increases:
● as the geometric complexity of the tool increases.
● as the parameterized collision tolerance decreases.

Note
Protection area bodies and collision tolerance
The protection area bodies of automatic tool protection areas are, as standard, created by the
control with a precision of 1/3 of the collision tolerance (Page 279).

6.2.2.7 Creation mode for automatic tool protection areas

The machine data defines how the control creates protection area bodies of automatic tool
protection areas.
MD18899 $MN_PROT_AREA_TOOL_MASK = <mode>

<Mode>
Bit Val‐ Meaning
ue
0 0 Do not apply heuristic model generation
1 Heuristic model generation using tool data

6.2.3 System variables: Protection areas

6.2.3.1 Overview
A protection area is parameterized with the following system variables:

Name Meaning
$NP_PROT_NAME Name of the protection area
$NP_CHAIN_ELEM Name of the kinematic element to which the protection area is as‐
signed
$NP_PROT_TYPE Type of the protection area
$NP_1ST_PROT Name of the first protection area element
$NP_PROT_COLOR Color and transparency of the protection area.
$NP_PROT_D_LEVEL Detail level for the protection area
$NP_BIT_NO Number of NC/PLC interface bits of the protection area
$NP_INIT_STAT Initialization status of the protection area
$NP_INDEX Address of the geometric data of the machine element to be protected
(only relevant for automatic protection areas)

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The system variables are described in detail in the following sections.

Note
Establish a defined initial state
It is recommended that a defined initial state be generated before parameterizing the protection
areas. To do this, set the system variables of the protection areas to their default values with
the DELOBJ() (Page 213) function.
Change system variable values
If the value of one of the system variables listed above is changed, the change becomes
immediately visible at the user interface, e.g. SINUMERIK Operate. The machine model of the
NC is only updated after explicitly requesting that the machine model is recalculated by calling
the PROTA() (Page 289) or PROTS() (Page 290) function.

6.2.3.2 $NP_PROT_NAME

Function
Enter the NC-wide unique protection area name in the system variable. The protection area
is referenced via this name, e.g. by a protection area element. The name is also displayed in
the graphical editor of SINUMERIK Operate.

Syntax
$NP_PROT_NAME[<m>] = "<name>"

Meaning

$NP_PROT_NAME: Name of the protection area

Data type: STRING
Default value: "" (empty string)
<m>: System variable or protection area index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_3D_MAXNUM_PROT_AREAS - 1)
<name>: Name of the protection area
Data type: STRING

Example
The 6th protection area is assigned the name "Spindle":

Program code Comment

N100 $NP_PROT_NAME[5] = "Spindle" ; 6. Protection area,
; name = "Spindle"

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6.2.3.3 $NP_CHAIN_ELEM

Function
Enter the name of the kinematic element (Page 195) to which the protection area will be
connected in the system variable.

Note
Reference coordinate system
The geometric data of the protection area, starting from the first protection area element
($NP_1ST_PROT (Page 237)), refer to the local coordinate system of the kinematic element,
with which the protection area is connected.

Syntax
$NP_CHAIN_ELEM[<m>] = "<name>"

Meaning

$NP_CHAIN_ELEM: Name of the kinematic element to which the protection area will be connected
Data type: STRING
Default value: "" (empty string)
<m>: System variable or protection area index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_3D_MAXNUM_PROT_AREAS - 1)
<name>: Name of the kinematic element
Data type: STRING
Range of values: Names parameterized in $NK_NAME (Page 195)

Example
The 6th protection area is connected to the kinematic element with the name "Z axis":

Program code Comment

N100 $NP_CHAIN_ELEM[5] = "Z ax- ; 6. Protection area,
is" ; name of the kin. element: "Z axis"

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6.2.3.4 $NP_PROT_TYPE

Function
The protection area type should be entered in the system variable:

Type Description
MACHINE Machine protection area
The protection area body is defined using one or several protection area elements.
$NP_1ST_PROT (Page 237) refers to the first protection area element.
TOOL Automatic tool protection area
The control calculates the dimensions of the protection area body from the tool data.
$NP_INDEX (Page 243) refers to the tool.

Syntax
$NP_PROT_TYPE[<m>] = "<type>"

Meaning

$NP_PROT_TYPE: Type of the protection area

Data type: STRING
Range of values: "MACHINE", "TOOL"
Default value: "" (empty string)
<m>: System variable or protection area index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_3D_MAXNUM_PROT_AREAS - 1)
<Type>: Type
Data type: STRING

Example
The 6th protection area is a machine protection area:

Program code Comment

N100 $NP_PROT_TYPE[5] = "MACHINE" ; 6. Protection area,
; type = "MACHINE"

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6.2.3.5 $NP_1ST_PROT

Function
Enter the name of the first protection area element (Page 245) in the system variable.

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Syntax
$NP_1ST_PROT[<m>] = "<name>"

Meaning

$NP_1ST_PROT: Name of the first protection area element of the protection area
Data type: STRING
Range of values: Names parameterized in $NP_NAME (Page 245)
Default value: "" (empty string)
<m>: System variable or protection area index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_3D_MAXNUM_PROT_AREAS - 1)
<name>: Protection area name
Data type: STRING

Automatic tool protection areas, $NP_PROT_TYPE == "TOOL"

For automatic tool protection areas, only the following values are permissible for
$NP_1ST_PROT:
● "" (empty string)
● Name of a protection area element, type "FRAME"

Behavior for value == "" (empty string)

When activating the associated tool, the control creates a protection area element for the tool
with a unique, internal name and protection area body generated from the geometric data of
the tool. The name is assigned system variable $NP_1ST_PROT.
● Protection area "TOOL" : $NP_1ST_PROT = "<internal name>"
The coordinates of the tool protection area refer to the local coordinate system of the kinematic
element to which it is assigned.

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Behavior for value == name of a protection area element, type "FRAME"

When activating the associated tool, the control creates a protection area element for the tool
with a unique, internal name and protection area body generated from the geometric data of
the tool. The name is assigned a system variable $NP_NEXT of the protection area element,
type "FRAME", to which $NP_1ST_PROT refers.
● Protection area "TOOL" : $NP_1ST_PROT = "WKZ_Frame" →
– Protection area element "WKZ_Frame" : $NP_NEXT = "<internal name>"
The coordinates of the tool protection area refer to the local coordinate system of the protection
area element, type "FRAME".
Possible applications: Tool definition independent of the position where it is mounted on the
machine.

Example
The 1st protection area element which makes up the 6th protection area has the name "Spindle
head":

Program code Comment

N100 $NP_1ST_PROT[5] = "Spindle head" ; 6. Protection area,
; 1. Protection area element =
"spindle box"

6.2.3.6 $NP_PROT_COLOR

Function
Enter the protection area element-specific value for alpha/transparency and color (ARGB) in
the system variable. This value is used for the display of the protection area or protection area
element on the user interface. If a separate value is entered for a protection area element in
$NP_COLOR (Page 249), this is used for the display of the protection area element.

Structure
Alpha/transparency and color are specified as a double word in hexadecimal format:
AARRGGBBH
● 1. - 3. Byte: RGB color value. See Chapter "Color chart (Page 231)".
● 4. Byte: Alpha channel or transparency value

Byte Meaning Range of values

OC 1 Blue 0 - 255D or 0 - FFH
GG 2 Green
RR 3 Red
AA 4 Alpha channel or transparency 1)
1) 0 = transparent or not visible, 255D = FFH = not transparent or filled

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Syntax
$NP_PROT_COLOR[<m>] = <value>

Meaning

$NP_PROT_COLOR: Alpha/transparency and color value of the protection area

Data type: DWORD
Range of values: 00000000H - FFFFFFFFH
Default value: 0000000H (black, not visible)
<m>: System variable or protection area index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_3D_MAXNUM_PROT_AREAS - 1)
<value>: Transparency and color value
Data type: DWORD

Example
The 6th protection area is to be displayed half transparent and in a green-blue color on the
user interface:
● AA = 7FH = 127D ≙ 50% transparency
● RR (red) = 00 ≙ no red component
● GG (green) = FFH = 255D ≙ 100% green color component
● BB (blue) = 33H = 51D ≙ 20% blue color component

Program code Comment

N100 $NP_PROT_COLOR[5] = 'H7F00FF33' ; 6. Protection area,
; alpha/transparency and color
value = H7F00FF33

6.2.3.7 $NP_PROT_D_LEVEL

Function
The detail level as of which the protection area or the protection area elements are displayed
on the user interface is specified via the system variable. If a separate value is entered for a
protection area element in $NP_D_LEVEL (Page 250), this is used for the display of the
protection area element.

Detail level
● Lowest detail level: 0
● Highest detail level: 3
If the detail level x is selected for the display on the HMI, all protection areas and protection
area elements are displayed for which the following applies for the detail level D: D ≤ x

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Syntax
$NP_PROT_D_LEVEL[<m>] = <value>

Meaning

$NP_PROT_D_LEVEL: Detail level for the protection area

Data type: INT
Range of val‐ 0≤D≤3
ues:
Default value: 0
<m>: System variable or protection area index
Data type: INT
Range of val‐ 0, 1, 2, ... ($MN_MM_3D_MAXNUM_PROT_AREAS - 1)
ues:
<value>: Detail level
Data type: INT

Example
The 6th protection area is to be displayed as of detail level 3:

Program code Comment

N100 $NP_PROT_D_LEVEL[5] = 3 ; 6. Protection area,
; detail level = 3

6.2.3.8 $NP_BIT_NO

Function
Enter the bit number of an NC/PLC interface signal of the 64-bit wide interface with which the
protection area is to be connected in system variable $NP_BIT_NO. If the protection area is
not to be connected to an NC/PLC interface signal, enter the value -1.

NC/PLC interface
Activation / deactivation of the protection area can be requested via NC/PLC interface signals
via the PLC user program or this can be used for feedback on the current status to the PLC
user program:
● Requirement: DB10, DBX234.0 - DBX241.7 (Page 833)
● Feedback: DB10, DBX226.0 - DBX233.7 (Page 834)

Precondition
In order that the NC/PLC interface is taken into consideration by the protection area, the status
of the protection area must be "preactivated" or "PLC-controlled": $NP_INIT_STAT
(Page 242) == "P" (preactivated or PLC-controlled)

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Syntax
$NP_BIT_NO[<m>] = <number>

Meaning

$NP_BIT_NO: Bit number of the interface signal to activate/deactivate the protection area
Data type: INT
Range of values: -1, 0, 1, 2, ... ($MN_MM_MAXNUM_3D_INTERFACE_IN - 1)
Default value: -1 (no interface signal selected)
<m>: System variable or protection area index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_3D_MAXNUM_PROT_AREAS - 1)
<number>: Bit number
Data type: INT

Example
The 6th protection area is assigned to the 18th bit of the interface (DB10.DBX236.1):

Program code Comment

N100 $NP_BIT_NO[5] = 17 ; 6. Protection area,
; DB10.DBX236.1

Assignment: Bit number to the interface signal

Bit DB10, DB10, Bit DB10, DB10, Bit DB10, DB10, Bit DB10, DB10,
→ (PLC→NC) (NC→PLC) → (PLC→NC) (NC→PLC) → (PLC→NC) (NC→PLC) → (PLC→NC) (NC→PLC)
0 DBX234.0 DBX226.0 8 DBX235.0 DBX227.0 16 DBX236.0 DBX228.0 24 DBX237.0 DBX229.0
1 DBX234.1 DBX226.1 9 DBX235.1 DBX227.1 17 DBX236.1 DBX228.1 25 DBX237.1 DBX229.1
2 DBX234.2 DBX226.2 10 DBX235.2 DBX227.2 18 DBX236.2 DBX228.2 26 DBX237.2 DBX229.2
3 DBX234.3 DBX226.3 11 DBX235.3 DBX227.3 19 DBX236.3 DBX228.3 27 DBX237.3 DBX229.3
4 DBX234.4 DBX226.4 12 DBX235.4 DBX227.4 20 DBX236.4 DBX228.4 28 DBX237.4 DBX229.4
5 DBX234.5 DBX226.5 13 DBX235.5 DBX227.5 21 DBX236.5 DBX228.5 29 DBX237.5 DBX229.5
6 DBX234.6 DBX226.6 14 DBX235.6 DBX227.6 22 DBX236.6 DBX228.6 30 DBX237.6 DBX229.6
7 DBX234.7 DBX226.7 15 DBX235.7 DBX227.7 23 DBX236.7 DBX228.7 31 DBX237.7 DBX229.7

Bit DB10, DB10, Bit DB10, DB10, Bit DB10, DB10, Bit DB10, DB10,
→ (PLC→NC) (NC→PLC) → (PLC→NC) (NC→PLC) → (PLC→NC) (NC→PLC) → (PLC→NC) (NC→PLC)
32 DBX238.0 DBX230.0 40 DBX239.0 DBX231.0 48 DBX240.0 DBX232.0 56 DBX241.0 DBX233.0
33 DBX238.1 DBX230.1 41 DBX239.1 DBX231.1 49 DBX240.1 DBX232.1 57 DBX241.1 DBX233.1
34 DBX238.2 DBX230.2 42 DBX239.2 DBX231.2 50 DBX240.2 DBX232.2 58 DBX241.2 DBX233.2
35 DBX238.3 DBX230.3 43 DBX239.3 DBX231.3 51 DBX240.3 DBX232.3 59 DBX241.3 DBX233.3
36 DBX238.4 DBX230.4 44 DBX239.4 DBX231.4 52 DBX240.4 DBX232.4 60 DBX241.4 DBX233.4

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Bit DB10, DB10, Bit DB10, DB10, Bit DB10, DB10, Bit DB10, DB10,
→ (PLC→NC) (NC→PLC) → (PLC→NC) (NC→PLC) → (PLC→NC) (NC→PLC) → (PLC→NC) (NC→PLC)
37 DBX238.5 DBX230.5 45 DBX239.5 DBX231.5 53 DBX240.5 DBX232.5 61 DBX241.5 DBX233.5
38 DBX238.6 DBX230.6 46 DBX239.6 DBX231.6 54 DBX240.6 DBX232.6 62 DBX241.6 DBX233.6
39 DBX238.7 DBX230.7 47 DBX239.7 DBX231.7 55 DBX240.7 DBX232.7 63 DBX241.7 DBX233.7

6.2.3.9 $NP_INIT_STAT

Function
Enter the protection area initialization status in the system variable.
The status of a protection area is set to the parameterized initialization status in the following
situations:
● When the control ramps up
● When calling the PROTA (Page 289) function after the protection area has been recreated
during operation by writing the protection-area-specific system variables
● When calling the PROTA (Page 289) function with parameter "R"
● When calling the PROTS (Page 290) function with parameter "R"

Syntax
$NP_INIT_STAT[<m>] = "<status>"

Meaning

$NP_INIT_STAT: Initialization status of the protection area

Data type: STRING
Range of values: "A", "a", "I", "i", "P", "p"
Value Protection area status
"A"or "a" Activated
"I"or "i" Inactive
"P"or "p" Preactivated or PLC-controlled1)
Default value: "I" (inactive)
<m>: System variable or protection area index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_3D_PROT_AREAS - 1)
<Status>: Initialization status
Data type: STRING
1) The activation/deactivation is performed via: DB10.DBX234.0 - DBX241.7

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Example
The initialization status of the 6th protection area is set to "P" (preactivated or PLC-controlled):

Program code Comment

N100 $NP_INIT_STAT[5] = "P" ; 6. Protection area,
; initialization status = "P"

The current status depends on the state of the interface signal parameterized in
$NP_BIT_NO (Page 240).

6.2.3.10 $NP_INDEX

Function
For automatic protection areas ($NP_PROT_TYPE (Page 236)), the address, under which the
geometric data of the machine part, tool, etc. to be protected is saved, should be entered in
the system variable. The control then automatically creates the geometrical dimensions of the
protection area from the geometric data.

Example
For example, for an automatic tool protection area ($NP_PROT_TYPE == "TOOL") the
geometrical dimensions of the protection area are created based on the tool data.

Syntax
$NP_INDEX[<m>,<i>] = <value>

Meaning

$NP_INDEX: Address of the geometric data for the automatic protection areas
Data type: INT[ 3 ]
<m>: System variable or protection area index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_3D_PROT_AREAS - 1)
<i>: Index
The meaning of the system variables $NP_INDEX[<m>,<i>], with i = 0, 1, 2, ...
is dependent on the type ($NP_PROT_TYPE) of the automatic protection area.
See type-specific tables.
Data type: INT
Range of values: 0, 1, 2
<value>: Address
Data type: INT

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Type: Automatic tool protection area ($NP_PROT_TYPE == "TOOL")

<i> <value>
When tool management is active Without tool management
0 Circular magazine: Tool location number Spindle number
No circular magazine: Spindle number
1 Magazine number ---
2 TOA area 1)

1) TOA area "1" can be addressed with 0 as well as also with 1.

Example
The 6th protection area is an automatic tool protection area ($NP_PROT_TYPE == "TOOL").
The geometrical dimensions of the protection area should be generated from the geometric
data of the tool at the following tool location:
● Tool location number: 1
● Magazine number: 9998 (spindle 1)
● TOA area: 1
Tool management is active.

Program code Comment

; The dimensions of the 6th protection area are based on the tool data
; of the tool located at the following position:
N100 $NP_INDEX[5,0] = 1 ; Tool location number = 1
N110 $NP_INDEX[5,1] = 9998 ; magazine number = 9998 (spin-
dle 1)
N120 $NP_INDEX[5,2] = 1 ; TOA area = 1

See also
$NP_PROT_TYPE (Page 236)

6.2.4 System variables: Protection area elements for machine protection areas

6.2.4.1 Overview
A protection area element of a machine protection area is parameterized with the following
system variables:

Name Meaning
$NP_NAME Name of the protection area element
$NP_NEXT Name of the following protection area element
$NP_NEXTP Name of the following protection area element parallel to $NP_NEXT

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Name Meaning
$NP_COLOR Color and transparency of the protection area element.
$NP_D_LEVEL Detail level for the protection area element
$NP_USAGE Use of the protection area element
$NP_TYPE Type of the protection area element
$NP_FILENAME File name of the STL file that contains the geometric data of the pro‐
tection area element
(only relevant for $NP_TYPE == "FILE")
$NP_PARA Geometric parameters of the protection area body
(only relevant for $NP_TYPE == "BOX" or "SPHERE" or "CYLINDER")
$NP_OFF Offset vector of the protection area element local coordinate system
$NP_DIR Direction vector for the rotation of the protection area element local
coordinate system
$NP_ANG Angle for the rotation of the protection area element local coordinate
system

The system variables are described in detail in the following sections.

Note
Establish a defined initial state
It is recommended that a defined initial state be generated before parameterizing the protection
area elements. To do this, set the system variables of the protection area elements to their
default values with the DELOBJ() (Page 213) function.
Change system variable values
If the value of one of the system variables listed above is changed, the change becomes
immediately visible at the user interface, e.g. SINUMERIK Operate. The machine model of the
NC is only updated after explicitly requesting that the machine model is recalculated by calling
the PROTA() (Page 289) or PROTS() (Page 290) function.

6.2.4.2 $NP_NAME

Function
Enter the NC-wide unique protection area element name in the system variable. The protection
area element is referenced via this name. The name is also displayed in the graphical editor
of SINUMERIK Operate.

Syntax
$NK_NAME[<n>] = "<name>"

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Meaning

$NP_NAME: Name of the protection area element

Data type: STRING
Default value: "" (empty string)
<n>: System variable or protection area element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_3D_PROT_AREA_ELEM -
1)
<name>: Name of the protection area element
Data type: STRING

Example
The 19th protection area element is assigned the name "Spindle head":

Program code Comment

N100 $NP_NAME[18] = "Spindle head" ; 19. protection area element,
; name = "Spindle head"

6.2.4.3 $NP_NEXT

Function
If a protection area is made up of several protection area elements, they must be linked. To
do this, the name of the following protection area element must be entered in the system
variable $NP_NEXT in every protection area element.

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If there is no following protection area element, the name must be entered as an empty string
"".

Offset and rotation

An offset and/or rotation in the current protection area element ($NP_OFF (Page 258),
$NP_DIR (Page 259) and $NP_ANG (Page 261)) affects the following protection area element
specified in $NP_NEXT. This means that the specification of the spatial position and orientation
of the following protection area element is relative to the current protection area element.

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Syntax
$NK_NEXT[<n>] = "<name>"

Meaning

$NP_NEXT: Name of the following protection area element

Data type: STRING
Range of values: All names contained in $NP_NAME (Page 245)
Default value: "" (empty string)
<n>: System variable or protection area element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_3D_PROT_AREA_ELEM -
1)
<name>: Protection area name
Data type: STRING

Example
The following protection area element with the name "Coolant nozzle 1" is attached to the 19th
protection area element:

Program code Comment

N100 $NP_NAME[18] = "Coolant nozzle 1" ; 19th protection area element,
; name of the following element:
"Coolant nozzle 1"

6.2.4.4 $NP_NEXTP

Function
The protection area element chain can be branched via the system variable $NP_NEXTP. To
do this, the following protection area elements must be specified in the system variables
$NP_NEXT and $NP_NEXTP in a protection area element. These protection area elements
are then parallel to one another in two separate subchains.


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13B1(;73
13B1(;7


① Following parallel protection area element

② Following protection area element of the same subchain

Figure 6-2 Protection area elements in parallel subchains

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Application example
The separate subchains can be used, for example, to model different machine parts of a
protection area for visualization or collision avoidance. Typically "C" (collision avoidance) is
specified for the protection area element referred to by $NP_NEXT for use in $NP_USAGE
(Page 251), and for the protection area element referred to in $NP_NEXTP, the value “V”
(visualization).

Offset and rotation

An offset and/or rotation in the current protection area element ($NP_OFF (Page 258),
$NP_DIR (Page 259) and $NP_ANG (Page 261)) affects the following protection area element
specified in $NP_NEXTP. This means that the specification of the spatial position and
orientation of the following protection area element is relative to the current protection area
element.

Syntax
$NP_NEXTP[<n>] = "<name>"

Meaning

$NP_NEXTP: Name of the branching protection area element

Data type: STRING
Range of values: All names contained in $NP_NAME (Page 245)
Default value: "" (empty string)
<n>: System variable or protection area element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_3D_PROT_AREA_ELEM -
1)
<name>: Protection area name
Data type: STRING

Example
The following parallel protection area element with the name "Coolant nozzle 2" is attached to
the 19th protection area element:

Program code Comment

N100 $NP_NEXTP[18] = "Coolant nozzle 2" ; 19. Protection area element,
; name of the parallel following
element: "Coolant nozzle 2"

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6.2.4.5 $NP_COLOR

Function
Enter the protection area element-specific value for alpha/transparency and color (ARGB) in
the system variable. This value is used for the display of the protection area element on the
user interface. If a specific value is not parameterized for a protection area element, the
protection area-specific value from $NP_PROT_COLOR (Page 238) applies.

Structure
Alpha/transparency and color are specified as a double word in hexadecimal format:
AARRGGBBH
● 1. - 3. Byte: RGB color value. See Chapter "Color chart (Page 231)".
● 4. Byte: Alpha channel or transparency value

Byte Meaning Range of values

OC 1 Blue 0 - 255D or 0 - FFH
GG 2 Green
RR 3 Red
AA 4 Alpha channel or transparency 1)
1) 0 = transparent or not visible, 255D = FFH = not transparent or filled

Syntax
$NP_COLOR[<n>] = <name>

Meaning

$NP_COLOR: Alpha/transparency and color value of the protection area element

Data type: DWORD
Range of values: 00000000H - FFFFFFFFH
Default value: 0000000H (black, not visible)
<m>: System variable or protection area element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_3D_PROT_AREA_ELEM -
1)
<value>: Transparency and color value
Data type: DWORD

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Example
The 19th protection area is to be displayed half transparent and in a green-blue color on the
user interface:
● AA = 7FH = 127D ≙ 50% transparency
● RR (red) = 00 ≙ no red component
● GG (green) = FFH = 255D ≙ 100% green color component
● BB (blue) = 33H = 51D ≙ 20% blue color component

Program code Comment

N100 $NP_COLOR[18] = 'H7F00FF33' ; 19. Protection area,
; alpha/transparency and color
value = 'H7F00FF33'

6.2.4.6 $NP_D_LEVEL

Function
The detail level as of which the protection area element is displayed on the user interface is
specified via the system variable. If no value different from the default value is assigned for a
protection area element the protection area-specific value takes effect
$NP_PROT_D_LEVEL (Page 239).

Detail level
● Lowest detail level: 0
● Highest detail level: 3
If the detail level x is selected for the visualization of the machine model, all protection areas
and protection area elements are displayed for which the following applies for the detail level
D: D ≤ x

Syntax
$NP_D_LEVEL[<n>] = <value>

Meaning

$NP_PROT_D_LEVEL: Detail level for the protection area element

Data type: INT
Range of val‐ 0≤D≤3
ues:
Default value: 0

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<m>: System variable or protection area element index

Data type: INT
Range of val‐ 0, 1, 2, ... ($MN_MM_MAXNUM_3D_PROT_AREA_ELEM
ues: - 1)
<value>: Detail level
Data type: INT

Example
The 19th protection area is always to be displayed ⇒ detail level 0:

Program code Comment

N100 $NP_PROT_D_LEVEL[18] = 0 ; 19. Protection area,
; detail level = 0

6.2.4.7 $NP_USAGE

Function
Enter the protection area element usage in the system variable. The usage specifies how the
protection area element is to be considered for the collision avoidance.
● Only visualization, no collision calculation
● Only collision calculation, no visualization
● Visualization and collision calculation

Usage Meaning
Visualization The protection area element is displayed in the machine model on the SINUMERIK Operate
user interface
Collision calculation The protection area element is also taken into account for the collision calculation

Syntax
$NP_USAGE[<n>] = "<value>"

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Meaning

$NP_USAGE: Use of the protection area element

Data type: CHAR
Range of values: "V", "v", "C", "c", "A", "a"
Value Meaning
"V" or "v" Only visualization, no collision calculation
"C" or "c" Only collision calculation, no visualization
"A" or "a" Visualization and collision calculation
Default value: "A"
<n>: System variable or protection area element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_3D_PROT_AREA_ELEM -
1)
<value>: Usage
Data type: CHAR

Example
The 19th protection area element is to be displayed on the user interface and included in the
collision calculation:

Program code Comment

N100 $NP_USAGE[18] = "A" ; 19. Protection area,
; usage = "A"

6.2.4.8 $NP_TYPE

Function
Enter the protection area element type in the system variable.

Type: "FRAME"
A protection area element of the "FRAME" type does not contain any bodies, but defines a
coordinate transformation of the local coordinate system. The coordinate transformation
affects all the following ($NP_NEXT (Page 246)) and/or parallel ($NP_NEXTP (Page 247))
protection area elements. The values of the coordinate transformation are set via:
● Offset: $NP_OFF (Page 258)
● Direction vector of the rotation: $NP_DIR (Page 259)
● Angle of rotation: $NP_ANG (Page 261)
No parameters are specified in $NP_PARA (Page 257) for the "FRAME" type.

Type: "BOX"
A protection area element of the "BOX" type defines a paraxial box in the local coordinate
system of the protection area element. The mid-point of the box is at the origin of the local

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coordinate system. At the same time as the definition of the body, the local coordinate system
can be transformed via the following system variables:
● Offset: $NP_OFF (Page 258)
● Direction vector of the rotation: $NP_DIR (Page 259)
● Angle of rotation: $NP_ANG (Page 261)

<
;

L Length in the X direction

B Width in the Y direction
H Height in the Z direction

Parameter specifications in $NP_PARA (Page 257): Length, width, height

Type: "SPHERE"
A protection area element of the "SPHERE" type defines a sphere in the local coordinate
system of the protection area element. The mid-point of the sphere is at the origin of the local
coordinate system. At the same time as the definition of the body, the local coordinate system
can be transformed via the following system variables:
● Offset: $NP_OFF (Page 258)
● Direction vector of the rotation: $NP_DIR (Page 259)
● Angle of rotation: $NP_ANG (Page 261)

Note
Rotation
As the center point of the sphere and the starting point of the direction vector are in the
coordinate origin of the local coordinate system of the protection area element, a rotation using
the direction vector $NP_DIR (Page 259) and angle of rotation $NP_ANG (Page 261) has no
effect on the position of the sphere.

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<
;
5

R Radius of the sphere:

Parameter specification in $NP_PARA (Page 257): Radius

Type: "CYLINDER"
A protection area element of the "CYLINDER" type defines a cylinder in the local coordinate
system of the protection area element. The mid-point of the cylinder is at the origin of the local
coordinate system. At the same time as the definition of the body, the local coordinate system
can be transformed via the following system variables:
● Offset: $NP_OFF (Page 258)
● Direction vector of the rotation: $NP_DIR (Page 259)
● Angle of rotation: $NP_ANG (Page 261)

<
;
5

H Height in the Z direction

R Radius in the X/Y plane

Parameter specification in $NP_PARA (Page 257): Height, radius

Type: "FILE"
A protection area element of the "FILE" type defines a body whose geometry data is contained
in the specified file in STL format (triangular areas), in the local coordinate system of the
protection area element. The zero point of the body is at the origin of the local coordinate
system. At the same time as the definition of the body, the local coordinate system can be
transformed via the following system variables:
● Offset: $NP_OFF (Page 258)
● Direction vector of the rotation: $NP_DIR (Page 259)
● Angle of rotation: $NP_ANG (Page 261)
Specify the file name in $NP_FILENAME (Page 255) for the "FILE" type.

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;
<

Figure 6-3 Example bodies in STL format

Syntax
$NP_TYPE[<n>] = "<type>"

Meaning

$NP_TYPE: Type of the protection area element

Data type: STRING
Range of values: "FRAME", "BOX", "SPHERE", "CYLINDER", "FILE"
Default value: "" (empty string)
<n>: System variable or protection area element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_3D_PROT_AREA_ELEM -
1)
<Type>: Type designation
Data type: STRING

Example
The 19th protection area element is a box:

Program code Comment

N100 $NP_TYPE[18] = "BOX" ; 19. Protection area element,
; type = "Box"

6.2.4.9 $NP_FILENAME

Function
For protection area elements of the "FILE" type ($NP_TYPE (Page 252)), enter the file name
of the STL file (file ending .STL) with the geometry data of the protection area element body
in the system variable.

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File format
The description of the body must be available in STL format (StandardTesselationFormat) and
in ASCII coding.

Search path
The specified file is sought in the predefined directories on the CompactFlash card in this order:
1. /card/oem/sinumerik/nck/prot_data/machine/3d_data/mm
2. /card/oem/sinumerik/nck/prot_data/machine/3d_data/inch

Interpretation of the length specifications

Depending on the storage directory, the length specifications contained in the STL file are
interpreted in mm or inches:
● .../mm: Interpretation of the length specifications in millimeters
● .../inch: Interpretation of the length specifications in inches

Syntax
$NP_FILENAME[<n>] = "<name>"

Meaning

$NP_FILENAME: Name of the STL file with the geometry data of the protection area element body
Data type: STRING
Default value: "" "" (empty string)
<n>: System variable or protection area element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_3D_PROT_AREA_ELEM -
1)
<name>: Name of the STL file
Data type: STRING

Example
The geometry data for the 19th protection area element is stored in the KUEHLDUESE_1.STL
file:

Program code Comment

N100 $NP_FILENAME[18] = "KUEHLDU- ; 19. Protection area element,
ESE_1.STL" ; file name = "KUEHLDUESE_1.STL"

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Note
Maximum length of the file name
The maximum file name length, including point and the file extension is 49 characters. For
more than 49 characters, an alarm is displayed when generating an archive.

6.2.4.10 $NP_PARA

Function
Enter the dimensions of the protection area body according to the type of the protection area
element ($NP_TYPE (Page 252)) in the system variable.

Coordinate system
The local coordinate system in which the position of the protection area body is specified, is
defined by the system variables $NP_OFF (Page 258), $NP_DIR (Page 259), $NP_ANG
(Page 261).

Syntax
$NP_PARA[<n>,<i>] = <value>

Meaning

$NP_PARA: Parameter values corresponding to the type of the protection area element
Data type: REAL
Default value: 0.0
<n>: System variable or protection area element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_3D_PROT_AREA_ELEM - 1)
<i>: Parameter index
Data type: INT
Range of values: 0, 1, 2
Parameter index Type of the protection area element
FRAME BOX SPHERE CYLINDER FRAME
0 --- Length 1) Radius 1) Height 1) ---
1 --- Width 1)
--- Radius 1)
---
2 --- Height 1)
--- --- ---
<value>: Parameter value
Data type: REAL
Range of values: 0.0 ≥ x ≥ max. REAL value
1) The parameter value must not be 0.
---: Parameters that are not evaluated

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Example
The 19th protection area element is a box with the dimensions:
● Length: 50.0
● Width: 100.0
● Height: 75.5

Program code Comment

; 19. Protection area element,
N100 $NP_TYPE[18] = "BOX" ; type = "BOX"
N120 $NP_PARA[18,0] = 50.0 ; Length = 50.0
N130 $NP_PARA[18,1] = 100.0 ; Width = 100.0
N140 $NP_PARA[18,2] = 75.5 ; Height = 75.5

6.2.4.11 $NP_OFF

Function
The offset vector by which the local coordinate system of the protection area element is moved
compared to the coordinate system of the previous protection area element should be entered
in the system variable.

Syntax
$NP_OFF[<n>,<i>] = <value>

Meaning

$NP_OFF: Offset vector

Data type: REAL
Range of values: - max. REAL value ≤ x ≤ ± max. REAL value
Default value: (0.0, 0.0, 0.0)
<m>: System variable or protection area element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_3D_PROT_AREA_ELEM -
1)
<i>: Coordinate index
Data type: INT
Range of values: 0 → X; 1 → Y: 2 → Z
<value>: Coordinate value
Data type: REAL
Range of values: - max. REAL value ≤ x ≤ ± max. REAL value

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Example
The local coordinate system of the 19th protection area element is moved by the following
vector compared to the coordinate system of the previous protection area element:
● X direction: 25.0
● Y direction: 50.0
● Z direction: 37.25

13B2))
<

˟
< ]
˞ [ ;

; \

X, Y, Z Coordinate system of the previous protection area element

X', Y', Z' Coordinate system of the current protection area element

Program code Comment

; 19. protection area element, offset vector
N100 $NP_OFF[18,0] = 25.0 X = 25.0
N110 $NP_OFF[18,1] = 50.0 Y = 50.0
N120 $NP_OFF[18,2] = 37.25 Z = 37.25

6.2.4.12 $NP_DIR

Function
The direction vector through which the local coordinate system of the protection area element
is rotated compared to the coordinate system of the previous protection area element should
be entered in the system variable. The angle of rotation should be entered in $NP_ANG
(Page 261).

Boundary conditions
● The absolute value of the direction vector must be greater than: 1*10–6
● A work offset parameterized in $NP_OFF (Page 258) is performed before the rotation.

Syntax
$NP_DIR[<n>,<i>] = <value>

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Meaning

$NP_DIR: Direction vector

Data type: REAL
Range of values: - max. REAL value ≤ x ≤ ± max. REAL value
Default value: (0.0, 0.0, 0.0)
<n>: System variable or protection area element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_3D_PROT_AREA_ELEM -
1)
<i>: Coordinate index
Data type: INT
Range of values: 0 → X; 1 → Y: 2 → Z
<value>: Coordinate value
Data type: REAL
Range of values: - max. REAL value ≤ x ≤ ± max. REAL value

Example
The local coordinate system of the 19th protection area element is rotated around the direction
vector compared to the coordinate system of the previous protection area element. The
direction vector is the unit vector (1; 0; 0), rotated through α=90° in the X/Y plane and β=10°
in the Y/Z plane, in relation to the world coordinate system. The following values result from
this for the individual components of the direction vector:
● X component = cos(α) * cos(β) = cos(90) * cos(10) = 0.0
● Y component = sin(α) * cos(β) = sin(90) * cos(10) ≈ 0.985
● Z component = sin(β) = sin(10) ≈ 0.174

13B',5
_Y_ 
˟
< ]
˞
[

; \

Program code Comment

; 19. protection area element, direction vector
N100 $NP_DIR[18.0] = COS(90) * COS(10) ; 0 = X component
N110 $NP_DIR[18.1] = SIN(90) * COS(10) ; 1 = Y component
N120 $NP_DIR[18.2] = SIN(10) ; 2 = Z component

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6.2.4.13 $NP_ANG

Function
The angle through which the local coordinate system of the protection area element is rotated
around the direction vector ($NP_DIR (Page 259)) compared to the coordinate system of the
previous protection area element should be entered in the system variable.

Syntax
$NP_ANG[<n>] = <value>

Meaning

$NP_ANG: Angle of rotation

Data type: REAL
Range of values: -360° < x ≤ 360°
Default value: 0.0
<n>: System variable or protection area element index
Data type: INT
Range of values: 0, 1, 2, ... ($MN_MM_MAXNUM_3D_PROT_AREA_ELEM -
1)
<value>: Angle
Data type: REAL

Example
The local coordinate system of the 19th protection area element is rotated by the angle by
δ=45.0° around the direction vector compared to the coordinate system of the previous
protection area element. The direction vector is the unit vector (1; 0; 0), rotated through
α=90° in the X/Y plane and β=10° in the Y/Z plane, in relation to the world coordinate system.
The following values result from this for the individual components of the direction vector:
● X component = cos(α) * cos(β) = cos(90) * cos(10) = 0.0
● Y component = sin(α) * cos(β) = sin(90) * cos(10) ≈ 0.985
● Z component = sin(β) = sin(10) ≈ 0.174
● Angle δ = 45.0°

=
13B$1*
13B',5 
R

=
_Y_ 
<

˟
< ]
˞
[

;
;
\

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Program code Comment

; 19. Protection area element, direction vector and angle of rotation
N100 $NP_DIR[18.0] = COS(90)*COS(10) ; 0 = X component
N110 $NP_DIR[18.1] = SIN(90)*COS(10) ; 1 = Y component
N120 $NP_DIR[18.2] = SIN(10) ; 2 = Z component
N130 $NP_ANG[18] = 45.0 ; Angle of rotation δ = 45°

6.2.5 System variables: Protection area elements for automatic tool protection areas
The protection area element of an automatic tool protection area is defined using the
subsequent system variables. The control automatically generates the values of the system
variables from the geometric data of the associated tool, and these can only be read.

Name 1) Meaning Analog to 2)

$NP_T_NAME[<n>] Name of the protection area element $NP_NAME
(Page 245)
$NP_T_TYPE[<n>] Type of the protection area element $NP_TYPE
(Page 252)
$NP_T_FILENAME[<n>] File name of the STL file that contains the geometric $NP_FILENAME
data of the protection area element (Page 255)
(only relevant for $NP_T_TYPE == "FILE")
$NP_T_PARA[<n>,<i>] Geometric parameters of the protection area body $NP_PARA
(only relevant for $NP_T_TYPE == "BOX" or (Page 257)
"SPHERE" or "CYLINDER")
$NP_T_OFF[<n>,<i>] Offset vector of the protection area element local co‐ $NP_OFF
ordinate system (Page 258)
$NP_T_DIR[<n>,<i>] Direction vector for the rotation of the protection area $NP_DIR
element local coordinate system (Page 259)
$NP_T_ANG[<n>] Angle for the rotation of the protection area element $NP_ANG
local coordinate system (Page 261)
1) n = 0, 1, ... ($MN_MM_MAXNUM_3D_T_PROT_ELEM – 1)
2) The system variables of the automatic tool protection areas correspond to those of the machine
protection areas.

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6.2.6 Boundary conditions

Protection area bodies for spindles

For spindles that are not in position-controlled operation, the associated protection area bodies
are only modeled statically. As a result the following boundary conditions must be met when
modeling protection area bodies connected with a spindle as a kinematic element:
● The protection area body must be symmetrical around its axis of rotation.
● The symmetrical axis of the protection area body must lie on the axis of rotation of the
spindle (collinear)
This should be taken into account for all types of protection area bodies:
● The protection area body is a basic geometrical body (sphere, cylinder).
● The protection area body comprises several, geometrical basic bodies.
● The protection area body comprises triangles (STL file).
● The protection area body for an automatic tool protection area is created from the geometric
tool data.
Note
Automatic tool protection areas
Only using tools that are symmetrical around the axis of rotation is recommended for
automatic tool protection areas in connection with spindles.

Following protection areas

The rotational symmetry and collinearity of the protection area body in respect of the axis of
rotation of the spindle must also be complied with for all protection areas that are connected
with elements of the kinematic chain ($NP_NEXT, $NP_NEXTP) following on from the spindle.
Schematic example of such a kinematic chain: ... → (rotary axis/spindle) → (offset) → (linear
axis) → (offset) → ...

Rotary axes
The boundary conditions stated above must also be observed in connection with rotary axes
where these are also operated as spindles.

Tool reference point and kinematic transformation

The position of the associated tool reference point is determined in principle through the
assignment of an automatic tool protection area to an element in the kinematic chain. However,
the position of the tool reference point can be changed through offsets within the automatic
tool protection area via the system variables $NP_T_OFF, $NP_T_DIR and $NP_T_ANG
(Page 262). A change in position for the tool reference point of this type is not captured by the
kinematic transformations. In the context of kinematic transformation it is therefore highly
recommended that no offsets are used for the geometric machine modeling which move the
tool reference point.

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6.3 Data lists

6.3.1 Machine data

6.3.1.1 NC-specific machine data

Number Identifier: $MN_ Description

MD18890 $MN_MM_MAXNUM_3D_PROT_AREAS Maximum number of protection areas
MD18892 $MN_MM_MAXNUM_3D_PROT_AREA_ELEM Maximum number of protection area elements
MD18893 $MN_MM_MAXNUM_3D_T_PROT_ELEM Maximum number of tool protection area elements
MD18897 $MN_MM_MAXNUM_3D_INTERFACE_IN Maximum number of NC/PLC interface signals for the
preactivation of protection areas
MD18895 $MN_MM_MAXNUM_3D_FACETS Maximum number of triangles for protection areas
MD18894 $MN_MM_MAXNUM_3D_FACETS_INTERN Maximum number of triangles for automatic tool pro‐
tection areas
MD18899 $MN_PROT_AREA_TOOL_MASK Creation mode for automatic tool protection areas

6.3.2 System variables

Identifier Description
$NP_PROT_NAME Name of the protection area
$NP_CHAIN_ELEM Name of the kinematic element to which the protection area will be connected
$NP_PROT_TYPE Type of the protection area
$NP_1ST_PROT Name of the first protection area element of the protection area
$NP_PROT_COLOR Transparency and color value of the protection area
$NP_PROT_D_LEVEL Detail level for the protection area
$NP_BIT_NO Bit number of the interface signal to activate/deactivate the protection area
$NP_INIT_STAT Initialization status of the protection area
$NP_INDEX Array for addressing the effective geometry data
$NP_NAME Name of the protection area element
$NP_NEXT Name of the following protection area element
$NP_NEXTP Name of the branching protection area element
$NP_COLOR Transparency and color value of the protection area element
$NP_D_LEVEL Detail level for the protection area element
$NP_USAGE Usage of the protection area element
$NP_TYPE Type of the protection area element
$NP_FILENAME Name of the STL file with the geometry data of the protection area element
body
$NP_PARA Parameter values corresponding to the type of the protection area element

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Identifier Description
$NP_OFF Offset vector
$NP_DIR Direction vector
$NP_ANG Angle of rotation

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7.1 Function description

7.1.1 Characteristics
The "Collision avoidance" function is used to prevent collisions of machine parts and tool
cutting edges while the machine axes are being traversed. To do this, the function cyclically
calculates the clearance to the protection areas enveloping the bodies to be protected. If two
protection areas approach one another to within a configurable safety clearance, an alarm is
displayed and the NC program stopped before the relevant traversing block (AUTOMATIC,
MDI mode) or the traversing motion is stopped (JOG mode).

Option
The "Collision avoidance (machine, tool)" function is an option that requires a license.
● Article number: 6FC5800-0AS02-0YB0

Boundary condition
Collision avoidance can currently be applied only with single-channel control configurations.

Sequence
The collision avoidance is set up in the following sequence:
1. Enable the "collision avoidance (machine, tool)" function by setting the option (see above)
or the corresponding machine data, see the section "Enable (Page 278)"
2. Setting the machine data for the basic parameterization of the functions:
– Kinematic chain, section "Machine data (Page 193)"
– Geometric machine modeling, section "Machine data (Page 232)"
– Collision avoidance, section "Machine data (Page 278)"
3. Writing of the machine kinematic structure through kinematic elements.
See Chapter "K7: Kinematic chain - only 840D sl (Page 187)".
4. Writing of the protection areas and protection area elements as enveloping geometry of
the machine parts, tools and workpieces to be protected. Assignment of the protection area
to elements of the kinematic chain.
See Chapter "K8: Geometric machine modeling - only 840D sl (Page 223)".
5. Definition of collision pairs, i.e. of two protection areas that are to be monitored for collision.
See Chapter "$NP_COLL_PAIR (Page 282)".
6. Triggering a recalculation of the kinematic and geometric model.
See Chapter "Request recalculation of the machine model of the collision avoidance
(PROTA) (Page 289)".

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7. Activation of the protection areas to be monitored.

See Chapter "Setting the protection area state (PROTS) (Page 290)".
8. Optional: Use of the extended functions and system variables

Limits of the collision avoidance

The function cannot guarantee complete protection against a collision when traversing
machine parts, tools of workpieces. On the one hand, the collision protection can only be as
good as the parameterized kinematic and geometric model or the machine and the protection
areas. On the other hand, bodies that have not been modeled cannot be monitored at all. For
this reason, it remains the responsibility of the machine operator to ensure that a traversing
motion is executed collision-free even when the collision protection is activated.

States of protection areas

Whether a protection area is taken into account for collisions, depends on the state of the
protection area:

State Meaning
Active The protection area is taken into account for collisions.
Inactive The protection area is not taken into account for collisions.
Preactivated The protection area is taken into account for collisions. A collision alarm is only issued
when it has also been activated by a protection area-specific NC/PLC interface signal.

State after control ramp-up

After control ramp-up, all protection areas are in the state corresponding to their respective
setting in $NP_INIT_STAT. See Chapter "$NP_INIT_STAT (Page 242)".

State change
The state of a protection areas can be changed by:
● The PROTS() (Page 290) procedure
● Change of the initialization state to $NP_INIT_STAT followed by recalculation of the
machine model through the PROTA() (Page 289)procedure.

Requirements
The following requirements must be satisfied so that the protection areas of a collision pair
can be monitored:
● Axes or spindles: referenced/synchronized
The position measurement system for the axes or spindles which move a protection area
must be referenced or synchronized. If this has not been done the corresponding protection
area is in an "inactive" state.
● External motion
With traversing motions that are not performed by the NC, e.g. PLC axis or manually moved
axis, the current axis position must be known in the NC.

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7.1.2 Reaction of the control to a risk of collision

The collision avoidance takes the following parameterizable limit values into account for the
collision detection:
● Collision tolerance
● Safety clearance

1
<
;
5
5
2

① Protection area 1 (static)

② Protection area 2 (can be moved in X and Y direction)
③ Current clearance
④ Safety clearance
⑤ Collision tolerance / 2
⑥ Collision clearance = safety clearance + collision tolerance

Figure 7-1 Current clearance, collision tolerance and safety clearance

Collision tolerance and safety clearance

Safety clearance
The safety clearance defines a clearance up to which two active protection areas, monitored
for collision, can approach one another. The collision avoidance ensures that this clearance
is not violated and that the collision is displayed.
The safety clearance can be set specifically for each collision pair via a system variable
(Page 283).
For all collision pairs for which no specific safety clearance is set via a system variable, the
general value that can be set via MD10622 $MN_COLLISION_SAFETY_DIST
(Page 279)Hotspot-Text (Page 279) applies.

Collision tolerance
The collision tolerance defines an NC-wide additional clearance valid to the safety clearance.
Two active protection areas monitored for collision may therefore approach each other up to
the collision clearance (safety clearance + collision tolerance). Ideally, the collision avoidance
stops the traversing motion of the protection areas exactly at the collision clearance and
displays the collision. However, it is permissible that the collision tolerance is not complied with
exactly or that a brief violation does not result in collision detection and the traversing motion
is not stopped.

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The collision tolerance is set the same for all collision pairs via MD10619
$MN_COLLISION_TOLERANCE (Page 279).

Note
Difference between collision tolerance and safety clearance
The collision tolerance can be violated and is permissible. The safety clearance is always
maintained.

Responses in the operating mode: AUTOMATIC

Collision detection during preprocessing

In automatic mode, the traversing blocks of the active program are already checked during the
preprocessing. If a collision is already detected there, this results in the following reactions:
● Stop of the traversing motions in the channel
● NC/PLC interface signal: DB21,... .DBX377.0 = 1 (collision avoidance: velocity reduction)
● Display of alarm 26260 with the block number of the relevant traversing block
● Cancelation of the program processing

Critical approach
Even in automatic mode, superimposed or asynchronous motions can occur that cannot be
considered in advance. For this reason, the traversing velocity is reduced or the traversing
motion is totally stopped at a critical approach of protection areas:
● Axial NC/PLC interface signal at a reduction of the traversing velocity:
DB31, ... .DBX77.0 == 1 (collision avoidance: velocity reduction)
● Channel-specific NC/PLC interface signal at a stop of the traversing motion:
DB21, ... .DBX377.0 == 1 (collision avoidance: stop)

Preactivated protection areas

If during the block processing in the preprocessing, it is determined in a traversing block that
two protection areas, of which at least one is only preactivated, would collide if they were active,
this does not yet produce the same reactions as described above in the "Collision detection
during preprocessing". The reactions only occur when both protection areas are active.
If the block at the activation time is already being traversed in the main run, a collision is
detected based on the collision calculation during preprocessing and the above reactions
triggered. The collision is detected irrespective of whether the protection areas are actually
colliding at the activation time.

Responses in the operating mode: JOG

If two protection areas approach one another when traversing in the JOG mode, the traversing
velocity is continuously braked down to standstill when the collision clearance is reached.
Alarm 26280 is output when the collision clearance is reached.
If the collision location is exited in the opposite direction, a continuously higher traversing
velocity is possible depending on the clearance of the protection areas.

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Traversing motion is always canceled when the collision clearance is reached. Continuation
of the traversing motion always requires a new travel request (e.g by pressing a traversing
key), irrespective of the traversing direction.

Responses in the operating mode: MDI

If two protection areas approach one another when traversing in the MDI mode, the traversing
velocity is continuously braked down to standstill when the collision tolerance is reached. Alarm
26280 is output when the collision clearance is reached.
Contrary to the AUTOMATIC, mode, for MDI, the traversing blocks are not checked in advance
(run-in) for collision.

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7.1.3 State diagram: Protection area

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SB Protection area
BA Operating mode
① UpdateAllCaSysVar(SB) function
All system variables of the collision avoidance are read-in in NCK-internal variables:
int... = $N...

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② UpdateAllCaSysVarExeptInitStat(SB) function
As with the UpdateAllCaSysVar(SB) function, but the $NP_INIT_STAT system variable is not
read in. Internally in the NCK, the last value of the intInitStat initialization status is therefore
retained.
③ CheckIntNckCaSysVarImages(SB) function
The NCK-internal variables read in from the system variables are checked for consistency.
Return value when an error is detected: FALSE; if error-free: TRUE.
④ UpdateCaSysVarInitStat(SB) function
Only the system variable $NP_INIT_STAT is read-in in the NCK-internal variable intInitStat.
⑤ The internal structure of the "Tool protection area" state is the same as the "Machine protection
area" state.
⑥ The internal structure of the "JOG mode" state is the same as the "AUTO/MDA mode" state.

7.1.4 Tools

Modeling
Protection areas for tools can be modeled automatically from the collision avoidance and be
updated automatically following a tool change with some limitations. The following conditions
must be fulfilled for this purpose:
● The protection area for the tool is modeled as an automatic tool protection area (type:
TOOL). See system variable $NP_PROT_TYPE (Page 236)
● The tool is managed by the control tool management.
● The tool data stored in the tool management matches the actual geometric dimensions of
the tool.
● The collision avoidance recognizes the completion of the tool change. Normally, by
programming the corresponding tool offset number Dx, with x = 0, 1, 2, 3, ...
● The collision avoidance recognizes the automatic tool protection area for which the tool
was changed.
● If the tool path refers to a normalized tool, the tool radius of the actual tool is specified as
either positive or negative deviations referred to the normalized tool. In this case, collision
avoidance calculates with the following values:
– Positive value: Tool radius = specified value, however, as a minimum, the value of the
parameterized collision tolerance
– Negative value: Tool radius = value of the parameterized collision tolerance

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Change to the machine model

If a tool which is located in a magazine or tool adapter modeled in the active machine model
of the collision avoidance is changed in the machine then the machine model must be updated.
This is the case where one of the following actions is carried out, for example:
● A tool is loaded / unloaded in a tool magazine modeled in the machine model.
Example: Tool change in a revolver (circular) magazine.
Update: The machine model update must be explicitly requested by the user using
PROTA once the tool change has completed.
● The tool that is in a tool holder is changed.
Example: Tool change in the tool holder of the main spindle.
Update: The machine model is automatically updated following the tool change (standard:
M6) with output of the programmed tool offset number Dx in the main run.

Tool changes
The collision avoidance only updates the active machine model after a tool change without an
explicit request by PROTA if a tool offset is selected (output of the programmed tool offset
number Dx at the NC/PLC interface).
However, at the control, tool changes can be made, which are not associated with a tool offset
selection. However, for these changes the active machine model is not updated. These types
of tool changes include, for example:
● Loading/unloading a tool at the user interface.
SINUMERIK Operate: Operating area "Parameter" > "Tool list" > Vertical softkey: "Loading"
or "Unloading"
● Carrying out a tool change via the PLC user program
● Directly writing to the tool buffer memory using the system variable $TC_MPP6[9998,
<location>]
● SETMS(<spindle number>): Changing the master spindle in the channel
● TMMVTL: PI service "Prepare magazine location for loading, unload tool"
Reference Function Manual Basic Functions; Chapter: "P3: Basic PLC program for
SINUMERIK 840D sl" > "Component descriptions" > "PI services" > "PI service: TMMVTL"
● MVTOOL: Command to move a tool
Reference Function Manual Tool Management; Chapter "Programming > "NC language
commands" > "MVTOOL - language command to move a tool"
If such a change is carried out, then the machine manufacturer must be requested to update
the machine module via the PLC user program. Examples of options include:
● A new channel reset is requested if the channel is in the "reset" state. When the reset
response is appropriately set (MD20110 $MC_RESET_MODE_MASK), then the actual tool
offset number Dxis output again.
● Starting an ASUB or manufacturer's cycle, which includes the output of the tool offset
number Dx and the request to update the machine model (PROTA).

Tool wear
Minimal tool changes do not have to be taken into account in the machine model, as generally
they are far less than the collision clearance.

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If a tool change occurs, which is relevant for collision avoidance, e.g. diameter changes for
grinding tools, then these must be taken into account by explicitly requesting that the machine
model is updated (PROTA).

No change to the machine model

The active machine model does not change if a fully modeled machine part with tools, e.g. a
tool magazine, is moved in the machine.

Example: Revolver magazine on a lathe

The revolver magazine on a lathe is fully modeled in the machine model of the collision
avoidance:
● The geometry of the magazine and the tools located inside it
● The motions of the magazine through the machine axes
A rotation of the revolver magazine then does not represent a change to the machine model:
● since no tools are changed inside the machine model the geometries of all the protection
areas remain unchanged.
● As the motions of the protection areas by the machine axes are fully captured by the collision
avoidance via the kinematic chain.

Supplementary conditions

Several spindles in the channel

For configurations with several spindles in the channel, the collision avoidance function
assumes that a tool change takes place in the master spindle of the channel (S1). As a result
only the automatic tool protection area of the master spindle is updated through the collision
avoidance once the tool change has taken place.

Unsupported tool configurations

Tool configurations in accordance with ISO modes 4 and 5 (H numbers) along with "flat D
numbers" are not supported by the collision avoidance.

7.1.5 Boundary conditions

Channel assignment
All of the machine components relevant for collision avoidance must be located in the first
channel of the NC:
● All axes and spindles of the kinematic chain.
See Chapter "K7: Kinematic chain - only 840D sl (Page 187)"
● All tools of the automatic tool protection areas of the geometric machine modeling.
See Chapter "K8: Geometric machine modeling - only 840D sl (Page 223)"

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Allowance for the following error

The collision avoidance uses the position setpoints of the relevant machine axes for the
clearance calculation of the protection areas. However, the actual positions of the machine
axes differ from the position setpoint by the following error. For this reason, there is also a
difference between the position setpoint and the actual position for the protection areas. This
difference must be taken into account by the user through configuration of a suitably large
safety clearance or enlargement of the protection area.

Compensations
The various compensation functions of the NC – for instance, temperature, spindle and pitch
error and sag compensation – ensure that positions programmed in the workpiece coordinate
system are actually assumed in the machine coordinate system. The collision avoidance takes
into account the position corrections made by the compensation functions.

WARNING
Risk of collision
If compensations are used for other purposes, e.g. in order to implement axis couplings in
the machine coordinate system, the collision avoidance working with position setpoints can
no longer be performed reliably. There is a risk of collision.

Actual value offset in the machine coordinate system with PRESETON

With active collision avoidance and use of an actual value offset in the machine coordinate
system with PRESETON, it is the sole responsibility of the user to ensure that the geometric
model of the collision avoidance remains consistent.

WARNING
Risk of collision
If an actual value offset is made in the machine coordinate system with PRESETON and the
geometric model of the collision avoidance not adapted accordingly, the collision avoidance
working with position setpoints can no longer be performed reliably. There is a risk of collision.

Block search
For the following types of block search there are no collision calculations carried out:
● Type 1: Block search without calculation
● Type 2: Block search with calculation at the contour
● Type 4: Block search with calculation at block end point
With the following type of block search collision calculations are carried out (in the
preprocessing) for:
● Type 5: Block search with calculation in "Program test" (SERUPRO) mode

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AUTOMATIC modes: Incomplete protection area data for collision

When a large number of protection areas have been configured, in exceptional cases, the
following behavior can occur:
● Several protection areas have approached one another, down to the collision tolerance
● Only two protection areas are specified in Alarm 26260 "Collision two protection areas" that
is displayed.
● The collision of the other protection areas is only displayed when manually traversing the
axes after changing into the JOG mode.

7.2 Commissioning

7.2.1 General

7.2.1.1 Overview
The commissioning of the "Collision avoidance" function is performed using:
● Machine data
– Specification of the quantity structure
– Specification of general properties of the collision pairs
● System variables
– Parameterization of the collision pairs and their properties

7.2.1.2 Structure of the system variables

The system variables are structured according to the following scheme:
$NP_<name>[<index_1>,<index_2>]

Note
Index_2 is not available for all system variables.

General
The system variables to describe the protection areas have the following properties:
● Prefix: $NP_, (N for NC, P for protection).
● They can be read and written via NC programs.
● They can be stored in archives and loaded to the NC again.

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Data type

STRING
All system variables of the STRING data type have the following properties:
● Maximum string length: 31 characters
● No distinction is made between upper and lower case
Example: "Axis1" is identical to "AXIS1"
● Spaces and special characters are permitted
Example: "Axis1" is not identical to "Axis 1"
● Names that start with two underscores "__" are reserved for system purposes and must
not be used for user-defined names.
Note
Leading space
Since spaces are valid and distinct characters, names that start with a space followed by two
underscores "__" can, in principle, be used for user-defined names. However, because they
can be easily mistaken for system names, this procedure is not recommended.

Index_1
The individual protection areas are addressed via index_1. Index 0 → 1st protection area, index
1 → 2nd protection area, ... n → (n+1) protection area, where n =
($MN_MM_MAXNUM_3D_PROT_AREAS - 1)
All system variables of a protection area have the same index.

Index_2
For system variables that define a collision pair, the protection areas of the collision pair are
addressed via index_2.
● 0 → 1. Protection area
● 1 → 2. Protection area

See also
Deletion of components (DELOBJ) (Page 213)

7.2.2 Machine data

7.2.2.1 Enable
The collision avoidance functions are enabled using machine data:

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MD19830 $ON_COLLISION_MASK.Bit x = 1

Bit Meaning
0 Collision avoidance (machine, tool)
1 - 31 reserved

7.2.2.2 Collision tolerance

The collision tolerance (accuracy of the collision check) for all protection areas of the NC
monitored for collision is set with the machine data. If the clearance of two safety areas is less
than the collision clearance, i.e. the sum of safety clearance (Page 279) and collision tolerance,
then there is a collision.
MD10619 $MN_COLLISION_TOLERANCE = <collision tolerance>

Accuracy of automatic generated protection areas

The collision tolerance also determines the accuracy of the protection area bodies of protection
areas produced automatically, e.g. automatic tool protection areas. The accuracy of the
protection area bodies approached using triangle areas is 1/3 of the collision tolerance.

Effects
The smaller the collision tolerance is set, the greater the number of triangular areas required
for the modelling of the automatically generated protection areas and the computation time
required for the collision detection.

Recommended setting
Collision tolerance ≈ 1 mm

See also
Reaction of the control to a risk of collision (Page 269)

7.2.2.3 Safety clearance

The safety clearance for all protection areas of the NC monitored for collision is set with the
machine data. The collision avoidance ensures that the safety clearance is not violated.
MD10622 $MN_COLLISION_SAFETY_DIST = <safety clearance>

Note
Collision pair-specific safety clearance
If a specific safety clearance has been set for a collision pair via the system variable
$NP_SAFETY_DIST (Page 283), this has priority over the NC-specific safety clearance set in
the machine data.

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See also
Reaction of the control to a risk of collision (Page 269)

7.2.2.4 Maximum memory space

The maximum value of the memory space in KB that can be allocated to the collision avoidance
is set with the machine data.
MD18896 $MN_MM_MAXNUM_3D_COLLISION = <value>

Value Meaning
0 The maximum value of the memory space is determined automatically by the control using
the following machine data:
● MD18890 $MN_MM_MAXNUM_3D_PROT_AREAS
● MD18892 $MN_MM_MAXNUM_3D_PROT_AREA_ELEM
● MD18894 $MN_MM_MAXNUM_3D_FACETS_INTERN
● MD18895 $MN_MM_MAXNUM_3D_FACETS
>0 Maximum value = parameterized value [KB]

Note
Only one > 0 value must be entered in the machine data when one of the following alarms is
displayed:
● Alarm 26262 "Insufficient memory space for the collision check of two protection areas"
● Alarm 26263 "Insufficient memory space for determining the clearance of two protection
areas"

Used memory space

Various system variables are available to determine the memory space used by the collision
avoidance. See section "Memory requirement (Page 286)".

7.2.2.5 Maximum number of collision pairs

The maximum number of possible collision pairs has an impact on:
● Length m of the system variable fields (e.g. $NP_COLL_PAIR[ m, ... ] )
● The user memory required for collision avoidance
● The size of the commissioning archive
The maximum number of collision pairs can be restricted with machine data:

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MD18898 $MN_MM_MAXNUM_3D_COLL_PAIRS = <value>

<Val‐ Meaning
ue>
0 The following applies to the maximum number of possible collision pairs MCP:
MCP = maximum value of the machine data
x>0 The following applies to the maximum number of possible collision pairs MCP:
MCP = x, with 0 < x ≤ maximum value of the machine data
A value greater than the maximum permissible value of the machine data is limited internally to the
maximum value. No feedback regarding this is sent to the user.

7.2.2.6 Protection levels for collision avoidance On/Off

The protection level for switching the collision avoidance On/Off is set with the machine data
via the user interface. The protection level can be specified according to operating mode and
protection area type.
Machine data = <protection level>

Number Identifier: $MN_ Meaning: Protection level for switching the collision avoidance On/Off
MD51160 ACCESS_WRITE_CA_MACH_JOG Machine protection areas, JOG/MDI operating mode
MD51161 ACCESS_WRITE_CA_MACH_AUTO Machine protection areas, AUTOMATIC mode,
MD51162 ACCESS_WRITE_CA_TOOL Tool protection areas

References
A detailed description of protection levels can be found in:
Function Manual, Basic Functions, Section: "A2: Various NC/PLC interface signals and
functions" > "Functions" > "Access protection via password and keyswitch"

7.2.3 System variables

7.2.3.1 Overview
A collision pair is parameterized with the following system variables:

Name Meaning
$NP_COLL_PAIR Name of a collision pair protection area
$NP_SAFETY_DIST Safety clearance of the protection area pair

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The system variables are described in detail in the following sections.

Note
Establish a defined initial state
It is recommended that a defined initial state be generated before parameterizing the collision
avoidance. To do this, set the system variables of the collision avoidance to their default values
with the DELOBJ() (Page 213) function.
Change system variable values
If the value of one of the system variables listed above is changed, the change becomes
immediately visible at the user interface, e.g. SINUMERIK Operate. The machine model of the
NC is only updated after explicitly requesting that the machine model is recalculated by calling
the PROTA() (Page 289) or PROTS() (Page 290) function.

7.2.3.2 $NP_COLL_PAIR

Function
The names of the two protection areas, which form a collision pair, is entered in a system
variable. The two protection areas can be in any sequence.

Collision pairs
As the collision check requires a lot of computation time, it does not make sense to monitor
all parameterized protection areas for collision with one another through the collision
avoidance. Examples in which a collision check does not make sense:
● Protection areas that cannot collide because of the construction
● Protection areas that have been defined without anchoring to the kinematic chain
The user must define which parameterized protection areas can actually collide on the machine
and define them as collision pairs. Only these protection areas are monitored by the collision
avoidance.
To define a collision pair, the names of the two protection areas must be entered in two system
variables with the same collision pair index. One protection area under the protection area
index 0, the other under the protection area index 1.

Part of a collision pair

Using the COLLPAIR() (Page 287) function, a check can be made as to whether two protection
areas are parameterized as collision pair.

Syntax
$NP_COLL_PAIR[<m>,<i>] = "<name>"

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Meaning

$NP_COLL_PAIR: Name of the first or second protection area of a collision pair

Data type: STRING
Default value: "" "" (empty string)
<m>: System variable or collision pair index
Data type: INT
Range of values: 0, 1, 2, ... (M -1) 1)
<i>: Protection area index
Data type: INT
Range of values: 0 (first protection area), 1 (second protection area)
<name>: Protection area name
Data type: STRING
1)
M = n * (n - 1) / 2
where n = $MN_MM_MAXNUM_3D_PROT_AREAS

Example
Two protection areas defined with the names "Rotary table" and "Tool in spindle" are to be
checked for collision. The two protection areas are to be mutually monitored for collision. The
definition for this is in the seventh collision pair:

Program code Comment

N100 $NP_COLL_PAIR[6,0] = "Rotary ta- ; 7. collision pair,
ble" ; 1. Protection area
N110 $NP_COLL_PAIR[6,1] = "Tool in spin- ; 7. collision pair,
dle" ; 2. Protection area

Supplementary conditions
The protection areas of a collision pair are only checked for collision when both protection
areas are in the "Protection area monitored" state. See Chapter "State diagram: Protection
area (Page 272)".

7.2.3.3 $NP_SAFETY_DIST

Function
The collision pair-specific safety clearance is entered in the system variable. The collision
avoidance ensures that this safety clearance is not violated.
If a value not equal to 0.0 is entered in the system variable, the general safety clearance from
MD10622 $MN_COLLISION_SAFETY_DIST (Page 279) is not taken into account for this
collision pair.

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If the value 0.0 is entered in the system variable, the safety clearance set in the machine data
applies.

Syntax
$NP_SAFETY_DIST[<m>] = <value>

Meaning

$NP_SAFETY_DIST: Safety clearance of the collision pair

Data type: REAL
Default value: 0.0
<m>: System variable or protection area index
Data type: INT
Range of values: 0, 1, 2, ... (M -1) 1)
<value>: Safety clearance
Data type: REAL
Range of values: 0.0 ≤ x ≤ +max. REAL value
Unit: mm or inch depending on the current dimensions set‐
ting
1)
M = n * (n - 1) / 2
where n = $MN_MM_MAXNUM_3D_PROT_AREAS

Example
The safety clearance for the protection areas of the seventh collision pair should be 1.0 mm
(input system: metric).

Program code Comment

N100 $NP_SAFETY_DIST[6] = 1.0 ; 7. collision pair,
; safety clearance = 1.0

See also
Reaction of the control to a risk of collision (Page 269)

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7.2.4 Extend system variables

7.2.4.1 Overview
Further information on the internal states and values of the collision avoidance can be read
via the following system variables:
● State data (Page 285)
● Memory requirement (Page 286)
● Braking distance estimations (Page 286)

7.2.4.2 State data

The state data of the collision avoidance can be read via the following system variables (OPI
variables)

System variable OPI variable Meaning

$AN_COLL_STATE[<m>] anCollState[<m>] Current state of a protection area (active/inactive) with regard
to the collision avoidance
$AN_COLL_STATE_COND[<m> anCollStateCond[<m>] Monitoring state (bit-coded) of a protection area
]
$AN_COLL_IPO_ACTIVE anCollIpoActive Activation state of the collision avoidance in the main run (ac‐
tive/inactive)
$AN_COLL_IPO_LIMIT anCollIpoLimit Velocity reduction through collision avoidance in the main run
(active/inactive)
$AN_COLL_LOAD[<i>] 1) anCollLoad[<i>] 1) Computation time requirement for the collision avoidance func‐
tion <i>
$AN_ACTI‐ anActivateColl‐ Current state of the NC/PLC interface DB10, DBX234.0 - DBX.
VATE_COLL_CHECK[<j>] Check[<j>] 241.7 (activate protection areas) with index j for each 8 bytes
$AN_COLL_CHECK_OFF anCollCheckOff Current state of the NC/PLC interface DB10, DBB58 (switch off
protection area groups depending on the operating mode)
$AA_COLLPOS[<a>] aaCollPos Position of axis <a> in the machine coordinate system (MCS)
when the last collision alarm occurred
$AC_COLLPOS[<k>] acCollPos Vector <k> for the collision position in the world coordinate sys‐
tem when the last collision alarm occurred
a: Axis name
i: 0 = function 1, 1 = function 2, 2 = function 3, ...
j: Index 0, 1, 2, ... for one bit field each of 8 bytes.
k: Coordinate index k = 1, 2, 3 for X, Y, Z coordinates
m: System variable or protection area index 0, 1, 2, ... (MD18890 $MN_MM_MAXNUM_3D_PROT_AREAS - 1)
1) The system variable can be reset by writing the value 0. Every other value is rejected with an error message.

References
For a detailed description of the system variables, refer to:
List Manual, System Variables

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7.2.4.3 Memory requirement

The data for the memory requirement of the collision avoidance can be read via the following
system variables (OPI variables).

System variable OPI variable Meaning

$AN_COLL_MEM_AVAILABLE anCollMemAvailable Size of the memory space in KB reserved for the collision
avoidance.
$AN_COLL_MEM_USE_MIN 1) anCollMemUseMin 1) Minimum value of the memory space used for the collision
avoidance as a percentage of the reserved memory.
$AN_COLL_MEM_USE_MAX 1) anCollMemUseMax 1) Maximum value of the memory space used for the collision
avoidance as a percentage of the reserved memory.
$AN_COLL_MEM_USE_ACT 1) anCollMemUseAct 1) Actual value of the memory space used for the collision avoid‐
ance as a percentage of the reserved memory.
1) The system variable can be reset by writing the value 0. Every other value is rejected with an error message.

References
For a detailed description of the system variables, refer to:
List Manual, System Variables

7.2.4.4 Braking distance estimations

The estimated total braking distance (linear approximation) and the proportional braking
distances of superimposed motions for an axis can be read via the following system variables
(OPI variables). The estimation only takes the current state of the axis into account. It returns,
e.g. the braking distance 0.0 for an axis that is just at the reversal point as part of a circular
path.

Note
The system variables are used for support in the development of user-specific functions as
part of the collision avoidance, and similar functions.

Table 7-1 Basic coordinate system (BCS)

System variable OPI variable Meaning

Total braking distance
$AA_DTBREB[<a>] aaDtbreb Estimated, linearly approximated total braking dis‐
tance
Proportional braking distances for superimposed motions
$AA_DTBREB_CMD[<a>] aaDtbrebCmd Command component
$AA_DTBREB_CORR[<a>] aaDtbrebCorr Correction component
$AA_DTBREB_DEP[<a>] aaDtbrebDep Coupling component
<a>: Axis name

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Table 7-2 Machine coordinate system (MCS)

System variable OPI variable Meaning

Total braking distance
$AA_DTBREM[<a>] aaDtbrem Estimated, linearly approximated total braking dis‐
tance
Proportional braking distances for superimposed motions
$AA_DTBREM_CMD[<a>] aaDtbremCmd Command component
$AA_DTBREM_CORR[<a>] aaDtbremCorr Correction component
$AA_DTBREM_DEP[<a>] aaDtbremDep Coupling component
<a>: Axis name

References
For a detailed description of the system variables, refer to:
List Manual, System Variables

7.3 Programming

7.3.1 Check for collision pair (COLLPAIR)

Function
The COLLPAIR() function determines whether two protection areas form a collision pair.

Syntax
[<RetVal> = ] COLLPAIR(<Name_1>,<Name_2>[,<NoAlarm>)])

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Meaning

COLLPAIR: Check whether part of a collision pair

<RetVal>: Function return value
Data type: INT
Value Meaning
≥0 The two protection areas form a collision pair. Return value ==
collision pair index m, see Section "$NP_COLL_PAIR (Page 282)"
-1 Either two strings have not been specified or at least one of the
two is the zero string.
-2 The protection area specified in the first parameter has not been
found.
-3 The protection area specified in the second parameter has not
been found.
-4 Neither of the two specified protection areas has been found.
-5 Both specified protection areas have been found, but not together
in a collision pair.
<Name_1>: Name of the first protection area
Data type: STRING
Range of val‐ Parameterized protection area names
ues:
<Name_2>: Name of the second protection area
Data type: STRING
Range of val‐ Parameterized protection area names
ues:
<NoAlarm>: Alarm suppression (optional)
Data type: BOOL
Default value: FALSE
Value Meaning
FALSE In the event of an error (<RetVal> < 0), the program processing
is stopped and an alarm displayed.
TRUE In the event of an error, the program processing is not stopped
and no alarm displayed.
Application:
User-specific reaction corresponding to the return value

See also
State diagram: Protection area (Page 272)

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7.3.2 Request recalculation of the machine model of the collision avoidance (PROTA)

Function
If system variables of the kinematic chain $NK_..., the geometric machine modeling or the
collision avoidance $NP_... are written in the part program, the PROTA procedure must
subsequently be called so that the change becomes effective in the NC-internal machine model
of the collision avoidance.

Syntax
PROTA[(<Par>)]

Meaning

PROTA: Request recalculation of the machine model of the collision avoidance

Boundary conditions:
● Triggers a preprocessing stop
● Must be alone in the block
<Par>: Parameter (optional)
Data type: STRING
Range of values: "R"
Value Meaning
--- No parameters.
The machine model is recalculated. The states of the protec‐
tion areas are retained.
"R" The machine model is recalculated. The protection areas are
set to their initialization status corresponding to $NP_IN‐
IT_STAT (Page 242).

Supplementary conditions

Simulation
The PROTA procedure must not be used in part programs in conjunction with the simulation
(simNCK).
Example: Avoiding the call of PROTA while the simulation is active.

Program code Comment

...
IF $P_SIM == FALSE ; IF simulation not active
PROTA ; THEN recalculate machine model
ENDIF ; ENDIF
...

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See also
Setting the protection area state (PROTS) (Page 290)

7.3.3 Setting the protection area state (PROTS)

Function
The PROTS() procedure sets the state of protection areas to the specified value.

Syntax
PROTS(<state>{, <name>})

Meaning

PROTS: Sets the state of protection areas

The status is set for all defined protection areas if a protection area is not specified.
Supplementary condition: Must be alone in the block
<state>: State to which the specified protection areas are to be set
Data type: CHAR
Value Status
"A"or "a" Active
"I"or "i" Inactive
"P"or "p" Preactivated or PLC-controlled 1)
"R"or "r" NC-internal value of the initialization status 2)
<name>: Name of one or more protection areas that are to be set to the specified state.
(optional)
Note
The maximum number of protection areas that can be specified as parameters
depends only on the maximum possible number of characters per program line.
Data type: STRING
Range of values: Parameterized protection area names
1) The activation/deactivation is performed via: DB10.DBX234.0 - DBX241.7
2) The status is set to the NC-internal value of the initialization status, i.e. to the value that the system
variable $NP_INIT_STAT (Page 242) had at the time of the last PROTA( ) (Page 289) call.

7.3.4 Determining the clearance of two protection areas (PROTD)

Function
The PROTD() function calculates the clearance of two protection areas.

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Function properties:
● The clearance calculation is performed independent of the protection area state (activated,
deactivated, preactivated).
● The clearance is calculated at the interpretation instant of the function with the axis positions
valid at the end of the previous block.
● Overlays that are included in the main run calculation, e.g. DRF offset or external work
offsets, are included in the clearance calculation with the values valid at the function
interpretation time.
Note
Synchronization
When using the PROTD() function, it is the sole responsibility of the user to synchronize
the main run and preprocessing, if required, with the STOPRE preprocessing stop.

Collision
If there is a collision between the specified protection areas, the function returns a clearance
of 0.0. There is a collision if both the protection areas touch or intersect each other.
The safety clearance for the collision check (MD10622 $MN_COLLISION_SAFETY_DIST) is
not taken into account in the clearance calculation.

Syntax
[<RetVal> = ] PROTD([<Name_1>],[<Name_2>],VAR <Vector>[,<System>])

Meaning

PROTD: Calculates the clearance of the two specified protection areas.

Supplementary condition: Must be alone in the block
<RetVal>: Function return value: Absolute clearance value of the two protection areas or 0.0
with collision (see above: collision paragraph)
Data type: REAL
Range of values: 0.0 ≤ x ≤ +max. REAL value
<Name_1>, Names of the two protection areas whose clearance is to be calculated.
<Name_2>: Data type: STRING
Default value: "" "" (empty string)
Range of values: Parameterized protection area names
<Vector>: Return value: 3-dimensional clearance vector from protection area <Name_2> to
protection area <Name_1> with:
● <Vector>[0]: X coordinate in the world coordinate system
● <Vector>[1]: Y coordinate in the world coordinate system
● <Vector>[2]: Z coordinate in the world coordinate system
With collision: <Vector> == zero vector
Data type: VAR REAL [3]
Range of values: <Vector>[n]: 0.0 ≤ x ≤ ±max. REAL value

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<System>: Measuring system (inch/metric) for clearance and clearance vector (optional)
Data type: BOOL
Default value: FALSE
Value Meaning
FALSE Measuring system corresponding to the currently active G func‐
tion from G group 13 (G70, G71, G700, G710).
TRUE Measuring system corresponding to the set basic system:
MD52806 $MN_ISO_SCALING_SYSTEM

7.4 Example

7.4.1 Specifications

General Information
The basic procedure when parameterizing collision avoidance using a part program is shown
using a simplified 3-axis milling machine as example. All of the system variables relevant for
collision avoidance are written to the part program:
● Kinematic chain $NK_...
● Geometric machine modeling $NP_...
● Collision avoidance $NP_...
The machine model is subsequently activated in the part program, so that after executing the
part program, the collision avoidance has been completely parameterized in the 3-axis milling
machine and is active.

Option and machine data

The following option and machine data must be set for the example:

No. Option data: $ON_ Value

MD19830 COLLISION_MASK 1

No. Machine data: $MN_ Value

MD10619 COLLISION_TOLERANCE 1
MD18880 MM_MAXNUM_KIN_CHAIN_ELEM 10
MD18890 MM_MAXNUM_3D_PROT_AREAS 10
MD18892 MM_MAXNUM_3D_PROT_AREA_ELEM 10
MD18893 MM_MAXNUM_3D_T_PROT_ELEM 1
MD18894 MM_MAXNUM_3D_FACETS_INTERN 1000
MD18895 MM_MAXNUM_3D_FACETS 3000

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No. Machine data: $MN_ Value

MD18896 MM_MAXNUM_3D_COLLISION 0
MD18897 MM_MAXNUM_3D_INTERFACE_IN 16
MD18899 PROT_AREA_TOOL_MASK 1

Principle design of the 3-axis milling machine

The principle machine design is shown in the following diagram.

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The machine parts and/or protection areas are assigned to the following machine axes.

Machine parts and/or protection areas Machine axis

Table X1, Y1
Z axis Z1
Column ---
Tool holder Z1
Tool Z1

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Dimension drawing
The dimensions of the protection area elements as well as their position (vectors to the center
point of the protection area element) referred to the machine zero point are specified in the
following dimension drawing.







9ZA




9S


9Tool





=
<



;
9T







Vectors to the center point of the protection area elements

vtool Tool adapter (0;0;25)
vZA Z axis (0;200;130)
vS Column (0;570;350)
vT Table (0;0;-50)

Kinematic chain
The kinematic chain (see next diagram) starts with an "Offset" type element. These are
assigned to all static protection areas of the machine. In the example, this is only the "Column"
protection area.
The kinematic elements of the machine axes follow the offset element:
● Z axis and X axis traverse independently of one another ⇒ $NK_PARALLEL
● The Y axis traverses dependent on the X axis ⇒ $NK_NEXT
The various protection areas of the geometric machine modeling are assigned the kinematic
elements of the machine axes

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Collision pairs
For the example, it is assumed that only the following collision pairs are to be taken into account:
● Tool adapter - table
● Tool - table

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7.4.2 Part program of the machine model

Program code
;***********************************************************
;************************* Example ************************
; milling machine: 3 linear axes, 1 spindle
; table => X1, Y1
; Z axis, tool adapter, tool => Z1
;***********************************************************
; status: 2/11/2013, 15:34
;
;===========================================================
; collision machine data used
;===========================================================
; MD10619 $MN_COLLISION_TOLERANCE = 1
;
; MD18880 $MN_MM_MAXNUM_KIN_CHAIN_ELEM = 100
; MD18890 $MN_MM_MAXNUM_3D_PROT_AREAS = 10
; MD18892 $MN_MM_MAXNUM_3D_PROT_AREA_ELEM = 10
; MD18893 $MN_MM_MAXNUM_3D_T_PROT_ELEM = 100
; MD18894 $MN_MM_MAXNUM_3D_FACETS_INTERN = 1000
; MD18895 $MN_MM_MAXNUM_3D_FACETS = 3000
; MD18896 $MN_MM_MAXNUM_3D_COLLISION = 0
; MD18897 $MN_MM_MAXNUM_3D_INTERFACE_IN = 16
; MD18899 $MN_PROT_AREA_TOOL_MASK = 1
;
; MD19830 $ON_COLLISION_MASK = 1 ; option
;
;
;===========================================================
; definitions
;===========================================================
DEF INT RETVAL = 0 ; return value of the delete function
;
DEF INT C_NKE = 0 ; index for kinematic elements
DEF INT C_NPC = 0 ; index for protection areas
DEF INT C_NPE = 0 ; index for protection area elements
DEF INT C_NPP = 0 ; index for collision pairs
;
;

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Program code
;===========================================================
; initialization of the collision data
;===========================================================
MSG("protection areas")
G4 F3
; reset all parameters to their initial setting
;
RETVAL = DELOBJ("KIN_CHAIN_ELEM")
IF (RETVAL <> 0)
MSG("error: DELOBJ KIN_CHAIN_ELEM")
G4 F5
ENDIF
;
RETVAL = DELOBJ("PROT_AREA_ALL")
IF RETVAL <> 0
MSG("error: DELOBJ PROT_AREA_ALL")
G4 F5
ENDIF
;
RETVAL = DELOBJ("PROT_AREA_COLL_PAIRS")
IF RETVAL <> 0
MSG("error: DELOBJ PROT_AREA_COLL_PAIRS")
G4 F5
ENDIF
;
;
;===========================================================
; kinematic chain
;===========================================================
; KE1: ROOT
; ----------------------------------------------------------
$NK_NAME[C_NKE] = "ROOT"
$NK_NEXT[C_NKE] = "X axis"
$NK_PARALLEL[C_NKE] = ""
$NK_TYPE[C_NKE] = "OFFSET"
;
$NK_OFF_DIR[C_NKE, 0] = 0.0 ; X
$NK_OFF_DIR[C_NKE, 1] = 0.0 ; Y
$NK_OFF_DIR[C_NKE, 2] = 0.0 ; Z
;
$NK_AXIS[C_NKE] = ""
$NK_A_OFF[C_NKE] = 0.0
;
C_NKE = C_NKE + 1 ; next kinematic element
;

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Program code
; ----------------------------------------------------------
; kinematic element: X axis
; ----------------------------------------------------------
$NK_NAME[C_NKE] = "X axis"
$NK_NEXT[C_NKE] = "Y axis"
$NK_PARALLEL[C_NKE] = "Z axis"
$NK_TYPE[C_NKE] = "AXIS_LIN"
;
$NK_OFF_DIR[C_NKE, 0] = 1.0 ; X
$NK_OFF_DIR[C_NKE, 1] = 0.0 ; Y
$NK_OFF_DIR[C_NKE, 2] = 0.0 ; Z
;
$NK_AXIS[C_NKE] = "X1"
$NK_A_OFF[C_NKE] = 0.0
;
C_NKE = C_NKE + 1 ; next kinematic element
;
; ----------------------------------------------------------
; kinematic element: Y axis
; ----------------------------------------------------------
$NK_NAME[C_NKE] = "Y axis"
$NK_NEXT[C_NKE] = ""
$NK_PARALLEL[C_NKE] = ""
$NK_TYPE[C_NKE] = "AXIS_LIN"
;
$NK_OFF_DIR[C_NKE, 0] = 0.0 ; X
$NK_OFF_DIR[C_NKE, 1] = 1.0 ; Y
$NK_OFF_DIR[C_NKE, 2] = 0.0 ; Z
;
$NK_AXIS[C_NKE] = "Y1"
$NK_A_OFF[C_NKE] = 0.0
;
C_NKE = C_NKE + 1 ; next kinematic element
;
; ----------------------------------------------------------
; kinematic element: Z axis
; ----------------------------------------------------------
$NK_NAME[C_NKE] = "Z axis"
$NK_NEXT[C_NKE] = ""
$NK_PARALLEL[C_NKE] = ""
$NK_TYPE[C_NKE] = "AXIS_LIN"
;
$NK_OFF_DIR[C_NKE, 0] = 0.0 ; X
$NK_OFF_DIR[C_NKE, 1] = 0.0 ; Y
$NK_OFF_DIR[C_NKE, 2] = 1.0 ; Z
;
$NK_AXIS[C_NKE] = "Z1"
$NK_A_OFF[C_NKE] = 0.0
;
C_NKE = C_NKE + 1 ; next kinematic element
;
;

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Program code
;===========================================================
; protection areas with protection area elements
;===========================================================
; protection area 1: Column
; ----------------------------------------------------------
$NP_PROT_NAME[C_NPC] = "column"
$NP_PROT_TYPE[C_NPC] = "MACHINE"
$NP_CHAIN_ELEM[C_NPC] = "ROOT"
$NP_1ST_PROT[C_NPC] = "SBE column"
$NP_PROT_COLOR[C_NPC] = 'HFFA0A0A4' ; AARRGGBB
$NP_BIT_NO[C_NPC] = -1
$NP_INIT_STAT[C_NPC] = "A"
;
C_NPC = C_NPC + 1 ; next protection area
;
; ----------------------------------------------------------
; protection area element 1.1: SBE column
; ----------------------------------------------------------
$NP_NAME[C_NPE] = "SBE column"
$NP_NEXT[C_NPE] = ""
$NP_NEXTP[C_NPE] = ""
$NP_TYPE[C_NPE] = "BOX"
; cube dimensions
$NP_PARA[C_NPE,0] = 160.0 ; length
$NP_PARA[C_NPE,1] = 140.0 ; width
$NP_PARA[C_NPE,2] = 800.0 ; height
; center point
$NP_OFF[C_NPE,0] = 0.0 ; X
$NP_OFF[C_NPE,1] = 570.0 ; Y: xxx rear table edge
$NP_OFF[C_NPE,2] = 350.0 ; Z: Lower edge equal to lower edge table
;
$NP_DIR[C_NPE,0] = 0.0
$NP_DIR[C_NPE,1] = 0.0
$NP_DIR[C_NPE,2] = 0.0
;
$NP_ANG[C_NPE] = 0.0
;
$NP_COLOR[C_NPE] = 0
$NP_D_LEVEL[C_NPE] = 0
$NP_USAGE[C_NPE] = "V" ; V = visualize only
$NP_FILENAME[C_NPE] = ""
;
C_NPE = C_NPE + 1 ; next protection area element
;

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Program code
;++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
; protection area 2: Tool adapter
; ----------------------------------------------------------
$NP_PROT_NAME[C_NPC] = "tool adapter"
$NP_PROT_TYPE[C_NPC] = "MACHINE"
$NP_CHAIN_ELEM[C_NPC] = "Z axis"
$NP_1ST_PROT[C_NPC] = "SBE tool adapter"
$NP_PROT_COLOR[C_NPC] = 'HFF0000FF' ; AARRGGBB
$NP_BIT_NO[C_NPC] = -1
$NP_INIT_STAT[C_NPC] = "A"
;
C_NPC = C_NPC + 1 ; next protection area
;
; ----------------------------------------------------------
; protection area element 2.1: SBE tool adapter
; ----------------------------------------------------------
$NP_NAME[C_NPE] = "SBE tool adapter"
$NP_NEXT[C_NPE] = ""
$NP_NEXTP[C_NPE] = ""
$NP_TYPE[C_NPE] = "CYLINDER"
; cylinder dimensions
$NP_PARA[C_NPE,0] = 50.0 ; height
$NP_PARA[C_NPE,1] = 60.0 ; radius
$NP_PARA[C_NPE,2] = 0.0
; center point
$NP_OFF[C_NPE,0] = 0.0 ; X
$NP_OFF[C_NPE,1] = 0.0 ; Y
$NP_OFF[C_NPE,2] = 25.0 ; Z: Half height
;
$NP_DIR[C_NPE,0] = 0.0
$NP_DIR[C_NPE,1] = 0.0
$NP_DIR[C_NPE,2] = 0.0
;
$NP_ANG[C_NPE] = 0.0
;
$NP_COLOR[C_NPE] = 0
$NP_D_LEVEL[C_NPE] = 0
$NP_USAGE[C_NPE] = "A"
$NP_FILENAME[C_NPE] = ""
;
C_NPE = C_NPE + 1 ; next protection area element
;

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7.4 Example

Program code
; ++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
; protection area 3: Tool
; ----------------------------------------------------------
$NP_PROT_NAME[C_NPC] = "WKZ"
$NP_PROT_TYPE[C_NPC] = "TOOL"
$NP_CHAIN_ELEM[C_NPC] = "Z axis"
$NP_1ST_PROT[C_NPC] = ""
$NP_PROT_COLOR[C_NPC] = 'HFFFF0000' ; AARRGGBB
$NP_BIT_NO[C_NPC] = -1
$NP_INIT_STAT[C_NPC] = "A"
; only relevant for type "TOOL"
$NP_INDEX[C_NPC,0] = 1 ; tool location No. / spindle No.
$NP_INDEX[C_NPC,1] = 9998 ; magazine No. / -
$NP_INDEX[C_NPC,2] = 1 ; TOA area
;
C_NPC = C_NPC + 1 ; next protection area
;

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K9: Collision avoidance - only 840D sl
7.4 Example

Program code
; ++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
; protection area 4: Z axis
; ----------------------------------------------------------
$NP_PROT_NAME[C_NPC] = "Z axis"
$NP_PROT_TYPE[C_NPC] = "MACHINE"
$NP_CHAIN_ELEM[C_NPC] = "Z axis"
$NP_1ST_PROT[C_NPC] = "SBE Z axis"
$NP_PROT_COLOR[C_NPC] = 'HFFA0A0A4' ; AARRGGBB
$NP_BIT_NO[C_NPC] = -1
$NP_INIT_STAT[C_NPC] = "A"
;
C_NPC = C_NPC + 1 ; next protection area
;
; ----------------------------------------------------------
; protection area element 4.1: SBE horizontal column
; ----------------------------------------------------------
$NP_NAME[C_NPE] = "SBE Z axis"
$NP_NEXT[C_NPE] = ""
$NP_NEXTP[C_NPE] = ""

$NP_TYPE[C_NPE] = "BOX"
;
$NP_PARA[C_NPE,0] = 160.0
$NP_PARA[C_NPE,1] = 600.0
$NP_PARA[C_NPE,2] = 160.0
;
$NP_OFF[C_NPE,0] = 0.0
$NP_OFF[C_NPE,1] = 200.0
$NP_OFF[C_NPE,2] = 130.0
;
$NP_DIR[C_NPE,0] = 0.0
$NP_DIR[C_NPE,1] = 0.0
$NP_DIR[C_NPE,2] = 0.0
;
$NP_ANG[C_NPE] = 0.0
;
$NP_COLOR[C_NPE] = 0
$NP_D_LEVEL[C_NPE] = 0
$NP_USAGE[C_NPE] = "A"
$NP_FILENAME[C_NPE] = ""
;
C_NPE = C_NPE + 1 ; next protection area element
;

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 K9: Collision avoidance - only 840D sl
7.4 Example

Program code
; ++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
; protection area 5: Table
; --------------------------------------------------------
$NP_PROT_NAME[C_NPC] = "table"
$NP_PROT_TYPE[C_NPC] = "MACHINE"
$NP_CHAIN_ELEM[C_NPC] = "Y axis"
$NP_1ST_PROT[C_NPC] = "SBE table"
$NP_PROT_COLOR[C_NPC] = 'HFF00FF00' ; AARRGGBB
$NP_BIT_NO[C_NPC] = -1
$NP_INIT_STAT[C_NPC] = "A"
;
C_NPC = C_NPC + 1 ; next protection area
;
; ----------------------------------------------------------
; protection area element 5.1: SBE table
; ----------------------------------------------------------
$NP_NAME[C_NPE] = "SBE table"
$NP_NEXT[C_NPE] = ""
$NP_NEXTP[C_NPE] = ""
$NP_TYPE[C_NPE] = "BOX"
;
$NP_PARA[C_NPE,0] = 1000.0
$NP_PARA[C_NPE,1] = 500.0
$NP_PARA[C_NPE,2] = 100.0
;
$NP_OFF[C_NPE,0] = 0.0
$NP_OFF[C_NPE,1] = 0.0
$NP_OFF[C_NPE,2] = -50.0
;
$NP_DIR[C_NPE,0] = 0.0
$NP_DIR[C_NPE,1] = 0.0
$NP_DIR[C_NPE,2] = 0.0
;
$NP_ANG[C_NPE] = 0.0
;
$NP_COLOR[C_NPE] = 0
$NP_D_LEVEL[C_NPE] = 0
$NP_USAGE[C_NPE] = "A"
$NP_FILENAME[C_NPE] = ""
;
C_NPE = C_NPE + 1 ; next protection area element
;
;

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K9: Collision avoidance - only 840D sl
7.5 Data lists

Program code
;===========================================================
; collision pairs
;===========================================================
$NP_COLL_PAIR[C_NPP, 0] = "Tool adapter"
$NP_COLL_PAIR[C_NPP, 1] = "Table"
;
C_NPP = C_NPP + 1 ; next collision pair
;
$NP_COLL_PAIR[C_NPP, 0] = "T"
$NP_COLL_PAIR[C_NPP, 1] = "Table"
;
C_NPP = C_NPP + 1 ; next collision pair
;
;
;===========================================================
; activating the machine model
;===========================================================
PROTA
PROTS("A")
;
M2
;========================= END ===========================

7.5 Data lists

7.5.1 Machine data

7.5.1.1 NC-specific machine data

Number Identifier: $MN_ Description

MD10619 COLLISION_TOLERANCE Collision tolerance
MD10622 COLLISION_SAFETY_DIST Safety clearance
MD18896 MM_MAXNUM_3D_COLLISION Memory location for the collision avoidance

7.5.2 System variables

Identifier Description
$NP_COLL_PAIR Name of the first or second protection area of a collision pair
$NP_SAFETY_DIST Safety clearance of the collision pair
$AN_COLL_STATE Current state of a protection area with regard to the collision avoidance
$AN_COLL_STATE_COND Monitoring state (bit-coded) of a protection area

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 K9: Collision avoidance - only 840D sl
7.5 Data lists

Identifier Description
$AN_COLL_IPO_ACTIVE Activation state of the collision avoidance in the main run
$AN_COLL_IPO_LIMIT Velocity reduction through collision avoidance in the main run
$AN_COLL_LOAD Computation time requirement for the collision avoidance function
$AN_ACTIVATE_COLL_CHECK Current state of the NC/PLC interface DB10, DBX234.0 - DBX.241.7 (activate
protection areas)
$AN_COLL_CHECK_OFF Current state of the NC/PLC interface DB10, DBB58 (switch off protection
area groups depending on the operating mode)
$AA_COLLPOS Position of an axis in the MCS when the last collision alarm occurred
$AC_COLLPOS Vector for the collision position in the world coordinate system when the last
collision alarm occurred
$AN_COLL_MEM_AVAILABLE Size of the memory space in KB reserved for the collision avoidance.
$AN_COLL_MEM_USE_MIN Minimum value of the memory space used for the collision avoidance as a
percentage of the reserved memory.
$AN_COLL_MEM_USE_MAX Maximum value of the memory space used for the collision avoidance as a
percentage of the reserved memory.
$AN_COLL_MEM_USE_ACT Actual value of the memory space used for the collision avoidance as a per‐
centage of the reserved memory.
$AA_DTBREB Estimated, linearly approximated total braking distance (BCS)
$AA_DTBREB_CMD Command component (BCS)
$AA_DTBREB_CORR Correction component (BCS)
$AA_DTBREB_DEP Coupling component (BCS)
$AA_DTBREM Estimated, linearly approximated total braking distance (MCS)
$AA_DTBREM_CMD Command component (MCS)
$AA_DTBREM_CORR Correction component (MCS)
$AA_DTBREM_DEP Coupling component (MCS)

7.5.3 Signals

7.5.3.1 Signals to NC

Signal name SINUMERIK 840D sl SINUMERIK 828D

Collision avoidance: Deactivate protection area group DB10.DBX58.0 - 7 ---
Collision avoidance: Activate protection area DB10.DBX234.0 - DBX241.7 ---

7.5.3.2 Signals from NC

Signal name SINUMERIK 840D sl SINUMERIK 828D

Collision avoidance: Protection area active DB10.DBX226.0 - DBX233.7 ---

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7.5 Data lists

7.5.3.3 Signals from channel

Signal name SINUMERIK 840D sl SINUMERIK 828D

Collision avoidance: Stop DB21, ... .DBX377.0 ---

7.5.3.4 Signals from axis

Signal name SINUMERIK 840D sl SINUMERIK 828D

Collision avoidance: Velocity reduction DB31, ... .DBX77.0 ---

Special functions
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M3: Coupled axes 8
8.1 Coupled motion

8.1.1 Brief description

8.1.1.1 Function
The "coupled motion" function enables the definition of simple axis links between a master
axis and a slave axis, taking into consideration a coupling factor.
Coupled motion has the following features:
● Any axis of the NC can be defined as a master axis.
● Any axis of the NC can be defined as a coupled axis with a specific coupling factor.
● The master axis and coupled motion axis or axes together form a coupled axis grouping.
● Any number of coupled motion axes can be assigned to a master axis.
● A total of 2 leading axes may be assigned to each coupled motion axis.
● A coupled motion axis can be the master axis of a further coupled axis grouping.
● Traversing movements of the master axis are executed in synchronism on all slave axes
based on the coupling factor.
● Coupled motion axes can be moved independently of the master axis while the coupling is
active (overlaid movements).
● The master and coupled motion axes of a coupled axis grouping are defined, and the
coupling switch on/switch off, by programming instructions in the part program or by
synchronized action.
● Coupled motion is also possible in the following manual modes: JOG, JOG REF, JOG INC,
etc.

8.1.1.2 Preconditions

Coupled motion function

The coupled motion function forms part of the NCK software.

Generic coupling
The coupled motion functionality is also available in the generic coupling.

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M3: Coupled axes
8.1 Coupled motion

However, for basic operation of generic coupling, the following restrictions apply:
● The maximum number of coupled motion groupings is limited to 4.
● Only 1 leading axes may be assigned to each coupled motion axis.
● Cascading is not possible.
Note
These restrictions do not apply when NCK software is supplied with the relevant options of
generic coupling (refer to " Preconditions (Page 380) " in the "Brief Description" of Generic
Coupling).

8.1.2 General functionality

The "Coupled motion" function allows the definition of simple axis couplings. Coupling is
performed from one leading axis to one or more following axes, the so-called coupled motion
axes. A separate coupling factor can be specified for each coupled motion axis.

Coupled axis grouping

The leading axis and all the coupled motion axes assigned to it together form a coupled axis
grouping. If the leading axis is traversed, all coupled motion axes traverse in accordance with
their coupling factors.
A coupled axis grouping can consist of any combination of linear and rotary axes.

Leading axes
Any axis of the NC, including simulated axes, can be used as leading axis.

Coupled axes
Any axis of the NC can be used as coupled motion axis.

Coupling factor
The ratio in which the coupled motion axis moves in relation to the leading axis is specified via
the coupling factor.
Coupling factor K = motion of the coupled motion axis / motion of the leading axis
Negative coupling factors (motion of the coupled motion axis in the opposite direction) are also
permitted.

Special functions
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 M3: Coupled axes
8.1 Coupled motion

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Figure 8-1 Application example: Two-sided machining

Multiple couplings
Up to 2 leading axes can be assigned to one coupled motion axis. The traversing movement
of the coupled motion axis then results from the sum of the traversing movements of the leading
axes.

Dependent coupled motion axis

A coupled motion axis is a "dependent coupled motion axis" when it traverses as a result of a
leading axis movement.

Independent coupled motion axis

A coupled motion axis is an "independent coupled motion axis" when it traverses as a result
of a direct traverse instruction. The traversing movement resulting from the coupled motion
axis is then the sum total of the traversing movements as a "dependent" and an "independent"
coupled motion axis.

Coupled motion axis as leading axis

A coupled motion axis can at the same time be the leading axis of a further coupled axis
grouping.

Coordinate system
Coupled axis motion is always executed in the base coordinate system (BCS).

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M3: Coupled axes
8.1 Coupled motion

Activating/deactivating
Coupled motion can be activated/deactivated via the part programs and synchronous actions.
In this context please ensure activating/deactivating is undertaken with the same programming:
● Activate: Part program → Deactivate: Part program
● Activate: Synchronous action → Deactivate: Synchronized action

Synchronization on-the-fly
If switch on is performed while the leading axis is in motion, the coupled motion axis is first
accelerated to the velocity corresponding to the coupling. The position of the leading axis at
the time the velocities of the leading and coupled motion axes are synchronized then serves
as the start position for further coupled motion.

Operating modes
Coupled motion is effective in the AUTOMATIC, MDA and JOG modes.

Reference point approach

The following applies for referencing of axes of a coupled axis grouping:
● Leading axes
When referencing the leading axis of a coupled axis grouping, the coupling to all coupled
motion axes is retained. The coupled motion axes move in synchronism with the leading
axis, as a function of their coupling factors.
● Coupled motion axis: JOG/REF mode
When referencing a coupled motion axis of a coupled axis grouping, the coupling to the
leading axis is cancelled. If the coupling is canceled, the following alarm is displayed:
Alarm 16772 "Channel Channel No. block Block No. Axis Axis No. is following axis, coupling
is opened."
The coupling is not activated again until JOG/REF mode is cancelled.
The display of this alarm can be suppressed using the following machine data:
MD11410 $MN_SUPPRESS_ALARM_MASK, Bit 29 = 1 (mask supporting special alarm
generation)

CAUTION
No coupling
When the coupled motion axis is referenced, the coupling to the leading axis is cancelled.
If referencing is executed immediately with the leading axis, i.e. without changing JOG/
REF mode, the coupled motion axis does not traverse with the leading axis.

● Coupled motion axis: Part program command G74

It is not possible to reference a coupled motion axis of a coupled axis grouping using the
G74 programming instruction.

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 M3: Coupled axes
8.1 Coupled motion

Distance-to-go: Coupled motion axis

The distance-to-go of a coupled motion axis refers to the total residual distance to be traversed
from dependent and independent traversing.

Delete distance-to-go: Coupled motion axis

Delete distance-to-go for a coupled motion axis only results in aborting of the independent
traversing movement of the leading axis.

Response to NC Start
The behavior of the coupled-axis groupings during NC Start depends on the setting in the
machine data:
MD20112 $MC_START_MODE_MASK (definition of initial control settings for NC-START)

Bit Value Meaning

8 0 Coupled-axis groupings are maintained in NC Start.
1 Coupled-axis groupings are phased out in NC Start.

Response to RESET/part program end

The behavior of the coupled-axis groupings during RESET/ part program end depends on the
setting in the machine data:
MD20110 $MC_RESET_MODE_MASK (definition of initial control settings after RESET / TP
end)

Bit Value Meaning

8 0 Coupled-axis groupings are invalidated on RESET / part program end.
1 Coupled-axis groupings remain active even beyond RESET/part program end.

Note
If with NC RESET or end of part program in a channel, the leading axis is not stopped as well
(cross-channel coupling, command axis, PLC axis, etc.), the requested RESET cannot be
completed.
Because of traversing of the leading axis, the coupled-motion axis is still active for the channel
in which the RESET is requested. With suitable actions (NC RESET in the channel of the
leading axis, stopping of the command or PLC axis), the leading axis must also be stopped in
parallel to the coupled-motion axis.

Special functions
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M3: Coupled axes
8.1 Coupled motion

8.1.3 Programming

8.1.3.1 Definition and switch on of a coupled axis grouping (TRAILON)

Definition and switch on of a coupled axis grouping take place simultaneously with the
TRAILON part program command.

Programming

Syntax: TRAILON(<coupled motion axis>, <leading axis>,

[<coupling factor>])
Effectiveness: modal
Parameters:
Coupled motion Type: AXIS
axis: Range of values:All defined axis and spindle names in the channel
Leading axis: Type: AXIS
Range of values:All defined axis and spindle names in the channel
Coupling factor: The ratio of the traversing movement of the coupled motion axis to the
leading axis is specified via the optional coupling factor:
Coupling factor = Path of the coupled-motion axis/path of the leading
axis
A negative coupling factor results in motion in opposite directions for
the leading and coupled motion axis.

Type: REAL
Range of values:± (2,2 * 10-308 … 1,8 * 10+308)
Default value: +1.0
Example:

Program code Comment

TRAILON(V,Y,2) ; Definition and switch on of the coupling of the
coupled-motion axis V with leading axis Y. The
coupling factor is 2.

8.1.3.2 Switch off (TRAILOF)

Switch off of the coupling of a coupled-motion axis with a leading axis takes place through the
TRAILOF part program command.

Programming

Syntax: TRAILON(<coupled motion axis>, <leading axis>)

TRAILOF(<coupled-motion axis>)
Effectiveness: modal

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 M3: Coupled axes
8.1 Coupled motion

Parameters:
Coupled motion Type: AXIS
axis: Range of val‐ All defined axis and spindle names in the channel
ues:
Leading axis: Type: AXIS
Range of val‐ All defined axis and spindle names in the channel
ues:
Example:

Program code Comment

TRAILOF(V,Y) ; Deactivation of the coupling of the coupled-motion
; axis
V to leading axis Y.

8.1.4 Effectiveness of PLC interface signals

Independent coupled motion axis

All the associated channel and axis specific interface signals of the coupled-motion axis are
effective for the independent motion of a coupled-motion axis, e.g.:
● DB21, ... DBX0.3 (Activate DRF)
● DB31, ... DBX0.0 - 0.7 (feed offset)
● DB31, ... DBX1.3 (axis blocking)
● DB31, ... DBX2.1 (control system enable)
● DB31, ... DBX4.0 - 4.2 (activate handwheel)
● DB31, ... DBX4.3 (feed stop)
● …
This allows the speed to be changed for the independent motion of a coupled motion axis using
a feed override or a DRF offset to be defined using the handwheel in AUTOMATIC and MDA
modes.

Dependent coupled motion axis

With respect to the motion of a coupled motion axis, which is dependent on the leading axis,
only the coupled-motion axis interface signals that effect termination of the motion (e.g. axis-
specific feed stop, axis inhibit, control system enable, etc.) are effective.

Special functions
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M3: Coupled axes
8.1 Coupled motion

Leading axis
When a coupled axis grouping is active, the interface signals (IS) of the leading axis are applied
to the appropriate coupled motion axis via the axis coupling, i.e.
● A position offset or feed control action of the leading axis is applied via the coupling factor
to effect an appropriate position offset or feed control action in the coupled motion axis.
● Shutdown of the leading axis as the result of an interface signal (e.g. axis-specific feed
stop, axis inhibit, servo enable, etc.) causes the corresponding coupled motion axis to shut
down.

Position measuring system 1/2 (DB31, ... DBX1.5/1.6))

Switch-over of the position measuring system for the leading and coupled motion axes is not
inhibited for an active coupled axis grouping. The coupling is not canceled.
Recommendation: Switch-over the measuring system when the coupling is deactivated.

Tracking (DB31, ... DBX1.4)

Activation of tracking for an axis is done via the PLC program by setting the following NC/PLC
interface signals:
DB31, ... DBX2.1 = 0 (control system enable)
DB31, ... DBX1.4 == 1 (tracking mode)
When activating tracking mode for a coupled axis grouping, the specified NC/PLC interface
signals must be set simultaneously for all axes (master and slave axes) of the coupled axis
group.
If tracking mode is activated for the master axis only, a permanent offset results within the
coupling.
Whether and which axis is a leading or a following axis can be seen from the following NC/
PLC interface signals and system variables:
DB31, ... DBX99.0 (leading axis/spindel active)
DB31, ... DBX99.1 (following axis/spindel active)
$AA_COUP_ACT[axis name] (see: Status of coupling)

8.1.5 Status of coupling

The coupling status of an axis can be determined using the following system variables:
$AA_COUP_ACT [axis name]

Value Meaning
0 No coupling active
1, 2, 3 Tangential tracking
4 Synchronous spindle coupling
8 Coupled motion active

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 M3: Coupled axes
8.1 Coupled motion

Value Meaning
16 Master value coupling
32 Following axis of electronic gearbox

Note
Only one coupling mode may be active at any given time.

8.1.6 Dynamics limit

The dynamics limit is dependent on the type of activation of the coupled axis grouping:
● Activation in part program
If activation is performed in the part program and all leading axes are active as program
axes in the activating channel, the dynamic response of all coupled-motion axes is taken
into account during traversing of the leading axes to avoid overloading the coupled-motion
axes.
If activation in part program takes place with leading axes that are not active as program
axes in the activating channel ($AA_TYP ≠ 1), then the dynamics of the coupled motion
axes is not considered while traversing the leading axes. This can result in an overload for
coupled motion axes with a dynamic response which is less than that required for the
coupling.
● Activation in synchronized action
If activation is performed in a synchronous action, dynamics of the coupled motion axes is
not taken into account during traversing of the leading axis. This can result in an overload
for coupled motion axes with a dynamic response which is less than that required for the
coupling.

CAUTION
Axis overload
If a coupled motion grouping
● in synchronized actions
● is activated in the part program with leading axes, that are not program axes in the
channel of the coupled motion axes,
it is the special responsibility of the user/machine manufacturer to provide suitable
measures to ensure that an overload of the coupled motion axes does not occur through
traversing of the leading axis.

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M3: Coupled axes
8.1 Coupled motion

8.1.7 Supplementary conditions

Control system dynamics

It is recommended to align the position control parameters of the leading axis and the coupled
motion axis within a coupled axis group.

Note
Alignment of the position control parameters of the leading axis and the coupled motion axis
can be performed via a parameter set changeover.

8.1.8 Examples

Application Example: Two-sided machining

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Example 1
Example of an NC part program for the axis constellation shown in Fig.:

Program code Comment

TRAILON(V,Y,1) ; Activation of 1st coupled axis group
TRAILON(W,Z,-1) ; Activation of 2nd coupled axis group

Special functions
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 M3: Coupled axes
8.2 Curve tables - 840D sl only

Program code Comment

G0 Z10 ; Infeed Z and W axes in opposite axial directions
G0 Y20 ; Infeed of Y and V axes in same axis
direction
G1 Y22 V25 ; Superimpose dependent and independent movement of coupled
motion axis "V"
TRAILOF(V,Y) ; Deactivate 1st coupled axis group
TRAILOF(W,Z) ; Deactivate 2nd coupled axis group

Example 2
The dependent and independent movement components of a coupled motion axis are added
together for the coupled motion. The dependent component can be regarded as a co-ordinate
offset with reference to the coupled motion axis.

Program code Comment

N01 G90 G0 X100 U100 ;
N02 TRAILON(U,X,1) ; Activation of coupled axis group
N03 G1 F2000 X200 ; Dependent movement of U, Upos=200, UTrail=100
N04 U201 ; Independent movement, Upos=U201+UTrail=301
N05 X250 ; Dependent movement of U, UTrail=UTrail(100)+50=150,
Upos=351
N06 G91 U100 ; Independent movement of Upos(351)+U100=451
N07 G90 X0 ; Dependent movement of U, Upos=Upos(451)-UTrail(250)=201
N10 TRAILOF(U,X)

8.2 Curve tables - 840D sl only

8.2.1 Product brief

8.2.1.1 Function
The "curve tables" function can be used to define the complex sequence of motions of an axis
in a curve table.
Any axis can be defined as a leading axis and a following axis can be traversed by taking a
curve table into account.
The command variable in these motion sequences is an abstract master value, which is
generated by the control or derived from an external variable (e.g. simulated position of an
axis).
Creating curve tables is performed via part program sequences.
The curve tables in the static NC memory remain valid after the part program has been been
closed or after POWER DOWN.

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M3: Coupled axes
8.2 Curve tables - 840D sl only

Curve tables can be saved in dynamic NC memory for faster access. Please note that tables
need to be reloaded after run-up.
Axis groupings with curve tables must be reactivated independently of the storage location of
the curve table after POWER ON.
Linear curve table segments are stored in separate areas to save memory space.

8.2.1.2 Preconditions

Memory configuration
Static NC memory
Memory space for curve tables in static NC memory is defined by machine data:
MD18400 $MN_MM_NUM_CURVE_TABS (number of curve tables)
MD18402 $MN_MM_NUM_CURVE_SEGMENTS (number of curve segments)
MD18403 $MN_MM_NUM_CURVE_SEG_LIN (number of linear curve segments)
MD18404 $MN_MM_NUM_CURVE_POLYNOMS (number of curve table polynomials)
Dynamic NC memory
Memory space for curve tables in dynamic NC memory is defined by machine data:
MD18406 $MN_MM_NUM_CURVE_TABS_DRAM (number of curve tables)
MD18408 $MN_MM_NUM_CURVE_SEGMENTS_DRAM (number of curve segments)
MD18409 $MN_MM_NUM_CURVE_SEG_LIN_DRAM (number of linear curve segments)
MD18410 $MN_MM_NUM_CURVE_POLYNOMS_DRAM (number of curve table polynomials)

8.2.2 General functionality

Curve table
A functional relation between a command variable "master value" and an abstract following
value is described in the curve table.
A following variable can be assigned uniquely to each master value within a defined master
value range.

Curve segment
The functional relation can be subdivided into separate sections of the master value axes,
called curve segments.
Within a curve segment, the relation between the master value and following value is generally
described by a polynomial up to the third order. Polynomials up to the 5th degree are also
permissible.

Special functions
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Reference:
Programming Manual, Production Planning
Curve segments are used if:
● Polynomes or circles are programmed
● Spline is active
● Compressor is active
● Polynomials or circles are generated internally (chamfer/rounding, approximate positioning
with G643, WRK etc.)

Tool radius compensation

Curve tables are available in which it is possible to specify the tool radius compensation in the
table definition even if polynomial blocks or blocks with no motion for an axis, or jumps for the
following axis, occur in the curve table (G41/G42/G40 in the table definition).
The equidistant curve (tool center point path of tool radius compensation) of a curve consisting
of polynomials can no longer be displayed exactly using polynomials. The associated curve
tables must be approximated stepwise, using polynomials in this case. This means that the
number of segments in the curve table no longer matches the number of programmed
segments. The number of segments required for the curve table is defined by the bend of the
curve. The larger the curvature for the programmed curve, the more segments are required
for the curve table.
On account of tool radius compensation for curve tables, more memory may be required.
Selection option of the memory type should not produce shortage of static NC memory.

Selection of memory type

While defining a curve table, it can be defined whether the curve table is created in the static
or dynamic NC memory.

Note
Table definitions in the static NC memory are available even after control system run-up. Curve
tables of the dynamic NC memory must be redefined after every control system run-up.

8.2.3 Memory organization

Memory configuration
The storage place available for the curve table in the static and dynamic NC memory is defined
during memory configuration (see Section "Memory configuration (Page 321)").

Special functions
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Memory optimization
In a curve table with linear segments, the linear segments can be stored efficiently in the
memory only if the two following machine data items are > 0:
MD18403 $MC_MM_NUM_CURVE_SEG_LIN (number of linear curve segments in the static
NC memory)
MD18409 $MC_MM_NUM_CURVE_SEG_LIN_DRAM (number of linear curve segments in
the dynamic NC memory)
If no memory areas are created with this machine data, then the linear segments are stored
as polynomial segments.

Alarm in case of insufficient memory

If memory has been configured for tables with linear and polynomial segments via machine
data and memory for linear segments runs out when generating a linear table, the the memory
for polynomial segments is used for the linear segments (if available). In this case, memory is
"wasted", as a polynomial segment requires an unnecessary amount of memory to store a
linear segment. This circumstance is conveyed through an alarm, which also discloses the
number of unnecessarily used polynomial segments. The alarm only displays awarning and
does not result in the interruption of the program or the generation of the curve table.
If a curve table consists of linear segments and polynomials of a high degree, a memory area
for linear segments and a memory area for polynomial segments is required for the storage of
the curve table. An alarm is output if insufficient memory is available in the relevant areas. The
alarm parameters can be used to detect the resources that are insufficient.

Insufficient memory
If a curve table cannot be created, because sufficient memory is not available, then the newly
created table is deleted immediately after the alarm.
If insufficient is available, then one or more table(s) that is/are no longer required can be deleted
with CTABDEL or, alternatively, memory can be reconfigured via machine data.

Temporary curve table

When a curve table is created, a temporary curve table is set up first in memory, which is then
extended block by block. Finally (CTABEND), the table is checked for consistency. The
temporary table is converted to a table that can be used in a coupling only if it is found to be
consistent.

Same table number

A new curve table may have the same number as an existing table. The new curve table then
overwrites the existing table with the same number. This is done only if the new curve table
does not contain any errors. If an error is detected in the new table, the old table is not
overwritten.
If the user wishes to have the option of overwriting an existing curve table without deleting it
first, then he will need to dimension the table memory so that there is always enough extra
memory to accommodate the table to be overwritten.

Special functions
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Overwriting curve tables

Curve tables that are not active in a master value coupling and are locked with CTABLOCK()
may be overwritten.

Deleting curve tables

Curve tables that are not active in a master value coupling and are locked with CTABLOCK()
may be overwritten.

8.2.4 Commissioning

8.2.4.1 Memory configuration

A defined storage space is available for the curve tables in the static and dynamic NC memory,
which is defined through the following machine data:

Static NC memory
MD18400 $MN_MM_NUM_CURVE_TABS Defines the number of curve tables that can be stored in the
static NC memory.
MD18402 $MN_MM_NUM_CURVE_SEGMENTS Defines the number of curve table segments that can be stored
in the static NC memory.
MD18403 $MN_MM_NUM_CURVE_SEG_LIN Defines the maximum number of linear segments in the static
NC memory.
MD18404 $MN_MM_NUM_CURVE_POLYNOMS Defines the number of curve table polynomes that can be stored
in the static NC memory.

Dynamic NC memory
MD18406 $MN_MM_NUM_CURVE_TABS_DRAM Defines the number of curve tables that can be stored in the
dynamic NC memory.
MD18408 $MN_MM_NUM_CURVE_SEGNENTS_DRAM Defines the number of curve table segments that can be stored
in the dynamic NC memory.
MD18409 $MN_MM_NUM_CURVE_SEG_LIN_DRAM Defines the maximum number of linear segments in the dynam‐
ic NC memory.
MD18410 $MN_MM_NUM_CURVE_POLYNOMS_DRAM Defines the number of curve table polynomes that can be stored
in the dynamic NC memory.

Note
A curve table with linear segments can be stored efficiently in the memory only if:
MD18403 > 0 or MD18409 > 0
If no memory areas are created with this machine data, then the linear segments are stored
as polynomial segments.

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8.2.4.2 Tool radius compensation

MD20900
Tool radius compensation can produce segments for which the following axis or leading axis
have no movement. A missing movement of the following axis does not normally represent
any problem. As against this, a missing movement of the leading axis requests a specification
as to how such discontinuities are to be handled, i.e., whether or not a curve table should be
generated in these cases. This specification is done in the machine data settings:
MD20900 $MC_CTAB_ENABLE_NO_LEADMOTION (curve tables with discontinuity of the
following axis)

Value Description
0 No curve tables that contain a discontinuity in the following axis are produced. Alarm 10949
is output and program processing is aborted.
1 Curve tables with a discontinuity in the following axis can be generated. If a segment contains
a discontinuity in the following axis, Alarm 10955 is output but program processing is continued.
2 Curve tables with a discontinuity in the following axis can be created without an alarm being
output.

Note
In the case of a curve table that contains segments without leading axis movement (this means
that the following axis jumps at this point), the following axis can only make a jump within its
dynamic limits (max. velocity and max. acceleration). This means that there is always a
deviation from the programmed curve.

8.2.4.3 Specification of memory type

MD20905
If there is no memory specification while defining or deleting a curve table, the memory type
can be determined through the following machine data:
MD20905 $MC_CTAB_DEFAULT_MEMORY_TYPE (default memory type for curve tables)

Value Description
0 Curve tabels are normally created in the static NC memory.
1 Curve tabels are normally created in the dynamic NC memory.

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8.2.5 Programming

Definition
The following modal language commands work with curve tables: (The parameters are
explained at the end of the list of functions.)
● Beginning of definition of a curve table:
CTABDEF(following axis, leading axis, n, applim, memType)
● End of definition of a curve table:
CTABEND()
● Deleting curve table(s):
CTABDEL(n)
; curve table n
CTABDEL(n, m)
; [n < m], more than one in the range of numbers
; it is deleted in static "SRAM" and in dynamic "DRAM" of NC memory.
● CTABDEL(n, m, memType)
; Delete with memory specification:
Those curve tables with the numbers in the range, which are in the specified memory type,
will be deleted. All other curve tables are retained.
Delete all tables in a particular memory type:
CTABDEL(, , "DRAM")
CTABDEL(, , "SRAM")
CTABDEL()
; all in DRAM or
; all in SRAM:
; all, irrespective of memory type
● Read the following value for a master value
CTAB(master value, n, degrees, [following axis, lead axis])
● Read the master value for a following value
CTABINV(following value, approx. master value, n, degrees, [following axis, leading axis])

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Access to curve table segments

● Read start value (following axis value) of a table segment
CTABSSV(leading value, n, degrees, [following axis, leading axis])
● Read end value (following axis value) of a table segment
CTABSEV(master value, n, degrees, [following axis, master axis])
Note
If curve table functions such as CTAB(), CTABINV(), CTABSSV() etc., in synchronous
actions are used, only main traverse variable, e.g. $AC_PARAM[ ... ] or $R[ ... ] is
permissible for the return value and the argument "degrees" of the function.
Example:
ID=1 WHEN TRUE DO $R1 = CTABSSV(10, 1, $R2)
or
ID=1 WHEN TRUE DO $AC_PARAM[1] = CTABSSV(10, 1, $AC_PARAM[2])

Enable/cancel blocking
The following functions can be used to enable or cancel deletion and overwrite blocks for parts.
programs.
● Enable deletion and overwrite block.
General form: CTABLOCK(n, m, memType)
● Cancel deletion and overwrite block.
CTABUNLOCK releases the tables locked with CTABLOCK. Tables involved in an active
coupling remain locked, i.e. they cannot be deleted. However, the CTABLOCK command is
cancelled, i.e. the table can be deleted as soon as the coupling is deactivated. It is not
necessary to call CTABUNLOCK again.
General form: CTABUNLOCK(n, m, memType)
Applications of the forms:
Curve table with number n
CTABLOCK(n)
Curve tables in the number range n to m.
CTABLOCK(n, m)
All curve tables, irrespective of memory type
CTABLOCK()
All curve tables in the specified memory type
CTABLOCK(, , memType)
Curve table with number n
CTABUNLOCK(n)
Curve tables in the number range n to m.
CTABUNLOCK(n, m)

Special functions
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All curve tables, irrespective of memory type

CTABUNLOCK()
All curve tables in the specified memory type
CTABUNLOCK(, , memType)
Other commands for calculating and differentiating between curve tables for applications for
diagnosing and optimizing the use of resources:
● Number of defined tables irrespective of memory type
CTABNO()
● Number of defined tables in SRAM or DRAM of NC memory
CTABNOMEM(memType)
● Number of possible curve tables in memory memType.
CTABFNO(memType)
● Table number of nth curve table.
General form: CTABID(n, memType)
Generates the table number of the nth curve table with memory type memType. CTABID(1,
memType) is used to read out the highest curve number (105) of the memory type specified.
CTABID(n)
Generates the table number of the nth curve table in the memory specified using the
following machine data:
MD20905 $MC_CTAB_DEFAULT_MEMORY_TYPE (default memory type for curve
tables)
CTABID(p)
Generates the ID (table number) of the curve table entered in the memory as the pth curve
table.
Note
If for example, the sequence is changed between consecutive calls of CTABID(), then
CTABID(n, ...) can be used to provide a different curve table than the one provided before
the change.

● Indicates the block state of curve table number n.

CTABISLOCK(n)
● Checks curve table number n.
CTABEXISTS(n)
● Returns the memory in which curve table number n is stored.
CTABMEMTYP(n)
● Returns the table periodicity.
CTABPERIOD(n)
● Number of curve segments already used in memory memType.
CTABSEG(memType, segType)
● Number of curve segments used in curve table number n
CTABSEGID(n, segType)
● Number of still possible curve segments in memory memType.
CTABFSEG(memType, segType)

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● Maximum number of possible curve segments in memory memType.

CTABMSEG(memType, segType)
● Number of polynomials already used in memory memType.
CTABPOL(memType)
● Number of curve polynomials used by curve table number n.
CTABPOLID(n)
● Number of still possible polynomials in memory memType.
CTABFPOL(n)
● Maximum number of possible polynomials in memory memType.
CTABMPOL(n)

Boundary values of curve tables

Behavior of the leading axis/following axes on the edges of the curve table:
● The value at the beginning of the curve table is read by a following axis.
CTABTSV(n, degrees, F axis), following value at the beginning of the curve table
● The value at the end of the curve table is read by a following axis.
CTABTEV(n, degrees, FAxis), following value at the end of the curve table
● The value at the beginning of the curve table is read by the leading axis.
CTABTSP(n, degrees, FAxis), master value at the beginning of the curve table
● The value at the end of the curve table is read by the leading axis.
CTABTEP(n, degrees, FAxis), master value at the end of the curve table
● Determine the value range of the following value.
CTABTMIN(n, FAxis), minimum following value of curve table
CTABTMAX(n, FAxis), maximum following value of the curve table

Parameter
● Following axis:
Name of axis via which the following axis is programmed in the definition.
● Leading axis:
Name of axis via which the leading axis is programmed.
● n, m
Numbers for curve tables.
Curve table numbers can be freely assigned. They are used exclusively to uniquely identify
a curve table.
In order to delete a curve table area using the command CTABDEL(n, m) must be greater
than n.
● p
Entry location (in memType memory area)

Special functions
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● applim:
Behavior at the curve table edges.
– 0 non-periodic (table is processed only once, even for rotary axes).
– 1 periodic, modulo (the modulo value corresponds to the LA table values).
– 2 periodic, modulo (LA and FA are periodic).
● Master value
Position value for which a following value is to be determined.
● Slave value
Position value for which a master value is to be calculated.
● aproxmastervalue
Position value that can be used to determine a unique master value in the case of an
ambiguous reversing function of the curve table.
● degrees
Parameter in which the pitch of the table function is returned.
● memType
Optional parameter for specifying memory type to be used n curve tables.
Possible values:
"SRAM" curve table is created in static NC memory.
"DSRAM" curve table is created in dynamic NC memory.
If an invalid type is entered, the value -2 is returned.
If the parameter is omitted, then the memory type set via the following machine data takes
effect:
MD20905 $MC_CTAB_DEFAULT_MEMORY_TYPE (default memory type for curve
tables)
● segType
Optional parameter for entry of segment type
Possible values:
segType "L" linear segments
segType "P" Polynomial segments
Reference:
Programming Manual, Production Planning; Axis Couplings, Section: Curve tables (CTAB)

Restrictions
The following restrictions apply when programming:
● It is not permissible that the NC block generates a preprocessing stop.
● No discontinuities may occur in leading axis motion.
● Any block that contains a traverse instruction for the following axis must also include a
traverse for the leading axis.
● The direction of motion of the leading axis must not reverse at any point in the rule of motion,
i.e. the position of the leading axis must always be unique within the sequence of motions.
The programmed contour may not move perpendicular to the leading axis.

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● Axis names from gantry axis groups cannot be used to define a table (only leading axis are
possible).
● Depending on the following machine data, jumps in the following axis may be tolerated if
a movement is missing in the leading axis.
MD20900 $MC_CTAB_ENABLE_NO_LEADMOTION (curve tables with discontinuity of the
following axis)
The other restrictions listed above still apply.

Axis assignment
Does not take effect until coupling is activated with curve table.

Note
The dynamic limit values of the motion commands for a curve table are not checked until
activation or interpolation.

Starting value
The first motion command in the definition of a curve table defines the starting value for the
leading and following value.
All instructions that cause a preprocessing stop must be hidden.

Example 1
Without tool radius compensation, without memory type

Program code Comment

N100 CTABDEF(AX2, AX1, 3,0) ; Start of the definition for the non-
; periodic curve table no. 3
N110 AX1=0 AX2=0 ; 1. Motion instruction specifies the start value
; Master value: 0, Following value: 0
N110 AX1=20 AX2=0 ; 1. Curve segment: Master value: 0...20,
; Slave value: Starting value …0
N120 AX1=100 AX2=6 ; 2. Curve segment: Master value: 20...100,
; Slave value: 0...6
N130 AX1=150 AX2=6 ; 3. Curve segment: Master value: 100...150,
; Slave value 6
N130 AX1=180 AX2=0 ; 4. Curve segment: Master value: 150...180,
; Slave value: 6...0
N200 CTABEND ; End of the definition, the curve table
; is generated in its internal representation.
; The advance is reorganized to the status
; at the start of N100

Special functions
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Example 2
Example of a curve table with active tool radius compensation:
Prior to definition of a curve table with CTABDEF(), tool radius compensation must not be active;
otherwise alarm 10942 is generated. This means that tool radius compensation must be
activated within the definition of the curve table. Similarly, it must be deactivated again before
the end of the curve table definition, using CTABEND.

Program code Comment

N10 CTABDEF(Y, X, 1, 0) ; Start of the definition for the non-
; periodic curve table no. 1
N20 X0 Y0
N30 G41 X10 Y0 ; WZR compensation on
N40 X20 Y20
N50 X40 Y0
N60 X60 Y20
N70 X80 Y0
N80 G40 X90 Y0 ; WZR compensation off
N90 CTABEND

Tool radius compensation is activated in block N30; this causes the approach movement for
radius compensation to be made in this block. Similarly, the approach movement for
deactivation of the radius compensation is made in block N80.

Note
The value pairs between CTABDEF and CTABENDmust be specified for precisely the axis
names that have been programmed in CTABDEF as the leading axis name and following axis
name. In the case of programming errors, alarms or incorrect contours may be generated.

8.2.6 Access to table positions and table segments

Reading table positions

With the program commands CTAB and CTABINV the following value for a master value
(CTAB) can be read from the part program and from synchronous actions, or alternatively the
master value can be read off for a following value. The pitch value can be used to calculate
the speed of the following axis or leading axis at any position in the table.

Reading segment positions

Segment positions of a curve table for the value for the following axis can be read using the
CTABSSV and CTABSEV calls.
The language commands CTABSSV and CTABSEV generally provide the start and end values
of the internal segments of the curve tables for the following axis. These values only agree
with the programmed values of the curve tables if the programmed segments can be converted

Special functions
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1:1 to the internal segments of the curve table. This is always the case if only G1 blocks or axis
polynomials are used to define the curve tables and no other functions are active.
Programmed sections may under certain circumstances not be transformed unchanged into
internal curve segments if:
1. Circles or involutes are programmed
2. Chamfer or rounding is active (CHF, RND)
3. Smoothing with G643 is active
4. Compressor is active (COMPON, COMPCURV, COMPCAD)
5. Tool radius compensation is active for polynomial interpolation.
In these cases, the language commands CTABSSV and CTABSEV may not be used to query
the start and end points of the programmed segments.

CTABINV
When using the inversion function for the curve tables CTABINV, it must be noted that the
following value mapped to the leading value may not be unique.
Within a curve table, the following value can assume the same value for any number of master
value positions. In order to resolve this ambiguity, the program command CTABINV requires
a further parameter, in addition to the following value, which it uses to select the 'correct' master
value. CTABINV always returns the master value that is closest to this auxiliary parameter.
This auxiliary value can, for example, be the master value from the previous interpolator clock
cycle.

Note
Although the auxiliary parameter permits calculation of a unique result for the reversal function
of the curve table, it should be noted that numerical inaccuracies may give rise to contours,
which can cause the reversal function to produce results that deviate from those that would
be obtained in a calculation where the accuracy is unrestricted.

Optional parameters
The functions CTAB, CTABINV, CTABSSV and CTABSEV have optional parameters for the
leading and following axes. If one of these parameters is programmed, the master value and
following value are modified using the scaling factors of the relevant axes.
This is particularly important if axes have been configured with different length units (inch/
metric). If no optional parameters are programmed, the master value and following value are
treated as path positions in the conversion from external to internal representation. This means
that the values are multiplied according to the configured resolution (decimal places) and the
remaining decimal places are truncated.

Special functions
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Identifying the segment associated with master value X

Example of reading the segment starting and end values for determining the curve segment
associated with master value X = 30 using CTABSSV and CTABSEV:

Program code Comment

N10 DEF REAL STARTPOS ; Beginning of the definition for the
start position of the curve table
N20 DEF REAL ENDPOS
N30 DEF REAL GRADIENT
N100 CTABDEF(Y,X,1,0) ; Start of table definition
N110 X0 Y0 ; Start position, 1st table segment
N120 X20 Y10 ; End position, 1st table segment =
; Start position 2nd table segment
N130 X40 Y40
N140 X60 Y10 ; 3. Curve segment
N150 X80 Y0 ; 4. Curve segment
N160 CTABEND ; End of table definition
N200 STARTPOS=CTABSSV(30.0,1,GRADIENT) ; Start position Y in segment 2 = 10.
N210 ENDPOS= ; End position Y in segment 2 = 40
CTABSEV(30.0,1,GRADIENT) ; Segment 2 belongs to LW X = 30.0

<

(QG


1 1



1 1
6WDUW


     ;
; 

Figure 8-2 Determining the curve segment associated with master value X = 30

Reading values at start and end

The values of the following axes and of the master axis at the start and end of a curve table
can be read with the following calls:
R10 =CTABTSV(n, degrees, F axis), following value at the beginning of the curve table
R10 =CTABTEV(n, degrees, F axis), following value at the beginning of the curve table
R10 =CTABTSP(n, degrees, F axis), following value at the beginning of the curve table

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R10 =CTABTEP(n, degrees, F axis), following value at the beginning of the curve table

Value range of the following value

The following example illustrates how the minimum and maximum values of the table are
determined using CTABTMIN and CTABTMAX:

Program code Comment

N10 DEF REAL STARTVAL ; Beginning of the definition for the start
and initial values of the curve table
N20 DEF REAL ENDVAL
N30 DEF REAL STARTPARA
N40 DEF REAL ENDPARA
N50 DEF REAL U_MINVAL
N60 DEF REAL U_MAXVAL
N70 DEF REAL GRADIENT
…
N100 CTABDEF(Y,X,1,0) ; Start of table definition
N110 X0 Y10 ; Start value of the 1st table segment
N120 X30 Y40 ; End position 1st table segment =
; start position 2nd table segment
N130 X60 Y5 ; End position of the 2nd table segment ...
N140 X70 Y30 ; End position of the 3rd curve segment ...
N150 X80 Y20 ; End position of the 4th curve segment ...
N160 CTABEND ; End of table definition
...
N200 STARTPOS=CTABTSV(1,GRADIENT) ; STARTPOS = 10
; Start position of table as well as
N210 ENDPOS=CTABTEV(1,GRADIENT) ; ENDPOS = 20
; End position of table
N220 STARTPARA=CTABTSP(1,GRADIENT) ; STARTPARA = 0
; Master value at beginning of curve table
N230 ENDPARA=CTABTEP(1,GRADIENT) ; ENDPARA = 80
; Read master value at the end of the curve
table from the value range of the following
axis
N240 U_MINVAL=CTABTMIN(1) ; Minimum value when Y = 5 and
N250 U_MAXVAL=CTABTMAX(1) ; Maximum value when Y = 40

Special functions
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<

 0D[LPXP
YDOXH
1
1 1


(QG
1 YDOXH
6WDUWLQJ
YDOXH 0LQLPXP
YDOXH

     ;

Figure 8-3 Determining the minimum and maximum values of the table

8.2.7 Activation/deactivation

Activation
The coupling of real axes to a curve table is activated through this command:
LEADON (<Following axis>, <Leading axis>, <n>)
with <n> =Number of the curve table
Activation is possible:
● In the part program
● in the definition of a synchronous action

Example:

...
N1000 LEADON(A,X,3) ; Axis A follows the master value X according to the rule
of motions defined in Curve Table No. 3
...

Deactivation
The switch off of the coupling to a curve table takes place through the following command:
LEADON (<Following axis>, <Leading axis>)

Special functions
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8.2 Curve tables - 840D sl only

Deactivation is possible:
● In the part program
● in synchronized actions
Note
While programming LEADOF, the abbreviated form is also possible without specification of
the leading axis.

Example:

...
N1010 LEADOF(A,X) ; The coupling of Axis A with its leading axis is canceled
...

Multiple use
A curve table can be used several times in a single part program to couple different channel
axes.

8.2.8 Modulo-leading axis special case

Position is absolute
When an axial master value coupling is active, the position of the following axis via a curve
table is unique, i.e. an absolute assignment to the master axis exists.
This means that, when a modulo rotary axis is used as the master axis, the position of the
master axis is absolute. In other words, the position of the modulo rotary axis entered in the
curve table is absolute, and not modulo-reduced.

Example
Let the position of a modulo rotary axis with LEADON be 210°. The position 210° degrees is
used as the starting value in the curve table. After one rotation of the modulo axis, the axis
position is again displayed as 210°. The absolute position 570° is however taken as the input
value in the curve table:
210° + 1 round (360°) = 570°

8.2.9 Behavior in AUTOMATIC, MDA and JOG modes

Activation
An activated curve table is functional in the AUTOMATIC, MDA and JOG modes.

Special functions
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8.2 Curve tables - 840D sl only

Basic setting after run-up

No curve tables are active after run-up.

8.2.10 Effectiveness of PLC interface signals

Dependent following axis

With respect to the motion of a following axis that is dependent on the leading axis, only the
following axis interface signals that effect termination of the motion (e.g. axis-specific feed
stop, axis inhibit, servo enable, etc.) are effective.

Leading axis
In an activated axis group, the interface signals move the leading axis through the axis coupling
to the associated following axis, i.e.:
● feed control of the leading axis causes a corresponding feed control of the following axis.
● A shutdown of the leading axis through interface signals (e.g., axis-specific feed stop, axis
inhibit, servo enable etc.) causes the corresponding following axis to shut down.
The effect of the axis inhibit of the leading axis on the following axis can be prevented through
the following MD setting:
MD37160 $MA_LEAD_FUNCTION_MASK, Bit 1 = 1

Position measuring system 1/2 (DB31, ... DBX1.5/1.6))

Switch-over of the position measuring system for the leading and following axes is not inhibited
for an active coupled axis group. The coupling is not canceled.
Recommendation: Switch the measuring system over when the coupling is deactivated.

8.2.11 Diagnosing and optimizing utilization of resources

The following functions allow parts programs to get information on the current utilization of
curve tables, table segments and polynomials.
One result of the diagnostic functions is that resources still available can be used
dynamically with the functions, without necessarily having to increase memory usage. The
description of the parameters in Chapter "Programming Curve Tables" also applies to the
following functions.

Special functions
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8.2 Curve tables - 840D sl only

a) Curve tables
● Determine total number of defined tables.
The definition applies to all memory types (see also CTABNOMEM)
CTABNO()
● Number of defined tables in SRAM or DRAM of NC memory.
CTABNOMEM (memType)
If memType is not specified, the memory type specified in the following machine data:
MD20905 $MC_CTAB_DEFAULT_MEMORY_TYPE (default memory type for curve tables)
Result:
>= 0: Number of defined curve tables
-2: Invalid memory type
● Determine number of curve tables still possible in memory.
CTABFNO(memType)
If memType is not specified, the memory type specified in the following machine data:
MD220905 $MC_CTAB_DEFAULT_MEMORY_TYPE
Result:
>= 0: Number of possible tables
-2: Invalid memory type
● Determine the table number of the pth table in the memory type specified optionally
CTABID(p, memType)
If memType is not specified, the memory type specified in the following machine data:
MD20905 $MC_CTAB_DEFAULT_MEMORY_TYPE
Result:
Table number or
Alarm for invalid p or memType
When using the CTABID(p, memType) function, no assumptions should be made
regarding the sequence of the curve tables in the memory. The CTABID(p, ...) function
supplies the ID (table number) of the curve table entered in memory as the pth curve table.
If the sequence of curve tables in memory changes between consecutive calls of
CTABID()CTABID(), e.g. due to the deletion of curve tables with CTABDEL(), the
CTABID(p, ...) function can supply a different curve table with the same number.

Special functions
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8.2 Curve tables - 840D sl only

To prevent this from happening, the curve tables concerned can be locked, using the
CTABLOCK(...) language command. In this case, it should be noted that the curve tables
concerned are then unlocked with CTABUNLOCK().
●
Determine block condition
Table n
CTABISLOCK(n)
Result:
> 0: Table is blocked
Reason for block:
1: by CTABLOCK()
2: by an active coupling
3: by CTABLOCK()and by an active coupling
= 0: Table is not blocked
- 1: Table does not exist
● Check whether the curve table exists
CTABEXISTS(n)
Result:
1: Table exists
0: Table does not exist
●
Determine memory type of a curve table
CTABMEMTYP(n)
Result:
0: Table in static SRAM NC memory
1: Table in dynamic "DRAM" NC memory
-1: Table does not exist
● by an active coupling periodic
CTABPERIOD(n)
Result:
0: Table is not periodic
1: Table is periodic in the leading axis
2: Table is periodic in the leading and following axes
-1: Table does not exist
b) Curve table segments
● Determine number of used curve segments of the type memType in the memory range.
● CTABSEG(memType, segType)
● If memType is not specified, the memory type specified in the following machine data:
MD20905 $MC_CTAB_DEFAULT_MEMORY_TYPE
Result:
>= 0: Number of curve segments
-2: Invalid memory type
If segType is not specified, the sum is produced via linear and polynomisl segments in the
memory type.
-2: segType not equal "L" or "P"

Special functions
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M3: Coupled axes
8.2 Curve tables - 840D sl only

● Determine number of used curve segments of the type memType in the memory range
CTABSEGID(n, segType)
Result:
>= 0: Number of curve segments
-1: Curve table with number n does not exist
-2: segType not equal "L" or "P"
● Determine number of free curve segments of the type memType in the memory range
CTABFSEG(memType, segType)
If memType is not specified, the memory type specified in the following machine data:
MD20905 $MC_CTAB_DEFAULT_MEMORY_TYPE
Result:
>= 0: Number of free curve segments
-2: Invalid memory type, segType not equal "L" or "P"
● Determine maximum number of possible curve segments of the type segType in the memory
CTABMSEG(memType, segType)
If memType is not specified, the memory type specified in the following machine data:
MD20905 $MC_CTAB_DEFAULT_MEMORY_TYPE
Result:
>= 0: Maximum number of possible curve segments
-2: Invalid memory type, segType not equal "L" or "P"
c) Polynomials
● Determine the number of used polynomials of the memory type
CTABPOL(memType)
If memType is not specified, the memory type specified in the following machine data:
MD20905 $MC_CTAB_DEFAULT_MEMORY_TYPE
Result:
>= 0: Number of polynomials already used in the memory type
-2: Invalid memory type
● Determine the number of curve polynomials used by a curve table
CTABPOLID(n)
Result:
>=0: Number of used curve polynomials
-1: Curve table with number n does not exist
● Determine the number of free polynomials of the memory type
CTABFPOL(memType)
If memType is not specified, the memory type specified in the following machine data:
MD20905 $MC_CTAB_DEFAULT_MEMORY_TYPE
Result:
>= 0: Number of free curve polynomials
-2: Invalid memory type
● Determine the maximum number of polynomials of the memory type
CTABMPOL(memType)
If memType is not specified, the memory type specified in the following machine data:
MD20905 $MC_CTAB_DEFAULT_MEMORY_TYPE
Result:
>= 0: Maximum number of possible curve polynomials
-2: Invalid memory type

Special functions
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8.2 Curve tables - 840D sl only

8.2.12 Supplementary conditions

Transformations
Transformations are not permissible in curve tables. TRAANG is an exception.

TRAANG
If TRAANG is programmed, the rule of motion programmed in the basic co-ordinate system is
transformed to the associated machine co-ordinate system. In this way it is possible to program
a curve table as Cartesian co-ordinates for a machine with inclined linear axes.
The condition that stipulates that "the direction of motion of the leading axis must not reverse
at any point of the rule of motion" must then be met in the machine co-ordinate system. Please
note that this condition in the basic co-ordinate system does not have the same meaning as
in the machine co-ordinate system, since the contour tangents are changed by the
transformation.

8.2.13 Examples

Definition of a curve table with linear sets

%_N_TAB_1_NOTPERI_MPF
;$PATH=/_N_WKS_DIR/_N_KURVENTABELLEN_WPD
; Def.TAB1 0-100mm Kue1/1 notperio.
N10 CTABDEF(YGEO,XGEO,1,0) ; FA=Y LA=X Curve No..=1 Not
period.
N1000 XGEO=0 YGEO=0 ; Start values
N1010 XGEO=100 YGEO=100
CTABEND
M30

Definition of a curve table with polynomial sets

%_N_TAB_1_NOTPERI_MPF
;$PATH=/_N_WKS_DIR/_N_KURVENTABELLEN_WPD
; Def.TAB1 0-100mm Kue1/1 notperio.
N10 CTABDEF(Y,X,1,0) ; FA=Y LA=X Curve
No..=1 Not period.
N16 G1 X0.000 Y0.000
N17 POLY PO[X]=(31.734,0.352,-0.412) PO[Y]=(3.200,2.383,0.401)
N18 PO[X]=(49.711,-0.297,0.169) PO[Y]=(7.457,1.202,-0.643)
N19 PO[X]=(105.941,1.961,-0.938) PO[Y]=(11.708,-6.820,-1.718)
N20 PO[X]=(132.644,-0.196,-0.053) PO[Y]=(6.815,-2.743,0.724)

Special functions
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8.2 Curve tables - 840D sl only

%_N_TAB_1_NOTPERI_MPF
N21 PO[X]=(147.754,-0.116,0.103) PO[Y]=(3.359,-0.188,0.277)
N22 PO[X]=(174.441,0.578,-0.206) PO[Y]=(0.123,1.925,0.188)
N23 PO[X]=(185.598,-0.007,0.005) PO[Y]=(-0.123,0.430,-0.287)
N24 PO[X]=(212.285,0.040,-0.206) PO[Y]=(-3.362,-2.491,0.190)
N25 PO[X]=(227.395,-0.193,0.103) PO[Y]=(-6.818,-0.641,0.276)
N26 PO[X]=(254.098,0.355,-0.053) PO[Y]=(-11.710,0.573,0.723)
N26 PO[X]=(254.098,0.355,-0.053) PO[Y]=(-11.710,0.573,0.723)
N27 PO[X]=(310.324,0.852,-0.937) PO[Y]=(-7.454,11.975,-1.720)
N28 PO[X]=(328.299,-0.209,0.169) PO[Y]=(-3.197,0.726,-0.643)
N29 PO[X]=(360.031,0.885,-0.413) PO[Y]=(0.000,-3.588,0.403)
CTABEND
N30 M30

Definition of a periodic curve table

Table No: 2
Master value range: 0 - 360
The following axis traverses from N70 to N90, a movement from 0 to 45 and back to 0.

N10 DEF REAL DEPPOS

N20 DEF REAL GRADIENT
N30 CTABDEF(Y,X,2,1)
N40 G1 X=0 Y=0
N50 POLY
N60 PO[X]=(45.0)
N70 PO[X]=(90.0) PO[Y]=(45.0,135.0,-90)
N80 PO[X]=(270.0)
N90 PO[X]=(315.0) PO[Y]=(0.0,-135.0,90)
N100 PO[X]=(360.0)
N110 CTABEND
N130 G1 F1000 X0 ; Testing the curve by coupling Y to X
N140 LEADON(Y,X,2)
N150 X360
N160 X0
N170 LEADOF(Y,X)
N180 DEPPOS = CTAB(75.0,2,GRADIENT) ; Reading the table position at master
value 75.0 from the curve table with
Table No. 2
N190 G0 X75 Y=DEPPOS ; Positions of leading and following
axis
N200 LEADON(Y,X,2) ; No synchronization of the following
axis is required after the coupling
is activated
N210 G1 X110 F1000
N220 LEADOF(Y,X)

Special functions
340 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 M3: Coupled axes
8.3 Master value coupling - 840D sl only

N10 DEF REAL DEPPOS

N230 M30

8.3 Master value coupling - 840D sl only

8.3.1 Product brief

8.3.1.1 Function
The "axial master value coupling" function can be used to process short programs cyclically
with close coupling of the axes to one another and a master value that is either generated
internally or input from an external source.
The master value can, for example, be derived from a conveyor belt or a vertical shaft.
The axial master value coupling can be switched on and off in the NC part program or via
synchronized action.

8.3.1.2 Preconditions
The option "Master Value Coupling and Curve Tables Interpolation" or the relevant option of
generic coupling (refer to " Preconditions (Page 380) " in the "Brief description" for generic
coupling) is a prerequisite for utilization of the function.

8.3.2 General functionality

Curve table
With the axial master value coupling, a leading and a following axis are moved in synchronism.
It is possible to assign the position of the following axis via a curve table or the resulting
polynomial uniquely to a position of the leading axis - simulated if necessary.

Master value object

The master value object is the input variable for the curve table.
The following can be defined as the position of the master value object:
● The axis actual position (actual value measured by transmitter)
or
● The setpoint position (calculated from interpolator) (default)
If the leading axis is interpolated by the same NCU, the setpoint coupling delivers a better
follow-up response than is possible for actual value coupling (in the same IPO cycle).

Special functions
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M3: Coupled axes
8.3 Master value coupling - 840D sl only

Virtual leading axis / simulated master value

If the leading axis is not interpolated by the same NCU, the interpolator that is implemented
in the NCU for this particular leading axis can be used for master value simulation. The following
machine data settings must be defined for this:
MD30132 $MA_IS_VIRTUAL_AX[n] = 1 (axis is virtual axis)
MD30130 $MA_CTRLOUT_TYPE[n] = 0 (simulation as output type of setpoint)
Properties of master value simulation:
● Separation of IPO and servo.
● Actual values of the axis are recorded.
● Setpoint values are produced by IPO but not passed on to the servo motor.
● When switching over to master value coupling, the simulation can be programmed with the
last actual value read, whereas the path of the actual value is generally outside the control
of the NCU.
● If, for purposes of master value simulation, the master value object is switched from actual
value coupling to setpoint value coupling and a traversing command is issued for the leading
axis in the same interpolator clock cycle, the interpolator for the axis is initialized by the
NCK so that the master value produces a constant path in the first derivation.

Note
Virtual axes assigned to a real drive must remain unblocked.

Offset and scaling

The setpoint value for the following axis can be offset and scaled. The following setting data
is used for this:
SD43102 $SA_LEAD_OFFSET_IN_POS (offset of master value with coupling to this axis)
SD43104 $SA_LEAD_SCALE_IN_POS (scaling of master value with coupling to this axis)
SD43106 $SA_LEAD_OFFSET_OUT_POS (offset of function value of the curve table)
SD43108 $SA_LEAD_SCALE_OUT_POS (scaling of function value of the curve table)
If (x) is a periodic curve table and this is interpreted as oscillation, the offset and scaling can
also be interpreted as follows:
SD43102 $SA_LEAD_OFFSET_IN_POS[Y] offsets the phase of the oscillation.
SD43106 $SA_LEAD_SCALE_OUT_POS[Y] affects the amplitude.
SD43108 $SA_LEAD_OFFSET_OUT_POS[Y] offsets the center of the oscillation
If the coupling is activated and synchronous, the new set position is approached as soon as
values are written to this setting data.

Special functions
342 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 M3: Coupled axes
8.3 Master value coupling - 840D sl only

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Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 343
M3: Coupled axes
8.3 Master value coupling - 840D sl only

Reaction to Stop
All leading value coupled following axes react to channel stop and MODE GROUP stop.
Master value coupled following axes react to a stop due to end of program (M30, M02) if they
have not been activated by static synchronized actions (IDS=...). The following machine
data is to be observed in this connection:
MD20110 $MC_RESET_MODE_MASK (definition of initial control settings after RESET / TP
End)
MD20112 $MC_START_MODE_MASK (definition of initial control settings for NC-START)
Leading axis and following axis must always interpolate in the same channel. A following axis
located in a different channel cannot be coupled (axis replacement).
START and mode change enable a following axis in the master value coupling that has been
stopped.
RESET also enables a stopped following axis in master value coupling. If enabling by RESET
is not desired, or if it is dangerous (e.g. because the following axis is coupled to an external
master value not controlled by the NC), then MD20110 must be programmed such that master
value couplings are switched off with RESET (=2001H, i.e. bit 13 set to 1).

Axial functions
Actual value coupling causes a position offset between the leading and following axis. The
cause of this is the IPO cycle-based dead time in the position controller, which lies between
the actual value of the leading axis and the following axis.
Normally, the position offset and the following error is compensated by a linear extrapolation
of the master value to the extent of this dead time, i.e. dead time compensation is active in
master value coupling. The following MD setting is defined to deactivate the dead time
compensation:
MD37160 $MA_LEAD_FUNCTION_MASK Bit 0 = 0

Interface to axis exchange

A master value coupled following axis receives its setpoint values from curve tables. Overlaid
programming of this axis is not possible in the part program. Therefore, the master value
coupled following axis is removed from the channel in the same way as for axis exchange.
This is carried out automatically when the coupling is activated in the part program.
If the coupling is to be activated with synchronized action, then it must be prepared for it in
advance with RELEASE.
After a master value coupling has been deactivated, the former following axis can be
programmed again in the part program.

Spindles in master value coupling

A spindle can only be used as the master value coupled following axis if it has been switched
to axis mode beforehand. The machine data parameter block of the axis drive then applies.

Special functions
344 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 M3: Coupled axes
8.3 Master value coupling - 840D sl only

Example: Activation from synchronized action

Program code Comment

SPOS=0
B=IC(0) ; switch spindle to axis operation.
RELEASE(Y) ; Enable for synchronized action.
ID=1 WHEN ($AA_IM[X]<-50) DO LEADON(B,X,2) ; Y is coupled to X via curve table No.
2.

8.3.3 Programming

Definition and activation

An axis master value coupling is defined and activated simultaneously with the modal effective
language command LEADON.
Syntax:
LEADON(<FA>,<LA>,<CTABn>)
Meaning:

<FA> Following axis as geometry-, channel- or machine axis name (X, Y, Z,...)
<LA> Leading axis as geometry-, channel- or machine axis name (X, Y, Z,...)
Software axis is also possible:
MD30130 $MA_CTRLOUT_TYPE=0 (setpoint output type)
<CTABn> Number of curve table
Range of values: 1 to 999

Example:

Program code Comment

LEADON(Y,X,1) ; Definition and activation of a master value coupling between
the leading axis X and the following axis Y. Curve Table No.
1 should be used to calculate the following value.

Special functions
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M3: Coupled axes
8.3 Master value coupling - 840D sl only

Boundary conditions:
● No reference point is required to activate the coupling.
● A defined following axis cannot be traversed in the JOG mode (not even if the "Synchronized
run fine" or. "synchronized run coarse" interface signal is not there).
● An activated coupling must first be deactivated with LEADOF before it can be activated again
with LEADON. The settings in the following machine data are to be considered in this
connection:
MD20112 MC_START_MODE_MASK (definition of initial control system settings with NC-
START)
MD20110 $MC_RESET_MODE_MASK (definition of initial control settings after RESET/TP-
End)

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Figure 8-6 Activating master value coupling

Switch off
An axis master value coupling is deactivated with the model language command LEADOF.
When the axis master value coupling is deactivated, the following axis becomes the command
axis and a stop command is generated implicitly for the following axis. The stop command can
be overwritten by another command with a synchronous action.
Syntax:
LEADON(<FA>,<LA>)

Special functions
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 M3: Coupled axes
8.3 Master value coupling - 840D sl only

Meaning:

<FA> Following axis as geometry-, channel- or machine axis name (X, Y, Z,...)
<LA> Leading axis as geometry-, channel- or machine axis name (X, Y, Z,...)
Software axis is also possible:
MD30130 $MA_CTRLOUT_TYPE=0 (setpoint output type)

Example:

Program code Comment

LEADOF(Y,X,1) ; Switching off of master value coupling between the leading
axis X and the following axis Y.

Note
Activating / deactivating the axis master value coupling with LEADON / LEADOF is permissible
both in the part program and in synchronous actions.
References:
Function Manual, Synchronized Actions

Coupling type
The coupling type is defined by the following axis-specific setting data:
SD43100 $SA_LEAD_TYPE[<LA>] (type of master value)
<LA>: Leading axis as geometry axis name, channel axis name or machine axis name (X, Y,
Z,...)

Value Meaning
0 Actual value coupling (this type of coupling must be used for external leading axes)
1 Setpoint coupling (default setting)
2 Simulated master value (note virtual axis, not evaluated for FA)

Switch-over between actual and setpoint value coupling is possible at any time (preferably in
the idle phase).

Special functions
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M3: Coupled axes
8.3 Master value coupling - 840D sl only

System variables of the master value

The following master value system variables can only be read from part program and from
synchronous actions:

System variable Meaning

$AA_LEAD_V[ax] Velocity of the leading axis
$AA_LEAD_P[ax] Position of the leading axis
$AA_LEAD_P_TURN Master value position
Portion that is deducted during modulo reaction.
The actual (not modulo-reduced) position of the leading axis is:
$AA_LEAD_P_TURN + $AA_LEAD_P

The speeds and positions of simulated master values (when $SA_LEAD_TYPE[ax]=2) can be
written in and read from the part program and synchronous actions.

System variable Meaning

$AA_LEAD_SV[ax] Simulated master value velocity per IPO cycle
$AA_LEAD_SP[ax] Simulated position in MCS

System variables of the following axis

For the following axis, the following system variables can be read in the part program and
synchronized action:

System variable Meaning

$AA_SYNC[ax] Condition of the coupling between following and leading axes
Value Meaning
0 not synchronized
1 "Coarse synchronous operation" 1)
2 "Fine synchronous operation" 2)
3 "Coarse synchronous operation" 1)
AND "Fine synchronous opera‐
tion" 2)
Corresponds to:
1) ● MD37200 $MA_COUPLE_POS_TOL_COARSE
● DB31, ... DBX98.1 (coarse synchronous operation)
2) ● MD37210 $MA_COUPLE_POS_TOL_FINE
● DB31, ... DBX98.0 (fine synchronous operation)
$AA_IN_SYNC[ax] Condition of the synchronization between following and leading axes
Value Meaning
0 Synchronization not started or ended.
1 Synchronization is running, i. e., the following axis is synchronized.
$AA_IN_SYNC[ax] corresponds to the NC/PLC interface signal:
DB31, ... DBX99.4 (synchronization running)

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Note
If the following axis is not enabled for travel, it is stopped and is no longer synchronous.

8.3.4 Behavior in AUTOMATIC, MDA and JOG modes

Efficiency
A master value coupling is active depending on the settings in the part program and in the
following machine data:
MD20110 $MC_RESET_MODE_MASK (definition of initial control settings after RESET / TP
End)
MD20112 $MC_START_MODE_MASK (definition of initial control system settings with NC-
START)

Manual mode
Once a master axis coupling has been activated, traversal of the master axis (e.g. with rapid
traverse or incremental dimension INC1 ... INC10000) results in a movement of the slave axis,
allowing for the curve table definition.

Referencing
A master value coupled following axis is to be referenced prior to activation of the coupling. A
following axis cannot be referenced when the coupling is activated.

Deletion of distance-to-go
When deletion of distance-to-go is performed for a leading axis, all axes in the associated,
activated master value coupling are shut down.

Basic setting after POWER ON

No master value couplings are active after POWER ON. (Options with ASUB).

Behavior after NC start/RESET

The following behavior results, depending on the settings of the machine data:
MD20110 $MC_RESET_MODE_MASK (bit 13) (definition of initial control settings after
RESET / TP End)

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MD20112 $MC_START_MODE_MASK (bit 13) (definition of initial control system settings with
NC-START)
● MD20110 $MC_RESET_MODE_MASK=2001H
&&
MD20112 $MC_START_MODE_MASK=0H
→ Master value coupling remains valid after RESET and START
● MD20110 $MC_RESET_MODE_MASK=2001H
&&
MD20112 $MC_START_MODE_MASK=2000H
→ Master value coupling remains valid after RESET and is canceled with START. However,
master value coupling activated via IDS=... remains valid.
● MD20110 $MC_RESET_MODE_MASK=1H
→ Master value coupling is canceled with RESET irrespective of machine data:
MD20112 $MC_START_MODE_MASK
Master value coupling activated via IDS=... can only be deactivated via an operator front
panel reset and remains valid after program end/reset (M30, M02).
● MD20110 $MC_RESET_MODE_MASK=0H
→ Master value coupling remains valid after RESET and is canceled with START, irrespective
of machine data:
MD20112 $MC_START_MODE_MASK
However, master value coupling activated via IDS=... remains valid.
Reference:
Function Manual, Basic Functions; Coordinate Systems, Axis Types,
Axis Configurations, ... (K2)

Activating, deactivating
Master value couplings activated via a static synchronous action (IDS=...) are:
● not deactivated during program start, regardless of the value of machine data:
MD20110 $MC_RESET_MODE_MASK (definition of initial control settings after RESET /
TP End)
and
MD20112 $MC_START_MODE_MASK (definition of initial control system settings with NC-
START)
● not deactivated during program end reset (M30, M02), regardless of the value of machine
data:
MD20110 $MC_RESET_MODE_MASK

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8.3.5 Effectiveness of PLC interface signals

Leading axis
When a coupled axis group is active, the interface signals (IS) of the leading axis are applied
to the appropriate following axis via axis coupling. i.e.:
● a feed control action of the leading axis is applied via the master value coupling to effect
an appropriate feed control action in the following axis.
● shutdown of the leading axis as the result of an IS (e.g. axis-specific feed stop, axis inhibit,
servo enable, etc.) causes the corresponding coupled motion axis to shut down.

Position measuring system 1/2 (DB31, ... DBX1.5/1.6))

Switch-over of the position measuring system for the leading and following axes is not inhibited
for an active coupled axis group. The coupling is not canceled.
Recommendation: Switch the measuring system over when the coupling is deactivated.

8.3.6 Special characteristics of the axis master value coupling function

Control dynamics
Depending on the application in question, it may be advisable to match the position controller
parameter settings (e.g. servo gain factor (KVfactor)) of the leading axis and following axis in
an axis grouping. It may be necessary to activate other parameter sets for the following axis.
The dynamics of the following axis should be the same or better than those of the leading axis.

Status of coupling
See Chapter "Status of coupling (Page 314)"

Actual value display

The display of the actual value is updated for all axes of in a master value coupled axis grouping
(only real axes) coupled via a master value.

Interpolation
When the movement defined in the curve table is interpolated, axis position and axis speed
are calculated for a master value and its speed.

Logging
The curve tables generated by the definition of motion sequences are stored in the battery-
backed memory.

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8.4 Electronic gear (EG)

The curve tables are not lost when the control system is switched off.
These functions have no effect on cyclic machines because they are performed without
operator actions. Nor does it make sense to perform automatic (re-)positioning via the NC with
external master values.

8.3.7 Supplementary conditions

External master value axes

When using the REPOS or REPOSA parts program instructions in conjunction with external
master value axes, it should be ensured that these are released by the channel or switched
to a "neutral state" using the RELEASE instruction.
When attempting to reposition without release of the axis, the message "Wait: Feed stop active"
is displayed and the processing of the part program is not continued.

8.4 Electronic gear (EG)

8.4.1 Product brief

8.4.1.1 Function

General
The "electronic gear" function makes it possible to control the movement of a following axis,
depending on up to five master axes. The relationship between each leading axis and the
following axis is defined by the coupling factor. Following axis motion components derived
from the individual leading axis motion components have an additive effect.
The coupling can be based on:
● Actual value of the leading axis
● Setpoint of the leading axis
The following functions of a gear grouping can be programmed using part program instructions:
● Defining
● Switch on
● Switch off
● Delete

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Curve tables
Non-linear relationships between lead and following axes can also be implemented using curve
tables.

Cascading
Electronic gearboxes can be cascaded, i.e. the following axis of an electronic gearbox can be
the leading axis for a subsequent electronic gearbox.

Synchronous position
An additional function for synchronizing the following axis allows a synchronous position to be
selected:
● Approach next division (tooth gap) time-optimized
● Approach next division (tooth gap) path-optimized
● Approach in positive direction of axis rotation, absolute
● Approach in negative direction of axis rotation, absolute
● Traverse time-optimized with respect to programmed synchronized position
● Traverse path-optimized with respect to programmed synchronized position
Application Examples:
● Machine tools for gear cutting
● Gear trains for production machines

8.4.1.2 Preconditions
The "Electronic Gearbox" option or the relevant option of generic coupling (refer to
" Preconditions (Page 380) " in the "Brief description" of Generic Coupling) is required for the
usage of function.

Function
With the aid of the "Electronic gearbox" the movement of a following axis FA can be interpolated
dependent of up to five leading axes LA. The relationship between each leading axis and the
following axis is defined by a coupling factor. The following axis motion components derived
in this manner from the individual leading axis motion components have an additive effect.
FAset = SynPosFA + (LA1-SynPosLA1)*CF1 +... +(LA5-SynPosLA5)*CF5
with:
SynPosFA, SynPosLAi: from call EGONSYN (see below)
FAsetpoint: Partial setpoint of the following axis.
LAi: Setpoint or actual value of the ith leading axis (depending on the type of coupling - see
below)
KFi: Coupling factor of the ith leading axis (see below)

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8.4 Electronic gear (EG)

All paths are referred to the basic co-ordinate system BCS.

When an EG axis group is activated, it is possible to synchronize the leading axes and following
axis in relation to a defined starting position.
From the part program a gearbox group can be:
● defined,
● activated,
● deactivated,
● deleted.

Extensions
The influence of each of the 5 leading axes can be specified using a curve table as an
alternative to a transmission ratio (KF=numerator/denominator).
It is thus possible for each curve (except for the special case of a straight line) for the leading
axis to influence the following axis in a non-linear manner. The function can only be used with
EGONSYN.
The function EG can be activated with curve tables with EGON.
The function EGONSYNE is available for approaching the synchronized position of the
following axis with a specified approach mode.
For special applications, it may be advisable configure the position controller as a PI
controller.

CAUTION
Application faults
Knowledge of the control technology and measurements with servo trace are an absolute
prerequisite for using this function.

References:
● CNC Commissioning Manual: NCK, PLC, drive
● Function Manual, Basic Functions; Velocities, Setpoint-Actual Value Systems, Closed-
Loop Control (G2)

Coupling type
The following axis motion can be derived from either of the following:
● Setpoints of leading axes
● Actual values of leading axes
The reference is set in the definition call for the EG axis group:
EGDEF
(see Chapter "Definition of an EG axis group (Page 361)")

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8.4 Electronic gear (EG)

Coupling factor
The coupling factor must be programmed for each leading axis in the group. It is defined by
numerator/denominator.
Coupling factor values numerator and denominator are entered per leading axis with the
following activation calls:
EGON
EGONSYN
EGONSYNE
(see Chapter "Activating an EG axis group (Page 362)")

Number of EG axis groups

Several EG axis groups can be defined at the same time. The maximum possible number of
EG axis groupings is set in the following machine data:
MD11660 $MN_NUM_EG
The maximum permissible number of EG axis groups is 31.

Note
The option must be enabled.

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8.4 Electronic gear (EG)

EG cascading
The following axis of an EG can be the leading axis of another EG. For a sample configuration
file, see Chapter "Examples".

/$
=
1

/$ &DVFDGLQJDOVRSRVVLEOH
=
1 /$.

=1
/$ /$.

= =1
1 /$.

=1
/$.
/$
= =1
/$.
1
ಯ6RIWZDUHರD[LV =1
/$
=
1

Figure 8-7 Block diagram of an electronic gearbox

Synchronous positions
To start up the EG axis group, an approach to defined positions for the following axis can first
be requested.
Synchronous positions are specified with:
EGONSYN (see below for details)
EGONSYNE (extended EGONSYN call).

Synchronization
If a gear is started with EGON(), EGONSYN() or EGONSYNE() see below, the actual position
of the following axis is only identical to the setpoint position defined by the rule of motion of
the gear specified by the positions of the leading axes at this time if the part program developer
makes sure that it is. The control then uses the motion of the following axis to ensure that the
setpoint and actual positions of the following axes correspond as quickly as possible if the
leading axes are moved further. This procedure is called synchronization. After synchronization
of the following axis, the term synchronous gearing is used.

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8.4 Electronic gear (EG)

Activation response
An electronic gearbox can be activated in two different ways:
1. On the basis of the axis positions that have been reached up to now in the course of
processing the command to activate the EG axis group is issued without specifying the
synchronizing positions for each individual axis.
EGON (see Chapter "Activating an EG axis group (Page 362)")
2. The command to activate the EG axis group specifies the synchronized positions for each
axis. From the point in time when these positions are reached, the EG should be
synchronized.
EGONSYN (see Chapter "Activating an EG axis group (Page 362)")
3. The command to activate the EG axis group specifies the synchronized positions and
approach mode for each axis. From the point in time when these positions are reached,
the EG should be synchronized.
EGONSYNE (see Chapter "Activating an EG axis group (Page 362)")

Synchronization with EGON

With EGON(), no specifications are made for the positions at which the following axis is to be
synchronized. The control system activates the EG and issues the signal "Synchronized
position reached".

Synchronization for EGONSYN

1. With EGONSYN(), the positions of the leading axes and the synchronization position for
the following axis are specified by the command.
● The control then traverses the following axis with just the right acceleration and velocity to
the specified synchronization position so that the following axis is in position with the leading
axes at its synchronization position.
● If the following axis is stationary: If the "Feed stop/spindle stop" DB 31, ... DBX 4.3 is set
for the following axis, the following axis is not set in motion by EGON or EGONSYN. A
traverse command is issued and block changing is blocked until the axis-specific feed is
enabled. EGOSYN is topped by RESET transformed into EGON. The programmed
synchronized positions are deleted.
● If the following axis is not stationary: The NST "Feed Stop/Spindle Stop" DB31, ... DBX4.3
has no direct influence on the electronic gearbox. As before, it does have an indirect effect
on the leading axes, if these are located in the same channel.
● For channel specific feed enabling and for override nothing is implemented. Override still
has no direct influence on the electronic gearbox. The axis-specific feed enable is set,
depending on the current override setting.

Synchronization for EGONSYNE

With EGONSYN(), the positions of the leading axes and the synchronization position for the
following axis are specified by the command.
The control system moves the following axis to the synchronized position according to the
program approach mode.

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8.4 Electronic gear (EG)

Synchronization abort with EGONSYN and EGONSYNE

1. The EGONSYN/EGONSYNE command is aborted under the following conditions and
changed to an EGON command:
● RESET
● Axis switches to tracking
The defined synchronization positions are ignored. Synchronous traverse monitoring still takes
synchronized positions into account.
Aborting position synchronization generates alarm 16774.
The alarm may be suppressed with the following machine data:
MD11410 $MN_SUPPRESS_ALARM_MASK Bit31 = 1

Synchronous monitoring
The synchronism of the gearbox is monitored in each interpolator clock cycle on the basis of
the actual values of the following and leading axes. For this purpose, the actual values of the
axes are computed according to the rule of motion of the coupling. The synchronism
difference is the difference between the actual value of the following axis and the value
calculated from the leading axis actual values according to the rule of motion. The synchronism
difference can be queried from the part program (see below).

Changes in the synchronism difference

The mass inertia of the axis systems during acceleration can cause dynamic fluctuations in
the synchronism difference. The synchronism difference is checked continuously and the
tolerance values in the machine data used to produce interface signals.
The synchronism difference is compared with the following machine data:
MD37200 $MA_COUPLE_POS_TOL_COARSE
MD37210 $MA_COUPLE_POS_TOL_FINE
Depending on the result of this comparison, the following signals are set:
NST "Synchronous travel fine" DB31, ... DBX98.0
NST "synchronous traverse coarse" DB31, ... DBX98.1

Difference > .. TOL_COARSE

As long as the synchronism difference is greater than the following machine data, the gearbox
is not synchronized and neither IS "Coarse synchronism" DB 31, ... DBX 98.1 nor IS "Fine
synchronism" DB 31, ... DBX 98.0 is active:
MD37200 $MN_COUPLE_POS_TOL_COARSE
Instead, the following interface signal is displayed:
NST "synchronization running" DB31, ... DBX99.4

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Difference < .. TOL_COARSE

As long as the synchronism difference is smaller than the following machine data, IS "Coarse
synchronism" DB 31, ... DBX 98.1 is at the interface and IS "Fine synchronism" DB31, ...
DBX99.4 is deleted:
MD37200 $MN_COUPLE_POS_TOL_COARSE

Difference > .. TOL_FINE

If the synchronism difference is smaller than the following machine data, then NST
"synchronous traverse fine" DB31, ... DBX98.0 is at the interface:
MD37210 $MA COUPLE_POS_TOL_FINE

Synchronism difference for EG cascades

Synchronism difference for EG cascades is the deviation of the actual position of the following
axis from setpoint position that results fro the rule of motion for the real axes involved.
Example:

/$
/$ )$
(*

)$
(*
)$
(*
/$ /$

)$Lൺ)ROORZLQJD[LVIURP(*L /$LൺUHDOOHDGLQJD[LV

Figure 8-8 Three-level EG cascade

According to the definition given, the synchronism difference of following axis FA3 in the
example below is determined by the value of following axis FA3Act and the value of leading
axis FA2Act and LA2Act, but not by LA1Act and FA1Act.
If FA2 is not a real axis, the actual value FA2Act is not available. In this case, the setpoint of
the axis derived solely from the leading axis value FA1Act must be used instead of the actual
value of the setpoint of the axis.

Other signals
If an EGON(), EGONSYN() or EGONSYNE() block is encountered in the main run, the signal
"Coupling active" is set for the following axis. If the following axis is only overlaid, the signals
"Coupling active" and "Axis override" are set. If EGON(), EGONSYN() or EGONSYNE() is
active and the following axis is also overlaid, the signals "Coupling active" and "Axis override"
are also set.
IS "following spindle active" DB31, ... DBX 99.1: Coupling active,

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IS "overlaid movement" DB31, ... DBX98.4: axis is overlaid,

IS "Enable following axis override" DB31, ... DBX26.4
In the case of the commands EGON() and EGONSYNE(), the "Enable following axis override"
signal must be present for the gear to synchronize to the specified synchronization position
for the following axis. If it is not present, alarm 16771 "Override movement not enabled" is
issued. If the signal is present, the following axis travels to the synchronized position with the
calculated acceleration and at the velocity set for the approach mode.

Further monitoring signals

Machine data MD37550 $MA_EG_VEL_WARNING allows a percentage of the speeds and
accelerations to be specified in the following machine data MD32000 $MA_MAX_AX_VELO
and MD32300 $MA_MAX_AX_ACCEL, with reference to the following axis, which results in
the generation of the following interface signals:
IS "Speed warning threshold" DB31, ... DBX98.5
IS "Acceleration warning threshold" DB31, ... DBX98.6
The monitoring signals can be used as trigger criteria for emergency retraction (see Chapter
"Trigger sources (Page 479)").
Machine data MD37560 $MA_EG_ACC_TOL allows a percentage with reference to machine
data MD32300 $MA_MAX_AX_ACCEL of the following axis to be defined, and the IS signal
"axis accelerates" DB31, ... DBX99.3 to be generated.

Request synchronism difference

1. The result of the synchronism difference calculation can be read as an amount in the part
program with system variable $VA_EG_SYNCDIFF. The relevant value with sign is
available in the system variables $VA_EG_SYNCDIFF_S. The following meanings apply:
● Negative value (in positive traverse direction for lead and following axis): The following axis
lags behind its calculated setpoint position.
● Positive value (in positive traverse direction for lead and following axis): The following axis
leads before its calculated setpoint position (overswing).
The amount of the synchronism difference with sign corresponds to the system variables
without sign from $VA_EG_SYNCDIFF.
$VA_EG_SYNCDIFF[ax] = ABS($VA_EG_SYNCDIFF_S[ax])

Block change mode

1. When an EG axis group is activated, it is possible to specify the conditions under which a
part program block change is to be executed:
2. The specification is made with a string parameter with the following meaning:
3. "NOC": Immediate block change
4. "FINE": Block change if "Fine synchronism" is present

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5. "COARSE": Block change if "Coarse synchronism" is present

6. "IPOSTOP": Block change if "Setpoint synchronism" is present

Note
When programmed in activation calls EGON, EGONSYN, EGONSYNE, each of the above
strings can be abbreviated to the first two characters.

If no block change has been defined for the EG axis group and none is currently specified,
"FINE" applies.

8.4.2 Definition of an EG axis group

Note
The following definition commands and switch instructions of the electronic gearbox must all
be contained in only one block of a parts program.
All commands of the electronic gearbox result in a preprocessing stop, except for the activation
commands:
● EGON
● EGONSYN
● EGONSYNE

Definition and activation

The definition described below and activation are separate processes. An activation is not
possible unless it has been defined previously.

Definition of an EG axis group

An EG axis group is defined through the input of the following axis and at least one, but not
more than five, leading axis, each with the relevant coupling type:
EGDEF(following axis, leading axis1, coupling type1, leading axis2, coupling type 2,...)
The coupling type does not need to be the same for all leading axes and must be programmed
separately for each individual leading axis.
Coupling type:
Evaluate actual value of leading axis: 0
Evaluate setpoint of leading axis: 1
The coupling factors are preset to zero when the EG axis group is defined. As such, the group
has no effect on the following axis until it is activated. (See EGON, EGONSYN, EGONSYNE).
Preconditions for defining an EG axis group:

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No existing axis coupling may already be defined for the following axis. (If necessary, an
existing axis must be deleted with EGDEL.)
EGDEF triggers preprocessing stop with alarm.
For an example of how to use the EG gearbox for gear hobbing, please see Chapter
"Examples", "Electronic Gearbox for Gear Hobbing".

EGDEF
The gearbox definition with EGDEF should also be used unaltered when one or more leading
axes affect the following axis via a curve table.
The variant extended with the addition of non-linear coupling via curve tables is illustrated in
an extended example in Chapter "Extended Example with non-linear Components".

8.4.3 Activating an EG axis group

Without synchronization
The EG axis group is activated without synchronization selection with:
EGON(FA, block change mode, LA1, Z1, N1, LA2 , Z2, N2,..LA5, Z5, N5.)
The coupling is activated immediately.
With:
FA: Following axis
Depending on block change mode, the next block will be activated:
"NOC": Block change takes place immediately
"FINE": Block change is performed in "Fine synchronism"
"COARSE": Block change is performed in "Coarse synchronism"
"IPOSTOP": Block change is performed for setpoint-based synchronism
LAi: Axis name of the leading axis i
Zi: Counter for coupling factor of leading axis i
Ni: Denominator for coupling factor of leading axis i
Only the leading axes previously specified with the EGDEF command may be programmed in
the activation line. At least one leading axis must be programmed.
The positions of the leading axes and following axis at the instant the grouping is switched on
are stored as "Synchronized positions". The "Synchronized positions" can be read with the
system variable $AA_EG_SYN.

With synchronization
The EG axis group is activated with synchronization selective:

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1. EGONSYN
EGONSYN(FA, block change mode, SynPosFA, LAi, SynPosLAi, Z_LAi, N_LAi)
With:
FA: Following axis
Block change mode:
"NOC": Block change takes place immediately
"FINE": Block change is performed in "Fine synchronism"
"COARSE": Block change is performed in "Coarse synchronism"
"IPOSTOP": Block change is performed for setpoint-based synchronism
SynPosFA: Synchronized position of the following axis
LAi: Axis name of the leading axis i
SynPosLAi: Synchronized position of leading axis i
Zi: Counter for coupling factor of leading axis i
Ni: Denominator for coupling factor of leading axis i

Note
The parameters indexed with i must be programmed for at least one leading axis, but for no
more than five.

Only leading axes previously specified with the EGDEF command may be programmed in the
activation line.
Through the programmed "Synchronized positions" for the following axis (SynPosFA) and for
the leading axes (SynPosLA), positions are defined for which the axis grouping is interpreted
as synchronous. If the electronic gear is not in the synchronized state when the grouping is
switched on, the following axis traverses to its defined synchronized position.
The position specification of the synchronized positions is specified in the configured basic
system independently of the programmable dimensions (G70/G71).
If the axis grouping includes modulo axes, their position values are reduced in the modulo,
This way the fastest possible synchronized position is approached reliably, e. g., the next tooth
from the tooth spacing (360 degree* Zn/Ni) and the associated synchronized positions.
(So-called relative synchronization.)
thereby ensuring that they approach the fastest possible synchronized position. (So-called
relative synchronization, e.g. the next tooth gap after "centering".)
If the following interface signal has not been set for the following axis, the axis will not travel
to the synchronization position.
DB31, ... DBX26.4 (Enable following axis override)
Instead the program is stopped at the EGONSYN block and the self-clearing alarm 16771 is
issued until the above mentioned signal is set.

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2. EGONSYNE
EGONSYNE(FA, block change mode, SynPosFA, Approach mode, LAi,SynPosLAi, Z_LAi,
N_LAi)
with:
"FA": Following axis
Block change mode:
"NOC": Block change takes place immediately
"FINE": Block change is performed in "Fine synchronism"
"COARSE": Block change is performed in "Coarse synchronism"
"IPOSTOP": Block change is performed for setpoint-based synchronism
SynPosFA: Synchronized position of the following axis
Approach mode:
"NTGT": NextToothGapTime-optimized, the next tooth gap is approached time-optimized
(preset is used if no setting is applied).
"NTGP": The next tooth gap is approached time-optimized.
"ACN": AbsoluteCoordinateNegative, Absolute measurement specification, rotary axis
traverses in negative rotation direction
"ACP": AbsoluteCoordinatePositive, Absolute measurement specification, rotary axis
traverses in positive rotation direction
"DCT": DirectCoordinateTime-optimized, Absolute measurement specification, rotary axis
traverses time-optimized to programmed synchronized position
"DCP": DirectCoordinatePath-optimized, Absolute measurement specification, rotary axis
traverses path-optimized to programmed synchronized position
LAi: Axis name of the leading axis i
SynPosLAi: Synchronized position of leading axis i
Zi: Counter for coupling factor of leading axis i
Ni: Denominator for coupling factor of leading axis i

Note
The parameters indexed with i must be programmed for at least one leading axis, but for no
more than five.

The function is active only for modulo following axes that are coupled to modulo leading axes.

Tooth gap
The tooth gap is defined as 360 degrees * Zi / Ni
Example:
EGONSYNE(A, "FINE", FASysPos, "Traversing mode", B, LASynPos, 2, 10)

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Tooth gap: 360*2/10 = 72 (degrees)

Approach response with FA at standstill

In this case, the time-optimized and path-optimized traversing modes are identical.
The table below shows the target positions and traversed paths with direction marker (in
brackets) for the particular approach modes:

Programmed Position of the fol‐ Traversing Traversing mode Traversing mode Traversing mode
synchronized posi‐ lowing axis before mode NTGT/ DCT/DCP ACP ACN
tion FaSysPos EGONSYNE NTGP
110 150 182 (+32) 110 (-40) 110 (+320) 110 (-40)
110 350 326 (-24) 110 (+120) 110 (+120) 110 (-240)
130 0 346 (-14) 130 (+130) 130 (+130) 130 (-230)
130 30 58 (+28) 130 (+100) 130 (+100) 130 (-260)
130 190 202 (+12) 130 (-60) 130 (+300) 130 (-60)
190 0 334 (-26) 190 (-170) 190 (+190) 190 (-170)
230 0 14 (+14) 230 (-130) 230 (+230) 230 (-130)

Approach response for moving FA

The following axis moves at almost maximum velocity in the positive direction when the
coupling is activated by EGONSYNE. The programmed synchronized position of the following
axis is 110, the current position 150. This produces the two alternative synchronized positions
110 and 182 (see table above).
In the case of traversing mode NTGP (path-optimized), synchronized position 182 is selected
independent of the current velocity. This has the shortest distance from the current position of
the following axis. Traversing mode NTGT (time-optimized) considers the current speed of the
following axis and produces a deceleration on account of the limit for the maximum axis speed
to reach synchronism in the shortest possible time (see Figure).

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17*3

YPD[

17*7

Figure 8-9 Reaching the next tooth gap, FA path-optimized (top) vs. time-optimized (bottom)

Sample notations
EGONSYNE(A, "FINE", 110, "NTGT", B, 0, 2, 10)
couple A to B, synchronized position A = 110, B = 0, coupling factor 2/10, approach mode =
NTGT
EGONSYNE(A, "FINE", 110, "DCT", B, 0, 2, 10)
couple A to B, synchronized position A = 110, B = 0, coupling factor 2/10, approach mode =
DCT
EGONSYNE(A, "FINE", 110, "NTGT", B, 0, 2, 10, Y, 15, 1, 3)
couple A to B, synchronized position A = 110, B = 0, Y = 15,
Coupling factor to B = 2/10, Coupling factor to Y = 1/3,
approach mode = NTGT

With synchronization
The syntax specified above applies with the following different meanings:
If a curve table is used for a leading axis, then the denominator of the linear coupling of the
coupling factor (Ni) must be set to 0 (denominator 0 would be impermissible for linear
couplings).
For control, denominator zero is the indicator that the counter of the coupling factor (Zi) is to
be interpreted as the number of the curve table to be used. The curve table with the specified
number must already be defined at power on (in accordance with Chapter "Curve Tables").
The leading axis specified (LAi) corresponds to the one specified for coupling via coupling
factor (linear coupling).

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8.4.4 Deactivating an EG axis group

Variant 1
There are different ways to deactivate an active EG axis grouping.
EGOFS(following axis)
The electronic gear is deactivated. The following axis is braked to a standstill. This call triggers
a preprocessing stop.

Variant 2
The following parameterization of the command makes it possible to selectively control the
influence of individual leading axes on the motion of the following axis.
EGOFS(following axis, leading axis 1, ... leading axis 5)

Note
At least one leading axis must be specified.

The influence of the specified leading axes on the slave is selectively inhibited. This call triggers
a preprocessing stop.
If the call still includes active leading axes, then the slave continues to operate under their
influence. If the influence of all leading axes is excluded by this method, then the following axis
is braked to a standstill.
If the command EGONSYN is deactivated selectively, no axis movement is performed.

Variant 3
EGOFC(following spindle)
The electronic gear is deactivated. The following spindle continues to traverse at the speed/
velocity that applied at the instant of deactivation. This call triggers a preprocessing stop.

Note
Call for following spindles available. For EGOFC a spindle name must be programmed.

8.4.5 Deleting an EG axis group

An EG axis grouping must be switched off, as described in Chapter "Switching off a EG Axis
Group", before its definition can be deleted.
EGDEL(following axis)
The defined coupling of the axis grouping is deleted. Additional axis groups can be defined by
means of EGDEF until the maximum number of simultaneously activated axis groups is
reached.

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8.4 Electronic gear (EG)

This call triggers a preprocessing stop.

8.4.6 Interaction between rotation feedrate (G95) and electronic gearbox

The FPR( ) part program command can be used to specify the following axis of an electronic
gear as the axis, which determines the rotational feedrate. The following behavior is applicable
in this case:
● The feedrate is determined by the setpoint velocity of the following axis of the electronic
gear.
● The setpoint velocity is calculated from the speeds of the leading spindles and modulo axes
(which are not path axes) and from their associated coupling factors.
● Velocity components from other leading axes and overlaid motions of the following axis are
not taken into account.
References: /V1/, Feeds

8.4.7 Response to POWER ON, RESET, operating mode change, block search

Function Behavior with regard to elect. gear

Coupling state Configuration
Mode change Is retained Is retained
End of part program Is retained Is retained
Reset Is retained Is retained
Power On 1)
Is not retained Is not retained
1) No coupling is active after Power On.

Block search
A search during active coupling (EG) is possible under the following supplementary conditions:
● Simulation is exclusively with setpoint coupling.
● No cross-channel leading axes may be disabled.
● Axis movements for which all real positions are known to the NC.
If it is technically not sensible or not possible to permit the target block for a block search with
calculation or SERUPRO within a part program section with active coupling, this section can
be locked for "continue machining at the contour".

Programming
● IPTRLOCK()
● IPTRUNLOCK()

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 M3: Coupled axes
8.4 Electronic gear (EG)

References
(K1) Mode group, channel, program operation, reset response , Section "Block search type 5
SERUPRO" > "Lock program section for continue machining at the contour"

8.4.8 System variables for electronic gearbox

Application
The following system variables can be used in the part program to scan the current states of
an EG axis group and to initiate appropriate reactions if necessary:

Table 8-1 System variables, R means: Read access possible

Name Type Access Preprocessing Meaning, value Cond. Index

stop
part Sync part pro‐ Sync
pro‐ act. gram act.
gram
$AA_EG_ INT R R Type of coupling: Axis name
TYPE[a,b] 0: actual value a: Following axis
1: Setpoint value coupling b: Leading axis
$AA_EG_ REAL R R Numerator of coupl. factor Axis name
NUMERA[a,b] KF a: Following axis
KF = numerator/denomina‐ b: Leading axis
tor
preset: 0
Number of curve table
when $AA_EG_DE‐
NOM[a,b] is 0.
$AA_EG_ REAL R R Denominator of coupl. fact. Axis name
DENOM[a,b] KF a: Following axis
KF = numerator/denomina‐ b: Leading axis
tor
preset: 1
Denominator must be posi‐
tive.
Denominator is 0, if instead
of the numerator
$AA_EG_NUMERA[a,b]
the number of a curve table
is specified.
$AA_EG_ REAL R R Synchronized position for Axis name
SYN[a,b] specified leading axis a: Following axis
Default: 0 b: Leading axis
$AA_EG_ REAL R R Synchronized position for Axis name
SYNFA[a] specified following axis a: Following axis
Default: 0

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8.4 Electronic gear (EG)

Name Type Access Preprocessing Meaning, value Cond. Index

stop
part Sync part pro‐ Sync
pro‐ act. gram act.
gram
$P_EG_BC[a] STRING R R Block change criterion for Axis name
EG activation calls: EGON, a: Following axis
EGONSYN:
"NOC": immediately
"FINE": Synchronoous tra‐
verse fine
"COARSE": Synchronous
traverse coarse
"IPOSTOP": Setpoint-
based synchronism
$AA_EG_ INT R R Number of leading axes de‐ Axis name
NUM_LA[a] fined with EGDEF. 0 if no a: Following axis
axis has been defined as a
following axis with EGDEF.
$AA_EG_ AXIS R R Axis name of leading axis Axis name
AX[n,a] whose index n has been n: Index of leading axis in
specified. the EG coupling 0 ... 4
a: Following axis
$AA_EG_ BOOL R R Determine power-on state Axis name
ACTIVE[a,b] of a leading axis: a: Following axis
0: Switched off b: Leading axis
1: activated
$VA_EG_ REAL R R R Actual value of synchron‐ Axis name
SYNCDIFF[a] ism difference. A compari‐ a: Following axis
son of machine data
MD37200 $MA_COU‐
PLE_POS_TOL_COARSE
and MD37210 $MA_COU‐
PLE_POS_TOL_FINE pro‐
duces interface signals.

8.4.9 Examples

8.4.9.1 Example using linear couplings

Use of axes
The following diagram shows the configuration of a typical gear hobbing machine. The machine
comprises five numerically closed loop controlled axes and an open loop controlled main
spindle. These are:
● The rotary motion of the workpiece table (C) and hobbing cutter (B).
● The axial axis (Z) for producing the feed motion over the entire workpiece width.
● The tangential axis (Y) for moving the hobbing cutter along its axis.

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8.4 Electronic gear (EG)

● The radial axis (X) for infeeding the cutter to depth of tooth.
● The cutter swivel axis (A) for setting the hobbing cutter in relation to the workpiece as a
function of cutter lead angle and angle of inclination of tooth.

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Figure 8-10 Definition of axes on a gear hobbing machine (example)

The functional interrelationships on the gear hobbing machine are as follows:

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In this case, the workpiece table axis (C) is the following axis which is influenced by three
master drives.

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M3: Coupled axes
8.4 Electronic gear (EG)

The setpoint of the following axis is calculated cyclically with the following logic equation:

nc = nb * (z0 / z2) + vz * (udz / z2) + vy * (udy / z2)

with: nc = Rotational speed of workpiece axis (C)

nb = Rotational speed of milling spindle (B)
z0 = Number of gears of the hobbing machine
z2 = Number of teeth of the workpiece
vz = Feed velocity of axial axis (Z)
vy = Feed velocity of tangential axis (Y)
udz = Axial differential constant
udy = Tangential differential constant

Quantities which influence the setpoint of workpiece axis C

The first addend of the above equation determines the speed ratio between workpiece table
and cutter, and thus the number of teeth of the workpiece.
The second addend effects the necessary additional rotation of the C axis as a function of the
axial feed motion of the cutter to produce the tooth inclination on helical teeth.
The third component also makes allowance for additional rotation of the C axis to compensate
for the tangential movement of the cutter in relation to the workpiece, thus ensuring that the
tool is equally stressed over its entire length.

Workpiece/tool parameter
The values z0, z2, udz, and udy are workpiece- or tool-dependent and are specified by the NC
operator or in the part program.

Differential constants
Differential constants udz and udy make allowance for the angle of workpiece teeth and for cutter
geometry. These differential constants can be determined in user-specific cycles.

udz = (sin β° / (mn * π) ) * 360 [degrees/mm]

udy = (cos γ° / (mn * π) ) * 360 [degrees/mm]

with: mn = Normal module (in mm)

β° = Incline angle of gear wheel
γ° = Pitch angle of hobbing machine

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8.4 Electronic gear (EG)

Extract from part program:

Program code Comment
EGDEF(C,B,1,Z,1,Y,1) ; Definition of EG axis grouping
with setpoint coupling (1) from
B, Z, Y to C (following axis).
EGON(C,"FINE",B,z0,z2,Z,udz,z2,Y,udy,z2) ; Activate coupling.
…

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8.4 Electronic gear (EG)

8.4.9.2 Extended example with non-linear components

Introduction
The following example extends the example (see "Figure 8-10 Definition of axes on a gear
hobbing machine (example) (Page 371)") with the following:
● Machine error compensations which are not linearly dependent on the Z axis, and
● a Z-axis dependent component with tooth geometry.
This can be used to create a slightly convex tooth surface, so that the centre of the tooth
is stressed more than the edges during operation.
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Figure 8-11 Extended example with non-linear machine fault compensation and non-linear components on the tooth
geometry

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8.4 Electronic gear (EG)

The following section of a part program is intended to illustrate the general concept;
supplementary curve tables and gear wheel/machine parameters are still to be added.
Components to be added are marked with <...> . Stated parameters may also have to be
modified, e.g. coupling factors.

Program code Comment

N100 CTABDEF(X, Z, 1, 0) ; declaration and specification of non-period-
ic curve table C1
N110 < ... ; Preset of curve table: Curve points or poly-
> nomial blocks
N190 CTABEND
N200 CTABDEF(Y, Z, 2, 0) ; declaration and specification of non-period-
ic curve table C2
N210 < ... ; Preset of curve table: Curve points or poly-
> nomial blocks
N290 CTABEND
N300 CTABDEF(A, Z, 3, 0) ; declaration and specification of non-period-
ic curve table C3
N310 < ... ; Preset of curve table: Curve points or poly-
> nomial blocks
N390 CTABEND
N400 CTABDEF(C, Z, 4, 0) ; declaration and specification of non-period-
ic curve table C4
N410 < ... ; Preset of curve table: Curve points or poly-
> nomial blocks
N490 CTABEND
N500 EGDEF(X, Z, 1) ; Declaration of path via C1, setpoint coupling
N510 G1 F1000 X10 ; declaration of command component of X
N520 EGONSYN(X, "NOC", ; Path switch-on via C1
<SynPosX>, Z,
<SynPosX_Z>, 1, 0)
N600 EGDEF(Y, Z, 1) ; Declaration of path via C2, setpoint coupling
N610 G1 F1000 Y10 ; declaration of command component of Y
N620 EGONSYN(Y, ; Path switch-on via C2
"COARSE", <SynPo-
sY>, Z, <SynPo-
sY_Z>, 2, 0)
N700 EGDEF(A, Z, 1) ; Declaration of path via C3, setpoint coupling
N710 G1 F1000 A10 ; declaration of command component of A
N720 EGONSYN(A, "FINE", ; Path switch-on via C3
<SynPosA>, Z, <Syn-
PosA_Z>, 3, 0)
; 1. Gear stage, C99 is the software axis between the two electronic gears
N800 EGDEF(C99, Y, 1, Z,
1, B, 1 )
N810 EGONSYN(C99, "NOC", ; Switch-on of leading axis B
<SynPosC99>, B,
<SynPosC99_B>, 18,
2, &

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Program code Comment

Y, <SynPosC99_Y>, ; Switch-on of leading axis Y
R1 * π, 1, &
Z, <SynPosC99_Z>, ; Switch-on of leading axis Z
10, 1)
; "&" character means: command continued in
next line, no LF nor comment permissible in
program
; 2. Gear stage
N900 EGDEF(C, C99, 1, Z, ; declaration of following C99 of step 1 as
1) leading axis of step 2,
; Setpoint value coupling
N910 ; Declaration of path via C4, setpoint cou-
pling
N920 EGONSYN(C, "NOC", ; Switch-on of software axis C99
<SynPosC>, C99,
<SynPosC_C99>, 1,
1, &
Z, <SynPosC_Z>, 4, ; and of leading axis Z via C4
0)
N999 M30

Machine data
Only one section is specified, which extends beyond the necessary geometry/channel
configuration and machine axis parameters.

$MN_NUM_EG = 5 ; Maximum number of gearboxes

$MN_MM_NUM_CURVE_TABS = 5 ; Maximum number of curve tables
$MN_MM_NUM_CURVE_SEGMENTS = 50 ; Maximum number of curve segments
$MN_MM_NUM_CURVE_POLYNOMS = 100 ; Maximum number of curve polynomials

Setting data
If the scaling described in Section "Electronic gear (EG) (Page 352) is used, the function value
from the following machine data changes according to the displacement:
MD43108 $SD_LEAD_SCALE_OUT_POS[4] = 1.2 ; scaling for table C4

System variables
In accordance with the above definitions, the following values are entered in the associated
system variables by the control.
Reference:
List Manual, System Variables

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8.4 Electronic gear (EG)

The system variables listed below are only used for explanatory purposes!

; ************** Gear X (G1)

$AA_EG_TYPE[X, Z] = 1 ; Setpoint value coupling
$AA_EG_NUMERA[X, Z] = 1 ; curve table No. = 1
$AA_EG_DENOM[X, Z] = 0 ; nominator = 0 → curve table applies
$P_EG_BC[X] = "NOC" ; Block change criterion
$AA_EG_NUM_LA[X] = 1 ; Number of leading axes
$AA_EG_AX[0, X] = Z ; name of leading axis
$AA_EG_SYN[X,Z] = <SynPosX_Z> ; Synchronized position of leading axis Z
$AA_EG_SYNFA[X] = <SynPosX> ; Synchronized position of the following axis
; ************** Gear Y (G2)
$AA_EG_TYPE[Y, Z] = 1 ; Setpoint value coupling
$AA_EG_NUMERA[Y, Z] = 2 ; curve table No. = 2
$AA_EG_DENOM[Y, Z] = 0 ; nominator = 0 → curve table applies
$P_EG_BC[Y10] = "COARSE" ; Block change criterion
$AA_EG_NUM_LA[Y] = 1 ; Number of leading axes
$AA_EG_AX[0, Y] = Z ; name of leading axis
$AA_EG_SYN[Y, Z] = <SynPosY_Z> ; Synchronized position of leading axis Z
$AA_EG_SYNFA[Y] = <SynPosY> ; Synchronized position of the following axis
; ************** Gear A (G3)
$AA_EG_TYPE[A, Z] = 1 ; Setpoint value coupling
$AA_EG_NUMERA[A, Z] = 3 ; curve table No. = 3
$AA_EG_DENOM[A, Z] = 0 ; nominator = 0 → curve table applies
$P_EG_BC[A10] = "FINE" ; Block change criterion
$AA_EG_NUM_LA[A] = 1 ; Number of leading axes
$AA_EG_AX[0, A] = Z ; name of leading axis
$AA_EG_SYN[A, Z] = <SynPosA_Z> ; Synchronized position of leading axis Z
$AA_EG_SYNFA[A] = <SynPosA> ; Synchronized position of the following axis
; ************** Gear C99 (G4)
$AA_EG_TYPE[C99, Y] = 1 ; Setpoint value coupling
$AA_EG_NUMERA[C99, Y] = 18 ; numerator for coupling factory
$AA_EG_DENOM[C99, Y] = 2 ; denominator for coupling factory
$AA_EG_TYPE[C99, Z] = 1 ; Setpoint value coupling
$AA_EG_NUMERA[C99, Z] = R1 * π ; numerator for coupling factorz
$AA_EG_DENOM[C99, Z] = 1 ; denominator for coupling factorz
$AA_EG_TYPE[C99, B] = 1 ; Setpoint value coupling
$AA_EG_NUMERA[C99, B] = 10 ; numerator for coupling factorb
$AA_EG_DENOM[C99, B] = 1 ; denominator for coupling factorb
$P_EG_BC[C99] = "NOC" ; Block change criterion
$AA_EG_NUM_LA[C99] = 3 ; Number of leading axes
$AA_EG_AX[0, C99] = Y ; name of leading axis Y
$AA_EG_AX[1, C99] = Z ; name of leading axis Z

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8.4 Electronic gear (EG)

$AA_EG_AX[2, C99] = B ; name of leading axis B

$AA_EG_SYN[C99, Y] = <SynPosC99_Y> ; Synchronized position of leading axis Y
$AA_EG_SYN[C99, Z] = <SynPosC99_Z> ; Synchronized position of leading axis Z
$AA_EG_SYN[C99, B] = <SynPosC99_B> ; Synchronized position of leading axis B
$AA_EG_SYNFA[C99] = <SynPosC99> ; Synchronized position of the following axis
; *************** Gear C (G5)
$AA_EG_TYPE[C, Z] = 1 ; Setpoint value coupling
$AA_EG_NUMERA[C, Z] = 4 ; curve table No. = 4
$AA_EG_DENOM[C, Z] = 0 ; nominator = 0 → curve table applies
$AA_EG_TYPE[C, C99] = 1 ; Setpoint value coupling
$AA_EG_NUMERA[C, C99] = 1 ; numerator for coupling factorC99
$AA_EG_DENOM[C, C99] = 1 ; denominator for coupling factorC99
$P_EG_BC[C] = "NOC" ; Block change criterion
$AA_EG_NUM_LA[C] = 2 ; Number of leading axes
$AA_EG_AX[0, C] = Z ; name of leading axis Z
$AA_EG_AX[1, C] = C99 ; name of leading axis C99
$AA_EG_SYN[C, Z] = <SynPosC_Z> ; Synchronized position of leading axis Z
$AA_EG_SYN[C, C99] = <SynPosC_C99> ; Synchronized position of leading axis C99
$AA_EG_SYNFA[C] = <SynPosC> ; Synchronized position of leading axis C

Machine data
Extract from MD:
; ************** Channel 1
CHANDATA(1)
; ************** Axis 1, "X"
$MC_AXCONF_GEOAX_NAME_TAB[0] = "X"
$MC_AXCONF_CHANAX_NAME_TAB[0] = "X"
$MC_AXCONF_MACHAX_USED[0]=1
$MN_AXCONF_MACHAX_NAME_TAB[0] = "X1"
$MA_SPIND_ASSIGN_TO_MACHAX[AX1] = 0
$MA_IS_ROT_AX[AX1] = FALSE
; *************** Axis 2, "Y"
$MC_AXCONF_GEOAX_NAME_TAB[1]="Y"
$MC_AXCONF_CHANAX_NAME_TAB[1] = "Y"
$MC_AXCONF_MACHAX_USED[1] = 2
$MN_AXCONF_MACHAX_NAME_TAB[1] = "Y1"
$MA_SPIND_ASSIGN_TO_MACHAX[AX2] = 0
$MA_IS_ROT_AX[AX2] = FALSE

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; *************** Axis 3, "Z"

$MC_AXCONF_GEOAX_NAME_TAB[2] = "Z"
$MC_AXCONF_CHANAX_NAME_TAB[2] = "Z"
$MC_AXCONF_MACHAX_USED[2]=3
$MN_AXCONF_MACHAX_NAME_TAB[2] = "Z1"
$MA_SPIND_ASSIGN_TO_MACHAX[AX3] = 0
$MA_IS_ROT_AX[AX3] = FALSE
; *************** Axis 4, "A"
$MC_AXCONF_CHANAX_NAME_TAB[3] = "A"
$MC_AXCONF_MACHAX_USED[3]=4
$MN_AXCONF_MACHAX_NAME_TAB[3] = "A1"
$MA_SPIND_ASSIGN_TO_MACHAX[AX4]=0
$MA_IS_ROT_AX[AX4] = TRUE
$MA_ROT_IS_MODULO[AX4] = TRUE
; *************** Axis 5, "B"
$MC_AXCONF_CHANAX_NAME_TAB[4] = "B"
$MC_AXCONF_MACHAX_USED[4]=5
$MC_SPIND_DEF_MASTER_SPIND = 1
$MN_AXCONF_MACHAX_NAME_TAB[4] = "B1"
$MA_SPIND_ASSIGN_TO_MACHAX[AX5] = 1
$MA_IS_ROT_AX[AX5] = TRUE
$MA_ROT_IS_MODULO[AX5] = TRUE
; ************** Axis 6, "C"
$MC_AXCONF_CHANAX_NAME_TAB[5] = "C"
$MC_AXCONF_MACHAX_USED[5]=6
$MN_AXCONF_MACHAX_NAME_TAB[5] = "C1"
$MA_SPIND_ASSIGN_TO_MACHAX[AX6] = 0
$MA_IS_ROT_AX[AX6] = TRUE
$MA_ROT_IS_MODULO[AX6] = TRUE
; ************** Axis 10, "C99"
$MC_AXCONF_CHANAX_NAME_TAB[9] = "C99"
$MC_AXCONF_MACHAX_USED[9]=10
$MA_SPIND_ASSIGN_TO_MACHAX[AX10] = 0
$MA_IS_ROT_AX[AX10] = TRUE
$MA_ROT_IS_MODULO[AX10] = TRUE

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8.5 Generic coupling

8.5 Generic coupling

8.5.1 Brief description

8.5.1.1 Function

Function
"Generic Coupling" is a general coupling function, combining all coupling characteristics of
existing coupling types (coupled motion, master value coupling, electronic gearbox and
synchronous spindle).
The function allows flexible programming:
● Users can select the coupling properties required for their applications (building block
principle).
● Each coupling property can be programmed individually.
● The coupling properties of a defined coupling (e.g. coupling factor) can be changed.
● Later use of additional coupling properties is possible.
● The coordinate reference system of the following axis (Base co-ordinate system or Machine
co-ordinate system) is programmable.
● Certain coupling properties can also be programmed with synchronous actions.
References:
Function Manual, Synchronized Actions

Adaptive cycles
Previous coupling calls for coupled motion (TRAIL*), Master value coupling (LEAD*), Electronic
Gearbox (EG*) and Synchronous spindle (COUP*) are still supported via adaptive cycles (see
Section "Adaptive cycles (Page 430)").

8.5.1.2 Requirements

CP version
The generic coupling is available in a basic version and four optional versions:
● CP-STATIC
● CP-BASIC
● CP-COMFORT
● CP-EXPERT

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This structure is based on the following considerations:

● Functional scope and required application knowledge increase from the basic version to
the optional CP_EXPERT version.
● The number of required couplings (following axes, following spindles) and their properties
are decisive in the selection of versions.
– Example of simultaneous operation:
If sequential operation of 1 x synchronous spindle pair for part transfer from the main to
the supplementary spindle and the 1 x multi-edge turning is required, then the CP-BASIC
option is suitable and sufficient. However, if it cannot be excluded that both operations
can overlap (multi-edge turning running when part transfer is started), the CP-
COMFORT option would be required.
– Example of property:
If a coupled axis grouping with a leading axis is required, the base version is sufficient.
For coupled motion groups with two leading axes, one of the optional versions is
required.
● Individual versions are independent of each other. They can be combined and can be
activated simultaneously.

Table 8-2 Quantity structure, which is dependent on the execution of coupling modules that can be simultaneously activated

Typ CP versions allow one or more different CPSETTYPE Base ver‐ CP- CP-BA‐ CP-COM‐ CP-EX‐
e coupling objects simultaneously: sion STATIC SIC FORT PERT
A Coupled motion 4 - 4 4 8
B Synchronous spindle with |1|:1 coupling - 1 - - -
C o./u. Synchronous spindles, multi-edge turning - - 1 4 8
o./u. Master value coupling / curve tables interpolation
o./u. MCS coupling
D o./u. Electronic gearbox "plain" - - - 1 8
o./u. Free generic coupling "basic"
E o./u. Electronic gear - - - - 5
o./u. Free generic coupling

o./u. stands for over/under

Table 8-3 Scaling of availability of coupling properties

Type A Type B Type C Type D Type E

20 1 13 9 5 Maximum number of CPSETTYPE-related functionalities (per

type)
TRAIL - coupled motion
20 - 13 9 5 Maximum number of coupled motion groups with the following
properties:
→ refer to CPSETTYPE="TRAIL"1)
1 2 2 2 Maximum number of master values
- - + + Coupling between a spindle and an axis

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Type A Type B Type C Type D Type E

+ + + + Coupling between a rotary axis and a linear axis
- + + + From part program and synchronous actions
+ + + + Superimposition / speed difference permitted
- - - + Cascading permitted
BCS BCS / BCS / BCS / Coordinate reference (default): CPFRS="BCS")
MCS MCS MCS
Synchronous spindle with |1|:1 coupling
- 1 - - - Maximum number of synchronous spindles / multi-edge turning
with the following properties:
→ refer to CPSETTYPE="COUP"1)
1 Maximum number of master values
- From part program and synchronous actions
- Superimposition / speed difference permitted
- Cascading permitted
MCS Coordinate reference fix (CPFRS="MCS")
COUP - synchronous spindle/multi-edge turning
- - 13 9 5 Maximum number of synchronous spindles / multi-edge turning
with the following properties:
→ refer to CPSETTYPE="COUP"1)
1 1 1 Maximum number of master values
- - - From part program and synchronous actions
+ + + Superimposition / speed difference permitted
- - - Cascading permitted
MCS MCS MCS Coordinate reference fix (CPFRS="MCS")
LEAD - master value coupling / curve tables interpolation
- - 13 9 5 Maximum number of master value couplings / curve tables inter‐
polation with the following properties:
→ refer to CPSETTYPE="LEAD"1)
1 1 1 Maximum number of master values
+ + + From part program and synchronous actions
+ + + Superimposition / speed difference permitted
- - + Cascading permitted
BCS / BCS / BCS / Coordinate reference (default): CPFRS="BCS")
MCS MCS MCS
EG - electronic gearbox
- - - 9 5 Maximum number of electronic gearboxes
with the following properties:
→ refer to CPSETTYPE="EG"1)
3 5 Maximum number of master values
- - From part program and synchronous actions
+ + Superimposition / speed difference permitted
- + Cascading permitted
BCS / BCS / Coordinate reference (default): CPFRS="BCS")
MCS MCS

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Type A Type B Type C Type D Type E

- + Non-linear coupling law (CPLCTID) permitted
CP - free generic coupling
- - - 9 5 Maximum number of free generic couplings
with the following properties:
Default (corresponds to CPSETTYPE="CP"1))
3 5 Maximum number of master values
+ + From part program and synchronous actions
+ + Superimposition / speed difference permitted
- + Cascading permitted
BCS / BCS / Coordinate reference (default): CPFRS="BCS")
MCS MCS
- + Non-linear coupling law (CPLCTID) permitted
1)
Refer to " Coupling types (CPSETTYPE) (Page 431) ".

Note
Existing coupling options (Master value coupling, Electronic gearbox and Synchronous
spindle) are not taken into consideration by generic coupling. Simultaneous operation of
existing coupling options and generic coupling is only possible if the couplings refer to different
axes/spindles.

Memory configuration
Memory space reserved in dynamic NC memory for generic coupling is defined in machine
data:
MD18450 $MN_MM_NUM_CP_MODULES (maximum allowed number of CP coupling
modules)
MD18452 $MN_MM_NUM_CP_MODUL_LEAD (maximum allowed number of CP master
values)

Note
Recommendation: Expected maximum values, which can be expected simultaneously for this
machine in its maximum configuration, should already be set during commissioning.

Hardware requirements
Systems with more than 6 axes are required when using the "CP-EXPERT" option.

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8.5.2 Fundamentals

8.5.2.1 Coupling module

With the aid of a coupling module, the motion of one axis, (→ following axis), can be interpolated
depending on other (→ leading) axes.

Coupling rule
The relationships between leading axis/values and a following axis are defined by a coupling
rule (coupling factor or curve table). The individual motion components from the individual
leading axes/values have an additive effect.
The relationship is demonstrated by the following example (following axis with two leading
axes):

&RXSOLQJUXOH

/HDGLQJD[LV /$ .)

&RXSOLQJUXOH

/HDGLQJD[LV /$ .)

)$'HS )$'HS

)ROORZLQJD[LV )$&PG   )$7RWDO

FATotal Total setpoint value of the following axis

FACmd Setpoint value set in part program
= independent motion component of the following axis
FADEP1 Dependent motion component of leading axis 1
FADEP2 Dependent motion component of leading axis 2
LA1 Setpoint or actual value of the 1st leading axis
LA2 Setpoint or actual value of the 2nd leading axis
SynPosLA1 Synchronized position of the 1st leading axis
SynPosLA2 Synchronized position of the 2nd leading axis
KF1 Coupling factor of the 1st leading axis
KF2 Coupling factor of the 2nd leading axis

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The following axis position results from the overlay (summation) of the dependent motion
components (FADEP1 and FADEP2), which result from the individual coupling relationships to the
leading axes, and of the independent motion component (FACmd) of the following axis:
FATotal = FACmd + FADEP1 + FADEP2
The motion components of the following axis are calculated as follows:

Dependent motion component of leading axis 1: FADEP1 = (LA1 - SynPosLA1) * KF1

Dependent motion component of leading axis 2: FADEP2 = (LA2 -SynPosLA2) * KF2
Independent motion component of the following axis: FACmd

Following axis overlay

The overlay of dependent and independent motion components of the following axis is called
following axis overlay.
The independent motion component of the following axis can be programmed with the full
range of available motion commands.

8.5.2.2 Keywords and coupling characteristics

Keywords
Programming is done via language commands, e.g. coupled motion with TRAILON(X,Y,2).
Keywords replace the language commands in generic coupling.
This has the following advantages:
● Coupling characteristics can be programmed individually (see following example).
● Programming of multiple couplings can be done in one block (since keywords do not require
their own block).
Advantage: Reduction of work off time

Example:
The properties set with the existing coupling call TRAILON(X,Y,2)(following axis, leading
axis and coupling factor) are defined in the generic coupling with the following keywords:
CPON=(X1) CPLA[X1]=(X2) CPLNUM[X1,X2]=2

CPON=(X1) Switch on coupling to following axis X1.

CPLA[X1]=(X2) Define axis X2 as leading axis.
CPLNUM[X1,X2]=2 Set numerator of the coupling factor to 2.

Notation

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8.5 Generic coupling

In order to be uniquely assigned, keywords are furnished with the prefix "CP", for Coupling).
Depending on meaning and application position, a third letter is used:

Keyword prefix Meaning Example

CP* Describes the characteristics of the entire coupling. CPON1)
CPF* Describes the characteristics of the following axis (Fol‐ CPFPOS1)
lowing axis).
CPL* Describes a property referring to the leading axis (Lead‐ CPLON1),
ing axis) or the coupling rule. CPLNUM1)
CPM* Describes a property of the entire coupling for special CPMRESET1)
states.
1)
For keyword meaning, please refer to the following table "Overview of all keywords and coupling
characteristics".

Overview of all keywords and coupling characteristics

The following table gives an overview of all keywords of the generic coupling and the
programmable coupling characteristics:

Keyword Coupling characteristics / meaning Default setting (CPSET‐

TYPE="CP")
CPDEF Creating a coupling module
CPDEL Deletion of a coupling module
CPLDEF Definition of a leading axis and creation of a coupling
module
CPLDEL Deleting a leading axis of a coupling module

CPON Switching on a coupling module

CPOF Switching off a coupling module
CPLON Switching on a leading axis of a coupling module
CPLOF Switching off a leading axis of a coupling module

CPLNUM Numerator of the coupling factor 1.0

CPLDEN Denominator of the coupling factor 1.0
CPLCTID Number of curve table Not set

CPLSETVAL Coupling reference CMDPOS

CPFRS Co-ordinate reference system BCS
CPBC Block change criterion NOC

CPFPOS + CPON Synchronized position of the following axis when Not set
switching on
CPLPOS + CPON Synchronized position of the leading axis when Not set
switching on
CPFMSON Synchronization mode CFAST

CPFMON Behavior of the following axis at switching on STOP

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Keyword Coupling characteristics / meaning Default setting (CPSET‐

TYPE="CP")
CPFMOF Behavior of the following axis at complete switch-off STOP
CPFPOS + CPOF Switch-off position of the following axis when switch‐ Not set
ing off

CPMRESET Coupling response to RESET NONE

CPMSTART Coupling behavior at part program start NONE
CPMPRT Coupling response at part program start under NONE
search run via program test

CPLINTR Offset value of the input value of a leading axis 0.0

CPLINSC Scaling factor of the input value of a leading axis 1.0
CPLOUTTR Offset value for the output value of a coupling 0.0
CPLOUTSC Scaling factor for the output value of a coupling 1.0

CPSYNCOP Threshold value of position synchronism "Coarse" MD37200

CPSYNFIP Threshold value of position synchronism "Fine" MD37210
CPSYNCOP2 Second threshold value for the "Coarse" position MD37202
synchronism
CPSYNFIP2 Second threshold value for the "Fine" position syn‐ MD37212
chronism
CPSYNCOV Threshold value of velocity synchronism "Coarse" MD37220
CPSYNFIV Threshold value of velocity synchronism "Fine" MD37230

CPMBRAKE Response of the following axis to certain stop signals 1

and stop commands
CPMVDI Response of the following axis to certain NC/PLC 0 (for bits 0 to 3, 5)
interface signals 1 (for bits 4, 6)
CPMALARM Suppression of special coupling-related alarm out‐ MD11410
puts MD11415

CPSETTYPE Coupling type CP

Note
Coupling characteristics, which are not explicitly programmed (in part program of synchronous
actions), become effective with their default settings (see right hand column of the table).
Depending on the settings of the keyword CPSETTYPE instead of the default settings
(CPSETTYPE="CP") preset coupling characteristics can become effective (see Section
"Coupling types (Page 431)").

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8.5 Generic coupling

8.5.2.3 System variables

The current state of a coupling characteristic set with a keyword, can be read and written to
with the relevant system variable.

Note
When writing in the part program, PREPROCESSING STOP is generated.

Notation
The names of system variables are normally derived from the relevant keywords and a
corresponding prefix.
The first letter of the prefix defines the access location when reading:

System variable prefix Access location during read Features

$PA_CP Reading of channel referenced axis Use in synchronous actions is not
specific coupling characteristics in possible.
block preparation (Preparation) Does not generate an implicit pre‐
processing stop.
$AA_CP Reading of the current state of the Use in the part program and in syn‐
coupling module (across channels). chronous actions is possible.
Generates an implicit preprocess‐
ing stop when used in the part pro‐
gram.

Note
The preprocessing value of a $PA_CP.. CP system variable only differs from the values of the
corresponding $AA_CP.. CP system variable during active part program processing.
At the end of the program or with abort, there is an appropriate synchronization of the
preprocessing with the main run states.

System variable list

A list of all system variables which can be used in a generic coupling is contained in the data
lists (see Section "System variables (Page 463)").
For a detailed description of system variables, refer to:
Reference:
Parameter Manual, System Variables

8.5.3 Creating/deleting coupling modules

8.5.3.1 Creating a coupling module (CPDEF)

An axial coupling module is created through the definition of the following axis.

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Programming

Syntax: CPDEF= (<following axis/spindle>)

Designation: Coupling Definition

Functionality: Definition of a coupling module The coupling is not activated.

Following axis/ Type: AXIS

spindle:

Range of values: All defined axis and spindle names in the channel

Example:

Programming Comment
CPDEF=(X2) ; A coupling module is created with axis X2 as following
axis.

Boundary conditions
● The maximum number of coupling modules is limited (see Section "Requirements
(Page 380)").
● The application of CPDEF to an already created coupling module is possible and will not
result in an alarm being generated.

8.5.3.2 Delete coupling module (CPDEL)

A coupling module created with CPDEF can be deleted with CPDEL.

Programming

Syntax: CPDEL= (<following axis/spindle>)

Designation: Coupling Delete

Functionality: Deletion of a coupling module. All leading axis modules are deleted with
the coupling module and reserved memory is released.

Following axis/ Type: AXIS

spindle:

Range of values: All defined axis and spindle names in the channel

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Example:

Programming Comment
CPDEL=(X2) ; Deletion of the coupling module with following axis X2.

Boundary conditions
● The switch command CPDEL results in a preprocessing stop with active coupling.
Exception: CPSETTYPE="COUP" does not result in a preprocessing stop.
● Applying CPDEL to a coupling module active in the block preparation results in implicit
deactivation of this coupling.
● Applying CPDEL to an undefined coupling module does not result in any action.

8.5.3.3 Defining leading axes (CPLDEF or CPDEF+CPLA)

The leading axes/spindles defined for a coupling can be programmed/created with the keyword
CPLDEF or with the keyword CPLA in conjunction with CPDEF.

Programming with CPLDEF

Syntax: CPLDEF[FAx]= (<leading axis/spindle>)

Designation: Coupling Lead Axis Definition

Functionality: Definition of leading axis/spindle for following axis/spindle FAx. A leading

axis/spindle module is created in the coupling module. If the coupling
module of the following axis/spindle has not yet been created, the coupling
module will be created implicitly.

Leading axis/ Type: AXIS

spindle:

Range of values: All defined axis and spindle names in the channel

Example:

Programming Comment
CPLDEF[X2]=(X1) ; Definition of leading axis X1 for following axis X2.

Programming with CPLA and CPDEF

Syntax: CPLA[FAx]= (<leading axis/spindle>)

Designation: Coupling Lead Axis

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Functionality: Definition of leading axis/spindle for following axis/spindle FAx.

Leading axis/spin‐ Type: AXIS

dle:

Range of values: All defined axis and spindle names in the channel

Example:

Programming Comment
CPDEF=(X2) CPLA[X2]=(X1) ; Definition of leading axis X1 for following axis
X2.

Boundary conditions
● CPLDEF is only allowed in blocks without CPDEF/CPON/CPOF/CPDEL.
(This limitation applies to the case where the keywords refer to the same coupling module.)
● The maximum number of leading axis modules per coupling module is limited (see Section
"Requirements (Page 380)").
● Definition of leading axes on an already defined or active coupling module is possible. Any
newly defined leading axes and their properties (e.g. coupling factor) are not active
immediately. A corresponding switch-on command like (CPON or CPLON) is required.

8.5.3.4 Delete leading axes (CPLDEL or CPDEL+CPLA)

Defined leading axes can be deleted with CPLDEL or with CPLA in conjunction with CPDEL,
i.e. removed from the coupling module.

Programming with CPLDEL

Syntax: CPLDEL[FAx]= (<leading axis/spindle>)

Designation: Coupling Lead Axis Delete

Functionality: Deletion of leading axis/spindle of following axis/spindle FAx. The leading

axis/spindle module will be deleted and the corresponding memory will
be released. If the coupling module does not have a leading axis/spindle
any more, the coupling module will be deleted and the memory will be
released.

Leading axis/ Type: AXIS

spindle:

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Range of values: All defined axis and spindle names in the channel

Example:

Programming Comment
CPLDEL[X2]=(X1) ; Deletion of leading axis X1 of the coupling to following
axis X2.

Programming with CPLA and CPDEL

Syntax: CPLA[FAx]= (<leading axis/spindle>)

Designation: Coupling Lead Axis

Functionality: Deleting a leading axis/spindle: The leading axis/spindle module will be

deleted and the corresponding memory will be released. If the coupling
module does not have a leading axis/spindle any more, the coupling mod‐
ule will be deleted and the memory will be released.

Leading axis/spin‐ Type: AXIS

dle:

Range of values: All defined axis and spindle names in the channel

Example:

Programming Comment
CPDEL=(X2) CPLA[X2]=(X1) ; Deletion of leading axis X1 of the coupling to fol-
lowing axis X2.

Boundary conditions
● CPLDEF is only allowed in blocks without CPDEF/CPON/CPOF/CPDEL.
(This limitation applies to the case where the keywords refer to the same coupling module.)
● If an active leading axis is deleted, the coupling to this leading axis is implicitly deactivated.
● Deletion of the last leading axis results in the entire coupling module to be deleted.

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8.5.4 Switching coupling on/off

8.5.4.1 Switching on a coupling module (CPON)

A defined coupling module is switched on with the switch command CPON.
Coupling characteristics like coupling reference can be programmed together with the switch
on command (see Section "Programming coupling characteristics (Page 396)").
Without programming, a coupled motion group or a synchronous spindle pair becomes
effective based on a setpoint coupling (default setting for CPLSETVAL) with the coupling rule
1:1 (default setting for CPLNUM/CPLDEN).

Programming

Syntax: CPON= (<following axis/spindle>)

Designation: Coupling On

Functionality: Activate the coupling of the following axis to all defined leading axes.

Following axis/ Type: AXIS

spindle:

Range of values: All defined axis and spindle names in the channel

Example:

Programming Comment
CPON=(X2) ; Activation of coupling of the following axis X2.

Boundary conditions
Application of CPON to an already active coupling results in a resynchronization. If applicable,
changed coupling properties become effective as a result. Any lost synchronization (for
example, following axis was in tracking mode) is restored.

8.5.4.2 Switch off coupling module (CPOF)

An activated coupling can be deactivated with the CPOF switching command. The deactivation,
i.e. the switching off of the coupling to the leading axis, is performed in accordance with the
set switch-off properties (see CPFMOF)

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Programming

Syntax: CPOF= (<Following axis / spindle>)

Designation: Coupling Off

Functionality: Deactivate the coupling of the following axis to all defined leading axes.

Following axis/ Type: AXIS

spindle:

Range of values: All defined axis and spindle names in the channel

Example:

Programming Comment
CPOF=(X2) ; Deactivation of coupling of following axis X2.

Boundary conditions
● The switch command CPOF results in a preprocessing stop with active coupling.
Exception: CPSETTYPE="COUP" does not result in a preprocessing stop
● A CPOF switching command on an already deactivated or deleted coupling module has no
effect and is not executed.
● CPOF can be programmed in synchronous actions.

8.5.4.3 Switching on leading axes of a coupling module (CPLON)

CPLON activates the coupling of a leading axis to a following axis. If several leading axes are
defined for a coupling module, they can be activated and deactivated separately with
CPLON.

Programming

Syntax: CPLON[FAx]= (<leading axis/spindle>)

Designation: Coupling Lead Axis On

Functionality: Activates the coupling of a leading axis/spindle to following axis/spindle

FAx.

Leading axis/ Type: AXIS

spindle:

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Range of values: All defined axis and spindle names in the channel

Example:

Programming Comment
CPLON[X2]=(X1) ; The coupling of leading axis X1 to following axis X2 is ac-
tivated.

Boundary conditions
CPON can be programmed in synchronous actions.

8.5.4.4 Switching off leading axes of a coupling module (CPLOF)

CPLOF deactivates the coupling of a leading axis to a following axis. If several leading axes
are defined for a coupling module, they can be deactivated separately with CPLOF.

Programming

Syntax: CPLOF[FAx]= (<leading axis/spindle>)

Identifiers: Coupling Lead Axis Off

Functionality: Deactivates the coupling of a leading axis/spindle to the following axis/

spindle FAx.

Leading axis/ Type: AXIS

spindle:

Range of values: Axes of the channel

Example:

Programming Comment
CPLOF[X2]=(X1) ; The coupling of leading axis X1 to following axis X2 is de-
activated.

Constraints
CPLOF can be programmed in synchronous actions.

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8.5.4.5 Implicit creation and deletion of coupling modules

Switch-on commands may also be used to create coupling modules (without prior definition
with CPDEF).

Example
Programming Comment
CPON=(X2) CPLA[X2]=(X1) ; Creates a coupling module for following axis X2 with
or leading axis X1 and activates the coupling module.

CPLON[X2]=(X1)
...
CPOF=(X2) ; After its deactivation, the implicitly created cou-
pling module is deleted.

Constraints
● Implicitly created coupling modules (via switch-on commands) are deleted once they are
completely deactivated (CPOF).
Advantage: Deleting them with CPDEL/CPLDEL is not necessary.
Disadvantage (possibly): All coupling properties which were set with CPOF are lost.
● Implicitly created coupling modules can be transformed into explicit coupling modules with
the following instruction CPDEF/CPLDEF. In this case CPOF does not delete the coupling
module and the data is retained.

8.5.5 Programming coupling characteristics

8.5.5.1 Coupling rule (CPLNUM, CPLDEN, CPLCTID)

The functional relationship between the leading value and the following value is specified by
a coupling rule for each leading axis. This functional relationship can be defined linear via a
coupling factor or non-linear via a curve table. The following axis components calculated in
this way from the individual leading values have an additive effect.

Programming: Coupling factor

When programming a coupling factor, a previously activated non-linear coupling relationship
(curve table) is deactivated.
The coupling factor is programmed with numerator and denominator.
In the default state, i.e. without explicit programming after creation of a new coupling module,
the numerator and denominator are each preset with 1.
If only the numerator is programmed, this is applied as the factor as the denominator is 1.
More exact linear relationships can be defined by programming numerators and denominators.

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Numerator of the coupling factor

Syntax: CPLNUM[FAx,LAx]= <value>

Designation: Coupling Lead Numerator

Functionality: Defines the numerator of the coupling factor for the coupling rule of the
following axis/spindle FAx to the leading axis/spindle LAx.

Value: Type: REAL

Range of values: -231 to +231

Default value: +1.0

Example:

Programming Comment
CPLNUM[X2,X1]=1.3 ; The numerator of the coupling factor of the coupling of
the following axis X2 to the leading axis X1 must be 1.3.

Denominator of the coupling factor

Syntax: CPLDEN[FAx,LAx]= <value>

Designation: Coupling Lead Denominator

Functionality: Defines the denominator of the coupling factor for the coupling rule of the
following axis/spindle FAx to the leading axis/spindle LAx.

Value: Type: REAL

Range of values: -231 to +231

Default value: +1.0

Example:

Programming Comment
CPLDEN[X2,X1]=2 ; The denominator of the coupling factor of the coupling of
the following axis X2 to the leading axis X1 must be 2.

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Programming: Curve table

When programming a table number, a previously activated non-linear coupling relationship
(coupling factor) is deactivated.
The leading axis specific coupling component for the leading value of the leading axis is
calculated using the specified curve table.

Syntax: CPLCTID[FAx,LAx]= <value>

Designation: Coupling Lead Curve Table Id

Functionality: Specifies the number of the curve table to be used to calculate how the
leading axis/spindle must act on the following axis/spindle.

Value: Type: INT

Range of values: -215 to +215

Example:

Programming Comment
CPLCTID[X2,X1]=5 ; The leading axis specific coupling component of the cou-
pling of the following axis X2 to the leading axis X1 is
calculated with curve table No. 5.

Supplementary conditions
● A coupling factor of zero (CPLNUM=0) is a permissible value. In this case, the leading axis/
spindle does not provide a path component for the following axis/spindle, however, it
remains a part of the coupling. Contrary to the switched-off state, the leading axis/spindle
still has an influence on the following axis/spindle. This affects, for example, reactions to
errors, limit switches and NC/PLC interface signals.
● CPLDEN=0 is not a valid value and is rejected with alarm.
● CPLNUM, CPLDEN and CPLCTID can be programmed in synchronous actions.
● Availability of non-linear coupling relationships (CPLCTID) depends on selected options
(see Section "Requirements (Page 380)").

8.5.5.2 Coupling relationship (CPLSETVAL)

The following value can be derived from either of the following:
● position setpoint of the leading axis
● speed setpoint of the leading axis
● position actual value of the leading axis

Special functions
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The following couplings can be programmed accordingly:

● Setpoint value coupling
● Speed coupling
● Actual value coupling

Programming

Syntax: CPLSETVAL[FAx,LAx]= <value>

Identifiers: Coupling Lead Set Value

Functionality: Defines tapping of the leading axis/spindle LAx and the reaction point
on the following axis/spindle FAx.

Coupling reference: Type: STRING

Range of values:
"CMDPOS" Commanded Position Setpoint value coupling
"CMDVEL" Commanded Velocity Speed coupling
"ACTPOS" Actual Value Actual value coupling

Default value: "CMDPOS"

Example:

Programming Comment
CPLSETVAL[X2,X1]="CMDPOS" ; The coupling of following axis X2 to leading ax-
is X1 is deducted from the setpoint.

Constraints
For a coupling module speed coupling cannot be activated simultaneously with setpoint or
actual value coupling of another leading axis.

8.5.5.3 Co-ordinate reference (CPFRS):

The co-ordinate reference of the following axis/spindle specifies in which co-ordinate reference
system the coupling component resulting from the coupling is applied. in the base co-ordinate
system or in the machine co-ordinate system.
It is further specified which co-ordinate reference the leading values of the leading axis spindle
must have. When a transformation is active and when the machine co-ordinate system is
specified as co-ordinate reference (CPFRS="MCS"), the initial transformation values are taken
as leading values.

Special functions
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Programming

Syntax: CPFRS[FAx]= (<co-ordinate reference>)

Identifiers: Coupling Following Relation System

Functionality: Defines the co-ordinate reference system for the coupling module of the
following axis/spindle FAx.

Co-ordinate refer‐ Type: STRING

ence:

Range of values:
”BCS” Basis Co-ordinate System Basic Coordinate System
”MCS” Machine Coordinate System Machine coordinate system

Default value: ”BCS”

Example:

Programming Comment
CPFRS[X2]="BCS" ; The base co-ordinate system is the co-ordinate reference for
the coupling module with following axis X2.

Constraints
● Co-ordinate reference has to be specified when creating a coupling module, else the default
value is used. It is not possible to effect subsequent changes.
● Simultaneous active transformation and coupling via RESET is not supported.
Solution: Switching off the coupling with CPMRESET="OF" with RESET switching it on again
with CPMSTART="ON" in the part program.
● Simultaneous operation of the previous function "Axial Coupling in the Machine Co-ordinate
System (MCS Coupling)" and the generic coupling is not supported.
● CPFRS is not available in the main run.

8.5.5.4 Block change behavior (CPBC)

The block change criterion can be used to specify under which conditions the block change
with activated coupling is to be permitted in the processing of the part program. The status of
the coupling influences the block change behavior. If the specified condition is not fulfilled, the
block change is disabled. The block change criterion is only evaluated with an active coupling.
The block change criterion can be defined with the keyword CPBC or with the programming
command WAITC. The instruction programmed last is valid.

Special functions
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Programming with PCBC

Syntax: CPBC[FAx]= "<block change criterion>"

Identifiers: Coupling Block Change Criterium

Functionality: Defines block change criterion with active coupling.

Block change criteri‐Type: STRING

on:

Range of values:
"NOC" Block change is performed irrespective of the coupling
status.
"IPOSTOP" Block change is performed with setpoint synchronism.
"COARSE" Block change is performed with actual value synchron‐
ism “coarse”.
"FINE" Block change is performed with actual value synchron‐
ism “fine”.

Default value: "NOC"

Example:

Programming Comment
CPBC[X2]="IPOSTOP" ; Block change during processing of the part program is
done with setpoint synchronism (with active coupling to
following axis X2).

Programming with WATC

Syntax: WAITC(FAx1,BC)

Identifiers: Wait for Coupling Condition

Functionality: Defines block change criterion with active coupling.

Parameter: Fax: Designates the following axis and therefore the coupling module.
BC: Defines the desired block change criterion.

FAx: Type: STRING

Range of values: Axes of the channel

Special functions
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BC: Type: STRING

Range of values:
"NOC" Block change is performed irrespective of the coupling
status.
"IPOSTOP" Block change is performed with setpoint synchronism.
"COARSE" Block change is performed with actual value synchron‐
ism “coarse”.
"FINE" Block change is performed with actual value synchron‐
ism “fine”.

Default value: "NOC"

Example:

Programming Comment
WAITC(X2,"IPOSTOP") ; Block change during processing of the part program is
done with setpoint synchronism (with active coupling to
following axis X2).

Constraints
WAITC can only occur singularly in a block, contrary to the keyword CPBC.

8.5.5.5 Synchronized position of the following axis when switching on (CPFPOS+CPON)

When switching on the coupling (CPON) approach of the following axis can be programmed for
a specified synchronized position.
The synchronized position takes immediate effect at switch on. The total position, resulting
from the synchronized position and the coupling rule, is approached according to the specified
synchronization mode (CPFMSON), taking into account the dynamic response limits.

Programming

Syntax: CPON=FAx CPFPOS[FAx]= <value>

Designation: Coupling Following Position

Functionality: Defines the synchronized position of the following axis when switching
on. AC, IC and GP are possible in position specification.

Value: Type: REAL

Range of values: All positions within the traverse range boundaries

Special functions
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Example:

Programming Comment
CPON=X2 CPFPOS[X2]=100 ; Activation of coupling to following axis X2. 100 is
taken as synchronized position of following axis X2.

Supplementary conditions
● CPFPOS is only effective as synchronized position with the switch-on command CPON/
CPLON.
The switch-off command CPOF evaluates CPFPOS as switch off position (see Section
"Following Axis Position on Switch off (Page 408)").
● CPFPOS without switch-on command results in an alarm.
● If the synchronized position of the following axis is not set during switch on, then the current
position of the following axis takes effect as synchronized position.
The program instruction IC can be used to move the current position.
● The position specification is specified in the configured basic system independently of the
programmable dimensions(G70/G71).

Part program section (Example)

Programming Comment
CPON=(X2) CPFPOS[X2]=100 ; Activation of coupling to following axis X2. 100
is taken as synchronized position of the following
axis.
...
G00 X2=123 ; Following axis X2 is traversed to position 123.
CPON=(X2) ; The current position (=123) is taken as synchron-
ized position of the following axis. The previous-
ly active synchronized position 100 becomes effec-
tive.

8.5.5.6 Synchronized position of the leading axis when switching on (CPLPOS)

The current leading axis position, taken as leading value, can be offset. The synchronized
position of the leading axis therefore defines the zero point of the input variable.

Programming

Syntax: CPLPOS[FAx,LAx]= <value>

Identifiers: Coupling Lead Position

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Functionality: Defines the synchronized position of the following axis at switch on. Only
AC is possible in the position specification.

Value: Type: REAL

Range of values: All position within the traverse range boundaries

Example:

Programming Comment
CPLPOS[X2,X1]=200 ; 200 is taken as synchronized position of the leading ax-
is X1 of the coupling to following axis X2.

Constraints
● CPFPOS can only set with the switch-on command CPON / CPLON. CPFPOS without switch-
on command results in an alarm.
● If the synchronized position of the leading axis is not set with the switch on command
(CPON), then the current position of the leading axis takes effect as synchronized position
and therefore as zero point of the input variable.
● The position specification is specified in the configured basic system independently of the
programmable dimensions(G70 / G71).

Part program section (Example)

Programming Comment
CPON=(X2) CPFPOS[X2]=100 CPLPOS[X2,X1]=200 ; Activation of coupling to following axis X2.
100 is taken as synchronized position of fol-
lowing axis and 200 for leading axis X1.
...
N20 X1=280 F1000 ; Leading axis X1 is traversed to position 280.
CPON=(X2) ; The current position X1=280 is taken as
synchronized position of the leading axis. The
previously active synchronized position of the
leading axis (200) becomes ineffective.

8.5.5.7 Synchronization mode (CPFMSON)

Synchronization mode determines synchronization behavior during switch-on of the
coupling.

Programming

Syntax: CPFMSON[FAx]= "<synchronization mode>"

Special functions
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Identifiers: Coupling Following Mode Strategy On

Functionality: Determines the synchronization mode during coupling.

Synchronization Type: STRING

mode:

Range of values:
"CFAST" Closed Coupling Fast The coupling is closed time-op‐
timized.
"CCOARSE" Closed If Gab Coarse The coupling is only closed
when the following axis posi‐
tion, required according to the
coupling rule, is in the range of
the current following axis posi‐
tion.
"NTGT" Next Tooth Gap Time The next tooth gap is ap‐
Optimized proached time-optimized.
"NTGP" Next Tooth Gap Path The next tooth gap is ap‐
Optimized proached path-optimized.
"NRGT" Next Ratio Gap Time The next segment is approach‐
Optimized ed in a time-optimized man‐
ner, in accordance with the ra‐
tio of the number of gears to
the number of teeth.
"NRGP" Next Ratio Gap Path The next segment is approach‐
Optimized ed in a path-optimized man‐
ner, in accordance with the ra‐
tio of the number of gears to
the number of teeth.
"ACN" Absolute Co-ordinate For rotary axes only!
Negative The rotary axis traverses to‐
wards the synchronized posi‐
tion in the negative axis direc‐
tion. Synchronization is effec‐
ted immediately.
"ACP" Absolute Coordinate For rotary axes only!
Positive The rotary axis traverses to the
synchronized position in the
positive axis direction. Syn‐
chronization is effected imme‐
diately.
"DCT" Direct Co-ordinate For rotary axes only!
Time Optimized The rotary axis traverses to the
programmed synchronized po‐
sition in time-optimized fash‐
ion. Synchronization is effec‐
ted immediately.

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8.5 Generic coupling

"DCP" Direct Co-ordinate For rotary axes only!

Path Optimized The rotary axis traverses to the
programmed synchronized po‐
sition in path-optimized fash‐
ion. Synchronization is effec‐
ted immediately.

Default value: "CFAST"

Example:

Programming Comment
CPFMSON[X2]="CFAST" ; CFAST is taken as synchronization mode of the coupling
to following axis X2.

8.5.5.8 Behavior of the following axis at switch-on (CPFMON)

The behavior of the following axis/spindle during switch-on of the coupling can be programmed
with the keyword CPFMON.

Programming

Syntax: CPFMON[FAx]= "<block change criterion>"

Identifiers: Coupling Following Mode On

Functionality: Defines the behavior of the following axis/spindle during switch-on of

the coupling.

Poweron response: Type: STRING

Range of values:
"STOP" Stop For spindles only!
An active motion of the following spin‐
dle is stopped before switch-on.
"CONT" Continue For spindles and main traverse axes
only!
The current motion of the following
axis/spindle is taken over into the
coupling as start motion.

Special functions
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"ADD" Additional For spindles only!

The motion components of the cou‐
pling operate in addition to the cur‐
rently overlaid motion, i.e. the current
motion of the following axis/spindle
is retained as overlaid motion.

Default value: "STOP"

Example:

Programming Comment
CPFMON[X2]="CONT" ; The current motion of following axis X2 is taken over as
start motion.

8.5.5.9 Behavior of the following axis at switch-off (CPFMOF)

The behavior of the following axis/spindle during complete switch-off of an active coupling can
be programmed with the keyword CPFMOF.

Programming

Syntax: CPFMOF[FAx]= "<switch-off behavior>"

Identifiers: Coupling Following Mode Off

Functionality: Defines the behavior of the following axis/spindle during complete

switch-off of the coupling.

Switch-off response: Type: STRING

Range of values:
"STOP" Stop Stop of a following axis/spindle.
An active overlaid motion is also
braked to standstill. Then the coupling
is opened, (deactivated).
"CONT" Continue For spindles and main traverse axes
only!
The following spindle continues to tra‐
verse at the speed/velocity that applied
at the instant of deactivation.

Default value: "STOP"

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8.5 Generic coupling

Example:

Programming Comment
CPFMOF[S2]="CONT" ; The following spindle S2 continues to traverse at the speed
that was applied at the instant of deactivation.

8.5.5.10 Position of the following axis when switching off (CPFPOS+CPOF)

When switching off a coupling (CPOF) traversing to a certain position can be requested for the
following axis.

Programming

Syntax: CPOF=(FAx) CPFPOS[FAx]= <value>

Functionality: Defines the switch-off position of the following axis FAx.

Value: Type: REAL

Range of values: All positions within the traverse range boundaries

Example:

Programming Comment
CPOF=(X2) CPFPOS[X2]=100 ; Deactivation of coupling to following axis X2. 100
is approached as switch-off position of the fol-
lowing axis.

Supplementary conditions
● CPFPOS is only effective as switch-off position with the switch-off command CPOF.
The switch command CPON evaluates CPFPOS as switch-on position (see Section
"Synchronized Position of the Following Axis on Switch-on (Page 402)").
● The setting of a switch-off position is only permitted with the switch-off mode:
CPFMOF=STOP
● Switch-off position is approached with maximum dynamics.
● Block change behavior depends on parameterization of the keyword CPBC.

8.5.5.11 Condition at RESET (CPMRESET)

With RESET, the coupling can be activated, deactivated or the current status can be retained.
The behavior can be set separately for each coupling module.

Special functions
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8.5 Generic coupling

Programming

Syntax: CPMRESET[FAx]= "<Reset behavior>"

Identifiers: Coupling Mode RESET

Functionality: Defines the behavior of a coupling at RESET.

Reset response: Type: STRING

Range of values:
"NONE" The current state of the coupling is retained.
"ON" When the appropriate coupling module is created, the
coupling is switched on. All defined leading axis relation‐
ships are activated. This is also performed when all or
parts of these leading axis relationships are active, i.e.
resynchronization is performed even with a completely
activated coupling.
"OF" An active overlaid motion is also braked to standstill. The
coupling is then deactivated. When the relevant coupling
module was created without an explicit definition
(CPDEF), the coupling module is deleted. Otherwise it is
retained, i.e. it can still be used.
"OFC" Possible only in spindles!
The following spindle continues to traverse at the speed/
velocity that applied at the instant of deactivation. The
coupling is switched off. When the relevant coupling
module was created without an explicit definition
(CPDEF), the coupling module is deleted. Otherwise it is
retained, i.e. it can still be used.
"DEL" An active overlaid motion is also braked to standstill. The
coupling is then deactivated and then deleted.
"DELC" Possible only in spindles!
The following spindle continues to traverse at the speed/
velocity that applied at the instant of deactivation. The
coupling is deactivated and then deleted.

Default value: "NONE"

Example:

Programming Comment
CPMRESET[X2]="DEL" ; On RESET the coupling to following axis X2 is deactiva-
ted and then deleted.

Special functions
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8.5 Generic coupling

Constraints
● The coupling characteristics set with CPMRESET is retained until the coupling module is
deleted with (CPDEL).
● For the coupling type (CPSETTYPE="TRAIL", "LEAD", "EG" or "COUP") the response is
defined by the following machine data during RESET:
MD20110 $MC_RESET_MODE_MASK (definition of initial control system settings after
RESET/TP-End)
→ See Section "Defaults" in " Coupling Types (CPSETTYPE) (Page 431) ".

8.5.5.12 Condition at parts program start (CPMSTART)

At part program start the coupling can be activated, deactivated or the current status can be
retained. The behavior can be set separately for each coupling module.

Programming

Syntax: CPMSTART[FAx]= <value>

Identifiers: Coupling Mode Start

Functionality: Defines the behavior of a coupling at part program start.

Value: Type: STRING

Range of values:
"NONE" The current state of the coupling is retained.
"ON" When the appropriate coupling module is created, the cou‐
pling is switched on. All defined leading axis relationships
are activated. This is also performed when all or parts of
these leading axis relationships are active, i.e. resynchro‐
nization is performed even with a completely activated
coupling.
"OF" The coupling is switched off. When the relevant coupling
module was created without an explicit definition (CPDEF),
the coupling module is deleted. Otherwise it is retained,
i.e. it can still be used.
"DEL" The coupling is deactivated and then deleted.

Default value: "NONE"

Example:

Programming Comment
CPMSTART[X2]="ON" ; At part program start, coupling to following axis X2 is
switched on.

Special functions
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8.5 Generic coupling

Constraints
● The coupling characteristics set with CPMSTART are retained until the coupling module is
deleted with (CPDEL).
● For the set coupling type (CPSETTYPE="TRAIL", "LEAD", "EG" or "COUP"), the response
is defined by the following machine data during part program start:
MD20112 $MC_START_MODE_MASK (Definition of the control default settings in case of
NC START)
→ See Section "Defaults" in " Coupling Types (CPSETTYPE) (Page 431) ".

8.5.5.13 Status during part program start in search run via program test (CPMPRT)
At part program start during search run via program test (SERUPRO), the coupling can be
activated, deactivated or the current status can be retained. The behavior can be set separately
for each coupling module.

Programming

Syntax: CPMPRT[FAx]= <value>

Identifiers: Coupling Mode Program Test

Functionality: Defines the behavior of a coupling at part program start during search run
via program test.

Value: Type: STRING

Range of values:
"NONE" The current state of the coupling is retained.
"ON" When the appropriate coupling module is created, the cou‐
pling is switched on. All defined leading axis relationships
are activated. This is also performed when all or parts of
these leading axis relationships are active, i.e. resynchro‐
nization is performed even with a completely activated
coupling.
"OF" The coupling is switched off. When the relevant coupling
module was created without an explicit definition (CPDEF),
the coupling module is deleted. Otherwise it is retained,
i.e. it can still be used.
"DEL" The coupling is deactivated and then deleted.

Default value: "NONE"

Special functions
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8.5 Generic coupling

Example:

Programming Comment
CPMPRT[X2]="ON" ; At part program start during search run via program
test, coupling to following axis X2 is switched on.

Constraints
● The coupling characteristics set with CPMPRT is retained until the coupling module is deleted
with (CPDEL).
● If CPMPRT="NONE" is set, then the response at part program start during search run via
program test (SERUPRO) is defined by CPMSTART.
● For the set coupling type (CPSETTYPE="TRAIL", "LEAD", "EG" or "COUP"), the response
is defined by the following machine data at part program start during search run via program
test:
MD22620 $MN_START_MODE_MASK_PRT(definition of initial control system settings
with special start)
MD22621 $MC_ENABLE_START_MODE_MASK_PRT (activation of MD22620)
MD20112 $MC_START_MODE_MASK (Definition of the control default settings in case of
NC START)
→ See Section "Defaults" in " Coupling Types (CPSETTYPE) (Page 431) ".

8.5.5.14 Offset / scaling (CPLINTR, CPLINSC, CPLOUTTR, CPLOUTSC)

An existing coupling relationship between a following axis and a leading axis can be scaled
and offset.
The effect of these functions on the total setpoint value of the following axes can be viewed
from the following formula:

)$7RWDO )$ FPG^WUDQV2XWVFDOH2XW >/$6\Q3RV/$ VFDOH,QWUDQV,Q@ .)`^WUDQV2XW VFDOH2XW  >/$6\Q3RV/$  VFDOH,Q WUDQV,Q @ .)`

FATotal Total setpoint value of the following axis

FACmd Setpoint set in the part program
LA1 / 2 Setpoint or actual value of the 1st or 2nd leading axis/value
SynPosLA1 / 2 Synchronized position of the 1st or 2nd leading axis/value
scaleIn1 / 2 Scaling factor of the 1st or 2nd lead value
transIn1 / 2 Offset of the 1st or 2nd lead value
KF1 / 2 Coupling factor of the 1st or 2nd leading axis/value
scaleOut1 / 2 Scaling factor of the 1st or 2nd output value
transOut1 / 2 Offset of the 1st or 2nd output value

Note
The scaling and offset values can be defined for each leading axis.

Special functions
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Programming
Offset of the input value

Syntax: CPLINTR[FAx,LAx]= <value>

Designation: Coupling Lead In Translation Displacement

Functionality: Defines the offset value for the input value of the LAx leading axis.

Value: Type: REAL

Default value: 0
Example:

Programming Comment
CPLINTR[X2,X1]=-50 ; The input value of the leading axis X1 is moved in the
negative direction by the value 50.

Scaling the input value

Syntax: CPLINSC[FAx,LAx]= <value>

Designation: Coupling Lead In Scale Factor

Functionality: Defines the scaling factor for the input value of the LAx leading axis.

Value: Type: REAL

Default value: 1
Example:

Programming Comment
CPLINSC[X2,X1]=0.5 ; The input value of the leading axis X1 is multiplied
with the factor 0.5.

Offset of the output value

Syntax: CPLOUTTR[FAx,LAx]= <value>

Designation: Coupling Lead Out Translation Displacement

Functionality: Defines the offset value for the output value of coupling the following axis
FAx to leading axis LAx.

Value: Type: REAL

Special functions
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8.5 Generic coupling

Default value: 0
Example:

Programming Comment
CPLOUTTR[X2,X1]=100 ; The output value of the coupling of the following axis
X2 with leading axis X1 is displaced by the value 100 in
the positive direction.

Scaling of the output value

Syntax: CPLOUTSC[FAx,LAx]= <value>

Designation: Coupling Lead Out Scale Factor

Functionality: Defines the scaling factor for the output value of coupling the following
axis FAx with leading axis LAx.

Value: Type: REAL

Default value: 1
Example:

Programming Comment
CPLOUTSC[X2,X1]=3 The output value of the coupling of the following axis X2
with leading axis X1 is multiplied with factor 3.

Note
The following setting data used in the existing coupling type "Master value coupling" is
considered in generic coupling independently of the set coupling type (CPSETTYPE):
SD43102 $SA_LEAD_OFFSET_IN_POS[FAx] (offset of master value)
SD43104 $SA_LEAD_SCALE_IN_POS[FAx] (scaling of master value)
SD43106 $SA_LEAD_OFFSET_OUT_POS[FAx] (offset of function value of the curve table)
SD43108 $SA_LEAD_SCALE_OUT_POS[FAx] (scaling of function value of the curve table)
These setting data have the following effect:
● on all leading axes that are coupled with the following axis via a curve table. This must be
taken into account for couplings with more than one leading axis!
● in addition to the CP key words CPLINTR, CPLINSC, CPLOUTTR and CPLOUTSC.

Special functions
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8.5.5.15 Synchronism monitoring stage 1 (CPSYNCOP, CPSYNFIP, CPSYNCOV, CPSYNFIV)

Synchronism monitoring stage 1

In each interpolator clock cycle, the synchronous operation of the coupling group is monitored
– both on the setpoint and actual value sides. The synchronous operation monitoring responds
as soon as the synchronous operation difference (the difference between the setpoint or actual
value of the following axis and the value calculated from the setpoints or actual values of the
leading axes according to the coupling rule) reaches one of the following programmed
threshold values:
● At setpoint / actual value coupling (see "Coupling relationship (CPLSETVAL) (Page 398)"):
– "Coarse" position synchronous operation threshold value
– "Fine" position synchronous operation threshold value
● For velocity coupling (see "Coupling relationship (CPLSETVAL) (Page 398)"):
– Threshold value of "Coarse" speed synchronous operation
– Threshold value of "Fine" speed synchronous operation
The actual synchronous operation difference can be read out with the following CP system
variables:

System variable Meaning

$AA_SYNCDIFF [FAx] Synchronous operation difference of the setpoint
$VA_SYNCDIFF [FAx] Synchronous operation difference of the actual value

Note
Synchronous operation differences are signed and enable the advance or delay of the following
axis to be determined.

Special functions
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8.5 Generic coupling

Status of the coupling during synchronous operation

State Description
Not synchronized Provided the synchronous operation difference is greater than the
threshold value for position "coarse" synchronous operation or
"coarse" speed synchronous operation, the coupled group is des‐
ignated as non-synchronous.
"Coarse" synchronous operation The synchronous operation difference has reached the threshold
reached value for "coarse" position synchronous operation or "coarse"
speed synchronous operation.
In case the actual value-based synchronous operation difference,
the following NC/PLC-interface signal is set:
DB31, ... DBX98.1 (coarse synchronous operation)
"Fine" synchronous operation The synchronous operation difference has reached the threshold
reached value for "fine" position synchronous operation or "fine" speed syn‐
chronous operation.
In case the actual value-based synchronous operation difference,
the following NC/PLC-interface signal is set:
DB31, ... DBX98.0 (fine synchronous operation)

The status of the coupling for the synchronous operation can be read with the following system
variables:

System variable Meaning

$AA_SYNC [FAx] State of the coupling
Value State
0 Not synchronized
1 "Coarse" synchronous operation reached
2 "Fine" synchronous operation reached

Signal reaction
Synchronous operation signals themselves do not stop the involved axes, but can release
them via synchronized action or NC/PLC interface signals (see Section "R3: Extended stop
and retract (Page 469)").

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Configuration
The threshold values for the first stage of the synchronous operation monitoring will be
adjusted:
● For setpoint / actual value coupling in the machine data:
– MD37200 $MA_COUPLE_POS_TOL_COARSE (threshold value for "coarse
synchronism")
– MD37210 $MA_COUPLE_POS_TOL_FINE (threshold value for "fine synchronism")
● For speed coupling in the machine data:
– MD37220 $MA_COUPLE_VELO_TOL_COARSE ("coarse" speed tolerance)
– MD37230 $MA_COUPLE_VELO_TOL_FINE ("fine" speed tolerance)

Programming
CP keywords can also be used to program the threshold values for the first stage of the
synchronous operation monitoring:

"Coarse" position synchronous operation threshold value

Syntax: CPSYNCOP[FAx]= <value>

Designation: Coupling Synchronous Difference Coarse Position

Functionality: Defines the threshold value for the "Coarse' position synchronous op‐
eration.

Value: Type: REAL

The default value corresponds to the setting in the machine data:

MD37200 $MA_COUPLE_POS_TOL_COARSE [FAx]

"Fine" position synchronous operation threshold value

Syntax: CPSYNFIP[FAx]= <value>

Designation: Coupling Synchronous Difference Fine Position

Functionality: Defines the threshold value for the "Fine" position synchronous opera‐
tion.

Value: Type: REAL

The default value corresponds to the setting in the machine data:

MD37210 $MA_COUPLE_POS_TOL_FINE [FAx]

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Threshold value of "Coarse" speed synchronous operation

Syntax: CPSYNCOV[FAx]= <value>

Designation: Coupling Synchronous Difference Coarse Velocity

Functionality: Defines the threshold value for the "Coarse'' speed synchronous oper‐
ation.

Value: Type: REAL

The default value corresponds to the setting in the machine data:

MD37220 $MA_COUPLE_VELO_TOL_COARSE [FAx]

Threshold value of "Fine" speed synchronous operation

Syntax: CPSYNFIV[FAx]= <value>

Designation: Coupling Synchronous Difference Fine Velocity

Functionality: Defines the threshold value for the "Fine" velocity synchronous opera‐
tion.

Value: Type: REAL

The default value corresponds to the setting in the machine data:

MD37230 $MA_COUPLE_VELO_TOL_FINE [FAx]

Example
Program code Comment
CPDEF=(S2) CPLA[S2]=(S1) ; Definition of a spindle coupling:
Leading spindle S1 to following spindle S2
CPON=(S2) CPSYNCOP[S2]=0.5 ; Activation of the coupling with following spin-
CPSYNFIP[S2]=0.25 dle S2. The threshold values for the position syn-
chronous operation are set to 0.5 ("coarse") and
0.25 ("fine").
...

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Supplementary conditions
● When considering the synchronous operation difference, an active coupling cascade is not
taken into account. This means: if in the considered coupling module, the leading axis is a
following axis in another coupling module, the current actual or setpoint position is still used
as input variable for the calculation of the synchronous operation difference. This
synchronous operation difference therefore does not show the total synchronous operation
error of the cascade.
● If the leading axis is not a real axis, but a simulated axis, then the actual value is not available
for the synchronous operation monitoring of the actual value. In this case, the modeled
actual values (according to the machine data setting) are used.

8.5.5.16 Synchronous operation monitoring stage 2 (CPSYNCOP2, CPSYNFIP2)

Synchronism monitoring stage 2

For active CP position coupling (setpoint or actual value coupling, see "Coupling relationship
(CPLSETVAL) (Page 398)"), after reaching the "COARSE"/"FINE" block change criterion (see
"Block change behavior (CPBC) (Page 400)"), the second stage of the synchronous operation
monitoring can be used to monitor that one of the threshold values of the first stage is
maintained on the actual value side, independent of the synchronism tolerance.
The following two threshold values must configured or programmed for the second stage of
synchronous operation monitoring:
● "Coarse" 2 position synchronous operation threshold value
● "Fine" 2 position synchronous operation threshold value

Technical background
As part of the "synchronous operation reached" and "exit synchronous window" monitoring
functions, for a correct assessment of any problems that arise during the multi-edge turning
(surface, waste, etc. ) and sometimes also for oscillating synchronous spindle it is often very
useful to define a tolerance range independent of the coarse/fine synchronous operation
tolerances of the first stage of the synchronous operation monitoring (similar to exact stop and
standstill monitoring for axes) in order to obtain a configurable error message or warning.

Configuration
The threshold values for the second stage of the synchronous operation monitoring are set in
the machine data:
MD37202 $MA_COUPLE_POS_TOL_COARSE_2 (second threshold value for "coarse
synchronous operation")

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MD37212 $MA_COUPLE_POS_TOL_FINE_2 (second threshold value for "fine synchronous

operation")

Note
If the appropriate threshold value = 0, the associated monitoring is inactive. This is also the
default value so that the compatibility with older software versions is retained.

Programming
CP keywords can also be used to program the threshold values for the second stage of the
synchronous operation monitoring:

"Coarse" 2 position synchronous operation threshold value

Syntax: CPSYNCOP2[FAx]= <value>

Designation: Coupling Synchronous Difference Coarse Position 2

Functionality: Defines the second threshold value for the "Coarse' position synchro‐
nous operation.

Value: Type: REAL

The default value corresponds to the setting in the machine data:

MD37202 $MA_COUPLE_POS_TOL_COARSE_2 [FAx]

"Fine" 2 position synchronous operation threshold value

Syntax: CPSYNFIP2[FAx]= <value>

Designation: Coupling Synchronous Difference Fine Position 2

Functionality: Defines the second threshold value for the "Fine" position synchronous
operation.

Value: Type: REAL

The default value corresponds to the setting in the machine data:

MD37212 $MA_COUPLE_POS_TOL_FINE_2 [FAx]

The programming applies similarly to the general CP behavior in the part program only with
the next switching command; for synchronized actions, immediately.

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Sequence

Starting
The second stage of the synchronous operation monitoring function starts with active coupling
as soon as the following conditions are fulfilled:
● The setpoint synchronous operation is reached:
DB31, ... DBX99.4 (synchronization running) = 0
● The actual value related "coarse"/"fine" synchronous operation of the tolerance of the first
stage of the synchronous operation monitoring (see "Synchronism monitoring stage 1
(CPSYNCOP, CPSYNFIP, CPSYNCOV, CPSYNFIV) (Page 415)") is reached:
DB31, ... DBX98.1 (coarse synchronous operation) = 1 / DB31, ... DBX98.0 (fine
synchronous operation) = 1

Monitor
As long as the synchronism difference of the actual the threshold values for "fine" 2 position
synchronous operation and "coarse" 2 position synchronous operation are not exceeded, the
following NC/PLC interface signals are set:
DB31, ... DBX103.4 (synchronous operation 2 fine)
DB31, ... DBX103.5 (synchronous operation 2 coarse)
If, due to temporary overload in machining process (e.g. infeed feedrate for multi-edge
machining too high), the following axis/spindle can no longer follow the specifications of the
leading axis(n)/spindle(s) and the deviation is greater than the set tolerance, the violation of
the "fine"/"coarse" tolerance displays a display alarm that can be deleted:
Alarm 22026 "Channel %1 Block %2 Following axis/spindle %3 Synchronism (2): Coarse
tolerance exceeded"
Alarm 22025 "Channel %1 Block %2 Following axis/spindle %3 Synchronism (2): Fine
tolerance exceeded"
This does not interrupt the machining.

Note
Both alarms can also occur simultaneously.

Exit
The second stage of the synchronous operation monitoring ends in the following cases:
● Deactivation of the coupling (for the power-down command: CPOF, CPDEL, CPLOF,
CPLDEL)
● New synchronization request by:
– CPON / CPLON / CPDO / CPLOF
– DB31, ... DBX31.4 (synchronize following spindle) = 1
– Internal synchronization requests
If, in these cases, the start conditions are satisfied again, the monitoring will be restarted.

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● For coupled block changes (CPLNUM, CPLDEN, CPLCTID) in synchronized actions

● Resetting the setpoint synchronous operation because of missing enable signals for the
following spindle (emergency stop, alarm responses)
The DB31, ... DBX103.4/5 signals are reset when the monitoring is ended.

Boundary conditions

Exclusion conditions
No monitoring is performed in the following cases:
● MD37202 or MD37212 = 0.
● Speed coupling is active (CPLSETVAL="CMDVEL").
● DB31, ... DBX31.5 (inhibit synchronization of the FS) = 1
● Rapid stop of the following axis/spindle or one of the active leading axes/spindles.
● SERUPRO or block search is active.
● For channel-related run-in when the following axis/spindle or an active leading axis/spindle
does not really move.
● DB31, ... DBX63.3 (axis/spindle disable active) = 1 for the following axis/spindle or for one
of the active leading axes/spindles.

"Track the synchronous operation deviation" is active

Monitoring is suspended while the "track the synchronous operation deviation" function is
active (DB31, ... DBX31.6 = 1; see "Tracking the deviation from synchronism (Page 446)").

Synchronous operation monitoring level 2 for the traditional coupling types

For the traditional coupled motion, master value coupling, electronic gearbox and synchronous
spindle coupling types, the "stage 2 synchronous operation monitoring" is available only with
the CP adaptive cycles (see "Adaptive cycles (Page 430) ").

Example
Program code Comment
G0 Z–300 X50
CPDEF=(S2) CPLA=(S1) CPLNUM=2 CPLDEN=1 ; Gear ratio in accordance with tool.
CPBC="FINE"
M3 S2000
CPON=(S2) CPLA=(S1) CPSYNCOP2[X]=1.6 ; Block change is performed on reaching "fine synchronous
CPSYNFIP2[X]=0.8 operation".
; Synchronous operation monitoring stage 2 is also activa-
ted
; (tolerances: coarse 1.6, fine 0.8).
X20
G1 Z–200 ; Machining block, material removal.
; Synchronous operation determines the quality.
CPOF=(S2) ; Deselect coupling, deactivate the monitoring function.

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8.5.5.17 Reaction to stop signals and commands (CPMBRAKE)

The response of the following axis to certain stop signals and commands can be defined with
the CP keyword CPMBRAKE.

Programming

Syntax: CPMBRAKE[FAx]= <value>

Designation: Coupling Mode Brake

Functionality: CPMBRAKE is a bit-coded CP keyword that defines the braking behavior of

the following axis FAx for the following events:
Bit Event
0 ● NST DB31, ... DBX4.3 (feed stop / spindle stop) present
or
● CP SW limit stop is set (see "CP SW limit monitoring
(Page 440)")
Note:
Bit 0 is significant only for a "Freely programmable" coupling type
(CPSETTYPE=CP).
Value Meaning
0 The brake is not transferred to the leading axes.
1 The brake is transferred to the leading axes depending
on the context.
1 - 31 Reserved
The following rules apply for the programming:
● CPMBRAKE must be programmed in one block with CPDEF or CPON (⇒
can only be programmed for an inactive coupling).
● While defining a coupling, the following values are captured without the
explicit programming of CPMBRAKE:
Bit 0 = 1 for pre-processing couplings with CPSETTYPE=CP (otherwise
bit 0 = 0)

Examples
Example 1:

Programming Comment
CPDEF=(AX5) CPLA[AX5]=(AX4) CPMBRAKE[AX5]=0 ; Defining a coupling (lead-
ing axis Ax4 with following
axis Ax5). NST "feed stop /
spindle stop" or "CP SW lim-
it stop" should not brake
the coupling group.
...

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8.5 Generic coupling

Example 2:

Programming Comment
CPDEF=(S2) CPLA[S2]=(S1) ; Definition of a spindle coupling:
Leading spindle S1 with following spindle S2
CPON=(S2) CPMBRAKE[S2]=1 ; Activation of the coupling with following
spindle S2. NST "feed stop / spindle stop"
or "CP SW limit stop" should brake the cou-
pling group.
...

8.5.5.18 Response to certain NC/PLC interface signals (CPMVDI)

The CP keyword CPMVDI can be used to define the coupling module's response to certain NC/
PLC interface signals.

Programming

Syntax: CPMVDI[FAx]= <value>

Designation: Coupling Mode VDI Signal

Functionality: CPMVDI is a bit-coded CP keyword, which defines the response of the cou‐
pling module of following axis FAx to certain NC/PLC interface signals.
The bit combination operators B_OR, B_AND, B_NOT, and B_XOR can be
used to set individual bits.

Special functions
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Bit Meaning
0 Reserved.
1 Reserved.
2 Reserved.
3 The effect of NC/PLC interface signal
DB31, ... DBX1.3 (axis/spindle disable)
on the following axis/spindle can be set via bit 3:
Bit 3 = 0 DB31, ... DBX1.3 has no effect on the following axis/
spindle. The state of the following axis/spindle with ref‐
erence to the axis/spindle disable is derived solely from
the state of the leading axes/spindles.
Bit 3 = 1 DB31, ... DBX1.3 has an effect on the following axis/
spindle. The state of the leading axes/spindles with ref‐
erence to the axis/spindle disable is not imposed on the
following axis/spindle.
Note:
If bit 3 = 1, the axis/spindle disable state of the following axis/spindle
only has an effect if the program test or SERUPRO states are not
active (see also bit 5).
4 Bit 4 is used to define the enable for the dependent motion compo‐
nents when the NC/PLC interface signal DB31, … DBX1.3 (axis/spin‐
dle disable) has an effect on the following axis/spindle:
Bit 4 = 0 Dependent motion components of the leading axes/spin‐
dles become effective irrespective of the state of the axis/
spindle disable of the relevant leading axis/spindle.
Bit 4 = 1 Dependent motion components of the leading axes/spin‐
dles only become effective if the state of the axis/spindle
disable of the leading axis/spindle matches that of the
axis/spindle disable of the following axis/spindle. Other‐
wise, the components are suppressed.
Note:
Bit 4 is only of significance if bit 3 is set, i.e. if the NC/PLC interface
signal DB31, … DBX1.3 (axis/spindle disable) has an effect on the
following axis/spindle (see bits 3 and 5).
5 The effect of NC/PLC interface signal
DB21, ... DBX25.7 (program test selected) or
DB21, ... DBX1.7 (activate program test)
on the following axis/spindle can be set via bit 5:
Bit 5 = 0 DB21, ... DBX25.7 or DB21, ... DBX1.7 has no effect on
the following axis/spindle. The state of the following axis/
spindle with reference to the axis/spindle disable is de‐
rived solely from the state of the leading axes/spindles.
Bit 5 = 1 If the "program test" state is active for an axis of the
coupling module, then for the following axis/spindle, its
own state is active regarding the axis/spindle disable.
The state of the leading axes/spindles with reference to
the axis/spindle disable is not imposed on the following
axis/spindle.

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8.5 Generic coupling

Note:
When bit 5 is set, the program test state still has an effect on the
following axis/spindle, even if the leading axes/spindles have a differ‐
ent state.
6 Bit 6 is used to define the enable for the dependent motion compo‐
nents when the NC/PLC interface signal DB21, … DBX25.7 (program
test selected) or DB21, ... DBX1.7 (activate program test) has an
effect on the following axis/spindle:
Bit 6 = 0 Dependent motion components of the leading axes/spin‐
dles become effective irrespective of the state of the axis/
spindle disable of the relevant leading axis/spindle.
Bit 6 = 1 Dependent motion components of the leading axes/spin‐
dles only become effective if the state of the axis/spindle
disable of the leading axis/spindle matches that of the
axis/spindle disable of the following axis/spindle. Other‐
wise, the components are suppressed.
Note:
Bit 6 is only of significance if bit 5 is set, i.e. if the program test state
has an effect on the following axis/spindle (see bits 3 and 5).
7 Reserved.
8 Reserved.

Note
The axis/spindle disable, which is set for the following axis/spindle via the NC/PLC interface
signal DB31, ... DBX1.3, can be overwritten by the program test (DB21, ... DBX25.7 or
DB21, ... DBX1.7) and SERUPRO states; this is also the case for every other axis/spindle.

Effect of bits 3/5 and 4/6

The effects of the different motion components on the following axis/spindle as a function of
the associated axis/spindle disable are illustrated in the table below:

A/S disable A/S disable A/S disable CPMVDI CPMVDI FATotal Meaning
FA LA1 LA2 Bit 3/5 Bit 4/6 for FA
0 0 0 0 0 FACmd + Real move‐
FADEP1 + ment.
FADEP2
0 0 0 1 0 FACmd + Real move‐
FADEP1 + ment.
FADEP2
0 1 1 0 0 FACmd + Simulated
FADEP1 + movement
FADEP2
0 0 1 0 0 - Alarm 16773,
different lead‐
ing axis states
with ref. to the
A/S disable

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A/S disable A/S disable A/S disable CPMVDI CPMVDI FATotal Meaning
FA LA1 LA2 Bit 3/5 Bit 4/6 for FA
1 0 0 0 0 FACmd + Real move‐
FADEP1 + ment, FA spin‐
FADEP2 dle disable has
no effect.
1 0 1 1 0 FACmd + Simulated
FADEP1 + movement, FA
FADEP2 spindle disable
has an effect.
1 0 1 1 1 FACmd + Simulated
FADEP2 movement, as
bit 4 is set,
FADEP1 is sup‐
pressed.
0 1 1 0 1 Alarm 19000,
bit 4/6 = 1 is on‐
ly supported if
bit 3/5 = 1.
1 0 0 0 1 Alarm 19000,
bit 4/6 = 1 is on‐
ly supported if
bit 3/5 = 1.

A/S disable: Axis/spindle disable

This refers to the resulting internal state of the axis/spindle disa‐
ble. The spindle disable, which is set via the NC/PLC interface
signal DB31, … DBX1.3 (axis/spindle disable), can be overwrit‐
ten by states such as program test (DB21, … DBX25.7 or
DB21, … DBX1.7) and SERUPRO, thus generating an axis/spin‐
dle state which differs from the NC/PLC interface signal.
FA: Following axis
LA1: Leading axis 1
LA2: Leading axis 2
FATotal: Total setpoint value of the following axis
FACmd: Independent motion component of the following axis
FADEP1: Dependent motion component of leading axis 1
FADEP2: Dependent motion component of leading axis 2
Real movement: Real movement means that positioning movements are transfer‐
red to the position control.
Simulated movement: Simulated movement means that no positioning movements are
transferred to the position control. The real machine axis remains
stationary. This corresponds to the state of an activated axis/
spindle disable or program test.

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8.5 Generic coupling

Note
The states in the columns for leading axes 1 and 2 also apply if there are several leading axes/
spindles, which have the same state with reference to the axis/spindle disable.

8.5.5.19 Alarm suppression (CPMALARM)

The CP keyword CPMALARM can be used to suppress coupling-related alarms.

Programming

Syntax: CPMALARM[FAx]= <value>

Designation: Coupling Mode Alarm

Functionality: CPMALARM is a bit-coded CP keyword for suppressing special coupling-re‐

lated alarm outputs.
The bit combination operators B_OR, B_AND, B_NOT, and B_XOR can be
used to set individual bits.

Bit Value Meaning

0 =1 Alarm 16772 is suppressed.
1 =1 Alarm 16773 is suppressed.
2 =1 Alarm 16774 is suppressed.
3 =1 Alarm 22012 is suppressed.
4 =1 Alarm 22013 is suppressed.
5 =1 Alarm 22014 is suppressed.
6 =1 Alarm 22015 is suppressed.
7 =1 Alarm 22016 is suppressed.
8 =1 Alarm 22025 is suppressed.
9 =1 Alarm 22026 is suppressed.
10 =1 Alarm 22040 is suppressed for the cyclic check in
case of previously activated position control for fol‐
lowing and leading spindles.
11 =1 Alarm 16771 is suppressed.
12 - 31 Reserved.

The default values correspond to the settings in the machine data:

● MD11410 $MN_SUPPRESS_ALARM_MASK (mask for suppressing
special alarm outputs)
● MD11415 $MN_SUPPRESS_ALARM_MASK_2 (suppress alarm
outputs)

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Example
Program code Comment
CPMALARM[X2]='H300' ; The 22025 and 22026 alarms are suppressed for the cou-
pling of the X2 following axis.

8.5.6 Coupling cascading

Coupling cascades
The coupling modules can be connected in series. The following axis/spindle of a coupling
module then becomes the leading axis/spindle of another coupling module. This results in a
coupling cascade.
Multiple coupling cascades in series is also possible. The internal computation sequence of
the individual coupling modules is performed so that there is no position offset in the coupling
relationship. This also applies for a cross-channel cascading.

Example:
Two new coupling modules are created. For the coupling module with following axis X2, the
leading axis X1 is defined. For the coupling module with following axis X2, the leading axis X2
and A1 are defined.

Programming
CPDEF=(X2) CPLA[X2]=(X1) CPDEF=(A2) CPLA[A2]=(X2) CPLA[A2]=(A1)

Supplementary conditions
● The availability of cascading is option-based (see Section "Requirements (Page 380)").
● Cascades between couplings of existing coupling functions and couplings of generic
couplings are not possible.
● A ring coupling is not permitted. It is rejected with alarm 16778:
"Ring coupling with following axis FAx and leading axis LAx not allowed"
(A ring coupling occurs when a following axis is also a leading axis of its own coupling
module or a leading axis in a series-connected coupling module).

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8.5 Generic coupling

8.5.7 Compatibility

8.5.7.1 Adaptive cycles

Adaptive cycles
The provision of adaptive cycles as fixed component of the NCK software ensures a syntactic
and functional compatibility to coupling calls of existing coupling types (coupled motion, master
value coupling, electronic gearbox and synchronous spindle). This means that as long as the
manufacturer/user does not need new coupling characteristics, it is not necessary to modify
present coupling calls and any dependent application components (e.g. PLC evaluation of
coupling signals).

Assignment to existing coupling commands

The number of adaptive cycles corresponds to the number of existing coupling commands.
The assignment is as follows:

Coupling commands Adaptive cycle

TRAILON cycle700
TRAILOF cycle701
LEADON cycle702
LEADOF cycle703
COUPDEF cycle704
COUPON cycle705
COUPONC cycle706
COUPOF cycle707
COUPOFS cycle708
COUPDEL cycle709
COUPRES cycle710
EGDEF cycle711
EGON cycle712
EGONSYN cycle713
EGONSYNE cycle714
EGOFC cycle715
EGOFS cycle716
EGDEL cycle717

Memory location
Adaptive cycles are stored in the directory "CST".

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User specific adaptive cycles

If necessary (functional completion) the user can copy an adaptive cycle to the directory "CMA"
or "CUS" and apply changes there. When reading adaptive cycles, the sequence CUS → CMA
→ CST is observed and cycle variants are taken over on a first found basis, i.e. the adaptive
cycles copied into the directory CMA/CUS by the user are selected on a priority basis.

Note
When upgrading the NCK software, a log file is saved in the "CST" directory (Changelog),
indicating necessary changes of the adaptive cycles.

8.5.7.2 Coupling types (CPSETTYPE)

Coupling types
If presetting of coupling types (coupled motion, master value coupling, electronic gearbox and
synchronized spindle) is required, when creating the coupling module (CPON/CPLON or CPDEF/
CPLDEF), the keyword CPSETTYPE needs to be used also.

Programming

Syntax: CPSETTYPE[FAx]= <value>

Designation: Coupling Set Type

Functionality: Defines the presettings of coupling characteristics (coupling type).

Value: Type: STRING

Range of values:
"CP" Freely programmable
"TRAIL" Coupling type "Coupled motion"
"LEAD" Coupling type "Master Value Coupling"
"EG" Coupling type "Electronic gearbox"
"COUP" Coupling type "Synchronized spindle"

Default value: "CP"

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Example:

Programming Comment
CPLON[X2]=(X1) CPSETTYPE[X2]="LEAD" ; Creates a coupling module for following
axis X2 with leading axis X1 and acti-
vates the coupling module. Coupling
properties are set such that they cor-
respond to the existing master value
coupling type.

Default settings
Presettings of programmable coupling characteristics for various coupling types can be found
in the following table:

Keyword Coupling type

Default Coupled motion Master value cou‐ Electronic gear Synchronous spin‐
(CP) (TRAIL) pling (EG) dle
(LEAD) (COUP)
CPDEF - -
CPDEL - -
CPLDEF - -
CPLDEL - -

CPON
CPOF
CPLON
CPLOF

CPLNUM 1.0 1.0 - 1.0 1.0

CPLDEN 1.0 1.0 - 1.0 1.0
CPLCTID Not set - 0 Not set -

CPLSETVAL CMDPOS CMDPOS CMDPOS CMDPOS CMDPOS

CPFRS BCS BCS BCS BCS MCS
CPBC NOC NOC NOC FINE IPOSTOP

CPFPOS + CPON Not set - - Not set Not set

CPFPOS + CPOF Not set - - - Not set
CPFMSON CFAST CFAST CCOARSE NRGT CFAST

CPFMON STOP VL1): STOP VL1): CONT STOP CONT

HL : CONT
2)
HL : CONT
2)

CPFMOF STOP VL1): STOP VL1): STOP STOP CONT

HL : STOP
2)
HL : STOP
2)

CPLPOS + CPON Not set - - Not set -

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Keyword Coupling type

Default Coupled motion Master value cou‐ Electronic gear Synchronous spin‐
(CP) (TRAIL) pling (EG) dle
(LEAD) (COUP)

CPMRESET NONE MD20110 MD20110 MD20110 MD20110

CPMSTART NONE MD20112 MD20112 MD20112 MD20112
CPMPRT NONE MD20112 / MD20112 / MD20112 / MD20112 /
MD226203) MD226203) MD226203) MD226203)

CPLINTR 0.0 0.0 0.0 0.0 0.0

CPLINSC 1.0 1.0 1.0 1.0 1.0
CPLOUTTR 0.0 0.0 0.0 0.0 0.0
CPLOUTSC 1.0 1.0 1.0 1.0 1.0

CPSYNCOP MD37200 MD37200 MD37200 MD37200 MD37200

CPSYNFIP MD37210 MD37210 MD37210 MD37210 MD37210
CPSYNCOP2 MD37202 MD37202 MD37202 MD37202 MD37202
CPSYNFIP2 MD37212 MD37212 MD37212 MD37212 MD37212
CPSYNCOV MD37220 MD37220 MD37220 MD37220 MD37220
CPSYNFIV MD37230 MD37230 MD37230 MD37230 MD37230

CPMBRAKE
Bit 0 1 - - - -

CPMVDI
Bit 3 0 0 0 0 0
Bit 4 1 1 1 1 1
Bit 5 0 0 0 0 0
Bit 6 1 1 1 1 1

CPMALARM MD11410 MD11410 MD11410 MD11410 MD11410

MD11415 MD11415 MD11415 MD11415 MD11415

Legend:
1)
Pre-processing
2)
Main run
3)
depends additionally on MD22621
- not relevant or not allowed

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Additional properties
Value ranges or availability of additional properties of a set coupling type (CPSETTYPE) can
be found in the following table:

Default Coupled motion Master value cou‐ Electronic gear Synchronous spindle
(CP) (TRAIL) pling ( (EG) (COUP)
LEAD)
Number of lead‐ ≦ 5 ≦2 1 ≦5 1
ing axes
Following axis Axis/spindle Axis/spindle Axis/spindle Axis/spindle Spindle
type
Defining/delet‐ CPDEF/CPDEL CPON/CPOF CPON/CPOF CPDEF/CPDEL CPDEF/CPDEL
ing coupling or
module CPON/CPOF
Defining/delet‐ CPLDEF/CPLDEL CPLON/CPLOF CPLON/CPLOF CPLDEF/CPLDEL CPLDEF/CPLDEL
ing leading axis or
CPLON/CPLOF
Cascading + + + + -
Dynamic obser‐ - - - - +
vation
of the leading
spindle
Implicit selec‐ - - - - +
tion/deselection
of state control1)

Legend:
1)
also refer to: Function Manual, Extended Functions; Synchronous Spindle (S3)
- not relevant or not allowed

Availability of the specified characteristics depends on the available version (see Section
"Requirements (Page 380)").
Example:
The coupled motion coupling type (CPSETTYPE="TRAIL") allows a maximum of two leading
axes and cascading. However, this is not available in the basic version, but requires the CP-
EXPERT option.

Supplementary conditions
● CPSETTYPE can be programmed in synchronous actions.
● If the coupling type (CPSETTYPE) is set, certain coupling characteristics are preset and
cannot be changed. Subsequent change attempts with keywords cause an error and are
rejected with an alarm:

CPSETTYPE= TRAIL LEAD EG COUP

CPDEF Alarm 16686 Alarm 16686
CPDEL Alarm 16686 Alarm 16686

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CPSETTYPE= TRAIL LEAD EG COUP

CPLDEF
CPLDEL

CPON Alarm 16686 Alarm 16686

CPLON
CPOF Alarm 16686 Alarm 16686
CPLOF

CPRES Alarm 16686 Alarm 16686 Alarm 16686

CPLNUM Alarm 16686 Alarm 16686

CPLDEN Alarm 16686 Alarm 16686
CPLCTID Alarm 16686 Alarm 16686

CPLSETVAL Alarm 16686 Alarm 16686 Alarm 16686

with CMDVEL with CMDVEL with CMDVEL
CPFRS Alarm 16686
with BCS
CPBC Alarm 16686 Alarm 16686

CPFPOS + CPON Alarm 16686 Alarm 16686

CPFPOS + CPOF Alarm 16686 Alarm 16686 Alarm 16686
CPFMSON Alarm 16686 Alarm 16686 Alarm 16686

CPFMON Alarm 16686 Alarm 16686 Alarm 16686 Alarm 16686

with ADD/STOP with STOP
CPFMOF Alarm 16686 Alarm 16686 Alarm 16686 Alarm 16686
with ADD/STOP with ADD with ADD
CPLPOS + CPON Alarm 16686 Alarm 16686 Alarm 16686

CPMRESET Alarm 16686 Alarm 16686 Alarm 16686 Alarm 16686

CPMSTART Alarm 16686 Alarm 16686 Alarm 16686 Alarm 16686
CPMPRT Alarm 16686 Alarm 16686 Alarm 16686 Alarm 16686

CPMBRAKE Alarm 16686 Alarm 16686 Alarm 16686 Alarm 16686

Number of leading Alarm 16672 Alarm 16672 Alarm 16672 Alarm 16672
axes (∑ LA) with ∑ LA > 2 with ∑ LA > 1 with ∑ LA > 5 with ∑ LA > 1
Following axis type Alarm 14092
with axis

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8.5 Generic coupling

8.5.7.3 Projected coupling (CPRES)

If the coupling type "Synchronous spindle" is set, (see CPSETTYPE), the coupling properties
contained in machine data can be activated instead of the programmed coupling properties.
References:
Functions Manual Extension Functions; Synchronous spindles (S3);
Chapter "Programming of synchronous spindle couplings"

Programming

Syntax: CPRES= (<following spindle>)

Designation: Coupling Restore

Functionality: Activates projected data of the synchronous spindle coupling to following

spindle FAx.

Following spindle: Type: AXIS

Range of values: All defined spindle names in the channel

Example:

Programming Comment
CPLON[S2]=(S1) CPSETTYPE[S2]="COUP" ; Creates a coupling module for follow-
ing spindle S2 with leading spindle S1
and activates the coupling module. Cou-
pling properties are set such that
they correspond to the existing syn-
chronous spindle coupling type.
...
CPRES=(S2) ; Activates projected data of the syn-
chronous spindle coupling to following
spindle S2.

Boundary conditions
● CPRES is only allowed when the coupling type "Synchronous spindle"
(CPSETTYPE="COUP") is set.
● Application of CPRES to an already active coupling results in a new synchronization.
● Applying CPRES to an undefined coupling module does not result in any action.

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8.5.8 Cross-channel coupling, axis replacement

The following and leading axes must be known to the calling channel.

Following axis
The following axis is requested for replacement in the channel when programming a CP
keyword in the part program, depending on the axis replacement projection (MD30552) with
the language command GETD.
Axis change of the following axis after activating the coupling module is only permitted in the
channel. Changing from channel to main run and vice versa is still possible, however a change
across channel boundaries is not. Supplementary conditions and properties still apply to axis
change. The axis replacement via channel axes is released again after deactivating the
coupling module.
Reference:
Function Manual, Extended Functions; Mode Groups, Channels, Axis Replacement (K5)

Leading axes
Axis change of leading axes can be performed independently of the state of the coupling.

8.5.9 Behavior with rotary axes

Rotary axes as leading or following axes

It is possible to couple rotary axes to a linear axis and vice versa. Note that a direct assignment
of degrees to mm must be performed using the coupling rule.
Example:
A = Rotary axis, X = Linear axis

Programming Comment
N10 G0 A0 X0 ; Traverse motion:
X = 0 mm, A = 0 degrees
N20 CPON=(A) CPLA[A]=(X) CPLNUM[A,X]=2 ; A coupling module for rotary ax-
is A with linear axis X as lead-
ing axis is created and activa-
ted. The coupling value is 2.
N30 X100 ; Traverse motion:
X = 100 mm, A = 200 degrees (=
100*2)

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Modulo reduced rotary axes as leading axes

With modulo reduced rotary axes as leading axes, the input variable is not reduced during the
reduction of the leading axis. The non-reduced position is still taken as the input variable, i.e.
the traversed distance is considered.
Example:
A = Modulo reduced rotary axis, X = Linear axis

Programming Comment
N10 G0 A0 X0 ; Traverse motion:
X = 0 degrees, X = 0 mm
N20 CPON=(X) CPLA[X]=(A) CPLNUM[X,A]=0.5 ; A coupling module for linear ax-
is X with rotary axis A as lead-
ing axis is created and activa-
ted. The coupling value is 0.5.
N30 A200 ; Traverse motion:
A = 200 degrees, X = 100 mm
(= 200*0.5)
N40 A=IC(200) ; A traverses through 200 degrees
in a positive direction to 400
degrees, Display A = 40. X tra-
verses through 100 mm to 200.
N50 A=IC(100) ; A traverses from 40 degrees to
140 degrees, X traverses through
additional 50mm to 250.
N60 A=ACP(80) ; A traverses in the positive di-
rection to 50 degrees, the tra-
versing path is 300 degrees in
the positive direction. X traver-
ses correspondingly by 150 mm in
the positive direction. The end
position is therefore X = 400.

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1 5HGXFWLRQRIWKHOHDGLQJD[LVE\
GHJUHHV



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     'HJUHHV

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(...) Position indication for X, A

Figure 8-12 Example: Modulo reduced rotary axis to linear axis

8.5.10 Behavior during POWER ON, ...

Power on
No coupling is active at power ON. Coupling modules are not available.

RESET
The behavior on RESET can be set separately for each coupling module (see CPMRESET).
The coupling can be activated, deactivated or the current state can be retained.

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Mode change
The coupling remains active during a mode change. The coupling is suppressed (not
deselected!) only in JOG-REF mode when referencing a following axis.

Reference point approach

G74 of the following axis is not possible with an active coupling. An alarm is output.
If the JOG-REF mode is selected and the following axis is traversed, the coupling is
suppressed. The coupling is only performed after JOG-REF mode is cancelled.

SERUPRO
The SERUPRO procedure will simulate the generic coupling and provide values for a restart.
With axial couplings, the simulation always assumes a setpoint coupling, which means, when
there is an actual value coupling, this is switched to setpoint coupling during the SERUPRO
procedure. This can mean that the simulation is not performed correctly.
Further deviations from the real procedure can occur due to increased simulation speed and
canceled axis dynamics limitations.

8.5.11 CP SW limit monitoring

8.5.11.1 Function

What is the purpose of the function?

The "CP-SW limit monitoring" function improves the braking response of a following axis or a
following spindle in axis operation when approaching a software limit switch.
Advantages:
● This avoids that the software limit switch is passed.
● If possible, synchronous operation of the coupling is kept.

Availability
The "CP SW limit monitoring" function can only be activated for following axes from:
● Generic couplings, type "Freely programmable (CPSETTYPE[FAx] = "CP")
● Couplings (generic coupling with CPSETTYPE[FAx] not equal to "CP", coupled motion,
electronic gearbox, master value coupling or synchronous spindle) with a maximum of one
active leading axis/spindle
In all other cases (and when "CP SW limit monitoring" is not activated) the previous function
of the software limit switch monitoring is active (see Chapter "Limit switch monitoring" in the
Function Manual, Basic Functions, A3: Axis Monitoring, Protection Areas).

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Monitoring and setting the brake

The "CP-SW limit monitoring" function checks, in every IPO cycle, as to whether the movement
of the following axis/spindle can be enabled for the following IPO cycle, so that the axis can
always stop in plenty of time before the software limit switch. If this is not the case, for the
following axis, a "CP-SW limit stop" is set; this signifies unconditional direction-specific braking
along the contour.

Transferring the brake to the axes

Setting the brake means that the coupling-independent motion component (CMD and CORR
component) of the following axis is stopped. On the other hand, the coupling-dependent motion
component (DEP component) of the following axis can only be braked by braking the leading
axes.
For couplings (generic coupling with CPSETTYPE[FAx] not equal to "CP", coupled motion,
electronic gearbox, master value coupling or synchronous spindle) with a maximum of one
active leading axis/spindle, the brake is also set for the (only) active leading axis in the collision
direction (depending on the coupling factor).
For generic couplings, type "freely programmable (CPSETTYPE[FAx] = "CP"), the brake is
only transferred to all of the active leading axes, if the coupling property CPMBRAKE[FAx]
Bit 0 = 1 has been programmed (see "Reaction to stop signals and commands
(CPMBRAKE) (Page 423)").
The collision direction depends on the coupling factor for the specific leading axis: With a
negative coupling factor, the collision direction reverses, there is no transfer for a coupling
factor of "zero". For non-linear couplings (e.g. curve table), the coupling factor is derived from
the gradient, determined as linear approximation.

Note
A brake set for a following axis can only influence its leading axes as long as the coupling is
active.

Braking behavior
The normal acceleration ramp is used when braking the axes towards the software limit switch
along the contour, maintaining the coupling definition.
When braking, the stop state 75 "brake request" and situation-dependent, the higher priority
stop states 22 "wait: spindle enable missing", 12 "wait for axis/spindle release" or 71 "wait for
enable, transformation axis" are displayed.
If the following axis is stationary as result of the "CP-SW limit stop", and cannot approach the
software limit switch any closer, then the following alarm is displayed:
10625 "%?C{channel %1: %}block %3 following axis/spindle %2 with CP-SW limit stop %4"

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This means that up to the "final" stopping position, the situation can be somewhat relieved by
moving the following axis in the opposite direction.

Note
For the "CP-SW limit monitoring", coupling involves maintaining synchronous operation. As a
consequence, it cannot be guaranteed that the axis stops at precisely the correct position, if
the coupling rule is to be maintained. If the brake is to be transferred to the leading axes, and
the interpolators brake as required, then the leading axis comes to a standstill in front of the
software limit switch. The maximum distance to the software limit switch is then obtained from
the actual maximum acceleration rate of the following axes multiplied by the square of the
interpolation cycle time.

Retraction
The user is responsible for retraction.
For diagnostic purposes, there are:
● the stop state 75 "brake request"
(if an axis has a travel command, but stops or may not traverse as a result of a braking
request)
● and the system variables:
$AA_BRAKE_STATE (actual brake status)
$AA_BRAKE_CONDB (context-sensitive conditions for the interpolator stop in the BCS)
$AA_BRAKE_CONDM (context-sensitive conditions for the interpolator stop in the MCS)
including the OPI variables aaBrakeState, aaBrakeCondB and aaBrakeCondM derived
from these.
Example for retraction:
1. acknowledge alarm 10625.
2. Switch to the JOG mode.
3. Traverse the leading axis using the traversing keys so that the following axis moves away
from the software limit switch.

8.5.11.2 Parameterization

Activation
The "CP SW limit monitoring" function is activated on an axis-for-axis basis using machine
data:
MD30455 $MA_MISC_FUNCTION_MASK (axis functions)

Bit Value Meaning

11 0 CP SW limit monitoring is not active.
1 CP SW limit monitoring is active.

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8.5.11.3 Programming

Transferring the brake to the leading axes

For generic couplings, type "freely programmable" (CPSETTYPE[FAx] = "CP"), by
programming the coupling property CPMBRAKE (see "Reaction to stop signals and commands
(CPMBRAKE) (Page 423)") it can be set as to whether the brake of the following axis, initiated
using the "CP-SW limit monitoring" function, should also be transferred to the leading axes.

8.5.11.4 Boundary conditions

Possible fault sources

If the axes do not brake as required, this could be due to the following reason:
At least one leading axis does not react to the brake, because it is also a leading axis in its
own right (cascade), and the brake is not transferred to its leading axes. A brake is only
transferred to the leading axes (recursive), if the following applies for the following axes
involved: CPSETTYPE[FAx] = "CP" and CPMBRAKE[Fax] bit 0 = 1
Even if all of the axes brake as required, the contour can be violated as a result of different
acceleration rates and/or coupling factors if these values have not been appropriately
configured and/or programmed.
Even if all of the previous preconditions are fulfilled, there are still some reasons why it cannot
be avoided that a following axis passes a software limit switch:
● The actual maximum acceleration of a leading axis changes.
● The actual maximum acceleration of the following axis becomes smaller.
● The velocity of the following axis when switching in the coupling or when the CP-SW limit
monitoring responds is already so high that with the actual
maximum acceleration it is no longer possible to stop the axis in the appropriate time.
If the axis cannot be stopped in the appropriate time, then as before, the previous software
limit switch monitoring responds, and stops the following axis at the software limit switch.

Braking response for transformations

If the axis to be braked is the output of a transformation, and it has a (MCS) travel command
in the collision direction, then the brake is transferred to all input axes of the transformation in
both directions, and a path stop is executed for this transformation. However, the following
exceptions apply: It does not apply to the independent axes of the transformation. For
TRANSMIT and TRAANG, these are the axes specified in machine data
$MC_TRAFO_AXES_IN_*[2]. For the transformations, braking is only transferred to their
dependent input axes.

DRF offset
Setting a CP-SW limit stop can cause a DRF movement to be canceled, as shown in the
following example:

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8.5 Generic coupling

The basic motion is path motion with extremely low velocity in the positive direction. A larger
DRF correction motion applies to this in the opposite direction. This results in a travel command
in the negative direction. If these movements are now stopped using a CP-SW limit stop, then
for standard machine data, this means that DRF motion is canceled, and only path motion is
continued after the stop is withdrawn.

NCU link
The following restriction must be taken into account for cross-NCU couplings based on lead-
link axis and axis container:
As the leading axis can be interpolated on another NCU, it can take between one and two IPO
cycles for the brake to be transferred to the NCU of the leading axis.

8.5.11.5 Examples

Example 1: Generic coupling type "freely programmable" (CPSETTYPE[FAx] = "CP")

Configuration:

MD26110 $MA_POS_LIMIT_PLUS[AX2]=15 ; Position of the 1st software limit

switch of the following axis for the tra‐
versing range limit in the positive di‐
rection
MD30455 $MA_MISC_FUNCTION_MASK[AX2] = Bit 11 = 1 (CP-SW limit monitoring is
'H800' ; activated)

Programming:

; start position of X and Y

N100 G0 X0 Y0
; coupling activation FA=Y LA=X
; set with CPMBRAKE bit 0 (transfer of the brake to the leading axis)
N120 CPON=Y CPSETTYPE="CP" CPLA=X CPLDEN=2 CPMBRAKE B_OR='H1'
N140 G4 F2

; traverse leading axis X

N200 G1 X=1000 F1000

Example 2: Couplings with a maximum of one active leading axis/spindle

With the following calls, the CP-SW limit monitoring is executed – including the transfer of the
brake to the leading axis – if MD30455 MA_MISC_FUNCTION_MASK[AX2] bit 11 is set:

TRAILON(Y,X,0.5) ; Definition and switching in the coupling of the coupled motion

axis Y two leading axis X.

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EGDEF(Y,X,1) ; Definition of an EG axis group with setpoint coupling

from X to Y (following axis).
EGON( Y,"FINE",X,1,2) ; Activating coupling.

8.5.12 Disturbance characteristic

8.5.12.1 Rapid stop

Function
The rapid stop stops the axis / spindle without ramp, i.e. the velocity setpoint value is specified
as zero. This default applies the brakes at the current limit. The servo enable is retained.
The rapid stop is set at:
● Stop A and Stop C (Safety Integrated)
● Alarms with rapid stop as configured braking behavior
● Reaching the hardware limit switch and rapid stop as configured braking behavior:
MD36600 $MA_BRAKE_MODE_CHOICE = 1

Switchover to actual-value coupling.

The actual values of the leading spindle are used to calculate the setpoint values as soon as
the rapid stop of the leading spindle is reported to a generic coupling.
The changeover to actual value coupling takes place smoothly and remains active till the servo
enable as well as the pulse enable is available again to the leading spindle and no more position
offset takes place. The setpoint value calculation is programmed as with CPLSETVAL only if
these conditions are fulfilled.

Note
A rapid stop that was initiated on reaching the hardware limit switch does not changeover the
actual value coupling.

Response of the following spindle

If a rapid stop is detected for a leading spindle and the following spindle does not execute any
rapid stop by itself, then the following spindle tries to follow the dynamics of the movement of
the leading spindle defined within its framework. As position synchronization is generated,
there may be oscillations in the following axis in relation to the position to be approached.

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The start of a rapid stop for a leading axis/spindle is detected across NCUs.

Note
A simultaneous rapid stop of the leading and following spindle is executed in the synchronized
spindle coupling type (CPSETTYPE="COUP") during a servo alarm.

8.5.13 Tracking the deviation from synchronism

8.5.13.1 Fundamentals

Deviation from synchronism

Workpiece machining operations which are to be carried out both on the face front and the
face rear require a workpiece transfer to another workpiece receptacle (e.g. a counterspindle
chuck).
When workpieces are transferred from front to rear machining, a position offset may result
from the closing of the workpiece receptacle. This could be down to square-edged workpieces
or due to the generation of an angular momentum when the workpiece receptacle (chuck) is
closed quickly during a movement. Depending on the resistance of the workpiece, the tension
can be detected by means of an increase in the current consumption of both the motors
involved in the coupling and/or by means of the workpiece being subjected to torsion.
This could lead to the following NC/PLC interface signals being reset, according to the
synchronism tolerance which has been set, and the magnitude of the offset:
DB31, ... DBX98.1 (coarse synchronous operation) and/or
DB31, ... DBX98.0 (fine synchronous operation)
For the setpoint coupling, the position and velocity setpoints are calculated precisely in
accordance with the programmed coupling rule and output to the Control Units. If identical
drives and a rigid workpiece are used, this will lead to a regulative deviation at the leading and
following spindle, half due to a setpoint difference and half due to an actual value difference.

Function
The "track the deviation from synchronism" function serves to detect the position offset which
has been imposed on the actual value and to correct the following spindle when calculating
the setpoint.

Requirement
A coupling closed via the part/chuck must be in place in order to use this function.

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Versions
There are two different options for determining the deviation from synchronism:
1. The deviation from synchronous operation is determined by the NCK (see "Measuring the
deviation from synchronism (Page 447)").
2. The deviation value is already known and entered by the user directly (see "Entering the
deviation from synchronism directly (Page 450)").
In both cases, the deviation value is then incorporated into the setpoint value calculation for
the following spindle, as a correction value.

Availability
The "track the deviation from synchronism" function was developed for machine couplings
(CPFRS="machine"). This means that it is also available for the "synchronous spindle"
coupling type (CPSETTYPE="COUP").
Like the other higher-level movements, the availability of the function (e.g. speed difference)
depends on the option (see "Requirements (Page 380)").

8.5.13.2 Measuring the deviation from synchronism

The controller measures the difference between the setpoint positions and actual positions
when the following spindle is operating in synchronism. This results in a correction value, which
is saved in a system variable.

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Requirements
The following requirements must be met to enable the controller to calculate the correction
value:
● Requirements if the set coupling type is "synchronous spindle" (CPSETTYPE="COUP"):
– The coupling has precisely one leading spindle (requirement is met if
CPSETTYPE="COUP").
– The coupling factor (quotient from CPLNUM and CPLDEN) is 1 or -1.
– The following value is derived from the setpoint position ("DV") or the actual position
("AV") of the leading spindle.
– Setpoint synchronism must be achieved:
DB31, ... DBX99.4 (synchronization running) = 0
– Setpoint synchronism must not decline again.
– No overlaid movement (DB31, ... DBX98.4 = 0) must be present.
– A dynamics limit is required for the leading spindle, in order to exclude the possibility of
the following spindle being subjected to excessive demands.
● Requirements for a free generic coupling with CPFRS="machine":
– The configured spindles are coupled.
– The coupling has precisely one leading spindle.
– The coupling factor (quotient from CPLNUM and CPLDEN) is 1 or -1.
– The following value is derived from the setpoint position (CPLSETVAL="CMDPOS") or
the actual position (CPLSETVAL="ACTPOS") of the leading spindle.
– Setpoint synchronism must be achieved:
DB31, ... DBX99.4 (synchronization running) = 0
– Setpoint synchronism must not decline again.
– No overlaid movement (DB31, ... DBX98.4 = 0) must be present.
– A dynamics limit is required for the leading spindle, in order to exclude the possibility of
the following spindle being subjected to excessive demands.

Note
Dynamics limit for the leading spindle
The "dynamics limit for the leading spindle" property is specified automatically when the
"synchronous spindle" coupling type (CPSETTYPE="COUP") is set. In the case of other
coupling types, it is the particular responsibility of the user/machine manufacturer to provide
suitable measures to ensure that the following spindle cannot become dynamically overloaded.

Activation
Measuring and tracking of the deviation from synchronism are activated by setting the following
NC/PLC interface signal to "1":
DB31, ... DBX31.6 (track synchronism)

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The signal only has an effect on the following spindle.

Note
In the following cases, signal DB31, ... DBX31.6 (track synchronism) is ignored:
● Axis/spindle disable is active (DB31, ... DBX1.3 = 1).
● Program test is selected.
● SERUPRO is active.
If one of these situations arises when the "track the deviation from synchronism" function is
already active, the function will be deactivated.

Time when measurement is performed

The time when the measurement is performed and the correction value is calculated depends
on the bit 7 setting made in the following item of machine data:
MD30455 $MA_MISC_FUNCTION_MASK (axis functions)

Bit Value Meaning

7 0 The correction value is calculated continuously, as long as the NC/PLC interface signal
DB31, ... DBX31.6 (track synchronism) is set and setpoint synchronism is active (cyclic
calculation).
1 The correction value is only calculated at the time when the NC/PLC interface signal
DB31, ... DBX31.6 (track synchronism) changes from 0 to 1 (edge evaluation).

Note
If a temporal extension is taken into account when relieving the tension between the leading
and the following spindle, bit 7 should be set to 0. The interface signal is then state-controlled.
The time required to relieve the tension can depend on various factors (e.g. KV factor of position
control, accelerating power of the motors) and must be determined by way of experiment.

Measuring sequence
The NC/PLC interface signal DB31, ... DBX31.6 (track synchronism) can only become effective
once setpoint synchronism has been achieved:
DB31, ... DBX99.4 (synchronization running) = 0
The actual values of the following spindle are read within the interpolation cycle and the
difference between them and the setpoint position is calculated, either for as long as signal
DB31, ... DBX31.6 is activated, or just once on that signal's rising edge (the frequency will
depend on the setting of bit 7 in MD30455; see the section titled "Time when measurement is
performed").
The correction value is the difference between the setpoint and actual-value synchronism
positions. This value is saved for the corresponding following spindle in the following system
variable:

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8.5 Generic coupling

$AA_COUP_CORR[S<n>] (following spindle: correction value for synchronous spindle

coupling)

Note
You must ensure that the velocity of the leading and following axes is kept as constant as
possible and that no acceleration jump occurs for the duration of the measurement.

Example
When the coupling of the synchronous spindle [S2] is activated, a position offset of 77 degrees
is also programmed:
CPON=S2 ... CPFPOS[S2]=AC(77)
When the workpiece receptacle is closed, this results in a mechanical position offset, which
leads to an actual-value position offset of 81 degrees.
When the "track the deviation from synchronism" function is activated (DB31, ... DBX31.6 = 1)
and setpoint synchronism has been achieved (DB31, ... DBX99.4 = 0), the actual-value position
offset ($VA_COUP_OFFS[S2] = 81) is compared with the setpoint position offset
($AA_COUP_OFFS[S2] = 77). This results in a correction value of 4 degrees, which is saved
in system variable $AA_COUP_CORR[S2].

8.5.13.3 Entering the deviation from synchronism directly

If the deviation value is known, it can be written directly to the system variable
$AA_COUP_CORR for the corresponding following spindle. This is executed via a part
program or synchronized action.

Note
Please note that the system variable can only be written once the mechanical coupling has
been created. Otherwise a new offset may arise when closing the chuck.

Requirements
To enable the system variable $AA_COUP_CORR to be written from the part program or
synchronized actions, a generic machine coupling must have been activated at least once for
the corresponding following spindle since the most recent controller power-up was performed.

8.5.13.4 Synchronism correction

If correction value $AA_COUP_CORR[S<n>] is a value other than zero and a generic machine
coupling has been active for following spindle S<n> (by means of CPFRS="machine" or
CPSETTYPE="COUP"), the following NC/PLC interface signal is set:
DB31, ... DBX103.0 (synchronism correction is taken into account)

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8.5 Generic coupling

The correction value is incorporated into the setpoint value calculation for the following spindle,
in the coupling module. Resetting the setpoint by the coupling offset relieves the tension
between the leading and following spindles.
The synchronism signals are produced by comparing the actual values with the corrected
setpoints. Once a correction process has been undertaken, the synchronism signals should
be present again:
DB31, ... DBX98.1 (coarse synchronism) and/or
DB31, ... DBX98.0 (fine synchronism)
The correction value can be implemented and the synchronism signals produced as well, since
the whole point of the "tracking the deviation from synchronism" function is to improve
synchronism when tension is present. When implementing this value, the accelerating power
is restricted to no more than 10% of the maximum acceleration and velocity.
When $AA_COUP_CORR[S<n>] has been implemented in full, the following NC/PLC interface
signal is set:
DB31, ... DBX99.2 (synchronism correction implemented)
This still applies even if $AA_COUP_CORR[S<n>] is zero and no correction needs to be
implemented.
When synchronism correction is complete, the NC/PLC interface signal DB31, ... DBX31.6
(track synchronism) must be reset to "0" in order to restore the rigidity of the coupling.
The correction value is not changed again once signal DB31, ... DBX31.6 has been reset or
once the coupling has been deactivated (with CPOF). The system variable
$AA_COUP_CORR[S<n>] then returns a constant value.
The correction value is taken into account until it is reset by setting system variable
$AA_COUP_CORR[S<n>] to "0", which must be done, at the very latest, once the workpiece
is removed from the spindle.

Note
The setpoint correction by means of the system variable $AA_COUP_CORR[S<n>] impacts
on all subsequent following spindle programming in the same way as a position offset, similar
to a DRF offset in the machine.

8.5.13.5 Diagnostics for synchronism correction

The current value of $AA_COUP_CORR (correction value for tracking the deviation in
synchronism) is displayed in the "Axis/Spindle Service" window, under the "Position offset for
the leading axis/spindle setpoint" line, for the purposes of diagnostics.
System variable $AA_COUP_CORR_DIST ($AA_COUP_CORR distance-to-go) can be used
to determine how much of the correction value is still be implemented.

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8.5 Generic coupling

8.5.13.6 Resetting synchronism correction

Versions
Synchronism correction can be reset in the following ways:
● Writing value "0" to variable $AA_COUP_CORR[S<n>].
Synchronism correction is suppressed via a ramp with reduced accelerating power (just as
when a correction value is implemented).
● Resetting synchronism correction via the PLC.
On the rising edge of the NC/PLC interface signal:
DB31, ... DBX31.7 (reset synchronism correction)
, the variable $AA_COUP_CORR[S<n>] is set to zero and synchronism correction is reset
as follows:
– If the spindle is in speed control mode, the correction movement is stopped. The existing
synchronism correction is then transferred to the setpoint position.
– In all other cases, the synchronism correction that has already been implemented is
reset in exactly the same way as when variable $AA_COUP_CORR[S<n>] is set to zero.

Requirements
A requirement for resetting synchronism correction is that the correction value is not currently
being calculated (see Section "Measuring the deviation from synchronism (Page 447)").

End of the reset procedure

When the reset procedure is complete, the following NC/PLC interface signal is set:
DB31, ... DBX99.2 (synchronism correction implemented)
If the NC/PLC interface signal DB31, ... DBX103.0 (synchronism correction is taken into
account) is also reset, so too can the NC/PLC interface signal DB31, ... DBX31.7 (reset
synchronism correction) be reset.

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 M3: Coupled axes
8.5 Generic coupling

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Note
If the correction path has not been traversed in full and the NC/PLC interface signal
DB31, ... DBX31.7 (reset synchronism correction) has not been reset, writing to variable
$AA_COUP_CORR[S<n>] will not have any effect.

8.5.13.7 Limitations and constraints

Several following spindles

If a leading spindle has several following spindles, each of these following spindles can be
processed with the axial NC/PLC interface signal DB31, ... DBX31.6 (track synchronism)
separately from one another.

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8.5 Generic coupling

Writing variable $AA_COUP_CORR

System variable $AA_COUP_CORR is only written from the part program or synchronized
actions when a generic machine coupling has been activated for the corresponding axis/
spindle at least once.

Correction value
If the correction value $AA_COUP_CORR is being written via a part program/synchronized
action, as well as being determined due to the "track the deviation from synchronism" function
being activated (DB31, ... DBX31.6 = 1), the most recent event to occur is always the one that
takes effect.

Resetting synchronism correction

Writing correction value $AA_COUP_CORR (via a part program or synchronized action or
when performing a calculation) has no effect when synchronism correction is being reset.

Response to channel/mode group reset

Synchronism correction is not reset in the event of a channel/mode group reset, it is retained
instead.

Response to search for reference and zero mark synchronization

If a search for reference or zero mark synchronization procedure is performed for spindles,
synchronism correction is reset automatically.
The system variable $AA_COUP_CORR must not be set during the search for reference/zero
mark synchronization and, as a result, no measurement may be taken for the deviation from
synchronism either.
Furthermore, the synchronism correction must have been implemented in full before the search
for reference/zero mark synchronization is started.

Response to an interruption
If an interruption occurs (e.g. emergency stop), synchronism correction is reset automatically,
the existing synchronism correction is transferred to the setpoint position, and the NC/PLC
interface signal DB31, ... DBX99.2 (synchronism correction implemented) is set.
If, once the interruption has been dealt with, the generic machine coupling remains active and
the NC/PLC interface signal DB31, ... DBX31.6 (track synchronism) is set, the following applies:
● If the signal is level-triggered (MD30455 $MA_MISC_FUNCTION_MASK, bit 7 = 0), the
deviation from synchronism is measured and written to $AA_COUP_CORR; the setpoints
are corrected accordingly.
● If the signal is edge-triggered (MD30455 $MA_MISC_FUNCTION_MASK, bit 7 = 1) and
the deviation from synchronism is to be measured, a new rising edge of the NC/PLC
interface signal DB31, ... DBX31.6 (track synchronism) needs to be executed.

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8.5 Generic coupling

8.5.14 Examples

8.5.14.1 Programming examples

Direct switch on/off with one leading axis

A coupling module is created and activated with following axis X2 and leading axis X1. The
coupling factor is 2.

CPON=(X2) CPLA[X2]=(X1) CPLNUM[X2,X1]=2

...
CPOF=(X2) ; The coupling is deactivated and the created
coupling module is deleted with CPOF.

Direct switch on/off with two leading axes

A coupling module is created and activated with following axis X2 and leading axes X1 and Z.
The coupling factor regarding leading axis X1 is 2, the coupling factor regarding leading axis
Z is 3.

CPON=(X2) CPLA=(X1) CPLNUM[X2,X1]=2 CPLA=(Z) CPLNUM[X2,Z]=3

...
CPOF=(X2) ; The coupling is deactivated and the created
coupling module is deleted with CPOF.

Selective switch-off with two leading axes

A coupling module is created and activated with following axis Y and leading axes X and Z.
The coupling factor regarding leading axis X is 2, the coupling factor regarding leading axis Z
is 1.2.

CPON=(X2) CPLA[X2]=(X1) CPLNUM[X2,X1]=2 CPLA[X2]=(Z) CPLNUM[X2,Z]=1.2

...
CPOF=(X2) CPLA[X1]=(Z) ; The coupling with leading axis Z is deactiva-
ted with CPOF, the coupling with leading axis
X1 is retained. The created coupling module
remains created.

Selective switch-on/off with three leading axes

A coupling module is created and activated with following axis X2 and leading axes X1, Z and
A.

N10 CPDEF=(X2) CPLA[X2]=(X1) CPLA[X2]=(Z) CPLA[X2]=(A)

N20 CPON=(X2) ; All leading axes become active, i.e. all
contribute a position component accord-
ing to the coupling rule (coupling com-
ponent) to axis X2.

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8.5 Generic coupling

N30 CPOF=(X2) ; All leading axes are deactivated.

N40 CPLON[X2]=(X1) ; Leading axis X1 is activated, only this
axis supplies a coupling component.
Leading axes Z and A remain deactivated.
N50 CPLON[X2]=(A) ; Leading axis X1 remains active, leading
axis A is deactivated, X1 and A contrib-
ute coupling components (→ selective
switch-on is additive, the condition of
the other leading axes is retained).
N60 CPLON[X2]=(Z) CPLOF[X2]=(A) ; Leading axis Z is activated, leading ax-
is A deactivated. Leading axes X 1and Z
are now active.
N70 CPLOF[X2]=(X1) ; Leading axis X1 is deactivated. Leading
axis Z remains active.

Definition/deletion of a coupling module

With CPDEF a coupling module is created and activated with following axis X2 and leading
axes X1 and Z. The coupling is not activated. Following axis X2 does not follow the coupling
rule!

CPDEF=(X2) CPLA[X2]=(X1) CPLNUM[X2,X1]=2 CPLA[X2]=(Z) CPLNUM[X2,Z]=3

...

Activation can be done with CPON, deactivation with CPOF.

After the deactivation of the coupling relationship to all leading axes, the coupling object can
be deleted. Reserved memory is released:

CPDEL=(X2)

8.5.14.2 Adapt adaptive cycle

Target
Coupled motion in the machine co-ordinate system must be possible with the existing coupling
command TRAILON. The adaptive cycle for TRAILON is supplemented with the coupling
characteristic "Co-ordinate reference" (CPFRS).

Procedure
1. Copy adaptive cycle 700 from directory "CST" to directory "CMA".
2. Supplement cycle 700 with the following entry:
CPFRS[_FA]="MCS"
3. Comment to cycle changes (e.g. user version number and change date).
4. Save cycle.

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 M3: Coupled axes
8.6 Dynamic response of following axis

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8.6 Dynamic response of following axis

8.6.1 Parameterized dynamic limits

The dynamics of the following axis is limited with the following machine data values:
MD32000 $MA_MAX_AX_VELO (maximum axis velocity)
MD32300 $MA_MAX_AX_ACCEL (Maximum axis acceleration)

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8.6 Dynamic response of following axis

8.6.2 Programmed dynamic limits

8.6.2.1 Programming (VELOLIMA, ACCLIMA)

Reducing or increasing dynamics limits

The dynamic limits of the following axis (FA) specified through MD32000 and MD32300 can
be reduced or increased from the part program:

Command Meaning
VELOLIMA[FA] Reducing or increasing the maximum Axis velocity
ACCLIMA[FA] Reducing or increasing the maximum Axis acceleration

The values specified during the programming of VELOLIMA[FA] and ACCLIMA[FA]are

process values. They define the proportion with which the parameterized dynamic limits
(MD32000 and MD32300) are to be considered:

Range of values Meaning

1 ≤ value < 100 effects a Reduction in the dynamic limit
100 ≤ value < 200 effects an increase in the dynamic limit

The dynamic limits for the velocity and acceleration of the following axis are then calculated
as follows:
Maximum axis velocity = MD32000 $MA_MAX_AX_VELO * VELOLIMA[FA]
Maximum axis acceleration = MD32300 $MA_MAX_AX_ACCEL * ACCLIMA[FA]

Note
The reduction / increase is effected on the overall dynamics of the axis, i.e., on the sum of the
axis component from overlay and coupling.

Programming in synchronized actions

The possibility of programming VELOLIMA[FA] and ACCLIMA[FA]in synchronized actions
depends on the coupling type:.

Coupling type Part program Synchronized actions

Tangential correction x
Coupled motion x x
Master value coupling x x
Electronic gearbox x
Synchronous spindle x
Generic coupling x x

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8.6 Dynamic response of following axis

Synchronization between following and leading axes

The acceleration characteristics set and the dynamics offsets set change the duration for
synchronization between following and leading axes during acceleration operations as follows:

Dynamic offset Activation

Dynamic reduction Prolongs the synchronism difference.
The monitoring from leading to following value may exceed the al‐
lowed range for extended periods.
Dynamic increase Shortens the synchronism difference.
The monitoring of leading and following values may exceed the
allowed range for short periods.

Note
The user must restore the technological synchronization between machining and the
synchronism difference.

Acceleration mode
Only BRISKAis available for the following axis, i.e., abrupt axis acceleration. Acceleration
modes SOFTA and DRIVEAare not available for the following axes described.
Furthermore, it is also possible to configure the positions controller as a PI controller.

CAUTION
Application faults
This option can only be used in conjunction with servo trace and with the appropriate technical
knowledge of the control.

References:
● CNC Commissioning Manual: NCK, PLC, drive
● Function Manual, Basic Functions; Velocities, Setpoint-Actual Value Systems, Closed-
Loop Control (G2)

POWER ON
During POWER ON the values of VELOLIMA and ACCLIMA are initialized to 100%.

Mode change
The dynamic offsets remain valid only on transition from AUTO → JOG mode.

RESET
The validities of the (VELOLIMA and ACCLIMA) dynamic offsets after RESET depend on the
setting in the channel-specific machine data:

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8.6 Dynamic response of following axis

MD22410 $MC_F_VALUES_ACTIVE_AFTER_RESET (F Function is active even after

RESET)

Value Meaning
0 The values of VELOLIMA[FA] and ACCLIMA[FA] are set to 100% after RESET.
1 The last programmed values of VELOLIMA[FA] and ACCLIMA[FA] are also active after
RESET.

This response also applies for dynamics offsets set using static synchronized actions. If this
is not the case even when MD22410 = 0, then the IDS synchronized action should trigger a
repeat or continuous writing of the dynamic offset.
References:
Function Manual, Synchronized Actions

8.6.2.2 Examples

Electronic gearbox
Axis 4 is coupled to X via an electronic gearbox coupling. The acceleration capability of the
following axis is limited to 70% of maximum acceleration. The maximum permissible velocity
is limited to 50% of maximum velocity. After POWER ON, the maximum permissible velocity
is set to 100% again.

...
N120 ACCLIMA[AX4]=70
N130 VELOLIMA[AX4]=50 ; reduced speed
N150 EGON(AX4,"FINE",X,1,2)
N200 VELOLIMA[AX4]=100 ; full speed
...

Master value coupling

Axis 4 is coupled to X via a master value coupling. The acceleration capability of the following
axis is limited to 80% of maximum acceleration.

...
N120 ACCLIMA[AX4]=80 ; 80%
N130 LEADON(AX4,X,2) ; Activate coupling
...

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8.7 General supplementary conditions

Master value coupling with synchronized action

Axis 4 is coupled to X via a master value coupling. The acceleration response is limited to
position 80% by static synchronized action 2 from position 100.

...
N120 IDS=2 WHENEVER $AA_IM[AX4] > 100 DO ACCLIMA[AX4]=80
N130 LEADON(AX4,X,2)
...

8.6.2.3 System variables

For geometry axis, channel axis, machine axis and spindle axis, the following readable system
variables are available in the part program and synchronous actions:

Identifier Data type Description Unit

Preprocessing
$PA_ACCLIMA[n] REAL Acceleration offset set with ACCLIMA[Ax] %
$PA_VELOLIMA[n] REAL Velocity offset set with VELOLIMA[Ax] %

Main run
$AA_ACCLIMA[n] REAL Acceleration offset set with ACCLIMA[Ax] %
$AA_VELOLIMA[n] REAL Velocity offset set with VELOLIMA[Ax] %

Note
Reading the main run variables, implicitly triggers a preprocessing stop.

8.7 General supplementary conditions

Note
Drive optimization
At a SINAMICS S120 drive unit, a maximum of 3 drives can be optimized or measured at the
same time (speed controller optimization/function generator). Therefore, for a coupling with
more than 3 coupled drives at the same time, we recommend that these are distributed over
several drive units.

Note
Block search with active coupling
For an active coupling, it is recommended to only use block search type 5, "Block search via
program test" (SERUPRO) for a block search.

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8.8 Data lists

8.8 Data lists

8.8.1 Machine data

8.8.1.1 NC-specific machine data

Number Identifier: $MN_ Description

11410 SUPPRESS_ALARM_MASK Screen form for suppressing special alarm outputs
11415 SUPPRESS_ALARM_MASK_2 Suppress alarm outputs
11660 NUM_EG Number of possible electronic gears
11750 NCK_LEAD_FUNCTION_MASK Functions for master value coupling
11752 NCK_TRAIL_FUNCTION_MASK couple motion functions
18400 MM_NUM_CURVE_TABS Number of curve tables (SRAM)
18402 MM_NUM_CURVE_SEGMENTS Number of curve segments (SRAM)
18403 MM_NUM_CURVE_SEG_LIN Number of linear curve segments (SRAM)
18404 MM_NUM_CURVE_POLYNOMS Number of curve table polynomials (SRAM)
18406 MM_NUM_CURVE_TABS_DRAM Number of curve tables in DRAM
18408 MM_NUM_CURVE_SEGMENTS_DRAM Number of curve segments in DRAM
18409 MM_NUM_CURVE_SEG_LIN_DRAM Number of linear curve segments (DRAM)
18410 MM_NUM_CURVE_POLYNOMS_DRAM Number of curve polynomials in DRAM
18450 MM_NUM_CP_MODULES Maximum number of allowed CP coupling modules
18452 MM_NUM_CP_MODUL_LEAD Maximum number of allowed CP master values

8.8.1.2 Channelspecific machine data

Number Identifier: $MC_ Description

20110 RESET_MODE_MASK Definition of control basic setting after run-up and RE‐
SET/part program end
20112 START_MODE_MASK Definition of control basic setting after run-up and RE‐
SET
22620 START_MODE_MASK_PRT Definition of the control basic settings for special start
22621 ENABLE_START_MODE_MASK_PRT Activation of MD22620
20900 CTAB_ENABLE_NO_LEADMOTION Curve tables with jump of following axis
20905 CTAB_DEFAULT_MEMORY_TYPE Default memory type for curve tables
21300 COUPLE_AXIS_1 Projection synchronous spindle pair

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8.8 Data lists

8.8.1.3 Axis/spindlespecific machine data

Number Identifier: $MA_ Description

30130 CTRLOUT_TYPE Setpoint output type
30132 IS_VIRTUAL_AX Axis is virtual axis
30455 MISC_FUNCTION_MASK Axis functions
35040 SPIND_ACTIVE_AFTER_RESET Own spindle RESET
37160 LEAD_FUNCTION_MASK Functions for master value coupling
37200 COUPLE_POS_TOL_COARSE Threshold value for "Coarse synchronous operation"
37202 COUPLE_POS_TOL_COARSE_2 Second synchronous operation monitoring: Threshold
value for "Coarse synchronous operation"
37210 COUPLE_POS_TOL_FINE Threshold value for "Fine synchronous operation"
37212 COUPLE_POS_TOL_FINE_2 Second synchronous operation monitoring: Threshold
value for "Fine synchronous operation"
37220 COUPLE_VELO_TOL_COARSE Velocity tolerance "coarse"
37230 COUPLE_VELO_TOL_FINE Velocity tolerance "fine"
37500 ESR_REACTION Reaction definition with extended stop and retract
37550 EG_VEL_WARNING, Threshold value for speed warning threshold
37560 EG_ACC_TOL Threshold value for the signal "Axis is accelerating"

8.8.2 Setting data

8.8.2.1 Axis/spindle-specific setting data

Number Identifier: $SC_ Description

43100 LEAD_TYPE Definition of master value type
43102 LEAD_OFFSET_IN_POS Offset of master value with coupling to this axis
43104 LEAD_SCALE_IN_POS Scaling of master value with coupling to this axis
43106 LEAD_OFFSET_OUT_POS Offset of the function value of the curve table
43108 LEAD_SCALE_OUT_POS Scaling of the function value of the curve table

8.8.3 System variables

Electronic gear (EG) and master value coupling

Identifier Meaning
$AA_EG_ACTIVE Coupling for leading axis b is active, i.e. switched on
$AA_EG_AX Name for nth leading axis

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8.8 Data lists

Identifier Meaning
$AA_EG_DENOM Numerator of the coupling factor for leading axis b
$AA_EG_NUMERA Numerator of the coupling factor for leading axis b
$AA_EG_NUMLA Number of leading axes defined with EGDEF
$AA_EG_SYN Synchronized position of leading axis b
$AA_EG_SYNFA Synchronous position of following axis a
$AA_EG_TYPE Type of coupling for leading axis b
$AA_IN_SYNC[FA] Synchronization status of the following axis
$AA_LEAD_P Current leading position value (modulo reduced).
$AA_LEAD_P_TURN current leading value - position component lost as a result of modulo reduction.
$AA_LEAD_SP simulated master value - position MCS
$AA_LEAD_SV Simulated master value - velocity
$AA_LEAD_V Current leading velocity value
$AA_SYNC Coupling status of the following axis for leading value coupling.
$P_EG_BC Block change criterion for EG activation calls: EGON, EGONSYN. WAITC = immediate
synchronism fine or coarse and setpoint synchronous operation.
$VA_EG_SYNCDIFF Synchronism difference

Generic coupling

Identifier Meaning
$AA_ACCLIMA Acceleration correction (main run) set with ACCLIMA
$AA_COUP_ACT Coupling type of a following axis/spindle
$AA_COUP_CORR Following spindle - correction value for tracking the deviation in synchronism
$AA_COUP_CORR_DIST $AA_COUP_CORR distance-to-go
$AA_COUP_OFFS Setpoint position offset
$AA_CPACTFA Name of active following axis
$AA_CPACTLA Name of active leading axis
$AA_CPBC Block change criterion
$AA_CPDEFLA Name of defined leading axis
$AA_CPFACT Coupling type of the following axis/spindle.
$AA_CPFCMDPT Axis setpoint position for all coupling components
$AA_CPFCMDVT Axis setpoint speed for all coupling components
$AA_CPFMOF Behavior of the following axis at switch-off
$AA_CPFMON Behavior of the following axis at switching on
$AA_CPFMSON Synchronization mode
$AA_CPFRS Coupling reference system
$AA_CPLCMDP Axis setpoint component of the leading axis
$AA_CPLCMDV Axis setpoint speed component of the leading axis
$AA_CPLCTID Table number of the active curve table
$AA_CPLDEN Denominator of the coupling factor
$AA_CPLNUM Numerator of the coupling factor

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8.8 Data lists

Identifier Meaning
$AA_CPLSETVAL Coupling reference of the leading axis
$AA_CPLSTATE State of the coupling
$AA_CPSYNCOP Threshold value of position synchronism "Coarse" (main run)
$AA_CPSYNCOV Threshold value of velocity synchronism "Coarse" (main run)
$AA_CPSYNFIP Threshold value of position synchronism "Fine" (main run)
$AA_CPSYNFIV Threshold value of velocity synchronism "Fine" (main run)
$AA_CPLINSC Scaling factor of the input value of a leading axis (main run)
$AA_CPLINTR Offset value of the input value of a leading axis (main run)
$AA_CPLOUTSC Scaling factor of the output value of the coupling (main run)
$AA_CPLOUTTR Offset value of the output value of the coupling (main run)
$AA_CPLTYPE Type of coupling
$AA_CPMRESET State of the coupling after RESET
$AA_CPMSTART State of the coupling after program start
$AA_CPNACTFA Number of active following axes
$AA_CPNACTLA Number of active leading axes
$AA_CPNDEFLA Number of defined leading axes
$AA_CPSETTYPE Preset coupling type
$AA_EG_ACTIVE Coupling for leading axis b is active
$AA_EG_AX Name for nth leading axis
$AA_EG_BC Block change criterion
$AA_EG_DENOM Denominator of the coupling factor
$AA_EG_NUMERA Numerator of the coupling factor
$AA_EG_NUM_LA Number of leading axes defined with EGDEF
$AA_EG_SYN Synchronized position of the leading axis
$AA_EG_SYNFA Synchronized position of the following axis
$AA_EG_TYPE Type of coupling
$AA_IN_SYNC[FA] Synchronization status of the following axis
$AA_JERKLIMA Jerk correction set with JERKLIMA (main run)
$AA_LEAD_SP Simulated master value - position with LEAD
$AA_LEAD_SV Simulated master value - speed with LEAD
$AA_LEAD_P_TURN Current leading value - position component lost as a result of modulo reduction.
$AA_LEAD_P Current leading value - position (modulo reduced)
$AA_LEAD_V Current leading velocity value
$AA_SYNC Coupling status of following axis
$AA_SYNCDIFF[FA] Synchronism difference of the setpoint
$AA_SYNCDIFF_STAT[FA] Status of the synchronism difference of the setpoint
$AA_TYP/TYPE Axis type
$AA_VELOLIMA Velocity correction set with VELOLIMA (main run)
$PA_ACCLIMA Acceleration correction set with ACCLIMA (pre-processing)
$PA_CPFACT Coupling type of the following axis/spindle.
$PA_CPFPOSSTAT Validity of synchronous and stop position

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8.8 Data lists

Identifier Meaning
$PA_CPSYNCOP Threshold value of position synchronism "Coarse" (pre-processing)
$PA_CPSYNCOV Threshold value of velocity synchronism "Coarse" (pre-processing)
$PA_CPSYNFIP Threshold value of position synchronism "Fine" (pre-processing)
$PA_CPSYNFIV Threshold value of velocity synchronism "Fine" (pre-processing)
$PA_CPLINSC Scaling factor of the input value of a leading axis (pre-processing)
$PA_CPLINTR Offset value of the input value of a leading axis (pre-processing)
$PA_CPLOUTSC Scaling factor of the output value of the coupling (pre-processing)
$PA_CPLOUTTR Offset value of the output value of the coupling (pre-processing)
$PA_CPSETTYPE Preset coupling type
$PA_JERKLIMA Jerk correction set with JERKLIMA (pre-processing)
$PA_VELOLIMA Velocity correction set with VELOLIMA (pre-processing)
$VA_COUP_OFFS[S2] Actual-value position offset of the synchronous spindle
$VA_EG_SYNCDIFF Synchronism difference
$VA_EG_SYNCDIFF_S Synchronism difference with sign
$VA_SYNCDIFF[FA] Synchronism difference of the actual value
$VA_SYNCDIFF_STAT[FA] Status of the synchronism difference
$P_COUP_OFFS[S2] Programmed position offset of the synchronous spindle
$P_EG_BC Block change criterion

Dynamics of following axis

Identifier Meaning
$AA_ACCLIMA Main run acceleration correction set with ACCLIMA
$AA_VELOLIMA Main run speed correction set with VELOLIMA
$PA_ACCLIMA Preprocessing acceleration correction set with ACCLIMA
$PA_VELOLIMA Preprocessing speed correction set with VELOLIMA

8.8.4 Signals

8.8.4.1 Signals to axis/spindle

Signal name SINUMERIK 840D sl SINUMERIK 828D

Feedrate override DB31, ... DBX0.0-7 DB380x.DBB0
Axis disable DB31, ... DBX1.3 DB380x.DBX1.3
Controller enable DB31, ... DBX2.1 DB380x.DBX2.1
Activate handwheel DB31, ... DBX4.0-2 DB380x.DBX4.0/1
Feed stop DB31, ... DBX4.3 DB380x.DBX4.3
Enable following axis overlay DB31, ... DBX26.4 DB380x.DBX5002.4
Synchronize following spindle DB31, ... DBX31.4 DB380x.DBX5007.4

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8.8 Data lists

Signal name SINUMERIK 840D sl SINUMERIK 828D

Disable synchronization DB31, ... DBX31.5 DB380x.DBX5007.5
Track synchronism DB31, ... DBX31.6 DB380x.DBX5007.6
Reset synchronism correction DB31, ... DBX31.7 DB380x.DBX5007.7

8.8.4.2 Signals from axis/spindle

Signal name SINUMERIK 840D sl SINUMERIK 828D

Limiting of differential speed DB31, ... DBX83.1 DB390x.DBX2001.1
Spindle in setpoint range, differential speed DB31, ... DBX83.5 DB390x.DBX2001.5
Speed limit exceeded, total speed DB31, ... DBX83.6 DB390x.DBX2001.6
Actual direction of rotation clockwise, total speed DB31, ... DBX83.7 DB390x.DBX2001.7
Synchronous mode DB31, ... DBX84.4 DB390x.DBX2002.4
Synchronism fine DB31, ... DBX98.0 DB390x.DBX5002.0
Synchronism coarse DB31, ... DBX98.1 DB390x.DBX5002.1
Actual value coupling DB31, ... DBX98.2 DB390x.DBX5002.2
Overlaid movement DB31, ... DBX98.4 DB390x.DBX5002.4
Velocity warning threshold DB31, ... DBX98.5 DB390x.DBX5002.5
Acceleration warning threshold DB31, ... DBX98.6 DB390x.DBX5002.6
Leading spindle active DB31, ... DBX99.0 DB390x.DBX5003.0
Following spindle active DB31, ... DBX99.1 DB390x.DBX5003.1
Synchronism correction implemented DB31, ... DBX99.2 DB390x.DBX5003.2
Following axis accelerated DB31, ... DBX99.3 DB390x.DBX5003.3
Synchronization in progress DB31, ... DBX99.4 DB390x.DBX5003.4
Maximum velocity reached DB31, ... DBX99.5 DB390x.DBX5003.5
Maximum acceleration reached DB31, ... DBX99.6 DB390x.DBX5003.6
Synchronism correction is taken into account DB31, ... DBX103.0 DB390x.DBX5007.0
Synchronism 2 fine DB31, ... DBX103.4 DB390x.DBX5007.4
Synchronism 2 coarse DB31, ... DBX103.5 DB390x.DBX5007.5

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8.8 Data lists

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9.1 Brief description
The extended stop and retract function - subsequently called ESR - offers the possibility of
flexibly responding when a fault situation occurs as a function of the process:
● Extended stop
Assuming that the specific fault situation permits it, all of the axes, enabled for extended
stopping, are stopped in an orderly fashion.
● Retract
The tool currently in use is retracted from the workpiece as quickly as possible.
● Generator operation (SINAMICS drive function "Vdc control")
If a parameterizable value of the DC link voltage is fallen below, e.g. because the line
voltage fails, the electrical energy required for retraction is generated by recovering the
braking energy of the drive intended for this purpose (generator operation).

ESR and active couplings

While stopping and retracting, active couplings are kept for a parameterizable time.

Retracting along a path

A straight line can be programmed as retraction path, as an alternative to purely axial retraction.

9.2 Control-managed ESR - 840D sl only

9.2.1 Extended stop and retract (ESR)

Using the Extended stop/retract (ESR)" function, axes that have been enabled for the function
are stopped and retracted in a defined, delayed fashion. This is done to quickly separate the
tool and workpiece in certain programmable system states.
In order that the energy required for the retraction motion is available in the drives involved –
even when the power fails – then one or several drives can be parameterized as "generators"

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using the SINAMICS S120 "Vdc control" drive function. Even when the power fails, their kinetic
energy is used to maintain the DC link voltage in order to permit NC controlled retraction motion.

Note
Detailed information on the SINAMICS S120 drive function "Vdc control" can be found in:
References
Function Manual SINAMICS S120 Drive Functions

NC-controlled responses
The function provides the following NC-controlled responses:
● "Extended stop"
Programmable, defined, delayed path-related stopping of traversing motion
● "Retraction"
Fastest possible retraction away from the machining plane to a safe retraction position to
separate the tool and workpiece
The responses are independent of each other. Retraction operations and temporary
continuation of axis couplings before stopping can be configured so that they are executed in
parallel from a time perspective. In this case, an axis in generator mode (Vdc control) can
maintain the DC link voltage.

Interaction of NC-controlled responses

The NC controlled responses are initiated via the channel-specific system variable
$AC_ESR_TRIGGER.
Using $AC_ESR_TRIGGER, interpolatory stopping along the path or contour is possible. The
NC-controlled retraction is performed in synchronism by the retraction axes in the channel.
For ESR-enabled axes, only precisely one channel may be assigned and it is not possible to
switch between channels.
For NC-controlled stopping, an existing traversing motion as well as an active electronic
coupling is maintained over an adjustable time (MD21380 $MC_ESR_DELAY_TIME1) even if
there is an alarm with motion stop. After the parameterized time has expired, the axis is braked
down to standstill along the programmed path.
In order to perform retraction outside the AUTOMATIC mode as well, triggering of this function
is linked to the system variable $AC_ESR_TRIGGER. Retraction initiated via
$AC_ESR_TRIGGER is locked, in order to prevent multiple retractions.

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9.2.2 Drive-independent reactions

Generator operation
Generator operation is a drive function. Using the "Vdc control" function, the SINAMICS S120
drive unit can monitor the DC link group for undervoltage. When an adjustable voltage value
is fallen below, then the drive intended for the purpose is switched into generator operation.
The kinetic energy of the drive is used to buffer the DC link voltage. This allows the axes that
are still moving to be stopped and retracted in an ordering fashion on the NC side.

Note
At the instant that it is switched into generator operation, if an axis is in closed-loop position
control, then additional alarms can occur.

References
For detailed information on the SINAMICS S120 drive function "Vdc control", see:
Function Manual SINAMICS S120 Drive Functions

9.2.3 Power failure detection and bridging

DC link voltage limit values

The DC link is monitored against the limit values shown in the following diagram:

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Figure 9-1 DC link voltage limit values

The drive and DC link pulses are cancelled at specific voltage levels, which means that the
drives coast-down. If this behavior is not desired, the excess energy can be discharged using

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a resistor module. The operating range of the resistor module (shown highlighted in the
diagram) lies below the critical voltage level.

Note
The pulse power of the resistor module is greater than the infeed power.

Monitoring the intermediate circuit minimum voltage limit

The DC link voltage can be monitored against a limit value that can be parameterized in the
drive:
● p1248 (DC link voltage – lower voltage threshold)
When the limit value is fallen below, the following signal is set in the message word (MELDW)
of the PROFIdrive telegram:
● MELDW.Bit4 = 1 (VDC_min controller is active (Vdc link < p1248))
The signal can be used in the NC to initiate ESR responses.

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Figure 9-2 Monitoring the DC link voltage

9.2.4 NC-controlled extended stop

Axis-specific parameterization
The NC-controlled extended stopping for a machine axis is activated using machine data:

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MD37500 $MA_ESR_REACTION[<axis>] = 22

Note
Path axes
If NC-controlled extended stopping is parameterized for a path axis, then the corresponding
behavior is also transferred to all other path axes of the channel.
Leading and following axis
During the extended stopping, a following axis of an electronic gearbox follows the leading
axes according to the parameterized/programmed motion principle. That is why independent
braking is not possible for the following axis during the times specified in MD21380
$MC_DELAY_TIME1 and MD21381 $MC_ESR_DELAY_TIME2. MD21380
$MC_DELAY_TIME1MD21381 $MC_ESR_DELAY_TIME2 A prerequsite for correct
functioning of ESR is that all necessary enable signals must be set and remain set.

Channel-specific parameterization
The timing within a channel is parameterized using the following machine data:
● MD21380 $MC_ESR_DELAY_TIME1[<axis>] (delay time ESR axes)
● MD21381 $MC_ESR_DELAY_TIME2[<axis>] (ESR time for interpolatory braking)

Time sequence
After initiating ESR, the axis continues to traverse with the actual speed. After a delay time
has expired (..._TIME1), the axis is braked, interpolating.
The set time (..._TIME 2) is the maximum time available for interpolatory braking. After this
time has expired, a setpoint of 0 is output for the axis, and the follow-up mode is activated.

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T1 MD21380 $MC_ESR_DELAY_TIME1 (delay time, ESR axes)

T2 MD21381 $MC_ESR_DELAY_TIME2 (ESR time for interpolatory braking)
n1 Actual speed, which could be braked to a standstill within T2
n2 Actual speed, which could not be braked to a standstill within T2 ⇒ fast braking

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Note
For safety reasons, the sum of T1 and T2 should not exceed a maximum value of approx. 1
second.

Precondition
To ensure that ESR is carried out, at least one of the axes involved in the movement must be
parameterized as an NC-controlled retraction or stopping axis: MD37500
$MA_ESR_REACTION > 20
For axes that are not parameterized as NC controlled retraction or stopping axis, fast braking
with subsequent tracking is realized immediately so that extended stopping starts
($AC_ESR_TRIGGER = 1).
Processing of all commands, especially those that result in an axis stop (e.g. Reset, Stop,
Stopall), as well as the standard alarm responses STOPBYALARM and NOREADY, is delayed
by the sum of the parameterized times:
Delay time = MD21380 $MC_ESR_DELAY_TIME1 + MD21381 $MC_ESR_DELAY_TIME2
An NC controlled stop is also active in conjunction with the "Electronic gearbox" function (see
Chapter "Electronic gear (EG) (Page 352)"). It contains the (selective) switchover of the
electronic gearbox to actual value coupling if there is a fault on the leading axes, and also
maintains traversing motion and the enable signals during the delay time for ESR axes:
MD21380 $MC_ESR_DELAY_TIME1

9.2.5 Retract

Parameterization
NC-controlled retraction is parameterized with:
MD37500 $MA_ESR_REACTION = 21

Behavior
If the channel-specific system variable $AC_ESR_TRIGGER = 1 is set, and if there is a
retraction axis in this channel and $AA_ESR_ENABLE=1 is set for this, then LIFTFAST is
activated in this channel.
Precondition
The retraction position must have been programmed in the part program. The enable signals
must be set and remain set for retraction motion.
Rapid lift to the position defined with POLF is triggered using the modal program command
LFPOS (46th G code group).
The retracting movement configured with LFPOS, POLF for the axes selected with
POLFMASK or POLFMLIN replaces the path motion defined for these axes in the part program.

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During retraction:
● The axes defined in POLFMASK independently travel to the positions specified with POLF.
● The axes defined in POLFMLIN travel to the positions specified with POLF in a linear
relationship.
The extended retraction (i.e. LIFTFAST/LFPOS initiated through $AC_ESR_TRIGGER )
cannot be interrupted and can only be terminated prematurely using EMERGENCY OFF.
Speed and acceleration limits for the axes involved in the retraction are monitored during the
retraction motion. The retracting movement takes place with BRISK, i.e. without jerk limitation.
The maximum time available for retraction is the sum of the following delay times:
● MD21380 $MC_ESR_DELAY_TIME1 (delay time, ESR axes)
● MD21381 $MC_ESR_DELAY_TIME2 (delay time, ESR axes)
After the delay time has expired, fast braking is also initiated for the retraction axis with
subsequent tracking.

Boundary conditions
Retraction and/or rapid lift is not executed for the following axes:
● Axes, which are not permanently assigned a channel
● Axes, which are in the open-loop speed-controlled mode (spindles)
● Axes, which are interpolated as positioning spindles (SPOS/SPOSA)
Modulo rotary axes respond to rapid lift as follows:
● For incremental programming of the target position, the latter is approached without modulo
offset.
● With absolute programming, the target position is approached time-optimized with the use
of modulo offsets. This is almost identical to positioning via the shortest path.
The retraction movement is interpolated linearly, using the maximum acceleration and speed
of the axes involved in POLFLIN.
Only one linear retraction is permitted in each channel. This means that multiple axis groups,
which approach their retraction positions linearly, cannot be created in the channel.
In parallel with linear retraction, additional axes can also use POLFMASK for independent axial
retraction movement to their programmed retraction positions.
If axes are used in both POLFMASK and in POLFMIN, it should be noted that the last state
programmed is always active for retracting movement. This means that an axis previously
activated with POLFMIN is removed from the linear relationship following programming in
POLFMASK and the retracting movement would then take place as an independent movement
(see the examples in Chapter "Lift fast with linear relation of axes (Page 506)").
The parameters valid at the triggering time are decisive for the retraction movement. If one of
these parameters (POLF, POLFMASK, POLFMLIN, Frame, etc.) changes during the retracting
movement (e.g. due to a block change), this change does not affect the retraction movement
that has already started.

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Supplementary conditions, path axes

If, for a path axis ESR_REACTION=21 (NC-controlled retraction) is configured and enabled
with $AC_ESR_ENABLE=1, then ESR_REACTION=22 (extended stopping) is active for all
path axes for which no ESR_REACTION=21 is configured or enabled.
Rapid lift without enabled retraction movement
If, for an axis, ESR_REACTION=21 is configured and enabled with $AC_ESR_ENABLE=1,
but e.g. no retraction motion is enabled with POLFMASK, then, for this axis,
ESR_REACTION=22 is active (extended stopping).
Examples for the behavior of path axes for different enable signals
"NC-controlled retraction" is configured for path axes X and Y:
● ESR_REACTION[X] =21
● ESR_REACTION[Y] =21
1. "Extended stop and retract" and retraction motion is enabled for both path axes:
– $AA_ESR_ENABLE(X)=1
– $AA_ESR_ENABLE(Y)=1
– POLFMASK(X,Y)
For rapid lift, X and Y execute the programmed retraction motion.
2. "Extended stop and retract" is only enabled for one path axis, but retraction motion is
enabled for both path axes:
– $AA_ESR_ENABLE(X)=0
– $AA_ESR_ENABLE(Y)=1
– POLFMASK(X,Y)
For rapid lift, for axis X, due to the path interrelationship, in spite of the fact that it is not
enabled, "extended stopping" corresponding to ESR_REACTION = 22 is executed.
Axis Y executes the programmed retraction motion.
3. However, for both path axes, "Extended stop and retract" is enabled – but retraction motion
only for one path axis:
– $AA_ESR_ENABLE(X)=1
– $AA_ESR_ENABLE(Y)=1
– POLFMASK(Y)
For rapid lift, for axis X, due to the path interrelationship, in spite of the missing enable
signal, retraction motion "extended stopping" corresponding to ESR_REACTION = 22 is
executed.
Axis Y executes the programmed retraction motion.

Responses to stop and axis enable signals

Stop behavior for the retracting movement in response to "Axial feed stop" and "Feed disable"
signals are defined with the following channel-specific machine data:

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MD21204 $MC_LIFTFAST_STOP_COND

Bit Value Description

0 Response to the axial NC/PLC interface signal DB31 DBB4.3 (feed stop) or context-sensitive
interpolator stop.
0 Retraction motion stop for axial feed stop or context-sensitive interpolator stop
1 No retraction motion stop for axial feed stop or context-sensitive interpolator stop
1 Response to the channel-spec. NC/PLC interface signal DB21 DBB6.0 (feed disable)
0 Retraction motion stop for feed disable in the channel
1 No retraction motion stop for feed disable in the channel

Note
Influence of the interface signals
● The axial NC/PLC interface signal DB31 DBB4.3 (feed stop) influences the complete
retraction motion. All axis motion defined using POLFMASK and POLFMLIN are stopped.
● The NC/PLC interface signal, DB21 DBB7.3 (NC stop) has no effect on the retraction
movement.

Programming
The destination position for the retraction axis is programmed with the language command:

Retraction position POLF

The retraction position for geometry and channel axes is programmed using the POLF program
command. The retraction position can be specified either absolutely or incrementally. When
the retraction position is incrementally specified, the effective retraction position is obtained
from the actual position of the axis at the time of rapid lift plus the programmed retraction
distance.
● Absolute: POLF[<axis name>] = <retraction position>
● Incremental: POLF[<axis name>] = IC(<retraction distance>)
POLFis modal.
Geometry axes
The retraction positions of geometry and channel axes are programmed in the workpiece
coordinate system WCS. The frame valid in the channel at the time of rapid lift is taken into
account for the retraction motion.

Note
Frames with rotation
Frames with rotation influence the retraction position of geometry axes.

Machine axes
The retraction positions of machine axes are programmed in the machine coordinate system

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MCS. The frame valid in the channel at the time of rapid lift is nottaken into account for the
retraction motion.

Note
Frames with rotation
Frames with rotation do not influence the retraction position of machine axes.

For the same axis names of a channel and machine axis, retraction motion is executed in the
workpiece coordinate system.

Enable for retraction without geometrical interrelationship POLFMASK

The program command POLFMASK allows axes to be selected, which, when rapid lift is
activated, traverse independently to their position defined with POLF. A variable parameter list
can be used to select any number of axes for rapid lift; however, all axes must be located in
the same coordinate system.

Enable for retraction with linear relationship POLFMLIN

The language command POLFMLIN allows axes to be selected that when rapid lift is activated,
should travel to their position defined with POLFin a linear relationship. A variable parameter
list can be used to select any number of axes for rapid lift; however, all axes must be located
in the same coordinate system, (i.e. only geo axes). Between initiating retraction and the linear
relationship being reached, a path is traveled, which, although deviating from the programmed
path, does not quite reach the linear relation. If the constellation is unsuitable, this transition
may last as far as the end points programmed with POLF. The control optimizes to the shortest
possible transition.

General
The following sections are equally valid for POLFMASK and POLFMLIN.
The parameters valid at triggering time are decisive for the retraction movement. If one of these
parameters (G code, POLF, POLFMASK, POLFMLIN, Frame, etc.) changes during retraction
(block change), this change does not affect the retracting movement that has already been
started.
Before rapid lift to a fixed position can be enabled via POLFMASKorPOLFMLINa position must
have been programmed with POLF for the selected axes. There is no machine data for pre-
assigning the values of POLF.
During interpretation of POLFMASK or POLFMLIN, alarm 16016 is issued if POLF has not been
programmed.
If retraction is activated, the position for retraction can still be changed. However, it is no longer
possible to change the coordinate system and an attempt is rejected with an alarm 16015.
If POLF is programmed again after enabling retraction, the position at which this axis was first
programmed must be specified in the coordinate system, in which this axis was first
programmed.

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Change coordinate system

If the coordinate system is to be changed, rapid lift must first be deactivated using
POLFMASK orPOLFMLIN, and only then can programming commence with POLF in the new
coordinate system.

Deactivate rapid lift

POLFMASK or POLFMLIN without specifying an axis deactivates rapid lift for all axes activated
in the enable call.

Interactions, POLFMASK/POLFMLIN
The last data entered for a specific axis in one of the two instructions applies. For example:

Program code Description

N200 POLFLIN(X,Y,Z) ; Linear retraction motion for X, Y and Z
...
N300 POLFMASK(Z) ; Independent retraction for Z
; (no longer any linear interpolation with X and Y)
N500 POLFMLIN(X,Z) ; Linear retraction motion for X and Z
; The independent retraction of Z, activated with POLFMASK, is
; deleted. The retraction of Y, activated with POLFMLIN, is
; also deleted.
; Only X and Z carry out a retraction movement

Part program start

The retraction positions (POLF) and axial enable signals (POLFMASK, POLFMLIN) are deleted
when the part program is started. This means that the user must reprogram the retraction
positions and the axial enable signals (POLFMASK, POLFMLIN) in every part program.

9.2.6 Trigger sources

A distinction must be made between the ESR trigger sources on a user-for-user basis by
evaluating system variables. This is the reason that all system variables are available, which
can be read in synchronized actions.

General trigger sources

● Digital inputs of the NCU module or the internal control image of digital outputs that can be
read back: $A_IN, $A_OUT
● Channel status: $AC_STAT
● NC/PLC interface signals

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● System variables written from the PLC: $A_DBB, $A_DBW, $A_DBD

It is not recommended to use these system variables, written by the PLC for time-critical
signals, as in this case, the PLC cycle time is included in the total response time.
Nevertheless, it is an appropriate way for the PLC to influence the sequence or release of
the extended stop and retract function. However, linking-in PLC states in such a fashion
does make sense if these are exclusively input from the PLC (e.g. Emergency-Stop, reset
button, stop button)
● Group signals from alarms: $AC_ALARM_STAT

Axial trigger sources

● $VA_SYNCDIFF[<following axis>] (synchronism difference, on the actual value side)
● $AA_ESR_STAT (axial return signal word: ESR status)

Alarm responses
When ESR is active, the alarm responses NOREADY and STOPBYALARM are delayed by
one IPO cycle. The self-clearing alarm is displayed to indicate this delay:
Alarm 21600 "Monitoring for ESR active".

Note
The display of this alarm can be suppressed by:
MD11410 $MN_SUPPRESS_ALARM_MASK, bit16 = 1

9.2.7 Logic gating functions: Source and reaction linking

The flexible logic operation possibilities of the static synchronized actions can be used to trigger
specific reactions based on sources. Linking all relevant sources using static synchronized
actions is the responsibility of the user/machine manufacturer. They can selectively evaluate
the source system variables as a whole or by means of bit masks, and then make a logic
operation with their desired reactions. The static synchronous actions are effective in all
operating modes. A detailed description of how to use synchronous actions can be found in:
References:
● Function Manual, Synchronized Actions
● Programming Manual Work Preparation (Synchronized Actions, System Variables)
Linking of axial sources with global or channel specific sources can be configured variably with
the aid of $AA_TYP (axis type).

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9.2.8 Activation

Option
The function "Extended stop and retract" is an option.

Axis-specific function enable ($AA_ESR_ENABLE)

The axis-specific function enable is realized using the system variable:
$AA_ESR_ENABLE[<axis>] = 1

Axis-specific enable for extended stopping

An axis is enabled for extended stopping with:
MD37500 $MA_ESR_REACTION[axis] = 22

Axis-specific enable for retraction

An axis is enabled for retraction using:
MD37500 $MA_ESR_REACTION[axis] = 21

Channel-specific trigger ($AC_ESR_TRIGGER)

ESR is triggered on a channel-for-channel basis by setting the following system variable:
$AC_ESR_TRIGGER = 1
ESR is then realized in all channel axes for which the following applies:
$AA_ESR_ENABLE[<axis>] == 1 AND MD37500 $MA_ESR_REACTION[axis] == 21 OR 22

9.2.9 Configuring aids for ESR

Voltage failure
For the following modules, when the line voltage fails, the power supply must be maintained
using suitable measures at least until it is ensured that the axes have come to a stop:
● SINUMERIK 840D sl NCU 7x0
● SINUMERIK NCU I/O modules
● SIMATIC PLC I/O modules
● SINAMICS drive system S120 (booksize)

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DC link energy
The energy available in the DC link of the drive units when the line supply fails is calculated
as follows:

E = 1/2 * C * (VDC linkalarm2 - VDC linkmin2)

E: Energy in Wattseconds [Ws]
C: Total capacity of intermediate circuit in Farad [F]
VDClinkalarm: DC link voltage below which an undervoltage is identified.
SINAMICS Parameter: r0296 + p0279
VDClinkmin: Lower limit of the DC link voltage for safe and reliable operation, tak‐
ing into account the motor-specific EMF.
Note VDC linkmin > VDC linkoff
This energy is available for a minimum time of tmin:

tP = E / Pn * η
E: Energy in Wattseconds [Ws]
tP: Buffer time in milliseconds [ms]
Pn: Power in kilowatt [kW]
η: Efficiency of the drive unit

Example
Assumptions:
● Pn = 16 kW, infeed (ALM) with 3-ph. 380 VAC
● C = Cis - 20% = 20,000 µF - 20% = 16,000 µF = 16 * 10-3 F, for safety, a 20% lower effectively
available capacity is assumed.
● VDC linkalarm = 550 V
● VDC linkmin = 350 V

E = 1/2 * 16*10-3 F * ( (550 V)2 - (350 V)2 ) = 1440 Ws

This energy is available for a time tmin, e.g. for a retraction:
● E = 1440 Ws
● Pn = 16 kW
● η = 0.9 (assumption)

tPmin = 1440 Ws / 16 kW * 0.9 = 81 ms

The following table shows a summary of the values for various SINAMICS infeeds (ALMs).
Whereby, the nominal (Cmax) and minimum (Cmin) capacitance are taken into account.
The total capacitance of the DC link available is made up, taking into account the respective
maximum capacitance Cmax (charge limit), from the capacitances of the infeed (ALM), the motor
modules as well as any capacitor modules.

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The capacitance specified in the table for the minimum energy content (Emin for Cmin) takes into
account a component tolerance of -20% (worst case).

Note
It is recommended that the SIZER configuration tool be used to determine the total capacitance
of the DC link available.

Table 9-1 SINAMICS infeeds (ALMs): Nominal and minimum buffer times

ALM Max. capacitance Energy content Energy content Emin Backup time tPmax Buffer time tPmin for
Pmax [kW] Cmax[μF] Emax for Cmax [Ws] for Cmin [Ws] for Pmax [ms] Pmax [ms]

16 20000 1800 1440 101,25 81,00

36 20000 1800 1440 45,00 36,00
55 20000 1800 1440 29,46 23,56
80 20000 1800 1440 20,25 16,20
120 20000 1800 1440 13,50 10,80

Energy balance
When configuring retraction motion, it is always necessary to consider the energy flow
(balance) to find out whether an additional capacitor module or a generator axis (with
correspondingly dimensioned flywheel effect) is required - or not.

Stopping as energy supply

From approx. the third interpolator clock cycle, the speed setpoints of the configured stopping
or retraction axes change. After this time the braking phase starts (if no drive independent
shutdown is projected for this axis).
As soon as the braking process is initiated, the energy released in this manner is available for
retraction motion. An energy balance must be used to ensure that the kinetic energy of the
braking axes is sufficient for retraction.
The energy balance shows the maximum setting for the interpolator clock cycle time, which
will allow a safe emergency retraction to be executed.

Example
With a 16 kW unit under maximum load and minimum intermediate circuit capacity it should
be possible to execute an emergency retraction without generator operation. Interpolator clock
cycle time may theoretically not be more than 4.86 ms, i.e. in this case a maximum of 4 ms
could be set.
If necessary, a more powerful NCU must be chosen in order to achieve optimal conditions.

Special functions
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Generator operation
For cases in which the DC link energy is not sufficient for safe and reliable retraction (minimum
3 IPO cycles), generator operation can be configured for a drive using the SINAMICS "Vdc
control" function. In this case, the mechanical energy of an axis is fed back into the DC link.
The energy stored in an axis can be calculated as follows:

E = 1/2 * Jtot * ω2
Jtot Total moment of inertia [kg*m2]
ω Angular velocity at the time of switchover to generator operation [s-1]
This energy is fed back into the DC link with an efficiency of approx. 90%:
When using infeeds with a high power rating (55, 80, 120 kW) for generator operation, it is
recommended to use a dedicated axis with additional flywheel effect. For this axis, after the
drive has accelerated to the rated speed, energy is only required to compensate for friction
losses.
However, in principle, any axis can be used for generator operation, if this is not directly
involved in extended stopping and retraction or in couplings that must be specifically
maintained.
In order to prevent that the DC link voltage does not become too high when using generator
operation (limit value: pulse cancelation, drive) and as a consequence that the pulses are
canceled for the axes, adequately dimensioned pulsed resistor modules must be used or the
SINAMICS function "Vdc control, overvoltage monitoring".

9.2.10 Control system response

9.2.10.1 Axis behavior depending on the enable signals

Systematic
If an axis is configured as NC-controlled retraction axis:
MD37500, $MA_ESR_REACTION[<axis>] = 21
The following enable signals must be available to execute retraction motion in the case of ESR:
● Axial ESR enable using system variable: $AA_ESR_ ENABLE[<axis>] = 1
● Axial retraction enable using a part program command: POLFMASK(<axis>)

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If one of the two enable signals is not available, then in the case of ESR, the axis responds
corresponding to the following table:

Enable signals Response in the case of ESR

● $AA_ESR_ ENABLE[<axis>] = 1 For the axis, implicit NC-controlled stopping becomes active, corresponding
to MD37500, $MA_ESR_REACTION[<axis>] = 22.
● No enable via POLFMASK
● $AA_ESR_ ENABLE[<axis>] = 0 Axis is a path axis:
For the axis, the ESR response is implicitly changed to NC-controlled stop‐
● Enable via POLFMASK(<axis>)
ping. The response corresponds then to a configuration of MD37500,
$MA_ESR_REACTION[<axis>] = 22
Axis is a special axis:
The axis is stopped with rapid stop.

Examples for axes with path relationship

For the subsequent examples, two path axes X and Y are assumed, which are configured as
NC-controlled retraction axes and are programmed for the retraction positions:
● MD37500, $MA_ESR_REACTION[X] = 21
● MD37500, $MA_ESR_REACTION[Y] = 21
● POLF[X]=<retraction position> LFPOS
● POLF[Y]=<retraction position> LFPOS

Initial situation Response in the case of ESR

● $AA_ESR_ ENABLE[X] = 1 Retraction motion in X and Y.
● $AA_ESR_ ENABLE[Y] = 1
● POLFMASK(X,Y)
● Program traversing motion: Y
● $AA_ESR_ ENABLE[X] = 0 X does not have ESR enable. As X is a path axis, for X, the ESR response
is implicitly changed to 22 (stopping). This is the reason that X continues to
● $AA_ESR_ ENABLE[Y] = 1
traverse corresponding to the programmed traversing motion.
● POLFMASK(X,Y)
Y executes retraction motion.
● Program traversing motion: X and Y After the delay time for ESR axes expires, MD21380, $MC_ESR_DE‐
LAY_TIME1, X is stopped with the path acceleration.
● $AA_ESR_ ENABLE[X] = 1 X has no retraction enable (POLFMASK). X does not execute any retraction
motion. As X is a path axis, for X, the ESR response is implicitly changed to
● $AA_ESR_ ENABLE[Y] = 1
22 (stopping). This is the reason that X continues to traverse corresponding
● POLFMASK(Y) to the programmed traversing motion.
● Program traversing motion: X Y executes retraction motion.
After the delay time for ESR axes expires, MD21380, $MC_ESR_DE‐
LAY_TIME1, X is stopped with the path acceleration.
● $AA_ESR_ ENABLE[X] = 1 Y has not been enabled for retraction (POLFMASK). see lines above, syntax
Y does not execute retraction motion. As Y is a path axis, for Y, the ESR
● $AA_ESR_ ENABLE[Y] = 1
response is implicitly changed to 22 (stopping). This is the reason that Y
● POLFMASK(X) continues to traverse corresponding to the programmed traversing motion.
● Program traversing motion: X and Y X executes retraction motion.
After the delay time for ESR axes expires, MD21380, $MC_ESR_DE‐
LAY_TIME1, Y is stopped with the path acceleration.

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Examples for axes without path relationship

For the subsequent examples, path axes X and a command axis B are assumed, which are
configured as NC-controlled retraction axis:
● MD37500, $MA_ESR_REACTION[X] = 21
● MD37500, $MA_ESR_REACTION[B] = 21

Initial situation Response in the case of ESR

● $AA_ESR_ ENABLE[X] = 1 B is not enabled for ESR. As B is not a path axis, B is immediately stopped
with a rapid stop.
● $AA_ESR_ ENABLE[B] = 0
X executes retraction motion.
● POLFMASK(X)
● Program traversing motion: X and B
● $AA_ESR_ ENABLE[X] = 1 B is not enabled for retraction (POLFMASK). However, as B is enabled for
ESR, for B, the ESR response is implicitly changed to 22 (stopping). This is
● $AA_ESR_ ENABLE[B] = 1
the reason that B continues to traverse corresponding to the programmed
● POLFMASK(X) traversing motion.
● Program traversing motion: X and B Y executes retraction motion.
After the delay time for ESR axes expires, MD21380, $MC_ESR_DE‐
LAY_TIME1, B is stopped with axial acceleration.

9.2.10.2 POWER OFF/POWER ON

If the user-specific retraction logic is programmed within motion synchronized actions, then it
must be observed that this is still not active when the control boots (POWER ON). A retraction
logic, which should be active after POWER ON, must therefore lie in an ASUB started from
the PLC or must be called event-controlled.

References
For detailed information about event-driven program calls see:
Function Manual, Basic Functions; Mode Group, Channel, Program Operation, Reset
Response (K1), Section: Eventcontrolled program calls

9.2.10.3 Operating mode change, NC Stop, reset

Static synchronized actions (IDS keyword) can be used for user-specific retraction logic as the
following system states or state change have no influence on this:
● Operating mode change, e.g. DB11 DBX0.0 (AUTOMATIC)
● NC stop, e.g. DB21, ... DBX7.3 (NC stop)
● Reset, e.g. DB21, ... DBX7.7 (reset)

Special functions
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Note
NC stop and command axes
Traversing command axes is interrupted for an NC stop.

Note
POLF/POLFMASK reset and program commands
For reset, the programmed absolute retraction positions (POLF) and the enable signals for the
retraction axes (POLFMASK) are not deleted.

9.2.10.4 Part program start, NC start

In order that a defined initial state is available when a part program starts, the programmed
absolute retraction positions and the enable signals of the retraction axes are deleted when
the part program starts.

Note
Retraction positions and enable signals
When a part program starts, the absolute retraction positions (POLF) and the enable signals
of the retraction axes (POLFMASK) must be reprogrammed corresponding to the actual
requirements.

9.2.10.5 Alarm behavior

The alarm response depends on the axis in which a fault occurs:
● Fault in an axis outside the axis grouping of an electronic gear:
This axis switches off "normally". Extended stopping and retraction continue to operate as
before - or are initiated by such a fault.
● Error in a leading axis (LA):
selective switchover to actual value linkage already during stop, otherwise as previously.
● Error in a following axis (FA):
– Carry out retract: Retraction axis may not be a following axis, that is, no conflict.
– Carry out stop: The following axis may react with uncontrollable behavior. Saving the
workpiece/tool must be left to the retraction; however, the stop should not disrupt the
process any further.

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● Error in the retraction axis: There is no retraction.

● Emergency Stop
An Emergency Stop is not a fault from a control system point of view, rather the response
is the same as for any other control signal. For safety reasons, Emergency Stop interrupts
the interpolation and all traversing motion, and also cancels the electronic coupling by
withdrawing the controller enable signals.
In applications where the coupling and traversing movements must remain valid after
Emergency Stop, the PLC must delay the Emergency Stop long enough for the required
NC or drive-end reactions to terminate.
The following interface signal is available as feedback signal to the PLC:
IS "ESR reaction not initiated" DB31, ... DBX98.7
If an alarm with cross-channel NOREADY reaction is issued during the active phase of the
ESR (i.e. NOREADY | NCKREACTIONVIEW | BAGREACTIONVIEW), then ESR is triggered
in all channels.

9.2.10.6 Block search, REPOS

Extended stop and retract does not affect block search or REPOS motions.

9.3 ESR executed autonomously in the drive

9.3.1 Fundamentals

Function
Drive-autonomous extended stop and retract (ESR) enables the fast separation of workpiece
and tool independent of the higher-level control (NC).
For this purpose, the following axial functions can be configured in the drive:
● Generator operation
● Extended stop
● Retract
The drive-autonomous responses are automatically initiated in error situations. The triggering
of the drive-autonomous responses can also be realized user-specific via the part programs
or synchronized actions from the higher-level control system.
As the stopping and retraction motion of the drive-autonomous ESR are purely axial, in contrast
to control-managed ESR, couplings are not taken into account.

Special functions
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ESR executed autonomously in the drive can also be used in combination with control-
managed ESR. This also allows stopping and retraction motion in the drives if they are no
longer specified from the control, e.g. as a result of a communication failure.

Note
DRIVE-CLiQ
For possibly occurring DRIVE-CLiQ errors, in order to keep the reaction to the functions of the
drive-autonomous ESR as low as possible, within the scope of ESR, we recommend that the
motor modules involved are not connected through a line-type topology, but instead are directly
connected to the Control Unit (CU).
Link axes
The "Drive-autonomous extended stop and retract (ESR)" function cannot be used in
conjunction with link axes.

Requirements
The following conditions must be fulfilled:
● SINAMICS and SINUMERIK software version: ≥ V4.4
● Servo drive object, PROFIdrive telegram: 102 - 199
● Servo drive object, function module "ESR" active
The function module "Extended stop and retract (ESR)" must be activated via the drive
wizard of SINUMERIK Operate. For a description of the drive wizard, see: SINUMERIK
Operate online help.
● Servo drive object, generator operation (Vdc control) active in a drive
● Control unit drive object, PROFIdrive telegram: 390, 391
● The 24 V power supply for the modules is buffered via CSM or UPS

9.3.2 Configuring stopping in the drive

Drive integrated shutdown is configured via the following drive parameters:

Parameter Description
p0888 ESR: Configuration
Value Meaning
1 Extended stopping (function integrated in the drive)

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Parameter Description
p0891 ESR: Off ramp
Value Meaning
0 OFF3 (default)
The drive is braked along the OFF3 down ramp by immediately entering n_set
= 0 (p1135: OFF3 ramp-down time).
1 OFF1
By immediately entering n_set = 0, the drive is braked along the ramp gener‐
ator down ramp (p1121: ramp-function generator ramp-down time).

Parameter Description
p0892 ESR: Timer
The drive travels at a constant velocity for the configured time with the speed setpoint
that was present when the fault occurred.

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7 7 7LPHW

T1 Time at which stopping was triggered

T2 Instant in time after the time that was configured in p0892 has expired
OFF3/OFF1 Braking ramp as a function of p0891

Figure 9-3 Response to drive-integrated stopping

Feedback signal
The stop status is returned to the control (see Section "Feedback of the ESR status
(Page 494)").

References
For a detailed description of drive parameters, refer to:
SINAMICS S120/S150 Parameter Manual

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9.3.3 Configuring retraction in the drive

Drive integrated retraction is configured using the following drive parameters:

Parameter Description
p0888 ESR: Configuration
Value Meaning
2 Extended retraction (function integrated in the drive)

Parameter Description
p0891 ESR: Off ramp
Value Meaning
0 OFF3 (default)
The drive is braked along the OFF3 down ramp by immediately entering n_set
= 0 (p1135: OFF3 ramp-down time).
1 OFF1
By immediately entering n_set = 0, the drive is braked along the ramp gener‐
ator down ramp (p1121: ramp-function generator ramp-down time).

Parameter Description
p0892 ESR: Timer
The parameter specifies the total time that elapses to reach the speed specified in
p0893 followed by constant velocity travel.
This is followed by an OFF1 or OFF3 ramp depending on the parameterization in p0891.

Parameter Description
p0893 ESR: Speed
The parameter specifies the speed (retraction speed) that is reached when initiating
retraction via an OFF3 ramp.

Special functions
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6SHHGQ
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$86
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$86 $86

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T1 Instant in time that retraction was initiated

T2 Instant in time when the retraction speed specified in p0893 is reached
T3 Instant in time after the time that was configured in p0892 has expired

Figure 9-4 Behavior for drive-integrated retraction

Feedback signal
The retract status is returned to the control (see Section "Feedback of the ESR status
(Page 494)").

References
For a detailed description of drive parameters, refer to:
SINAMICS S120/S150 Parameter Manual

9.3.4 Configuring generator operation in the drive

The generator mode for the drive-autonomous ESR is configured using the following drive
parameters:

Parameter Description
p0888 ESR: Configuration
Value Meaning
3 Generator operation (Vdc controller)

Parameter Description
p1240 Vdc controller or Vdc monitoring configuration
Value Meaning
2 When reaching the lower DC link voltage threshold (p1248) - for ESR - the
motor is braked in order to utilize its kinetic energy to buffer the DC link.

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Parameter Description
p1248 Lower DC link voltage threshold
Setting the lower threshold for the DC link voltage. For p1240 = 2, this threshold is used
as setpoint limit for the Vdc_min controller.

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p1244 Upper DC link voltage threshold

p1248 Lower DC link voltage threshold
r0208 Rated power unit line supply voltage.
The pulses are canceled if the DC link voltage drops below 0.9*r0208
T1 Instant in time at which generator operation was triggered
T2 Instant in time at which generator operation was exited

Figure 9-5 Configuring_drive_integrated_generator_operation

Generator minimum speed

The lower limit of the motor speed of the generator axis is configured using drive parameter
p2161:

Parameter Description
p2161 Speed threshold value 3
Speed threshold value for the message: |n_act| < speed threshold value 3

Feedback signal
The generator operation status is returned to the control (see Section "Feedback of the ESR
status (Page 494)").

References
A detailed description of drive parameters and the Vdc control can be found in:
● SINAMICS S120/S150 List Manual
● SINAMICS S120 Function Manual; Section "Servo control" > "Vdc control"

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9.3.5 ESR is enabled via system variable

The ESR response of an axis, configured via drive parameter, must be programmed on a user-
specific basis in a part program/synchronized action using the following axis-specific system
variable:

$AA_ESR_ENABLE[<axis>]
Value Meaning
1 ESR responses enabled in the drive
0 ESR responses inhibited in the drive

9.3.6 Triggering ESR via system variable

Triggering ESR responses, configured via drive parameter and enabled via
$AA_ESR_ENABLE[<axis>], must be programmed on a user-specific basis in a part program/
synchronized action via the following NC-specific system variable:

$AN_ESR_TRIGGER
Value Meaning
1 trigger drive-integrated ESR reactions that have been released
0 do not trigger drive-integrated ESR reactions that have been released

Note
The trigger signal must be active in the part program/synchronized action for at least 2 IPO
cycles to ensure that the PROFIdrive telegram is transferred to the drive.

Mapping in the drive unit

System variable $AN_ESR_TRIGGER is mapped to drive parameter p0890.0. Interconnecting
drive parameter p0890.0 with the corresponding information in telegram 390 or 391 to the
Control Unit is realized automatically when the drive unit commissions the ESR reactions.

References
For a detailed description of drive parameters, refer to:
SINAMICS S120/S150 List Manual

9.3.7 Feedback of the ESR status

The drive signals back the actual ESR status to the control using the message word (MELDW)
of the cyclic PROFIdrive telegram. In the PLC, the status can be read via system variables
and NC/PLC interface signals.

Special functions
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System variable
The system variables can be evaluated in the part program / synchronized action, for example,
in order to trigger the drive-autonomous ESR (see Section "Triggering ESR via system
variable (Page 494)") or to acknowledge the ESR reactions triggered in the drive (see Section
"Acknowledge ESR reactions (Page 495)").

Interrelationship between signals

MELDW System variable NC/PLC interface signal Meaning

MELDW.Bit 9 $AA_ESR_STAT.Bit 2 DB31, … DBX95.2 ESR: Reaction triggered or generator operation
(r0887.12) active (r0887.12)
MELDW.Bit 4 $AA_ESR_STAT.Bit 3 DB31, … DBX95.1 ESR: DC link undervoltage (p1248)
(r0056.15)
MELDW.Bit 2 $AA_ESR_STAT.Bit 4 DB31, … DBX95.3 ESR, generator operation: Speed lower than min‐
(r2199.0) imum (p2161)

9.3.8 Acknowledge ESR reactions

Acknowledging axis-specific drive-independent ESR reactions must be programmed on a user-
specific basis in a part program/synchronized action. After the ESR reaction in the drive has
been completed, an edge change must be generated in the system variables
$AA_ESR_ENABLE: 1→0→1. In order that the drive-integrated ESR reactions can be
retriggered, the system variable $AN_ESR_TRIGGER must also be reset to a value of 0.

Special functions
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System variable and drive parameters

The following diagram shows the relationship between system variables and drive parameters
when triggering and acknowledging ESR reactions.

 

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① NC: Enabling the ESR reaction via $AA_ESR_ENABLE = 1 (axis-specific)

② NC: Triggering ESR responses via $AN_ESR_TRIGGER = 1
③ Drive: The triggering of the ESR reaction has been detected (CU_STW.2 == 1) ⇒
r0887.12 = 1 AND r0887.13 = 1
Feedback signal to the NC via $AA_ESR_STAT.BIT2 = 1 (axis-specific)
④ NC: Acknowledging the ESR reaction via $AA_ESR_ENABLE = 0 (axis-specific)
Black: At instant in time ④, the ESR reaction no longer runs (r0887.13 == 0) ⇒
⑤ Drive: Reset "ESR triggered": r0887.12 = 0
Feedback signal to the NC via $AA_ESR_STAT.BIT2 = 0 (axis-specific)
⑥ NC: The ESR reaction can be re-enabled ⇒
$AA_ESR_ENABLE = 1 AND $AN_ESR_TRIGGER = 0
Red: At instant in time ④, the ESR reaction still runs (r0887.13 == 1) ⇒
⑤ Drive: "ESR initiated" is only reset (r0887.12 = 0), if the ESR response in the drive has been
completed: r0887.13 == 0
Feedback signal to the NC via $AA_ESR_STAT.BIT2 = 0 (axis-specific)
⑥ See ⑥ above

Figure 9-6 Sequence: Trigger and acknowledge drive-integrated ESR reactions

9.3.9 Configuring ESR in the part program

Configuring drive-autonomous ESR functions "stop" and "retract" can be changed using the
commands from the part program described in the following.

Special functions
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9.3.9.1 Stopping (ESRS)

Syntax
ESRS(<access_1>,<stopping time_1>[,...,<axis_n>,<stopping time_n>])

Meaning

ESRS: Using the function, drive parameters can be changed regarding the drive-au‐
tonomous "stop" ESR function.
Special situations:
● Must be alone in the block
● Triggers a preprocessing stop
● Cannot be used in synchronized actions
● A maximum of five axes can be programmed per function call; n = 5
<axis_n>: For the specified axis, writes to drive parameter p0888 (configuration): p0888
=1
Data type: AXIS
Range of values: Channel axis name
<stopping For the axis specified under <Axis_n>, writes to drive parameter p0892 (tim‐
time_n>: er): P0892 = <stopping time_n>
Unit: s
Data type: REAL
Range of values: 0.00 - 20.00

9.3.9.2 Retraction (ESRR)

Syntax
ESRR(<axis_1>,<retraction distance_1>,<retraction
velocity_1>[,...,<axis_n>,<retraction distance_n>,<retraction
velocity_n>])

Special functions
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Meaning

ESRR: Using the function, drive parameters can be changed regarding the drive-au‐
tonomous "retract" ESR function.
Special situations:
● Must be alone in the block
● Triggers a preprocessing stop
● Cannot be used in synchronized actions
● A maximum of five axes can be programmed per function call; n = 5
<axis_n>: For the specified axis, writes to drive parameter p0888 (configuration): p0888
=2
Data type: AXIS
Range of values: Channel axis name
<retraction For the axis specified under <Axis_n>, writes to drive parameter p0893 (re‐
velocity_n>: traction speed):
p0893 = (<retraction velocity> based on the currently effective total transmis‐
sion ratio converted into the corresponding retraction speed)
Unit: mm/min, inch/min, degrees/min (depending on the unit of
the axis)
Data type: REAL
Range of values: 0.00 - MAX
<retraction For the axis specified under <Axis_n>, writes to drive parameter p0892 (re‐
distance_n>: traction time):
p0892 = <retraction distance_n> / <retraction velocity _n>
Unit: mm, inches, degrees (depending on the unit of the axis)
Data type: REAL
Range of values: MIN - MAX

Note
Retraction speed
It should be ensured that the drive can reach the programmed retraction speed (see
parameters <retraction velocity_n>) within the retraction time (see parameter <retraction
distance _n>). The settings in the following drive parameters should be checked:
● p1082[0...n] (maximum speed)
● p1135[0...n] (OFF3 ramp-down time)
Retraction path
The conversion of the retraction path into a retraction duration for drive parameter p0892 is
performed under the assumption that the retraction motion is triggered at axis standstill (see
"Figure 9-5 Configuring_drive_integrated_generator_operation (Page 493)").
If retraction motion is triggered while the axis is traversing, the actually traversed retraction
distance differs from the programmed retraction distance due to the fact that traversing motion
is superimposed on the retraction motion.

Special functions
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Dependencies
The programmed values for the retraction path and the retraction velocity refer to the load side.
Before writing to the drive parameters these are converted over to the motor side. The
transmission ratio effective in the NC at the execution time is applicable for the conversion. If
the drive-autonomous ESR for an axis is enabled ($AA_ESR_ENABLE[<axis>] == 1), then it
is not permissible to change the axial transmission ratio.

Note
Changing the transmission ratio
If the drive-autonomous ESR is not enabled for an axis ($AA_ESR_ENABLE[<axis>] == 0),
then the axial transmission ratio can be changed. After the change, it is the sole responsibility
of the user/machine manufacturer to appropriately adapt the retraction distance and the
retraction velocity.

See also
Configuring generator operation in the drive (Page 492)

9.3.9.3 Boundary conditions

Consistent parameter change

In order that the drive parameters are consistently effective, in the part program the drive-
autonomous ESR enable signals must be withdrawn before the functions ESRS(...) and
ESRR(...).
Example:

Program code Comment

N100 $AA_ESR_ENABLE[X1]=0 ; Withdraw ESR enable signals
N110 $AA_ESR_ENABLE[Z1]=0
N120 $AA_ESR_ENABLE[Y1]=0

N130 ESRR(X1,20.0,10000.0,Z1,-15.0,20000.0) ; Change ESR parameters

N140 ESRS(Y1,0.5,B1,0.5)

N150 $AA_ESR_ENABLE[X1]=1 ; Set ESR enable signals

N160 $AA_ESR_ENABLE[Z1]=1
N170 $AA_ESR_ENABLE[Y1]=1

When executing the functions ESRS(...) and ESRR(...) further execution of the part
program is stopped until writing to the drive parameters has been acknowledged. During this
time, the following message is used as feedback signal for the user: "Wait for drive parameters
from <Function>" is displayed.

Block search with calculation

During the block search with calculation, the functions ESRS(...) and ESRR( ... ) are
collected and executed in the action block.

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9.3 ESR executed autonomously in the drive

Block search with calculation in "Program test" (SERUPRO) mode

During SERUPRO, the functions ESRS(...) and ESRR( ... ) are executed immediately.

Reset behavior
The parameter values written using the functions ESRS(...) and ESRR(...) are
overwritten with the parameter values saved in the drive when the drive runs up or for a drive
warm restart.
Drive parameters can be saved from the HMI user interface or in the drive. From the HMI user
interface:
● Operating area "Commissioning" > "Machine data" > "Drive MD" > "Save/Reset" > "Save"
> "Drive object"or "drive unit" or " drive system"

Control power-up (POWER ON)

If the drive-autonomous ESR should already be active after the control has powered up
(POWER ON), then the programming and enable must be realized within one of the ASUBs
started from the PLC – or using the PROGEVENT mechanism.
References
For detailed information about event-controlled program calls, refer to:
Basic Functions Function Manual, Mode Group, Channel, Program Operation, Reset
Response (K1);
Chapter: Event-driven program calls

9.3.10 ESR and Safety Integrated (840D sl)

Delay times
In order that drive-integrated ESR reactions in conjunction with Safety Integrated are executed
before the safety reactions associated with STOP E, STOP F or communication failure, then
the corresponding delay times regarding safety reactions must be configured in the control
and in the drive.
Delay times are configured in the controller using the following machine data:
● MD36954 $MA_SAFE_STOP_SWITCH_TIME_E (transition time, STOP E to safe
standstill)
● MD36955 $MA_SAFE_STOP_SWITCH_TIME_F (transition time, STOP F to STOP B)
● MD36961 $MA_SAFE_VELO_STOP_MODE (stop response, safely-reduced speed)
● MD36963 $MA_SAFE_VELO_STOP_REACTION (stop response, safely-reduced speed)
● MD10089 $MN_SAFE_PULSE_DIS_TIME_BUSFAIL (wait time pulse cancellation when
the bus fails)
Delay times in the drive are configured using the following drive parameters:
● p9554 (transition time from STOP E to "Safe Operating Stop" (SOS))
● p9555 (transition time STOP F to STOP B)

Special functions
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● p9561 (SG stop response)

● p9563 (SG-specific stop response)
● p9580 (wait time after which the pulses are safely cancelled after bus failure)
● p9697 (delay time for the pulse suppression after bus failure)
● p9897 (delay time for the pulse suppression after bus failure)
Note
The drive parameters are automatically aligned with the corresponding NC machine data
using the Safety Integrated commissioning function "Copy SI data".

Trigger drive-integrated ESR reactions

The feedback signal of the safety stop reaction – currently active in the drive – sent to the
control is realized using the following axis-specific system variable:
● $VA_STOPSI[<axis>] (actual stop reaction)
By evaluating the system variable in a part program/synchronized action, a user-specific
response can be realized to the particular stop reaction of the axis, e.g. by triggering the drive-
integrated and/or control-managed ESR reactions using the system variable
$AN_ESR_TRIGGER and/or $AC_ESR_TRIGGER or $AA_ESR_TRIGGER.

References
A detailed description for configuring and the interaction of drive-integrated ESR responses
and Safety Integrated functions is given in:
References
Function Manual SINUMERIK Safety Integrated

9.3.11 ESR and Safety Integrated (828D)

No feedback signal of the safety stop reaction

Within the scope of SINUMERIK 828D, the safety stop reaction currently active in the drive is
not signaled back to the control. Therefore, in conjunction with Safety Integrated, only drive-
autonomous ESR functions can be used.
The ESR reactions triggered from the drive can be determined on the control side using the
axis-specific system variable $AA_ESR_STAT (see Chapter "Feedback of the ESR status
(Page 494)") and additional ESR reactions can be triggered on a user-specific basis via
$AN_ESR_TRIGGER.

Special functions
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9.4 Boundary conditions

ESR reactions that are not influenced by safety reactions

In order that drive-autonomous ESR reactions in conjunction with Safety Integrated are not
influenced by safety reactions as a result of STOP E, STOP F executed in parallel or
communication failure, then the appropriate delay times must be configured in the drive
regarding safety reactions and the corresponding safety trigger sources to trigger the drive-
autonomous ESR reactions.

Delay times
Delay times in the drive are configured using the following drive parameters:
● p9554 (transition time from STOP E to "Safe Operating Stop" (SOS))
● p9555 (transition time STOP F to STOP B)
● p9580 (wait time after which the pulses are safely cancelled after bus failure)
● p9697 (delay time for the pulse suppression after bus failure)

Safety trigger sources

Using a BICO interconnection of drive parameter p0890 (BI: ESR trigger) ESR reactions can
also be triggered with the safety reactions STOP E, STOP F and communication failure:

Parameter BICO interconnection Effect: Trigger ESR reactions for

with:
p0890[1] r9721[15] Safety STOP E
p0890[2] r9723[1] Safety STOP F
p0890[3] r9723[2] Safety communication failure

References
A detailed description of the drive parameters and the BICO technology can be found in:
● SINAMICS S120/S150 List Manual
● SINAMICS S120 Function Manual; Chapter "Fundamentals of drive technology" > "BICO
technology: Interconnecting signals"

9.4 Boundary conditions

Transformation
If NC-controlled extended stopping and retraction is activated for anaxis involved in an active
transformation, then extended stopping and retraction must also be activated for all other axes
involved in the transformation. Otherwise, when activating extended stopping and retraction,
it is possible that the transformation group will ungrouped.

Special functions
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9.5 Examples

Drive components
In order that the configured stopping or retraction responses can be executed, the drive
components involved must be fully functional. Axis-specific servo or drive alarms, which
indicate the failure of one of these components, are also implicitly signaling that the configured
stopping or retraction response of the axis involved is no longer available or only partially.

Motion-synchronous actions
Motion-synchronous actions are executed in the interpolator clock cycle. Increasing the
interpolator clock cycle, e.g. due to a high number of active motion-synchronous actions,
results in a coarser time grid for evaluating trigger conditions and triggering responses for
extended stopping and retraction.

9.5 Examples

9.5.1 NC-controlled reactions

Task
The A axis is to operate as the generator drive, while the X axis should retract 10 mm at
maximum velocity in the event of a fault. The Y and Z axes should stop after a delay of 100
ms so that the X retraction axis has sufficient time to cancel the mechanical coupling.
The example is performed using NC-controlled reactions.
Only the essential parts of the entire functionality are displayed.

Requirements
The following functions must be available:
● Extended stopping and retraction (ESR)
● Static synchronized actions
● Asynchronous subprograms (ASUBs)

Settings

Machine data
Axis-specific operating mode of the ESR
● MD37500 $MA_ESR_REACTION[X] = 21 (NC-controlled retraction axis)
● MD37500 $MA_ESR_REACTION[Y] = 22 (NC-controlled stop axis)
● MD37500 $MA_ESR_REACTION[Z] = 22 (NC-controlled stop axis)

Special functions
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9.5 Examples

Configuration: NC-controlled extended stop

● MD21380 $MC_ESR_DELAY_TIME1 = 0.1 (duration of the path interpolation in seconds)
● MD21381 $MC_ESR_DELAY_TIME2 = 0.04 (braking duration in seconds)

Programming

Program code Comment

LFPOS Axis-specific lift to a position
POLF[X]=IC(10) Retraction position, incremental
POLFMASK(X) Enable retraction
; Enable "Extended stop and retract"
$AA_ESR_ENABLE[X]=1 ; X axis
$AA_ESR_ENABLE[Y]=1 ; Y axis
$AA_ESR_ENABLE[Z]=1 ; Z axis

Trigger conditions and static synchronized actions

Example 1
Trigger condition is the occurrence of alarms, which activate the follow-up (tracking) mode:

Program code
IDS=02 WHENEVER ($AC_ALARM_STAT B_AND 'H2000') > 0 DO $AC_ESR_TRIGGER=1

Example 2
Trigger condition is when the ELG synchronous monitoring responds, if, e.g. Y is defined as
ELG following axis and the max. permissible synchronism difference is 100 mm:

Program code
IDS=03 WHENEVER $VA_EG_SYNCDIFF[Y] > 0.1 DO $AC_ESR_TRIGGER=1

9.5.2 Retraction while thread cutting

During thread cutting, for a fault/interruption, axis X should be retracted to the position specified
under POLF as response. Axis Z continues to traverse until it is stopped as normal.

Program code Comment

N10 G0 G90 X200 Z0 S200 M3 ;
N20 G0 G90 X170 ;
N30 POLF[X]=210 ; Retraction position axis X, absolute
N40 LFPOS ; Retraction via POLF/POLFMASK ON
N50 POLFMASK(X) ; Enable retraction, axis X
N60 LFON ; Fast retraction for thread cutting ON
; Thread cutting
N70 G33 X100 I10 ; Retraction response, axial: X (abs.)
N80 X130 Z-45 K10 ; dto.

Special functions
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9.5 Examples

Program code Comment

N90 X155 Z-128 K10 ; dto.
N100 X145 Z-168 K10 ; dto.
N110 X120 I10 ; dto.
N120 G0 Z0 LFOF ; Fast retraction for thread cutting OFF
N130 POLFMASK() ; Disable retraction of all axes

9.5.3 Rapid lift using ASUB and fast input

Activating ASUB using the LIFTFAST program command (rapid lift) via fast input 1:

Program code Comment

N10 SETINT (1) PRIO=1 ABHEB_Y LIFTFAST ; ASUB activation, fast input 1
N20 LFPOS ; Retraction via POLF/POLFMASK ON
N30 POLF[X]=19.5 POLF[Y]=33.3 ; Retraction positions axis X Y, absolute
N40 POLF[Z]=100 ; Retraction position axis Z, absolute
N50 X0 Y0 G0 ;
N60 POLFMASK(X, Y) ; Enable retraction, axis X Y
N70 Z100 G1 F1000 ; Retraction response, axial: X, Y (abs.)
N80 POLFMASK(Z) ; Disable retraction, axis X Y and
; Enable retraction, axis Z
N90 Y10 ; Retraction response, axial: Z (abs.)
N100 POLFMASK() ; Disable retraction of all axes

9.5.4 Rapid lift, absolute and incremental

Retraction to absolute positions and through an incremental distance:

Program code Comment

N10 $AA_ESR_ENABLE[X]=1 ; Enable retraction, axis X
N20 $AA_ESR_ENABLE[Z]=1 ; Enable retraction, axis Z
N30 $AA_ESR_ENABLE[Y]=1 ; Enable retraction, axis Y
N40 LFPOS ; Retraction via POLF/POLFMASK ON
N50 POLF[X]=IC(3.0) POLF[Y]=-4.0 ; Retraction position axis X, incremental
; Retraction position axis Y, absolute
N60 POLF[Z]=100 ; Retraction position axis Z, absolute
N70 G0 X0 Y0 Z0 ;
N80 POLFMASK(X, Y) ; Enable retraction, axis X Y
N90 Z100 G1 F1000 ; Retraction response, axial: X (inc.), Y (abs.)
N100 POLF[X]=10 ; Retraction position axis X, absolute
N110 Y0 G1 F1000 ; Retraction response, axial: X, Y (abs.)
N120 POLFMASK(Z) ; Disable retraction, axis X Y and
; Enable retraction, axis Z
N130 Y10 ; Retraction response, axial: Z (abs.)

Special functions
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9.6 Data lists

Program code Comment

N140 POLFMASK() ; Disable retraction of all axes

9.5.5 Lift fast with linear relation of axes

Retracting in a linear relationship, absolute and incremental

Program code Comment

N10 $AA_ESR_ENABLE[X]=1 ; Enable retraction, axis X
N20 $AA_ESR_ENABLE[Y]=1 ; Enable retraction, axis Y
N30 $AA_ESR_ENABLE[Z]=1 ; Enable retraction, axis Z
N40 LFPOS ; Retraction via POLF/POLFMASK ON
N50 POLF[X]=IC(3.0) POLF[Z]=-4.0 ; Retraction position axis X, incremental
; Retraction position axis Z, absolute
N60 POLF[Y]=100 ; Retraction position axis Z, absolute
N70 X0 Y0 Z0 G0 ; ---
N80 POLFMLIN(X, Y) ; Enable retraction, axis X Y, linear
; Relationship
N85 POLFMASK(Z) ; Enable retraction, axis Z
N90 Z100 G1 F1000 ; Retraction response:
; - linear relation: X (inc.), Y (abs.)
; - axial: Z (abs.)
N95 POLF[X]=10 ; Retraction position axis X, absolute
N100 Y0 G1 F1000 ; Retraction response:
; - linear relation: X (inc.), Y (abs.)
; - axial: Z (abs.)
N110 POLFMLIN() ; Disable retraction, axis X Y
N120 Y10 ; Retraction response, axial: Z (abs.)
N130 POLFMASK() ; Disable retraction of all axes

9.6 Data lists

9.6.1 Machine data

9.6.1.1 Channelspecific machine data

Number Identifier: $MC_ Description

21204 LIFTFAST_STOP_COND Stop characteristics for rapid lift
21380 ESR_DELAY_TIME1 Delay time (STOPBYALARM, NOREAD) for ESR axes
21381 ESR_DELAY_TIME2 Time for interpolatory braking of ESR axes

Special functions
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9.6 Data lists

9.6.1.2 Axis/spindlespecific machine data

Number Identifier: $MA_ Description

37500 ESR_REACTION Reaction definition with extended stop and retract

9.6.2 System variables

Identifier Meaning
$A_DBB Read/write data byte from/to PLC
$A_IN Digital input
$A_OUT Digital output
$AA_ESR_ENABLE[<axis>] Enable "Extended stop and retract"
$AA_TYP[<axis>] Axis type
$AA_ESR_TRIGGER[<axis>] Initiate ESR for PLC controlled axis (single axis)
$AC_ALARM_STAT Alarm status in the channel
$AC_ESR_TRIGGER Trigger ESR, channel-specific
$AC_STAT Channel status

9.6.3 Signals

9.6.3.1 Signals to channel

Signal name SINUMERIK 840D sl SINUMERIK 828D

Feedrate disable DB21, ... DBX6.0

9.6.3.2 Signals to axis/spindle

Signal name SINUMERIK 840D sl SINUMERIK 828D

Feed stop DB31, ... DBX4.3

Special functions
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9.6 Data lists

9.6.3.3 Signals from axis/spindle

Signal name SINUMERIK 840D sl SINUMERIK 828D

ESR: DC link undervoltage (p1248) DB31, ... DBX95.1 DB390x.DBX4003.1
ESR: Reaction triggered / generator operation active DB31, ... DBX95.2 DB390x.DBX4003.2
(r0887.12)
ESR, generator operation: Speed lower than minimum DB31, ... DBX95.3 DB390x.DBX4003.3
(p2161)

Special functions
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S9: Setpoint exchange - 840D sl only 10
10.1 Brief description

Function
The "setpoint exchange" function is used in applications in which the same motor is used to
traverse different machine axes.

Replacing the technology function "setpoint changeover" (TE5)

The "setpoint changeover" function replaces the technology function "setpoint changeover"
(TE5). Migration of the technology function to the functionality of the "setpoint changeover"
function means that you must make changes in the machine data and in the PLC user program:
● Machine data MD63750 is no longer required.
● The meanings of various NC/PLC interface signals have changed.
● Alarms 70451 and 70452 are no longer applicable.
● A setpoint changeover with simulated axes (MD30130 = 0) is no longer supported.
● The known restrictions relating to the technology card function are no longer applicable.

10.2 Startup
The "setpoint exchange" function is required in applications in which a single motor needs to
drive a number of axes/spindles such as, for example, on milling machines with special
millheads. The spindle motor is operated as both a tool drive and a millhead orienting
mechanism.

'LUPLOOKHDG 0LOOKHDGKROGHU
HQFRGHU

0RWRU

0RWRU *HDU 6SLQGOH

HQFRGHU

Figure 10-1 Example 1: 1 motor encoder, extra encoder for millhead

Special functions
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S9: Setpoint exchange - 840D sl only
10.2 Startup

'LUPLOOKHDG 0LOOKHDGKROGHU
HQFRGHU

0RWRU

6SLQGOH

0RWRUHQFRGHU

*HDU 'LUVSLQGOH
HQFRGHU

Figure 10-2 Example 2: 1 motor encoder, separate millhead encoder and spindle encoder

Configuration
Setpoint exchange enables a number of axes to use the same drive.
The same setpoint channel on this drive is assigned a number of times to define the axes
participating in setpoint exchange. For this, the following machine data must be pre-assigned
with the same logical drive number for every axis:
MD30110 $MA_CTRLOUT_MODULE_NR (setpoint assignment: module number)

Note
Alarm 26018 is output if the option is missing.

The encoder assignment is programmed in machine data:

MD30230 $MA_ENC_INPUT_NR
(actual-value assignment: Input on drive module/measuring circuit module)

Special functions
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 S9: Setpoint exchange - 840D sl only
10.2 Startup

0DFKLQHD[HV
6HWSRLQWFKDQQHODVVLJQPHQWYLD0'
0$B&75/287B02'8/(B15>$@ 
0$B&75/287B02'8/(B15>%@ 
; < = $ %

/RJLFDOGULYHQXPEHU
0'
   


 

*HDU

*
0 0 0 1
0

 *
0

*
0 0RWRU
* (QFRGHU

Figure 10-3 Setpoint exchange with 2 axes

Activation
The setpoint is exchanged and the corresponding interface signals are evaluated in the PLC
user program.

Note
An existing PLC user program may need to be modified due to changes in the meaning of
interface signals in comparison with the technology card solution.

Only one of the machine axes with the appropriate logical drive number may have control via
the setpoint channel of the drive at any one time.
Requests to transfer drive control are sent using NC/PLC interface signal:
DB31, ... DBX24.5 (change setpoint output assignment)
The current status of drive control is displayed in the NC/PLC interface signal:
DB31, ... DBX96.5 (setpoint output assignment)
Access rights to the shared drive must be managed in the PLC user program.

Special functions
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10.3 Interface signals

Transfer conditions
● Axis standstill of all axes involved.
● Special functions such as reference point approach, measuring, travel to fixed stop, function
generator, star/delta changeover, drive parameter set changeover are not active in the axis
with drive control.
● No sign-of-life error and no faults pending on PROFIBUS drive.
The PLC interface provides constant information about the current state of the exchange. At
any one time, only one axis has drive control DB31, ... DBX96.5=1.
During exchange, servo enables on all axes involved are automatically withdrawn by the
control.
Axes without drive control are not in closed-loop control. Therefore, a brake control must be
set up for vertical axes.

Special cases
If a number of transfer requests are made simultaneously, exchange will not take place. The
last axis used remains in control of the drive. This is also the case if there are no transfer
requests pending.
If there are no transfer requests during machine power-up, drive control is assigned to the first
machine axis located with the same logical drive number. The interface signal
DB31, ... DBX24.5 (change setpoint output assignment) must be set explicitly in advance to
be able to traverse the axis. Logical drive numbers are scanned in ascending order.
MD30110 $MA_CTRLOUT_MODULE_NR[0,AX1] = 1
MD30110 $MA_CTRLOUT_MODULE_NR[0,AX2] = 2
MD30110 $MA_CTRLOUT_MODULE_NR[0,AX3] = 3
MD30110$MA_CTRLOUT_MODULE_NR[0,AX4] = 4 ; Drive control during power-up
MD30110 $MA_CTRLOUT_MODULE_NR[0,AX5] = 4

10.3 Interface signals

Axisspecific signals
Despite assignment of a drive to several machine axes, the use of NC/PLC interface signals
remains unchanged. This requires an explicit coordination of access operations to the NC/PLC
interface signals in the PLC user program.

Status signals
The status signals contained in the following bytes are always displayed in the same way for
all of the machine axes involved in the changeover:
DB31, ... DBB92 to DBB95

Special functions
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10.3 Interface signals

Control signals
The control signals contained in the following bytes are only active in the machine axes, which
are currently assigned to the drive:
DB31, ... DBB20 to DBB21

Controller enable
The NC/PLC interface signal:
DB31, ... DBX2.1 (controller enable)
is only effective if the machine axis currently has control of the drive:
DB31, ... DBX96.5 == 1 (status setpoint changeover)
Axes without drive control are subject to functional restrictions and are therefore operated in
the follow-up mode. To do this, the control automatically withdraws the controller enable signals
for these machine axes.

Schematic sequence of a setpoint changeover

Initial state: Machine axis AX1 currently controls the drive.
Objective: Machine axis AX2 should assume control.

Special functions
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S9: Setpoint exchange - 840D sl only
10.3 Interface signals

$;7UDYHUVLQJFRPPDQGLVSUHVHQW
'%'%; 

$;&RQWUROYLDWKHGULYHDFWLYH"   \HV

'%'%;
 QR

$;&ORVHEUDNH

$;5HOLQTXLVKGULYHFRQWURO
'%'%; 

 QR
$;$;7UDFNLQJDFWLYH"
'%'%;
'%'%;   \HV

&KDQJHRYHUPHFKDQLFDOV\VWHP

$;5HTXHVW
GULYHFRQWURO
'%'%; 

 QR
$;FRQWURODFFHSWHG
'%'%;
  \HV

$;VHWFRQWUROOHUHQDEOH
'%'%; 

$;2SHQEUDNH

Figure 10-4 Schematic setpoint changeover from machine axes AX1 to AX2

Special functions
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 S9: Setpoint exchange - 840D sl only
10.7 Supplementary conditions

10.4 Interrupts
Drive alarms are only displayed for axes with drive control

10.5 Position control loop

During setpoint exchange, the drive train and therefore the position control loop are isolated.
In order to avoid instabilities, exchange only takes place at standstill and once all servo enables
have been deleted.
The use of a single drive means that only one of the control loops can be closed at any one
time. Axes without drive control are operated with open position controller and following
positions.

10.6 Reference points

The use of load-side encoders does not affect the axial reference points of a setpoint exchange.
However, the mechanical reference to the load can be lost following setpoint exchange for a
load-side position derived solely from the motor encoder. These types of axis must be
referenced again after every setpoint exchange.

10.7 Supplementary conditions

Parameter sets
A setpoint exchange is not performed if one of the following states is present:
● A parameter set changeover in one of the two machine axes has not completed.
● The parameter sets of the two machine axes are not the same.

Note
No message is displayed.

"Parking" operating status

The "parking" operating state can only be exited using the axis with the drive checking function.

Service display drive

The "Drive Service Display" HMI diagnostics screen does not take into account the changes
in assignments between machine axes and the drive.

Special functions
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S9: Setpoint exchange - 840D sl only
10.8 Data lists

Commissioning via SinuCom NC

The SinuCom NC commissioning tool can be used to commission the setpoint exchange only
via the expert list.

Safety Integrated (only 840D sl)

A detailed description of the supplementary conditions for setpoint changeover in conjunction
with Safety Integrated is available in:
References:
Manual SINUMERIK Safety Integrated

10.8 Data lists

10.8.1 Machine data

10.8.1.1 Axis/spindlespecific machine data

Number Identifier: $MA_ Description

30130 CTRLOUT_TYPE Output type of setpoint
30200 NUM_ENCS Number of encoders
30220 ENC_MODULE_NR Actual-value assignment:
Drive number / measurement circuit number
30230 ENC_INPUT_NR Actual-value assignment:
Input on drive module/measuring circuit module

Special functions
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T3: Tangential control - 840D sl only 11
Using the "Tangential control" function, a rotary axis is coupled as following axis to two
geometry axes as leading axes, so that the alignment of the following axis is a function of the
path tangent of the leading axes.

<

1
 


1

1


 
& ;
|

① Initial position and positive direction of rotation of the following/rotary axes C

② Angle of the path tangent in machining plane X/Y
③ Offset angle = 270° or -90°
④ Rounding clearance and present angular deviation

The path-defining leading axes, geometry axes X and Y and rotary axis C the following axis
of the tangential coupling can be seen in the diagram. The rotary axis is tracked with a
programmable offset angle of 270° with respect to the path tangent. At the block transition
from N10 to N20, the contour has a discontinuous transition or corner. As a result of a dynamic
response that is too low, the following axis cannot follow the path tangent over part of the path
(blue). However, the dynamic response of the following axis is sufficient so that it can precisely
follow circular blocks N20 and N30 further along the contour.

Properties
The tangential coupling sets itself apart as a result of the following features:
● The leading axes of the tangential coupling must be two geometry axes.
● The following axis of the tangential coupling must be a rotary axis.
● The tangential coupling can be defined, activated, deactivated and deleted in the NC
program.
● Tangential control is defined for the basic and the workpiece coordinate system.
● The positive direction of the path tangent is the same as the traversing direction of the path.
● For an offset angle of 0° between the rotary axis and the path tangent, shows the 0° direction.
● The axes of the tangential coupling must be the channel axes of the same channel.

Special functions
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11.1 Commissioning

● The position of the following axis can act as the input value for an additional transformation.
● The tangential coupling is only active in the AUTOMATIC and MDI modes.

Application examples
● Tangential positioning a rotatable tool during nibbling
● Tracking the workpiece alignment for a belt saw.
● Positioning a dressing tool on a grinding wheel
● Positioning a cutting wheel for cutting glass or paper
● Tangentially feeding a wire for 5-axis welding.

Corner behavior:
If the contour described by the leading axes has a discontinuous block transition or corner,
then one of the following corner behaviors can be selected.
● The dynamic response of the rotary axis has no effect on the leading axes
● The dynamic response of the rotary axis is considered in the path planning of the leading
axes together with programmable parameters "rounding clearance" and "angular
tolerance".
● The leading axes are stopped before the corner, and in an automatically generated
intermediate block, the following axis is realigned.
The corner angle is detected depending on the value of machine data MD37400
$MA_EPS_TLIFT_TANG_STEP (tangential angle for corner detection).

11.1 Commissioning

Machine data

Corner detection TLIFT()

In conjunction with the corner detection function TLIFT() (Page 521), a discontinuity in the
programmed path of the leading axes is identified as a corner if the change in the tangential
angle for the following axis is greater at this location than the value specified in the machine
data:
MD37400 $MA_EPS_TLIFT_TANG_STEP[<following axis>] = <tangent change angle>

Parameterizable offset angle

A parameterizable offset angle is specified for the following axis using the machine data:
Maschinendatum MD37402 $MA_TANG_OFFSET[<following axis>] = <parameterizable
offset angle>
The offset angle of the following axis is the angle between the zero position of the following
axis and the path tangent of the programmed path of the leading axes when tangential coupling
is active.

Special functions
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11.2 Programming

The active offset angle is the sum of the offset angle parameterized in the machine data and
the offset angle programmed with TANGON() (Page 522) when tangential coupling is activated:

Block search settings

Using the machine data, the velocity is selected with which the tangential axis traverses to its
position when tangential coupling is activated during or after a block search:
● Rapid traverse velocity (G0)
● Programmed velocity (G1 F....)
● Setting data SD42121 $SC_AX_ADJUST_FEED ≠ 0
MD11450 $MN_SEARCH_RUN_MODE, bit 7
See also: Supplementary conditions (Page 526)

System variables

$AC_BLOCKTYPE block type

System variable $AC_BLOCKTYPE can be used to determine as to whether the actual block
is an intermediate block generated by TLIFT(). The actual block is an intermediate block
generated by TLIFT() if the following applies:
$AC_BLOCKTYPE == 6

11.2 Programming

11.2.1 Defining coupling (TANG)

Via the predefined procedure TANG(...), a tangential coupling between a rotary axis is defined
as the following axis and two geometry axes as the leading axes. The following axis is
continuously aligned with the path tangent of the leading axes.

Syntax
TANG(<following axis>, <leading axis_1>, <leading axis_2>, <coupling
factor>, <coordinate system>, <optimization>)

Meaning

TANG(...): Define tangential coupling

<following axis>: Axis name of the following axis (rotary axis)
Data type: AXIS
Range of values: Channel axis names

Special functions
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11.2 Programming

<leading axis_1> Axis names of the leading axes (geometry axes) 1)

<leading axis_2>: Data type: AXIS
Range of values: Geometry axis names of the channel
<coupling factor>: Factor n of the angle change of the following axis for changing the path
tangent of the leading axes:
Angle changefollowing axis = angle changepath tangent * n
Data type: REAL
Default value: 1.0
<coordinate system>: Active coordinate system 2)
Data type: CHAR
Value: "B": Basic coordinate system (default value)
"W": Workpiece coordinate system (not availa‐
ble)
<optimization>: Optimization type
Data type: CHAR
Value: "S": Standard (default value)
The dynamic response of the rotary axis
has no effect on the leading axes If the dy‐
namic response of the rotary axis is greater
than required for tracking, this method is
sufficiently precise. If the dynamic re‐
sponse of the rotary axis is not great
enough to follow the change in the path
tangent, the orientation of the rotary axis
will deviate from the target orientation
along an undefined rounding clearance.
"P": The dynamic response of the rotary axis is
considered in the path planning of the lead‐
ing axes.
For this purpose, on activation of the tan‐
gential coupling with TANGON(), two addi‐
tional parameters must be specified:
● Rounding clearance
● Angular tolerance
See Section "Activating the coupling (TAN‐
GON) (Page 522)"
Note
With kinematic transformations, we recom‐
mend using optimization method "P."
Note
Default values do not have to be programmed explicitly.

Special functions
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11.2 Programming

1)
Note
As the leading axes for tangential coupling, the geometry axes must be used that travel along the
programmed path in the machine coordinate system (MCS) with reference to the initial position of the
machine. For example, if swivel cycle CYCLE800 is used on a milling machine with a swivel head,
depending on how the cycle is configured, interpolation will be performed in the WCS, e.g. with the
geometry axes X and Y. The tangential coupling, however, must be defined with the geometry axes as
the leading axes, which travel along the programmed path in the MCS. For this purpose, the geometry
axes in the non-swiveled condition of the machine must be used as the leading axes.
2)
Note
The basic coordinate system (BCS) must not be rotated with respect to the MCS. For example, if the
BCS is rotated with the ROT command or with the swivel cycle CYCLE800, the tangential control is no
longer correct.

11.2.2 Activating intermediate block generation (TLIFT)

If the tangent change of the following axis at any position along the programmed path of the
leading axes exceeds the limit parameterized in machine data MD37400
$MA_EPS_TLIFT_TANG_STEP, further path planning will depend on the set behavior at
corners. Without use of the predefined procedure TLIFT(...), the path is traversed in
accordance with the rounding behavior programmed in connection with TANG(...) (Page 519)
and TANGON(...) (Page 522).

Activating intermediate block generation

If TLIFT(...) is programmed after TANG(...), an intermediate block automatically generated by
the control is inserted at this point when a corner is detected during preprocessing.
When the program is executed, the leading axes are stopped when the intermediate block is
reached. In the intermediate block, the following axis is rotated with maximum axis dynamics
toward the path tangent of the following block. The leading axes are then traversed further on
the programmed path.

Deactivating intermediate block generation

To deactivate intermediate block generation, the tangential coupling must be defined again
using TANG(...), but without subsequent activation of intermediate block generation by means
of TLIFT(...).

Syntax
TLIFT(<following axis>)

Meaning

TLIFT(...): Activate corner detection with intermediate block calculation

<following axis>: Axis name of the following axis (rotary axis)
Data type: AXIS
Range of values: Channel axis names

Special functions
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11.2 Programming

Speed of rotation of the following axis

Path axis
If the following axis had already been traversed as a path axis before tangential coupling was
activated, the rotational movement is performed in the intermediate block as a path axis.
If you specify the reference radius with FGREF[<axis>]=0.001, the rotational movement
will be performed with the parameterized maximum axis velocity:
MD32000 $MA_MAX_AX_VELO[<following axis>]

Positioning axis
If the following axis had not yet been traversed as a path axis before tangential coupling was
activated, the rotation is performed in the intermediate block as a positioning axis.
The rotational movement is performed with the parameterized positioning axis velocity:
MD32060 $MA_POS_AX_VELO[<following axis>]

11.2.3 Activating the coupling (TANGON)

Via the predefined procedure TANGON(...), a tangential coupling previously defined with
TANG(...) (Page 519) is activated. The following axis is then continuously aligned with the path
tangent during subsequent travel.

Angle of the following axis

The angle of the following axis with respect to the path tangent depends on the transformation
ratio specified in TANG(...), the offset angle parameterized in the machine data MD37402
$MA_TANG_OFFSET, and the offset angle specified for TANGON(...), which is applied
additively.

Optimization "P"
If the value "P" was specified as the optimization parameter in the definition of the tangential
coupling (TANG(...)), the parameter "rounding clearance" and optionally the parameter
"angular tolerance" must be set when coupling is activated.
If the value 0 is specified as the angular tolerance, only the parameter "rounding clearance"
will be active.
If a value greater than 0 is specified as the angular tolerance, the active rounding clearance
results from the minimum of the parameterized rounding clearance and the rounding clearance
based on the parameterized angular tolerance.
If the dynamic response of the following axis is not sufficient to follow the parameterized
conditions, the path velocity of the leading axes will be reduced accordingly.

Syntax
TANGON(<following axis>, <offset angle>, <rounding clearance>,
<angular tolerance>)

Special functions
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11.2 Programming

Meaning

TANGON(...): Activate tangential coupling

<following axis>: Axis name of the following axis (rotary axis)
Data type: AXIS
Range of values: Channel axis names
<offset angle>: Offset angle of following axis with respect to the path tangent
The reference point is the zero point of the rotary axis.
Data type: REAL
<rounding clearance>: Maximum permissible rounding clearance
If the rounding clearance is increased due to the dynamic conditions,
the path velocity of the leading axes is reduced.
Data type: REAL
<angular tolerance>: Maximum permissible tolerance with respect to the specified angle be‐
tween the following axis zero setting and the path tangent
Data type: REAL

11.2.4 Deactivating the coupling (TANGOF)

Via the predefined procedure TANGOF(...), a tangential coupling defined with TANG(...)
(Page 519) and activated with TANGON(...) (Page 522) is deactivated. The following axis is
then no longer aligned with the path tangent of the leading axis. However, the coupling of the
following axis to the leading axes is retained even after deactivation, which prevents the
following functions, for example:
● Plane change
● Geometry axis switchover
● Definition of a new tangential coupling for the following axis
Final cancellation of the connection of the coupling of the following axis to the leading axes is
not completed until the coupling has been deleted with TANGDEL(...) (Page 524).

Programming
TANGOF(<following axis>)

Meaning

TANGOF(...): Deactivate a tangential coupling

<following axis>: Axis name of the following axis (rotary axis)
Data type: AXIS
Range of values: Channel axis names

Special functions
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11.2 Programming

11.2.5 Deleting a coupling (TANGDEL)

A tangential coupling defined with TANG(...) (Page 519) will be retained even after deactivation
of the tangential coupling with TANGOF(...) (Page 523). The existing tangential coupling then
continues to prevent, for example, the following functions:
● Plane change
● Geometry axis switchover
● Definition of a new tangential coupling for the following axis
With the predefined procedure TANGDEL(...), the existing tangential coupling is deleted after
the tangential coupling has been deactivated with TANGOF(...).

Syntax
TANGDEL(<following axis>)

Meaning

TANGDEL(...): Delete a tangential coupling defined with TANG()

Effective: Non-modal
<following axis>: Axis name of the following axis whose tangential coupling is to be de‐
leted
Data type: AXIS
Range of values: Channel axis names

Examples

Leading axis change

Before a new tangential coupling can be defined with another leading axis for the following
axis, the existing tangential coupling must first be deleted.

Program code Comment

N10 TANG(A, X, Y, 1) ; Define tangential couping for following axis A: A to
X and Y
N20 TANGON(A) ; Activate tangential coupling for following axis A
N30 X10 Y20
...
N80 TANGOF(A) ; Deactivate tangential coupling for following axis A
N90 TANGDEL(A) ; Delete tangential coupling for following axis A
...
N120 TANG(A, X, Z) ; Define new tangential coupling for following axis A
N130 TANGON(A) ; Activate new tangential coupling for following axis A
...

Special functions
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 T3: Tangential control - 840D sl only
11.3 Limit angle

Geometry axis switchover

Before geometry axis switchover can be performed for an existing coupling, the coupling must
first be deleted.

Program code Comment

N10 GEOAX(2,Y1) ; 2nd geometry axis = machine axis Y1
N20 TANG(A, X, Y) ; Define tangential coupling for following axis A
N30 TANGON(A, 90) ; Activate tangential coupling for following axis A
N40 G2 F8000 X0 Y0 I0 J50 ; Motion block
N50 TANGOF(A) ; Deactivate tangential coupling for following axis A
N60 TANGDEL(A) ; Delete tangential coupling for following axis A
N70 GEOAX(2, Y2) ; 2nd geometry axis = machine axis Y2
N80 TANG(A, X, Y) ; Define new tangential coupling for following axis A
N90 TANGON(A, 90) ; Activate new tangential coupling for following axis
A
...

11.3 Limit angle

For alternating traversing motion, the direction of the path tangent jumps through 180° at the
reversal point. The alignment of the following axis also jumps through 180 °. This behavior is
generally not practical (see Fig., ②). Instead, for return motion, the following axis should be
traversed with the same alignment as for the forward motion (see Fig., ③).

r r
<

 r  r


&
|
;

① Initial position and positive direction of rotation of the following/rotary axis C

② Forward and reverse motion with the same offset angle 270°
③ Forward and reverse motion with alternating offset angles, 270° and -270°

Special functions
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T3: Tangential control - 840D sl only
11.5 Examples

Avoiding reversal jump

Using the working area limitation G25 (lower limit) and G26 (upper limit), for the following axis,
a minimum and a maximum value must be entered for the position values referred to the basic
coordinate system. After this, the working area limitation for the following axis should be
activated/deactivated depending on the machining situation using the WALIMON / WALIMOF
commands. At the path reversal instant , the working area limitation must beactive.

Effect
If the following axis traverses with the actual offset angle with the axis position outside the
active working area limitation, then the control system checks whether the following axis, when
using the negative offset angle, would move in a permissible working area. If this is the case,
then the following axis is traversed with the negative offset angle.

Reference
Programming Guide Fundamentals; Chapter "Supplementary commands" > "Working area
limitation" > "Working area limitation in the BCS (G25/G26, WALIMON, WALIMOF)"

11.4 Supplementary conditions

Block search with active tangential coupling

If tangential control is active, it is recommended that for a block search only optimization type
"P" and block search type 2 ("Block search with calculation at the contour"), programmable
under TANG() (Page 519), or 5 ("Block search with calculation in the program test mode
(SERUPRO)") are used.

Explicit positioning of the following axis

If the following axis explicitly traverses an active tangential coupling, then the traversed
distance is additive to the programmed offset angle.

11.5 Examples

Example 1: Define and activate tangential coupling

Program code Comment
; Define tangential coupling:
; - Following axis C, leading axes X and Y
; - Coupling factor: 1.0
; - Coordinate system: BCS
; - Optimization type: "P"
N10 TANG(C,X,Y,1,"B","P") ; Simplified: TANG(C,X,Y,,,"P")
; Activate tangential coupling:
; - Offset angle: 90°

Special functions
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11.5 Examples

Program code Comment

N20 TANGON(C,90)
...

Example 2: Plane change

Program code Comment
; Define tangential coupling:
; - Following axis A, leading axes X and Y
; - Coupling factor: 1.0
; - Coordinate system: BCS
; - Optimization type: "S"
N10 TANG(A,X,Y)
; Activate tangential coupling:
; - Offset angle: 0°
N20 TANGON(A)
N30 X10 Y20 ; Traverse leading axes
...
N80 TANGOF(A) ; Deactivate tangential coupling
N90 TANGDEL(A) ; Delete tangential coupling
...
; Define NEW tangential coupling:
; - Following axis A, leading axes X and Z
; - Coupling factor: 1.0
; - Coordinate system: BCS
; - Optimization type: "S"
TANG(A,X,Z)
TANGON(A)
...

Example 3: Geometry axis switchover

Program code Comment
N10 GEOAX(2,Y1) ; 2nd geometry axis: Y1
; Define tangential coupling:
; - Following axis A, leading axes X and Y
; - Coupling factor: 1.0
; - Coordinate system: BCS
; - Optimization type: "S"
N20 TANG(A,X,Y)
; Activate tangential coupling:
; - Offset angle: 90°
N30 TANGON(A,90)
N40 G2 F8000 X0 Y0 I0 J50 ; Traverse circle

Special functions
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T3: Tangential control - 840D sl only
11.5 Examples

Program code Comment

N50 TANGOF(A) ; Deactivate tangential coupling
N60 TANGDEL(A) ; Delete tangential coupling
N70 GEOAX(2,Y2) ; 2nd geometry axis: Y2
; Define NEW tangential coupling:
; - Following axis A, leading axes X and Y
; - Coupling factor: 1.0
; - Coordinate system: BCS
; - Optimization type: "S"
N80 TANG(A,X,Y)
; Activate tangential coupling:
; - Offset angle: 90°
N90 TANGON(A,90)
...

Example 4: Optimization type "P"

Program code Comment
...
N100 G0 C0
N110 G1 X1000 Y500 F50000
N120 TRAORI ; Activate transformation
N130 G642 ; Activate smoothing
N171 TRANS X50 Y50 ; Work offset WCS
; Define tangential coupling:
; - Following axis C, leading axes X and Y
; - Coupling factor: 1.0
; - Coordinate system: BCS
; - Optimization type: "P"
N180 TANG(C,X,Y,1,,"P")
; Activate tangential coupling:
; - Offset angle: 0°
; - Rounding clearance 5.0 mm
; - Angular tolerance 2.0°
N190 TANGON(C,0,5.0,2.0)
N210 G1 X1310 Y500
N215 G1 X1420 Y500
N220 G3 X1500 Y580 I=AC(1420) J=AC(580)
N230 G1 X1500 Y760
N240 G3 X1360 Y900 I=AC(1360) J=AC(760)
N250 G1 X1000 Y900
N280 TANGOF(C) ; Deactivate tangential coupling
N290 TRAFOOF ; Deactivate transformation
...

Special functions
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11.6 Data lists

Example 5: Corner in space

Program code ; Comment
; Define tangential coupling:
; - Following axis A, leading axes X and Y
; - Coupling factor: 1.0
; - Coordinate system: BCS
; - Optimization type: "S" (standard)
TANG(A,X,Y,1.0,"B")
TLIFT(A) ; Activate intermediate block generation
G1 G641 X0 Y0 Z0 A0 ; Go to initial position
; Activate tangential coupling:
; - Offset angle: 0°
TANGON(A,0)
N4 X10 ; Traverse leading axis X
N5 Z10 ; Traverse geometry axis Z
N6 Y10 ; Traverse leading axis Y
M30

By traversing the geometry axes in blocks N4 and N6, a discontinuous characteristic is

obtained, i.e. a corner in the contour of the leading axes of the tangential coupling. By
programming TLIFT(), an intermediate block is inserted in front of N6, in which following axis
A is rotated through 90° in the tangential direction of the Y axis. Only then is the Y axis traversed
in N6.

11.6 Data lists

11.6.1 Machine data

11.6.1.1 NC-specific machine data

Number Identifier: $MN_ Description

11450 SEARCH_RUN_MODE Block search parameterization

11.6.1.2 Axis/spindlespecific machine data

Number Identifier: $MA_ Description

37400 EPS_TLIFT_TANG_STEP Tangential angle for corner recognition
37402 TANG_OFFSET Default angle for tangential follow-up control

Special functions
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11.6 Data lists

11.6.2 Setting data

11.6.2.1 Channel-specific setting data

Number Identifier $SC_ Description

42121 AX_ADJUST_FEED Path feed in adjustment motion of the tangential axes

11.6.3 System variables

Identifier Description
$AC_BLOCKTYPE Current block is an intermediate block generated by TLIFT

Special functions
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T4: Automatic post optimization with AST (option) -
only 840D sl 12
12.1 Function

Note
The "Automatic post optimization with AST" function is an option for SINUMERIK 840D sl that
requires a license.

With the "Automatic post optimization with AST" function, axes with a changed mechanical
system can be post optimized from the part program.
SIEMENS provides predefined cycles for the functions of the Automatic Servo Tuning (AST)
(post optimization) (see "Programming (Page 534)"). They can be used by machine
manufacturers to create their own tuning cycles. The machine operator must only use the
machine manufacturer's cycle.

Application

General problem description: Dependency on the loading

After changing the load - and therefore the moment of inertia, for all directly-driven axes, the
current setpoint filters must be adapted to ensure that the speed control loop remains stable.
Such axes are:
● Tables with torque motors
● Linear axes with linear motors that support different masses
● Directly driven main spindles with different clamping fixtures (lathe chuck)

Special functions
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12.1 Function

All conventionally driven axes (servomotor with ballscrew spindle and possibly with gearbox)
do not require that the speed controller is post optimized (retuned).

Note
If, after the load has changed, the actual parameter data set no longer fits, in order to traverse
directly-driven axis reliably without any instability, then parameter values must be adapted
before setting the controller enable (DB31, ... DBX2.1 = 1). Automatic post optimization with
AST is only possible after the controller has been enabled.
The following measures are possible:
● The active parameter data set is set so that it is suitable for all load conditions - and can
be used without adaptation ("moderately" adjusted parameter data set).
● A "moderately" adjusted parameter data set is adapted using automatic post optimization
with AST, and is then subsequently activated.
● The required parameter values are assigned by the PLC (FB3, PI services, …) and/or
manufacturer cycle beforesetting the controller enable.

Typical applications
For typical applications, see Chapter "Examples (Page 555)".

Setting up optimization cycles/troubleshooting

We recommend that an optimization cycle that has been newly created or modified is executed
and tested before the machine is shipped.
The reasons for this are as follows:
● For programming errors - or if the appropriate preconditions are not available (e.g. XML file
with optimization strategy is missing), then the program is canceled. Based on the alarm
that is output, the program line with the error can be identified and the error subsequently
resolved. As soon as the optimization cycle can be executed without any errors, program
stops should no longer occur for the end user.
● If the user interface-based automatic servo optimization (AST) had not been previously
used on the machine, and the machine data is not set for the current recommendation for
precontrol (e.g. MD33000 $MA_FIPO_TYPE = 3, MD32620 $MA_FFW_TYPE = 4), then
the first time that the AST cycles are executed results in this machine data being set, and
a power on (NCK reset) or a channel reset is necessary.

Reference:
For information on user interface-based automatic servo optimization, see:
● CNC Commissioning Manual: NC, PLC, Drive

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12.2 Commissioning

System requirements
● SINUMERIK 840D sl with SINUMERIK Operate
● CNC software as of version 4.7 SP1
● "Automatic post optimization with AST" option is set.

Machines with several HMI components

The "Automatic post optimization with AST" function can always be assigned to an HMI.
In order to change the actual assignment, in the HMI intended for the function, window
≫Automat. servo optimization: options≪ must be called, and option ≫Assign this HMI for
"Call AST from the part program" ≪ selected.

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12.3 Programming

12.3.1 Overview

Predefined cycles for automatic post optimization with AST

SIEMENS provides machinery builders (OEMs) the following cycles so that they can program
their own optimization cycles:
● CYCLE751 - Open/execute/close optimization session (Page 535)
● CYCLE752 - Add axis to an optimization session (Page 536)
● CYCLE753 - Select optimization mode (Page 539)
● CYCLE754 - Add/remove data set (Page 540)
● CYCLE755 - Backup/restore data (Page 541)
● CYCLE756 - Activate optimization results (Page 542)
● CYCLE757 - Save optimization data (Page 543)
● CYCLE758 - Change a parameter value (Page 547)
● CYCLE759 - Read parameter value (Page 548)
Internally, each of these cycles calls CYCLE750, which contains the MMC command with the
actual function call.

Data handling

Archived in standard directories

Automatic servo optimization (AST) uses three standard directories in the file system to save
specific data:

Directory path To archive the following files

/card/user/sinumerik/nck/data/optimization ● XML files with axis and/or path-specific optimization data, which
are automatically generated for the user interface-based
automatic servo optimization.
● XML files with axis and/or path-specific optimization data, which
are automatically generated for automatic post optimization with
AST using CYCLE757.
/card/user/sinumerik/nck/data/optimization/restore ● Backup files that are generated by the automatic post
optimization with AST using CYCLE755.
/card/user/sinumerik/nck/data/optimization/data ● CSV files that are generated by the automatic post optimization
with AST using CYCLE757.

Addressing using relative path data

The starting point for addressing an optimization file with relative path data is the data-specific
standard directory in the file system. When addressing an XML file with axis-specific

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optimization data, the relative path would be specified, e.g. starting at /card/user/sinumerik/
nck/data/optimization.
The relative path is specified, starting without a forward slash ("/").
Subdirectories can be specified.
Example:
data/my_ast_ax1.xml
(corresponds to the absolute path /card/user/sinumerik/nck/data/optimization/data/
my_ast_ax1.xml)

Addressing using absolute path data

Using absolute path data, optimization files outside the standard directories can be addressed.
When addressing an optimization file by specifying an absolute path, the complete file address
is specified.
For Linux, the complete address comprises the following elements:
● Directory path
● File name
Example:
● /card/user/sinumerik/hmi/log/optimization/data/my_ast_ax1.xml

Addressing files in external memories

When addressing optimization files in an external memory, the drive name must be specified
at the beginning of the path.
All symbolic device names configured in card/user/sinumerik/hmi/cfg/logdrive.ini are
permissible.
Examples:
● LOCAL_DRIVE:/… (local drive)
● //DEV_5:/… (user-defined drive)

12.3.2 CYCLE751 - Open/execute/close optimization session

Syntax
CYCLE751(<S_I_SESSIONCOMMAND>)

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Parameter

No. Parameters
1 <S_I_SESSIONCOMMAND>
Data type: INT
Value: 0 Not defined
1 Open new optimization session
Note:
Multiple sessions cannot be open concurrently. Opening a new session closes the current session
automatically.
2 Close current optimization session
3 Execute optimization functions of the current session with immediate transfer of the optimization
results
The scope of the optimization functions (measurement of the speed control loop, measurement of
the position control loop, optimization of the path interpolation) to be executed depends on the axis-
specific optimization strategies set from the user interface.
The optimization results are transferred immediately (update the axis and drive parameters, update
the optimization files).
4 Execute optimization functions of the current session without immediate transfer of the optimization
results
Unlike 3, the optimization results are not transferred immediately. Transfer can be realized later in
the optimization session using CYCLE756.

12.3.3 CYCLE752 - Add axis to an optimization session

After opening the optimization session, CYCLE752 specifies which axes should be
reoptimized. If a reoptimization of the path interpolation is provided, CYCLE752 also specifies
the axes required for the comparison of the path interpolation.

Syntax
CYCLE752(<S_I_AXIS>, <S_I_ACTIONREQUEST>, <S_B_ISPATHMEMBER>,
<S_SZ_FILENAME>)

Parameters

No. Parameters
1 <S_I_AXIS>
Meaning: Machine axis number
Specifies the axis to be added to the optimization session.
Note:
For gantry or master-slave couplings, only the leading or master axis of the coupling group should be
specified.
Data type: INT

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No. Parameters
2 <S_I_ACTIONREQUEST>
Meaning: Specifies whether the stored optimization data (optimization strategy and optimization results) should
be used or the axis with AST default settings reoptimized for the axis to be added.
Note:
If the axis has already been optimized and the optimization data has been saved in an optimization
file, this data is normally accessed first. CYCLE753 can then specify the further procedure.
Data type: INT
Value: 0 Not defined
1 Reoptimization with AST default settings
The axis should be remeasured and reoptimized with the AST default settings. The selected
AST settings are not considered on the user interface.
2 Optimization data from a user-defined optimization file
The stored optimization data from the specified user-defined optimization file (see <S_SZ_FIL‐
ENAME> parameter) is used for the axis.
Note:
This setting is only possible if the axis has already been optimized once, and the results have
been saved to a user-defined optimization file.
3 Optimization data from the standard optimization file
The stored optimization data from the axis-specific standard optimization file is used for the axis.
The selected AST settings are not considered on the user interface.
Note:
For the user interface-based automatic servo optimization, the standard optimization files are
automatically generated to backup optimization information and data (optimization strategy,
measuring and optimization results) and saved in the file system under /card/user/sinumerik/nck/
data/optimization. There is a standard optimization file for every axis – and a standard optimiza‐
tion file for the path interpolation.
For example, the setting <S_I_ACTIONREQUEST> = 2 or 3 is used in the following cases:
● The axis should be post-optimized using the saved strategy and measurement settings. To do this,
the saved optimization data is loaded with CYCLE752 and the deployed optimization mode defined
with CYCLE753.
● On completion of the reoptimization of the individual axes, the path interpolation must be
reoptimized.
● Saved optimization results (values for NC and drive parameters) should be restored.
3 <S_B_ISPATHMEMBER>
Meaning: Consideration of the axis for the last optimization step (optimization of the path interpolation)
Data type: BOOL
Value: 0 (FALSE) Do not consider the axis for the optimization of the path interpolation
1 (TRUE) Consider the axis for the optimization of the path interpolation
All axes, which are added using CYCLE752( , , TRUE, ), are taken into account when
optimizing path interpolation. This is realized within the scope of the optimization, e.g.
started using CYCLE751(3).

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No. Parameters
4 <S_SZ_FILENAME>
Meaning: Address of the user-defined, axis-specific optimization file (only relevant for <S_I_ACTIONREQUEST>
= 2!)
If the file was generated via the program-based automatic post optimization with AST using CYCLE757,
then as default setting, the file is in directory /card/user/sinumerik/nck/data/optimization and it is not
necessary to specify a directory path.
However, the more frequent use case is that the file is generated via the user interface-based automatic
servo optimization, and was saved in directory /card/user/sinumerik/hmi/log/optimization. In addition
to the file name, the address must also include the directory path (unless the file was subsequently
copied to the standard directory /card/user/sinumerik/nck/data/optimization). See also "Example 6:
Measuring an axis without optimization (Page 570)".
Data type: STRING [100]

Note
Gantry/master-slave coupling
For gantry or master-slave couplings, with CYCLE752, only the leading or master axis of the
coupling group is specified. The AST software automatically adds the coupled following or
slave axes.
AST then automatically measures all axes of a coupling group – and optimizes them with
identical controller settings. The position controller gains are set the same, the integral time in
the speed controller is selected the same and the effective speed controller gain (relative to
the overall moment of inertia) is selected the same. The current setpoint filters can be optimized
differently.
Coupled axes must be referenced (homed) before the automatic optimization!

Note
Premeasurement
The decision for performing a premeasurement depends on the available axis optimization
data.
● Cases in which the control unit performs a premeasurement for determining the measuring
parameters:
– The optimization strategy envisages a premeasurement; data from an earlier
premeasurement is not available.
– The optimization data does not specify any optimization strategy.
● Cases in which no premeasurement is performed:
– The optimization strategy envisages a premeasurement; data from an earlier
premeasurement is available.
– The optimization strategy does not envisage any premeasurement (the optimization
strategy takes precedence over the "Perform premeasurement for determining the
excitation" option selected from the user interface).

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12.3.4 CYCLE753 - Select optimization mode

CYCLE753 must be programmed when different strategy settings should act for the axis than
those stored as standard or selected from the user interface. For example, this the case when
an axis with user-defined strategy and measuring settings from a stored optimization file should
be remeasured and reoptimized.

Syntax
CYCLE753(<S_I_AXIS>, <S_I_ACTION>, <S_B_SAVEBOOTFILES>)

Parameters

No. Parameters
1 <S_I_AXIS>
Meaning: Machine axis number
Data type: INT
2 <S_I_ACTION>
Meaning: Specifies the optimization mode for the specified axis.
Data type: INT
Value: 0 Not defined
1 Match the path interpolation
The axis (path axis) should not be remeasured and reoptimized, but rather considered and
adapted only for the optimization of the path interpolation.
The stored results from the optimization file are used for the axis. The optimization of the path
interpolation means that the axis-specific machine data and drive parameters can change.
2 Reoptimization with a different optimization strategy based on stored measurements
The axis should be reoptimized based on the results from an earlier measurement and currently
valid optimization strategy changed from the user interface or CYCLE758.
This mode is used, for example, to eliminate known periodic disturbance frequencies (see "Ex‐
ample 5: Reoptimize the speed control loop to eliminate known periodic disturbance frequen‐
cies. (Page 568)").
3 Measurement and reoptimization (→ Mode for changed mechanics/loading!)
The mechanics/loading has changed. The axis should be remeasured and reoptimized using
the user-defined strategy and measuring settings from an optimization file. The strategy and
measuring settings can be adapted from the user interface or with CYCLE758.
3 <S_B_SAVEBOOTFILES>
Meaning: Save updated drive parameter values as persistent data
Data type: BOOL
Value: 0 (FALSE) No
1 (TRUE) Yes (default)

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12.3.5 CYCLE754 - Add/remove data set

If the optimization results rather than the current data set should overwrite a specific axis or
drive data set, the data set to be overwritten must be added to the data set list with CYCLE754.
This list involves an invisible internal function list used to define data sets to be optimized. As
default setting, only the currently selected data set is included in it. CYCLE754 must also be
used to remove a data set from the list.

Note
Adding or removing an axis or drive data set using CYCLE754 only refers to the data set list,
i.e an axis or drive data set removed from the list still remains in the control or in the drive.

Syntax
CYCLE754(<S_I_AXIS>, <S_I_ACTIONREQUEST>, <S_I_DATASETTYPE>,
<S_I_INDEX>)

Parameters

No. Parameters
1 <S_I_AXIS>
Meaning: Machine axis number
Data type: INT
2 <S_I_ACTIONREQUEST>
Meaning: Specifies whether the specified axis or drive data set should be added to or removed from the data
set list.
Data type: INT
Value: 0 Not defined
1 Add a data set
2 Remove a data set
3 Remove all data sets from the list
Note:
If the list is empty, the optimization results can be written only to the active data set.
3 <S_I_DATASETTYPE>
Meaning: Data set type
Data type: INT
Value: 0 Not defined
1 Axis data set (servo parameter set)
2 Drive data set (DDS)

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No. Parameters
4 <S_I_INDEX>
Meaning: Data set index
Specifies the data set to be added and into which the optimization results should be written or should
be removed from the list.
Note:
The following applies to the axisdata set index: <n> = parameter set number - 1
Example: Index 0 ≙ parameter set 1
Data type: INT
Range of values: -1, 0, 1, ... <MAX_INDEX>
-1 active data set

12.3.6 CYCLE755 - Backup/restore data

Using CYCLE755, backup files can be created in the file system that permit the backup of the
actual data, and therefore facilitate specific data restoration at any time during the optimization
session. Data restoration is also called using CYCLE755. Further, CYCLE755 is used to query
the existence of a backup file as well as to delete backup files.

Note
The backup files are no longer required after the optimization session has been successfully
completed. This is the reason that these should be deleted again at the end of the optimization
session with CYCLE755.

Typical examples for using CYCLE755 include:

● Undoing data changes, which are only to be temporarily valid.
● Restoring data after an interrupted optimization session.
A program that queries the existence of a backup file, and for a positive result, restores the
data from this file, can be used to return to a defined initial state after an optimization session
has been interrupted.

Syntax
CYCLE755(<S_I_ACTIONREQUEST>, <S_SZ_NAME>, <S_SZ_GUD_BOOL_NAME>)

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Parameters

No. Parameters
1 <S_I_ACTIONREQUEST>
Data type: INT
Value: 0 Not defined
1 Backup data for a later restore
This setting saves the data values at the time of the cycle call in the specified file.
The following parameters define the content of the data backup:
● the currently valid optimization strategy
● the axes currently added to the optimization session
● the current list of parameter sets to be written
2 Restore data
This setting restores the data from the specified file.
Requirements:
● The optimization session is still active.
● The axis and data set selection at the time of the backup is still available.
3 Delete backup file
4 Querying the existence of a backup file
The result of the query is saved to a channel-global user variable (GUD), type BOOL (see pa‐
rameter <S_SZ_GUD_BOOL_NAME>).
2 <S_SZ_NAME>
Meaning: Name of backup file
The file name can be freely selected with the following restriction: it is not permissible that the sequence
of letters "AST" is located at the beginning of the file name.
Specifying a path (absolute or relative) is only required if the file is not to be saved to the standard
directory /card/user/sinumerik/nck/data/optimization/restore.
Data type: STRING [100]
3 <S_SZ_GUD_BOOL_NAME>
Meaning: Name of the GUD, in which the result of the file query should be saved
(only relevant, if <S_I_ACTIONREQUEST> = 4!)
Note:
The specified GUD must be defined in a definition file as a channel-global variable, type BOOL:
DEF CHAN BOOL
Data type: STRING [50]

12.3.7 CYCLE756 - Activate optimization results

CYCLE756 can be used to activate the optimization results at a specific time / under specific
conditions. The conditions must be queried in the manufacturer cycle. CYCLE756 can also
specify which control parameters should be active: original data, axis-optimum data or path-
optimum data.

Syntax
CYCLE756(<S_I_AXIS>, <S_I_REGULATOR_ROLE>, <S_B_SAVEBOOTFILES>)

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Parameters

No. Parameters
1 <S_I_AXIS>
Meaning: Machine axis number
Data type: INT
2 <S_I_REGULATOR_ROLE>
Meaning: Specifies which optimization results should act for the specified axis in the control unit and in the drive.
Note:
If the axis is part of a gantry group or a master-slave coupling, then optimization factors are included
in the optimization results, which would be necessary to adapt the dynamic response of all axes of the
coupling group.
Data type: INT
Value: 0 Not defined
1 The original data should act for the specified axis.
2 The current optimization results without optimization of the path interpolation should become
active for the specified axis (axis-optimum data)
3 The current optimization results with optimization of the path interpolation should become active
for the specified axis (path-optimum data).
3 <S_B_SAVEBOOTFILES>
Meaning: Save updated drive parameter values as persistent data
Data type: BOOL
Value: 0 (FALSE) No
1 (TRUE) Yes (default)

Application
Some situations for which CYCLE756 is useful:
● CYCLE751(4) executes the optimization functions of the current session without
transferring the optimization results immediately. The optimization results can be activated
later during the optimization session with CYCLE756. Prior to the activation, the data can
be read and tested with CYCLE758/759.
● CYCLE752 loads the saved optimization data from an optimization file. CYCLE756
activates the loaded data.

12.3.8 CYCLE757 - Save optimization data

Contrary to the user interface-based automatic servo optimization, where optimization data
are automatically saved (standard optimization files), saving optimization data for program-
based automatic post optimization with AST must be explicitly called by programming
CYCLE757.

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The following user-defined optimization files can be created in CYCLE757:

● Optimization files in the XML format:
– for the axis-specific optimization data
– for the data to optimize path interpolation
● Optimization files in the CSV format with frequency, amplitude and phase of the following
frequency responses:
– measured speed-controlled system
– measured mechanical frequency response
– calculated closed speed controller
– calculated closed position controller
– measured closed speed controller
– measured closed position controller
If a path is not specified, the files are saved in the file system in the following standard
directories:
● XML files: /card/user/sinumerik/nck/data/optimization
● CSV files: /card/user/sinumerik/nck/data/optimization/data

NOTICE
Data loss
If CYCLE757 is not programmed, measurement data as well as parameters for assessment
and offline optimization are no longer available after the optimization session has been closed.
However, the optimization (depending on the strategy) is written to the axis and drive
parameters.
Remedy: Save optimization data to be backed up before closing the optimization session with
CYCLE757.

Syntax
CYCLE757(<S_I_AXIS>, <S_SZ_FILENAME>, <S_I_CONTENT_TYPE>,
<S_I_FORMATFILTER>, <S_I_SUPPINFO>)

Parameters

No. Parameters
1 <S_I_AXIS>
Meaning: Machine axis number
Data type: INT

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No. Parameters
2 <S_SZ_FILENAME>
Meaning: Name of the optimization file to be created (with file extension ".xml" or ".csv")
The file name can be freely selected with the following restriction: it is not permissible that the sequence
of letters "AST" is located at the beginning of the file name.
Specifying a path (absolute or relative) is only required if the file is not to be saved to the standard
directory.
Examples:
● AXIS.xml
● PATH.xml
● SPEEDCTRL_PLANT.csv
● POSCTRL_MECHRESP.csv
Special case:
● Empty string (""); only valid, if <S_I_CONTENT_TYPE> = 1 or 2
Entering an empty string means that the data of the program-based automatic post optimization
are written to the standard optimization file for the axis (<S_I_CONTENT_TYPE> = 1) or for the
path interpolation (<S_I_CONTENT_TYPE> = 2).
Notice:
The standard optimization files contain the data of the user interface-based automatic servo
optimization. By programming <S_SZ_FILENAME> = "", these are overwritten by the data of the
program-based automatic post optimization.
Data type: STRING [100]

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No. Parameters
3 <S_I_CONTENT_TYPE>
Meaning: Specifies which optimization data should be saved in the created optimization file.
Data type: INT
Value: 0 Not defined
1 Creates an XML file in which the axis-specific optimization data for the specified axis is saved.
The following data is included:
● Measuring conditions
● Measurement results
● Optimization strategy
● Optimization results
Note:
If the axis is part of a gantry group or a master-slave coupling, then the optimization information
for the axis, includes the optimization information for all other axes of the coupling group.
2 Creates an XML file in which the data for optimization of the path interpolation is saved.
The following data is included:
● List of all involved axes.
● Strategy for optimization of the path interpolation
3 Creates a CSV file, in which the data for the frequency characteristic of the measured speed
controlled system is to be saved.
The data is stored as a 3-column table:
● Column 1: Frequency [Hz]
● Column 2: Linear amplitude
● Column 3: Phase [rad]
4 Creates a CSV file in which the data for the measured mechanical frequency response is saved.
The data is stored as a 3-column table:
● Column 1: Frequency [Hz]
● Column 2: Linear amplitude
● Column 3: Phase [rad]
5 Creates a CSV file, in which the data for the frequency response of the calculated closed speed
controller is saved.
The data is stored as a 3-column table:
Column 1: Frequency [Hz]
Column 2: Linear amplitude
Column 3: Phase [rad]
6 Creates a CSV file, in which the data for the frequency response of the calculated closed position
controller is saved.
The data is stored as a 3-column table:
Column 1: Frequency [Hz]
Column 2: Linear amplitude
Column 3: Phase [rad]
7 Creates a CSV file, in which the data for the frequency response of the measured closed speed
controller is saved.
The data is stored as a 3-column table:
Column 1: Frequency [Hz]

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No. Parameters
Column 2: Linear amplitude
Column 3: Phase [rad]
8 Creates a CSV file, in which the data for the frequency response of the measured closed position
controller is saved.
The data is stored as a 3-column table:
Column 1: Frequency [Hz]
Column 2: Linear amplitude
Column 3: Phase [rad]
4 <S_I_FORMATFILTER>
Meaning: Reserved
Data type: INT
5 <S_I_SUPPINFO>
Meaning: Reserved
Data type: INT

12.3.9 CYCLE758 - Change a parameter value

CYCLE758 changes individual strategy and measuring settings prior to the optimization or the
optimization results after the optimization.

Syntax
CYCLE758(<S_I_AXIS>, <S_I_PARAMID>, <S_I_MEASTYPE>, <S_I_MEASINDEX>,
<S_SZ_NEWVALUE>)

Parameters

No. Parameters
1 <S_I_AXIS>
Meaning: Machine axis number (not relevant for parameters that affect the optimization of the path interpolation!)
Data type: INT
Note:
Are the measurement parameters of a following or slave axis to be changed
2 <S_I_PARAM
ID>
Meaning: ID number of the parameter whose value should be changed
Parameter IDs, see "List of the parameters for the automatic servo optimization (Page 549)".
Data type: INT

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No. Parameters
3 <S_I_MEASTYPE>
Meaning: Measuring type to which the parameter refers (relevant only for measuring parameters!)
Uniquely identifies measuring parameters with the same ID number.
Data type: INT
Value: 1 Mechanical frequency response
2 Closed position control loop
3 Closed speed control loop
4 Speed-controlled system
5 Speed setpoint step change
4 <S_I_MEASINDEX>
Meaning: Measurement index to which the parameter refers (relevant only for measuring parameters!)
Uniquely identifies measuring parameters with the same ID number that refer to the same measuring
type. It must be specified only when multiple measurements of a measuring type exist.
Data type: INT
5 <S_SZ_NEWVALUE>
Meaning: New parameter value
Data type: STRING [20]

Note
Gantry/master-slave coupling
If the measurement parameters of a specific following or slave axis must be changed, then in
CYCLE758 the corresponding number of this axis must be specified (not the number of the
leading or master axis, as when adding coupled axes with CYCLE752 (Page 536)).

12.3.10 CYCLE759 - Read parameter value

CYCLE759 reads the strategy and measuring parameters and the optimized controller
parameters. This is useful for checking the file loaded with CYCLE752 prior to the optimization
or reading the results after the optimization (e.g. determined total inertia, determined gain).

Syntax
CYCLE759(<S_I_AXIS>, <S_I_PARAMID>, <S_I_MEASTYPE>, <S_I_MEASINDEX>,
<S_SZ_GUDRESULT>)

Parameters

No. Parameters
1 <S_I_AXIS>
Meaning: Machine axis number (not relevant for parameters that affect the optimization of the path interpolation!)
Data type: INT

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No. Parameters
2 <S_I_PARAM
ID>
Meaning: ID number of the parameter whose value should be read
Parameter IDs, see "List of the parameters for the automatic servo optimization (Page 549)".
Data type: INT
3 <S_I_MEASTYPE>
Meaning: Measuring type to which the parameter refers (relevant only for measuring parameters!)
Uniquely identifies measuring parameters with the same ID number.
Data type: INT
Value: 1 Mechanical frequency response
2 Closed position control loop
3 Closed speed control loop
4 Speed-controlled system
5 Speed setpoint step change
4 <S_I_MEASINDEX>
Meaning: Measurement index to which the parameter refers (relevant only for measuring parameters!)
Uniquely identifies measuring parameters with the same ID number that refer to the same measuring
type. It must be specified only when multiple measurements of a measuring type exist.
Data type: INT
5 <S_SZ_GUDRESULT>
Meaning: Name of the global user variable (GUD) into which the parameter value should be copied.
Note:
The specified GUD must be defined in a definition file. The data type of the GUD must match the data
type of the parameter.
Data type: STRING [20]

12.3.11 List of the parameters for the automatic servo optimization

The ID of a parameter for the automatic servo optimization whose value should be changed
with CYCLE758 or read with CYCLE759 can be taken from the following table:

ID Meaning Unit Data Value range Write Read

type with with
CYCLE758 CYCLE759

Measuring conditions
001 Start position of the axis during a measurement mm or de‐ - +
grees
002 Direction sequence during a measurement INT 1, 2, 3, 4 + +
● 1 = plus
● 2 = minus
● 3 = plus, then minus
● 4 = minus, then plus

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ID Meaning Unit Data Value range Write Read

type with with
CYCLE758 CYCLE759
003 Number of measurement repetitions for deter‐ INT 0 to + +
mining the frequency range averaging
004 Number of time range windows in each time INT 1 to + +
range averaging
005 Settling time: The wait time after the PRBS exci‐ s 0 to + +
tation before the first measuring window is ac‐
quired
006 Bandwidth for the measurement Hz Float: 0 ... fs/2 + +
007 Time for performing an individual measurement s - +
(without repetition, ramp-up and settling time)
008 Time required to bring the speed offset to the s - +
setpoint
009 Estimated travelled distance during the maxi‐ m or rad - +
mum traversing motion in the repetition se‐
quence
010 Estimated total time of the axis motion during the s - +
measurement
011 Specifies the measurement type: - +
● 1 = frequency response of the mechanical
parts
● 2 = closed position control loop
● 3 = closed speed control loop
● 4 = speed-controlled system
● 5 = speed setpoint increment
012 Specifies whether the axis motion lies within the BOOL 0 (= FALSE) - +
traverse range limits 1 (= TRUE)
013 Specifies whether a measurement is performed BOOL 0 (= FALSE) - +
with the maximum bandwidth 1 (= TRUE)
021 Amplitude of the excitation Nm, N, m/ Dynamic + +
s, rad/s,
m, rad (de‐
pendent
on the
measure‐
ment
type1) )
022 Velocity offset m/s or rad/ Dynamic + +
s (depend‐
ing on
measure‐
ment
type1) )

Speed control (controller)

031 Proportional gain for the speed control loop Nms/rad + +
or Ns/m

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ID Meaning Unit Data Value range Write Read

type with with
CYCLE758 CYCLE759
032 Integral time for the speed control loop s + +
033 Motor moment of inertia kgm 2
- +
or kg
034 Total moment of inertia of the axis expressed in kgm2 + +
the units of the motor or kg
035 Specifies whether the reference model is activa‐ BOOL 0 (= FALSE) + +
ted for the speed control 1 (= TRUE)
036 Frequency of the PT2 reference model Hz + +
037 Damping of the PT2 reference model + +
038 Ratio of the Kp proportional gain to the moment 1/s - +
of inertia that represents the 1/s bandwidth of the
idealized PT1-equivalent (proportional-control‐
led) systems

Position control (controller)

101 Position control loop gain 1000/min + +
102 Specifies whether DSC (dynamic stiffness con‐ BOOL 0 (= FALSE) + +
trol) is active 1 (= TRUE)
103 Specifies the precontrol type: 0, 1, 2 + +
● 0 = none
● 1 = speed precontrol
● 2 = speed and torque precontrol
104 Total moment of inertia of the axis as parameter kg m2 + +
for the torque precontrol or kg
105 Delay of the speed precontrol in the drive (e.g. s + +
p1429)
106 Equivalent time constant of the speed control s + +
loop as parameter for the speed precontrol
107 Adapted parameter value 106 for considering s + +
the following effects:
● Inconsistent delays
● Changes by the NCK
108 Equivalent time constant of the current control s + +
loop as parameter for the torque precontrol
109 Adapted parameter value 108 for considering s + +
the following effects:
● Inconsistent delays
● Changes by the NCK
110 PT1 time constant of the axis to adapt the dy‐ s + +
namic response
(MD32910 $MA_DYN_MATCH_TIME)
111 Time constant used for the dynamic response s + +
adaptation for the axis-specific setpoint phase
filter (MD32895 $MA_DESVAL_DELAY_TIME)

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ID Meaning Unit Data Value range Write Read

type with with
CYCLE758 CYCLE759
112 Calculated total time constant for the positioning s - +
response, including precontrol and all prefilters.
This time constant is only intended to provide
users with information. You can use it as a target
time constant for the position controller strategy
for another axis. By forcing the same total time
constant, interpolation fits already after axis op‐
timization.

Position control (strategy)

151 Adaptation factor (reduction) for the optimized 0.1 ... 1.0 + +
maximum Kv value
152 Not defined
153 Specifies the additional method for maximizing 0 ... 3 + +
the Kv value:
● 0 = none (standard)
● 1 = PT1 speed filter 2
● 2 = damping of the optimum speed controller
● 3 = PT1 speed filter 1
154 DSC + +
155 Select precontrol type: 0, 1, 2 + +
● 0 = none
● 1 = speed precontrol
● 2 = speed and torque precontrol
156 Maximum permissible Kv value 1000/min 0.1 ... 99.0 + +
157 Specifies whether the precontrol should always BOOL 0 (= FALSE) + +
be active for the axis 1 (= TRUE)
158 Setpoint for the equivalent time of the position s + +
controller overall response (including precontrol
and setpoint filter)
159 Indicates whether an attempt should be made to BOOL 0 (= FALSE) + +
attain the nominal equivalent time 1 (= TRUE)
160 Specifies the jerk filter technology to be selected: 0 ... 2 + +
● 0 = keep the existing jerk filter settings in the
machine data
● 1 = deactivates the jerk filter
● 2 = use jerk filter, type 2 (= sliding average
value generation)
161 Time constant (MD32410 s 0 … 0.5 + +
$MA_AX_JERK_TIME) for type 2 jerk filter (pa‐
rameter 160 = 2)

Speed control (strategy)

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ID Meaning Unit Data Value range Write Read

type with with
CYCLE758 CYCLE759
201 Setpoint for the amplitude reserve for the optimi‐ dB + +
zation
202 Setpoint for the phase reserve for the optimiza‐ deg + +
tion
203 Indicates whether the reference model should be BOOL 0 (= FALSE) + +
activated 1 (= TRUE)
204 Specifies the permissible minimum value for the s 0.001 ... 1.000 + +
integral time of the speed control loop
205 Specifies whether the design of band-stop filters BOOL 0 (= FALSE) + +
should deploy a constant reduction (for the case 1 (= TRUE)
that significantly more poles are available as fil‐
ter)
206 Optimization aggressiveness of the speed con‐ 0 ... 1 + +
troller
A higher value produces a better optimization re‐
sult coupled with a reduction of the robustness
207 Kp upper limit based on the bandwidth of a PT1- Hz + +
equivalent proportionally-controlled system
208 Indicates whether a gain filter for eliminating fre‐ BOOL 0 (= FALSE) + +
quency-specific periodic disturbances should be 1 (= TRUE)
designed and deployed
209 Frequency of the optional gain filter for eliminat‐ Hz + +
ing frequency-specific periodic disturbances

Optimization of path interpolation (strategy)

251 Indicates whether an attempt should be made to BOOL 0 (= FALSE) + +
achieve an agreement with the effective Kp value 1 (= TRUE)
252 Indicates whether an attempt should be made to BOOL 0 (= FALSE) + +
achieve an agreement with the Tn integral time 1 (= TRUE)
253 The maximum proportion with which the Kp val‐ 0.1 ... 1.0 + +
ue may be reduced to order to achieve an agree‐
ment with the effective Kp value
254 Specifies whether non-agreements of the Kv val‐ BOOL 0 (= FALSE) + +
ue between axes are permitted 1 (= TRUE)
255 Indicates whether the axes without precontrol or BOOL 0 (= FALSE) + +
with speed precontrol must have matched refer‐ 1 (= TRUE)
ence models
256 Specifies the strategy for the path compensation: INT 0, 1 + +
● 0 = adapt the equivalent time of the control
loop with controller parameters and/or
MD32800/MD32810
● 1 = use MD32895 (time constant for the axial
setpoint phase filter) for adaptation

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ID Meaning Unit Data Value range Write Read

type with with
CYCLE758 CYCLE759
257 Specifies whether the precontrol should always BOOL 0 (= FALSE) + +
be active for all axes in the group 1 (= TRUE)
258 Specifies whether the equivalent times should BOOL 0 (= FALSE) + +
be identical for all axes 1 (= TRUE)
1)
The parameter value unit depends on the measurement type:
● The following measurements were carried out in the drive. This is the reason that the units
refer to the motor side. The resulting axis velocity is obtained, taking into account the
gearbox ratios or spindle pitch. The velocity specified here is only equal to the axis velocity
for linear motors and torque motors (without gearbox). Here, it should be noted that the
axis velocity is specified in the AST screen forms, e.g. mm/min. Here, the numerical values
cannot be taken from the screen forms.

Unit
Parameter 021: Parameter 022:
Amplitude of the excitation Velocity offset
Measurement type Rotary motor Linear motor Rotary motor Linear motor
Speed-controlled system Nm N rad/s m/s
Closed speed control loop rad/s m/s rad/s m/s

● The following measurement were carried out via the control. Here, the units refer to the
axis, i.e. to the load side. It may be necessary to convert to SI units.

Unit
Parameter 021: Parameter 022:
Amplitude of the excitation Velocity offset
Measurement type Rotary axis Linear axis Rotary axis Linear axis
Mechanical frequency response rad/s m/s rad/s m/s
Closed position control loop rad m rad/s m/s

12.4 Diagnostics
If an error occurs when executing cycles, then an appropriate HMI alarm is output (number
range 150001 to 150004) as well as NC alarm 61840. Based on the block number specified
in alarm 61840, the user can define which NC block with a CYCLE75x call caused the error.
Reference:
For alarm descriptions, refer to the Diagnostics Manual Alarms.

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12.5 Supplementary conditions

"Automatic post optimization with AST" for active coupling

The following table lists which coupling function support the "Automatic post optimization with
AST":

Coupling function "Automatic post optimization with AST" can be used?

Gantry axes +
Master-slave coupling +
Coupled motion -
Leading value coupling -
Electronic gear -
Synchronous spindle -

12.6 Examples

12.6.1 Example 1: Measuring an axis with AST default settings

The rotary axis (here: 4th axis) driven with a torque motor depends greatly on the inertia of the
clamped mass. If the load inertia changes, the axis must be measured again. No controller
values for AST should be overwritten; the optimization, however, is determined with new
measurements. The results, such as the complete inertia, can be read with CYCLE759. The
newly calculated values also indicate whether the controlled system has changed. In specific
cases, switching can be made to predefined controller data sets or the acceleration changed.
The AST default setting includes the speed and position controller optimization with "normal"
optimization objective. The determined controller data is, however, not activated in this
example.

Programming

Definition of global user variables (GUD)

To read out the complete moment of inertia, a new type CHAN REAL variable must be defined
in file MGUD.DEF (it is possible that this file must be newly created):

; Definition of GUD to read out the total moment of inertia:

DEF CHAN REAL _AST_R_ESTINERTIA

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Optimization cycle

Note
In the following program example, those cycle calls required for the measurement are
highlighted bold.
Any cycle calls not highlighted are optional.

DEF INT myaxiswithnewload=4

; Switch to a safe data set.
; Traverse axis to the safe position / home position.
; Is the optimization strategy set from the user interface?
; Is a destination data set (DDS) available that may be overwritten?

; Open the optimization session.

CYCLE751(1)

; Optimize axis 4: Optimization with a selected strategy based on a new

measurement.
; Optimization with default values (the selection from the AST user
interface is not used).
; No path interpolation, no values are written by AST.
CYCLE752(myaxiswithnewload,1,false)

; Save the original state in a file.

CYCLE755(1,"restorepoint1")

; Start the optimization without activating the results.

CYCLE751(4)

; Save the optimization data in an XML file.

CYCLE757(myaxiswithnewload,"axis_retuned.xml",1,,)

; Export the speed-controlled system.

CYCLE757(myaxiswithnewload,"speedctrlplant.csv",3,,)

; Fetch the inertia.

CYCLE759(myaxiswithnewload,34,,,"_AST_R_ESTINERTIA")

; If required check the optimization results, and then activate.

; Do not activate the results.
; Use predefined parameter sets.

; Close the optimization session.

CYCLE751(2)

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; Switch to the newly optimized DDS or select the predefined DDS depending
on the load inertia.
; Limit the acceleration depending on the new inertia.

M17

12.6.2 Example 2: Reoptimize the speed controller of an axis

The controller setting of the rotary axis (here: 4th axis), which is driven by a torque motor,
depends on the clamping equipment and the load moment of inertia. If the clamping equipment
or the load inertia changes, the axis must be measured again. A new controller parameter set
must be determined (a DDS will be overwritten), otherwise the axis would be unstable because
of the new resonances. New current setpoint filters must probably by set. Only the speed
controller is reoptimized. Because the position control remains identical and the precontrol
should not be changed, a similar bandwidth of the speed controller should be attained again.
For this purpose, a target bandwidth can be selected in the speed controller optimization
strategy. This is set to 100 Hz for the "normal compensation" optimization objective. If the new
load inertia and the clamping make many filters necessary and the ratio from the load inertia /
motor inertia is large, this objective may possibly not be achieved. In this case, a message is
issued. And the axis machine data is still set correctly from the first optimization (initial
commissioning). This means that the precontrol mode (MD32620 $MA_FFW_MODE), DSC
(MD32640 $MA_STIFFNESS_CONTROL_ENABLE), position controller gain (MD32200
$MA_POSCTRL_GAIN) and equivalent time precontrol (MD32800
$MA_EQUIV_CURRCTRL_TIME or MD32810 $MA_EQUIV_SPEEDCTRL_TIME) are set
correctly so that the loop interpolation is correct.
The results of the reoptimization, such as the complete inertia, can be read with CYCLE759.
The newly optimized speed controller is written to another data set. The path interpolation is
not considered here, because it is assumed that the precontrol data does not change
significantly or another axis has a larger time constant in MD32800
$MA_EQUIV_CURRCTRL_TIME. The optimization strategy for axis and speed controllers,
selected from the user interface, is deployed and was stored in the XML file for this axis (/card/
user/sinumerik/nck/data/optimization/AST_AX4_A1….xml).

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Preparation
● Select optimization strategy 105 from the user interface:

● If necessary, change the optimization objective (fast, moderate, robust) with the "Speed"
softkey.

Programming

Definition of global user variables (GUD)

To read out the complete moment of inertia, a new type CHAN REAL variable must be defined
in file MGUD.DEF (it is possible that this file must be newly created):

; Definition of GUD to read out the total moment of inertia:

DEF CHAN REAL _AST_R_ESTINERTIA

Optimization cycle

Note
In the following program example, those cycle calls required for the reoptimization are
highlighted bold.
Any cycle calls not highlighted are optional.

DEF INT myaxiswithnewload=4

; Switch to a safe data set.

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; Traverse axis to the safe position / home position.

; Is the optimization strategy set from the user interface?
; Is a destination data set (DDS) available that may be overwritten?

; Open the optimization session.

CYCLE751(1)

; Optimize axis 4: Optimization with a selected strategy based on a new

measurement.

; Add axis 4.
; Accept the optimization strategy from the standard optimization file (XML
file).
; The axis is not considered for an optimization of the path interpolation.
CYCLE752(myaxiswithnewload,3,false)

; Remove the current DDS from the data set list.

CYCLE754(myaxiswithnewload,2,2,-1)

; Add DDS3 to the data set list and overwrite after optimization.
CYCLE754(myaxiswithnewload,1,2,3)

; Save the original state in a file.

CYCLE755(1,"restorepoint1")

; Start the optimization by activating the results.

; CYCLE751(3)

; Start optimization without activation of the results, if necessary, check

the results first.
CYCLE751(4)

; Save the optimization data in an XML file.

CYCLE757(myaxiswithnewload,"axis_retuned.xml",1,,)

; Export the speed-controlled system.

CYCLE757(myaxiswithnewload,"speedctrlplant.csv",3,,)

; The inertia can be used to limit the acceleration:

; Fetch the inertia.
CYCLE759(myaxiswithnewload,34,,,"_AST_R_ESTINERTIA")

; If required check the optimization results, and then activate.

; Activate result:
; Activate axis-optimum results.

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; Save boot files.

CYCLE756(myaxiswithnewload,2,1)

; Close the optimization session.

CYCLE751(2)

; Switch to the newly optimized DDS or limit the acceleration depending on

the new inertia.

M17

12.6.3 Example 3: Reoptimize the speed controller and the position controller of an axis
The controller setting of the rotary axis (here: 4th axis), which is driven by a torque motor,
depends on the clamping equipment and the load moment of inertia. If the clamping equipment
or the load inertia changes, the axis must be measured again. New current setpoint filters must
probably by set. The speed controller must be reoptimized. Because it is not known whether
the low-frequency behavior has changed, the position controller must also be reoptimized and
the associated mechanical frequency response measured.
The results, such as the complete inertia, can be read with CYCLE759. The newly optimized
speed controller is written to another data set. The newly optimized position controller can be
written to any desired axis parameter set. The correct path interpolation is guaranteed by a
target value for the (precontrolled) positioning behavior being specified in accordance with the
previously optimized axes. The optimization strategy for axis and speed controllers, selected
from the user interface, is deployed and was stored in the XML file for this axis (/card/user/
sinumerik/nck/data/optimization/AST_AX4_A1….xml).

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Preparation
● Select optimization strategy 102 from the user interface:

● Press the "Position" softkey to display the window for adaptation of the position controller
strategy and select "User-defined strategy 209":

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● Select the "Force equivalent time target value" option.

Note
The "Force equivalent time target value" option is set, when in addition to the speed
controller, the position controller is also reoptimized, and despite an equivalent time of the
precontrol specified, the path interpolation should not be reoptimized.
To ensure the correct path interpolation, an equivalent time can be specified. This should
correspond to the equivalent time of the axes previously optimized on the path.

● Take the equivalent time (MD32800 $MA_EQUIV_CURRCTRL_TIME or MD32810

$MA_EQUIV_SPEEDCTRL_TIME depending on MD32620 $MA_FFW_MODE) from the
other axes (here, 3 ms).
● The following parameters must be set in the servo parameter set:
– Precontrol equivalent time (MD32800 $MA_EQUIV_CURRCTRL_TIME) = 3 ms
– Position controller gain (MD32200 $MA_POSCTRL_GAIN)

Note
For the automatic operation, the servo parameter set with the appropriate path-optimum
values must then be selected in the other axes (here: with equivalent time = 3 ms).

Programming

Definition of global user variables (GUD)

To read out the complete moment of inertia, a new type CHAN REAL variable must be defined
in file MGUD.DEF (it is possible that this file must be newly created):

; Definition of GUD to read out the total moment of inertia:

DEF CHAN REAL _AST_R_ESTINERTIA

Optimization cycle

Note
In the following program example, those cycle calls required for the reoptimization are
highlighted bold.
Any cycle calls not highlighted are optional.

DEF INT myaxiswithnewload=4

; Switch to a safe data set.
; Traverse axis to the safe position / home position.
; Strategy settings were made from the user interface: target value for the
equivalent time!
; Is a destination data set (DDS) available that may be overwritten?

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; Open the optimization session.

CYCLE751(1)

; Optimize axis 4: Optimization with a selected strategy based on a new

measurement.
; Add axis 4.
; Accept the optimization strategy from the standard optimization file (XML
file).
; The axis is not considered for an optimization of the path interpolation.
CYCLE752(myaxiswithnewload,3,false)

; Remove the current DDS from the data set list.

CYCLE754(myaxiswithnewload,2,2,-1)

; Add DDS3 to the data set list and overwrite after optimization.
CYCLE754(myaxiswithnewload,1,2,3)

; Axis: Add parameter set 4 to the data set list and overwrite after
optimization.
CYCLE754(myaxiswithnewload,1,1,3)

; Save the original state in a file.

CYCLE755(1,"restorepoint1")

; Start the optimization by activating the results.

; CYCLE751(3)

; Start optimization without activation of the results, if necessary, check

the results first.
CYCLE751(4)

; Save the optimization data in an XML file.

CYCLE757(myaxiswithnewload,"axis_retuned.xml",1,,)

; Export the speed-controlled system.

CYCLE757(myaxiswithnewload,"speedctrlplant.csv",3,,)

; The inertia can be used to limit the acceleration:

; Fetch the inertia.

CYCLE759(myaxiswithnewload,34,,,"_AST_R_ESTINERTIA")

; If required check the optimization results, and then activate.

; Activate result:
; Activate axis-optimum results.

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; Save boot files.

CYCLE756(myaxiswithnewload,2,1)

; Close the optimization session.

CYCLE751(2)

; Switch to the newly optimized DDS.

; Has Kv been optimized in the current parameter set?
; The equivalent time of the precontrol was forced by the strategy.
; For path interpolation, all axes must select the correct servo parameter
set.
; Limit the acceleration depending on the new inertia.

M17

12.6.4 Example 4: Reoptimization of the path interpolation

For a 5-axis machine, the rotary axis with torque motor (here: 4th axis) must position very
accurate and participate in the path interpolation. The changes of the clamping situation and
the inertia are completely unknown or so large that even large changes of the equivalent time
(also power controller) are expected. The unknown equivalent time means that the path
interpolation must be tested and compensated again after the axis optimization.
Only the rotary axis (workpiece-dependent) should be reoptimized. The other axes need to be
adapted in the precontrol only when the dynamic response of the rotary axis has changed
significantly. The rotary axis has several DDS. A safe data set that has a stable setting for
clamping the workpieces is selected. It must be considered that the mass inertia to be clamped
is not known. Consequently, the maximum inertia must be used for the calculation.
New current setpoint filters must probably be set for the rotary axis. The speed controller must
be reoptimized. Because it is not known whether the low-frequency behavior has changed,
the position controller must also be reoptimized and the associated mechanical frequency
response measured.
The results, such as the complete inertia, can be read with CYCLE759. The newly optimized
speed controller is written to another data set. The newly optimized position controller can be
written to any desired axis parameter set. The correct path interpolation is guaranteed by all
axes involved by being optimized by AST and now, after the reoptimization of the axis, the
path interpolation optimization is performed again by AST. The optimization strategy for axis
and speed controller, selected from the user interface, is deployed and was stored in the XML
file for this axis (/card/user/sinumerik/nck/data/optimization/AST_AX4_A1….xml). The path
optimization strategy set from the user interface is deployed and stored in the XML file for the
optimization of the path interpolation.

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Preparation
● No equivalent time is forced, namely, the predefined strategies for the position controller
optimization are deployed:

● For the path interpolation, the strategy (all equivalent times identical or use MD32895
$MA_DESVAL_DELAY_TIME) was already chosen for the first optimization.

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The following selection sets the balancing times (in MD32800

$MA_EQUIV_CURRCTRL_TIME or MD32810 $MA_EQUIV_SPEEDCTRL_TIME) of all
involved axes to the largest time constant:

● The following questions must be answered:

– Which axis parameter set may be reparameterized (for the path interpolation)?
– May the first axis parameter set be overwritten?
– Does the spindle need to be part of the path interpolation?
– If the thread cutting should also run with this axis configuration, parameter set 2 for the
axes and the gear stages in the spindle (parameter set 2 ... 6) may need to be optimized.
● Save the original path data!

Programming

Definition of global user variables (GUD)

To read out the complete moment of inertia, a new type CHAN REAL variable must be defined
in file MGUD.DEF (it is possible that this file must be newly created):

; Definition of GUD to read out the total moment of inertia:

DEF CHAN REAL _AST_R_ESTINERTIA

Optimization cycle

Note
In the following program example, those cycle calls required for the reoptimization are
highlighted bold.
Any cycle calls not highlighted are optional.

DEF INT myaxiswithnewload=4

; Switch to a safe data set.
; Traverse axis to the safe position / home position.
; Strategy settings were made from the user interface: target value for the
equivalent time!
; Is a destination data set (DDS) available that may be overwritten?

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; Each axis was already optimized once with AST (using the screen forms).
; As a consequence, the standard file for CYCLE752 exists for each axis.

; Open the optimization session.

CYCLE751(1)

; Optimize axis 4, with path interpolation.

; Select strategy:
; Add axis 4.
; Accept the optimization strategy from the standard optimization file (XML
file).
; The axis is considered for an optimization of the path interpolation.
CYCLE752(myaxiswithnewload,3,true)

; Measure axis 4 again and reoptimize, save the boot files.

CYCLE753(myaxiswithnewload,3,1)

; Add axis 1 because of the path interpolation.

CYCLE752(1,3,true)
; Axis 1, only post-optimize path interpolation.
CYCLE753(1,1,true)

; Add axis 2 because of the path interpolation.

CYCLE752(2.3,true)
; Axis 2, only post-optimize path interpolation.
CYCLE753(2,1,true)

; Add axis 3 because of the path interpolation.

CYCLE752(3.3,true)
; Axis 3, only post-optimize path interpolation.
CYCLE753(3,1,true)

; Add axis 6 because of the path interpolation.

CYCLE752(6,3,true)
; Axis 6, only post-optimize path interpolation.
CYCLE753(6,1,true)

; Remove the current DDS from the data set list.

CYCLE754(myaxiswithnewload,2,2,-1)
; Add DDS3 to the data set list and overwrite after optimization.
CYCLE754(myaxiswithnewload,1,2,3)

; Axis: Add parameter set 4 to the data set list and overwrite after
optimization.
CYCLE754(myaxiswithnewload,1,1,3)

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12.6 Examples

; Save the original state in a file.

CYCLE755(1,"restorepoint1")

; Start the optimization by activating the results.

CYCLE751(3)

; Save the optimization data in an XML file.

CYCLE757(myaxiswithnewload,"axis_retuned.xml",1,,)

; Save the measurement data of the speed controlled system to file.

CYCLE757(myaxiswithnewload,"speedctrlplant.csv",3,,)

; Save the result of the path optimization to file.

CYCLE757(1,"path_retuned.xml",2,0,0)

; Fetch the inertia.

CYCLE759(myaxiswithnewload,34,,,"_AST_R_ESTINERTIA")

; Close the optimization session.

CYCLE751(2)

; Switch to the newly optimized DDS.

; Kv has been optimized; switch to the appropriate parameter set.
; The path interpolation has been reoptimized.
; Limit the acceleration in axis 4 depending on the new inertia.

M17

12.6.5 Example 5: Reoptimize the speed control loop to eliminate known periodic
disturbance frequencies.
This example shows how the speed controller from the part program is reoptimized without
new measurement. The objective of the reoptimization is to minimize vulnerability to known
process-related periodic disturbance frequencies. The path interpolation is not reoptimized in
this example because the optimization strategy for the position controller provides a dynamic
customization by setting an equivalent time.

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12.6 Examples

Preparation
In the simplest case, only a speed controller optimization is necessary:
● Select optimization strategy 105 from the user interface:

Programming
DEF INT myAxis=4

; Open the optimization session.

CYCLE751(1)

; Add axis.
; The optimization data is loaded from the standard optimization file.
; The axis is not considered for an optimization of the path interpolation.
CYCLE752(myAxis,3,false,)

; The axis dynamic response is not measured again.

; The axis is reoptimized on the basis of the loaded measurement results
and the currently valid optimization strategy.
CYCLE753(myAxis,2,)

; Activate the use of the gain filter.

CYCLE758(myAxis,208,,,"true" )

; Gain filter: set the optimum frequency to 40 Hz.

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12.6 Examples

CYCLE758(myAxis,209,,,"40.0" )

; Perform the optimization.

CYCLE751(3)

; Save the axis-specific optimization data for the offline analysis.

CYCLE757(myAxis,"AX1_TEMP_40HZ.XML",1,,)

; For known periodic disturbance frequencies (40 Hz):

; Deactivate the use of the gain filter.

CYCLE758(myAxis,208,,,"false" )

; Perform the optimization.

CYCLE751(3)

; Close the optimization session.

CYCLE751(2)

; For normal broadband disturbances:

M17

12.6.6 Example 6: Measuring an axis without optimization

By selecting a strategy, which does not carry out any optimization, then the axis can be
automatically measured. This can be used to diagnose mechanical changes. These can
involve:
● Load weight
● Component stiffness
Using the automatic measurement, it can also be checked as to whether the control loop has
the same response as when the system was originally delivered, for example. This AST
strategy then supplies the actual measurement of the closed loop in the CSV format.
The following data can be automatically measured and exported:
● Speed controlled system
● Closed speed control loop (calculated and/or check measurement)
● Mechanical frequency response (if there are 2 encoders)
● Closed position control loop (calculated and/or check measurement of the position control
loop)

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12.6 Examples

Preparation
1. Select optimization strategy 109 from the user interface:

2. Measure and check controller settings.

3. Accept measurement results.
4. Save data under a new name (e.g. RESULT_STRATEGY109_AX1.xml) as user-defined
file (so that the standard optimization file is not overwritten).
The user-defined file is saved as standard to directory /card/user/sinumerik/hmi/log/
optimization.

Programming
Example of a cycle to measure an axis without optimization:

; Release brake
DEF INT AxNr=1

; Open the optimization session.

CYCLE751(1)

; For axis 1, the saved data are used from the user-defined file
RESULT_STRATEGY109_AX1.xml.
CYCLE752(AxNr,2,0,"/card/user/sinumerik/hmi/log/optimization/
RESULT_STRATEGY109_AX1.xml")

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12.6 Examples

; Start automatic measurement.

CYCLE751(4)

; Export the speed-controlled system in the CSV format.

CYCLE757(AxNr,"speedctrlplant.csv",3)

; Export the mechanical frequency response in the CSV format.

CYCLE757(AxNr,"mechresponse.csv",4)

; Export the speed control loop (calculated) in the CSV format.

CYCLE757(AxNr,"speedloopcalc.csv",5)

; Export the position control loop (calculated) in the CSV format.

CYCLE757(AxNr,"posloopcalc.csv",6)

; Export the speed control loop (measured) in the CSV format.

CYCLE757(AxNr,"speedloopmeas.csv",7)

; Export the position control loop (measured) in the CSV format.

CYCLE757(AxNr,"posloopmeas.csv",8)

; Close the optimization session.

CYCLE751(2)

M17

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cycles 13
Contents
The following sections describe how technology and special functions in the form of individual
loadable compile cycle files (*.ELF) are installed and activated in the control.

Technology functions available from Siemens in the form of compile cycles

● 1D/3D clearance control in position control cycle
Compile cycle: CCCLC.ELF
References: Function Manual Special Functions; Clearance Control (TE1)
● Handling transformation package
Compile cycle: CCRCTRA.ELF
References: Function Manual Special Functions; Handling Transformation Package (TE4)
● Setpoint exchange
Compile cycle: CCSETP.ELF
References: Function Manual Special Functions; Setpoint Exchange (S9)
● Axial coupling in the machine coordinate system (MCS coupling)
Compile cycle: CCMCSC.ELF
References: Function Manual Special Functions; MCS Coupling (TE6)
● Continue machining at the contour (retrace support)
Compile cycle: CCRESU
References: Function Manual Special Functions; Retrace Support (TE7)
● Fast laser switching signal
Compile cycle: CCHSLC.ELF
References: Function Manual Special Functions; Cycle-Independent Path-Synchronous
Signal Output (TE8)
● Axis pair collision protection
Compile cycle: CCPROT.ELF
References: Function Manual Special Functions; Axis Pair Collision Protection (TE9)

Compile cycle files (*.ELF) and CNC software versions

Compile cycle files (*.ELF) that have been generated for CNC software versions up to SW 4.4
cannot run on systems with CNC software versions as of SW 4.5.

Technology and special functions provided by Siemens in the form of compile cycles
New compile cycle files (*.ELF) for Siemens technology and special functions for CNC software
versions as of SW 4.5 can be obtained from your regional Siemens sales office.

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13.1 Loading compile cycles

Technology and special functions provided by third parties in the form of compile cycles
Compile cycle files (*.ELF) that have been generated for CNC software versions up to SW 4.4
must be adapted and recompiled with the generation environment for CNC software versions
as of SW 4.5. Details on the adaptation of the user-specific technology and special functions
can be found in the the Open Architecture (OA) documentation.

Compile cycles
Compile cycles are functional expansions of the NCK system software that can be created by
the machine manufacturer and/or by Siemens and then imported in the control later.
As part of the open NCK system architecture, compile cycles have comprehensive access to
data and functions of the NCK system level via defined software interfaces. In this way, compile
cycles significantly extend the functionality of the NCK.
Including a compile cycle in the NCK system software is performed by loading the compile
cycle into the file system of the NCK. The compile cycle can be loaded at any time.

Siemens compile cycles

Siemens compile cycles are the technological functions supplied by Siemens.
When you order one of these technological functions, you get only the corresponding software
license number. To obtain the compile cycle in the form of a loadable file (".ELF" extension for
"executable and linking format") please contact your regional Siemens sales partner.

Note
Compile cycles created by Siemens are options that require explicit activation and licensing.
References:
Ordering information in Catalog NC 60/61

13.1 Loading compile cycles

13.1.1 Loading a compile cycle with SINUMERIK Operate

Requirement
● The compile cycle to be transferred to the control must be saved on a storage medium
which can be directly connected to the control, such as a USB-FlashDrive.
● Access authorization of protection level 1 "Machine manufacturer" (default password
"SUNRISE") must be available.
● If there are no cursor keys on the operator panel, a mouse or keyboard must be connected
in order to perform the operator actions.

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13.1 Loading compile cycles

Execution
Perform the following steps to load a compile cycle from a USB-FlashDrive, for example:
1. Insert the USB-FlashDrive in the USB interface on the front of the operator panel.
2. At the user interface, change into the "System data" area:
Horizontal softkey bar: "Operating area switchover" > "Commissioning" > "System data"
3. Open the USB-FlashDrive: Directory "USB" (keyboard: "Enter" key).
4. Select the compile cycle and copy it:
Vertical softkey bar: "Copy"
5. Within the "System data" area, switch into the directory "NC data" > "Compile cycles" and
insert the compile cycle there:
Vertical softkey bar: "Insert"
6. Initiate an NCK reset to activate the compile cycle:
Horizontal softkey bar: "Operating area switchover" > "Commissioning" > "Machine data"
Vertical softkey bar: "Reset (po)"

13.1.2 Loading a compile cycle with HMI Advanced

Precondition
To transfer a compile cycle to the control, the following requirements must be met:
A storage medium (e.g. USB FlashDrive), which stores the compile cycle, is connected to the
PCU.

Execution
Perform the following operation to load a compile cycle from a USB FlashDrive to the NC:
1. Insert the USB FlashDrive into the PCU 50/70.
2. Open the USB FlashDrive as the local drive:
Operating area switchover > Services > Data admin > Local USB
If the "Local USB" is displayed as disabled, it implies the USB FlashDrive was not detected.
Wait until HMI Advanced has detected the USB FlashDrive.
3. Select the compile cycle and copy it:
vertical "Copy" softkey
4. Go to the OEM directory of the NC card:
ETC key (">") > "NC card" > Directory: "cc" or "Loadable Compile Cycles"
5. Add the compile cycle to the NC card's OEM directory:
Vertical "Add" softkey
6. Initiate an NCK reset.

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13.2 Interface version compatibility

13.1.3 Loading a compile cycle from an external computer with WinSCP3

Precondition
To transfer a compile cycle to the control, the following requirements must be met:
● The external computer (programming device / PC) which the compile cycle is loaded onto
is linked to the PCU via a network (TCP / IP).
● The program "WinSCP3" is installed on the external computer.
● The host name or the IP address of the PCU is known.
● The user name and the password to log onto the PCU are known.

Execution
Perform the following operation to load a compile cycle from an external computer into the
NCK:
1. Start the "WinSCP3" program on the external computer (programming device / PC)
2. Establish a connection to the PCU by selecting an appropriate profile or by entering the
host name or IP address, the user name and the password.
3. Copy the compile cycle from the external computer into the following directory on the PCU:
/card/oem/sinumerik/data/cc
The file name of the compile cycle should have any capital letters in the directory of the
PCU.
4. Initiate an NCK reset.

13.2 Interface version compatibility

The compile cycle and the NCK system software communicate via a SINUMERIK-specific
interface. The interface version used by the loaded compile cycle must be compatible with the
interface version of the NCK system software.

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13.2 Interface version compatibility

Interface versions
The relevant interface versions are displayed under:
● Interface version of the NCK system software
HMI Advanced:
Diagnosis > Service Display > Version > NCU Version
Display (excerpt)
-------------------------------------------
CC Interface Version:
@NCKOPI . . . .@Interfaces=<1st digit>.<2nd digit> . . . .
Loaded Compile Cycles:
....
-------------------------------------------
● Interface version of a compile cycle that has not yet been loaded
HMI Advanced (excerpt):
Services > <Medium> > Softkey: "Properties"
Display:
-------------------------------------------
Contents: Loadable compile cycle
Interface: . . . . @Interfaces=<1st digit>.<2nd digit> . . . .
-------------------------------------------
● Interface version of a loaded compile cycle
HMI Advanced:
Diagnosis > Service Display > Version > NCU Version
Display (excerpt)
-------------------------------------------
CC Interface Version:
@NCKOPI . . . .
Loaded Compile Cycles:
<Identifier> <Version> <Generation Data>
CC start address
_N_<Identifier><Version>IF<1st digit><2nd digit>_ELF . . .
-------------------------------------------
Example:
_N_CLC407IF003001_ELF corresponds to interface version: 3.1

Dependencies
The following dependencies exist between the interface versions of a compile cycle and the
NCK system software:
● 1. Position of the interface version number
The 1st digit of the interface version number of a compile cycle and the NCK system
software must be the same .
● 2. Position of the interface version number
The 2nd digit of the interface version number of a compile cycle must be less than or
equal to the 2nd digit of the NCK system software.
Note
If alarm 7200 is displayed after powering-up, this means no compile cycle has been loaded!

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13.4 Activating the technological functions in the NCK

13.3 Software version of a compile cycle

The SW version of a compile cycle is displayed under:
HMI Advanced:
Diagnosis > Service Display > Version > NCU Version
Display (excerpt)
-------------------------------------------
CC Interface Version:
@NCKOPI . . . .
Loaded Compile Cycles:
<Identifier> <Version> <Generation Data>
CC start address
_N_<Identifier><Version>IF<1st digit><2nd digit>_ELF . . .
Code=<Address> Data=<Address> . . .
-------------------------------------------
Example:
_N_CLC407IF003001_ELF corresponds to software version 4.7

Note
The display of code and data range start addresses of a compile cycle are provided for
diagnostics purposes only and have no significance in normal operation.

13.4 Activating the technological functions in the NCK

Requirement
The corresponding option must be enabled before activating a technology function as
described below.
If the option data has not been set, the following alarm appears every time the NCK boots and
the technology function will not be activated:
Alarm 7202 "XXX_ELF_option_bit_missing: <Bit number>"

Function-specific machine data

Each technology function loaded by compile cycle creates a function-specific global NCK
machine data within the range of numbers from 60900 to 60999 in accordance with the
following pattern:
$MN_CC_ACTIVE_IN_CHAN_<identifier>[n], with n = 0, 1
Example:

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13.6 Creating alarm texts

$MN_CC_ACTIVE_IN_CHAN_MCSC[0]
$MN_CC_ACTIVE_IN_CHAN_MCSC[1]

Activation for 1st NC channel

The technology functions are activated in the first NC channel via:
$MN_CC_ACTIVE_IN_CHAN_<identifier>[0], bit0 = 1
The meaning of machine data bits Bit1 - Bit31 are described in the relevant function description
(TE1 - REn).
After the NCK is booted up next, the activated technology functions are integrated into the
system software.

CAUTION
SINUMERIK 840D sl
The following alarm is displayed when a bit is set for the first time in the function-specific NCK
machine data:
$MN_CC_ACTIVE_IN_CHAN_XXXX[0]
:
Alarm 4400 "MD modification causes reorganization of the buffered memory (data loss)"
And you are warned that all user data (part programs, tool data, etc.) will be deleted on the
next run-up. If necessary, an archive should be created after setting the date and before
triggering NCK RESET.

13.5 Function-specific startup

Further function-specific installation routines are described in the corresponding function
description (TE1 - TEn).

13.6 Creating alarm texts

The alarm texts of the technology functions are stored in the system. If a new alarm is required,
then the alarm texts can be supplemented accordingly. The general process depends on the
existing interface.

13.6.1 Creating alarm texts with SINUMERIK Operate

The following alarms should be added to the alarm texts of the technology functions:
075999 0 0 "Channel %1 Sentence %2 Call parameter is invalid"

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13.6 Creating alarm texts

Proceed as follows
1. Please copy the "oem_alarms_deu.ts" file from the "/siemens/sinumerik/hmi/template/lng"
directory to the "/oem/sinumerik/hmi/lng" directory.
2. Rename the file ("xxx_deu.ts").
3. Open the file in the editor and add the new alarm number and the new alarm text in German:
<message>
<source>075999/NCK</source>
<translation>
Channel %1 block %2 call parameter is invalid
</translation>
</message>
Note
Each alarm starts with the <message> tag and ends with the </message> tag. The
<source> tag contains the alarm number and the source URL. The <translation> tag
contains the alarm text.

4. To create an alarm text file in a foreign language, copy the just changed file and modify the
language code in the filename (e.g., "xxx_eng.ts for English").
5. Open the foreign language alarm text file in the editor and record the translated alarm text
in the <translation> tag.
6. Please copy the "oem_slaesvcadapconf.xml" file from the "/siemens/sinumerik/hmi/base"
directory to the "/oem/sinumerik/hmi/cfg" directory.
7. Rename the file to "slaesvcadapconf.xml".
8. Open the "slaesvcadapconf.xml" file in the editor and record the new base name (filename
of the newly created alarm text file without language code and postfix), e.g.:
<BaseNames>
<BaseName_02 type="QString" value="xxx"/>
</BaseNames>
9. Restart SINUMERIK Operate.
More information about creating alarm texts with SINUMERIK Operate can be found in:
References:
SINUMERIK 840D sl Base Software and Operating Software Commissioning Manual;
SINUMERIK Operate (IM9) Commissioning Manual, Section: Configuring machine data/alarms

13.6.2 Creating alarm texts with HMI Advanced

The following alarms should be added to the alarm texts of the technology functions:
075999 0 0 "Channel %1 Sentence %2 Call parameter is invalid"

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13.7 Upgrading a compile cycle

Proceed as follows
1. Copy the "mbdde.ini" file from the "F:\mmc2" directory to the "F:\oem" directory.
2. Add the following two lines in the "mbdde.ini" file:
[TextFiles]
UserCZYK=F:\oem\alc_
3. Create the language-dependent "alc_XX.com" text files in the "F:\oem" directory, e.g.:
"alc_GR.com" for German
"alc_UK.com" for English
4. Insert the new alarm text in the language-dependent text files, e.g.:
075999 0 0 "Channel %1 Sentence %2 Call parameter is invalid"
in the text file in German.
5. Restart HMI Advanced.
For more information about creating alarm texts with HMI Advanced, please refer to:
References:
SINUMERIK 840Di sl/840D sl/840D Base Software and HMI Advanced Commissioning
Manual; HMI-Advanced (IM4) Commissioning Manual, Section: Configuring user alarms

Note
HMI reinstallation
Retain the added alarm texts in the text files of the F:\oem even after a reinstallation of HMI.

13.7 Upgrading a compile cycle

To upgrade a compile cycle installed in the control, under no circumstances is it sufficient to
just exchange the corresponding ELF file. If only the ELF file is replaced, then this can result
in undefined behavior of the NCK software due to inconsistent data of the memory and data
management.

Execution
Perform the following actions to upgrade a compile cycle:
1. Create an NC archive without compile cycles:
Operating area: "Commissioning" > "ETC" key > "Commissioning archive" > "Creating a
commissioning archive" > "OK" >
– Selection: "NC data" selected
– Selection: "with Compile cycles" not selected!
2. Delete the old compile cycle:
Operating area: "Commissioning" > "System data" in the directory: NC data > "Compile
cycles" > file: <Identifier>.ELF
3. Download the new compile cycle (see Section "Loading compile cycles (Page 574)")

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TE01: Installation and activation of loadable compile cycles
13.8 Deleting a compile cycle

4. Initiate a power on reset with an NCK general reset (NCK commissioning switch: position
"1"). See:
References:
Commissioning Manual IBN CNC: NCK, PLC, Drive; Section: General tips > Separate NCK
and PLC general reset > NCK general reset
5. Download the NC archive created under Point 1 into the NCU again.
Operating area: "Commissioning" > "ETC" key > "Commissioning archive" > "Read-in
commissioning archive" > "OK"

Note
Version check
To check the version of the newly loaded compile cycle, see Section "Software version of a
compile cycle (Page 578)"
Several loaded compile cycles
If several compile cycles are loaded in the control, when upgrading a compile cycle according
to the process described above, the other compile cycles remain unchanged.
Newly created data
If the new compile cycle creates new data, which were still not available in the previous version,
then after subsequently booting the control, these are preassigned default values.

13.8 Deleting a compile cycle

If a loaded compile cycle is to be completely deleted in the control, it is not enough to only
delete the corresponding ELF file. With this procedure, the following data is kept in the retentive
memory of the control:
● Activation data: $MN_CC_ACTIVE_IN_CHAN_<identifier>[n]
● Function-specific machine data

Execution
Perform the following actions to delete a compile cycle:
1. Create an NC archive without compile cycles:
Operating area: "Commissioning" > "ETC" key > "Commissioning archive" > "Creating a
commissioning archive" > "OK" >
– Selection: "NC data" selected
– Selection: "with Compile cycles" not selected!
2. Delete the compile cycle:
:Operating area: "Commissioning" > "System data" in the directory: NC data > "Compile
cycles" > File: Select "<Identifier>.ELF" > "Delete"

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13.9 Data lists

3. Initiate a power on reset with an NCK general reset (NCK commissioning switch: position
"1"). See:
References:
Commissioning Manual IBN CNC: NCK, PLC, drive; Chapter: General tips > Separate NCK
and PLC general reset > NCK general reset
4. Download the NC archive created under Point 1 into the NCU again.
Operating area: "Commissioning" > "ETC" key > "Commissioning archive" > "Read-in
commissioning archive" > "OK"

Note
Several loaded compile cycles
If several compile cycles are loaded in the control, when deleting a compile cycle according
to the process described above, the other compile cycles remain unchanged.
Efficient memory usage
To use the memory resources in the NCK as efficiently as possible, you should only load the
compile cycles (ELF files) that are actually required into the machine.

13.9 Data lists

13.9.1 Machine data

13.9.1.1 NC-specific machine data

Number Identifier: $MN_ Description

60900 + i CC_ACTIV_IN_CHAN_XXXX[n] n = 0:
with: with: Activating the technology function in NC channels
i = 0, 1, 2, XXXX = function code n = 1:
3, ... n = 0 or 1 Additional functions within the technology function

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13.9 Data lists

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TE02: Simulation of Compile Cycles (only HMI
Advanced) 14
14.1 Brief description

14.1.1 Function
If, at the SINUMERIK user interface "HMI Advanced" part programs are simulated that use
compile cycles, depending on the compile cycle being used, general specific conditions must
be established. These are described in the subsequent chapters.

14.2 OEM transformations

When using OEM transformations, the simulation runtime environment has to be set.

Proceed as follows
1. On the computer, on which HMI Advanced is installed, in addition to the directory available
as standard "<HMI Advanced installation path>/MMC2", create a new directory "<HMI
Advanced installation path>/OEM".
2. In the "OEM" directory, create the file "DPSIM.TEA" with the following content:
$MN_NC_USER_CODE_CONF_NAME_TAB[196]="TRAORI"
$MN_NC_USER_CODE_CONF_NAME_TAB[197]="_TRAORI"
$MN_NC_USER_CODE_CONF_NAME_TAB[198]="TRACON"
$MN_NC_USER_CODE_CONF_NAME_TAB[199]="_TRACON"
CHANDATA(1)
$MC_AXCONF_GEOAX_ASSIGN_TAB[0]=1
$MC_AXCONF_GEOAX_ASSIGN_TAB[1]=2
$MC_AXCONF_GEOAX_ASSIGN_TAB[2]=3
$MC_TRAFO_RESET_VALUE=0
; Make sure that transformation types 4096 - 4101 are deleted
$MC_TRAFO_TYPE_1=0
$MC_TRAFO_TYPE_2=0
$MC_TRAFO_TYPE_3=0
; Delete transformation chains with OEM transformations
$MC_TRACON_CHAIN_1[0]=0
$MC_TRACON_CHAIN_1[1]=0
; NOTICE! No spaces after M30
M30
3. In the "OEM" directory, create the file "DPSIM.INI" with the following content:
[PRELOAD]
CYCLES=1
CYCLEINTERFACE=0

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TE02: Simulation of Compile Cycles (only HMI Advanced)
14.2 OEM transformations

4. Close the HMI application.

5. Launch the HMI application.
6. In the directory for the manufacturer cycles, create the file "TRAORI.SPF" with the following
content:
PROC TRAORI(INT II)
RET
7. In the directory for the manufacturer cycles, create the file "TRACON.SPF" with the
following content:
PROC TRACON(INT II)
RET
Note
The "TRAORI.SPF" and "TRACON.SPF" manufacturer cycles created under 6. and 7. must
not be loaded onto the NC.

8. Start the simulation.

9. Run a data comparison for the cycles after the simulation has started up:
HMI Advanced: Data comparison > Compare cycles
Note
At least the password for protection level 3 "End user: Service" is needed for the data
comparison.

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TE1: Clearance control - 840D sl only 15
15.1 Brief description

15.1.1 General information

Function description
The "clearance control" technological function is used to maintain a one-dimensional (1D) or
three-dimensional (3D) clearance required for technological reasons during a defined
machining process. The clearance to be maintained may be e.g. the distance of a tool from
the workpiece surface to be machined.

Function code
The code for the "clearance control" technological function for function-specific identifiers of
program commands, machine data, etc. is:
CLC = Clearance Control

Function restriction
The "clearance control" technological function is only available in the first NC channel, even
on controls with more than one NC channel. This means:
● Only channel axes in the first NC channel may be used as clearance-controlled axes.
● CLC part program commands for the clearance control may only be used in part programs
processed in the first NC channel.
Note
The "clearance control" technological function is only available in the first NC channel!

Availability
The "clearance control" technological function is available in SINUMERIK 840D sl.

Compile cycle
The "clearance control" technological function is a compile cycle.
For a description of the system-specific availability and use of compile cycles (see Section
"TE01: Installation and activation of loadable compile cycles (Page 573)").

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15.1 Brief description

15.1.2 Function description

Laser cutting technology is used as an example for the detailed description of the "clearance
control" functionality.

Laser cutting
During laser cutting, a divergent parallel laser beam is directed across a fiber-optic cable or
via a mirror to a light-collecting lens mounted on the laser machining head. The collecting lens
focuses the laser beam at its focal point. Typical focal lengths are from 5 to 20 cm.
The position of the focal point in relation to the workpiece is an extremely critical process
parameter in laser cutting operations and must be kept constant within a tolerance of ≤100 µm.
The distance between the focal point and the workpiece, which is also a key process variable,
is usually measured by means of a high-speed capacitive clearance sensor. The analog output
voltage of the clearance sensor is approximately proportional to the distance between the
sensor and the workpiece surface.
The output voltage of the clearance sensor is transmitted as a digital input value via an analog
I/O module to the control where, in the event of deviations from the setpoint clearance, it
generates an additional velocity setpoint for the machining head motion axes.

System overview (840D sl)

An overview of the system components required for clearance control in conjunction with
SINUMERIK 840D sl is provided in the following diagram.

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 TE1: Clearance control - 840D sl only
15.2 Clearance control

1D/ 3D machining
Clearance control can be used for 1D and 3D machining with up to five interpolatory axes.
● 1D machining
For the 1D machining, only one axis is affected by the clearance control. For example, axis
Z, as shown in the machine configuration described in the system overview (see previous
figure). Clearance control acts only in the direction of the Z axis.
● 3D machining
3 linear axes are used to position the tool. One or two rotary axes are used for the orientation
of the tool vector (5-axis machining). Up to 3 linear axes are controlled by the clearance
control. The direction of the compensation movement can be defined either in the direction:
– of the tool orientation vector (normal case)
– of the programmable compensation vector

15.2 Clearance control

15.2.1 Control dynamics

Control loop gain KV

The dynamic response of the closed control loop (sensor - open-loop control - axis) is
determined by the maximum closed-loop control gain KV.
The closed-loop control gain KV is defined as:

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15.2 Clearance control

Clearance control characteristics

Clearance control is based on the two characteristics shown in the following diagram:
● Clearance sensor characteristic (sensor property)
● Clearance control characteristic (can be parameterized via machine data)
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● The clearance sensor measures the actual distance from the workpiece surface and returns
as its output variable a voltage in [V], which is almost directly proportional to the distance.
● The clearance control function uses the parameterized voltage/velocity characteristic from
the voltage provided by the clearance sensor to calculate a compensatory velocity for the
clearance-controlled axes that is appropriate for the clearance.
From the point of view of the control, the unit for the closed-loop control gain is [(mm/min)/V].
In the same way as the setpoint clearance in standardized in [mm], values can only be
standardized in [(mm/min)/mm] by using the sensor electronics.

Max. closed-loop control gain

The maximum achievable closed-loop control gain is determined by the following delay and
reaction times of the overall system:
1. Reaction time of sensor
2. Delay time of A/D converter
3. Signal processing delay times/deadtimes
4. Reaction time of position controller
5. Reaction times of speed and current controllers
6. Time constants of motor and mechanical components
In practice, only items 3 and 4 are relevant.

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 TE1: Clearance control - 840D sl only
15.2 Clearance control

The influencing variables together produce an effective time constant. A closed-loop control
gain set too high based on this time constant will induce natural oscillations in the range of
several hertz in the axis/axes to be controlled.
The objective when starting up the clearance control is to minimize important time constants
so that the closed-loop control gain required by the process can be set without inducing natural
oscillation of this type.

Dead time
In order to maximize the dynamics of the control response, clearance control takes place on
the highest priority position controller level of the NCK.
SINUMERIK 840D sl with I/O modules and drives connected via PROFIBUS DP produces a
deadtime Tdead of:
Tdead = 2 * position controller cycle + 2 * speed controller cycle + input lead time Ti

15.2.2 Velocity feedforward control

Eliminating the delay time

The closed-loop control gain, KV, set for the position controller, corresponds to a delay time
Δt. The display time, Δt, is the time which elapses until the actual position of the axis to be
controlled reaches the set position at a prescribed velocity of v.


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Optimizing the control response

If the control response of the axis is too rigid due to the velocity feedforward control, the control
response can be optimized with the following axis-specific NC machine data:
● MD32410 $MA_AX_JERK_TIME (time constant for the axial jerk filter)
● MD32610 $MA_VELO_FFW_WEIGHT (feedforward control factor for speed)

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15.2 Clearance control

The speed filters of the SINAMICS S120 drive provide additional damping capabilities:
● Parameter 1414 and following: (time constant for speed setpoint filter 1, 2)
Note
Every damping measure implemented contributes to increasing the overall time constant
of the control loop!

You will find a complete description of the velocity feedforward control in:

References
Function Manual, Extended Functions; Compensation (K3),
Chapter: Following error compensation (feedforward control)

15.2.3 Control loop structure

The figures below provide an overview of how the clearance control function is embedded in
the control loop structure of the NC position controller and the internal structure of the function.

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 TE1: Clearance control - 840D sl only
15.2 Clearance control

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15.2.4 Compensation vector

Standard compensation vector

The compensation vector of the clearance control and the tool orientation vector are normally
identical. Consequently, the compensation movement of the clearance control is normally
always in the direction of the tool orientation.

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15.2 Clearance control

Note
In all the figures in this section, the traversing movement of the machining head needed in
order to machine the workpiece is in the direction of the Y coordinate, i.e. perpendicular to the
drawing plane.

As long as the tool orientation, and hence the compensation vector, is perpendicular to the
workpiece surface, no disadvantage for the machining process results from the compensation
movements of the clearance control.
If a tool setting angle is needed for technological reasons, with the result that the tool orientation
is no longer perpendicular to the workpiece surface, the machining point on the workpiece
surface is shifted during compensation movements of the clearance control along the standard
compensation vector.

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The reason for the shift in the machining point is the X component (KX) of the compensation
vector parallel to the workpiece surface. The TCP of the tool, and thus the machining point B,
is shifted by this amount.

Programmable compensation vector

When using the programmable compensation vector, the compensation movements of the
clearance control are in the direction of the programmed vector, and not in the direction of the
tool orientation.
The X component specified above (KX) is omitted because the programmable compensation
vector is defined perpendicular to the workpiece surface. This does not cause the machining
point (B) to be shifted as a result of the compensation movement of the clearance control.

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15.2 Clearance control

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Changes in orientation
Based on the above observations, a different behavior also results when the orientation of the
machining head is changed while the clearance control is active.
In the following diagram the normal case is shown on the left (compensation vector == tool
orientation vector); and the case with the programmed compensation vector is shown on the
right.

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15.3 Technological features of clearance control

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

1. Programmed position of the machining head
2. Actual position of the machining head with clearance control active before the orientation
change
3. Programmed position of the machining head after the change in orientation
4. Actual position of the machining head with clearance control active after the orientation
change
The machining head movement visible on the machine when the change in orientation takes
place is direct from position 2 to position 4.

15.3 Technological features of clearance control

Clearance control is characterized by the following technological features:
● Dynamic Response
The overlaid sensor motion uses the current residual dynamic response that is still in
reserve after the programmed axis motion (velocity and acceleration). The proportion of
residual acceleration that must be used can be set as a percentage in a machine data.
● Sensor characteristic
The gain characteristic of a sensor can be defined with up to 10 interpolation points.
● Sensors
Two sensors with different gain characteristics (e.g. a mechanical and a capacitive sensor)
can be used simultaneously. The active sensor characteristic can be switched over block-
synchronously by means of a language command in the part program.
● Closed-loop control gain of clearance control
The closed-loop control gain configured in the NC machine data for clearance control can
be changed block-synchronously by means of a language command in the part program.
● Motion limitation
The lower and upper limits configured in the NC machine data for the axis movements
induced by clearance control can be changed block-synchronously by means of a language
command in the part program.
An alarm appears when a limit is reached. The alarm response (stop all traversing
movements or display only) can be parameterized. The current position offset can be frozen
by means of a PLC signal.
● Response on deactivation
The deactivation response of the clearance control function can be programmed either for
synchronization with the current axis positions (no compensating movement) or for
compensating axis movements to the last programmed axis positions (axis positions
without clearance control).
● Programmable clearance setpoint
An additional voltage value can be programmed in order to alter the setpoint distance set
in the sensor electronics on a block-related basis.

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15.4 Sensor collision monitoring

● Control options via the PLC interface

The following signals are available at the PLC interface:
Status signals:
– Closed-loop control active
– Overlaying movement at standstill
– Lower limit reached
– Upper limit reached.
Control signals:
– Path override for sensor movement active
● Status data of clearance control
Both the current values and the min/max values of the sensor signal and of the position
offset are available as GUD and/or OPI variables.
● Sensor signal
The sensor signal can be smoothed via a PT1 filter with adjustable time constant.

15.4 Sensor collision monitoring

Sensor signal
If the clearance sensor used has an additional "sensor collision" signal for detecting a collision
between the sensor and the workpiece being machined, this signal can be made available to
the clearance control function via a digital NCK peripheral input.
In response to this signal, the clearance control function applies a retraction motion in all
clearance-controlled axes. The retraction motion is executed independently of the current
value of the velocity override with maximum traversing velocity in a positive control direction
until the currently valid upper limit of the control range is reached. Path motion is stopped
simultaneously.
Once all traversing movements have come to a standstill, part program processing can be
resumed with NC START.

Parameterization
The digital peripheral input, which the "sensor collision" signal is wired to, is assigned to the
clearance control function via the following machine data:
MD62504 $MC_CLC_SENSOR_TOUCHED_INPUT (digital peripheral input for "sensor
collision" signal)
The digital peripheral input is specified by entering the input number in the same way as $A_IN/
$A_OUT digital I/O peripheral system variables are specified ($A_IN[input number]).
If a negative input number is entered, the "sensor collision" signal will be processed with
internal inversion by the clearance control function (fail safe method).

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15.5 Startup

15.5 Startup

Compile cycle
Before commissioning the technological function, ensure that the corresponding compile cycle
has been loaded and activated (see Section "TE01: Installation and activation of loadable
compile cycles (Page 573)").

15.5.1 Activating the technological function

The technological function is activated via the machine data:
MD60940 $MN_CC_ACTIVE_IN_CHAN_CLC[0], bit n = 1
n = channel number - 1; bit0 = channel 1, bit1 = channel 2, etc.

Note
The technological function can be activated for several channels simultaneously.

15.5.2 Configuring the memory

The technological function requires additional data in the NCK-internal block memory. The
values must be increased for the following memory configuring channel-specific machine data:
● MD28090 $MC_MM_NUM_CC_BLOCK_ELEMENTS += 4 (number of block elements for
compile cycles)
● MD28100 $MN_MM_NUM_CC_BLOCK_USER_MEM += 20 (size of block memory for
compile cycles (DRAM) in KB)

15.5.3 Parameter settings for input signals (840D sl)

The following input signals must be parameterized in the machine data:
● Clearance sensor input voltage
– 1 analog input
● "Sensor collision" input signal (optional)
– 1 digital input

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15.5 Startup

Analog input
The following machine data must be parameterized for the analog input:
● MD10300 $MN_FASTIO_ANA_NUM_INPUTS (number of active analog NCK inputs)
● MD10362 $MN_HW_ASSIGN_ANA_FASTIN (per analog module) (hardware assignment
for the fast analog NCK inputs)
Specifying the physical address activates the analog input module

Digital input
The following machine data must be parameterized for the digital input:
● MD10350 $MN_FASTIO_DIG_NUM_INPUTS (number of active digital NCK input bytes)
● MD10366 $MN_HW_ASSIGN_DIG_FASTIN (per digital module) (hardware assignment for
the external digital NCK inputs)
Specifying the physical address activates the digital input module.
A complete description of the analog and digital inputs appears in:
References:
Function Manual, Extended Functions, Digital and Analog NCK I/Os (A4)

15.5.4 Parameters of the programmable compensation vector

Reference coordinate system

The programmable compensation vector specifies the direction in which the compensation
movement of the clearance control takes place. The compensation vector always refers to the
basic coordinate system (machine coordinate system).
The start coordinates [Xa, Ya, Za] of the compensation vector coincide with the origin of the
basic coordinate system and are thus always [0, 0, 0].
The end coordinates [Xe, Ye, Ze] of the compensation vector are determined by the actual
positions of 3 channel axes, known as the direction axes.

Direction axes
The direction axes must meet the following conditions:
1. The direction axes must be channel axes of the channel in which the clearance control is
activated.
2. The direction axes must be linear axes.
Note:
Since the direction axes are only used to interpolate the direction components, they do not
need mechanical axes and can therefore be configured as simulation axes.
3. [mm] or [inch] must be selected as the unit of measurement for the direction axes.

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15.5 Startup

4. The direction axes may not participate in an axis coupling, e.g. transformation, electronic
gear, etc.
5. To ensure that the dynamic response of the path is not limited by the dynamic response of
the direction axes, the following machine data for the direction axes must be set equal to
or more than the corresponding values of the geometry axes of the channel:
– MD32000 $MA_MAX_AX_VELO[x] (maximum axle velocity)
– MD32200 $MA_POSCTRL_GAIN[x] (Kv factor)
– MD32230 $MA_MAX_AX_ACCEL[x] (position controller structure configuration)
x = axle number
The following machine data is used to specify which channel axis is the direction axis:
● MD62528 $MC_CLC_PROG_ORI_AX_MASK (progr. orientation vector: axis mask)
Each machine data bit corresponds to a channel axis.

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● Coordinate X = channel axis corresponding to bit a

● Coordinate Y = channel axis corresponding to bit b
● Coordinate Z = channel axis corresponding to bit c
with a < b < c

Current difference angle

The difference angle is the angle between the tool orientation vector and the compensation
vector. If the current difference angle of the clearance control is to be output in a system
variable $AC_PARAM[n], index n of the system variable should be entered in the following
machine data:
MD65530 $MC_CLC_PROG_ORI_ANGLE_AC_PARAM ()

Permissible limit angle

The permissible limit angle specifies the maximum difference angle allowed between the tool
orientation vector and the compensation vector. The limit angle is configured via the following
machine data:
MD65520 $MC_CLC_PROG_ORI_MAX_ANGLE ()

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15.5 Startup

15.5.5 Parameter settings for clearance control

The part program name

The following machine data must be parameterized for the declaration of the function-specific
part program name CLC_GAIN and CLC_VOFF:
● MD10712 $MN_NC_USER_CODE_CONF_NAME_TAB[0] = "OMA1" (list of re-configured
NC codes)
● MD10712 $MN_NC_USER_CODE_CONF_NAME_TAB[1] = "CLC_GAIN"
● MD10712 $MN_NC_USER_CODE_CONF_NAME_TAB[2] = "OMA2"
● MD10712 $MN_NC_USER_CODE_CONF_NAME_TAB[3] = "CLC_VOFF"

1D/ 3D clearance control

The following machine data is used to select 1D or 3D clearance control:
● MD62500 $MC_CLC_AXNO = <n> (axis assignment for clearance control)
– <n> > 0: 1D clearance control where <n> = axis number of the clearance-controlled
channel axis
– <n> = -1: 1. 5-axis transformation configured in channel
– <n> = -2: 2. 5-axis transformation configured in channel

Input signals
The clearance sensor input signals parameterized above are made known to the clearance
control function with the following machine data (see also Section "Parameter settings for input
signals (840D sl) (Page 598)"):
● MD62502 $MN_CLC_ANALOG_IN = <n> (analog input for the clearance control)
<n= input number, analog to the addressing of the system variables $A_INA[<n>]
● MD62504 $MN_CLC_SENSOR_TOUCHED_INPUT = <n> (assignment of an input bit for
the "sensor collision" signal)
<n= input number, analog to the addressing of the system variables $A_IN[<n>]

Exact stop
In order to be able to meet a programmed "Exact stop coarse/fine reached" block change
condition (G601/G602), the traversing velocity induced by the clearance control function in the
clearance-controlled axes must be lower than the standstill velocity tolerance at least for the
duration of the standstill delay time.
The following machine data must be modified to optimize the block change time:
● MD36000 $MA_STOP_LIMIT_COARSE[<x>] (exact stop coarse)
● MD36010 $MA_STOP_LIMIT_FINE[<x>] (exact stop fine)
● MD36020 $MA_POSITIONING_TIME[<x>] (delay time exact stop fine)

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15.5 Startup

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

● MD36060 $MA_STANDSTILL_VELO_TOL[<x>] ("axis/ spindle stopped" velocity/speed
threshold)
<x> = axis number of clearance-controlled machine axis

15.5.6 Starting up clearance control

Clearance sensor
The clearance sensor outputs should be connected to the I/O modules that were activated
using the following machine data:
● MD10362 $MN_HW_ASSIGN_ANA_FASTIN (I/O address of the I/O module) (hardware
assignment of the fast analog NCK inputs)
● MD10366 $MN_HW_ASSIGN_DIG_FASTIN (I/O address of the I/O module) (hardware
assignment of the external digital NCK inputs)
(See also Section " "Supplementary conditions > I/O modules (Page 621)").

Test control direction

Proceed as follows to test the control direction of the clearance control function:
● Activating the clearance control function using the part program with CLC(1) (see Chapter
"Activating and deactivating clearance control (CLC) (Page 604)")
● Generate an input voltage, e.g. via the following synchronized action:

Program code
N100 $AC_TIMER[1]=2.5
N110 ID = 1 EVERY $AC_TIMER[1] >= 2.5 DO $AC__TIMER[1]=0
N120 ID = 2 WHENEVER $AC_TIMER[1] < 2.0 DO $A_OUTA[6] = 100000.0 *
($AC_TIMER[1] - 1.0)
N130 ID = 3 WHENEVER $AC_TIMER[1] >= 2.0 DO $A_OUTA[6] = 0.0

2XWSXWYROWDJH>9@


    7LPH>V@



Figure 15-9 Output voltage for synchronized action

Special functions
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15.5 Startup

The voltage specification for the analog output $A_OUTA[6] used in the synchronized action
is subtracted from the clearance sensor input voltage by the clearance control function and
therefore has the opposite polarity to the input signal.
Set the following machine data to induce the clearance control function to use analog output
6 ($A_OUTA[6]) as an additional input overlaid on the sensor input:
MD62522 $MN_CLC_OFFSET_ASSIGN_ANAOUT = 6 (hardware assignment of the external
digital NCK inputs)

Note
Before the clearance control function is activated for the first time, check that the entire working
range enabled for clearance control is collision-free:
● MD62505 $MC_CLC_SENSOR_LOWER_LIMIT (lower clearance control motion limit)
● MD62506 $MC_CLC_SENSOR_UPPER_LIMIT (upper clearance control motion limit)

An incorrect control direction can be corrected using one of the following methods:
● Reversing the polarity of the analog input
● Changing the sign of all values in the following machine data:
– MD62511 $MC_CLC_SENSOR_VELO_TABLE_1 (coordinate velocity of interpolation
points sensor characteristic 1)
– MD62513 $MC_CLC_SENSOR_VELO_TABLE_2 (coordinate velocity of interpolation
points sensor characteristic 2)

Sensor signal

Signal quality
The quality of the analog input signal can be checked using the function-specific display data
(see Chapter "Function-specific display data (Page 617)").

Input voltage range

The input voltage range for the measuring signal of the sensor can be adapted using the
machine data for the weighting factor for the analog NCK inputs:
MD10320 $MN_FASTIO_ANA_INPUT_WEIGHT[<analog input>] = <weighting factor>
The following machine data must be set in order that the weighting factor from the clearance
control function is included in the calculation:
MD62508 $MC_CLC_SPECIAL_FEATURE_MASK, Bit 13 = 1

Function-specific alarm texts

To display function-specific alarm texts, these must first be incorporated in the appropriate
HMI data management (see Chapter "Creating alarm texts (Page 579)").

Special functions
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15.6 Programming

Completion
A data backup is recommended once the start-up procedure has been completed.
References:
Commissioning Manual IBN CNC: NCK, PLC, drive

Note
A data backup is recommended once the start-up procedure has been completed.

15.6 Programming

15.6.1 Activating and deactivating clearance control (CLC)

Syntax
CLC(Mode)
Mode
● Format: Integer
● Range of values: -1, 0, 1, 2, 3
CLC(...) is a procedure call and must therefore be programmed in a dedicated part program
block.

Functionality
The following modes are available for activating/ deactivating clearance control:
● CLC(1)
Activation of the clearance control with compensation vector in the direction of the tool
orientation
The evaluation of the sensor collision signal is deactivated.
● CLC(2)
Activation of the clearance control with compensation vector in the direction of the tool
orientation
The evaluation of the sensor collision signal is activated.
● CLC(3)
Activation of the clearance control with programmed compensation vector
The evaluation of the sensor collision signal is deactivated.

Special functions
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● CLC(0)
Deactivation of clearance control without canceling the position offset.
If the clearance-controlled axes are still moving at the instant of deactivation due to the
sensor signal, they are stopped. The workpiece coordinate system (WCS) is then
synchronized with the corresponding standstill positions. An automatic preprocessing stop
is executed.
● CLC(-1)
Deactivation of clearance control with cancellation of the position offset
If the clearance-controlled axes are still moving at the instant of deactivation due to the
sensor signal, they are stopped. A position offset to the last programmed position is
canceled automatically with the deactivation command.

RESET behavior
CLC(0) is executed implicitly on a reset (NC RESET or end of program).

Parameterizable RESET behavior

The reset response of a 1D clearance control function can be determined via the channel-
specific NCK OEM machine data:
● MD62524 $MC_CLC_ACTIVE_AFTER_RESET (reset response with active CLC)

CAUTION
Clearance control
The channel-specific NCK OEM machine data MD62524 is only effective in conjunction
with a 1D clearance control function.
For 3D clearance control, CLC(0) is always effective in the event of a RESET.

The following response can be parameterized:

● MD62524 $MC_CLC_ACTIVE_AFTER_RESET = 0
In the event of a reset, the clearance control function responds as it does to deactivation
with CLC(0) (see "Functionality" section).
● MD62524 $MC_CLC_ACTIVE_AFTER_RESET = 1
The current state of the clearance control function is retained.

Boundary conditions
Please note the following supplementary conditions:

Continuous-path mode
Activating/ deactivating clearance control (CLC(mode)) during active continuous-path mode
(G64/G64x) will induce a drop in velocity for path motions. To avoid voltage drops of this type,
clearance control must be activated before a path section with constant path velocity. During
the corresponding path section, if necessary, clearance control can be blocked and then re-
enabled via the programmed gain factor for clearance control (CLC_GAIN).

Special functions
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15.6 Programming

Block change with exact stop

If exact stop is active at the end of the block (G60/G09 with G601/G602) the block change
may be delayed due to axis movements induced by the clearance control sensor signal.

Sensor collision monitoring

A digital input for an additional collision signal can be configured by the sensor using the
following machine data:
MD62504 $MC_CLC_SENSOR_TOUCHED_INPUT (assignment of the input signal for the
"sensor collision" signal)
This collision monitor can be activated and deactivated block-synchronously through alternate
programming of CLC(1)/CLC(2).
As a reaction to the sensor collision signal, the clearance control moves, irrespective of the
feedrate override setting, at maximum velocity in the plus direction until it reaches the currently
valid upper limit. The path motion is stopped simultaneously.
NC-START can be used to resume processing.

3D clearance control and 5-axis transformation

If 3D clearance control is activated before the 5-axis transformation required for clearance
control in the direction of the tool orientation has been activated, the clearance control function
will be dependent on the active working plane (G17/G18/G19):
● G17: Direction of clearance control = Z
● G18: Direction of clearance control = Y
● G19: Direction of clearance control = X
Activation of 5-axis transformation
When 5-axis transformation is activated, the tool orientation specified by means of the rotary
axis positions must tally with the control direction specified by the active working plane on
activation of clearance control.
If the tool orientation of the 5-axis transformation and the control direction of the clearance
control function do not tally, the following CLC alarm will appear:
● Alarm "75016 Channel number Block number CLC: Orientation changed with TRAFOOF"
Deactivation of 5-axis transformation
If 5-axis transformation is deactivated when clearance control is active, the last control direction
before 5-axis transformation was deactivated is retained.

Tool radius compensation

3D clearance control can only be deactivated if no tool radius compensation is active in the
channel at the time of deactivation (G40). If tool radius compensation is active (G41/G42), the
following alarm appears:
● Alarm "75015 Channel number Block number CLC(0) with active TRC."

Special functions
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15.6 Programming

Compensation vector
Actual position of the direction axes
If the clearance control is activated with a programmable compensation vector at a position of
0 on all 3 direction axes, a compensation vector cannot be calculated from this information.
The following alarm is then displayed:
● Alarm "75019 Channel number, error ID: 1, angle 0.0"
Referencing of the direction axes
The direction axes must be referenced before clearance control is activated with
programmable compensation vector CLC(3).
Interface signals of the direction axes
The following interface signals must be set for all 3 direction axes by the PLC user program,
before clearance control is activated with programmable compensation vector CLC(3).
● DBX31, … DBX1.5 = 1 (position measuring system 1)
● DBX31, … DBX2.1 = 1 (servo enable)
● DBX31, … DBX21.7 = 1 (pulse enable)
x = axle number
Switchover of clearance control
Direct switchover of clearance control from CLC(1) or CLC(2) to CLC(3) or vice-versa is not
possible. Such switchovers are ignored without a checkback message. If a switchover is
necessary, the clearance control must first be deactivated with CLC(0) or CLC(-1) and then
activated in the desired mode.
Interpolation of the compensation vector
If the compensation vector is required to follow a non-linear workpiece surface, such as an
arc, with respect to its orientation, this can be achieved by programming the direction axes.
Example
Orientation of the compensation vector perpendicular to a semi-circular workpiece surface.
The programming of the traversing movement is not considered.

Special functions
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15.6 Programming

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Figure 15-10 Interpolation of the compensation vector

The compensation vector must be oriented by programming the direction axes at [1, 0, 0]
before part program block N100. In part program block N100, the end position of the
compensation vector is oriented by programming the direction axes at [0, 0, -1].
The intermediate values are generated by path interpolation of all axes programmed in the
part program block:
● Geometry axes for the movement of the machining head
● Direction axes of the compensation vector
It is necessary to break the movement down into part program blocks N100 and N200, because
an antiparallel orientation of the compensation vector of [1, 0, 0] at the start of the movement
and [-1, 0, 0] at the end of the movement (semi-circle) would otherwise result. In this case, the
interpolator would interpolate only the X coordinate of the compensation vector, and the
orientation of the compensation vector would remain unchanged.
Antiparallel orientation of the compensation vector
When an antiparallel orientation of the compensation vector is programmed in a part program
block, the following alarm is displayed:
● Alarm "75018 Channel number Block number CLC in programmable direction, error ID: 1"
Note
Interpolation of the compensation vector
The interpolation of the compensation vector is not a genuine vector interpolation, as
described above, but results from the interpolation of the actual positions of the direction
axes.

Consequently, if the compensation vector changes due to the workpiece contour, the
interpolation of the direction axes is included in the path interpolation of the geometry axes. In
order to minimize the impact of the direction axes on the path interpolation, it is recommended
to configure the dynamic response of the direction axes at least equal to or greater (by a factor
of approx. 10) than the dynamic response of the geometry axes.

Special functions
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15.6 Programming

In the case of a re-orientation (rotation) of the compensation vector, it is also necessary to note
the ratio between the programmed traversing path and the configured dynamic response of
the direction axes. The ratio should be chosen such that the programmed traversing path is
not traversed in one or a small number of interpolation cycles, due to the dynamic response
of the axis. This causes heavy loads on the machine and, in certain circumstances, may trigger
axial alarms and abort part program execution.
Example
Rotation of the compensation vector and thus the machining head through 90°:
● Initial orientation: Parallel to coordinate axis X
● Target orientation: Parallel to coordinate axis Y
Bad programming of re-orientation:
● [1, 0, 0] → [0, 1, 0]
Good programming of re-orientation:
● [100, 0, 0] → [0, 100, 0]
Rotation of the workpiece coordinate system
As described above, the compensation vector always refers to the basic coordinate system
(machine coordinate system). If the workpiece coordinate system (rotation, mirroring) is
transformed to machine a workpiece in such a way that the coordinate axes of both coordinate
systems are no longer parallel with the same orientation, a corresponding transformation must
be carried out for the compensation vector.

CAUTION
Unequal orientation
If the workpiece coordinate system is transformed such that the coordinate axes of the basic
and workpiece coordinate systems are no longer parallel with the same orientation, it is the
sole responsibility of the user to ensure that an appropriate transformation of the
compensation vector is carried out.

15.6.2 Closed-loop control gain (CLC_GAIN)

Syntax
CLC_GAIN = Factor
Factor
● Format: Real
● Range of values: y 0.0
CLC_GAIN is an NC address and can therefore be written together with other instructions in
a part program block.
When a negative factor is programmed, the absolute value is used without an alarm output.

Special functions
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15.6 Programming

Functionality
The current closed-loop control gain for clearance control is produced by the active
characteristic specified via machine data:
● MD62510 $MC_CLC_SENSOR_VOLTAGE_TABLE1 (coordinate voltage of interpolation
points sensor characteristic 1)
● MD62511 $MC_CLC_SENSOR_VELO_TABLE1 (coordinate velocity of interpolation points
sensor characteristic 1)
or
● MD62512 $MC_CLC_SENSOR_VOLTAGE_TABLE2 (coordinate voltage of interpolation
points sensor characteristic 2)
● MD62513 $MC_CLC_SENSOR_VELO_TABLE2 (coordinate velocity of interpolation points
sensor characteristic 2)
CLC_GAIN can be used to multiply the closed-loop control gain of the characteristic by a
programmable factor.

NOTICE
Imprecise characteristic
Increasing the gain (CLC_GAIN > 1.0) may lead to oscillation in the controlled axes!

Instant of activation
The modified closed-loop control gain is effective in the part program block in which CLC_GAIN
has been programmed or, if this block does not contain any executable instructions, in the next
part program block with executable instructions.

Response to characteristic changeover

The programmed factor remains active even when the gain characteristic is changed over with
CLC_SEL, i.e. it is immediately applied to the newly selected characteristic.

Response to CLC_GAIN=0.0
If the closed-loop control gain for clearance control is deactivated with CLC_GAIN=0.0, the
CLC position offset present at the time of deactivation is retained and is not changed. This can
be used for example when laser-cutting sheet steel to "skip over" sections of sheet that are
not to be machined without foundering.
If the tool orientation is changed when 3D clearance control is active and the closed-loop
control gain has been deactivated (CLC_GAIN=0.0), the CLC offset vector is rotated
simultaneously. This generally induces an offset in the CLC operating point on the workpiece
surface (see following diagram).

Special functions
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15.6 Programming

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Figure 15-11 Response of the CLC offset vector when CLC_GAIN=0.0

Reset
Within a part program, a modified gain factor must be reset by means of explicitly programming
CLC_GAIN=1.0.

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

15.6.3 Limiting the control range (CLC_LIM)

Syntax
CLC_LIM(lower limit, upper limit)
Lower limit, upper limit
Format and value range as machine data:
● MD62505 $MC_CLC_SENSOR_LOWER_LIMIT[n] (lower clearance control motion limit)
● MD62506 $MC_CLC_SENSOR_UPPER_LIMIT[n] (upper clearance control motion limit)
CLC_LIM(...) is a procedure call and must therefore be programmed in a dedicated part
program block.

Special functions
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15.6 Programming

Functionality
The maximum control range for clearance control can be modified on a block-specific basis
using CLC_LIM. The maximum programmable lower/upper limit is limited by the limit value
preset in the relevant machine data:
● MD62505 $MC_CLC_SENSOR_LOWER_LIMIT[1] (lower clearance control motion limit)
● MD62506 $MC_CLC_SENSOR_UPPER_LIMIT[1] (upper clearance control motion limit)

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Figure 15-12 Value range limits for lower and upper limit

The control range limit is effective in relation to the current programmed setpoint position of
the axis. If the limits are changed so that the actual position is located outside the limit, the
clearance control automatically effects travel back to the limit range.

Reset
Within a part program, a modified control range limit can be reset by explicitly programming
CLC_LIM without a "CLC_LIM( )" argument. This reapplies the limits from the following
machine data:
● MD62505 $MC_CLC_SENSOR_LOWER_LIMIT[0] (lower clearance control motion limit)
● MD62506 $MC_CLC_SENSOR_UPPER_LIMIT[0] (upper clearance control motion limit)

RESET response
The default setting from the above-mentioned machine data becomes effective after power on
reset, NC RESET and end of program.

Special functions
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15.6 Programming

Error messages
The following programming errors are displayed with an alarm:
● Programming more than 2 arguments
– CLC alarm "75005 Channel number Block number CLC_LIM: general programming
error"
● Programming arguments outside the permissible limits
– CLC alarm "750010 Channel number Block number CLC_LIM Value greater than MD
limit"

15.6.4 Direction-dependent traversing motion disable

Syntax
$A_OUT[number] = enabling signal
Number
Number of the parameterized digital output (see "Parameter Assignment" section)
● Format: Integer
● Range of values: 1, 2, . . . max. number of digital outputs
Enabling signal
Invertable enable signal (see "Parameter Assignment" section)
● Format: Integer
● Range of values: 0, 1
System variable $A_OUT[n] can be set block-synchronously in the part program or
asynchronously via synchronized actions.

Functionality
Parameterizable digital outputs (system variable $A_OUT) can be used for direction-
dependent disabling of the traversing motion (manipulated variable) induced via clearance
control. As long as e.g. the negative traversing direction is disabled, the clearance-controlled
axes will only travel in a positive direction due to the sensor signal.
This can be used for example when laser-cutting sheet steel to "skip over" sections of sheet
that are not to be machined without foundering.

Special functions
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15.6 Programming

Parameterization
The following machine data is used to parameterize the digital outputs:
● MD62523 $MC_CLC_LOCK_DIR_ASSIGN_DIGOUT[n] (assignment of the digital outputs
for disabling the CLC movement)
n = 0 → Digital output for disabling the negative traversing direction
n = 1 → Digital output for disabling the positive traversing direction

Example
The following digital outputs are to be used:
● $A_OUT[3] to disable the negative traversing direction
● $A_OUT[4] to disable the positive traversing direction
Parameter settings in the machine data:
● MD62523 $MC_CLC_LOCK_DIR_ASSIGN_DIGOUT[0] = 3 (assignment of the digital
outputs for disabling the CLC movement)
● MD62523 $MC_CLC_LOCK_DIR_ASSIGN_DIGOUT[1] = 4
Effect:
● $A_OUT[3] = 0 → Negative traversing direction enabled
● $A_OUT[3] = 1 → Negative traversing direction disabled
● $A_OUT[4] = 0 → Positive traversing direction enabled
● $A_OUT[4] = 1 → Positive traversing direction disabled

Inversion of the evaluation

Enter the negative number of the digital output to evaluate the digital output signal with
inversion:
Parameter settings in the machine data:
● MD62523 $MC_CLC_LOCK_DIR_ASSIGN_DIGOUT[0] = -3 (assignment of the digital
outputs for disabling the CLC movement)
● MD62523 $MC_CLC_LOCK_DIR_ASSIGN_DIGOUT[1] = -4
Effect:
● $A_OUT[3] = 0 → Negative traversing direction disabled
● $A_OUT[3] = 1 → Negative traversing direction enabled
● $A_OUT[4] = 0 → Positive traversing direction disabled
● $A_OUT[4] = 1 → Positive traversing direction enabled

Special functions
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15.6 Programming

15.6.5 Voltage offset, can be set on a block-specific basis (CLC_VOFF)

Syntax
CLC_VOFF = Voltage offset
Voltage offset
● Format: Real
● Unit: Volts
● Range of values: No restrictions
CLC_VOFF is an NC address and can therefore be written together with other instructions in
a part program block.

Functionality
CLC_VOFF can be used to preset a constant voltage offset for clearance control, which is
subtracted from the input voltage of the clearance sensor. The programmed voltage offset
therefore changes the setpoint distance between the workpiece and the clearance sensor or
offsets the operating point for clearance control.
The quantitative effect of the voltage offset is dependent on the additional parameters for
clearance control and can therefore not be standardized in a generally valid format.

Instant of activation
The voltage offset is effective in the part program block in which CLC_VOFF has been
programmed or, if this block does not contain any executable instructions, in the next part
program block with executable instructions.

Reset
Within a part program, a voltage offset must be reset by means of explicitly programming
CLC_VOFF=0.0.

RESET response
CLC_VOFF =0.0 becomes effective after a power on reset, NC RESET or end of program.

15.6.6 Voltage offset definable by synchronized action

Syntax
$A_OUTA[number] = Voltage offset
Number

Special functions
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15.6 Programming

Number of the parameterized analog output (see "Parameter Assignment" section)

● Format: Integer
● Range of values: 1, 2, . . .max. number of analog outputs
Voltage offset
Just like the voltage offset for CLC_VOFF (see Section "Voltage offset, can be set on a block-
specific basis (CLC_VOFF) (Page 615)").

Functionality
A parameterizable output (system variable $A_OUTA) can be used to apply a voltage offset
for clearance control, which, like CLC_OFF, is subtracted from the input voltage of the
clearance sensor.
The voltage offset can be modified in the interpolator clock cycle by programming the analog
output within a synchronized action.

Parameterization
The following machine data is used to parameterize the analog output:
MD62522 $MC_CLC_OFFSET_ASSIGN_ANAOUT (modification of the setpoint distance by
means of sensor signal override)

Example
An external voltage Uext is present at analog input $A_INA[3], which is to be overlaid on the
sensor voltage as a continuously variable voltage offset e.g. for test or start-up purposes.
$A_OUTA[2] is used as an analog output for the clearance control voltage offset.
Parameter setting for the analog output for clearance control voltage offset:
MD62522 $MC_CLC_OFFSET_ASSIGN_ANAOUT = 2 (modification of the setpoint distance
by means of sensor signal override)
The analog input $A_INA[3] is assigned to the clearance control analog output $A_OUTA[2]
within a synchronized action:
ID=1 DO $A_OUTA[2] = $A_INA[3]

15.6.7 Selection of the active sensor characteristic (CLC_SEL)

Syntax
CLC_SEL(characteristic number)
Characteristic number
● Format: Integer
● Range of values: 1, 2

Special functions
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15.7 Function-specific display data

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

program block.
Characteristic number = 2 selects characteristic 2. Any other value selects characteristic 1
without alarm.

Functionality
CLC_SEL can be used to switch between the sensor characteristics defined in the machine
data.
● Characteristic 1:
– MD62510 $MC_CLC_SENSOR_VOLTAGE_TABLE_1 (coordinate voltage of
interpolation points sensor characteristic 1)
– MD62511 $MC_CLC_SENSOR_VELO_TABLE_1 (coordinate velocity of interpolation
points sensor characteristic 1)
● Characteristic 2:
– MD62512 $MC_CLC_SENSOR_VOLTAGE_TABLE_2 (coordinate voltage of
interpolation points sensor characteristic 2)
– MD62513 $MC_CLC_SENSOR_VELO_TABLE_2 (coordinate velocity of interpolation
points sensor characteristic 2)

RESET response
Characteristic 1 becomes effective after a power on reset, NC RESET or end of program.

15.7 Function-specific display data

The "clearance control" technological function provides specific display data for supporting
start-up and for service purposes.

Possible applications
Application options for display data include for example:
● Determination of form variances and transient control errors via the variables for the
maximum and minimum position offset/sensor voltage.
● Determination of the voltage noise detected by the A/D converter via the variables for the
maximum and minimum sensor input voltage. This requires a constant clearance between
the clearance sensor and the workpiece surface and the deactivation of clearance control
via CLC_GAIN = 0.0.
The minimum and maximum values are detected in the position controller cycle.

Special functions
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15.7 Function-specific display data

Types of variable
The display data is available both as channel-specific GUD (Global User Data) variables and
as OPI variables.

15.7.1 Channel-specific GUD variables

The "clearance control" technological function provides the following channel-specific GUD
variables for HMI applications:
● SINUMERIK HMI Advanced
● SINUMERIK Operate

Table 15-1 Channel-specific GUD variables

GUD variables Description Unit Access

CLC_DISTANCE[0] Current position offset mm read only
CLC_DISTANCE[1] Absolute minimum of position off‐ mm read/write
set
CLC_DISTANCE[2] Absolute maximum of position off‐ mm read/write
set
CLC_VOLTAGE[0] Current sensor input voltage V read only
CLC_VOLTAGE[1] Absolute minimum of sensor input V read/write
voltage
CLC_VOLTAGE[2] Absolute maximum of sensor input V read/write
voltage

Once the technological function has been started up successfully, the GUD variables listed
are not displayed automatically on the HMI interface.

SINUMERIK HMI Advanced

Proceed as follows to create and display the GUD variables in HMI Advanced.
1. Setting the password
Enter the password for protection level 1: (machine manufacturer).
2. Activate the "definitions" display.
Operating area switchover > Services > Data Selection
3. If no SGUD.DEF file is yet available:
Operating area switchover > Services > Data admin > New...
● Name: SGUD
● Type: Global data/system
Confirm with OK.
This opens the file in the editor.

Special functions
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15.7 Function-specific display data

1. Edit the GUD variable definitions

DEF CHAN REAL CLC_DISTANCE[3] ; Array of real, 3 elements
DEF CHAN REAL CLC_VOLTAGE[3] ; Array of real, 3 elements
M30
2. Save the file and close the editor.
3. Activate the SGUD.DEF file.
The GUD variables for clearance control are now displayed under:
Operating area switchover > Parameters > User data > Channel user data

SINUMERIK Operate
Proceed as follows to create and display the GUD variables for SINUMERIK Operate.
1. Setting the password
Enter the password for protection level 1: (machine manufacturer).
2. If no SGUD.DEF file is yet available:
Operating area switchover > Commissioning > System data > Open NC data directory: Set
cursor to definitions > New...
● Name: SGUD
● Type: DEF
Confirm with OK.
This opens the file in the editor.
1. Edit the GUD variable definitions
DEF CHAN REAL CLC_DISTANCE[3] ; Array of real, 3 elements
DEF CHAN REAL CLC_VOLTAGE[3] ; Array of real, 3 elements
M30
2. Save the file and close the editor.
3. Activate the SGUD.DEF file.
The GUD variables for clearance control are now displayed under:
Operating area switchover > Parameters > User variables > GUD channel

SINUMERIK NCK
The new GUD variables, which are already being displayed, will only be detected by the
clearance control function and supplied with up-to-date values following an NCK POWER ON
RESET.

Note
Once the GUD variables have been created, an NCK POWER ON RESET must be carried
out in order for the clearance control function to update the GUD variables.

Special functions
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TE1: Clearance control - 840D sl only
15.7 Function-specific display data

15.7.2 OPI variable

The technology function "Clearance control" provides the following channel-specific OPI
variables as display data for the HMI application:

OPI variable Description Unit Access

CLC[0] Current position offset mm read only
CLC[1] Absolute minimum of position offset mm read/write
CLC[2] Absolute maximum of position offset mm read/write
CLC[3] Current sensor input voltage V read only
CLC[4] Absolute minimum of sensor input V read/write
voltage
CLC[5] Absolute maximum of sensor input V read/write
voltage
CLC[6] 1st component of the normalized - read only
tool orientation vector
CLC[7] 2nd component of the normalized - read only
tool orientation vector
CLC[8] 3rd component of the normalized - read only
tool orientation vector

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

Defining OPI variables

The following operator actions must be carried out to define OPI variables.
1. Create the CLC-specific definition file: CLC.NSK
Note:
We recommend that you create the file in the \OEM directory rather than in the \MMC2
directory so that it is not overwritten when a new software version is installed.
2. Define the CLC-specific OPI variables.
Add the following line to the CLC.NSK file:
LINK("CLC" ,200,"2 1 1 1 1F# /NC 5 0 1",100)
3. Create/expand the user-specific definition file: USER.NSK
(See item 1: Note)
4. The call of the CLC-specific definition file CLC.NSK must be added to the USER.NSK
definition file. To do this, insert the following line:
CALL(CLC.NSK)

Using LinkItem
In order to use the OPI variables in a DDE control, the "LinkItem" property of the DDE control
must be set in accordance with the following example:
label1.LinkItem = "CLC[u1,1,9](" "!d%15.4lf" ")"
The format string can be modified if necessary.

Special functions
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 TE1: Clearance control - 840D sl only
15.9 Supplementary conditions

The following code lines provide an example of how the variables supplied by means of NCDDE
access can be distributed on a field of labels:
FOR i = 0 To 8
label2.Caption[i] = Trim$(Mid$(label1.Caption, 1+15*i, 15))
NEXT

15.8 Function-specific alarm texts

For details of the procedure for creating function-specific alarm texts, see Section "Creating
alarm texts (Page 579)".

15.9 Supplementary conditions

15.9.1 I/O modules

The analog output voltage of the distance sensor for the A/D conversion must be connected
to the NC using an I/O module with an analog input.

Connection options
The SIMATIC ET 200S I/O for SINUMERIK 840D sl is connected via PROFIBUS DP. The
clearance sensor is connected via an analog S7 I/O module.

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Suitable I/O modules

As the A/D conversion time directly affects the deadtime of the clearance control servo loop,
only one I/O module may be used with low conversion time.

Special functions
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TE1: Clearance control - 840D sl only
15.9 Supplementary conditions

Suitable SIMATIC S7 I/O modules for the clearance control are:

● Analog I/O module 2 AI, U, high-speed for ET 200S
● Analog I/O module 2 AO, U, high-speed for ET 200S

I/O module connection

The SIMATIC I/O devices of the Production Series ET200, e.g. ET200M, are brought into the
S7 project as usual, and configured.

Note
To check whether a module selected from the hardware catalog complies with the module in
the automation system, the following procedure is recommended:
1. Note the article numbers of all modules used in the automation system.
2. Select the corresponding module in the hardware catalog and compare the article number
of the module used in the automation system with the article number that is displayed in
the hardware catalog. Both article numbers must match one another.

15.9.1.1 External smoothing filters

If an external filter is to be interconnected to smooth the output voltage of the clearance sensor
before the A/D conversion of the output voltage by the I/O module, please ensure that the
resulting time constant is small in relation to the NC position controller cycle.

Note
It is better for the control if electromagnetic shielding is used to ensure a large signal-noise
ratio than if smoothing filters are used in the signal path.

15.9.2 Function-specific supplementary conditions

Complete NC Stop
If in conjunction with an NC Stop, not only the programmed path motion but also the traversing
movement of the clearance-controlled axes should be stopped, the following NC/PLC interface
signals must be set:
● DB21, ... DBX7.3 = 1 (NC Stop)
● DB21, ... DBX7.4 = 1 (NC stop axes and spindles)

Followup
If a clearance-controlled axis is to be switched as an alarm response or via the corresponding
interface signal from the NC/PLC in "follow-up" mode, setpoint output will cease for clearance
control on this axis.

Special functions
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 TE1: Clearance control - 840D sl only
15.9 Supplementary conditions

Travel without software limit switches

If the clearance-controlled axes are to travel without referencing (travel without software limit
switches), values outside the used traversing range must still be parameterized for the axis-
specific software limit switches:
● MD36100 $MA_POS_LIMIT_MINUS (1st software limit switch minus)
● MD36110 $MA_POS_LIMIT_PLUS (1st software limit switch plus)
● MD36120 $MA_POS_LIMIT_MINUS2 (2nd software limit switch minus)
● MD36130 $MA_POS_LIMIT_PLUS2 (2nd software limit switch plus)
Clearance control takes the machine data into account even if an axis is not being referenced.

Disabling digital/ analog inputs

Neither the analog input for the input voltage of the clearance sensor nor the digital input used
by the clearance control in the context of the "Lift fast with position controller cycle" special
function can be controlled (disabled) via the PLC:
DB10, DBB0 (Disable digital NCK inputs)
DB10, DBB146 (Disable analog NCK inputs)
See also the description of machine data:
● MD62508 $MC_CLC_SPECIAL_FEATURE_MASK, bit 4 and 5 (Special functions and
operating modes of the clearance control)

Gantry axes: Only leading axes

Only one of the clearance-controlled axes may be configured as the master axis of a gantry
grouping:
MD37100 $MA_GANTRY_AXIS_TYPE (gantry axis definition)
The use of following axes in a gantry grouping is not permitted.

Displaying the axis position

The actual current axis position of a clearance-controlled axis as the sum of an interpolatory
axis position and the current position offset of clearance control is not displayed in the main
machine screen:
● SINUMERIK HMI Advanced:
The actual current axis position is displayed in the Service screen: Operating area
switchover > Diagnosis > Service displays > Axis/spindle displayed as the "actual position
value".
● SINUMERIK Operate:
The actual current axis position is displayed in the Service screen: Operating area
switchover > Diagnosis > Axis dialog > Service axis > displayed as the "measuring system
1 and 2 actual position value".

Special functions
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TE1: Clearance control - 840D sl only
15.9 Supplementary conditions

No virtual axes
Clearance-controlled axes must not be parameterized as virtual axes:
MD30132 $MA_IS_VIRTUAL_AX[<axis>] (axis is virtual axis)

Computing time requirements

The additional computing time required for the "clearance control" technological function must
be taken into account on control systems in which the cycle times set for the interpolator and
position controller cycle have been substantially optimized in comparison with the default
setting:
The additional required computing time results after the activation of the clearance control in
the CLC( ... ) part program. If the interpolation or position controller cycle is exceeded,
the following alarm appears:
● Interrupt: "4240 Computing time overflow at IPO or position controller level, IP point in part
program"
Execution of the part program is aborted.

1D clearance control function

Alarm "1016: System error, ID550010" can occur in the following situation:
● The clearance-controlled axis (e.g. Z axis) is parameterized as geometry axis
● Within any command sequence in which STOPRE is initiated implicitly or explicitly, the
clearance control with CLC(0) is switched off
This is the reason that it is recommended to parameterize the clearance-controlled axis of a
1D clearance control (e.g. Z axis) so that it is no longer the geometry axis of the channel.

Parameter assignment: Machine data

● MD20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[<Z axis>] = 0
● MD20060 $MC_AXCONF_GEOAX_NAME_TAB[<Z axis>] = "NO_Z_AXIS"

Programming: Rotations around the Z axis

As the Z axis is no longer a geometry axis after reparameterization, for rotation around the Z
axis, instead of the predefined function CROT() the predefined procedureCRPL() must be
used:
CROT(Z,<angle>) → CRPL(1,<angle>)

Special functions
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 TE1: Clearance control - 840D sl only
15.10 Data lists

15.10 Data lists

15.10.1 Machine data

15.10.1.1 NC-specific machine data

Number Identifier: $MN_ Description

10300 FASTIO_ANA_NUM_INPUTS Number of active analog NCK inputs
10350 FASTIO_DIG_NUM_INPUTS Number of active digital NCK input bytes
10362 HW_ASSIGN_ANA_FASTIN Hardware assignment of external analog NCK inputs:
0...7
10712 NC_USER_CODE_CONF_NAME_TAB List of renamed NC identifiers

15.10.1.2 Channelspecific machine data

Number Identifier: $MC_ Description

28090 MM_NUM_CC_BLOCK_ELEMENTS Number of compile cycle block elements (DRAM)
28100 MM_NUM_CC_BLOCK_USER_MEM Memory for compile cycle block elements (DRAM) in
kB
28254 MM_NUM_AC_PARAM Number of parameters for synchronized actions

Clearance control
62500 CLC_AXNO Axis assignment for clearance control
62502 CLC_ANALOG_IN Analog input for clearance control function
62504 CLC_SENSOR_TOUCHED_INPUT Input bit assignment for the "sensor collision" signal
62505 CLC_SENSOR_LOWER_LIMIT Lower motion limit of clearance control
62506 CLC_SENSOR_UPPER_LIMIT Upper motion limit of clearance control
62508 CLC_SPECIAL_FEATURE_MASK Special functions and operating modes of the clear‐
ance control
62510 CLC_SENSOR_VOLTABE_TABLE_1 Coordinate voltage of interpolation points sensor char‐
acteristic 1
62511 CLC_SENSOR_VELO_TABLE_1 Coordinate velocity of interpolation points sensor char‐
acteristic 1
62512 CLC_SENSOR_VOLTAGE_TABLE_2 Coordinate voltage of interpolation points sensor char‐
acteristic 2
62513 CLC_SENSOR_VELO_TABLE_2 Coordinate velocity of interpolation points sensor char‐
acteristic 2
62516 CLC_SENSOR_VELO_LIMIT Clearance control movement velocity
62516 CLC_SENSOR_ACCEL_LIMIT Clearance control movement acceleration
62520 CLC_SENSOR_STOP_POS_TOL Positional tolerance for status message "Clearance
control zero speed"

Special functions
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TE1: Clearance control - 840D sl only
15.10 Data lists

Number Identifier: $MC_ Description

62521 CLC_SENSOR_STOP_DWELL_TIME Dwell time for status message "Clearance control zero
speed"
62522 CLC_OFFSET_ASSIGN_ANAOUT Modification of the setpoint distance by means of sen‐
sor signal override
62523 CLC_LOCK_DIR_ASSIGN_DIGOUT Assignment of the digital outputs for disabling the CLC
movement
62524 CLC_ACTIVE_AFTER_RESET Clearance control remains active after RESET
62525 CLC_SENSOR_FILTER_TIME PT1 filtering time constant of sensor signal
62528 CLC_PROG_ORI_AX_MASK Programmed orientation vector: Axis mask
62529 CLC_PROG_ORI_MAX_ANGLE Programmed orientation vector: Maximum difference
angle
62530 CLC_PROG_ORI Programmed orientation vector: Index of the $AC_PAR‐
AM variables for the output of the current difference
angle

15.10.1.3 Axis/spindlespecific machine data

Number Identifier: $MA_ Description

32070 CORR_VELO Axis velocity for handwheel, external zero offsets, SA
clearance control
32410 AX_JERK_TIME Time constant for axis jerk filter
32610 VELO_FFW_WEIGHT Feedforward control factor for velocity feedforward con‐
trol
36000 STOP_LIMIT_COARSE Exact stop coarse
36010 STOP_LIMIT_FINE Exact stop fine
36040 STANDSTILL_DELAY_TIME Delay time zero speed monitoring
36060 STANDSTILL_VELO_TOL Axis/ spindle velocity stopped
36750 AA_OFF_MODE Value calculation mode for axial position override

15.10.2 Drive parameters (SINAMICS S120)

Number Short name Long name

p1414[0...n] n_soll_filt current Speed setpoint filter activation 1, 2
p1415[0...n] n_soll_filt 1 type Speed setpoint filter 1 type
p1416[0...n] n_soll_filt 1 T Speed setpoint filter 1 time constant
p1417[0...n] n_soll_filt 1 fn_n Speed setpoint filter 1 denominator natural frequency
p1418[0...n] n_soll_filt 1 D_n Speed setpoint filter 1 denominator damping
p1419[0...n] n_soll_filt 1 fn_z Speed setpoint filter 1 numerator natural frequency
p1420[0...n] n_soll_filt 1 D_z Speed setpoint filter 1 numerator damping
p1421[0...n] n_soll_filt 2 type Speed setpoint filter 2 type
p1422[0...n] n_soll_filt 2 T Speed setpoint filter 2 time constant

Special functions
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 TE1: Clearance control - 840D sl only
15.10 Data lists

Number Short name Long name

p1423[0...n] n_soll_filt 2 fn_n Speed setpoint filter 2 denominator natural frequency
p1424[0...n] n_soll_filt 2 D_n Speed setpoint filter 2 denominator damping
p1425[0...n] n_soll_filt 2 fn_z Speed setpoint filter 2 numerator natural frequency
p1426[0...n] n_soll_filt 2 D_z Speed setpoint filter 2 numerator damping

15.10.3 Signals

15.10.3.1 Signals to channel

DB number Byte.bit Description

21, ... 1.4 Stop CLC motion
21, ... 1.5 Feedrate override acts on CLC

15.10.3.2 Signals from channel

DB number Byte.bit Description

21, ... 37.3 CLC is active
21, ... 37.4-5 CLC motion has stopped
21, ... 37.4 CLC motion at lower motion limit
21, ... 37.5 CLC motion at upper motion limit

Special functions
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TE1: Clearance control - 840D sl only
15.10 Data lists

Special functions
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TE3: Speed/torque coupling, master-slave 16
16.1 Brief description
A master-slave coupling is a speed setpoint coupling between a master and any number of
slave axes - performed at the position controller level - with and without torque equalization
control. The coupling can be permanently switched on, dynamically switched on/off and
reconfigured.

Note
The following restrictions apply for the SINUMERIK 828D with regard to the "Master-slave
coupling":
● Only one master-slave grouping is possible.
● Only one slave axis can be coupled to the master axis.

Applications
Possible applications of a master-slave coupling include:
● Increase the power for mechanically coupled drives
● Compensating gear and gear tooth flank play by entering a pre-tensioning torque

Dynamic master-slave coupling of two axes

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Special functions
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TE3: Speed/torque coupling, master-slave
16.2 Coupling diagram

16.2 Coupling diagram

If the coupling is closed, the slave axis is traversed only with the load-side setpoint speed of
the master axis. It is therefore only speed-controlled, not position-controlled. There is no
differential position control between the master and slave axis.
The torque required between the master and slave axis is distributed using the torque
equalization controller. When using different motors, this distribution can be adapted to the
specific requirements using a weighting factor.
A tension can be established between the master and slave axes by entering a supplementary
torque (tensioning torque).

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Special functions
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 TE3: Speed/torque coupling, master-slave
16.3 Configuring a coupling

16.3 Configuring a coupling

Static assignment
For a speed setpoint coupling and torque equalization control, the static assignment of master
and slave axis is defined separately in the following machine data:
● Speed setpoint coupling
MD37250 $MA_MS_ASSIGN_MASTER_SPEED_CMD[<slave axis>] =
<machine axis number of the master axis for the speed setpoint coupling>
● Torque equalization control
MD37252 $MA_MS_ASSIGN_MASTER_TORQUE_CTR[<slave axis>] =
<machine axis number of the master or slave axis for torque equalization control>
(see Section "Tension torque (Page 635)")

Dynamic assignment (only 840D sl)

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

Defining assignments
Assignment of one or several slave axes to a master axis:
MASLDEF (<slave axis_1>, <slave axis_2>, ..., <master axis>)
In principle, any number of slave axes can be assigned. The assignment is kept even after an
operating mode change, reset and end of part program.

Deleting assignments
Delete assignment of one or several slave axes to their associated master axis:
MASLDEL (<slave axis_1>, <slave axis_2>, ...)
An active coupling is first implicitly switched off before deleting the assignment.

Axis assignment for speed setpoint coupling and torque equalization control
For the speed setpoint coupling, the slave axis refers to the master axis specified when defining
the assignment (MASLDEF).
The axis to which the slave axis refers for torque equalization control is defined in the following
machine data:
MD37253 $MA_MS_FUNCTION_MASK[<slave axis>], bit 1 = <value>

<value> Description
0 In the case of dynamic assignment (MASLDEF), the slave axis for the torque equalization
control – as well as for speed setpoint coupling – refers to the master axis of the master-
slave grouping.
1 In the case of dynamic assignment (MASLDEF), the slave axis for the torque equalization
control refers to the axis, master or slave axis of the master-slave grouping specified in
machine data:
MD37252 $MA_MS_ASSIGN_MASTER_TORQUE_CTR<slave axis> = <axis>

Special functions
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TE3: Speed/torque coupling, master-slave
16.3 Configuring a coupling

(See Section "Tension torque (Page 635)")

Supplementary conditions
The following supplementary conditions must be observed for the dynamic assignment:
● When the coupling is switched on, a change to the assignment using MASLDEF has no
effect. The change only becomes effective the next time that the coupling is switched off.
● The same master axis is always used for the speed setpoint coupling and torque
equalization control.
● A plausibility check of the assignment is only made when the coupling is switched on.

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

A user-specific standard assignment, which is always effective after a reset, can be defined
in PROG_EVENT.SPF using the program commands MASLDEF and MASLDEL.
The following machine data should be set in order that PROG_EVENT.SPF is executed for a
reset: MD20108 $MC_PROG_EVENT_MASK.Bit 2 = 1

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

The assignment of slave axis AX3 is changed from master axis AX1 to master AX2. To do this,
the coupling must be temporarily switched off (see Section "Closing/opening a coupling
(Page 639)").

Programming Description
① MASLDEF (AX3, AX1) Assignment of slave axis AX3 to master axis AX1
② MASLON (AX3) Switching on the coupling
③ MASLDEL (AX3) Switch off the coupling and cancel the assignment between AX3 and AX1
④ MASLDEF (AX3, AX2) Assignment of slave axis AX3 to master axis AX2

   

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Figure 16-2 Alternating assignment of the slave axis

Special functions
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 TE3: Speed/torque coupling, master-slave
16.4 Torque compensatory controller

General supplementary conditions

Please note the following general supplementary conditions:
● A slave axis can only be assigned to one master axis
● A master axis can be assigned several slave axes
● A slave axis must not be a master axis or be in another master-slave relationship.
Note
Drive optimization
At a SINAMICS S120 drive unit, a maximum of three drives can be optimized or measured
at the same time (speed controller optimization / function generator). Therefore, for a
coupling with more than three coupled drives at the same time, we recommend that these
are distributed over several drive units.

16.4 Torque compensatory controller

The torque equalization controller (PI control) calculates a load-side initial speed setpoint. The
additional speed setpoint can be differently entered via the following machine data:
MD37254 $MA_MS_TORQUE_CTRL_MODE[<slave axis>] = <value>

<value> Input of the additional speed setpoint at:

0 Master and slave axis (default value)
1 Slave axis
2 Master axis
3 is not input at any of the axes

Note
Several slave axes
For a master-slave grouping with one master and several slave axes, the input of the additional
speed setpoint to the master and slave axes - set as standard in MD37254 - can result in
instability. For several axes, the input of an additional speed setpoint should only be done in
the slave axes:
MD37254 $MA_MS_TORQUE_CTRL_MODE = 1

SINAMICS S120: Current setpoint filter

Up to four current setpoint filters (p1656 - p1674, function block diagram [5710]) can be
activated in the SINAMICS S120. In a master-slave group, it is recommended that for the
master and all of the slave axes, only filters with the same data are activated at any instant in
time.

Special functions
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TE3: Speed/torque coupling, master-slave
16.4 Torque compensatory controller

Scaling
Scaling the machine data:
● MD37256 $MA_MS_TORQUE_CTRL_P_GAIN (gain factor (P component))
● MD37260 $MA_MS_MAX_CTRL_VELO (speed setpoint limiting)
Must be entered using the following machine data:
MD37253 $MA_MS_FUNCTION_MASK[<slave axis>], bit 0 = <value>

<value> Description
0 MD37256 and MD37260 are internally multiplied with the following factor: 1 / Ipo cycle[s]
1 MD37256 and MD37260 are accepted unchanged

Note
It is recommended to set MD37253 $MA_MS_FUNCTION_MASK[<slave axis>], bit 0 = 1.

Gain factor (P component)

The gain factor of the torque equalization controller is set in the following machine data as a
percentage of the ratio of the maximum load-side axis velocity of the slave axis (MD32000
$MA_MAX_AX_VELO) to its rated torque (SINAMICS S120: p2003):
MD37256 $MA_MS_TORQUE_CTRL_P_GAIN[<slave axis>]
Note: Scaling via MD37253 $MA_MS_FUNCTION_MASK[<slave axis>], bit 0

Integral time (I component)

The integral time of the torque equalization controller is set in the following machine data:
MD37258 $MA_MS_TORQUE_CTRL_I_TIME[<slave axis>]
The I component is deactivated as standard.

Speed setpoint limiting

The speed setpoint calculated by the torque equalization controller can be limited using the
following machine data. The input is a percentage referred to the maximum, load-side axis
velocity of the slave axis (MD32000 $MA_MAX_AX_VELO).
MD37260 $MA_MS_MAX_CTRL_VELO[<slave axis>]
Note: Scaling via MD37253 $MA_MS_FUNCTION_MASK[<slave axis>], bit 0

Special functions
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 TE3: Speed/torque coupling, master-slave
16.5 Tension torque

Deactivating the torque equalization controller

If the following settings are made, the torque compensatory controller will be inactive:
● MD37254 $MA_MS_TORQUE_CTRL_MODE[<slave axis>] = 3
● MD37256 $MA_MS_TORQUE_CTRL_P_GAIN[<slave axis>] = 0

Torque weighting
The percentage of the torque generated by the slave axis of the total torque can be set using
the torque weighting.
MD37268 $MA_MS_TORQUE_WEIGHT_SLAVE[<slave axis>]
Using the torque weighting, it is possible to configure a different torque distribution between
the master and slave axes for motors with different rated torques. For motors of the master
and slave axes with the same rated torques, it makes sense to have a 50% torque distribution
(default setting).
The torque provided by the master axis is given by:

Torque provided by the master axis = 100% - MD37268

Note
Mechanical coupling
When using the torque equalization controller, it is absolutely necessary to have a mechanical
coupling between the master and slave axis. Otherwise, the two drives involved could
accelerate in an uncontrollable fashion.

Activating/deactivating via the NC/PLC interface

The torque equalization controller can be activated on an axis-for-axis basis via the NC/PLC
interface:
DB31, ... DBX24.4 (torque equalization controller on)
Activating via the NC/PLC interface must be explicitly enabled:
MD37254 $MA_MS_TORQUE_CTRL_MODE[<slave axis>] = 1
The actual activation state can be read back via:
DB31, ... DBX96.4 (master/slave equalization controller active)

16.5 Tension torque

The tension torque is a supplementary torque which is switched to the active torque
equalization controller. This means that a mechanical tension can be established between
axes within a master-slave grouping. Establishing a tension is not only possible between the
master and a slave axis, but also between two slave axes by declaring one of the slave axes
the reference axis for the torque equalization controller.

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16.5 Tension torque

Setting
The tension torque is entered as a percentage of the rated torque of the slave axis and is active
immediately:
MD37264 $MA_MS_TENSION_TORQUE[<slave axis>] = <tension torque>
As can be seen from the structure of the torque equalization controller (Chapter "Torque
compensatory controller (Page 633)"), the tension torque is entered via a PT1 filter. The filter
time constant is set using the following machine data:
MD37266 $MA_MS_TENSION_TORQ_FILTER_TIME[<slave axis>] = <time constant>
A value for the filter time constant greater than 0 activates the filter.

NOTICE
No axis equalization
If a tension torque is entered without a mechanical coupling between the master and slave
axis then this causes the axes to move.

Note
Minimum tension torque
The tension torque chosen must be high enough to ensure that the resulting torque does not
drop below the minimum required tension even during acceleration.
Reducing the motor temperature rise
The tension torque can be reduced when the motor is at a standstill to reduce the motor
temperature rise.

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

A master-slave application is parameterized so that one master axis is assigned three slave
axes and a tension torque is entered for one axis pair. As a consequence, the master axis
alone does not have to establish the tension torque with respect to all of the slave axes.
Assumption regarding machine axes:
● 1st to 4th machine axis: AX1, AX2, AX3, AX4
Static coupling for all slave axes
● MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX2] = 1
● MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX3] = 1
● MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX4] = 1

Axis Reference axis of the speed set‐ Reference axis of the torque equal‐ Input of the torque equalization
point coupling ization controller contr.
MD37250 = value MD37252 = value MD37254 = value
Value Description Value Description Value Description
AX1 0 No reference axis 0 No reference axis 0 Master and slave
AX2 1 Master axis, AX1 1 Master axis, AX1 0 Master and slave

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 TE3: Speed/torque coupling, master-slave
16.5 Tension torque

Axis Reference axis of the speed set‐ Reference axis of the torque equal‐ Input of the torque equalization
point coupling ization controller contr.
MD37250 = value MD37252 = value MD37254 = value
Value Description Value Description Value Description
AX3 1 Master axis, AX1 0 No reference axis 3 No input
AX4 1 Master axis, AX1 3 2nd slave axis, AX3 0 Master and slave

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Figure 16-3 Example 1: Torque equalization control in pairs

Example 2 (840D sl): Dynamic coupling with 1x4 and 2x2 axes grouped in pairs
Assumption regarding machine axes:
● 1st to 4th machine axis: AX1, AX2, AX3, AX4
Dynamic coupling for all slave axes:
● MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX2] = 0
● MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX3] = 0
● MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX4] = 0
For a dynamic coupling, the master axis specified when defining the coupling (MASLDEF) is,
as standard, the reference axis for speed setpoint coupling and torque equalization control.
The definition of reference axis AX3 for the torque equalization control of the 3rd slave axis
AX4 is required for the application "1x4 axes" where the following machine data is set:
MD37253 $MA_MS_FUNCTION_MASK[AX4], Bit 1 = 1 (see part program)

Axis Reference axis of the speed set‐ Reference axis of the torque equal‐ Input of the torque equalization
point coupling ization controller contr.
MD37250 = value MD37252 = value MD37254 = value
Value Description Value Description Value Description
AX1 0 No reference axis 0 No reference axis 0 Master and slave
AX2 0 No reference axis 0 No reference axis 0 Master and slave
AX3 0 No reference axis 0 No reference axis 3 No input
AX4 0 No reference axis 3 Machine axis AX3 0 Master and slave

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TE3: Speed/torque coupling, master-slave
16.5 Tension torque

Program code Comment

PROC MASL_SWITCH IPRTLOCK DISPLOF
IF MASL_REQUEST==4 ; Activate "1x4 axes"
MASLOF(AX2, AX4) ; Switch off coupling
MASLDEL(AX2, AX4) ; Delete coupling
$MA_MS_FUNCTION_MASK[AX4]= ; MD37253, bit1 = 1:
$MA_MS_FUNCTION_MASK[AX4] B_OR 'B10' ; Reference axis of the torque equalization controller

; from AX4, is AX3 (MD37252)

NEWCONF ; Activate machine data change
STOPRE
MASLDEF(AX2, AX3, AX4, AX1) ; Define assignment for "1x4 axes"
MASLON(AX2, AX3, AX4) ; Switch on couplings
MASL_ACTIVE=4 MASL_REQUEST=0 ; Feedback signal: "1x4 axes" switched-in
ENDIF
IF MASL_REQUEST==2 ; Activate "2x2 axes"
MASLOF(AX2, AX3, AX4) ; Switch off coupling
MASLDEL(AX2, AX3, AX4) ; Delete coupling
$MA_MS_FUNCTION_MASK[AX4]= ; MD37253, bit1 = 0:
$MA_MS_FUNCTION_MASK[AX4] B_AND ; Reference axis of the torque equalization controller
'HFFFD'
; from AX4, is the master axis defined
; with MASLDEF
NEWCONF
STOPRE
MASLDEF(AX2, AX1) ; Define assignment for the 1st "2x2 axes"
MASLDEF(AX4, AX3) ; Define assignment for the 2nd "2x2 axes"
MASLON(AX2, AX4) ; Switch on couplings
MASL_ACTIVE=2 MASL_REQUEST=0 ; Feedback signal: "2x2 axes" switched on
ENDIF
RET

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 TE3: Speed/torque coupling, master-slave
16.6 Closing/opening a coupling

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Figure 16-4 Example 2: Alternating coupling with 1x4 and 2x2 axes

16.6 Closing/opening a coupling

Default setting
After the control has booted, the following machine data defines whether the coupling is
permanently switched on (static) or can be dynamically switched on/off and reconfigured:
MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[<slave axis>] = <switch on mode>

Statically switching on a coupling

MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[<slave axis>] = 1
After the control boots, the coupling is statically switched on.
By writing the machine data in the part program or synchronized action with subsequent warm
restart NEWCONF, then a static coupling can also be switched off/on at a later time.
Example: Switching the static coupling for slave axis AX2 off and on

Program code Comment

N100 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX2] = 0 ; Coupling type: static -> dynamic
N110 NEWCONF ; Activate machine data.
N120 MASLOF(AX2) ; Switch off coupling.
....
N200 PRESETON(AX2,...) ; E.g. actual value setting of the slave axis.
....

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TE3: Speed/torque coupling, master-slave
16.6 Closing/opening a coupling

Program code Comment

N300 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX2] = 1 ; Coupling type: dynamic -> static, switch on cou-
pling.

Note
A statically switched on coupling can neither be switched on/off nor reconfigured using the
master-slave-specific NC/PLC interface signals and/or program commands.

Dynamically switching a coupling on/off

MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[<slave axis>] = 0
The coupling can be dynamically switched on and off and reconfigured.
The coupling can be switched on/off by:
● Machine data MD37262
Writing the machine data to switch on ( = 1) or switch off ( = 0) in the part program or
synchronized action. The change becomes active immediately.
● NC/PLC interface
DB31, ... DBX24.7 = 1 or 0 (master-slave on or off)
● Program commands (only 840D sl)
– Switch on: MASLON (<slave axis_1>, <slave axis_2>, ...)
– Switch off: MASLOF (<slave axis_1>, <slave axis_2>, ...)
– Switching off with braking of the slave spindles:
MASLOFS (<slave spindle_1>, < slave spindle_2>, ...)
– Switching off and deleting the assignment:
MASLDEL (<slave axis_1>, <slave axis_2>, ...)
Note
Changing the static assignment
The setting:
MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[<slave axis>] = 0
Permits the coupling to be dynamically changed. This means that it is possible to define
a new assignment using MASLDEF. The assignment parameterized in the machine data
(see static assignment, Section "Configuring a coupling (Page 631)") takes effect only
after the control has been rebooted (NCK reset).

Coupling state

System variable
The actual coupling state of a slave axis can be read in the part program and synchronized
action using the following system variable:

Special functions
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 TE3: Speed/torque coupling, master-slave
16.7 Response on activation/deactivation

$AA_MASL_STAT[<slave axis>]

Value Description
0 1) The coupling of the slave axis is not active.
2) The specific axis is not a slave axis
>0 The coupling is active.
<value> == Machine axis number of the master axis

NC/PLC interface signal

The current coupling state of a slave axis can be read using the following axis-specific NC/PLC
interface signal:
DB31, ... DBX96.7 (master/slave coupling active)

Setpoint state
Requests to switch on/off a master-slave coupling (NC/PLC interface signal and/or program
commands) that consecutively follow one another mutually overwrite one another. The
effective setpoint state results from the last chronological request (see Section "Response on
activation/deactivation (Page 641)").

16.7 Response on activation/deactivation

On/off at standstill (axis)

A request to switch on/off the coupling only becomes effective when the master and slave axis
are at a standstill (zero speed):
DB31, ... DBX61.4 == 1 (axis/spindle stationary)
In this case, the coupled axes must be in the closed-loop controlled mode.


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Figure 16-5 Activation procedure

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TE3: Speed/torque coupling, master-slave
16.7 Response on activation/deactivation

When switching on the coupling using the program command MASLON, the system waits until
the coupling is closed before the block is changed. The "Master-slave switchover active"
message will be displayed on the user interface during this time.

Switching on/off during motion (spindle)

Note
Switching on/off during motion
During the motion, the coupling can be switched on/off only for spindles in speed control
mode.

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 TE3: Speed/torque coupling, master-slave
16.7 Response on activation/deactivation

Switching on
When switching on during the motion, the coupling operation divides itself at different speeds
in two phases.
● Phase 1
The PLC user program must request the switch on of the coupling with:
DB31, ... DBX24.7 = 1 (master/slave ON)
The slave spindle accelerates or brakes along a ramp to the setpoint speed of the master
spindle.
When the setpoint speed is reached, the coupling is switched on and the NC/PLC interface
signal is set:
DB31, ... DBX96.7 == 1 (coupling active)
If the master spindle is accelerated while the coupling is being switched on, then Phase 1
is extended corresponding to the dynamic difference between the master and the slave
spindle.
● Phase 2
The following synchronous signals are generated from the actual speed difference between
the master and slave spindle(s):
– DB31, ... DBX96.3 (speed tolerance, coarse)
– DB31, ... DBX96.2 (speed tolerance, fine)
The associated limits are set using the following machine data:
– MD37270 $MA_MS_VELO_TOL_COARSE ("Tolerance coarse")

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TE3: Speed/torque coupling, master-slave
16.7 Response on activation/deactivation

– MD37272 $MA_MS_VELO_TOL_FINE ("Tolerance fine").

Note
The "Speed tolerance coarse" signal can be used to implement a monitoring function
on the PLC side that checks a coupled master-slave grouping for loss of speed
synchronism.
The "Speed tolerance fine" signal can be used to directly derive the time taken to close
the coupling mechanically and switch on the torque equalization controller.

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Figure 16-6 Coupling operation at different speeds

Switch off without braking

If the coupling is switched off with the MASLOF program command, the coupling will be switched
off immediately for spindles in speed control mode. The slave spindles maintain their speeds
at the time that the coupling is switched off until a new speed is programmed.

Special functions
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 TE3: Speed/torque coupling, master-slave
16.8 Supplementary conditions

Switch off with braking

If the coupling is switched off with the MASLOFS program command, the coupling will be
switched off immediately for spindles in speed control mode and the slave spindles braked.

Note
The implicit preprocessing stop is omitted for MASLON and MASLOF. The missing preprocessing
stop means that the $P system variables of the slave spindles do not supply updated values
until reprogrammed.

Coupling characteristics
The behavior regarding the program commands MASLON, MASLOF, MASLOFS, MASLDEL (only
840D sl) and the NC/PLC interface signal: DB31, ... DBX24.7 (master/slave on) is, for spindles
in the open-loop speed controlled mode, set using the following machine data:
MD37263 $MA_MS_SPIND_COUPLING_MODE[<slave spindle>] = <value>

<value> Description
0 Coupling and disconnection take place only at standstill.
The current coupling state is retained until all axes involved have actually come to a stand‐
still. The MASLOFS and MASLOF operations are identical; the slave spindle is not decelerated
automatically.
1 Coupling and disconnection takes place immediately and therefore during motion.
During coupling, the slave spindles are accelerated automatically to the current speed of
the master spindle.
On disconnection, the slave spindles rotating at this time retain their speeds until next speed
programming. However, a slave spindle disconnected with MASLOFS decelerates automat‐
ically.

16.8 Supplementary conditions

16.8.1 Functional boundary conditions

General
● Master and slave axes must be on the same NCU.
● A coupling is closed or opened independent of the channel state the next time that the axis
is at a standstill.
● Slave axes can only be traversed via the master axis when the coupling is closed.
● A coupled slave axis cannot be switched further via the axis container.
● A requested axis interchange of coupled slave axes is not executed.

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16.8 Supplementary conditions

● When the coupling is switched-in (closed) via the slave axis, the master axis is braked
automatically, if the channel axis is in the same channel: ⇒ asymmetrical behavior when
activating and deactivating the coupling:
– Activate: the leading axis is automatically braked
– Deactivating: no automatic braking of the leading axis
● The setpoint position of a coupled slave axis corresponds to its actual position.
● For axes and spindles in the positioning mode, the coupling is only switched-in (closed)
and switched-out (opened) at standstill (zero speed).
● The leading-following coupling must be deactivated prior to a gear change or a star-delta
switchover.

Axial monitoring functions

● Except monitoring the speed setpoint and actual speed, axial monitoring functions like
contour and standstill in the slave axis are inactive because of the missing position
controller. The position control circuit parameters like gain factor, precontrol, balancing can
thus be set differently for master and slave axes without the monitoring functions
responding.
● In order to ensure the same braking behavior for all axes of a master-slave group, when
the coupling is active, the same alarm reaction is applied to all of the axes of the master-
slave group.
● When canceling error states, the slave axes do not reposition to the point of interruption.

Virtual axis
Master and/or slave axes must not be "virtual" axes:
MD30132 $MA_IS_VIRTUAL_AX (axis is virtual axis)

Modulo rotary axes

● For slave axes, when the coupling is closed, the actual value displayed in the service display
is not modulo 360°. Independent of the setting in machine data:
MD30310 $MA_ROT_IS_MODULO[<slave axis>]

Spindles
● If a master-slave coupling is activated with spindles, the slave spindle is operated in the
open-loop speed controlled mode. The actual value of the slave spindle is not displayed
as modulo 360° in the service display. However, in the automatic basic display the actual
value is displayed as modulo 360°.
● If the spindles are accelerated at the current limit, this may mean that no adjusting reserves
are left over in the coupled state for the torque compensatory controller to use to distribute
the torque between the master and the slave as required.

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16.8 Supplementary conditions

● The maximum master spindle chuck speed must be configured in the following machine
data to be lower than or equal to that of the following spindles:
MD35100 $MA_SPIND_VELO_LIMIT[<master spindle>]
● The axial velocity monitoring function should be adapted to the chuck speed:
MD36200 $MA_AX_VELO_LIMIT[<master spindle>]

16.8.2 Axial NC/PLC interface signals

● In the brake control logic, the NC/PLC interface signal may longer be evaluated for slave
axes: DB3x.DBX61.5 (position controller active
). When the coupling is closed, the signal is no longer set. Instead, the following NC/PLC
interface signal should be used:
DB31, ... DBX96.7 (master-slave coupling active).
● When requested, and for a closed coupling, the following NC/PLC interface signals are
directly taken from the master axis for the slave axis:
DB31, ... DBX2.1 (controller enable)
DB31, ... DBX21.7 (pulse enable)
● When the controller enable is cancelled for the master axis:
DB31, ... DBX2.1 (controller enable) = 0
within the configured time of:
MD36610 $MA_AX_EMERGENCY_STOP_TIME
then this also results in interpolatory braking of the slave axis. The corresponding speed
and current controller enable signals are only cancelled after the configured time has expired
MD36620 $MA_SERVO_DISABLE_DELAY_TIME
● In order to facilitate a standard braking behavior for all coupled axes, it is recommended
that the following parameters are set the same.
– MD36620 $MA_SERVO_DISABLE_DELAY_TIME
– p9560 (pulse suppression, shutdown speed)
– p1228 (pulse suppression, delay time)

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16.8 Supplementary conditions

● If, for the master or slave axis, one of the following drive status signals is not set:
DB31, ... DBX61.7 (current controller active) == 0 OR
DB31, ... DBX61.6 (speed controller active) == 0
then, when the slave axis is at a standstill, the status signal is reset:
DB31, ... DBX96.7 (master/slave active) = 0
As soon as the master and slave axis are again in closed-loop control:
DB31, ... DBX61.7 (current controller active) == 1 AND
DB31, ... DBX61.6 (speed controller active) == 1
then for the slave axis, the status signal is again set:
DB31, ... DBX96.7 (master/slave active) = 1
● The torque equalization controller can be activated via the NC/PLC interface using:
DB31, ... DBX24.4 = 1 (torque equalization controller on)
The status of the torque equalization controller is displayed in:
DB31, ... DBX96.4 (master/slave equalization controller active)
Note
The slave axis is only closed-loop speed controlled when the coupling is closed. The NC/
PLC interface signal: DB31, ... DBX61.5 (position controller active) is no longer set.

16.8.3 Interaction with other functions

Function generator
To calibrate the speed control loop with activated coupling, it is recommended that a low value
should be set for the torque weighting of the slave axis (MD37268
$MA_MS_TORQUE_WEIGHT_SLAVE). Traversing of a mechanical coupled-motion slave
axis is not prevented by the torque compensatory controller.

Reference point approach

If the coupling is switched on, only the master axis can be referenced. Referencing of slave
axes is suppressed. The referencing requirement does not have to be explicitly canceled for
the slave axis in order to do this. The referencing status of coupled slave axes remains
unchanged. The slave axis position is generally not the same as the master axis position. This
difference in position is not significant. If the coupling is separated, each axis can be referenced
separately as usual.

Position-related compensations
Position-related compensations of the slave axis, such as spindle pitch errors, backlash,
temperature and sag offsets are not active because the position controller of the slave axis is
not active.
Correct calculation of the backlash compensation requires that the backlash of the slave axis
is always overtraveled by the motion of the master axis in coupled mode. Disconnecting the
coupling during an axis reversal error will generate an incorrect actual value for the slave axis.

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16.8 Supplementary conditions

Dynamic stiffness control (DSC)

The "Dynamic stiffness control (DSC)" function must either be active or not active for all axes
of a master-slave grouping.
MD32640 $MA_STIFFNESS_CONTROL_ENABLE

Speed/torque feedforward control (FFW)

The "Speed/torque feedforward control (FFW)" function does not have to be activated explicitly
in the slave axis. The corresponding settings of the master axis are used. The speed
feedforward value of the master axis is already incorporated in the speed setpoint of the slave
axis. For an active torque feedforward control, the load-side torque feedforward control value
of the master axis is also active in the slave drive.
The mechanical situation changes when the coupling is switched on. Axis-specific settings
must be adapted accordingly. All coupled drives should have the same speed control dynamics.

Gantry
If one master-slave relationship is defined on each side of the gantry grouping to increase the
gain, only the leading axis or following axis may be operated as master axis.

Travel to fixed stop (FXS)

The "Travel to fixed stop (FXS)" function can be programmed only in the master axis when a
coupling is active and has a different effect on the master and slave axes:
● The programmed value is expressed as a percentage of the rated drive torque of the master
axis. The master axis detects when the fixed stop has been reached.
● The programmed value is also active on the slave axis, but refers to the drive torque of the
slave axis.
If the rated torque values of the master and slave axes are different, they can be adapted to
each other through the following slave axis machine data:
MD37014 $MA_FIXED_STOP_TORQUE_FACTOR
Specifying a factor < 1 reduces the programmed clamping torque in the slave axis.
Please note the following supplementary conditions:
● Torque distribution between the master and slave axes is not possible during clamping as
the torque compensatory controller is switched off during clamping operations.
● Status changes to the master-slave coupling have no effect during travel to fixed stop.
Specification of a new status is only accepted when the fixed stop function has been
completed.

Safety Integrated (new 840D sl)

As the slave axis is traversed via the master axis speed setpoint, the axis-specific setpoint
limitation MD36933 $MA_SAFE_DES_VELO_LIMIT is inactive in the coupled slave axes. All
safety monitoring functions remain active in the slave axes however.

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16.8 Supplementary conditions

Gear stage change with activated master-slave coupling

An automatic gear stage change in a coupled slave spindle is not possible and can only be
implemented indirectly using the master spindle. The point in time at which the gear stage is
changed is then derived from the master spindle. The oscillating motion of the coupled slave
spindle is generated implicitly via the oscillating motion of the master spindle.
In contrast to the master spindle, the associated parameter block must be explicitly selected
in the coupled slave spindle. To enable the parameter set specification, the following machine
data must be set:
MD35590 $MA_PARAMSET_CHANGE_ENABLE = 2

Note
For more information about gear stage change and parameter sets for changes in spindle
mode, see:
References:
Function Manual, Basic Functions; Spindles (S1)

Axis container
If a coupled slave axis is configured as a container axis, alarm "4025 Switch axis container
%3 not permitted: Master-slave active channel %1 Axis %2" is displayed for an axis container
rotation.
Axis containers with changing master can be used to make the relevant spindle the master
spindle following a rotation of the axis container. Both master and slave spindles can be
container spindles.
For a coupling to be closed after axis container rotation using a different spindle in each case,
the old coupling must be separated before the rotation, the configuration deleted and the new
coupling configured and closed after the rotation.
Example of a cyclic coupling sequence (position = 3 / container = CT1)

Program code Comment

MASLDEF(AUX,SPI(3)) ; S3 master for AUX
MASLON(AUX) ; Coupling in for AUX
M3=3 S3=4000 ; Machining ...
MASLDEL(AUX) ; Delete configuration and release coupling
AXCTSWE(CT1) ; Axis container rotation

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16.8 Supplementary conditions

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Figure 16-8 Coupling between container spindle S3 and auxiliary motor AUX (after to rotation)

Hardware and software limit switches

If the software or hardware limit switch is overtraveled by a slave axis, the master-slave
grouping is stopped via the master axis. The relevant slave axis is shown in the alarm. The
limit switch of the slave axis is overtraveled by the amount of the deceleration distance of the
master axis.

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16.8 Supplementary conditions

The movement away of the slave axis from the limit switch must be performed via the traversing
of the master axis. Switching off the coupling (MASLOF) and traversing the slave axis is not
possible. The coupling cannot be switched off until the cause of the error has been removed.

NOTICE
Power Off/On or warm restart (reset (po)) after overtravel of the software or hardware limit
switch and switching off the coupling with MASLOF
If the software or hardware limit switch is overtraveled by a slave axis and an attempt is made
to switch off the coupling with MASLOF while the slave axis is still behind the limit switch, the
message "Waiting for coupled slave axis" is displayed. The coupling can only be switched off
by means of a Power Off/On or warm restart (reset (po)).

Block search

Static coupling
The "Block search with calculation" function (SERUPRO) can be used without any restrictions
in conjunction with a static master-slave coupling.

Dynamic coupling (only 840D sl)

For a dynamic coupling, the following restrictions must be observed with regard to the program
commands MASLON and MASLOF:
● The coupled axes must be on the same NCU.
● The coupled axes must be in the same channel when the block search is executed.
● After the block search has been completed, the coupling state, the associated axis positions
and speeds must be subsequently influenced by the user via the system ASUB
"PROGEVENT.SPF". System variables are available for this purpose.
– $P_PROG_EVENT: This variable provides information about the event which activated
the subprogram. A value of 5 stands for block search.
– $P_SEARCH_MASLC[slave axis name]: This variable stands for alteration of the
coupling status during a block search.
– $P_SEARCH_MASLD[slave axis name]: This variable indicates the positional offset
calculated in the block search between the slave and master axes at the instant the
coupling was closed.
– $AA_MASL_STAT[slave axis name]: This variable indicates the current coupling state.

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16.8 Supplementary conditions

● The system ASUB "PROGEVENT.SPF" must be saved under the following path: /
_N_CMA_DIR/_N_PROG_EVENT_SPF
● The following machine data should be parameterized so that PROGEVENT.SPF is started.
NC-specific machine data:
– MD11450 $MN_SEARCH_RUN_MODE = 'H02'
– MD11602 $MN_ASUP_START_MASK = 'H01'
– MD11604 $MN_ASUP_START_PRIO_LEVEL = 100
Channel-specific machine data:
– MD20105 $MC_PROG_EVENT_IGN_REFP_LOCK = ’H3F’

Table 16-1 Example 1: PROGEVENT.SPF: Example 1

Program code Comment
N10 IF $P_PROG_EVENT==5 ; Block search active
N20 IF (($P_SEARCH_MASLC[Y]<>0) AND ; The coupling state has changed during
($AA_MASL_STAT[Y]<>0)) block search AND the current state is
"coupled"
N30 MASLOF(Y) ; Disconnect coupling
N40 SUPA Y=$AA_IM[X]-$P_SEARCH_MASLD[Y] ; Traverse through the position offset
using the slave axis
N50 MASLON(Y) ; Close coupling
N60 ENDIF
N70 ENDIF
N80 REPOSA

Table 16-2 Example 2: PROGEVENT.SPF

Program code Comment
N10 IF $P_PROG_EVENT==5 ; Block search active
N20 IF (($P_SEARCH_MASLC[SPI(2)]<>0) AND ; The state of the second spindle has
($AA_MASL_STAT[SPI(2)]==0)) changed during block search AND the cur-
rent state is "disconnected"
N30 M2=$P_SEARCH_SDIR[2] ; Update direction of rotation
N40 S2=$P_SEARCH_S[2] , Update speed
N50 ENDIF
N60 ENDIF
N70 REPOSA

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16.9 Examples

For more application examples (see Chapter "Examples (Page 654)).

Note
For an activated coupling, it is recommended to only use block search type 5, "Block search
via program test" (SERUPRO) for a block search.
More information about event-driven program calls and "block search using the program test"
(SERUPRO) is included in:
References:
Function Manual, Basic Functions;
● Auxiliary function outputs to PLC (H2)
● Mode group, channel, program operation, reset response (K1)
● Spindles (S1)

16.9 Examples

16.9.1 Master-slave coupling between AX1=Master and AX2=Slave.

Configuration
Master-slave coupling between AX1=Master and AX2=Slave.
1. Machine axis number of master axis for speed setpoint coupling
MD37250 $MA_MS_ASSIGN_MASTER_SPEED_CMD[AX2] = 1
2. Master axis with torque distribution identical to master axis with speed setpoint coupling
MD37252 $MA_MS_ASSIGN_MASTER_TORQUE_CTR[AX2] = 0
3. Permanent coupling
MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE[AX2] = 1
4. Torque is injected in both the master and slave axes
MD37254 $MA_MS_TORQUE_CTRL_MODE[AX2] = 0
5. Torque distribution between the master and slave axes is 50% to 50%
MD37268 $MA_MS_TORQUE_WEIGHT_SLAVE[AX2] = 50
6. Parameters of the torque compensatory controller
MD37256 $MA_MS_TORQUE_CTRL_P_GAIN[AX2] = 0.5
MD37258 $MA_MS_TORQUE_CTRL_I_TIME[AX2] = 5.0

16.9.2 Close coupling via the PLC

This application allows you to close or separate a master-slave coupling between the machine
axes AX1=Master axis and AX2=Slave axis during operation.

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16.9 Examples

Preconditions
● One configured master axis
MD37250 $MA_MS_ASSIGN_MASTER_SPEED_CMD ≠ 0
● Activation of a master-slave coupling via
MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE=0
● The coupling is open.

Typical sequence of operations

Action Effect/comment
● Approach coupling position Each axis moves to the coupling position.
● Close coupling mechanically Both axes are mechanically coupled to one anoth‐
er.
● Request to close the coupling PLC interface signal "Master/slave on" DB32, ...
DBX24.7 is set.
● Read back coupling state When the axis is at a standstill, the coupled slave
axis sets PLC interface signal "Master/slave ac‐
tive" DB32, ... DBX96.7 and clears "Position con‐
troller active" DB32, ... DBX61.5.
Wait for checkback signal.
● Moving the master-slave group The master axis is moved.

16.9.3 Closing/separating the coupling via the part program for the SINUMERIK 840D
sl
This application allows you to close or separate a master-slave coupling between the machine
axes AX1=Master axis and AX2=Slave via the part program.

Preconditions
● A configured master axis MD37250 0 0.
● Not a static master-slave coupling:
MD37262 $MA_MS_COUPLING_ALWAYS_ACTIVE= 0
● The coupling is open.

Parts program
Program code Comment
N10 G0 AX1=0 AX2=0 ; Approach the coupling position on an axis-for-axis basis
N20 MASLON (AX2) ; (mechanically connect the axes)
; Close the coupling.
N30 AX1=100 ; Move the master-slave group using the master axis.

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16.9 Examples

Program code Comment

N40 MASLOF (AX2) ; Open the coupling.
; (Mechanically separate the axes)
N50 AX1=200 AX2=200 ; Move the axes separately.
N60 M30

16.9.4 Release the mechanical brake

This application allows implementation of a brake control for machine axes AX1=Master axis
and AX2=Slave axis in a master-slave coupling.

Preconditions
● Master-slave coupling is configured.
● Axes are stationary.
● No servo enable signals.

Typical sequence of operations

Action Effect/comment
● Request to close the coupling The following PLC interface signal is set:
DB31, ... DBX24.7 (Master/Slave ON)
● Set controller enable PLC interface signal "Servo enable" DB31, ...
DBX2.1 is set for both axes.
● Interpreting the feedback Link PLC interface signals of the master axis using
AND:
DB31, ... DBX61.7 (current controller active)
DB31, ... DBX61.6 (speed controller active)
DB31, ... DBX61.5 (position controller active)
Link PLC interface signals of the saster axis using
AND:
DB31, ... DBX61.7 (current controller active)
DB31, ... DBX61.6 (speed controller active)
DB31, ... DBX96.7 (master/slave active)
● Release brakes If the result of the AND operations on the master
and slave axes is ≠ 0, the brake may be released.

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16.10 Data lists

16.10 Data lists

16.10.1 Machine data

16.10.1.1 Axis/spindlespecific machine data

Number Identifier: $MA_ Description

37250 MS_ASSIGN_MASTER_SPEED_CMD Leading axis for speed setpoint coupling
37252 MS_ASSIGN_MASTER_TORQUE_CTR Leading axis for torque distribution
37254 MS_TORQUE_CTRL_MODE Connection of torque control output
37255 MS_TORQUE_CTRL_ACTIVATION Activate torque compensatory control
37256 MS_TORQUE_CTRL_P_GAIN Gain factor of torque compensatory controller
37258 MS_TORQUE_CTRL_I_TIME Reset time for torque compensatory controller
37260 MS_MAX_CTRL_VELO Limitation of torque compensatory control
37262 MS_COUPLING_ALWAYS_ACTIVE Permanent master-slave coupling
37263 MS_SPIND_COUPLING_MODE Coupling characteristics of a spindle
37264 MS_TENSION_TORQUE Master-slave tension torque
37268 MS_TORQUE_WEIGHT_SLAVE Torque weighting of the slave axis
37270 MS_VELO_TOL_COARSE Master-slave velocity tolerance "coarse"
37272 MS_VELO_TOL_FINE Master-slave velocity tolerance "fine"
37274 MS_MOTION_DIR_REVERSE Invert master-slave direction of travel

16.10.2 System variables

After a block search, the coupling status and associated axis positions can be adjusted
subsequently by means of a system ASUB (asynchronous subroutine) "PROGEVENT.SPF".
System variables $P_SEARCH_MASL_C, $P_SEARCH_MASL_D and $AA_MASL_STAT are
available for this purpose; they can be used to alter the positional offset between the coupled
axes and the coupling status:

Identifier Meaning
$P_SEARCH_MASLC[following axis name] This variable registers a change in the coupling state during the
SERUPRO block search.
$P_SEARCH_MASLD[following axis name] This variable indicates the positional offset between the slave and
master axes at the instant the coupling was closed.
$AA_MASL_STAT[following axis name] This variable indicates the current coupling state.
Value ≠ 0: "Master-slave coupling active"
In this case, it contains the current machine number of the master
axis and, if the NCU link is active (several operating panel fronts
and NCUs), also the NCU No. at the hundreds position.
Example: 201 for Axis 1 on NCU2.

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16.10 Data lists

16.10.3 Signals

16.10.3.1 Signals to axis/spindle

Signal name SINUMERIK 840D sl SINUMERIK 828D

Request master-slave torque compensatory controller DB31, ... .DBX24.4 DB380x.DBX5000.4
On==1 / Off==0
Request master-slave coupling On==1 / Off==0 DB31, ... .DBX24.7 DB380x.DBX5000.7

16.10.3.2 Signals from axis/spindle

Signal name SINUMERIK 840D sl SINUMERIK 828D

State master-slave speed difference "fine" DB31, ... DBX96.2 DB390x.DBX5000.2
State master-slave speed difference "coarse" DB31, ... DBX96.3 DB390x.DBX5000.3
State master-slave torque compensatory controller On==1 / DB31, ... DBX96.4 DB390x.DBX5000.4
Off==0
State master-slave coupling On==1 / Off==0 DB31, ... DBX96.7 DB390x.DBX5000.7

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17.1 Brief description

Functionality
The handling transformation package has been designed for use on manipulators and robots.
The package is a type of modular system, which enables the customer to configure the
transformation for his machine by setting machine data (provided that the relevant kinematics
are included in the handling transformation package).

Section structure
The "Handling transformation package" section deals with the following topics:
● The "Kinematic transformation" section describes the kinematic transformation
environment.
● The "Definition of terms" section explains some basic terms.
● The "Configuration of the kinematic transformation" section explains the machine data
required for the configuration.
● The "Kinematic descriptions" section uses configuring examples to illustrate the most
commonly used 2-axis to 5-axis kinematics that can be configured with the "Handling
transformation package".
● The "Tool orientation" to "Tool programming" sections handle the programming. describing
orientation programming, the entry of tool parameters and transformation calls.

Abbreviations

FL Flange coordinate system

HP Wrist point coordinate system
IRO Internal robot coordinate system (= basic coordinate system)
p3, q3, r3 Coordinates of the last basic axis
RO Robot or base center point coordinate system
WS Workpiece coordinate system
T Tool coordinate system
x3, y3, z3 Coordinates of the first wrist axis

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17.3 Definition of terms

17.2 Kinematic transformation

Task of a transformation
The purpose of a transformation is to transform movements in the tool tip, which are
programmed in a Cartesian coordinate system, into machine axis positions.

Fields of application
The handling transformation package described here has been designed to cover the largest
possible number of kinematic transformations implemented solely via parameter settings in
machine data. Currently, kinematics with two to maximum six axes to be included in the
transformation can be configured with this package, corresponding to up to five spatial degrees
of freedom. In this case, a maximum of 3 degrees are available for translation and 3 degrees
for orientation, This package thus allows a tool (milling cutter, laser beam) to be oriented by a
5-axis machine in any desired relation to the workpiece in every point of the machining space.
The workpiece is always programmed in the rectangular workpiece coordinate system; any
programmed or set frames rotate and shift this system in relation to the basic system. The
kinematic transformation then converts this information into motion instructions for the real
machine axes. The kinematic transformation requires information about the design
(kinematics) of the machine, which are stored in machine data.

Kinematic categories
The handling transformation package is divided into two categories of kinematics, which can
be selected via machine data:
MD62600 $MC_TRAFO6_KINCLASS (kinematic category)
● STANDARD: This category includes the most commonly used kinematics.
● SPECIAL: Special kinematics

17.3 Definition of terms

17.3.1 Units and directions

Lengths and angles

In the transformation machine data, all lengths are specified in millimeters or inches and, unless
otherwise stated, all angles in degrees at intervals of [ -180°, 180° ].

Direction of rotation
In the case of angles, arrows in the drawings always indicate the mathematically positive
direction of rotation.

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17.3 Definition of terms

17.3.2 Definition of positions and orientations using frames

In order to make a clear distinction from the term "frame" as it is used in the NC language, the
following description explains the meaning of the term "frame" in relation to the handling
transformation package.

Frame
A frame can be used to translate one coordinate system into another. In this respect, a
distinction must be made between translation and rotation. Translation results in an offset; a
rotation, a rotation of the coordinate system with respect to the initial system. Coordinates X,
Y and Z are used as designator for a translation. They are defined so as to result in a legal
coordinate system.

Translation
A translation is always specified in relation to the coordinate directions of the initial system.
These directions are assigned to machine data as follows:
● X direction: ..._POS[ 0 ]
● Y direction: ..._POS[ 1 ]
● Z direction: ..._POS[ 2 ]

Rotation
A rotation is specified in RPY angles A, B and C (R=roll, P=pitch, Y=yaw). The positive direction
of rotation is defined by the right hand rule, i.e. if the thumb on the right hand is pointing in the
direction of the axis of rotation, then the fingers are pointing in the positive angular direction.
Angles A and C are defined in the interval [ -180; +180 ], and B in the interval [ -90; +90 ].
The definitions of the RPY angles are as follows:
● Angle A: 1. rotation about the Z axis of the initial system
● B angle: 2. Rotation through the rotated Y axis
● C angle: 3. rotation about the twice rotated X axis
The RPY angles are assigned to machine data as follows:
● Angle A: ..._RPY[ 0 ]
● B angle: ..._RPY[ 1 ]
● C angle: ..._RPY[ 2 ]
The following diagram shows an example for a rotation through the RPY angle. The initial
coordinate system X1, Y1, Z1 is transitioned into the coordinate system X4, Y4, Z4
1. Rotation through angle A around the Z1 axis
2. Rotation through angle B around the Y2 axis
3. Rotation through angle C around the X3 axis.

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17.3 Definition of terms

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Figure 17-1 Example of rotation through RPY angles

17.3.3 Definition of a joint

Meaning
A sliding joint is implemented using a translatory axis, and a swivel joint, using a rotary axis.
The basic axis identifiers result from the arrangement and sequence of the individual joints.
These are specified using letter codes (S, C, R, N).

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17.4 Configuration of a kinematic transformation

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17.4 Configuration of a kinematic transformation

Meaning
In order to ensure that the kinematic transformation can convert the programmed values into
axis motions, it must have access to some information about the mechanical construction of
the machine. This information is stored in machine data:
● Axis assignments
● Geometry information

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17.4 Configuration of a kinematic transformation

17.4.1 General machine data

MD24100 $MC_TRAFO_TYPE_1 (definition of transformation 1 in the channel)

The value 4100 must be entered in this data for the handling transformation package.

MD24110 $MC_TRAFO_AXES_IN_1 (axis assignment for transformation)

The axis assignment at the transformation input defines which transformation axis is mapped
internally onto a channel axis. It is specified in machine data:
MD24110 $MC_TRAFO_AXES_IN_1
There is a predetermined axis sequence for the handling transformation package, The basic
axes are entered in the first three components (index 0…2). The upper three components
(index 3…5) are assigned to the manual axes.
● MD24110 $MC_TRAFO_AXES_IN_1[0] = 1 ; 1. Basic axis
● MD24110 $MC_TRAFO_AXES_IN_1[1] = 2 ; 2. Basic axis
● MD24110 $MC_TRAFO_AXES_IN_1[2] = 3 ; 3. Basic axis
● MD24110 $MC_TRAFO_AXES_IN_1[3] = 4 ; 1. Manual axis
● MD24110 $MC_TRAFO_AXES_IN_1[4] = 5 ; 2. Manual axis
● MD24110 $MC_TRAFO_AXES_IN_1[5] = 6 ; 3. Manual axis

MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1 (assignment between geometry axis and channel

axis for transformation 1)
The translational degrees of freedom that are available for the transformation are entered via
machine data:
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1
The 3 geometry axes normally correspond to Cartesian axis directions X, Y and Z.
In this case, the first three channel axis numbers must be transferred from MD24110
$MC_TRAFO_AXES_IN_1 to MD24120 $MC_TRAFO_GEO_AX_ASSIGN_TAB_1.
● MD24120 $MC_TRAFO_GEO_AX_ASSIGN_TAB_1[0] = 1
● MD24120 $MC_TRAFO_GEO_AX_ASSIGN_TAB_1[1] = 2
● MD24120 $MC_TRAFO_GEO_AX_ASSIGN_TAB_1[2] = 3

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17.4 Configuration of a kinematic transformation

17.4.2 Parameterization using geometry data

Modular principle
The machine geometry is parameterized according to a type of modular principle. With this
method, the machine is successively configured in geometry parameters from its base center
point to the tool tip, thereby producing a closed kinematic loop. In this case, frames are used
to describe the geometry. While the control is powering up, the configuration machine data is
checked and alarms displayed when relevant. All axes of the mode group are tracked as alarm
response. The alarms can be deleted using POWER ON.
As shown in the following diagram "Closed kinematic loop illustrated by the example of a robot",
the kinematic transformation converts the tool operating point (tool coordinate system: XTO,
YTO, ZTO), specified relative to the base coordinate system (BCS = robot coordinate system:
XRO, YRO, ZRO), in machine axis values (MCS positions: A1, A2, A3, ...). The operating point
(XWZ, YWZ, ZWZ) is specified in the part program in relation to the workpiece to be machined
(workpiece coordinate system WCS: XWS, YWS, ZWS). The programmable frames make it
possible to create an offset between the workpiece coordinate system (WCS) and the base
coordinate system (BCS).

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Note
For more detailed information about coordinate systems, please see:
Reference:
Function Manual Basic Functions;
Chapter "K2, axes, coordinate systems, frames" > "Coordinate systems"

The following machine data is available for configuring kinematic transformations:

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17.4 Configuration of a kinematic transformation

Frame between base center point and internal coordinate system

The frame T_IRO_RO links the base center point of the machine (BCS = RO) with the first
internal coordinate system (IRO) determined by the transformation.
● MD62613 $MC_TRAFO6_TIRORO_RPY (frame between base center point and internal
coordinate system (rotation component), n = 0...2)
● MD62612 $MC_TRAFO6_TIRORO_POS (frame between base center point and internal
coordinate system (position component), n = 0...2)

Basic axis arrangement

The type of basic axis arrangement is specified in machine data:
● MD62603 $MC_TRAFO6_MAIN_AXES (basic axis identifier)
The first three axes included in the transformation are generally referred to as the "basic axes".
They must always be mutually parallel or perpendicular.
The handling transformation package contains the basic axis kinematics shown in the following
diagram. Every basic axis arrangement has its own special identifier (see Chapter "Definition
of a joint (Page 662)").

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17.4 Configuration of a kinematic transformation

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② CC: MD62603 = 2, SCARA (1 linear axis, 2 rotary axes (in parallel))
③ CS: MD62603 = 6, SCARA (2 linear axes, 1 rotary axis (spin axis))
④ NR: MD62603 = 3, articulated arm (3 rotary axes (2 axes in parallel))
⑤ SC: MD62603 = 4, SCARA (2 linear axes, 1 rotary axis (swivel axis))
⑥ RR: MD62603 = 5, articulated arm (1 linear axis, 2 rotary axes (vertical))
⑦ NN: MD62603 = 7, articulated arm (3 rotary axes)

Figure 17-4 Overview of basic axis configuration

Basic axis lengths A and B

The basic axis lengths A and B are specified with machine data:
● MD62607 $MC_TRAFO6_MAIN_LENGTH_AB (basic axis lengths A and B, n = 0...1)
As Fig. "Overview of basic axis configurations" illustrates, these are specially defined for each
type of basic axis.

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17.4 Configuration of a kinematic transformation

Position of the 4th axis

Whether the 4th axis is mounted parallel, anti-parallel or perpendicular to the last rotary basic
axis is specified in machine data:
● MD62606 $MC_TRAFO6_A4PAR (axis 4 is parallel/anti-parallel to last basic axis)

Description of the wrist axis

Frame to attach the wrist axis

Frame T_X3_P3 links the last coordinate system of the basic axes with the first wrist axis
coordinate system.
● MD62608 $MC_TRAFO6_TX3P3_POS (attachment of wrist axis (position component], n
= 0...2)
● MD62609 $MC_TRAFO6_TX3P3_RPY (attachment of wrist axis (rotation component), n =
0...2)

Frame between wrist point and flange coordinate system

Frame T_FL_WP links the last hand wrist axis coordinate system with the flange coordinate
system.
● MD62610 $MC_TRAFO6_TFLWP_POS (frame between wrist point and flange coordinate
system (position component), n = 0...2)
● MD62611 $MC_TRAFO6_TFLWP_RPY (frame between wrist point and flange coordinate
system (rotation component), n = 0...2)
This data is explained in more detail in the following sections.

Description of the wrist axis type

These parameters describe the wrist axis type.
● MD62604 $MC_TRAFO6_WRIST_AXES (wrist axis identifier)
The term wrist axes generally refers to axes four to six.

Wrist axes included in every transformation

The fourth axis and all further axes are generally referred to as "wrist axes". The handling
transformation package can only identify wrist axes with rotary axes. The wrist axis identifier
for three-axis wrists is entered in machine data:
● MD62604 $MC_TRAFO6_WRIST_AXES (wrist axis identifier)
When there are fewer than three wrist axes, the identifier for the inclined wrist axis or a central
wrist axis is entered in the machine data:
● MD62604 $MC_TRAFO6_WRIST_AXES (wrist axis identifier)
The current software only supports the central and inclined wrist axis types.

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17.4 Configuration of a kinematic transformation

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Figure 17-5 Overview of wrist axis configuration

Parameterization of wrist axes

With the following machine data, using a special frame type, the geometry of the wrist axis
and/or the position of the coordinate system in the wrist axis with respect to one another is
defined.
● MD62614 $MC_TRAFO6_DHPAR4_5A (parameter A for configuring the wrist axis, n = 0...1)
● MD62615 $MC_TRAFO6_DHPAR4_5D (parameter D for configuring the wrist axis, n =
0...1)
● MD62616 $MC_TRAFO6_DHPAR4_5ALPHA. (Parameter ALPHA for configuring the wrist
axis, n = 0...1)
For this purpose, the machine data corresponds to certain frame components (see Section
"Definition of positions and orientations using frames (Page 661)"):
● X component: MD62614 $MC_TRAFO6_DHPAR4_5A ≙ MD62608
$MC_TRAFO6_TX3P3_POS[ 0 ]
● Z component: MD62615 $MC_TRAFO6_DHPAR4_5D ≙ MD62608
$MC_TRAFO6_TX3P3_POS[ 2 ]
● C angle: MD62616 $MC_TRAFO6_DHPAR4_5ALPHA ≙ MD62609
$MC_TRAFO6_TX3P3_RPY[ 2 ]
The other components of the frame are zero.

Central wrist axis

On a central wrist axis, all wrist axes intersect at one point. All parameters must be set as
shown in Table "Configuring data for a central wrist axis".

]
+3

]
[ [ [+3

Figure 17-6 Central wrist axis, 5-axis machine

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17.4 Configuration of a kinematic transformation

Table 17-1 Configuring data for a central wrist axis

Machine data Value

MD62604 $MC_TRAFO6_WRIST_AXES 2
MD62614 $MC_TRAFO6_DHPAR4_5A [0.0, 0.0]
MD62615 $MC_TRAFO6_DHPAR4_5D [0.0, 0.0]
MD62616 $MC_TRAFO6_DHPAR4_5ALPHA [-90.0, 90.0]

Inclined wrist axis

The inclined wrist axis differs from the central wrist axis in two respects, i.e. the axes do not
intersect nor are they mutually perpendicular. Parameters a4, d5, and a4 are available for this
type of hand, as shown in Table "Configuring data for a central wrist axis".

] ]
 +3

[ [
 +3

 


[

]


① MD62614 $MC_TRAFO6_DHPAR4_5A[ 0 ]
② MD62616 $MC_TRAFO6_DHPAR4_5ALPHA[ 0 ]
③ MD62615 $MC_TRAFO6_DHPAR4_5D[ 1 ]

Figure 17-7 Inclined wrist axis, 5-axis machine

Table 17-2 Configuring data for an inclined wrist axis (5-axis

Machine data Value

MD62604 $MC_TRAFO6_WRIST_AXES 6
MD62614 $MC_TRAFO6_DHPAR4_5A [a4, 0.0]
MD62615 $MC_TRAFO6_DHPAR4_5D [0.0, d5]
MD62616 $MC_TRAFO6_DHPAR4_5ALPHA [α4, 0.0]

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17.4 Configuration of a kinematic transformation

7B;B3 7B)/B:3

$
] $ $ $ $
,52 U [
\ T \
+3 [
,52  ] )/
 +3
[ S [ \
,52  +3 \
)/
]
] )/
7B,52B52 

$
]
52 \
52
[
52

Figure 17-8 Link frames

Frame: T_IRO_RO
Frame T_IRO_RO provides the link between the base center point coordinate system (RO)
defined by the user and the internal robot coordinate system (IRO). The internal robot
coordinate system is predefined in the handling transformation package for each basic axis
type and included in the kinematic diagrams for the basic axis arrangements. The base center
point system is in the Cartesian zero point of the machine, corresponding to the basic
coordinate system. If no FRAMES are programmed, the basic coordinate system equals the
workpiece coordinate system.

Note
For more detailed information about FRAMES, please see:
References:
Programming Manual Fundamentals

Frame T_IRO_RO is not subject to any restrictions for 5-axis kinematics.

The following restrictions apply in relation to 4-axis kinematics:
● The first rotary axis must always be parallel/anti-parallel to one of the coordinate axes of
the base center point coordinate system (RO).
● No further restrictions apply to type SS basic axes.
● In the case of type CC, CS or SC basic axes, no further restrictions apply provided that the
4th axis is parallel to the last rotary basic axis.
● With respect to all other basic axes, and basic axes of type CC, CS or SC if the 4th axis is
perpendicular to the last rotary basic axis, the Z axis of RO must be parallel to the Z axis
of IRO.

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17.4 Configuration of a kinematic transformation

Frame: T_X3_P3
Frame T_X3_P3 describes the method used to attach the wrist axis to the basic axes. Frame
T_X3_P3 is used to link the coordinate system of the last basic axis (p3_q3_r3 coordinate
system) with the coordinate system of the first wrist axis (x3_y3_z3 coordinate system). The
p3_q3_r3 coordinate system is included in the kinematic diagrams for the basic axis
arrangements.
The z3 axis is always on the 4th axis.
Depending on the number of axes to be included in the transformation, frame T_X3_P3 is
subject to certain restrictions relating to the wrist and basic axes:
● For 5-axis kinematics, frame T_X3_P3 can be freely selected in the following cases:
– If the basic axes are of the SS type.
– If the basic axes are of the CC, CS or SC type, the transformation must either include
a central wrist axis or the 4th axis must be positioned in parallel to the last rotary basic
axis.
– If the basic axes are of the NR or RR type, the transformation must either include a
central wrist axis or the 4th axis must be positioned in parallel to the last basic rotary
axis and an X flange must intersect the 5th axis.
– If the basic axes are of the NN type, the transformation must include a central wrist axis.
● For 4-axes, ensure that the Z3 axis is always parallel/anti-parallel or perpendicular to the
last basic axis.

Frame: T_FL_WP
Frame T_FL_WP links the flange with the last internal coordinate system (wrist point coordinate
system) preset by the handling transformation package.
For kinematics with less than 6 axes, this frame is subject to certain restrictions. These
restrictions are explained by the relevant kinematics.

Other configuring data

Number of transformed axes
The number of axes included in the transformation is defined in machine data:
● MD62605 $MC_TRAFO6_NUM_AXES (number of transformed axes)
The number of transformed axes can currently lie between two and six axes.

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17.4 Configuration of a kinematic transformation

Changing the axis sequence

Rearrangement of axes: MD62620

Note
With certain types of kinematics, it is possible to transpose axes without changing the behavior
of the kinematic transformation. Machine data:
MD62620 $MC_TRAFO6_AXIS_SEQ (rearrangement of axes)
The axes on the machine are numbered consecutively from 1 to 6 and must be entered in the
internal sequence in machine data:
MD62620 $MC_TRAFO6_AXIS_SEQ[0] ...[4]
All other axis-specific machine data refer to the sequence of axes on the machine.

Table 17-3 Changing the axis sequence

Basic axis kinematics Options for changing axis sequence

SS, CC Any
SC 1 and 2
CS 2 and 3

Example 1
There are two kinematics, such as those shown in Fig. "Rearrangement of axes 1". Kinematic
1 is directly included in the handling transformation package. It corresponds to a CC kinematic
with a wrist axis parallel to the last basic rotary axis.
Kinematic 2 is the same as kinematic 1 inasmuch as it is irrelevant for the resulting robot
movement whether the translational axis is axis 1 or axis 4. In this instance, the data for
kinematic 2 must be entered as follows in machine data:
● MD62620 $MC_TRAFO6_AXIS_SEQ (rearrangement of axes)
The input is as follows:
● MD62620 $MC_TRAFO6_AXIS_SEQ[ 0 ] = 4
● MD62620 $MC_TRAFO6_AXIS_SEQ[ 1 ] = 1
● MD62620 $MC_TRAFO6_AXIS_SEQ[ 2 ] = 2
● MD62620 $MC_TRAFO6_AXIS_SEQ[ 3 ] = 3

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① Kinematics 1
② Kinematics 2

Figure 17-9 Rearrangement of axes 1

Example 2
This example involves a SCARA kinematic transformation as illustrated in Fig.
"Rearrangement of axes 2", in which the axes can be freely transposed. Kinematic 1 is directly
included in the handling transformation package. It corresponds to a CC kinematic. As regards
the transposition of axes, it is irrelevant how many wrist axes are involved in the transformation.


  

   


  

① Kinematics 1: Axis sequence 1 2 3

② Kinematics 2: Axis sequence 2 1 3
③ Kinematics 3: Axis sequence 2 3 1

Figure 17-10 Rearrangement of axes 2

Changing the directions of axes

A rotational or offset direction is preset for each axis in the handling transformation package.
This direction is not necessarily the same as the corresponding direction on the machine. The
following machine data must be set to -1 for the relevant axis if the direction is to be inverted,
or otherwise to +1:
● MD62618 $MC_TRAFO6_AXES_DIR[ ] (matching of physical and mathematical directions
of rotation [axis no.]: 0...5)

Adapting the zero points of the axes

Offset between mathematical and mechanical zero points

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17.4 Configuration of a kinematic transformation

The mathematical zero points of axes are preset in the handling transformation package.
However, the mathematical zero point does not always correspond to the mechanical zero
point (calibration point) of axes. In order for the zero point of each axis to fit one another, the
difference between the mathematical zero point and the alignment point for each axis must be
entered in the following machine data:
● MD62617 $MC_TRAFO6_MAMES[ ] (offset between mathematical and mechanical zero
points [axis no.]: 0...5)
The deviation to be entered corresponds to the difference between the mechanical zero point
and the mathematically positive direction of rotation of the axis.

Example
Jointed arm kinematics are shown in the following diagram.
In the mathematical zero position ②, axis 2 (A2) has a value of 90º. This value should be
entered into the machine data for axis 2 (index 1):
● MD62617 $MC_TRAFO6_MAMES[ 1 ] = 90
Axis 3 (A3) is counted relative to the previous axis 2 (A2) in the kinematic chain, and in the
mechanical zero position ① has the value: -90º:
● MD62617 $MC_TRAFO6_MAMES[ 2 ] = -90

$

$
 $

$

$ $

 

① mechanical zero position (adjusted position):

② MD62617 $MC_TRAFO6_MAMES[ 2 ] = -90
③ mathematical zero position
④ MD62617 $MC_ TRAFO6_MAMES[ 1 ] = 90

Figure 17-11 Matching mathematical and mechanical zero points

Axis type for transformation

Which axis type is handled is specified in machine data:
● MD62601 $MC_TRAFO6_AXES_TYPE (axis type for transformation [axis no.]: 0...5)

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17.4 Configuration of a kinematic transformation

The transformation package distinguishes between the following axis types:

● Linear axis: MD62601 = 1
● Rotary axis: MD62601 = 3

Velocities and acceleration rates

Separate velocities for the Cartesian movement components are introduced for axes that are
traversed with G00 and active transformation.
The velocity is preset via path feed F for axis traversal with G01 or G02.

Cartesian velocity
The velocities for individual translational motion directions for axis traversal with G00 can be
preset in machine data:
● MD62629 $MC_TRAFO6_VELCP[i] (Cartesian velocity [no.]: 0...2)
– Index i = 0 : X component of basic system
– Index i = 1 : Y component of basic system
– Index i = 2 : Z component of basic system

Cartesian acceleration rates

The acceleration rates for individual translational motion directions for axis traversal with G00
can be preset in machine data:
● MD62630 $MC_TRAFO6_ACCCP[i] (Cartesian acceleration rates [no.]: 0...2)
– Index i = 0 : X component of basic system
– Index i = 1 : Y component of basic system
– Index i = 2 : Z component of basic system

Orientation angle velocities

The velocities for individual directions of orientation for axis traversal with G00 can be preset
in machine data:
● MD62631 $MC_TRAFO6_VELORI[i] (orientation angle velocities [no.]: 0...2)
– Index i = 0 : A angle
– Index i = 1 : B angle
– Index i = 2 : C angle

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17.5 Descriptions of kinematics

Orientation angle acceleration rates

The acceleration rates for individual directions of orientation for axis traversal with G00 can be
preset in machine data:
● MD62632 $MC_TRAFO6_ACCORI[i] (orientation angle acceleration rates [no.]: 0...2)
– Index i = 0 : A angle
– Index i = 1 : B angle
– Index i = 2 : C angle

Reduction factor for the velocity controller

A reduction factor for the velocity controller in the JOG mode can be specified with the machine
data:
● MD62633 $MC_ROBX_DYN_LIM_REDUCE (reduction factor for the velocity controller)

Time constant for the velocity controller

A time constant for the PT1 filter of the speed controller can be specified with the machine
data:
● MD62634 $MC_ROBX_VEL_FILTER_TIME (time constant for the velocity controller)

17.5 Descriptions of kinematics

The following descriptions of kinematics for transformations involving 2 to 5 axes explain the
general configuring procedure first before describing how the machine data need to be
configured, using a configuring example for each kinematic type. These examples do not
include all possible lengths and offsets. The direction data refer to the positive directions of
traversal and rotation for the transformation. The axis positions correspond to their zero
position for the relevant transformation.

17.5.1 3-axis kinematics

3-axis kinematics normally possess three translational degrees of freedom, but do not have a
rotational degree of freedom for orientation. As a consequence, 3-axis kinematics only have
basic axes.

Configuration
The procedure for configuring a 3-axis kinematic is as follows:
1. Enter "Standard" kinematic category in machine data:
MD62600 $MC_TRAFO6_KINCLASS (kinematic category)
2. Set the number of axes for transformation in machine data:
MD62605 $MC_TRAFO6_NUM_AXES = 3 (number of transformed axes)

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17.5 Descriptions of kinematics

3. Compare the basic axes with the basic axes contained in the handling transformation
package. → Enter the basic axis identifier in machine data:
MD62603 $MC_TRAFO6_MAIN_AXES (basic axis identifier)
4. If the axis sequence is not the same as the normal axis sequence, it must be corrected in
machine data:
MD62620 $MC_TRAFO6_AXIS_SEQ (rearrangement of axes)
5. As identifier for the wrist axes, the following machine data must be set to 1 (no wrist axis):
MD62604 $MC_TRAFO6_WRIST_AXES = 1 (wrist axis identifier)
6. Enter the axis types for the transformation in machine data:
MD62601 $MC_TRAFO6_AXES_TYPE (axis type for transformation)
7. Compare the directions of rotation of axes with the directions defined in the handling
transformation package and correct in machine data:
MD62618 $MC_TRAFO6_AXES_DIR (matching of physical and mathematical directions
of rotation)
8. Enter the mechanical zero offset in machine data:
MD62617 $MC_TRAFO6_MAMES (offset between mathematical and mechanical zero
points)
9. Enter the basic axis lengths in machine data:
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB (basic axis lengths A and B)
10.Define frame T_IRO_RO and enter the offset in machine data:
MD62612 $MC_TRAFO6_TIRORO_POS (frame between base center point and internal
system (position component))
Enter the rotation in machine data:
MD62613 $MC_TRAFO6_TIRORO_RPY (frame between base center point and internal
system (rotation component))
11.Determine the flange coordinate system. For this purpose, the p3_q3_r3 coordinate system
must be regarded as the initial system. The offset is entered in machine data:
MD62610 $MC_TRAFO6_TFLWP_POS (frame between wrist point and flange (position
component))
The rotation is entered in machine data:
MD62611 $MC_TRAFO6_TFLWP_RPY (frame between wrist point and flange (rotation
component))

SCARA kinematics
SCARA kinematics are characterized by the fact that they possess both translational and rotary
axes. The kinematics have different names depending on how the basic axes are arranged
with respect to one another, e.g.: CC, SC, CS kinematics (see Chapter "Definition of a joint
(Page 662)").

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17.5 Descriptions of kinematics

3-axis CC kinematics

&& 0' 0'

75$)2B0$,1B/(1*7+B$%>@ 75$)2B7)/:3B326>@

T ])/

\)/
S [)/
 ]:= \
U :=

 [:=

\,52

 [,522
],52
]52 0'
\52 75$)2B7,5252B326>@

[52

Figure 17-12 3-axis CC kinematics

Table 17-4 Configuration data for 3-axis CC kinematics

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 1
MD62605 $MC_TRAFO6_NUM_AXES 3
MD62603 $MC_TRAFO6_MAIN_AXES 2
MD62604 $MC_TRAFO6_WRIST_AXES 1
MD62601 $MC_TRAFO6_AXES_TYPE [3, 1, 3, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [2, 1, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [0.0, 300.0]
MD62612 $MC_TRAFO6_TIRORO_POS [0.0, 0.0, 500.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 90.0]
MD62608 $MC_TRAFO6_TX3P3_POS [0.0, 0.0, 0.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [0.0, 0.0, 0.0]
MD62610 $MC_TRAFO6_TFLWP_POS [200.0, 0.0, 0.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, 0.0, -90.0]

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17.5 Descriptions of kinematics

3-axis SC kinematics

6& ],52 U ])/

T
\,52  \)/
[)/
[,52 S
 ]:= \
0' ],52
:=

75$)2B7,5252B326>@ [:=
\,52

[,52

0' 0'
75$)2B0$,1B/(1*7+B$%>@ 75$)2B7)/:3B326>@

Figure 17-13 3-axis SC kinematics

Table 17-5 Configuration data for 3-axis SC kinematics

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 1
MD62605 $MC_TRAFO6_NUM_AXES 3
MD62603 $MC_TRAFO6_MAIN_AXES 4
MD62604 $MC_TRAFO6_WRIST_AXES 1
MD62601 $MC_TRAFO6_AXES_TYPE [1, 1, 3, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [500.0, 0.0]
MD62612 $MC_TRAFO6_TIRORO_POS [0.0, 0.0, 500.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 0.0]
MD62608 $MC_TRAFO6_TX3P3_POS [0.0, 0.0, 0.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [0.0, 0.0, 0.0]
MD62610 $MC_TRAFO6_TFLWP_POS [300.0, 0.0, 0.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, 0.0, 0.0]

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17.5 Descriptions of kinematics

3-axis CS kinematic

U
&6 T
]
)/
 
\
)/

S [
)/

] \
:=
:=
] [
,52 :=
\
,52

[
,52

0'
75$)2B7,5252B326>@ 

]
52 \
52
[
52

0'
75$)2B7)/:3B326>@
0'
75$)2B0$,1B/(1*7+B$%>@

Figure 17-14 3-axis CS kinematic

Table 17-6 Configuration data for 3-axis CS kinematics

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 1
MD62605 $MC_TRAFO6_NUM_AXES 3
MD62603 $MC_TRAFO6_MAIN_AXES 6
MD62604 $MC_TRAFO6_WRIST_AXES 1
MD62601 $MC_TRAFO6_AXES_TYPE [3, 1, 1, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [500.0, 0.0]
MD62612 $MC_TRAFO6_TIRORO_POS [0.0, 0.0, 500.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 0.0]
MD62608 $MC_TRAFO6_TX3P3_POS [0.0, 0.0, 0.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [0.0, 0.0, 0.0]
MD62610 $MC_TRAFO6_TFLWP_POS [300.0, 0.0, 0.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, 0.0, 0.0]

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17.5 Descriptions of kinematics

Articulated-arm kinematics
3-axis NR kinematics

0'
75$)2B0$,1B/(1*7+B$%>@


=,52 5
=)/
<,52 4
<)/

;,52 3 ;)/
 =:=

<:=
;:=

0'75$)B
7,5252B326>@ =52
<52 0'75$)2B
7)/:3B326>@
;52 0'75$)2B
0$,1B/(1*7+B$%>@

Figure 17-15 3-axis NR kinematics

Table 17-7 Configuration data 3-axis NR kinematic

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 1
MD62605 $MC_TRAFO6_NUM_AXES 3
MD62603 $MC_TRAFO6_MAIN_AXES 3
MD62604 $MC_TRAFO6_WRIST_AXES 1
MD62601 $MC_TRAFO6_AXES_TYPE [3, 3, 3, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [300.0, 500.0]
MD62612 $MC_TRAFO6_TIRORO_POS [0.0, 0.0, 500.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 0.0]
MD62608 $MC_TRAFO6_TX3P3_POS [0.0, 0.0, 0.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [0.0, 0.0, 0.0]
MD62610 $MC_TRAFO6_TFLWP_POS [300.0, 0.0, 0.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, 0.0, 0.0]

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17.5 Descriptions of kinematics

3-axis RR kinematics

55

0' 0'
75$)2B0$,1B/(1*7+B$%>@
 75$)2B7)/:3B326>@
 


=,52 5
<,52 =)/
4
<)/
;,52
3 ;)/
  =:=
<:=
 
;:=

=52
<52
;52

Figure 17-16 3-axis RR kinematics

Table 17-8 Configuration data for 3-axis RR kinematics

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 1
MD62605 $MC_TRAFO6_NUM_AXES 3
MD62603 $MC_TRAFO6_MAIN_AXES 5
MD62604 $MC_TRAFO6_WRIST_AXES 1
MD62601 $MC_TRAFO6_AXES_TYPE [3, 1, 3, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [300.0, 0.0]
MD62612 $MC_TRAFO6_TIRORO_POS [0.0, 0.0, 300.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 0.0]
MD62608 $MC_TRAFO6_TX3P3_POS [0.0, 0.0, 0.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [0.0, 0.0, 0.0]
MD62610 $MC_TRAFO6_TFLWP_POS [200.0, 0.0, 0.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, 0.0, 0.0]

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17.5 Descriptions of kinematics

3-axis NN kinematics

0' 0'
75$)2B0$,1B/(1*7+B$%>@
 75$)2B7)/:3B326>@
 


4 =)/
<)/

3 ;)/
=:=
5 
<:=
0' ;:=
75$)2B0$,1B
/(1*7+B$%>@


 <,52

;,52

0'
=,52 
75$)2B7,5252B
326>@ =52

 <52
;52

Figure 17-17 3-axis NN kinematics

Table 17-9 Configuration data for 3-axis NN kinematics

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 1
MD62605 $MC_TRAFO6_NUM_AXES 3
MD62603 $MC_TRAFO6_MAIN_AXES 7
MD62604 $MC_TRAFO6_WRIST_AXES 1
MD62601 $MC_TRAFO6_AXES_TYPE [3, 3, 3, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [300.0, 500.0]
MD62612 $MC_TRAFO6_TIRORO_POS [0.0, 0.0, 300.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 90.0]
MD62608 $MC_TRAFO6_TX3P3_POS [0.0, 0.0, 0.0]
MD62609 $MC_TRAFO6_TX3P3_RPYFehler! Bookmark not defined. [0.0, 0.0, 0.0]
MD62610 $MC_TRAFO6_TFLWP_POS [400.0, 0.0, 0.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, 0.0, -90.0]

17.5.2 4-axis kinematics

4-axis kinematics normally have 3 translational degrees of freedom and one rotational degree
of freedom for orientation.

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17.5 Descriptions of kinematics

Restrictions
The following restrictions apply to 4-axis kinematics:
The frame T_FL_WP is subject to the following condition:
● MD62611 $MC_TRAFO6_TFLWP_RPY = [ 0.0, 90.0, 0.0 ] (frame between wrist point and
flange (rotation component))
● X flange and X tool must be parallel to the 4th axis.
● Two successive basic axes must be parallel or orthogonal.
● The 4th axis must only be mounted in a parallel or orthogonal way to the last basic axis.

Configuration
The procedure for configuring a 4-axis kinematic is as follows:
1. Enter "Standard" kinematic category in the machine data:
MD62600 $MC_TRAFO6_KINCLASS (kinematic category)
2. Set the number of axes for transformation in the machine data:
MD62605 $MC_TRAFO6_NUM_AXES=4 (number of transformed axes)
3. Compare the basic axes with the basic axes contained in the handling transformation
package.
– Enter the basic axis identifier in machine data:
MD62603 $MC_TRAFO6_MAIN_AXES (basic axis identifier)
4. If the axis sequence is not the same as the normal axis sequence, it must be corrected in
machine data:
MD62620 $MC_TRAFO6_AXIS_SEQ (rearrangement of axes)
5. As identifier for the wrist axes, the following machine data must be set (no wrist axis):
MD62604 $MC_TRAFO6_WRIST_AXES = 1 (wrist axis identifier)
6. Whether axis 4 runs parallel/anti-parallel to the last rotary basic axis is entered into the
machine data:
MD62606 $MC_TRAFO6_A4PAR (axis 4 is parallel/anti-parallel to last basic axis)
7. Enter the axis types for the transformation in machine data:
MD62601 $MC_TRAFO6_AXES_TYPE (axis type for transformation)
8. Compare the directions of rotation of axes with the directions defined in the handling
transformation package and correct in the machine data:
MD62618 $MC_TRAFO6_AXES_DIR (matching of physical and mathematical directions
of rotation)
9. Enter the mechanical zero offset in the machine data:
MD62617 $MC_TRAFO6_MAMES (offset between mathematical and mechanical zero
points)
10.Enter the basic axis lengths in the machine data:
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB (basic axis lengths A and B)

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17.5 Descriptions of kinematics

11.Define frame T_IRO_RO and enter the offset in the machine data:
MD62612 $MC_TRAFO6_TIRORO_POS (frame between base center point and internal
system (position component))
Enter the rotation in the machine data:
MD62613 $MC_TRAFO6_TIRORO_RPY (frame between base center point and internal
system (rotation component))
12.Specification of frame T_X3_P3 to attach wrist axis. For this purpose, the p3_q3_r3
coordinate system must be regarded as the initial system. The offset is entered in the
machine data:
MD62608 $MC_TRAFO6_TX3P3_POS (attachment of wrist axis (position component))
The rotation is entered in the machine data:
MD62609 $MC_TRAFO6_TX3P3_RPY (attachment of wrist axis (rotation component))
is entered.
13.Determine the flange coordinate system. For this purpose, the wrist point coordinate system
must be regarded as the initial system. The offset is entered in the machine data:
MD62610 $MC_TRAFO6_TFLWP_POS (frame between wrist point and flange (position
component))
The rotation is entered in the machine data:
MD62611 $MC_TRAFO6_TFLWP_RPY (frame between wrist point and flange (rotation
component))

SCARA kinematics
4-axis CC kinematics

 

T

S
 U 

[+3
\,52 
 \+3
[,52 ]+3 
],52  \)/
])/ [)/
\:=
]:=
[:=

① MD62612 $MC_TRAFO6_TIRORO_POS[2]
② MD62607 $MC_TRAFO6_MAIN_LENGTH_AB[1]
③ MD62608 $MC_TRAFO6_TX3P3_POS[0]
④ MD62608 $MC_TRAFO6_TX3P3_POS[1]
⑤ MD62610 $MC_TRAFO6_TFLWP_POS[0]

Figure 17-18 4-axis CC kinematics

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17.5 Descriptions of kinematics

Table 17-10 Configuration data for 4-axis CC kinematics

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 1
MD62605 $MC_TRAFO6_NUM_AXES 4
MD62603 $MC_TRAFO6_MAIN_AXES 2
MD62604 $MC_TRAFO6_WRIST_AXES 1
MD62606 $MC_TRAFO6_A4PAR 1
MD62601 $MC_TRAFO6_AXES_TYPE [3, 1, 3, 3, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [2, 1, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR) [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [0.0, 300.0]
MD62612 $MC_TRAFO6_TIRORO_POS [0.0, 0.0, 500.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 90.0]
MD62608 $MC_TRAFO6_TX3P3_POS [300.0, 0.0, -200.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [-90.0, 90.0, 0.0]
MD62610 $MC_TRAFO6_TFLWP_POS [0.0, 0.0, 200.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, -90.0, 0.0]

4-axis SC kinematics

],52 U \)/
\,52  T  ] [)/
\:=
[,52 S [ ])/ [:=

\ ]:=
 ]52
\52

[52

  

① MD62612 $MC_TRAFO6_TIRORO_POS[2]
② MD62607 $MC_TRAFO6_MAIN_LENGTH_AB[0]
③ MD62608 $MC_TRAFO6_TX3P3_POS[0]
④ MD62610 $MC_TRAFO6_TFLWP_POS[0]

Figure 17-19 4-axis SC kinematics

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17.5 Descriptions of kinematics

Table 17-11 Configuration data for 4-axis SC kinematics

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 1
MD62605 $MC_TRAFO6_NUM_AXES 4
MD62603 $MC_TRAFO6_MAIN_AXES 4
MD62604 $MC_TRAFO6_WRIST_AXES 1
MD62606 $MC_TRAFO6_A4PAR 1
MD62601 $MC_TRAFO6_AXES_TYPE [1, 1, 3, 3, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [300.0, 0.0]
MD62612 $MC_TRAFO6_TIRORO_POS [0.0, 0.0, 300.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 0.0]
MD62608 $MC_TRAFO6_TX3P3_POS [200.0, 0.0, 0.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [0.0, 0.0, -90.0]
MD62610 $MC_TRAFO6_TFLWP_POS [200.0, 0.0, 0.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, -90.0, 180.0]

4-axis CS kinematic

U
T

S

],52 
\,52 [+3
 
\+3
[,52 ]+3 

\)/
 
])/ [)/
]52 \:=
\52
]:=
[52 [:=

 

① MD62612 $MC_TRAFO6_TIRORO_POS[2]
② MD62607 $MC_TRAFO6_MAIN_LENGTH_AB[0]
③ MD62608 $MC_TRAFO6_TX3P3_POS[0]
④ MD62608 $MC_TRAFO6_TX3P3_POS[2]
⑤ MD62610 $MC_TRAFO6_TFLWP_POS[2]

Figure 17-20 4-axis CS kinematic

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17.5 Descriptions of kinematics

Table 17-12 Configuration data for 4-axis CS kinematics

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 1
MD62605 $MC_TRAFO6_NUM_AXES 4
MD62603 $MC_TRAFO6_MAIN_AXES 6
MD62604 $MC_TRAFO6_WRIST_AXES 1
MD62606 $MC_TRAFO6_A4PAR 1
MD62601 $MC_TRAFO6_AXES_TYPE [3, 1, 1, 3, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [400.0, 0.0]
MD62612 $MC_TRAFO6_TIRORO_POS [0.0, 0.0, 400.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 0.0]
MD62608 $MC_TRAFO6_TX3P3_POS [500.0, 0.0, -200.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [90.0, 0.0, 180.0]
MD62610 $MC_TRAFO6_TFLWP_POS [200.0, 0.0, 0.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, -90.0, 0.0]

Articulated-arm kinematics
4-axis NR kinematics

 

],52 U
T \)/
\,52 ]+3
[)/

[,52 \+3 ])/

  S  [:=
[+3 \:=
]:=


 

]52
\52

[52

① MD62612 $MC_TRAFO6_TIRORO_POS[2]
② MD62607 $MC_TRAFO6_MAIN_LENGTH_AB[0]
③ MD62607 $MC_TRAFO6_MAIN_LENGTH_AB[1]
④ MD62608 $MC_TRAFO6_TX3P3_POS[0]
⑤ MD62610 $MC_TRAFO6_TFLWP_POS[0]

Figure 17-21 4-axis NR kinematics

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17.5 Descriptions of kinematics

Table 17-13 Configuration data 4-axis NR kinematic

Machine data Value

MD62600 $MC_TRAFO6_ KINCLASS 1
MD62605 $MC_TRAFO6_NUM_AXES 4
MD62603 $MC_TRAFO6_MAIN_AXES 3
MD62604 $MC_TRAFO6_WRIST_AXES 1
MD62606 $MC_TRAFO6_A4PAR 1
MD62601 $MC_TRAFO6_AXES_TYPE [3, 3, 3, 3, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [300.0, 300.0]
MD62612 $MC_TRAFO6_TIRORO_POS [0.0, 0.0, 500.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 0.0]
MD62608 $MC_TRAFO6_TX3P3_POS [300.0, 0.0, 0.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [0.0, 0.0, -90.0]
MD62610 $MC_TRAFO6_TFLWP_POS [200.0, 0.0, 0.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, -90.0, 180.0]

See also
Definition of a joint (Page 662)

17.5.3 5-axis kinematics

5-axis kinematics usually imply 3 degrees of freedom for translation and 2 for orientation.

Restrictions
The following restrictions apply to 5-axis kinematics:
1. There are restrictions for the flange coordinate system because the X flange axis must
intersect the 5th axis, nevertheless, it must not be parallel to it.
2. The frame T_FL_WP is subject to the following condition as far as 5-axis articulated-arm
kinematics are concerned:
– MD62610 $MC_TRAFO6_TFLWP_POS = [0.0, 0.0, Z] (frame between wrist point and
flange (position component))
– MD62611 $MC_TRAFO6_TFLWP_RPY = [A, 0.0, 0.0] (frame between wrist point and
flange (rotation component))
3. There are restrictions for the tool as far as 5-axis articulated-arm kinematics are concerned:
– 4. Axis parallel to the 3rd axis: 2-dimensional tool is possible [X, 0.0, Z]
– 4. Axis perpendicular to the 3rd axis: Only 1-dimensional tool is possible [X, 0.0, 0.0]

Special functions
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17.5 Descriptions of kinematics

4. There are restrictions for the tool as far as 5-axis Scara kinematics are concerned:
– 4. Axis perpendicular to the 3rd axis: 1-dimensional tool is possible [X, 0.0, 0.0]
5. Two successive basic axes must be parallel or orthogonal.
6. The 4th axis must only be mounted in a parallel or orthogonal way to the last basic axis.

Configuration
The procedure for configuring a 5-axis kinematic is as follows:
1. Enter "Standard" kinematic category in machine data:
MD62600 $MC_TRAFO6_KINCLASS (kinematic category)
2. Set the number of axes for transformation in the machine data:
MD62605 $MC_TRAFO6_NUM_AXES = 5 (number of transformed axes)
3. Compare the basic axes with the basic axes contained in the handling transformation
package.
– Enter the basic axis identifier in machine data:
MD62603 $MC_TRAFO6_MAIN_AXES (basic axis identifier)
4. If the axis sequence is not the same as the normal axis sequence, it must be corrected in
machine data:
MD62620 $MC_TRAFO6_AXIS_SEQ (rearrangement of axes)
5. ID specification for the wrist axes. If axis 4 and 5 intersect, a central hand (ZEH) is present.
In all other cases, the ID for beveled hand with elbow (BHE) must be entered in the machine
data:
MD62604 $MC_TRAFO6_WRIST_AXES (wrist axis identifier)
6. Whether axis 4 runs parallel/anti-parallel to the last rotary basic axis must be entered into
the machine data:
MD62606 $MC_TRAFO6_A4PAR (axis 4 is parallel/anti-parallel to last basic axis)
7. Enter the axis types for the transformation in machine data:
MD62601 $MC_TRAFO6_AXES_TYPE (axis type for transformation)
8. Compare the directions of rotation of axes with the directions defined in the handling
transformation package and correct in machine data:
MD62618 $MC_TRAFO6_AXES_DIR (matching of physical and mathematical directions
of rotation)
9. Enter the mechanical zero offset in the machine data:
MD62617 $MC_TRAFO6_MAMES (offset between mathematical and mechanical zero
points)
10.Enter the basic axis lengths in machine data:
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB (basic axis lengths A and B)
11.Define frame T_IRO_RO and enter the offset in machine data:
MD62612 $MC_TRAFO6_TIRORO_POS (frame between base center point and internal
system (position component))
Define frame T_IRO_RO and enter the rotation in machine data:
MD62613 $MC_TRAFO6_TIRORO_RPY (frame between base center point and internal
system (rotation component))

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17.5 Descriptions of kinematics

12.Specification of frame T_X3_P3 to attach hand. The offset is entered in machine data:
MD62608 $MC_TRAFO6_TX3P3_POS (attachment of hand (position component))
The rotation is entered in the machine data:
MD62609 $MC_TRAFO6_TX3P3_RPY (attachment of hand (rotation component))
13.Specification of wrist axes parameters. For this purpose, only the parameters for axis 4
must be entered in the machine data:
MD62614 $MC_TRAFO6_DHPAR4_5A[0] (parameter A for configuring the hand)
MD62616 $MC_TRAFO6_DHPAR4_5ALPHA[0] (parameter A for configuring the hand)
All other parameters must be set to 0.0.
14.Determine the flange coordinate system. For this purpose, the hand-point coordinate
system must be regard as the initial system. The offset is entered in the machine data:
MD62610 $MC_TRAFO6_TFLWP_POS (frame between wrist point and flange (position
component))
The rotation is entered in the machine data:
MD62611 $MC_TRAFO6_TFLWP_RPY (frame between wrist point and flange (rotation
component))

SCARA kinematics
5-axis CC kinematics

0'
&& 0' 0&B75$)2B'+3$5B$>@
0&B75$)2B0$,1B
0'
/(1*7+B$%>@
0' 0&B75$)2B7)/:3B326>@
0&B75$)2B7;3B326>@

T ] \ ]+3 ])/

S [ [+3 [)/ ]:=


U [:=
  \+3 \)/

\,52
\:=

],52 [,52

0'
]52 0&B75$)2B7,5252B326>@
\52

[52

Figure 17-22 5-axis CC kinematics

Table 17-14 Configuration data for 5-axis CC kinematics

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 1
MD62605 $MC_TRAFO6_NUM_AXES 5

Special functions
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17.5 Descriptions of kinematics

Machine data Value

MD62603 $MC_TRAFO6_MAIN_AXES 2
MD62604 $MC_TRAFO6_WRIST_AXES 5
MD62606 $MC_TRAFO6_A4PAR 1
MD62601 $MC_TRAFO6 _AXES_TYPE [3, 1, 3, 3, 3, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [2, 1, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [0.0, 500.0]
MD62612 $MC_TRAFO6_TIRORO_POS [0.0, 0.0, 500.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 90.0]
MD62608 $MC_TRAFO6_TX3P3_POS [300.0, 0.0, -200.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [0.0, 0.0, -90.0]
MD62610 $MC_TRAFO6_TFLWP_POS [200.0, 0.0, 0.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, 0.0, 0.0]
MD62614 $MC_TRAFO6_DHPAR4_5A [200.0, 0.0]
MD62615 $MC_TRAFO6_DHPAR4_5D [0.0, 0.0]
MD62616 $MC_TRAFO6_DHPAR4_5ALPHA [-90.0, 0.0]

5-axis NR kinematics

15
0' 0'
0&B75$)2B0$,1B/(1*7+B$%>@ 0&B75$)2B7;3B326>@

],52 U
T ]+3 ])/ ]:=
\,52

[:=
[,52 S \+3 [)/
   
[+3 \)/ \:=

0' 0'
0' 0&B75$)2B0$,1B 0&B75$)2B7)/:3B326>@
0&B75$)2B  /(1*7+B$%>@
7,5252B326>@

]52
\52

[52

Figure 17-23 5-axis NR kinematics

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17.5 Descriptions of kinematics

Table 17-15 Configuration data 5-axis NR kinematic

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 1
MD62605 $MC_TRAFO6_NUM_AXES 5
MD62603 $MC_TRAFO6_MAIN_AXES 3
MD62604 $MC_TRAFO6_WRIST_AXES 2
MD62606 $MC_TRAFO6_A4PAR 0
MD62601 $MC_TRAFO6_AXES_TYPE [3, 3, 3, 3, 3, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [30.0, 300.0]
MD62612 $MC_TRAFO6_TIRORO_POS [0.0, 0.0, 500.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 0.0]
MD62608 $MC_TRAFO6_TX3P3_POS [500.0, 0.0, 0.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [0.0, 90.0, 0.0]
MD62610 $MC_TRAFO6_TFLWP_POS [0.0, -300.0, 0.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [-90.0, 0.0, 0.0]
MD62614 $MC_TRAFO6_DHPAR4_5A [0.0, 0.0]
MD62615 $MC_TRAFO6_DHPAR4_5D [0.0, 0.0]
MD62616 $MC_TRAFO6_DHPAR4_5ALPHA [-90.0, 0.0]

See also
Definition of a joint (Page 662)

17.5.4 6-axis kinematics

6-axis kinematics usually imply 3 degrees of freedom for translation and 3 more for orientation.
This allows for the tool direction to be manipulated freely in space. Also, the tool can be rotated
along its own axis to the machining surface or inclined with a tilting angle.
This kinematic type is supported by the software, but only for very specific solutions as the
auxiliary method for this handling transformation package. A general, comprehensive and
universally applicable software version is still not available for 6-axis kinematics.

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 TE4: Handling transformation package - 840D sl only
17.5 Descriptions of kinematics

17.5.5 Special kinematics

MD62602 $MC_TRAFO6_SPECIAL_KIN (special kinematic type)

Special kinematics are kinematics that are not directly included in the building block system
of the Handling transformation package. They are frequently missing a degree of freedom or
are characterized by mechanical links between the axes or with the tool. Set the following
machine data for these kinematics:
MD62600 $MC_TRAFO6_KINCLASS = 2 (kinematic category)
Which special kinematic is handled is specified in machine data:
MD62602 $MC_TRAFO6_SPECIAL_KIN (special kinematic type)

Special 2-axis SC kinematic

This special kinematic is characterized by the fact that the tool is always maintained in the
same orientation via a mechanical linkage. It implies two Cartesian degrees of protection. The
identifier for this kinematic is machine data:
MD62602 $MC_TARFO6_SPECIAL_KIN = 3 (special kinematic type)

[:=
]:=

[)/ \:=
])/

\)/
0'0&B75$)2B0$,1B/(1*7+B$%>@

0' $
[,52
0&B75$)2B0$,1B/(1*7+B$%>@ ],52

\,52
$ [52
0'0&B75$)2B7,5252B326>@
]52

\52

Figure 17-24 Special 2-axis SC kinematic

Table 17-16 Configuring data for a special 2-axis SC kinematic

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 2
MD62602 $MC_TRAFO6_SPECIAL_KIN 3
MD62605 $MC_TRAFO6_NUM_AXES 2
MD62603 $MC_TRAFO6_MAIN_AXES 2
MD62604 $MC_TRAFO6_WRIST_AXES 1
MD62601 $MC_TRAFO6_AXES_TYPE [1, 3, 3, ...]

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17.5 Descriptions of kinematics

Machine data Value

MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [400.0, 500.0]
MD62612 $MC_TRAFO6_TIRORO_POS [0.0, 0.0, 300.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 0.0]
MD62608 $MC_TRAFO6_TX3P3_POS [0.0, 0.0, 0.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [0.0, 0.0, 0.0]
MD62610 $MC_TRAFO6_TFLWP_POS [0.0, 0.0, 0.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, 0.0, 0.0]

Special 3-axis SC kinematic

The special kinematic has 2 Cartesian degrees of freedom and one degree of freedom for
orientation. The identifier for this kinematic is:
MD62602 $MC_TRAFO6_SPECIAL_KIN = 4 (special kinematic type)

0' 0'
0&B75$)2B7;3B326>@ 0&B75$)2B7)/:3B326>@

\:= [:=
],52 \)/
\,52 ] [)/ ]:=

$ [,52 $ [ ])/
0'
0&B75$)2B7,5252B326>@ \
]52
\52

[52
$

Figure 17-25 Special 3-axis SC kinematic

Table 17-17 Configuring data for a special 3-axis SC kinematic

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 2
MD62602 $MC_TRAFO6_SPECIAL_KIN 4
MD62605 $MC_TRAFO6_NUM_AXES 3
MD62603 $MC_TRAFO6_MAIN_AXES 2
MD62604 $MC_TRAFO6_WRIST_AXES 1
MD62601 $MC_TRAFO6_AXES_TYPE [1, 3, 3, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6]

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17.5 Descriptions of kinematics

Machine data Value

MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [0.0, 0.0]
MD62612 $MC_TRAFO6_TIRORO_POS [0.0, 0.0, 400.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 0.0]
MD62608 $MC_TRAFO6_TX3P3_POS [400.0, 0.0, 0.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [0.0, 0.0, -90.0]
MD62610 $MC_TRAFO6_TFLWP_POS [200.0, 0.0, 0.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, -90.0, 180.0]

Special 4-axis SC kinematic

This special kinematic is characterized by the fact that axis 1 and axis 2 are mechanically
coupled. This coupling ensures that axis 2 is maintained at a constant angle when axis 1 is
swiveled. This kinematic also guarantees that axes 3 and 4 always remain perpendicular,
irrespective of the positions of axes 1 and 2. The identifier for this kinematic is:
MD62602 $MC_TRAFO6_SPECIAL_KIN = 7 (special kinematic type)

0' 0'
0&B75$)2B7;3B326>@ 0&B75$)2B0$,1B/(1*7+B$%>@

],52 ]
U \
\,52 T

 [,52 S [


0'
 0&B75$)2B7)/:3B
0' \)/ 326>@
0&B75$)2B0$,1B/(1*7+B$%>@
]52
\52 ])/ \:=

[)/ ]:=
[52

[:=

Figure 17-26 Special 4-axis SC kinematic

Table 17-18 Configuring data for a special 4-axis SC kinematic

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 2
MD62602 $MC_TRAFO6_SPECIAL_KIN 7
MD62605 $MC_TRAFO6_NUM_AXES 4
MD62603 $MC_TRAFO6_MAIN_AXES 2

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17.5 Descriptions of kinematics

Machine data Value

MD62604 $MC_TRAFO6_WRIST_AXES 1
MD62601 $MC_TRAFO6_AXES_TYPE [3, 3, 1, 3, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [100.0, 400.0]
MD62612 $MC_TRAFO6_TIRORO_POS [100.0, 0.0, 1000.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, 0.0]
MD62608 $MC_TRAFO6_TX3P3_POS [300.0, 0.0, 0.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [0.0, 0.0, 0.0]
MD62610 $MC_TRAFO6_TFLWP_POS [0.0, 0.0, -600.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, 90.0, 0.0]

Special 2-axis NR kinematics

This special kinematic is characterized by the fact that axis 1 and axis 2 are mechanically
coupled. Another special feature is the tool. With this kinematic, it maintains its orientation in
space irrespective of the positions of the other axes.
The identifier for this kinematic is:
MD62602 $MC_TRAFO6_SPECIAL_KIN = 5 (special kinematic type)
Without a mechanical coupling between axis 1 and 2, it has the following identifier:
MD62602 $MC_TRAFO6_SPECIAL_KIN = 8 (special kinematic type)

0' 0'0&B75$)2B
0&B75$)2B7;3B326>@ 0$,1B/(1*7+B$%>@

],52
])/
U ] \
\,52 T \)/

[)/
[,52 S [
  ]:=
\:=

0' [:=
0'
0&B75$)2B 0&B75$)2B0$,1B/(1*7+B$%>@
7,5252B326>@
0'
\52 0&B75$)2B7,5252B326>@

[52
]52

Figure 17-27 Special 2-axis NR kinematics

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17.6 Tool orientation

Table 17-19 Configuration data for special 2-axis NR kinematics

Machine data Value

MD62600 $MC_TRAFO6_KINCLASS 2
MD62602 $MC_TRAFO6_SPECIAL_KIN 5 (8)
MD62605 $MC_TRAFO6_NUM_AXES 2
MD62603 $MC_TRAFO6_MAIN_AXES 3
MD62604 $MC_TRAFO6_WRIST_AXES 1
MD62601 $MC_TRAFO6_AXES_TYPE [3, 3, ...]
MD62620 $MC_TRAFO6_AXIS_SEQ [1, 2, 3, 4, 5, 6]
MD62618 $MC_TRAFO6_AXES_DIR [1, 1, 1, 1, 1, 1]
MD62617 $MC_TRAFO6_MAMES [0.0, 0.0, 0.0, 0.0, 0.0, 0.0]
MD62607 $MC_TRAFO6_MAIN_LENGTH_AB [100.0, 400.0]
MD62612 $MC_TRAFO6_TIRORO_POS [100.0, 500.0, 0.0]
MD62613 $MC_TRAFO6_TIRORO_RPY [0.0, 0.0, -90.0]
MD62608 $MC_TRAFO6_TX3P3_POS [400.0, 0.0, 0.0]
MD62609 $MC_TRAFO6_TX3P3_RPY [0.0, 0.0, 0.0]
MD62610 $MC_TRAFO6_TFLWP_POS [0.0, 0.0, 0.0]
MD62611 $MC_TRAFO6_TFLWP_RPY [0.0, 0.0, 0.0]

17.6 Tool orientation

=


< %
;
$

① Tool axis

Figure 17-28 Peripheral milling with 5-axis transformation

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17.6 Tool orientation

Machine data

Identifiers of the Euler angles

The identifiers with which the Euler angles are programmed in the NC program can be set
using:
MD10620 $MN_EULER_ANGLE_NAME_TAB (name of Euler angles)
Standard identifier: "A2", "B2", "C2"

Identifier of the direction vector components

The identifier with which the components of the direction vector are programmed in the NC
program can be set using:
MD10640 $MN_DIR_VECTOR_NAME_TAB (name of normal vectors)
The tool orientation can be located in any block. Above all, it can be programmed alone in a
block, resulting in a change of orientation in relation to the tool tip which is fixed in its
relationship to the workpiece.

Channel-specific input: Euler or RPY angle

Whether the tool orientation programming is realized in the channel with Euler angle or RPY
angle can be set using:
MD21100 $MC_ORIENTATION_IS_EULER (angle definition for orientation programming)

G code for orientation interpolation

The type of interpolation for the orientation is specified using machine data:
MD21104 $MC_ORI_IPO_WITH_G_CODE = <value>

<value> Meaning
TRUE G commands for orientation interpolation: ORIWKS and ORIMKS
FALSE G commands of the 51st G group for orientation interpolation: ORIAXES, ORIVECT,
ORIPLANE, ...

Channel-specific initial setting for the tool orientation

The G function of the 25th G group: "Tool orientation reference" which takes effect after a
channel or end of program reset, can be set via:
MD20150 $MC_GCODE_RESET_VALUES[24] (25th G group: Tool orientation reference)

Programming

Function
The tool orientation can be programmed via:
● Directly programming the rotary axes
● Programming the Euler or RPY angle
● Programming the direction vector

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17.6 Tool orientation

The coordinate system in which motion is executed is defined using the ORIWKS and
ORIMKS commands.

Syntax
ORIWKS
ORIMKS

Meaning

ORIWKS: Tool orientation in the workpiece coordinate system (WCS)

In the case of a change in orientation with the tool tip at a fixed point in space, the tool
moves along a large arc on the plane extending from the start vector to the end vector.
Transitioning a tool orientation at the start of a block to an orientation at the end of the
block is only possible in the WCS.
Effective: Modal
ORIMKS: Tool orientation in the machine coordinate system (MCS)
In the case of a change in orientation of a tool tip at a fixed point in space, linear
interpolation takes place between the rotary axis positions.
Effective: Modal

Note
● ORIWKS is the preferred approach for a program independent of a particular machine.
● It is not possible to program the tool orientation using Euler angles, RPY angles or direction
vectors for kinematics involving fewer than 5 axes. For 4-axis kinematics with only one
rotary axis, there is only one degree of freedom for orientation. This orientation angle can
only be programmed with orientation axis angle "A".
● Transferring an orientation using ORIMKS is not allowed in the handling transformation
package. With an active transformation, the machine axis angles are not programmed and
traversed, but rather the "orientation angles" (RPY angles according to robotics definition,
see Section "Definition of positions and orientations using frames (Page 661)").

17.6.1 Orientation programming for 4-axis kinematics

Tool orientation for 4-axis kinematic

4-axis kinematics possess only one degree of freedom for orientation. When the orientation is
programmed using RPY angles, Euler angles or direction vectors, it is not generally possible
to guarantee that the specified orientation can be approached. If used at all, this type of
orientation programming is only suitable for certain types of kinematic, i.e. those which feature
an invariance in orientation angles relative to the basic axes. This is the case for the SCARA
kinematic, for example.
For this reason, orientation programming is only permitted via "orientation angle" A for 4-axis
kinematics. This angle corresponds to the RPY angle C according to the robotics definition,
i.e. one rotation about the Z-RO axis, as illustrated in Fig. "Orientation angle for 4-axis
kinematic".

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17.6 Tool orientation

[+3
$
\+3

]52 ]+3
\)/

])/
\52 [)/

$
[52 \:=
]:=

[:=

Figure 17-29 Orientation angle for 4-axis kinematic

17.6.2 Orientation programming for 5-axis kinematics

Tool orientation for 5-axis kinematics

For 5-axis kinematics, when programming via orientation vector, it is assumed that the
orientation vector corresponds to the x component of the tool.
When programming via orientation angle (RPY angle according to robotics definition), the x
component of the tool is considered as the initial point for rotations.
For this purpose, the vector in the x tool direction, as shown in Fig. "Orientation angle for 5-
axis kinematic", is first rotated around the Z axis by the angle A and then around the rotated
Y axis by the angle B. The rotation by the angle C is not possible for 5-axis kinematics because
of the restricted degrees of freedom for the orientation.

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17.7 Singular positions and how they are handled

]:=
]52 ])/

\)/
\:=

[)/
\52

%
[52
$

[:=

Figure 17-30 Orientation angle for 5-axis kinematic

The following machine data can be used to set the flange coordinate system on the user side
so that Z can be set as tool direction for 5-axis kinematics:
MD62636 $MC_TRAFO6_TFL_EXT_RPY (adaptation of the flange coordinate system)
The following machine data can be used to specify whether the tool direction should be set
according to the robotics convention (0 = default setting) or the NC convention:
MD62637 $MC_TRAFO6_TOOL_DIR (definition of the tool direction)
To provide a tool calculation function as usually available for machine tools, set the following
machine data:
MD62637 $MC_TRAFO6_TOOL_DIR = 1 (standard definition of the tool direction)
This machine data also has an effect on the rotation sequence of the virtual orientation axes.
For this purpose, the vector in the Z tool direction is first turned through angle A at the X axis
and then through angle B at the rotated Y axis. The rotation by the angle C is not possible for
5-axis kinematics because of the restricted degrees of freedom for the orientation.

Note
Additional information can be found in:
Function Manual, Special Functions, Section "Orientation axes"
and
Programming Manual, Job Planning, Section "Orientation axes".

17.7 Singular positions and how they are handled

The calculation of the machine axes to a preset position, i.e. position with orientation, is not
always clear. Depending on the machine kinematic, there may be positions with an infinite
number of solutions. These positions are called "singular".

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17.8 Call and application of the transformation

Singular positions
● A singular position is, for example, characterized by the fact that the fifth axis is positioned
at 0°. In this case, the singular position does not depend on a specified orientation. The
fourth axis is not specified in this position, i.e., the fourth axis does not have any influence
on the position or the orientation.
● A singular position also applies for articulated arm and SCARA kinematics if the third axis
is at 0° or 180°. These positions are called leveling/diffraction singularity.
● Another singular position exists for articulated arm kinematics if the hand point is above
the rotary axis of axis 1. This position is called overhead singularity.

Extreme velocity increase

If the path runs in close vicinity to a pole (singularity), one or several axes may traverse at a
very high velocity. Alarm 10910 "Irregular velocity run in a path axis" is then triggered.

Behavior at pole
The unwanted behavior of fast compensating movements can be improved by reducing the
velocity in the proximity of a pole. Traveling through the pole with active transformation is
usually not possible.

17.8 Call and application of the transformation

Activating
The transformation is activated by means of the TRAORI(1) command.
Once the TRAORI(1) command has been executed and the transformation thus activated,
the interface signal switches to "1":
DB21, … DBX33.6 (transformation active)
If the machine data have not been defined for an activated transformation grouping, the NC
program stops and the control displays the alarm 14100 "Orientation transformation does not
exist".
For more information, go to:
References:
Programming Manual, Production Planning,
Section: "5-axis machining"

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17.9 Actual value display

Deactivating
The currently active transformation is deactivated by means of TRAFOOF or TRAFOOF().

Note
When the "Handling transformation package" transformation is deactivated, no preprocessing
stop and no synchronization of the preprocessing with the main run is performed.

RESET/end of program
The control behavior in terms of transformation following run-up, end of program or RESET
depends on machine data:
MD20110 $MC_RESET_MODE_MASK (definition of control basic setting na)

Bit 7: Reset behavior of "active kinematic transformation"

Bit 7 = 0 For this reason, the initial setting is defined for active transformation after the
end of part program or RESET, according to the following machine data:
MD20140 $MC_TRAFO_RESET_VALUE (transformation data block run-up (re‐
set/part program end))
Meaning:
0: After RESET no transformation is active.
1 to 8: The set transformation is active according to machine data:
MD24100 $MC_TRAFO_TYPE_1 (definition of transformation 1 in
the channel)
To machine data:
MD24460 $MC_TRAFO_TYPE_8 (channel transformation 8)
Bit 7 = 1 The current setting for the active transformation remains unchanged after a
RESET or end of part program.

17.9 Actual value display

MCS machine coordinate system

The machine axes are displayed in mm/inch and/or degrees in MCS display mode.

WCS workpiece coordinate system

If the transformation is active, the tool tip (TCP) is specified in mm/inch and the orientation by
the RPY angles A, B and C in WCS display mode. The tool orientation results from turning a
vector in the Z direction firstly with A around the Z axis, then with B around the new Y axis and
lastly with C around the new X axis.
If the transformation is deactivated, the axes will be displayed with the channel axis names.
Otherwise the geometry axis names will be displayed.

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17.10 Tool programming

17.10 Tool programming

Meaning
The tool lengths are specified in relation to the flange coordinate system. Only 3-dimensional
tool compensations are possible. Depending on the kinematic type, there are additional tool
restrictions for 5-axis and 4-axis kinematics. For a kinematic as illustrated in Fig. "5-axis NR
kinematic", only a 1-dimensional tool with lengths in the x direction is permitted.
The tool direction is dependent on the machine's initial setting, as specified with G codes G17,
G18 and G19. The tool lengths refer to the zero position specified by G17. This zero position
should not be modified in the program.

Example
An example of a 2-dimensional tool mounted on a 5-axis Scara is described below (see Fig.
"5-axis CC kinematic"). Type 100 (cutting tool) is specified as the tool identifier. The tool lengths
result from the specifications shown in Fig. "Tool length programming". X-TOOL must be
entered as tool length x and Y-TOOL must be entered as tool length y in the tool parameters.

$TC_DP1[1,1] = 100; Cutting tool type

$TC_DP3[1,1 ] = 0.0 ; (z) Length offset vector
$TC_DP4[1,1 ] = Y-TOOL ; (y) Length offset vector
$TC_DP5[1,1 ] = X-TOOL ; (x) Length offset vector

;722/

]+3 ])/

[+3 [)/
]:=
<722/
\+3 \)/
$ $
[:=

\:=

Figure 17-31 Tool length programming

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17.12 Startup

17.11 Cartesian PTP travel with handling transformation package

It is possible to use the "Cartesian PTP travel" function with the handling transformation
package (see Section "Cartesian PTP travel (Page 40)"). For this, the following machine data
must be set:
MD24100 $MC_TRAFO_TYPE_1 = 4100 (definition of transformation 1 in the channel)

References
For additional information on the function "Cartesian PTP travel" see:
Programming Manual, Job Planning; Transformations,
Section: Cartesian PTP travel

17.12 Startup

17.12.1 General commissioning

The handling transformation package is a compile cycle.
The general commissioning of a compile cycle is described in Chapter "TE01: Installation and
activation of loadable compile cycles (Page 573)".

17.12.2 Function-specific commissioning

Option
The "Handling transformation package" function is an option for which a license must be
purchased:
● Transformation Handling RCTRA, Order No.: 6FC5800-0AM31-0YB0
A detailed description of licensing, for instance the assignment between a license and
hardware, is provided in:

References
Commissioning Manual, CNC Commissioning: NCK, PLC, drive
Section: "Licensing"

User-specific alarm texts

To create user-specific alarm texts in conjunction with compile cycles, see Chapter "Creating
alarm texts (Page 579)"

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17.12 Startup

Parameterizing transformation
1. Enter the transformation type into the machine data:
– MD24100 $MC_TRAFO_TYPE_1 = 4100 (definition of transformation 1 in the channel)
2. Enter the assignment of the channel axes involved in the transformation in the machine
data (axis numbers, starting at 1):
– MD24110 $MC_TRAFO_AXES_IN_1[0 ... 5] (axis assignment for transformation)
3. Enter the geometry axes corresponding to the Cartesian degrees of freedom of the machine
in the machine data:
– MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1[0 ... 2] (assignment between
geometry axis and channel axis for transformation 1)
4. Enter the kinematic identifier in the machine data:
– MD62600 $MC_TRAFO6_KINCLASS (kinematic category)
5. Enter the identifier for special kinematics, if there are any, in machine data:
– MD62602 $MC_TRAFO6_SPECIAL_KIN (special kinematic type)
6. Enter the number of axes in the machine data:
– MD62605 $MC_TRAFO6_NUM_AXES (number of transformed axes)
7. If the travel direction of the involved axes is opposed to the transformation definition, then
change the factory setting in the machine data:
– MD62618 $MC_TRAFO6_AXES_DIR[ ] (matching of physical and mathematical
directions of rotation)
8. Enter the data which define the basic axes:
– MD62603 $MC_TRAFO6_MAIN_AXES (basic axis identifier)
– MD62607 $MC_TRAFO6_MAIN_LENGTH_AB (basic axis lengths A and B)
9. Enter any changes to the axis sequence in the machine data:
– MD62620 $MC_TRAFO6_AXIS_SEQ (rearrangement of axes)
10.Enter the data which define the wrist axis:
– MD62604 $MC_TRAFO6_WRIST_AXES (wrist axis identifier)
– MD62614 $MC_TRAFO6_DHPAR4_5A (parameter A for configuring the wrist axis)
– MD62615 $MC_TRAFO6_DHPAR4_5D (parameter D for configuring the wrist axis)
– MD62616 $MC_TRAFO6_DHPAR4_5ALPHA (parameter ALPHA for configuring the
wrist axis)
– MD62606 $MC_TRAFO6_A4PAR (axis 4 is parallel/anti-parallel to last basic axis)
11.Enter the geometry parameters:
– Frame T_IRO_RO
– Frame T_X3_P3
– Frame T_FL_WP

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17.13 Supplementary conditions

12.Enter the position in relation to the calibration point in the machine data:
– MD62617 $MC_TRAFO6_MAMES (offset between mathematical and mechanical zero
points)
13.Enter the Cartesian velocities and acceleration rates.

17.13 Supplementary conditions

Clearance control
The handling transformation package cannot be used together with the technology function:
"clearance control".

Moving to fixed end stop

The handling transformation package cannotbe used in conjunction with the "Travel to fixed
stop".

Several transformations
The handling transformation package can be activated just once per channel in all channels.

Tool programming
Tools can only be parameterized by specifying tool lengths. It is not possible to program an
orientation for the tool.

Programming of orientation
The programming possibilities of the orientation depend on the number of axes available on
the machine:
● Number < 5:
– Orientation axis angle
● Number = 5:
– Orientation axis angle
– Orientation vector

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17.14 Data lists

Singularities
A pole cannot be directly passed through when a transformation is active.

NOTICE
Traversing close to the pole
When traversing close to the pole, the axes involved can be overloaded. This is because the
control does not automatically reduce or limit the feedrate, acceleration or jerk. As a
consequence, the user is responsible in limiting the feedrate of the axes involved and/or the
clearance to the pole.

17.14 Data lists

17.14.1 Machine data

17.14.1.1 General machine data

Number Identifier: $MN_ Description

10620 EULER_ANGLE_NAME_TAB[n] Name of Euler angle
19410 TRAFO_TYPE_MASK, bit 4 Option data for OEM transformation
60943 CC_ACTIVE_IN_CHAN_RCTR Activation of the handling transformation for the corre‐
sponding channels
19610 TECHNO_EXTENSION_MASK Option data for handling transformation

17.14.1.2 Channelspecific machine data

Number Identifier: $MC_ Description

21100 ORIENTATION_IS_EULER Angle definition for orientation programming
21110 X_AXIS_IN_OLD_X_Z_PLANE Coordinate system with automatic FRAME definition
24100 TRAFO_TYPE_1 Definition of transformation
24110 TRAFO_AXES_IN_1 Axis assignment for transformation 1
24120 TRAFO_GEOAX_ASSIGN_TAB_1 Assignment of geometry axes to channel axes

17.14.1.3 Channel-specific machine data for compile cycles

Number Identifier: $MC_ Description

62600 TRAFO6_KINCLASS Kinematic category
62601 TRAFO6_AXES_TYPE Axis type for transformation

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17.14 Data lists

Number Identifier: $MC_ Description

62602 TRAFO6_SPECIAL_KIN Special kinematic type
62603 TRAFO6_MAIN_AXES Basic axis identifier
62604 TRAFO6_WRIST_AXES Wrist axis identifier
62605 TRAFO6_NUM_AXES Number of transformed axes
62606 TRAFO6_A4PAR Axis 4 is parallel/anti-parallel to last basic axis
62607 TRAFO6_MAIN_LENGTH_AB Basic axis lengths A and B
62608 TRAFO6_TX3P3_POS Attachment of hand (position component)
62609 TRAFO6_TX3P3_RPY Attachment of hand (rotation component)
62610 TRAFO6_TFLWP_POS Frame between wrist point and flange (position compo‐
nent)
62611 TRAFO6_TFLWP_RPY Frame between wrist point and flange (rotation compo‐
nent)
62612 TRAFO6_TIRORO_POS Frame between base center point and internal system
(position component)
62613 TRAFO6_TIRORO_RPY Frame between base center point and internal system
(rotation component)
62614 TRAFO6_DHPAR4_5A Parameter A for configuring the hand
62615 TRAFO6_DHPAR4_5D Parameter D for configuring the hand
62616 TRAFO6_DHPAR4_5ALPHA Parameter ALPHA for configuring the hand
62617 TRAFO6_MAMES Offset between mathematical and mechanical zero
points
62618 TRAFO6_AXES_DIR Matching of physical and mathematical directions of ro‐
tation
62619 TRAFO6_DIS_WRP Mean distance between wrist point and singularity
62620 TRAFO6_AXIS_SEQ Rearrangement of axes
62621 TRAFO6_SPIN_ON Configuration includes triangular or trapezoidal spin‐
dles
62622 TRAFO6_SPIND_AXIS Axis that is controlled by triangular spindle
62623 TRAFO6_SPINDLE_RAD_G Radius G for triangular spindle
62624 TRAFO6_SPINDLE_RAD_H Radius H for triangular spindle
62625 TRAFO6_SPINDLE_SIGN Sign for triangular spindle
62626 TRAFO6_SPINDLE_BETA Angular offset for triangular spindle
62627 TRAFO6_TRP_SPIND_AXIS Axes driven via trapezoidal connection
62628 TRAFO6_TRP_SPIND_LEN Trapezoid lengths
62629 TRAFO6_VELCP Cartesian velocities
62630 TRAFO6_ACCCP Cartesian acceleration rates
62631 TRAFO6_VELORI Orientation angle velocities
62632 TRAFO6_ACCORI Orientation angle acceleration rates
62634 TRAFO6_DYN_LIM_REDUCE Reduction factor for velocity controller during the JOG
travel
62635 TRAFO6_VEL_FILTER_TIME Time constant for PT1 filter during the JOG travel
62636 TRAFO6_TFL_EXT_RPY Adaptation of the flange coordinate system
62637 TRAFO6_TOOL_DIR Definition of the tool direction

Special functions
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17.14 Data lists

17.14.2 Signals

17.14.2.1 Signals from channel

DB number Byte.bit Description

21, … 29.4 Activate PTP traversal
21, … 33.6 Transformation active
21, … 232 Number of active G function of G function group 25 (ORIWKS, ORIMKS, ORIPATH)
21, … 317.6 PTP traversal active

Special functions
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18.1 Brief description
If there are two or more separately traversable machining heads on a machine tool and a
transformation is required for machining, the orientation axes of the machining heads cannot
be coupled via the standard coupling functions COPON, TRAILON. The coupling is performed
in the workpiece coordinate system (WCS). However, under the aforementioned conditions
the coupling of the orientation axes must be performed in the machine coordinate system
(MCS).
The compile cycle "MCS coupling" can be used to parameterize coupling in the machine
coordinate system (MCS) with coupling factors "1" and "-1" for a master axis, referred to as
CC_Master in the following, and several slave axes, referred to as CC_Slave in the following.
The couplings can be switched on and off via commands in the part program.

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Figure 18-1 Application example: Double slide gantry-type milling machine

Master and slave axes

A CC_Master can be master for several CC_Slaves. A CC_Slave cannot be a CC_Master at
the same time.

Special functions
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18.2 Description of MCS coupling functions

The following functions are not possible for a CC_Slave:

● To be a PLC axis
● To be a command axis
● To be traversed separately from the CC_Master in JOG mode

Tolerance window
When the coupling is active, the actual values of the CC_Master and CC_Slave are monitored
for compliance with a parameterizable tolerance window.

Programming a CC-Slave
If a CC_Slave is programmed in a channel, either an alarm is displayed or the axis is requested
for the channel via an implicitly triggered axis interchange (GET), depending on the setting in
machine data:
MD30552 $MA_AUTO_GET_TYPE = <GET type> (automatic GET for axis)

Switching the coupling on/off

A coupling is switched on and off via OEM-specific language commands and can be active in
all operating modes.

Collision protection
In order to protect the machining heads against collision in decoupled operation or in mirrored
coupling, a collision protection can be parameterized. The activation is performed via machine
data or the NC/PLC interface. The assignment of the protected pairs is not dependent on the
CC_Master and CC_Slave pairs.

18.2 Description of MCS coupling functions

18.2.1 Defining coupling pairs

A CC_Slave axis is matched to its CC_Master axis via the following axial machine data:
MD63540 $MA_CC_MASTER_AXIS (specifies the CC_Master axis assigned to a CC_Slave
axis)
The coupling's axes can only be changed when the coupling is not active.
A CC_Slave axis is displayed in axial VDI-Out byte:
DB31, … DBX97.0 (axis is slave axis)

Special functions
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18.2 Description of MCS coupling functions

Requirements
● The CC_Master and CC_Slave axes must be either both rotary axes or both linear axes.
● Spindles cannot be coupled by this function.
● Neither the CC_Master nor CC_Slave axis may be an exchange axis
($MA_MASTER_CHAN[AXn]=0)

18.2.2 Switching the coupling ON/OFF

Activating the coupling

● Activating the 1:1 coupling. Monitoring of the tolerance window is active.
CC_COPON([<axis1>][<axis2>][<axis3>][<axis4>][<axis5>])
● Activating the 1:-1 coupling (mirror). Monitoring of the tolerance window is not active.
CC_COPONM([<axis1>][<axis2>][<axis3>][<axis4>][<axis5>])

Axis name
An axis can be specified via:
● Machine axis name
● Channel axis name
● Geometry axis name

Boundary conditions
● A programmed axis must be involved in a coupling.
● CC_Master axes, CC_Slave axes or both can be programmed simultaneously. All defined
couplings are switched on with CC_COPON or CC_COPONM.
● An alarm is output if an axis not involved in a coupling is programmed.

NC/PLC interface signals

All NC/PLC interface signals of a coupling refer to the CC_Slave axes.
● DB31, … DBX97.1 (coupling active)
● DB31, … DBX97.2 (mirroring active)
● DB31, … DBX24.2 (suppress CC_Slave axis coupling)
If the coupling is suppressed, an alarm is not output for the CC_Slave axis.

Deactivating the coupling

CC_COPOFF([<axis1>][<axis2>][<axis3>][<axis4>][<axis5>])
As for switching on the coupling with the difference that no alarm is output if an axis is
programmed that is not involved in a coupling.
An existing coupling can also be switched off by the axial NC/PLC interface signal of the
CC_Slave axis.

Special functions
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18.2 Description of MCS coupling functions

Boundary condition
A coupling can only be switched on or off when the axes are at standstill.

18.2.3 Tolerance window

A monitoring window is specified via axial machine data:
MD63541 $MA_CC_POSITION_TOL (monitoring window)
The absolute difference between the actual values of CC_Slave axis and CC_Master axis must
never be greater than this value. Alarm 70010 is output if the tolerance window is violated.
The monitoring function is not active:
● if the machine data is set to 0,
● if the coupling is switched off,
● if axis/spindle inhibit is set for one of the axes,
● if an axis is in follow-up mode,
● for the 1:-1 coupling.
If the offset stored at the instant of coupling activation changes when 1:1 coupling is active,
the change is indicated by NC => PLC VDI-SS:
DB31, … DBX97.3 (offset after start-up)

Note
The offset might change:
● if the SW limit monitor was active for one axis during the main run,
● if one axis has been switched to follow-up mode,
● if collision protection was active for one axis.

18.2.4 Memory configuration: Block memory

The technological function requires additional data in the NC-internal block memory. The
values must be increased for the following memory configuring channel-specific machine data:
● MD28090 $MC_MM_NUM_CC_BLOCK_ELEMENTS += 1 (number of block elements for
compile cycles)
● MD28100 $MN_MM_NUM_CC_BLOCK_USER_MEM += 1 (size of block memory for
compile cycles (DRAM) in KB)

Special functions
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18.3 Description of collision protection

18.3 Description of collision protection

18.3.1 Defining protection pairs

A ProtecSlave axis (PSlave) is matched to its ProtecMaster (PMaster) axis via the following
axial machine data:
MD63542 $MA_CC_PROTECT_MASTER (specifies the PMaster axis assigned to a PSlave
axis)
The protection pairs can thus be defined independently of the coupling pairs. A PSlave axis
may act as the PMaster axis for another axis. The axes must be either both rotary axes or both
linear axes.

18.3.2 Switching collision protection ON / OFF

The minimum clearance between PSlave and PMaster is provided in the axial machine data
of the PSlave axis:
MD63544 $MA_CC_COLLISION_WIN (collision protection window)
No collision protection is implemented if the value entered here is less than 0. The 0 position
offset between PSlave and PMaster is provided in the axial machine data (PSlave axis):
MD63545 $MA_CC_OFFSET_MASTER ( zero point offset between PSlave and PMaster)
Before the collision protection is switched on, the monitoring function for each individual axis
must be enabled in the following machine data:
MD63543 $MA_CC_PROTECT_OPTIONS
In the same machine data for the PSlave axis, a setting is entered to specify whether the
collision protection must be active continuously or whether it is activated via VDI interface
signal (PLC => NC):
DB31, … DBX24.3
If collision protection is active, the setpoint positions of the PSlave and PMaster in the next
IPO cycle are extrapolated and monitored in the IPO clock cycle using the current setpoint
position and current velocity.
If the axes violate the minimum clearance, they are braked at the configured maximum
acceleration rate:
MD32300 $MA_MAX_AX_ACCEL (Axis acceleration)
Or at a 20% faster acceleration rate, defined in machine data:
MD63543 $MA_CC_PROTECT_OPTIONS

Special functions
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18.3 Description of collision protection

An alarm is output as soon as the axes reach zero speed.

WARNING
Risk of collision when starting
If the axes are forced to brake, the positions displayed in the workpiece coordinate system
are incorrect!
These are not re-synchronized again until a system RESET.

If the axes are already violating the minimum clearance when collision protection is activated,
they can only be traversed in one direction (retraction direction). The retraction direction is
configured in machine data:
MD63543 $MA_CC_PROTECT_OPTIONS
The collision protection status is optionally displayed in axial VDI-Out byte of the PSlave:
DB31, … DBX66.0 (activate monitoring)
● DB31, … DBX66.0=1 → collision protection active
● DB31, … DBX66.0=0 → collision protection inactive
This output is activated via Bit7 in machine data of the PSlave axis:
MD63543 $MA_CC_PROTECT_OPTIONS

18.3.3 Configuring example

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Figure 18-2 Configuring example

Special functions
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18.4 User-specific configurations

Note
Since the collision protection function extrapolates the target positions from the "current
velocity + maximum acceleration (or +20%)", the monitoring alarm may be activated
unexpectedly at reduced acceleration rates:
Example:
PMaster = X, PSlave = X2, $MA_CC_COLLISION_WIN = 10mm
Starting point in part program: X=0.0 X2=20.0
N50 G0 X100 X2=90
; the monitoring alarm is activated because X and X2 are interpolating together: for this reason,
the acceleration rate of X2 < maximum acceleration.
Remedy:
● N50 G0 POS[X]=100 POS[X2]=90
● or switch the monitoring function off.

18.4 User-specific configurations

Parking the machining head

In this context, "parking" means that the relevant machining head is not involved in workpiece
machining. All axes are operating under position control and positioned at exact stop.
Even if a machining head is being used in production, coupling should be active! This is
essential primarily if only the second head (Y2....) is being used. "Axis/spindle inhibit" must
then be set axially (PLC -> NCK) for the "parked" head.

Note
When an axis/spindle inhibit is active, a part program can be executed if this axis is not
operating under position control.

Spindle functionalities
Since an MCS coupling cannot be activated for spindles, other types of solutions should be
configured for these.
● Positioning the spindle (SPOS= ...)
Instead, a cycle is called from SPOS. SPOS is called for all active spindles in this cycle.
● Speed default
Speed and direction of rotation inputs can be detected via synchronized actions or PLC
and passed on to all other active spindles.
● Synchronous spindle function

Special functions
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18.5 Special operating states

18.5 Special operating states

Reset
The couplings can remain active after a RESET.

Reorg
No non-standard functionalities.

Block search
During a block search, the last block containing an OEM-specific language command is always
stored and then output with the last action block. This feature is illustrated in the following
examples. The output positions of the axes are always 0.
Example 1:
N01 M3 S1000
N02 G01 F1000 X10 Y10
N03 CC_COPON( X, Y)
TARGET:
If this program is started normally, axes X and Z traverse to X10 Z10 in the decoupled state.
After block search to TARGET: axes X and Y traverse to this position in the coupled state!
Example 2:
N01 M3 S1000
N02 CC_COPON( X)
N03 G01 F1000 X100 Y50
N04 CC_COPOFF( X)
N05 CC_COPON( Y)
N06 Y100
N10 CC_COPOFF()
TARGET:
After block search to TARGET: the axes traverse to X100 Y100 in the decoupled state.
Example 3:
N01 CC_COPON( X, Y, Z)
N02 ...
...
N10 CC_COPOFF( Z)
TARGET:
After block search to TARGET: no coupling is active!

Special functions
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18.7 Data lists

Single block
There are no nonstandard functionalities.

18.6 Boundary conditions

Validity
The function is configured only for the first channel.

Braking behavior
Braking behavior at the SW limit with path axes
The programmable acceleration factor ACC for braking at the SW limit corresponds to the path
axes.
The axes in an MCS coupling are principal axes that are referred to as geometry axes due to
their geometric arrangement.
Braking geometry axes using synchronized actions
The faster deceleration capacity as required for path axes can be implemented for geometry
axes as follows using a synchronized action:
ACC[x2]=190

Axial acceleration limitation with G0

The following machine data is not considered by the MCS coupling:
MD32434 $MA_G00_ACCEL_FACTOR (scaling of the acceleration limitation with G0)
A value deviating from the standard value affects the braking ramp up to the software limit
switch.

18.7 Data lists

18.7.1 Machine data

18.7.1.1 Channelspecific machine data

Number Identifier: $MC_ Description

28090 NUM_CC_BLOCK_ELEMENTS Number of block elements for compile cycles.
28100 NUM_CC_BLOCK_USER_MEM Total size of usable block memory for compile cycles

Special functions
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18.7 Data lists

18.7.1.2 Axis/spindlespecific machine data

Number Identifier: $MA_ Description

63540 CC_MASTER_AXIS Specifies the CC_Master axis assigned to a CC_Slave
axis.
63541 CC_POSITION_TOL Monitoring window
63542 CC_PROTEC_MASTER Specifies the PMaster axis assigned to a PSlave axis.
63543 CC_PROTEC_OPTIONS
63544 CC_COLLISION_WIN Collision protection window
63545 CC_OFFSET_MASTER Zero point offset between PSlave and PMaster

Special functions
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TE7: Continue machining at the contour (retrace
support) - 840D sl only 19
19.1 Brief description

Function
The "Continue machining - Retrace support (RESU)" technological function supports the
retracing of uncompleted 2-dimensional machining processes such as laser cutting, water jet
cutting, etc.
In the event of a fault during the machining process, e.g. loss of the laser, RESU can be used
even by machine operators who do not have specific knowledge of the active part program to
interrupt machining and travel back along the contour from the interruption point to a program
continuation point necessary for machining purposes.
After reaching the "continue machining" point, the machine operator triggers the re-machining.
As part of the retrace process, an implicit block search takes place along the contour with
calculation followed by repositioning on the contour and automatic retracing of the part program
machining process.
The retrace option is selected and deselected in advance using part program commands within
the machining program. The program continuation point can be selected at any position within
the contour ranges specified in this way.

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Figure 19-1 Programmed contour with program continuation and interruption points

Precise retracing of contours is possible on all programmed contours comprising straight and
circular elements. During retracing, other programmed contour elements such as splines or
automatically inserted non-linear contour elements (circle, parable, etc. e.g. through tool radius

Special functions
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19.2 Function description

compensation) are mapped as straight lines through the start and end points of the
corresponding contour element, thereby preventing precise retracing of contours.

Function code
The code for the "Continue Machining - Retrace support" technological function for function-
specific identifiers of program commands, machine data, etc. is:
RESU (= REtrace SUpport)

Restrictions
The use of the "Continue Machining Retrace support" technological function is subject to the
following restrictions:
● The technological function is available only in the 1st channel of NC.
● Program continuation or reverse travel is only possible for part program blocks that contain
traversing blocks in the configured RESU working plane (e.g. 1st and 2nd geometry axis
of the channel, see Section "Definition of the RESU working plane (Page 730)").

References
The "Continue Machining - Retrace support" technological function is a compile cycle. For the
handling of compile cycles, see Section "TE01: Installation and activation of loadable compile
cycles (Page 573)".

19.2 Function description

19.2.1 Function

Block search with calculation on contour

To be able to resume interrupted machining at a specific point in a part program, a block search
can be carried out using the "Block search with calculation on contour" standard function.
However, detailed knowledge of the part program is required to be able to enter the block
number of the part program block required for the block search (i.e. the number of the block
the search needs to locate).

Continue machining - Retrace support

The "Continue machining - Retrace support" technological function supports the continuation
of the machining operation by means of an implicit block search with calculation on the contour
without the machine operator needing to know the part program block required.

Special functions
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 TE7: Continue machining at the contour (retrace support) - 840D sl only
19.2 Function description

Continue machining might be required for example in a laser cutting application if the laser is
lost during the machining operation and machining needs to resume at the point at which it
was interrupted.
RESU supports the machining continuation via the following automatically running sub-
functions:
● Function-specific reverse travel along the contour to the required program continuation point
● Automatic identification of the part program block associated with the program continuation
point
● Block search with calculation on the contour for the part program block identified
● Repositioning on the contour at the program continuation point
● Continuation of part program machining
To approach the required program continuation point exactly, it is possible to switch several
times between reverse and forward travel along the contour during the continue machining
process.

Retraceable contour areas

RESU is activated via programming of the function-specific part program command
CC_PREPRE (1). Only the contour range lying between the RESU start (CC_PREPRE(1))
and the interruption point (NC stop) is retraceable in the sense of "continue machining".
Once RESU has been launched, all part program blocks in which traversing movements are
programmed are logged by RESU for possible subsequent reverse travel. Contour ranges for
which continuing machining is irrelevant can be excluded from the log using RESU stop
CC_PREPRE (0).
Contour ranges which are not logged are bridged by straight lines between the starting and
end points during reverse/forward travel.

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Figure 19-2 Retraceable contour range

Special functions
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19.2 Function description

19.2.2 Definition of terms

Interruption point
The interruption point is the point of the contour at which the traversing movement comes to
a standstill following an NC stop and reverse travel is activated.

Program continuation point

The program continuation point is the point of the contour at which reverse travel terminates
and program continuation is activated.

Retraceable contour range

Retraceable contour ranges consist of traversing blocks in the configured RESU working plane
(e.g. 1st and 2nd geometry axis of the channel), that are programmed in the part program
between the RESU start command CC_PREPRE(1) and the RESU stop command
CC_PREPRE(0) (see "Figure 19-2 Retraceable contour range (Page 725)").

19.2.3 Functional sequence (principle)

The principle sequence of the RESU function between the interruption point, program
continuation point and continuation of part program processing is described below.

Requirements
A part program with traversing blocks in the configured RESU working plane (e.g. 1st and 2nd
geometry axis of the channel) as well as the part program command for the RESU start has
been started in the 1st channel.

Functional sequence
1. Interrupt part program processing:
The part program processing / traversing movement may be interrupted any number of
traversing blocks after RESU start by NC stop.
2. Select reverse travel:
The selection of the reverse travel is by PLC interface signal:
DB21, … DBX0.1 = 1 (forward / reverse)
3. Reverse travel:
The contour is traversed in the RESU working plane in the reverse direction with NC start.
Instead of the current machining program, RESU selects the automatically generated
RESU main program.
For more about RESU programs, see Section "RESU-specific part programs (Page 736)".
4. End reverse travel:
Once the required program continuation point on the contour has been reached, reverse
travel is ended using NC stop.

Special functions
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19.2 Function description

5. Select forward travel (optional):

For forward travel, reverse travel must be deselected via PLC interface signal:
DB21, … DBX0.1 = 0
6. Forward travel (optional):
The contour is traversed in the RESU working plane in the forward direction with NC start.
7. End forward travel (optional):
Once the required program continuation point on the contour has been reached, forward
travel is ended using NC stop.
8. Retrace support:
Continue machining is initiated via PLC interface signal:
DB21, … DBX0.2 = 1 (start retrace support)
For retrace support, RESU automatically selects the original machining program and
launches a block search with calculation as far as the program continuation point.
9. Continuation of part program machining:
Part program processing continues at the program continuation point in accordance with
the "Block search with calculation" standard function when two NC start commands occur
one after the other.
The first NC start command processes the action blocks. Retrace support ASUB
"CC_RESU_BS_ASUP.SPF" is initiated when the last action block is reached:
DB21, … DBX32.6 = 1 (last action block active)
To ASUB (see Section "RESU-specific part programs (Page 736)").
The second NC start command processes the approach block before part program
processing is resumed.
Note
Points 3 to 8 can be repeated as often as required.
Following retrace support, a new reverse travel is possible up to a maximum of the last
program continuation point.

Special functions
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19.2 Function description

Signal chart for interface signals

The principle sequence of the RESU function is illustrated in the following figure as a signal
chart of the interface signals involved:

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① Reverse travel is started.

② Forward travel is started (optional).
③ Continue machining is started (block search).
④ Search destination (target block) was found.
⑤ 1. NC start → Action blocks are output.
⑥ Last action block is activated.
The RESU ASUB "CC_RESU_BS_ASUP.SPF" is triggered when the last action block is acti‐
vated.
⑦ 2. NC start →Return travel to approach block for program continuation point.
⑧ Part program processing (target block) resumed

Figure 19-3 Signal chart

Special functions
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19.2 Function description

19.2.4 Maximum retraceable contour area

In multiple machining continuation within a contour area, the reverse travel on the contour is
always possible only up to the last machining continuation point (W). In first-time reverse travel
after RESU start, reverse travel up to the start of the contour range is possible.
This response must be illustrated via the following graph. For the sake of simplicity, the
interruption point (U) is always the same:

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Figure 19-4 Maximum Retraceable contour range

1st reverse travel

In first-time reverse travel, reverse travel is possible maximum up to the start of the first contour
element (N20) after RESU start (N15) (W1max).
If reverse travel takes place up to the machining continuation point W1, W1 defines the
maximum RESU range for a possible further reverse travel after machining continuation and
forward travel.
2nd reverse travel
A renewed reverse travel can now be undertaken maximum only up to the last machining
continuation point W2max = W1.
If reverse travel goes as far back as program continuation point W2, the maximum RESU range
is restricted further.

Special functions
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19.3 Startup

19.3 Startup

19.3.1 Activation
Before commissioning the technological function, ensure that the corresponding compile cycle
has been loaded and activated (see also Section "TE01: Installation and activation of loadable
compile cycles (Page 573)").

Activation
The "Continue machining - Retrace support" technology function is activated via the following
machine data:
MD60900+i $MN_CC_ACTIVE_IN_CHAN_RESU[0], bit 0 = 1

Note
The "Continue machining - Retrace support" technological function is available only in the
1st channel of NC.

19.3.2 Definition of the RESU working plane

Machining continuation/reverse travel is possible only for part program blocks that contain
traversing blocks in the configured RESU working plane.
The RESU working plane is defined with the following machine data:
MD62580 $MC_RESU_WORKING_PLANE

Value Meaning
1 The RESU working plane is formed by the 1st and 2nd Geometry axes of the 1st channel (for
G17).
2 The RESU working plane is formed by the 1st and 3rd Geometry axes of the 1st channel (for
G18).
3 The RESU working plane is formed by the 2nd and 3rd Geometry axes of the 1st channel (for
G19).

19.3.3 Memory configuration: Block memory

The technological function requires additional data in the NCK-internal block memory. The
values must be increased for the following memory configuring channel-specific machine data:
● MD28090 $MC_MM_NUM_CC_BLOCK_ELEMENTS += 4 (number of block elements for
compile cycles)
● MD28100 $MN_MM_NUM_CC_BLOCK_USER_MEM += 20 (size of block memory for
compile cycles (DRAM) in KB)

Special functions
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19.3 Startup

19.3.4 Memory configuration: Heap memory

Memory requirements
RESU requires compile cycles heap memory for the following function-specific buffers:
● Block buffer
The larger the block buffer (see "Figure 19-6 RESU-specific part programs (Page 736)"),
the larger the number of part program blocks that can be traversed backwards.
32 bytes are required per part program block.
The block buffer can be parameterized directly.
● Block search buffer
The block search buffer contains the information required for processing subprogram
searches in the context of RESU.
180 bytes are required for each subprogram. The block search buffer requires at least 2880
bytes (16 subprogram calls with 180 bytes each).
The block search buffer cannot be parameterized directly.
A function-specific GUD variable displays the size of the block search buffer (for creation
of GUD variables, see Section "Channel-specific GUD variables (Page 746)").

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Memory configuration
Size of the compile cycle heap memory
The size of the heap memory in KB that can be used by the user for compile cycles is defined
via the memory configuring channel-specific machine data:
MD28105 $MC_MM_NUM_CC_HEAP_MEM
For RESU, the already existing machine data value (x) is adjusted as follows:
MD28105 $MC_MM_NUM_CC_HEAP_MEM = x + 50
Size of the block buffer

Special functions
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19.3 Startup

The size of the block buffer is adjusted via the machine data:
MD62571 $MC_RESU_RING_BUFFER_SIZE
Default setting:
MD62571 $MC_RESU_RING_BUFFER_SIZE = 1000
RESU portion of the total heap memory
The RESU portion of the total heap memory that can be used for compile cycles is set via the
machine data:
MD62572 $MC_RESU_SHARE_OF_CC_HEAP_MEM
Default setting:
MD62572 $MC_RESU_SHARE_OF_CC_HEAP_MEM = 100

Error messages
The block search buffer requires at least 2880 bytes (corresponding to 16 subprogram calls
with 180 bytes each). Otherwise, the following alarm will be generated during NC power-up:
Alarm 75600 "Channel 1 Retrace Support: Incorrect MD configuration, error no. 5"
If the block search buffer is not big enough during operation, the following alarm appears:
Alarm 75606 "Channel 1 retraceable contour shortened"

19.3.5 RESU main program memory area

Memory configuration
The storage location of the RESU main program CC_RESU.MPF can be set with the following
machine data (see Section "Main program (CC_RESU.MPF) (Page 737)"):
MD62574 $MC_RESU_SPECIAL_FEATURE_MASK (additional RESU features)

Bit Value Meaning

1 0 The RESU main program is stored in the dynamic NC memory (default).
1 The RESU main program is stored in the static NC memory (default).

Storage in the dynamic NC memory (default)

If the RESU main program is created in the dynamic NC memory, the memory area available
to the user for file storage must be increased as follows:
MD18351 $MN_MM_DRAM_FILE_MEM_SIZE = x1) + 100
1)
already available machine data value

Special functions
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19.3 Startup

Storage in the static NC memory

If the RESU main program is created in the static memory area of the NC, it is retained even
after a POWER OFF. However, since RESU regenerates the RESU main program every time
the retrace support function is used, this parameter setting is not recommended.

19.3.6 Storage of the RESU subroutines

Storage as user or manufacturer cycles

The following RESU-specific subroutines can be stored as user cycles or manufacturer cycles:
● INI program: CC_RESU_INI.SPF
● END program CC_RESU_END.SPF
● Retrace support ASUB CC_RESU_BS_ASUP.SPF
● RESU ASUB CC_RESU_BS_ASUP.SPF
The setting is done using machine data:
MD62574 $MC_RESU_SPECIAL_FEATURE_MASK (additional RESU features)

Bit Value Meaning

2 0 The RESU-specific subroutines are stored as user cycles (default).
1 The RESU-specific subroutines are stored as manufacturer cycles.

Series commissioning
Due to the default setting of MD62574 Bit 2, the RESU-specific subroutines along with their
contents are stored as user cycles the first time the NC is powered up after the activation of
the technological function.
If the setting is then changed to specify that the RESU-specific subroutines are to be stored
as manufacturer cycles, the RESU-specific subroutines already created as user cycles are
retained even after a new power-up and must be deleted.
As support for series commissioning, the RESU-specific subroutines present as user cycles
can be deleted without prompting when the NC is powered up:
MD62574 $MC_RESU_SPECIAL_FEATURE_MASK, Bit 3 = 1

19.3.7 ASUB enable

Note
A requirement for using ASUBs is that the "Cross-mode actions" option must be available.

Special functions
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19.3 Startup

The following machine data must be set for the start enable for the RESU-specific ASUB
CC_RESU_ASUP.SPF while the channel is in the NC STOP state:
MD11602 $MN_ASUP_START_MASK, bit 0 = 1 (ignore stop reason for ASUB)
MD11604 $MN_ASUP_START_PRIO_LEVEL = 1 (priorities from which MD11602 is
effective)

19.3.8 PLC user program

Requirements
The following functionality is necessary for the sequential coordination of the RESU function
in the PLC user program:

IF DB21, … DBX32.2 "Retrace support active" == 1

THEN DB21, … DBX0.1 "Forward/Reverse" = 0
DB21, … DBX0.2 "Start retrace support" = 0

IF DB11, … DBX0.7 "Mode group reset" == 1

OR DB21, … DBX7.7 "Reset" == 1
THEN DB21, … DBX0.1 "Forward/Reverse" = 0
DB21, … DBX0.2 "Start retrace support" = 0

The following signals should be reset for safety reasons:

IF DB21, … DBX0.2 "Start retrace support" == 1

THEN DB21, … DBX0.1 "Forward/Reverse" = 0

IF DB21, … DBX0.1 "Forward/Reverse" == 1

THEN DB21, … DBX0.2 "Start retrace support" = 0

Program example
The following program extract implements the changes described above:

U DB21, … DBX32.2 // IF "Retrace support active" == 1

R DB21, … DBX0.1 // THEN "Forward/Reverse" = 0
R DB21, … DBX0.2 // "Start retrace support" = 0
O DB11, … DBX0.7 // IF "Mode group reset" == 1
O DB21, … DBX7.7 // OR "Reset" == 1
R DB21, … DBX0.1 // THEN "Forward/Reverse" = 0
R DB21, … DBX0.2 // "Start retrace support" = 0
U DB21, … DBX0.2 // IF "Start retrace support" == 1
R DB21, … DBX0.1 // THEN "Forward/Reverse" = 0

Special functions
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19.4 Programming

U DB21, … DBX0.1 // IF "Forward/Reverse" == 1

R DB21, … DBX0.2 // THEN "Start retrace support" = 0

19.4 Programming

19.4.1 RESU Start/Stop/Reset (CC_PREPRE)

Using procedure CC_PREPRE (Prepare Retrace) the "Start", "Stop" and "Reset" modes can be
activated for retracing:

Syntax
CC_PREPRE(<mode>)

Meaning

CC_PREPRE: Retrace mode

Alone in the block: Yes
<mode>: Mode
Data type: INT
Value range: -1, 0, 1
Value Meaning
-1 Starts logging the traversing blocks.
The information required for traversing backward is logged on a
block-specific basis in a RESU-internal block buffer. The traversing
information is related to the two geometry axes of the RESU work‐
ing plane e.g. the 1st and 2nd geometry axes of the channel:
MD20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[x]; with x = 0
and 1
Or, if transformation is active:
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB[x]; with x = 0 and
1
0 Stops logging the traversing blocks.
Thus irrelevant contour areas can be excluded from the log.
These excluded contour areas are bridged by a straight line be‐
tween the starting point and end point when traversing backward.
1 Deactivates logging of the traversing blocks and deletes the func‐
tion-internal block buffer. Contour areas located before the instant
of deactivation of the part program are therefore no longer availa‐
ble to RESU.

Special functions
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19.5 RESU-specific part programs

RESET response
For the following reset events, CC_PREPRE(-1) is implicitly executed:
● Power on (warm restart)
● Channel reset
● End of program reset (M30)

19.5 RESU-specific part programs

19.5.1 Overview
RESU uses the following, automatically generated and partially adjustable part programs:

Program Name
Main program CC_RESU.MPF
INI program CC_RESU_INI.SPF
END program CC_RESU_END.SPF
Continue machining ASUB CC_RESU_BS_ASUP.SPF
RESU ASUB CC_RESU_ASUP.SPF

The following figure provides an overview of the internal structure of the technological function
and the relationship between the various part programs.

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Figure 19-6 RESU-specific part programs

Special functions
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19.5 RESU-specific part programs

19.5.2 Main program (CC_RESU.MPF)

Function
In addition to the calls for the RESU-specific subprograms, the RESU main program
"CC_RESU.MPF" contains the traversing blocks generated from the traversing blocks logged
in the block buffer for reverse/forward travel along the contour. The program is always
regenerated by the RESU function if, once the part program has been interrupted, the status
of the following interface signal changes:
DB21, … DBX0.1 (Reverse / Forward)

Note
CC_RESU.MPF must not be changed. User-specific adjustments are to be made in the
corresponding RESU-specific subprograms.

Error messages
By default, RESU generates traversing blocks for the entire retraceable contour range logged
in the block buffer. If there is not enough memory for all traversing blocks to be generated in
the parameterized memory area of the RESU main program (see Section "RESU main program
memory area (Page 732)"), RESU reduces the number of generated traversing blocks.
The lacking memory and/or reduction in the number of the generated traversing blocks is
indicated by an alarm:
RESU alarm 75608 "Channel number NC memory limit reached, RAM type type"
If the RESU main program is created in the static user memory, the following system alarm
appears at the same time as the RESU alarm:
Alarm 6500 "NC memory full"

Note
If the number of traversing blocks generated is reduced due to insufficient memory, the entire
retraceable contour can still be retraced for retrace support. To do this, proceed as follows:
● Reverse travel up to the end of the RESU main program
● Two-time change of the interface signal:
DB21, … DBX0.1 (Reverse/Forward)
Using the current position as a new interruption point enables RESU to generate a new RESU
main program.
Subsequently, travel is possible as far as the end of the retraceable contour range or, if the
limits have changed, as far as the starting point of the last traversing block that can be
generated.
The procedure described can be repeated as many times as required both for reverse and
forward travel.

Special functions
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19.5 RESU-specific part programs

19.5.3 INI program (CC_RESU_INI.SPF)

Function
The RESU-specific subprogram "CC_RESU_INI.SPF" contains the defaults required for the
reverse travel:

● Metric input system: G71

● Absolute dimensions: G90
● To switch off the adjustable zero-point offsets / frames G500
(see Chapter "Frames (Page 751)"):
● To switch off the active tool offsets (see Chapter "Tool T0
offsets (Page 751)"):
● Switching off the tool radius offset: G40
● Traversing velocity: F200

Program structure
CC_RESU_INI.SPF has the following content by default:

PROC CC_RESU_INI

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19.5 RESU-specific part programs

G71 G90 G500 T0 G40 F200

;system frames that are present are deactivated
;actual value and scratching
if $MC_MM_SYSTEM_FRAME_MASK B_AND 'H01'
$P_SETFRAME = ctrans()
endif
;external zero point offset
if $MC_MM_SYSTEM_FRAME_MASK B_AND 'H02'
$P_EXTFRAME = ctrans()
endif
;tool carrier
if $MC_MM_SYSTEM_FRAME_MASK B_AND 'H04'
PAROTOF
endif
if $MC_MM_SYSTEM_FRAME_MASK B_AND 'H08'
TOROTOF
endif
;workpiece reference points
if $MC_MM_SYSTEM_FRAME_MASK B_AND 'H10'
$P_WPFRAME = ctrans()
endif
;cycles
if $MC_MM_SYSTEM_FRAME_MASK B_AND 'H20'
$P_CYCFRAME = ctrans()
endif
;transformations
if $MC_MM_SYSTEM_FRAME_MASK B_AND 'H40'
$P_TRAFRAME = ctrans()
endif
; bit mask for global basic frames
$P_NCBFRMASK = 0
;bit mask for channel-specific basic frames
$P_CHBFRMASK = 0
;programmable frame
$P_PFRAME = ctrans()
M17

CAUTION
Program changes
By changing the content of the RESU-specific subprogram "CC_RESU_INI.SPF", the user
(machine manufacturer) takes over the responsibility for the correct sequence of the
technological function.

Note
CC_RESU_INI.SPF may be changed.
CC_RESU_INI.SPF must not contain any RESU part program commands. CC_PREPRE(x).

Special functions
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19.5 RESU-specific part programs

19.5.4 END program (CC_RESU_END.SPF)

Function
The task of the RESU-specific subroutine "CC_RESU_END.SPF" is to stop reverse travel once
the end of the retraceable contour is reached. If the RESU function is parameterized
appropriately, this scenario will not arise under normal circumstances.

Program structure
CC_RESU_END.SPF has the following content by default:

PROC CC_RESU_END
M0
M17

CAUTION
Program changes
By changing the content of the RESU-specific subroutine "CC_RESU_END.SPF", the user
(machine manufacturer) takes over the responsibility for the correct sequence of the
technological function.

Note
CC_RESU_END.SPF may be changed.
CC_RESU_END.SPF must not contain any RESU part program commands. CC_PREPRE(x).

19.5.5 Retrace support ASUB (CC_RESU_BS_ASUP.SPF)

Function
The NC is forced to approach the current path point during machining continuation with the
help of the RESU-specific ASUB "CC_RESU_BS_ASUP.SPF":

● Reapproach next point on path: RMN

● Approach along line on all axes: REPOSA

Program structure
CC_RESU_BS_ASUP.SPF has the following content by default:

PROC CC_RESU_BS_ASUP SAVE

RMN
REPOSA

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19.5 RESU-specific part programs

M17

CAUTION
Program changes
By changing the content of the RESU-specific subroutine "CC_RESU_BS_ASUP.SPF", the
user (machine manufacturer) takes over the responsibility for the correct sequence of the
technological function.

Note
CC_RESU_BS_ASUP.SPF may be changed.
User-specific modifications must be inserted before the part program block RMN.

19.5.6 RESU ASUB (CC_RESU_ASUP.SPF)

Function
The RESU-specific ASUB "CC_RESU_ASUP.SPF" is required internally for the function. The
ASUB is initiated if the following RESU interface signal is switched over in the NC stop state:
DB21, … DBX0.1 (Forward/Reverse)

Program structure
CC_RESU_ASUP.SPF has the following content:

PROC CC_RESU_ASUP
; siemens system asub - do not change
G4 F0.001
M0
REPOSA
M17

Note
CC_RESU_ASUP.SPF must not be changed.

Special functions
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19.6 Retrace support

19.6 Retrace support

19.6.1 General information

Retrace support refers to the entire operation from initiation of retracing through the interface
signal DB21, … DBX0.2 = 1 (start machining continuation) up to to the continuation of the part
program processing of the programmed contour.

Requirement
In order for retrace support to function, the retrace mode, launched by means of the request
for reverse travel, must be active in the channel:
DB21, … DBX32.1 = 1 (retrace mode active)
(See Section "Functional sequence (principle) (Page 726)")

Subfunctions
The two essential subfunctions of retrace support are the standard NC functions:
● Block search with calculation on contour
● Repositioning on the contour via shortest route (REPOS RMN)

19.6.2 Block search with calculation on contour

Function
The block search with calculation on the contour initiated implicitly by RESU within the
framework of the retrace support has the following tasks:
● Set the program pointer on the part program block on which repositioning was done with
the help of Reverse / Forward travel
● Calculates the axis positions on the basis of the programmed traversing blocks from the
start of the part program to the target block
● Collates the instructions programmed from the start of the part program to the target block,
which are executed in the action block. These include:
– Auxiliary functions
– Tool change
– Spindle functions
– Feedrate programming

Special functions
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19.6 Retrace support

All part program instructions which are not executed in the action block but are required for
retrace support in the part program must be entered manually in the RESU-specific retrace
support ASUB CC_RESU_BS_ASUP.SPF, e.g.:
● Synchronized actions
● M functions

References
The complete description of the Block search is available in:
Basic Functions Function Manual; Mode Group, Channel, Program Mode (K1), Program test

19.6.3 Reposition

Function
Following the end of the last action block (last traversing block before repositioning), NC Start
outputs the approach block for repositioning all channel axes programmed in the part program
as far as the target block.

Special functions
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19.6 Retrace support

Geometry axes
In the approach block, the geometry axes of the RESU working plane (e.g. 1st and 2nd
geometry axes of the channel) traverse the shortest route along the contour to the program
continuation point.

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Figure 19-7 Retraceable contour ranges and REPOS

Channel axes
All other channel axes programmed in the part program travel to the relevant position
calculated in the block search.

19.6.4 Temporal conditions concerning NC start

NC start should be initiated twice by the machine operator within the framework of continue
machining (see Section "Functional sequence (principle) (Page 726)").
The following conditions must be met:
● In NC start for outputting the action blocks:
– The block search must be completed:
DB21, … DBX33.4 = 0 (block search active)
● In NC start for outputting the approach blocks:
– The RESU ASUB "CC_RESU_BS_ASUP" must be completed:
DB21, … DBX318.0 = 1 (ASUB stopped)

Special functions
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19.6 Retrace support

19.6.5 Block search from last main block

The block search with calculation on the contour executed within the framework of the
machining continuation via the use of the most powerful NCU in very large part programs can
itself lead to computation times of several minutes up to the reaching of the target block.
A significant reduction of this waiting period is possible through the use of the "Block search
from the last main block".

Functionality
For retrace support with block search from the last main block, the search for the target block
takes place in 2 stages:
1. Block search without calculation from start of machining program to last main block before
target block. Subprograms are ignored during this search, i.e. it takes place exclusively in
the main program.
2. Block search with calculation on contour from main block to target block. This block search
does not ignore subprograms.

Requirement
To enable a search from last main block for retrace support, at least one main block must be
programmed after the RESU start CC_PREPRE(1).

Main block
All instructions required for processing the subsequent section of the part program must be
programmed in one main block.
The main blocks are to be designated with a Main Block No. consisting of the sign ":" and a
positive whole number (block number).
References:
Programming Manual, Fundamentals; Fundamentals of NC Programming, Language
Elements of the Programming Language

Activation
Activation of the block search from the last main block is performed using the RESU-specific
machine data:
MD62575 $MC_RESU_SPECIAL_FEATURE_MASK_2, bit 0 (additional RESU features)

Bit Value Meaning

0 0 Retrace support is performed using block search with calculation on contour.
1 Retrace support is performed using block search from the last main block.

Special functions
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19.7 Function-specific display data

Supplementary conditions
In order that a new retrace support operation can take place following a retrace support
operation with block search from last main block, the RESU start CC_PREPRE(1) must be
programmed in the retrace support ASUB "CC_RESU_BS_ASUP.SPF".
Programming example:

PROC CC_RESU_BS_ASUP SAVE

; (synchronized actions, M functions, etc. required for retrace support
)
CC_PREPRE(1)
RMN
REPOSA
M17

19.7 Function-specific display data

19.7.1 Channel-specific GUD variables

As display data for the size of the block search buffer, RESU provides the following channel-
specific GUD variables:

GUD variable Meaning Value Access

CLC_RESU_LENGTH_BS_BUFFER Size of block search buf‐ Byte read only
fer

After the startup of the technological function, the GUD variable is not displayed automatically
on the operator panel.

Creating and displaying the GUD variable

Perform the following steps to create and display the GUD variables in the operator panel:
1. Set password:
The password of protection level 1 (machine manufacturer) is to be input.
2. Activate the "Definitions" display
3. The file is recreated if an "SGUD.DEF" file is still not available:
Name: SGUD
Type: Global data /system
Confirm entry with OK.
This opens the file in the editor.
4. Edit the GUD variable definitions:
DEF CHAN REAL CLC_RESU_LENGTH_BS_BUFFER
M30
5. Save the file and close the editor.
6. Activate the "SGUD.DEF" file.

Special functions
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19.9 Boundary conditions

The GUD variable is not displayed on the operator panel.

Note
The new GUD variable, which is already being displayed, will be detected by the RESU function
and supplied with an up-to-date value only following an NCK POWER ON Reset. Hence, a
NCK POWER-ON must be initiated after the creation.

References
The exact procedure to be following while creating and displaying GUD variables depends on
the software version of the existing operator panel and is described in the:
● Operating Manual

19.8 Function-specific alarm texts

For details of the procedure for creating function-specific alarm texts, see Section "Creating
alarm texts (Page 579)".

19.9 Boundary conditions

19.9.1 Function-specific supplementary conditions

19.9.1.1 Continue machining within subprograms

Subprogram call outside or inside a program loop

Clear retrace support within subprograms depends on whether the subprogram call is made
outside or inside a program loop:
● Outside
Clear retrace support is possible if a subprogram is called outside a program loop.
● Inside
Clear retrace support may not be possible if a subprogram is called inside a program loop
(see Section "Continue machining within program loops (Page 748)").

Number of passes P
Subprogram repetitions using number of passes P are taken into account for retrace support.
This means that retrace support is performed in the part program with the correct reference to
the part program block and number of passes P to the program continuation point of the contour.

Special functions
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19.9 Boundary conditions

19.9.1.2 Continue machining within program loops

In NC high-level language, program loops can be programmed using:

● LOOP ENDLOOP
● FOR ENDFOR
● WHILE ENDWHILE
● REPEAT UNTIL
● CASE/IF-ELSE-ENDIF in conjunction with GOTOB

WARNING
Risk of collision
Significant contour deviations can occur during the machining if the programmed continuation
point at the programmed contour is the result of a loop run that is not equal to the first loop
run.
If retrace support is performed within program loops, the retrace support is always effective
in the first loop run.

19.9.1.3 Machining continuation on full circles

In full circles, the block starting and end points coincide at one contour point. As no clear
differentiation is possible in this case, one always starts from the block start point during
machining continuation on this kind of a contour point. The first part program block following
retrace support is then the circular block.
A contour point just before the block end point of the circular block must be selected to avoid
traversing the circular block after the machining continuation.

19.9.1.4 Automatically generated contour elements

The automatic generation of non-linear / non-circular contour elements by the NC takes place,
for example, when programming the following NC functions in the part program:
● RND
● G641/G642
● Tool radius compensation
For reverse / forward travel as part of RESU these contour elements can be replaced by straight
lines between the start and end of the block.

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19.9 Boundary conditions

19.9.2 Supplementary conditions for standard functions

19.9.2.1 Axis replacement

As long as RESU is active, the two geometry axes of the RESU working plane (e.g. the 1st
and 2nd geometry axes of the channel) must not be transferred to another channel via axis
replacement ( RELEASE(x)/GET(x)).
The RESU activity:
● Starts:
– with the part program command CC_PREPRE(1)
● Ends with:
– the program end
or
– with the part program command CC_PREPRE(-1)

19.9.2.2 Traversing movements of the channel axes

Other channel axes, except the two geometry axes of the RESU working plane, are not
considered by RESU.
If traversing movements in other channel axes are required for machining continuation or
reverse travel, these can either be undertaken by the machined operator manually, or
programmed as travel block in the RESU-specific subroutine "CC_RESU_INI.SPF".

WARNING
Risk of collision when traversing
The machine operator must ensure that collision of the associated traversing movements
does not take place during the entire machining continuation operation within the framework
of the technological function of RESU.

19.9.2.3 Block numbers

The following RESU-specific subroutines and their subroutines must not contain block
numbers:
● CC_RESU_INI.SPF
● CC_RESU_END.SPF
The following alarm appears in the event of an error:
Alarm 75604 "Reverse travel not possible, error no. number"

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19.9 Boundary conditions

19.9.2.4 Block search

Block search with calculation

RESU is subject to the following constraints in the context of the "block search with calculation
(on contour/at end of block") standard function:
● The last block of the RESU part program command CC_PREPRE(x) run during the block
search is effective in the target block.
● The retraceable contour range starts with the REPOS approach block.

Block search without calculation

RESU part program commands CC_PREPRE(x) haveno effect in the "block searches without
calculation" function.

19.9.2.5 Transformations
RESU can also be used for active kinematic transformation (e.g. 5-axis transformation) subject
to restrictions, as the traversing movements of the two geometry axes of the RESU working
plane are recorded in the basic coordinate system (BCS) and therefore before the
transformation (see also Section "TE4: Handling transformation package - 840D sl only
(Page 659)").

Transformation changeover
While RESU is active, no transformation changes are permitted to take place and
transformation must not be activated/deactivated.
The RESU activity:
● Starts:
– with the part program command CC_PREPRE(1)
● Ends with:
– the program end
or
– with the part program command CC_PREPRE(-1)

References
A full description of the transformations is available in:
Function Manual, Extended Functions; Kinematic Transformation (M1)

19.9.2.6 Compensations
RESU can be used in interaction with compensations, because the traversing movements of
the two geometry axes of the RESU working plane is recorded in the basic coordinate system
(BCS) and therefore before the compensation.

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19.9 Boundary conditions

A full description of the compensations can be found in:

References:
Function Manual, Extended Functions; Compensations (K3)

19.9.2.7 Frames
RESU can be used in conjunction with frames.
However, as the traversing movements of the two geometry axes of the RESU working plane
are recorded in the basic coordinate system (BCS) and therefore after the frames have been
taken into account, the frame offsets must be deactivated during retrace support (reverse /
forward travel).
The frame offsets are deactivated during retrace support via the standard default settings of
the RESU-specific subprogram "CC_RESU_INI.SPF" (see Section: "INI program
(CC_RESU_INI.SPF) (Page 738)").
A full description of the frames can be found in:
Reference:
Function Manual, Basic Functions; Axes, Coordinate Systems, Frames (K2)

19.9.2.8 Tool offsets

RESU can be used in conjunction with tool offsets.
However, as the traversing movements of the two geometry axes of the RESU working plane
are recorded in the basic coordinate system (BCS) and therefore after the tool offsets have
been taken into account, the tool offsets must be deactivated during retrace support (reverse /
forward travel).
The tool offsets are deactivated during retrace support via the standard default settings of the
RESU-specific subprogram "CC_RESU_INI.SPF" (see Section "INI program
(CC_RESU_INI.SPF) (Page 738)").
Specific instances of tool radius compensation, e.g. compensation on outside corners
G450 DISC=x may generate contour deviations between the contour traversed during retrace
support and the contour programmed in the machining program.
Contour deviations are always generated if tool radius compensation produces contour
elements that are non-linear or circular. For example, G450DISC=x, where x > 0 produces
parabolic or hyperbolic contour elements.
A full description of the tool radius compensation can be found in:
Reference:
Function Manual, Basic Functions; Tool Compensation (W1)

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19.10 Data lists

19.10 Data lists

19.10.1 Machine data

19.10.1.1 General machine data

Number Identifier: $MN_ Meaning

11602 ASUP_START_MASK Ignore stop reasons if an ASUB is running.
11604 ASUP_START_PRIO_LEVEL Defines the ASUB priority from which MD11602 is effec‐
tive.
18351 MM_DRAM_FILE_MEM_SIZE Size of the part program memory in DRAM (in kByte)

19.10.1.2 Channelspecific machine data

Number Identifier: $MC_ Description

20050 AXCONF_GEOAX_ASSIGN_TAB Assignment 'geometry/channel axis'
24120 TRAFO_GEOAX_ASSIGN_TAB_1 Assignment of geometry - channel axes for transforma‐
tion 1
28090 MM_NUM_CC_BLOCK_ELEMENTS Number of block elements for compile cycles (CC)
28100 MM_NUM_CC_BLOCK_USER_MEM Size of block memory for CC in KB
28105 MM_NUM_CC_HEAP_MEM Heap memory in KB for CC applications (DRAM)
62571 RESU_RING_BUFFER_SIZE Size of ring buffer (RESU-internal block buffer)
62572 RESU_SHARE_OF_CC_HEAP_MEM RESU portion of the total CC heap memory
62573 RESU_INFO_SA_VAR_INDEX Indices of the synchronized action variables
62574 RESU_SPECIAL_FEATURE_MASK Additional RESU features
62575 RESU_SPECIAL_FEATURE_MASK_2 Additional RESU properties
62580 RESU_WORKING_PLANE Selection of the RESU working plane

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20.1 Brief description

Function
The "Cycle-independent path synchronized switching signal output" technological function
serves the purpose of switching time-critical, position-based machining processes on and off
quickly, e.g. high speed laser cutting (HSLC; High Speed Laser Cutting).
The switching signal output can be block-related or path length-related:
● Block-related switching signal output
The switching signal output and therefore, the activation / deactivation of the machining is
undertaken independently of the status changes:
– Rapid travel mode G00 active / inactive
– Programmed feed threshold fell short / exceeded
● Path length-related switching signal output
The switching signal output and therefore, the activation / deactivation of the machining
takes place in a continuous change and is monitored along the traversed path.
This enables a regular machining without the individual switching positions having to be
programmed explicitly.
The activation or selection of the mentioned options leads to the monitoring of the output of
the digital signal which is programmed with a part program command.

I/Os
Only the on-board I/Os of the NC module can be used as the digital I/O via which the switching
signal is output: The switching signal can only be output via one of the 4 on-board digital outputs
on the NCU module.

Restrictions
The use of the "Cycle-independent path synchronized switching signal output" technological
function is subject to the following restriction:
● The technological function is available only in one channel of NC.

References
The "cycle-independent path-synchronous switching signal output" technological function is a
compile cycle. For the handling of compile cycles, see Section "TE01: Installation and
activation of loadable compile cycles (Page 573)".

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20.2 Functional description

20.2 Functional description

20.2.1 General information

Note
The functionality is described with examples, with the help of the "High speed laser cutting
technology (HSLC, High Speed Laser Cutting).

20.2.2 Calculating the switching positions

20.2.2.1 Block-related switching signal output

Switching criteria
During high-speed laser cutting, e.g. as used to manufacture perforated sheets, it is absolutely
essential to switch the laser beam on/off exactly at the programmed setpoint positions during
the machining process.
In order to minimize programming overheads, the switching positions of the technology
function are calculated using the velocity of the geometry axes programmed in the part program
block.
The following criteria define the setpoint position programmed in the part program block (end
of block position) as a switching position:
1. G0 edge change
2. Overshooting/undershooting a freely programmable velocity threshold

G0 edge change as switching criterion

If G0 (rapid traverse) is active in a part program block (programmed or modal), the switching
signal is switched off. On the other hand: If G0 (rapid traverse) is not active in a part program
block, the switching signal is switched on. The G0 edge change marks the programmed end
of block position of the previous block as the switching position.
Example:

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20.2 Functional description

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The following block positions function as switching positions:

● Position X30 for G0-edge change from N10 to N20
● Position X100 for G0-edge change from N30 to N40

Freely programmable velocity threshold value as switching criterion

A freely programmable velocity threshold value is used to define the setpoint velocity
programmed in the part program block at and above which the switching signal is activated/
deactivated.
● If the setpoint velocity programmed in the part program block is above the programmed
threshold, the switching signal is switched off.
● If the setpoint velocity is at or below the threshold value, the switching signal is switched
on.
The edge change marks the programmed end of block position of the previous block as the
switching position.
Example:

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20.2 Functional description

The following block positions function as switching positions:

● Position X30 for edge change from N10 to N20
● Position X70 for edge change from N20 to N30
Note
G0 always deactivates the switching signal, regardless of the threshold value.

20.2.2.2 Path length-related switching signal output

Programmable paths as the switching criterion

In path-related switching signal output, the switching positions are defined with the help of the
two freely programmable paths s1 and s2.

Functional sequence
The path length-related switching signal output starts with a switch on signal at the beginning
of the first traversing block after activation with CC_FAST_CONT (refer to ① in the screen).
The processing is active till a deactivation signal is set after the traversing of a programmable
path s1 (refer to ② in screen). This way the processing is interrupted till a switch on signal is
set again after the traversing of a programmable path s2 (refer to ③ in screen).
The changeover between activation and deactivation signal, and therefore between processing
and interruption phase is path length dependent at the end of either of the stretch sections s1
and s2. This enables a continuous and regular machining without the individual switching
positions having to be programmed explicitly.
The path length-related switching signal output ends with the start of the first traversing block
(or of another executable block) after deactivation with CC_FASTOFF (refer to ④ in screen).

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Figure 20-1 Path length-related switching signal output

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20.2 Functional description

20.2.3 Calculating the switching instants

In order for the switching to be as precise as possible at the switching positions calculated,
the control calculates the positional difference between the actual position of the geometry
axes involved and the switching difference in every position controller cycle.
If the positional difference is less than 1.5 position controller cycles, the control converts it into
a temporal difference taking into account the current path velocity and acceleration rate of the
geometry axes.
With the temporal difference specified, a hardware timer is started, which triggers the switching
signal at exactly the instant calculated in advance regardless of the position controller cycle.

20.2.4 Switching frequency and switching position distance

Maximum switching frequency

The maximum switching frequency is: 1 signal edge change per IPO cycle

Note
Special case: IPO cycle time = position controller cycle time
In this case, the maximum switching frequency is:
1 signal edge change per 2 IPO cycles

Minimum switching position clearance

The minimum possible distance between the switching positions placed one above the other
depends on:
● The duration of an IPO cycle
● The feed rate
The theoretically possible minimum distance can be determined from these dimensions as
follows:

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Example:
For IPO cycle times of 2 ms and position controller cycle times of 1 ms as well as a feed rate
of 20000 mm/min, the theoretically possible minimum distance between switching positions
one above the other is limited to:
20000 mm/min * 2 ms = 0.667 mm

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20.2 Functional description

Value below minimum switching position distance

For path length-related switching signal output, the value may fall below the minimum switching
position distance, e.g. due to:
● Increase in feed rate
● Decrease in programmable switching position distance s1 and s2
The following reactions take place if the value falls below the minimum:
● Alarm 75501 "Channel %1 HSLC: CC_FASTON_CONT speed too high" is displayed.
● The switching signal at the current switching position is omitted. To maintain the machining
rhythm, the function also suppresses the switching signal at the following switching position.
The position of all the following switching positions is not affected by this. In the further
course of the path, one can witness alternating output and suppression of two switching
signals following each other.

20.2.5 Approaching switching position

If in block-related switching signal output a switching position is not reached exactly, e.g. in
continuous-path mode and travel in more than one geometry axis, then switching takes place
at the instant at which the positional difference between the actual position of the geometry
axes involved and the programmed switching position increases again.

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Figure 20-2 Switching position offset in path control mode

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20.2 Functional description

20.2.6 Programmed switching position offset

Programmed switching position offset

For block-related switching signal output, a positional offset of the switching position can be
programmed :
● Offset distance negative = lead
With a negative offset distance, the switching position is offset before the set point position
programmed in the part program block.
If an excessively large negative offset distance is programmed, i.e. the setpoint has already
been exceeded by the time the edge is detected, the signal is switched immediately.
● Offset distance positive = follow-up
With a positive offset distance, the switching position is offset behind the set point position
programmed in the part program block.

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Figure 20-3 Programmed switching position offset

Path reference
The offset distance is a positional specification that refers to the programmed path. This way
one can start from a simplified linear motion. Path curves are not taken into account.

Response to single block and G60

Due to the internal motion logic, negative offset distances (lead) have no effect when used
with the following standard functions:
● Single Block
● Exact stop at block end (G60)

20.2.7 Response to part program interruption

Following an interruption in the part program (NC-STOP) and subsequent change to JOG
mode, the technological function is deactivated or switching signals cease to be output.
The technology function is reactivated or switching signals are output again only after switching
to the AUTOMATIC mode and continuing the part program (NC-START).

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20.3 Startup

20.3 Startup

20.3.1 Activation
Before commissioning the technological function, ensure that the corresponding compile cycle
has been loaded and activated (see also Section "TE01: Installation and activation of loadable
compile cycles (Page 573)").

Activation
The "Cycle-independent path synchronized switching signal output" technology function is
activated via the following machine data:
MD60948 $MN_CC_ACTIVE_IN_CHAN_HSLC[0], Bit 0 = 1

Note
The "Cycle-independent path-synchronized switching signal output" is available only in one
channel of NC.

20.3.2 Memory configuration

The technological function requires additional data in the NCK-internal block memory. The
values must be increased for the following memory configuring channel-specific machine data:
● MD28090 $MC_MM_NUM_CC_BLOCK_ELEMENTS += 1 (number of block elements for
compile cycles)
● MD28100 $MN_MM_NUM_CC_BLOCK_USER_MEM += 10 (size of block memory for
compile cycles (DRAM) in KB)

20.3.3 Parameterizing the digital on-board outputs

Parameter assignment
A digital output from the local I/O is required for the switching signal.
For this, at least 1 digital output byte must be defined through the following machine data:
MD10360 $MN_FASTIO_DIG_NUM_OUTPUTS ≥ 1 (number of active digital output bytes)

References
A full description of the parameterization of a digital output can be found in:
● Function Manual, Extended Functions, Digital and Analog NCK I/Os (A4)

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20.3 Startup

20.3.4 Parameterizing the switching signal

Output number of the switching signal

Once the compile cycle has started up, the following function-specific machine data appears
in the channel-specific machine data:
MD62560 $MC_FASTON_NUM_DIG_OUTPUT (number of the digital output of the switching
signal)
The number n of the on-board digital output through which the switching signal is to be output,
must be entered in it:
n = 1, 2, 3 or 4

Disable
Entering the number of the digital output n = 0 deactivates the function. No message or alarm
is output.

Effect on other output signals

The hardware-timer-controlled output of the switching signal at the parameterized output
delays the signal output for the other digital on-board outputs, e.g. due to synchronized actions,
by 2 IPO cycles.

20.3.5 Parameterization of the geometry axes

Standard setting
Machines for high-speed laser cutting normally have two geometry axes that are configured
in the following two machine data:
MD20050_$MC_AXCONF_GEOAX_ASSIGN_TAB[0]
MD20050_$MC_AXCONF_GEOAX_ASSIGN_TAB[1]
The calculation of the switching instants is derived from these two geometry axes.

Note
The configured axis selection for calculating the switching instants can be changed by
redefining the first and second geometry axes in the part program with the help of program
instructions GEOAX(1,<axis name>) and GEOAX(2,<axis name>).
Important:
For the function change to be considered correctly, it should occur before the interpretation of
the CC_FASTON command.

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20.4 Programming

Changing the default setting

For a deviating machine configuration (e.g. definition of a third geometry axis), the default
setting can be adjusted via the following machine data:
MD60948 $MN_CC_ACTIVE_IN_CHAN_HSCL[1]

Value Meaning
$MN_CC_ACTIVE_IN_CHAN_HSCL[1]='H3' Default setting.
The calculation of the switching instants is derived
from the first and second geometry axis.
$MN_CC_ACTIVE_IN_CHAN_HSCL[1]='H7' The calculation of the switching instants is derived
from the first, second and third geometry axis.

Any change is effective only after the next NCK booting.

20.4 Programming

20.4.1 Activating the block-related switching signal output (CC_FASTON)

Syntax
CC_FASTON (DIFFON, DIFFOFF [,FEEDTOSWITCH])
CC_FASTON() is a procedure call and must therefore be programmed in a dedicated part
program block.

Parameter
The parameters for the CC_FASTON() procedure have the following meaning:

Parameter Meaning
<DIFFON> Length* of the offset distance for setting the switching signal.
<DIFFOFF> Length* of the offset distance for deactivating the switching signal.
<FEEDTOSWITCH> This parameter is optional.
If the parameter is not specified in the procedure call, the G0 edge change
is used as the switching criterion.
If the parameter is specified in the procedure call, it contains as a switching
criterion the velocity threshold value, which, when undershot or exceeded,
activates or deactivates the switching signal accordingly.
* The basic unit (inch or mm) depends on the current dimensions programming (G70 / G71 / G700 /
G710).

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20.4 Programming

Programming example
Programming Comment
DEF REAL DIFFON= -0.08 ; Length* of the offset distance for
activating the switching signal =
-0.08
DEF REAL DIFFOFF= 0.08 ; Length* of the offset distance for
deactivating the switching signal =
0.08
DEF REAL FEEDTOSWITCH= 20000 ; Speed threshold value = 20000
CC_FASTON(DIFFON,DIFFOFF,FEEDTOSWITCH) ; Activating block-related switching
signal output (with speed threshold
value as switching criterion)

Changing parameters
The parameters for the CC_FASTON() procedure can be modified at any time during the
execution of the part program. To do this, enter the procedure call again with the new parameter
values. The switching criterion (G0 edge change / velocity threshold value) may also be
changed.

Reset response
A reset (NC RESET or end of program) deactivates the function.

20.4.2 Activating the path length-related switching signal output (CC_FASTON_CONT)

Syntax
CC_FASTON_CONT (PATH_DISTANCE_ON, PATH_DISTANCE_OFF)
CC_FASTON_CONT() is a procedure call and must therefore be programmed in a dedicated
part program block.

Parameter
The parameters for the CC_FASTON_CONT() procedure have the following meaning:

Parameter Meaning
< PATH_DISTANCE_ON > Length* of the stretch section with machining (s1).
< PATH_DISTANCE_OFF> Length* of the stretch section without machining (s2).
* The basic unit (inch or mm) depends on the current dimensions programming (G70 / G71 / G700 /
G710).

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20.5 Function-specific alarm texts

Programming example
Programming Comment
DEF REAL PATH_DISTANCE_ON = 0.5 ; Length* of the stretch section with
machining = 0.5
DEF REAL PATH_DISTANCE_OFF = 1.0 ; Length* of the stretch section
without machining = 1.0
CC_FASTON_CONT (PATH_DISTANCE_ON, PATH_DISTANCE_OFF) ; Activating path
length-related
switching signal out-
put.

Changing parameters
The parameters for the CC_FASTON_CONT( ) procedure can be modified at any time during
the execution of the part program. For this, the procedure call must be specified again with the
new parameter values.

Reset response
A reset (NC RESET or end of program) deactivates the function.

20.4.3 Deactivation (CC_FASTOFF)

Syntax
CC_FASTOFF
CC_FASTOFF is a procedure call and must therefore be programmed in a dedicated part
program block.

Functionality
The CC_FASTOFF procedure call deactivates the "Cycle independent, path synchronized
switching signal output" function.

20.5 Function-specific alarm texts

For details of the procedure for creating function-specific alarm texts, see Section "Creating
alarm texts (Page 579)".

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20.6 Supplementary conditions

20.6 Supplementary conditions

20.6.1 Block search

Switching signal output for block search

If a block search is on a part program block which lies after a CC_FASTON() procedure call
for activating the technology function, then the switching signal is activated with the next
traversing motion. One of the specific consequences of this is to initiate travel along the contour
from the start position of the geometry axes back to the program continuation point with an
activated switching signal.

Example
Normal process:
In the normal process of the part program machining, the switching signal is activated for the
first time at the beginning of part program block N60.

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Process sequence after block search:

If a block search is executed for the block end point of part program block N60 the switching
signal is activated on reaching the start position of the geometry axes.

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20.6 Supplementary conditions

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Suppressing the switching signal output

The user (machine manufacturer) must take appropriate measures, e.g. disable the switching
signal, in order to suppress the activation of the switching signal in the REPOS block in the
constellation described above.

Note
It is the sole responsibility of the user (machine manufacturer) to suppress the output of the
switching signal during repositioning, e.g. after a block search.

References
You will find a description of the block search in:
Function Manual, Basic Functions, Mode Group, Channel, Program Operation, Reset Behavior
(K1)

20.6.2 Transformations
The function will only run correctly with deactivated transformation. There is no monitoring
function.
For a description of the transformations (see Section "TE4: Handling transformation package
- 840D sl only (Page 659)").
References:
Function Manual Extended Functions; Kinematic Transformation (M1)

Special functions
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20.6 Supplementary conditions

20.6.3 Compensations
The following compensations are considered while calculating the switching positions:
● Temperature compensation
● Sag compensation
A description of the compensations can be found in:
Reference:
Function Manual, Extended Functions; Compensations (K3)

20.6.4 Tool radius compensation (TRC)

As part of tool radius compensation, control-internal part program blocks (compensation
blocks) are inserted into the part program. With reference to the switching signal output, a
compensation block is always added to the next programmed part program block.
A description of the tool radius compensation can be found in:
Reference:
Function Manual, Basic Functions; Tool Compensations (W1), Section: Tool radius
compensation

20.6.5 Continuous-path mode

Continuous-path mode
Although the CC_FASTON(), CC_FASTON_CONT() and CC_FASTOFF procedure calls must
be programmed in dedicated part program blocks, this will not lead to a drop in velocity while
continuous-path mode is active (G64, G641, ...).

Continuous-path mode (ADIS)

If in continuous-path mode with programmable rounding response (G641 ADIS) a part
program block is inserted in the part program, then the originally programmed switching
position is not reached and the switching signal output takes place nevertheless in the center
of the rounding block.

References
You will find a description of the continuous-path mode in:
Function Manual, Basic Functions, Continuouspath Mode, Exact Stop and Look Ahead (B1)

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20.7 Data lists

20.6.6 Software cams

Because the hardware timer is also used for the "software cam" function, it is not possible to
use the "clock-independent switching signal output" function with software cams at the same
time.
The following alarm appears in the event of an error:
Alarm 75500 "Channel Channel No., wrong configuration of function: clock-independent
switching signal output"
A description of the software cams can be found in:
Reference:
Function Manual, Extended Functions; Software cams, Position switching signals (N3)

20.7 Data lists

20.7.1 Machine data

20.7.1.1 General machine data

Number Identifier: $MN_ Description

10360 FASTO_NUM_DIG_OUTPUTS Number of digital output bytes

20.7.1.2 Channelspecific machine data

Number Identifier: $MC_ Description

20050 AXCONF_GEOAX_ASSIGN_TAB Assignment of geometry axis to channel axis
28090 MM_NUM_CC_BLOCK_ELEMENTS Number of block elements for CC
28100 MM_NUM_CC_BLOCK_USER_MEM Size of block memory for CC
62560 FASTON_NUM_DIG_OUTPUT Number of the on-board digital output for the switching
signal

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21.1 Brief description

21.1.1 Brief description

Function
The "axis pair collision protection" function enables machine axes, which are arranged on the
same guide element of a machine, to be monitored in pairs to ensure that no collisions occur
and that the maximum distance between the two axes is not exceeded.

Function code
The code for function-specific identifiers of machine data, system variables, etc., is:
PROTECT (axial collision PROTECTion)

References
The "axis pair collision protection" function is realized as compile cycle. For the handling of
compile cycles (see Chapter "TE01: Installation and activation of loadable compile cycles
(Page 573)".

21.2 Functional description

The "axis pair collision protection" function is a protection function for machine axes which are
arranged in a machine tool in such a way (on the same guide rail, for example) that incorrect
operation or programming could cause them to collide with one another.
The machine axes are always monitored in pairs, i.e. parameters always need to be assigned
for two machine axes in each case, which are then monitored in relation to one another. The
machine axes being monitored may be located in different machine coordinate systems.

Collision protection
The function uses the current actual positions and actual velocities, as well as the offset for
the machine coordinate systems and the axis-specific brake acceleration values, to calculate
the distance between the standstill positions of the machine axes, on a cyclical basis. If the
resulting distance is shorter than the protection window that has been set, the machine axes
are decelerated to a standstill. This ensures that the minimum distance defined using the
protection window is not undershot.

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21.3 Startup

Distance monitoring
If the offset vector is selected accordingly, the function can also be used to monitor the
maximum distance between the two machine axes (maximum distance vector).

0DFKLQHD[LV$ 0DFKLQHD[LV$

0LQLPXPFOHDUDQFHYHFWRU

$FWXDOFOHDUDQFHYHFWRU

0D[LPXPFOHDUDQFHYHFWRU
0&6B$ 0&6B$
 

0&6BRIIVHWYHFWRU

Figure 21-1 Basic design

Monitoring status
The actual status of an axis pair can be read out of _PROTECT_STATUS (Page 775),
optionally defined global user variables in the NC program (GUD).

21.3 Startup

21.3.1 Enabling the technology function (option)

The function is enabled using the option data:
MD19610 $ON_TECHNO_EXTENSION_MASK[ 2 ], BIT4 = 1

21.3.2 Activating the technology function

Before commissioning the function, ensure that the corresponding compile cycle has been
loaded and activated (see also Chapter "TE01: Installation and activation of loadable compile
cycles (Page 573)").

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21.3 Startup

Channel-specific activation
The function must be activated in the following NC channels:
● Always in the 1st channel of the NC
● All channels that are assigned – with the appropriate machine data parameterization – to
machine axes to be monitored
● All channels, which are assigned at a later point in time, e.g. through axis interchange, to
machine axes to be monitored
The function is activated on a channel-specific basis using machine data:
MD60972 $MN_CC_ACTIVE_IN_CHAN_PROT[0], bit n = 1
with bit n = 1: Activation in the (n+1)th channel of the NC, with n = 0, 1, 2, ...

21.3.3 Definition of an axis pair

Definition
A pair of machine axes to be monitored is defined in the following item of machine data:
MD61516 $MN_CC_PROTECT_PAIRS[<axis pair>] = <yyxx>
<axis pair>: Axis pair index, with n = 0, 1, 2, ... (maximum number of axis pairs - 1)

<yyxx> Meaning
xx 1. and 2nd decimal place ⇒ axis number of the 1st machine axis
yy 3. and 4th decimal place ⇒ axis number of the 2nd machine axis

Boundary conditions

Maximum number of axis pairs

A maximum of 12 axis pairs can be defined.

Axis number
The axis number m of a machine axis relates to machine data MD10002
$MN_AXCONF_LOGIC_MACHAX_TAB[ i ] where i = (m - 1).

Same axis types

The machine axes in an axis pair must be of the same axis type: Linear axis or rotary axis.

Modulo rotary axes

It is not permissible that machine axes of an axis pair are modulo rotary axes
● MD30300 $MA_IS_ROT_AX = 1 (rotary axis)
● MD30310 $MA_ROT_IS_MODULO = 0 (! OK, no modulo rotary axis !)

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21.3 Startup

21.3.4 Retraction direction

The direction of travel for retracting the corresponding machine axis is entered in the following
item of machine data:
MD61517 $MN_CC_PROTECT_SAFE_DIR[<axis pair>] = <yyxx>

<yyxx> Meaning
xx Retraction direction for the 1st axis pair
yy Retraction direction for the 2nd axis pair
Retraction in the positive direction of travel of the machine axis: xx or yy > 0
Retraction in the negative direction of travel of the machine axis: xx or yy = 0

Note
Machine data change
Machine data $MN_...SAFE_DIR[<axis pair>] may only be made changed for an axis pair, if
the protection function for this axis pair is not active ($MN_...PAIRS[<axis pair>] = 0).

21.3.5 Offset for the machine coordinate systems

The offset vector for the machine coordinate systems of both machine axes in the axis pair is
specified in the following item of machine data:
MD61518 $MN_CC_PROTECT_OFFSET[<axis pair>] = <offset vector>
If both machine axes are located in separate machine coordinate systems, the offset vector is
specified as a vector from the origin of the machine coordinate system for the 2nd axis of the
axis pair to the origin of the machine coordinate system for the 1st axis, with reference to the
machine coordinate system for the 1st axis.
If both machine axes are located in the same machine coordinate system, an offset vector of
0 must be specified.

$FKVH $FKVH


0.6 0.6


9 

 9 

① Case 1: Equidirectional MCS orientation

② Case 2: Counterdirectional MCS orientation
V Offset vector

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21.3 Startup

Note
Machine data change
Machine data $MN_...OFFSET[<axis pair>] may only be made changed for an axis pair, if the
function for the axis pair is not active ($MN_...PAIRS[<axis pair>] = 0).

21.3.6 Protection window

Using the machine data, the minimum clearance is defined, which the axes of an axis pair
must not fall below:
MD61519 $MN_CC_PROTECT_WINDOW[<axis pair>] = <minimum clearance>
The axes are braked, if the axis clearance approaches the minimum clearance.
For instance, in the part program, the protection window can be dynamically expanded
(Page 774).

Note
Machine data change
A change to machine data $MN_...WINDOW[<axis pair>] may also be activated when the
($MN_...PAIRS[<axis pair>] ≠ 0) function is activated.

21.3.7 Orientation
The orientation of the axes of the axis pair to one another is specified in the following machine
data:
MD61532 $MN_CC_PROTECT_DIR_IS_REVERSE[<axis pair>] = <value>

<value> Meaning
0 Equidirectional orientation
1 Counterdirectional orientation

Note
Machine data change
A change to machine data item $MN_... DIR_IS_REVERSE[<axis pair>] must only be activated
when the function is inactive ($MN_...PAIRS[n] = 0).

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21.3 Startup

21.3.8 Protection window extension

The protection window can be expanded using the protection window (Page 773) extension
function. The protection window extension is set in the following item of machine data:
MD61533 $MN_CC_PROTECT_WINDOW_EXTENSION[<axis pair>] = <extension>
The resulting effective protection window of an axis pair is as follows:
Effective protection window = $MN_...WINDOW (protection window) +
$MN_...WINDOW_EXTENSION (protection window extension)

Note
Machine data change
A change to machine data item $MN_...WINDOW_EXTENSION[<axis pair>] may also be
made when the protection function is active, for example, from the part program and activated
when "NewConfig" is initiated.

21.3.9 Activating the protection function

The function is active if the following conditions are met:
● A valid machine axis pair is entered in machine data $MN_...PAIRS[<axis pair>]
● Machine data $MN_...PAIRS[<axis pair>] is active
● Both machine axes of the axes pair have been referenced
If, at the time when the protection function is activated, the distance between the two machine
axes is shorter than the minimum distance for which parameters have been assigned, the
machine operator must retract the machine axes. Traversing motion towards each other is
prevented.

21.3.10 Axis-specific acceleration

The acceleration of one machine axis, braked using the function "axis pair collision protection"
when approaching the other axes of the axis pair, is set using:
MD63514 $MA_CC_PROTECT_ACCEL[<axis>] = <acceleration>
with <axis>: Machine axis name, e.g. AX1, AX2, ...

Note
Without jerk limitation
The acceleration set in MD63514 is always effective without jerk limitation.

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21.3 Startup

21.3.11 Monitoring status (GUD)

The actual status of one axis pair is displayed using the global user variable
_PROTECT_STATUS. The system variable is not available as standard default setting. When
required, it must be defined in the GUD.DEF definition window.

Definition
DEF NCK INT _PROTECT_STATUS[<number of parameterized axis pairs> ]
with <number of parameterized axis pairs> = 1, 2, ... (maximum number of axis pairs
(Page 771) - 1)

Range of values

Value Meaning: The monitoring of the axis pair is ...

0 Not active
1 selected, but not yet active
2 active, the axes are currently not being braked
3 active, the axes are currently being braked
4 deselected, however still active

21.3.12 PLC interface for axis-specific braking operations

Using the following machine data, within the general system variable field $A_DBD, a double
word (four bytes) can be defined as axis-specific interface to the PLC. When the axes of the
axis pair approach one another, the braking of the machine axes is displayed via this interface.
$MN_CC_PROTECT_A_DBD_INDEX = <value>

<value> Meaning
-1 Deactivation of the output.
≥0 Starting index of the interface within the system variable field $A_DBD in byte (0, 1, 2, ... )

Note
Double word index
The starting index can be specified in the machine data, byte-by-byte (0, 1, 2, ...). System
variable $A_DBD is accessed from the PLC using a double word. This means that a starting
index, which is not located at a double word boundary (0, 4, 8, ...), is rounded off to the next
double word boundary: Index = (index DIV 4) * 4
Examples: 3 ⇒ 0; 5 ⇒ 4; 10 ⇒ 8;

Interface
Each interface bit is assigned a machine axis:

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21.4 Limitations and constraints

Bit n → (n+1)th machine axis, with n = 0, 1, 2, ...

Bit n Meaning
0 Machine axis (n+1) is not braked
1 Machine axis (n+1) is braked

21.4 Limitations and constraints

21.4.1 Precedence of function-specific acceleration

The function only uses the function-specific acceleration of the machine axes MD63514
$MA_CC_PROTECT_ACCEL (Page 774) to calculate the time at which the axis should be
braked. This means that the protection function does not take the actual acceleration of the
machine axis in the channel into account.

Note
Path reference
If machine axes being monitored by the function are traversed by a channel with a path
reference to other axes, this path reference is lost as soon as the protection function causes
the axis grouping to decelerate. The machine axes being monitored by the function are braked
using their function-specific acceleration values from machine data item MD63514
$MA_CC_PROTECT_ACCEL. The remaining axes in the axis grouping are decelerated using
the current path acceleration value of the channel.

21.4.2 Axis container

If the assignment of the machine axes to be monitored changes dynamically during the course
of a machining process – for example when using axis containers – the function must be
deactivated, its parameters reassigned, and then reactivated prior to the change (e.g. axis
container rotation) being made.

Example
The protection function is to monitor logical machine axes 1 and 13. These relate to slots 1
and 2 of axis container CT1. The associated real machine axes are AX1 and AX13.
In an axis container rotation, the axis container makes a transition by one step, which causes
the real machine axes to be changed.
Machine axis AX13 is retracted in the positive direction of travel. Machine axis AX1 is retracted
in the negative direction of travel.

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21.4 Limitations and constraints

Assigning parameters for the NC

Logical machine axes: axis numbers 1 and 13
● MD10002 $MN_AXCONF_LOGIC_MACHAX_TAB [ 0 ] = "CT1_SL1" (log. mach. axis 1)
● MD10002 $MN_AXCONF_LOGIC_MACHAX_TAB [ 12 ] = "CT1_SL2" (log. mach. axis 13)
Axis container CT1, slot 1 and slot 2
● MD12750 $MN_AXCT_NAME_TAB[ 0 ] = "CT1"
● MD12701 $MN_AXCT_AXCONF_ASSIGN_TAB1[ 0 ] = "AX1" (slot 1)
● MD12701 $MN_AXCT_AXCONF_ASSIGN_TAB1[ 1 ] = "AX13" (slot 2)
Real machine axes: machine axis names AX1 and AX13
● MD10000 $MN_AXCONF_MACHAX_NAME_TAB[ x ] = "AX1"
● MD10000 $MN_AXCONF_MACHAX_NAME_TAB[ y ] = "AX13"
Parameterizing the "axis pair collision protection" function before axis container rotation
● MD61516 $MN_CC_PROTECT_PAIRS[0] = 01 13
● MD61517 $MN_CC_PROTECT_SAVE_DIR[0] = 01 00
Performing the axis container rotation
1. Deactivate the protection function
MD61516 $MN_CC_PROTECT_PAIRS[0] = 00 00
2. Trigger a reset in the 1st NC channel in order to adopt the change made to the machine
data
MD60972 $MN_CC_ACTIVE_IN_CHAN_PROT[0], BITx, ...
3. Execute the axis container rotation
AXCTSWED(CT1)
Re-parameterizing the "axis pair collision protection" function after axis container rotation:
● MD61516 $MN_CC_PROTECT_PAIRS[0] = 13 01
● MD61517 $MN_CC_PROTECT_SAFE_DIR[0] = 01 00
or
● MD61516 $MN_CC_PROTECT_PAIRS[0] = 01 13
● MD61517 $MN_CC_PROTECT_SAFE_DIR[0] = 00 01
Trigger a "reset" in the 1st NC channel in order to adopt the change made to the machine data.

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21.5 Examples

21.4.3 Interpolatory couplings

Assumption
1. A machine axis is part of an interpolatory coupling, e.g.:
– Generic coupling (CP)
– Coupled motion(TRAIL)
– Master value coupling (LEAD)
– Electronic gear (EG)
– Synchronous spindle(COUP)
2. The machine axis is not traversed in the first channel of the NC.
3. The machine axis is monitored using the "axis pair protection" function.

Effect
If the machine axis is not traversed in the first channel of the NC, then the components, created
from the interpolatory couplings for the position and velocity setpoint are only available after
a deadtime of one interpolator clock cycle of the "axis pair collision protection" function.
Therefore, the machine axes are monitored, offset by these components. The absolute value
of the components is independent of the interpolator clock cycle and the actual velocity and
acceleration of the machine axis.

21.5 Examples

21.5.1 Collision protection

The figure shows the arrangement of 3 machine axes and the offset and orientation of the
machine coordinate systems (machine).

$ $ $

0&6B$ 0&6B$ 0&6B$

  

0&6BRIIVHWYHFWRU  0&6BRIIVHWYHFWRU 

Figure 21-2 Collision protection for 2 axis pairs

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21.5 Examples

Parameter assignment: Protection function 1

Axis pair: 1st machine axis A3, 2nd machine axis A1
● MD61516 $MN_CC_PROTECT_PAIRS[0] = 01 03
Retraction direction: A1 in negative direction, A3 in positive direction
● MD61517 $MN_CC_PROTECT_SAFE_DIR[0] = 00 01
Offset vector from machine coordinate system machine_A1 to machine_A3 with reference to
machine_A3
● MD61518 $MN_CC_PROTECT_OFFSET[0] = 70.0
Example protection window, 10.0 mm
● MD61519 $MN_CC_PROTECT_WINDOW[0] = 10.0
Orientation of the machine coordinate systems to one another: same direction
● MD61532 $MN_CC_PROTECT_DIR_IS_REVERSE[0] = 0
Protection window extension: none
● MD61533 $MN_CC_PROTECT_WINDOW_EXTENSION[0] = 0.0

Parameter assignment: Protection function 2

Axis pair: 1st machine axis A1, 2nd machine axis A12
● MD61516 $MN_CC_PROTECT_PAIRS[1] = 12 01
Retraction direction: A12 in positive direction, A1 in positive direction
● MD61517 $MN_CC_PROTECT_SAFE_DIR[1] = 01 01
Offset vector from machine coordinate system machine_A12 to machine_A1 with reference to
machine_A1
● MD61518 $MN_CC_PROTECT_OFFSET[1] = 32.0
Example protection window, 5.0 mm
● MD61519 $MN_CC_PROTECT_WINDOW[1] = 5.0
Orientation of the machine coordinate systems to one another: opposite direction
● MD61532 $MN_CC_PROTECT_DIR_IS_REVERSE[1] = 1
Protection window extension: by 5.0 mm to give a total of 10.0 mm
● MD61533 $MN_CC_PROTECT_WINDOW_EXTENSION[1] = 5.0

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21.5 Examples

21.5.2 Collision protection and distance limiter

The figure shows the arrangement of two machine axes, the offset and orientation of the
machine coordinate systems (machine), and the minimum and maximum distance vectors.

$FWXDOYDOXHB$ PP $FWXDOYDOXHB$ PP

0LQFOHDUDQFHYHFWRU 

$FWXDOFOHDUDQFHYHFWRU 

0D[FOHDUDQFHYHFWRU 

0&6B$ 0&6B$
 

0&6BRIIVHWYHFWRU 

Figure 21-3 Collision protection and distance limiter for one axis pair

Parameter assignment: Protection function 1 - Collision protection

Axis pair: 1st machine axis A1, 2nd machine axis A3
● MD61516 $MN_CC_PROTECT_PAIRS[0] = 03 01
Retraction direction: A1 in negative direction, A3 in positive direction
● MD61517 $MN_CC_PROTECT_SAFE_DIR[0] = 01 00
Offset vector from machine coordinate system machine_A3 to machine_A1 with reference to
machine_A1
● MD61518 $MN_CC_PROTECT_OFFSET[0] = -100.0
Example protection window, 40.0 mm
● MD61519 $MN_CC_PROTECT_WINDOW[0] = 40.0
Orientation of the machine coordinate systems to one another: same direction
● MD61532 $MN_CC_PROTECT_DIR_IS_REVERSE[0] = 0
Protection window extension: none
● MD61533 $MN_CC_PROTECT_WINDOW_EXTENSION[0] = 0.0

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21.6 Data lists

Parameter assignment: Protection function 2 - Distance limiter

Axis pair: 1st machine axis A1, 2nd machine axis A3
● MD61516 $MN_CC_PROTECT_PAIRS[1] = 03 01
Retraction direction: A1 in positive direction, A3 in negative direction
● MD61517 $MN_CC_PROTECT_SAFE_DIR[1] = 00 01
Offset vector = "offset vector from machine coordinate system machine_A3 to machine_A1
with reference to machine_A1" - "maximum distance vector with reference to machine_A1"

Note
Maximum distance vector
The maximum distance vector from the 1st machine axis to the 2nd machine axis is the vector
from the origin of the machine coordinate system for the 1st machine axis to the maximum
permissible position of the 2nd machine axis, with reference to the machine coordinate system
for the 1st machine axis.

● MD61518 $MN_CC_PROTECT_OFFSET[1] = -100.0 - 500.0 = 400.0

Example protection window, 20.0 mm
● MD61519 $MN_CC_PROTECT_WINDOW[1] = 20.0
Orientation of the machine coordinate systems to one another: same direction
● MD61532 $MN_CC_PROTECT_DIR_IS_REVERSE[1] = 0
Protection window extension: none
● MD61533 $MN_CC_PROTECT_WINDOW_EXTENSION[1] = 0.0
If machine axis A1 has a value of 0, the settings above will limit the traversing range of machine
axis A3 to between -60.0 and 380.0, with reference to machine_A3.

21.6 Data lists

21.6.1 Option data

Number Identifier: $ON_ Description

19610 TECHNO_EXTENSION_MASK[6] Enable the technology function via BIT4 = 1

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21.6 Data lists

21.6.2 Machine data

21.6.2.1 NC-specific machine data

Number Identifier: $MN_ Description

60972 CC_ACTIVE_IN_CHAN_PROT[n] Channel-specific activation of the technology function
BIT0 = 1 => activation in the 1st NC channel
BIT1 = 1 => activation in the 2nd NC channel,
etc.
61516 CC_PROTECT_PAIRS[n] Definition of the axis pair = yy xx
xx = axis number of 1st machine axis (1st/2nd decade)
yy = axis number of 2nd machine axis (3rd/4th decade)
61517 CC_PROTECT_SAFE_DIR[n] Retraction direction = yy xx
xx = retraction direction of 1st machine axis (1st/2nd decade)
yy = retraction direction of 2nd machine axis (3rd/4th decade)
61518 CC_PROTECT_OFFSET[n] Offset of the two machine coordinate systems
61519 CC_PROTECT_WINDOW[n] Protection window or minimum distance
61532 CC_PROTECT_DIR_IS_REVERSE[n] Orientation of the machine coordinate systems of the two machine
axes to one another
0: orientation in the same direction
1: orientation in the opposite direction
61533 CC_PROTECT_WINDOW_EXTENSION[n] Protection window extension

21.6.2.2 Axis/Spindle-specific machine data

Number Identifier: $MA_ Description

61514 CC_PROTECT_ACCEL Protection function-specific brake acceleration

21.6.3 User data

21.6.3.1 Global user data (GUD)

Identifier Description
_PROTECT_STATUS[n] Status of the protection function (optional)

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V2: Preprocessing 22
22.1 Brief description

Preprocessing
The programs stored in the directories for standard and user cycles can be preprocessed to
reduce runtimes.
Preprocessing is activated via machine data.
Standard and user cycles are preprocessed when the power is switched on, i.e. as an internal
control function, the part program is translated (compiled) into a binary intermediate code
optimized for processing purposes.
All program errors that can be corrected by means of a compensation block are detected during
preprocessing. In addition, when the program includes branches and check structures, a check
is made to ensure that the branch destinations are present and that structures are nested
correctly.
The full scope of control functionality is available:
● Override influence
● Reactions to data and signals that are input by the PLC or the operator
● Current block display
● The programs can be processed in single block mode (SBL1 and SBL2). Block searches
can be executed. The compilation cannot be stored; it is concealed from the user and
regenerated every time the power is switched on.
Preprocessing can be used:
● To optimize the runtimes of part programs with high-level language components (branches,
check structures, motion-synchronous actions)
● CPU time intensive part programs (e.g. stock removal cycles)
● Faster processing of time-critical sections (e.g. program continuation after preprocessing
stop during rapid deletion of distance-to-go, or return stroke, or in the tool change cycle).

General information
Preprocessing standard and user cycles is possible. The processing time of part programs
can then be reduced without restricting the control functionality.
The standard and user cycles are preprocessed when machine data is set accordingly:
MD10700 $MN_PREPROCESSING_LEVEL (program preprocessing level)
Preprocessing is carried out program-specifically. It is possible to mix preprocessed part
programs and part programs interpreted in ASCII format. Preprocessing serves to reduce
incidental times.

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22.1 Brief description

Memory is required for preprocessing cycles. You can optimize your memory in two ways:
● The program to be executed can be shortened with the command DISPLOF (display off).
● MD10700 $MN_PREPROCESSING_LEVEL has been expanded by bit 2 and 3. This allows
selective cycle preprocessing of the individual directories (e.g. user cycles).
MD10700 $MN_PREPROCESSING_LEVEL has been expanded by bit 4. This allows you to
select preprocessing for user cycles from the _N_CMA_DIR directory.
MD10700 $MN_PREPROCESSING_LEVEL has been expanded by bit 5. This allows selective
preprocessing of the specific individual user cycles that have the command PREPRO after the
PROC instruction.
Pretranslated cycles are stored in the dynamic NC memory by default. MD10700
$MN_PREPROCESSING_LEVEL has been expanded by bit 6. This allows specifying that the
compiled programs that are now stored in the dynamic NC memory and no longer have enough
space can be stored in static NC memory.

Functionality
The programs stored in the directories for standard and user cycles are preprocessed when
the power is switched on, i.e. the part program is translated (compiled) into an intermediate
binary code optimized for processing purposes. The compilation is processed when called.

Runtime optimization
The preprocessing function is primarily suited for optimizing the runtimes of part programs with
high-level language components (branches, check structures, motion-synchronous actions).
While branches and check structures are invalidated by a search through all blocks (block
start) when part programs are interpreted in ASCII format (active as default), a branch is made
directly to the destination block in a preprocessed part program.
The runtime differences between branches and check structures are thus eliminated.
Example of a preprocessing runtime:
Runtime reduction by 30% with active compressor
DEF INT COUNTER
Target: G1 G91 COMPON
G1 X0.001 Y0.001 Z0.001 F100000
COUNTER=COUNTER +1
COUNTER=COUNTER -1
COUNTER=COUNTER +1
IF COUNTER<= 100000 GOTOB TARGET
CPU time intensive programs and programs with symbolic names are processed faster.
Runtime-critical sections (e.g. continuation of processing after deletion of distance-to-go or
preprocessing stop in cycles) can be processed faster.
If the interrupt routine is available as a preprocessed cycle, processing can be continued more
rapidly after the program interrupt.

Special functions
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 V2: Preprocessing
22.2 Program handling

22.2 Program handling

Activation/Deactivation
Cycles are preprocessed on POWER ON if the following machine data is set:
MD10700 $MN_PREPROCESSING_LEVEL, bit 1 (program preprocessing level)

Bit Value Meaning

0 No preprocessing
0 Call description of cycles is not known by default.
Cycles, like normal subprograms, have to be stated as external before the cycle call.
This is a sensible setting when no cycles with call parameters are used.
1 During control power-up, the call description of the cycles is generated. All user cycles
(_N_CUS_DIR directory) and Siemens cycles (_N_CST_DIR directory) with transfer
parameters can be called up without external statement. Changes to the cycle-call
interface do not take effect until the next POWER ON.
The following machine data must be set:
MD18170 $MN_MM_NUM_MAX_FUNC_NAMES (number of auxiliary actions)
MD18180 $MN_MM_NUM_MAX_FUNC_PARAM (number of auxiliary parameters for
cycles)
1 1 During control power-up, all cycles are preprocessed into a compilation optimized for
processing. All user cycles (_N_CUS_DIR directory) and standard cycles
(_N_CST_DIR directory) are processed at high speed. Program changes to cycle
programs do not take effect until the next POWER ON.
2 1 During control power-up, the standard cycles in the _N_CST_DIR directory are pre‐
processed in a compilation optimized for processing.
3 1 During control power-up, the user cycles in the _N_CUS_DIR directory are prepro‐
cessed in a compilation optimized for processing.
4 1 Preprocessing of user cycles from the directory _N_CMA_DIR
5 1 Preprocessing the user cycles with the PREPRO command in the PROC instruction
line. Unmarked files of directories marked with bits 1-4 are not preprocessed.
If bit 0, then control of the preprocessing is carried out in accordance with the speci‐
fications of bits 0-4.
6 0 The compilation is stored in the dynamic NC memory as long as free memory is still
available. If sufficient memory is not available, preprocessing is aborted.
The size of the dynamic NC memory is obtained with this machine data:
MD18351 $MN_MM_DRAM_FILE_MEM_SIZE.

The areas occupied in the dynamic NC memory by the compilation are visible to the user.
Bit combinations are permissible.

Special functions
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V2: Preprocessing
22.2 Program handling

Compiling
In the directories for standard cycles: _N_CST_DIR, _N_CMA_DIR and user cycles:
Subprograms (_SPF file extension) located in _N_CUS_DIR, and, if necessary, the
subprograms marked with PREPRO are compiled. The name of the compilation corresponds
to the original cycle with extension _CYC.

Note
Program changes to precompiled programs do not take effect until the next POWER ON.

Access rights
The preprocessed program can only be executed, but not read or written. The compilation
cannot be modified or archived. The original cycles _SPF files are not deleted.
The compilation is not changed when the ASCII cycle is altered, i.e. changes do not take effect
until after the next POWER ON.

Memory requirements
The memory requirement for compiled cycles is approximately factor 2 in addition to the ASCII
part program.
The memory requirements for variables defined in the part programs are defined by the
following machine data:
MD28020 $MC_MM_NUM_LUD_NAMES_TOTAL (number of local user variables)
MD28010 $MC_MM_NUM_REORG_LUD_MODULES (number of modules for local user
variables with REORG)
MD28040 $MC_MM_LUD_VALUES_MEM (memory size for local user variables)
MD18242 $MC_MM_MAX_SIZE_OF_LUD_VALUE (memory block size for LUD/GUD
values)
References:
Function Manual, Extended Functions; Memory Configuration (S7)
While preprocessing is in progress, the amount of memory required is the same as if the
preprocessed program were called on the first subprogram level.
When programs are preprocessed after POWER ON, a name is counted for each branch
destination/label as if it were a variable. These names must be taken into account in the
following machine data:
MD28020 $MC_MM_NUM_LUD_NAMES_TOTAL (number of local user variables)
Example:

Program code Comment

PROC NAMES ; 1 name
DEF INT VARIABLE, ARRAY[2] ; 2 names
START: ; 1 name, only for preprocessing
FOR VARIABLE = 1 TO 9 ; 1 name, only for preprocessing

Special functions
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22.2 Program handling

Program code Comment

G1 F10 X=VARIABLE*10-56/86EX4+4*SIN(VARIABLE/3)
ENDFOR ; 1 name, only for preprocessing
M17

In order to execute this program normally, the following machine data must specify at least 3
names:
MD28020 $MC_MM_NUM_LUD_NAMES_TOTAL
Six names are required to compile this program after POWER ON.
Preprocessed programs/cycles are stored in the dynamic NC memory. The space required for
each program must be flashed over unmodified as outlined above. Adjustment of the memory
mapping in the static NC memory is required only if bit 6 = 1 is set in the following machine
data:
MD10700 $MN_PREPROCESSING_LEVEL (program processing level)
In this case, the program compilations for which there is insufficient space in the dynamic NC
memory are stored in the static NC memory.
Examples for appropriate machine data settings can be found under "Examples" in the
Subsection "Preprocessing in the dynamic NC memory".

Special functions
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V2: Preprocessing
22.3 Program call

22.3 Program call

Overview

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Figure 22-2 Generation and call of preprocessed cycles with parameters

Special functions
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 V2: Preprocessing
22.3 Program call

Start
● Compiled cycle: A compiled cycle is called in exactly the same way as a normal subroutine.
Example: CYCLE
● Preprocessing is activated: The compiled cycle is called instead of the ASCII cycle.
– If the subroutine is called explicitly with extension _SPF, then the ASCII cycle is called
even if a compilation is available.
Example: CYCLE_SPF; ASCII cycle call
– If the subroutine is called explicitly with extension _CYC, then the preprocessed cycle
is called if available. An error message is output if no compilation is available.
Example: CYCLE_CYC; Preprocessed cycle call
– If bit 5 is set and a file that is not marked with PREPRO is called explicitly with the
extension _CYC, an error message is issued with Alarm 14011.
● If a subroutine is called without explicit extension, an attempt is first made to load the
program. If this is not possible (not marked with PREPRO), an attempt is made to load the
SPF program.
● The change to an external language mode with G291 is rejected and an alarm issued. When
the pre-compiled cycle is called, an explicit change is made to the Siemens language mode.
● When the subroutine is called, it is checked whether the compiled file is older than the cycle.
If so, the compile file is deleted and an alarm issued. The user must preprocess the cycles
again.
Note
Only cycles without parameters may be called with the extension _SPF or _CYC.
Do not use PUDs in cycles that are preprocessed. The PUDs are created in the calling
main program. At the time of compilation after POWER ON, this data is not known to the
cycles.

The current program display shows whether the current ASCII cycle or the compilation has
been called (extension _SPF or _CYC).

Call condition
All cycles in the cycle directories must be compiled before preprocessing is activated. Non-
compiled cycles in _N_CUS_DIR and _N_CST_DIR which were loaded after POWER ON, for
example, can only be called through explicit specification of extension _SPF.
If preprocessing is active and bit 5 is set, all programs that do not start with the PREPRO PROC
instruction are not precompiled.

Syntax check
All program errors that can be corrected by means of a compensation block are detected during
preprocessing. In addition, when the program includes branches and check structures, a check
is made to ensure that the branch destinations are present and that structures are nested
correctly.
Branch destinations and labels must be unique in the program.

Special functions
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V2: Preprocessing
22.4 Constraints

After the errors detected during preprocessing have been corrected, preprocessing must be
started again by means of an NCK POWER ON.

22.4 Constraints

Availability of the "preprocessing" function

The function is an option ("Program pre-processing"), which must be assigned to the hardware
via the license management.

Language scope
The full vocabulary of the NC language is available in the part program.
There are no restrictions on the calculation of measured process variables and in the reaction
to signals from the process and other channels (override, deletion of distance-to-go, motion-
synchronous actions, channel coordination, interrupt processing, etc.).

Axis name
Part programs are compiled independently of channels. For this reason, the geometry and
channel names set in the following machine data must be identical in all channels if they are
used directly in the precompiled cycles:
MD20060 $MC_AXCONF_GEOAX_NAME_TAB (name of the geometry axis in the channel)
MD20080 $MC_AXCONF_CHANAX_NAME_TAB (name of the channel axis in the channel)
Generally speaking, axis names are not used directly in machining cycles since cycles are
written as follows:
● independently of channels and
● independently of the axis names defined on the machine.

Special functions
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 V2: Preprocessing
22.5 Examples

The axes to be traversed are addressed indirectly via machine data or transferred as
parameters:
● Indirect axis programming:
– IF $AA_IM[AXNAME($MC_AXCONF_CHANAX_NAME_TAB[4])] > 5
; This branch will pass through if the actual value of the 5th channel axis
; with reference to the machine coordinate system is greater than 5.
– G1 AX[AXNAME($MC-AXCONF-GEOAX-NAME-TAB[0])] = 10
F1000 G90.
; Traverse the 1st geometry axis to the value 10.
ENDIF
● Transfer of axis to be traversed from the main program:
– Cycle definition
PROC DRILL(AXIS DRILL_AXIS)
WHILE $AA_IW[DRILL_AXIS] > -10
G1 G91 F250 AX[DRILL_AXIS] = -1
ENDWHILE
– Call from the main program
DRILL(Z)

22.5 Examples

22.5.1 Preprocessing individual files

Program code Comment

PROC UP1 PREPRO ; Preprocessing if bit 5 = 1
; in PREPROCESSING_LEVEL
N1000 DEF INT COUNTER
N1010 TARGET: G1 G91 COMPON
N1020 G1 X0.001 Y0.001 Z0.001 F100000
N1030 COUNTER=COUNTER+1
N1040 COUNTER=COUNTER-1
N1050 COUNTER=COUNTER+1
N1060 IF COUNTER<=10 GOTOB TARGET
N1070 M30

Special functions
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V2: Preprocessing
22.5 Examples

Program code Comment

PROC UP2
N2000 DEF INT VARIABLE, ARRAY[2]
N2010 IF $AN_NCK_Version < 3.4
N2020 SETAL(61000)
N2030 ENDIF
N2040 START:
N2050 FOR VARIABLE = 1 TO 5
N2060 G1 F1000 X=VARIABLE*10-56/86EX4+4*SIN(VARIABLE/3)
N2070 ENDFOR
N2080 M17
PROC MAIN
N10 G0 X0 Y0 Z0
N20 UP1
N30 G0 X10 Y10 Z10
N40 UP2
N50 G0 X100 Y100
N60 UP3
N70 G0 X10 Y10
N80 M30

Sample constellations:
a) Bit 5 = 1
MD10700 $MN_PREPROCESSING_LEVEL=45 ; bit 0, 2, 3, 5
Subprogram UP1 is pretranslated, and the call description is generated.
Subprogram UP2 is not pretranslated, but the call description is generated.
b) Bit 5 = 0
MD10700 $MN_PREPROCESSING_LEVEL=13 ; bit 0, 2, 3,
Both subprograms are pretranslated, and the call description is generated.
c) Example of an invalid subprogram with activated compiling:

Program code Comment

PROC SUB1 PREPRO
G291 ; ← Alarm when compiling, G291 not possible
G0 X0 Y0 Z0
M17

Special functions
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 V2: Preprocessing
22.6 Data lists

22.5.2 Preprocessing in the dynamic NC memory

Machine data for preprocessing only in the dynamic NC memory with selective selection:

Program code Comment

; Bit 5 = 1 Selective program selection
; Bit 6 =0 no switch to
; static NC memory if
; dynamic NC memory is full
N30 $MN_MM_DRAM_FILE_MEM_SIZE = 800 ; Reserve space
N40 $MN_PREPROCESSING_LEVEL = 63 ; Bit 0-5 = 1
M17

Machine data for preprocessing in the dynamic NC memory with the option of using the static
NC memory and selective selection:

Program code Comment

; Bit 5 = 1 Selective program selection
; Bit 6 = 1 switch to static
; NC memory if dynamic NC
; memory full
N30 $MN_MM_DRAM_FILE_MEM_SIZE = 800 ; Reserve space
N40 $MN_PREPROCESSING_LEVEL = 127 ; Bit 0-6 = 1
M17

22.6 Data lists

22.6.1 Machine data

22.6.1.1 General machine data

Number Identifier: $MN_ Description

10700 PREPROCESSING_LEVEL Program preprocessing level
18242 MM_MAX_SIZE_OF_LUD_VALUE Maximum LUD-variable array size

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V2: Preprocessing
22.6 Data lists

22.6.1.2 Channelspecific machine data

Number Identifier: $MC_ Description

28010 MM_NUM_REORG_LUD_MODULES Number of blocks for local user variables for REORG
(DRAM)
28020 MM_NUM_LUD_NAMES_PER_PROG Number of local user variables (DRAM)
28040 MM_LUD_VALUES_MEM Memory size for local user variables (DRAM)

Special functions
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W5: 3D tool radius compensation - 840D sl only 23
23.1 Brief description

23.1.1 General information

Why 3D TRC?
3D tool radius compensation is used to machine contours with tools that can be controlled in
their orientation independently of the tool path and shape.

Note
This description is based on the specifications for 2D tool radius compensation.
References:
Function Manual Basic Functions; Tool Offset (W1)

How 21/2 D and 3D TRC differ

● With 21/2D TRC, it is assumed that the tool is always space-bound. Tools with constant
orientation (cylindrical tools) are used for circumferential milling operations.
While the orientation of the machining surface is not constant when other tools are used,
it is determined by the contour and cannot thus be controlled independently of it.
● With 3D TRC, surfaces with variable orientation are generated.
The prerequisite for circumferential milling is that the tool orientation can be changed, i.e.
in addition to the 3 degrees of freedom needed to position the tool (normally 3 linear axes),
a further two degrees of freedom (2 rotary axes) are required to set the tool orientation (5-
axis machining).
End faces can be milled with 3 or 5 degrees of freedom.

Special functions
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W5: 3D tool radius compensation - 840D sl only
23.1 Brief description

Circumferential milling, face milling

The following diagram shows the differences between 21/2D and 3D TRC with respect to
circumferential milling operations.

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Figure 23-1 21/2D and 3D tool radius compensation

The parameters for display in the "Face milling" screen are described in detail in Chapter "Face
milling (Page 809)".

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Figure 23-2 Face milling

Special functions
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 W5: 3D tool radius compensation - 840D sl only
23.1 Brief description

Orientation
With 3D TRC, a distinction must be drawn between:
● Tools with space-bound orientation
● Tools with variable orientation

23.1.2 Machining modes

There are two modes for milling spatial contours:
● Circumferential milling
● Face milling
Circumferential milling mode is provided for machining so-called ruled surfaces (e.g. taper,
cylinder, etc.) while face milling is used to machine curved (sculptured) surfaces.

Circumferential milling
Tools will be applied as follows for circumferential milling:
● with space-bound orientation (21/2D TRC) and
● with variable orientation (3D TRC)
3D TRC can therefore be applied in circumferential milling only if the tool orientation is variable.
Intermediate blocks that are required from non-tangential transitions for mathematical reasons
can be avoided using the intersection procedure. In these cases, the two curves in question
are extended; the intersection of both extended curves is approached.

Face milling
Tools of both types, i.e. with constant or variable orientation, can be used for face milling
operations.
Tools with variable orientation offer the following advantages:
● Better approximation of end contour
● Greater cutting capability
● Wider selection of tool shapes
● Wider range of surfaces can be machined (relief cuts).

Special functions
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W5: 3D tool radius compensation - 840D sl only
23.2 Circumferential milling

23.2 Circumferential milling

Circumferential milling
The variant of circumferential milling used here is implemented through the definition of a path
(directrix) and the associated orientation. In this machining mode, the tool shape is irrelevant
on the path and at the outside corners. The only decisive factor is the radius at the tool contact
point.

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Figure 23-3 Circumferential milling

Insertion depth (ISD)

Program command ISD (insertion depth) is used to program the tool insertion depth for
circumferential milling operations. This makes it possible to change the position of the
machining point on the outer surface of the tool.
ISD defines the distance between cutter tip FS and cutter construction point FH. Point FH is
obtained by projecting the programmed machining point onto the tool axis. ISD is evaluated
only when 3D TRC is active.

Special functions
798 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 W5: 3D tool radius compensation - 840D sl only
23.2 Circumferential milling

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Figure 23-4 Insertion depth

23.2.1 Corners for circumferential milling

Outside corners/inside corners

Outside corners and inside corners must be treated separately. The terms inside corner and
outside corner are dependent on the tool orientation. When the orientation changes at a corner,
for example, the corner type may change while machining is in progress. Whenever this occurs,
the machining operation is aborted with an error message.

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Figure 23-5 Corner type

Special functions
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W5: 3D tool radius compensation - 840D sl only
23.2 Circumferential milling

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Figure 23-6 Change of corner type during machining

23.2.2 Behavior at outer corners

In the same manner as 21/2D tool radius compensation procedures, a circle is inserted at outer
corners for G450 and the intersection of the offset curves is approached for G451.
With nearly tangential transitions, the procedure for active G450 is as with G451 (limit angle
is set via machine data). Conversely, if G451 is active, a circle is also inserted (procedure as
for G450) if there is no intersection or if the corner angle exceeds a specific value (MD).
If there is a change in orientation between the two traversing blocks, a circle is always inserted.

G450
Outside corners are treated as if they were circles with a 0 radius. The tool radius compensation
acts on these circles in the same way as on any other programmed path.
The circle plane extends from the final tangent of the first block to the start tangent of the
second block.
The orientation can be changed during block transition.
A change in orientation between two programmed blocks is executed either before the circle
block or in parallel to it. Circles are always inserted. The command DISC is not evaluated.

Programming
● ORIC: Change in orientation and path movement in parallel
(ORIentation Change Continuously)
● ORID: Change in orientation and path movement consecutively
(ORIentation Change Discontinuously)
The ORIC and ORID program commands are used to determine whether changes in orientation
programmed between two blocks are executed before the inserted circle block is processed
or at the same time.

Special functions
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 W5: 3D tool radius compensation - 840D sl only
23.2 Circumferential milling

When the orientation needs to be changed at outside corners, the change can be implemented
in parallel to interpolation or separately from the path motion. When ORID is programmed, the
inserted blocks are executed first without a path motion (blocks with changes in orientation,
auxiliary function outputs, etc.). The circle block is inserted immediately in front of the second
of the two traversing blocks which form the corner.

ORIC
If ORIC is active and there are two or more blocks with changes in orientation (e.g. A2= B2=
C2=) programmed between the traversing blocks, then the inserted circle block is distributed
among these intermediate blocks according to the absolute changes in angle.

Change in orientation
The method by which the orientation is changed at an outer corner is determined by the
program command that is active in the first traversing block of an outer corner.

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Figure 23-7 ORIC: Change in orientation and path movement in parallel

Example:

Program code Comment

N10 A0 B0 X0 Y0 Z0 F5000 ; Radius=5
N20 T1 D1 ; Transformation selection
N30 TRAORI(1) ; 3D TRC selection

Special functions
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W5: 3D tool radius compensation - 840D sl only
23.2 Circumferential milling

Program code Comment

N40 CUT3DC
N50 ORIC ; TRC selection
N60 G42 X10 Y10
N70 X60 ; Change in orientation to the for N70

N80 A3=1 B3=0 C3=1 ;

N90Y60 ; and N90 generated outside corner
N100 X10 ;
N110 G40 X0 Y0 ;
N120 M30 ;

The circular motion and change in orientation are executed in parallel in block N80 (ORIC
active).

Special case
Intermediate blocks without traversing and orientation motions are executed at the
programmed positions, e.g. auxiliary functions.
Example:

Program code Comment

N70 X60
N75 M20 ; Auxiliary function call
N80 A3=1 B3=0 C3=1 ; Change in orientation to the for N70
N90 Y60 ; and N90 generated outside corner

Blocks N75 and N80 are executed after N70. The circle block is then executed with the current
orientation.

Special functions
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23.2 Circumferential milling

ORID
If ORID is active, then all blocks between the two traversing blocks are executed at the end of
the first traversing block. The circle block with constant orientation is executed immediately
before the second traversing block.

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Figure 23-8 ORID: Change in orientation and path movement consecutively

Example:

Program code Comment

N10 A0 B0 X0 Y0 Z0 F5000
N20 T1 D1 ; Radius=5
N30 TRAORI(1) ; Transformation selection
N40 CUT3DC ; 3D TRC selection
N50 ORID
N60 G42 X10 Y10 ; TRC selection
N70 X60
N80 A3=1 B3=0 C3=1 ; Change in orientation to the for N70
N90 Y60 ; and N90 generated outside corner
N100 X10
N110 G40 X0 Y0
N120 M30

Special functions
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W5: 3D tool radius compensation - 840D sl only
23.2 Circumferential milling

Note
The command DISC is not evaluated.

G451
The intersection is determined by extending the offset curves of the two participating blocks
and defining the intersection of the two blocks at the corner in the plane perpendicular to the
tool orientation. If no such intersection is available, a circle is inserted.
If an intersection is found in the plane perpendicular to the tool, this does not mean that the
curves also intersect in space. Rather the curves in the direction of the tool longitudinal axis
are considered, which are generally a certain distance apart. The positional offset is eliminated
over the entire block length in direction of the tool.
The way this offset is processed in tool direction at outside corners is the same as for inside
corners.

No intersection procedure
The intersection procedure is not used when at least one block containing a change to the tool
orientation was inserted between the traversing blocks in question. In this case a circle is
always inserted at the corner.

Blocks without traversing information

Blocks without relevant traversing information (neither tool orientation nor position of geometry
axes are changed) are permissible. The intersection procedure is applied to the adjacent
blocks as if these intermediate blocks did not exist. In the same manner, tool direction motions
in the tool direction may also be programmed in intermediate blocks.

23.2.3 Behavior at inside corners

Collision monitoring
With the 3D compensation function, only adjacent traversing blocks are taken into account in
the calculation of intersections.
Path segments must be long enough to ensure that the contact points of the tool do not cross
the block limits into other blocks when the orientation changes at an inside corner.

Special functions
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23.2 Circumferential milling

1&KDQJHLQRULHQWDWLRQ 1

1
1

Figure 23-9 The contact points of the tool must not cross the limits of block N70 or N90 as a result of
the change in orientation in block N80

Example:

Program code Comment

N10 A0 B0 X0 Y0 Z0 F5000
N20 T1 D1 ; Radius=5
N30 TRAORI(1) ; Transformation selection
N40 CUT3DC ; 3D TRC selection
N50 ORID
N60 G42 X10 Y10 ; TRC selection
N70 X60
N80 A3=1 B3=0 C3=1 ; Change in orientation to the for
N90 X10 ; N70 and N90 generated inside corner
N100 G40 X0 Y0
N120 M30

Without change in orientation

If the orientation is not changed at the block limit, then the contour need only be considered
in the plane vertical to the tool axis. In this case, the tool cross-section is a circle which touches
the two contours. The geometric relations in this plane are identical to those for 21/2D
compensation.

With change in orientation

If the orientation changes on a block transition, the tool moves in the inside corner so that it is
constantly in contact with the two blocks forming the corner.
When the orientation changes in a block that is one of the two blocks forming the inside corner,
then it is no longer possible to adhere to the programmed relationship between path position
and associated orientation. This is because the orientation must reach its end value even
though the path end position is not reached. This response is identical to the response of
synchronized axes with 21/2 D tool radius compensation.

Special functions
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23.2 Circumferential milling

3URJUDPPHG
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Figure 23-10 Path end position and change in orientation at inside corners

Change in insertion depth

Generally speaking, the contour elements that form an inside corner are not positioned on the
plane perpendicular to the tool. This means that the contact points between the two blocks
and the tool are at different distances from the tool tip.
This means: the insertion depth (ISD) changes abruptly from the 1st to the 2nd block at an
inside corner.
To ensure that this difference in depth is not an abrupt step change, it is distributed continuously
among the blocks involved during interpolation. The depth-compensating motion is executed
in the current tool direction.
This solution prevents the contour from being violated by cylindrical tools if the length of the
tool prevents the cutter contact point on the lateral surface of the cutter leaving the range in
which machining is possible.

Special functions
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23.2 Circumferential milling

1HZ
2OG ,6'
,6'
)6

6HW

6HW

Figure 23-11 Change in insertion depth

Special functions
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23.2 Circumferential milling

Example of inside corners

1

1

:5.

Figure 23-12 Change in orientation at an inside corner

Example:

Program code Comment

N10 A0 B0 X0 Y0 Z0 F5000
N20 T1 D1 ; Radius=5
N30 TRAORI(1) ; Transformation selection
N40 CUT3DC ; 3D TRC selection
N50 ORID
N60 G42 X10 Y10 G451 ; TRC selection
N70 Y60
N80 A3=1 B3=0 C3=1 ; Change in orientation to the for
N90 X60 Y90 ; N70 and N90 generated inside corner
N100 G40 X... Y...
...
N190 CDOF
N200 M30

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23.3 Face milling

23.3 Face milling

The face milling function allows surfaces with any degree or form of curvature to be machined.
In this case, the longitudinal axis of the tool and the surface normal vector are more or less
parallel. In contrast, the longitudinal axis and the surface normal vector of the surface to be
machined in a circumferential milling operation are at right angles to one another.
Information about the surfaces to be machined is absolutely essential for face milling
operations, i.e. a description of the linear path in space is not sufficient. The tool shape must
also be known in order to implement the tool offset (the term "Tool radius compensation" is
not appropriate in this case).
The relations in face milling are shown in the Figure below.

Z
)6
G
H G
Q)

)(

Figure 23-13 Face milling with a torus

23.3.1 Cutter shapes

The following table lists the possible tool shapes that may be used for face milling with their
dimensions.

Table 23-1 Tool shapes for face milling

Cutter type Tool No. d r a

Ball end mill (cylindrical die sinker) 110 >0 X X
Ball end mill (tapered die sinker) 111 >0 >d X
End milling cutter without corner rounding 120, 130 >0 X X
End mill with corner rounding (torus) 121, 131 >r >0 X
Bevel cutter without corner rounding 155 >0 X >0
Bevel cutter with corner rounding 156 >r >0 >0

If a tool number other than any of those specified in the table above is used in the NC program,
then the tool type is assumed to be a ball end mill (tool type 110). Tool parameters marked
with an X in the tool table are not evaluated. A value other than zero is meaningless for the
tool offset for face milling.
An alarm is output if tool data are programmed that violate the limits specified in the table
above.

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23.3 Face milling

The shaft characteristics are not taken into account on any of the tool types. For this reason,
the two tool types 120 (end mill) and 155 (bevel cutter), for example, have an identical
machining action since only the section at the tool tip is taken into account. The only difference
between these tools is that the tool shape is represented differently (dimensions).

G
G G

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7\SH 7\SH 7\SH

Figure 23-14 Tool types for face milling

The tool data are stored under the following tool parameter numbers:

Table 23-2 Tool parameter numbers for tool data

Tool data Geometry Wear

d $TC_DP6 $TC_DP15
r $TC_DP7 $TC_DP16
a $TC_DP11 $TC_DP20

Note
The geometry and wear values of a tool data are added.

The reference point for tool length compensation (also referred to as tool tip or tool center point
(TCP)) on all tool types is the point at which the longitudinal axis of the tool penetrates the
surface.
A new tool with different dimensions may be programmed only when the tool compensation is
activated for the first time (i.e. on transition from G40 to G41 or G42) or, if the compensation
is already active, only when G41 or G42 are reprogrammed.
In contrast to circumferential milling, therefore, there are no variable tool dimensions in one
block.
This restriction applies only to the tool shape (tool type, dimensions d, r and a).

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23.3 Face milling

A change in tool involving only a change in other tool data (e.g. tool length) is permitted
provided that no other restrictions apply. An alarm is output if a tool is changed illegally.

23.3.2 Orientation
The options for programming the orientation have been extended for 3D face milling.
The tool offset for face milling cannot be calculated simply by specifying the path (e.g. a line
in space). The surface to be machined must also be known. The control is supplied with the
information it requires about this surface by the surface normal vector.
The surface normal vector at the block beginning is programmed with A4, B4, C4, and the
vector at the block end with A5, B5, C5. Components of the surface normal vector that are
not programmed are set to zero. The length of a vector programmed in this way is irrelevant.
A vector of zero length (all three components are zero) is ignored, i.e. the direction programmed
beforehand remains valid, no alarm is generated.
If only the start vector is programmed (A4, B4, C4) in a block, then the programmed surface
normal vector remains constant over the entire block. If only the end vector is programmed
(A5, B5, C5), then large-circle interpolation is used to interpolate between the end value of
the preceding block and the programmed end value. If both the start and end vectors are
programmed, then interpolation takes place between both directions using the large-circle
interpolation method. The fact that the start vector may be reprogrammed in a block means
that the direction of the surface normal vector can change irregularly on a block transition.
Irregular transitions of the surface normal vector always occur in cases where there is no
tangential transition between the surfaces (planes) involved, i.e. if they form an edge.
Once a surface normal vector has been programmed, it remains valid until another vector is
programmed. In the basic setting, the surface normal vector is set to the same values as the
vector in the z direction. This basic setting direction is independent of the active plane (G17 -
G19). If ORIWKS is active, surface normal vectors refer to the active frame, i.e. when the frame
is rotated, the vectors rotate simultaneously. This applies both to programmed orientations as
well as to those derived from the active plane. If ORIWKS is active, the surface normal vectors
are adjusted when a new frame becomes active. An orientation modified as the result of frame
rotations is not returned to its original state on switchover from ORIWKS to ORIMKS.
It must be noted that the programmed surface normal vectors may not necessarily be the same
as those used internally. This always applies when the programmed surface normal vector is
not perpendicular to the path tangent. A new surface normal vector is then generated which
is positioned in the plane extending from the path tangent to the programmed surface normal
vector, but which is at right angles to the path tangent vector. This orthogonalization is
necessary because the path tangent vector and surface normal vector for a real surface must
always be perpendicular to one another. However, since the two values can be programmed
independently, they may contain mutually contradictory information. Orthogonalization
ensures that the information contained in the path tangent vector has priority over the data in
the surface normal vector. An alarm is output if the angle between the path tangent vector and
the programmed surface normal vector is smaller than the limit value programmed in machine
data:
MD21084 $MC_CUTCOM_PLANE_PATH_LIMIT (minimum angle between surface normal
vector and path tangent vector)
If a block is shortened (inside corner), then the interpolation range of the surface normal vector
is reduced accordingly, i.e. the end value of the surface normal vector is not reached as it

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23.3 Face milling

would be with other interpolation quantities such as, for example, the position of an additional
synchronized axis.
In addition to the usual methods of programming orientation, it is also possible to refer the tool
orientation to the surface normal vector and path tangent vector using the addresses LEAD
(lead or camber angle) and TILT (side angle). The lead angle is the angle between the tool
orientation and the surface normal vector. The side angle is the angle between the path tangent
and the projection of the tool vector into the surface to be machined. Specification of the angle
relative to the surface normal is merely an additional option for programming tool orientation
at the block end. It does not imply that the lead and side angles reach their programmed values
before the path end point is reached.
The final tool orientation is calculated from the path tangent, surface normal vector, lead angle
and side angle at the block end. This orientation is always implemented by the end of the block,
particularly in cases where the block is shortened (at an inside corner). If the omitted path
section is not a straight line in a plane, the lead and side angles generally deviate from their
programmed values at the path end point. This is because the orientation has changed relative
to the surface normal vector or path tangent vector when the absolute orientation of the tool
is the same as at the original path end point.

23.3.3 Compensation on path

Tool longitudinal axis parallel to surface normal

A special case must be examined with respect to face milling operations, i.e. that the machining
point on the tool surface moves around. This may be the case on a torus cutter whenever
surface normal vector nF and tool vector w become collinear (i.e. the tool is at exact right angles
to the surface) since it is not a single point on the tool that corresponds to this direction, but
the entire circular surface on the tool end face. The contact point is not, therefore, defined with
this type of orientation. A path point in which tool longitudinal axis and surface normal are
parallel is therefore referred to below as a singular point or a singularity.
The above case is also meaningful in practical terms, e.g. in cases where a convex surface,
which may have a vertical surface normal (e.g. hemisphere), must be machined with a
perpendicular tool (e.g. face milling with constant orientation). The machining point on the
contour remains fixed, but the machine must be moved to bring the machining point from one
side of the tool to the other.
The problem described is only a borderline case (lead angle β = 0 and side angle y = 0). If the
lead angle β = 0 and the side angle y has a low value, then the tool must be moved very rapidly
(in borderline case in steps) to keep the machining point resulting from the milling conditions
close to the arc-line forming the end face, see the following Figure.

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23.3 Face milling

6LQJXODUSRLQW

Figure 23-15 Change in the machining point on the tool surface close to a point in which surface normal
vector and tool orientation are parallel

The problem is basically solved as follows: If the angle d between the surface normal vector
nF and tool orientation w is smaller than a limit value (machine data) δmin, then the side angle
y on tools with a flat end face (e.g. torus cutter or cylindrical mill) must be 0. This restriction
does not apply to tool types with a spherical end face (e.g. ball end mill, die sinker) since
angular changes close to the singular point do not lead to abrupt changes in the machining
point on the surface of such tools. If δ now becomes 0, i.e. the sign of lead angle b changes,
the machining point moves from its current position to the opposite side of the tool. This
movement is executed in an inserted linear block.
The machining operation is aborted with an alarm if an attempt is made to machine within the
illegal angular range for the side angle y (i.e. δ < δmin and γ , 0).
The insertion of linear blocks makes it necessary to split the original blocks at the singular
points. The partial blocks created in this way are treated as if they were original, which means,
for example, that a concave path containing a singularity is treated like an inside corner, i.e.
there is no contour violation. Each new partial block must contain at least one tool contact point
since this is always calculated on the basis of adjacent traversing blocks.
Singularities do not just occur at isolated points, but along whole curves. This is the case, for
example, if the curve to be interpolated is a plane curve (i.e. a curve with a constant osculating
plane) and the tool is constantly aligned in parallel to the binormal vector, i.e. perpendicular to
the osculating plane. A simple example is a circular arc in the x-y plane that is machined by a
tool aligned in parallel to the z axis. On paths of this type, the tool offset is reduced to a tool
length compensation, i.e. the tool is moved so that its tip FS is positioned on the programmed
path.
On transition between singular and non-singular curves, linear blocks must be inserted in the
same way as for isolated singular points so that the machining point on the tool can move from
the tool tip FS to the periphery (on outside corners and convex surfaces) or the paths must be
shortened to avoid contour violations (on inside corners and concave surfaces).

23.3.4 Corners for face milling

Two surfaces which do not merge tangentially form an edge. The paths defined on the surfaces
make a corner. This corner is a point on the edge.
The corner type (inside or outside corner) is determined by the surface normal of the surfaces
involved and by the paths defined on them.

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23.3 Face milling

The surface normals of the two surfaces forming the edge may point in opposite directions of
the overall surface (the front edge of one surface is continued on the rear edge of the second
surface), see also the following Figure. Such transitions are not permissible and are rejected
with an alarm.
The scalar product of the surface normal vector and (possibly variable) tool orientation on one
corner/path must be positive at each point, i.e. it is not permissible to machine from the rear
face of the surface. Failure to observe this rule results in an alarm. The permissible ranges of
validity of tool orientation for inside and outside corners are illustrated in the following Figure.
These ranges are further restricted by the condition that the angle between the surfaces to be
machined and the "steepest" surface line of the tool surface must not be lower than a particular
machine data setting. The "steepest" surface line is a line at angle a to the tool longitudinal
axis (this line is in the same direction as the tool longitudinal axis on cylindrical tools). This
restriction must be imposed to ensure that the contact point on the tool does not leave the
permissible range.

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Figure 23-16 Corners for face milling

It is possible to insert blocks that contain no motion commands (e.g. auxiliary function outputs)
and/or that include motions of axes not involved in the path between two blocks which contain
a path definition. Changes in orientation can also be programmed in such intermediate blocks.
The only exception applies to the activation and deactivation of the 3D tool radius
compensation function, i.e. intermediate blocks with changes in orientation may not be inserted
between the activation block and the first corrected block or between the last corrected block
and the deactivation block. Other intermediate blocks are, however, permitted.

23.3.5 Behavior at outer corners

Outside corners are treated as if they were circles with a 0 radius. The tool radius compensation
acts on these circles in the same way as on any other programmed path.
The circle plane extends from the final tangent of the first block to the start tangent of the
second block.
The orientation can be changed during block transition.
A circle block is always inserted at an outside corner.
A change in orientation between two programmed blocks is executed either before the circle
block or in parallel to it.

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23.3 Face milling

Programming
● ORIC: Change in orientation and path movement in parallel
(ORIentation Change Continuously)
● ORID: Change in orientation and path movement consecutively
(ORIentation Change Discontinuously)
The ORIC and ORID program commands are used to determine whether changes in orientation
programmed between two blocks are executed before the inserted circle block is processed
or at the same time.
When the orientation needs to be changed at outside corners, the change can be implemented
in parallel to interpolation or separately from the path motion. When ORID is programmed, the
inserted blocks are executed first without a path motion (blocks with changes in orientation,
auxiliary function outputs, etc.). The circle block is inserted immediately in front of the second
of the two traversing blocks which form the corner.

ORIC
If ORIC is active and there are two or more blocks with changes in orientation (e.g. A2= B2=
C2=) programmed between the traversing blocks, then the inserted circle block is distributed
among these intermediate blocks according to the absolute changes in angle.

Change in orientation
The method by which the orientation is changed at an outer corner is determined by the
program command that is active in the first traversing block of an outer corner.
If the tool orientation at an outside corner is not constant, then the change in orientation is
implemented in exactly the same way as described in Subsection "Behavior at outer corners"
for circumferential milling operations.

23.3.6 Behavior at inside corners

The position of the tool in which it is in contact with the two surfaces forming the corner must
be determined at an inside corner. The contact points must be on the paths defined on both
surfaces. It is not usually possible to solve this problem exactly since, when the tool is moved
along the path on the first surface, it normally touches a point on the second surface which is
not on the path.
For this reason, the tool is not moved along the path on the first surface, but deviates from the
path in such a way as to ensure that the distance between the contact points and the relevant
contours in the position in which the tool contacts both surfaces is minimal, see also the
following Figure.

Special functions
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23.3 Face milling

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7RROVXUIDFH

3DWKRIIVHWS 3DWK
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Figure 23-17 Inside corner with face milling (view in direction of longitudinal axis of tool)

Note
The amount by which the contact points deviate from the programmed contour will generally
be small since the explanatory example shown in the Figure, in which the machining point
"changes" the cutter side at an inside corner (the value of the angular difference Ψ about the
tool longitudinal axis between the two contact points on the tool surface is approximately 180°)
is more likely to be the exception (see also the following Figure, on the right). The angle Ψ will
normally stay almost constant so that the distance between the contact points on the tool
surface will be relatively small (see also the following Figure, on the left).

Figure 23-18 Machining at inside corners

The difference between the programmed point on the path and the point actually to be
approached (path offset p) is eliminated linearly over the entire block length. Differences
resulting from inside corners at the block start and block end are overlaid. The current
difference in a path point is always perpendicular to the path and in the surface defined by the
surface normal vector.
If the tool orientation at an inside corner is not constant, the change in orientation is
implemented in the same way as described in Subsection "Behavior at inside corners" for 3D
circumferential milling, i.e. the tool is moved in the corner so that it contacts the two adjacent
surfaces at the block start, block end and at two points 1/3 and 2/3 of the change in orientation.
A 3rd-degree polynomial is used to interpolate between these 4 points.

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23.4 Selection/deselection of 3D TRC

A variable tool orientation in a block that is shortened owing to an inside corner is also treated
in the same way as described in Subsection "Behavior at inside corners" for 3D milling, i.e.
the entire change in orientation is executed in the shortened block. Consequently, the
functional relationship between path tangent, surface normal and tool orientation also changes.
This results in new, previously nonexistent singularities or impermissible side angles (at points
which are virtually singular) occurring in the shortened block. If this type of situation is detected
during processing of an inside corner, the machining operation is aborted with an alarm. No
block division takes place at the singular points since the compensatory motions this would
involve frequently cause contour violations and the change in machining side on the tool is not
generally intended or even foreseen by the user. The alarm is also output during examination
of an inside corner if the singularity occurs in the second of the two blocks without the transition
to the next block being considered. The system does not therefore detect that a block of this
type will form an inside corner in conjunction with the following block and that the singularity
would be eliminated again by the second block reduction.
The surface normal vector nF is not affected by the reduction of a block. This means that in
contrast to the tool orientation, the change in orientation that may need to be executed for this
vector will not be imaged onto the reduced traversing interval. This is necessary because a
surface other than that programmed would be machined. Unlike the tool orientation, no
problems arise as the result of an abrupt change in the surface normal vector at a block
transition since it does not reflect any axis motions.
Analogously to 3D circumferential milling, (see Section "Behavior at inside corners
(Page 804)"), the two traversing blocks that form an inside corner must contain contact points.
There is no evaluation of several traversing blocks (i.e. no bottleneck detection), CDON/CDOF
are not evaluated. If no contact point can be found, the machining operation is aborted with
an alarm (risk of collision).

23.3.7 Monitoring of path curvature

The path curvature is not monitored, i.e. the system does not usually detect any attempt to
machine a concave surface that is curved to such a degree that the tool currently in use is not
capable of performing the machining operation. A possible exception are blocks that are split
owing to a singularity. The transition between the two partial blocks created after the split is
then treated like an inside corner. Except for such special cases, the user is responsible for
ensuring that only tools that can machine along the entire contour without violating it are used.

23.4 Selection/deselection of 3D TRC

The following commands are used to select/deselect 3D tool radius compensation for
circumferential milling or face milling:
● CUT3DC (circumferential milling)
● CUT3DFS (face milling)
● CUT3DFF (face milling)
● CUT3DF (face milling)

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23.4 Selection/deselection of 3D TRC

23.4.1 Selection of 3D TRC

CUT3DC
3D radius compensation for circumferential milling (only when 5-axis transformation is
active).

CUT3DFS
3D tool offset for face milling with constant orientation. The tool orientation is determined by
G17 - G19 and is not influenced by frames.

CUT3DFF
3D tool offset for face milling with constant orientation. The tool orientation is the direction
defined by G17 - G19 and, in some case, rotated by a frame.

CUT3DF
This programming command selects the 3D tool offset for face milling with change in orientation
(only when 5-axis transformation is active).

TRC selection
The program commands used to select 3D TRC are the same as those for 2D TRC. G41/
G42 specify the compensation on the left or right in the direction of motion (the response on
selection of G41 and G42 for 3D face milling is identical). Tool radius compensation is
deactivated with G40. The approach response is always controlled with NORM. Activation must
be in a linear block.
Example:

Program code Comment

N10 A0 B0 X0 Y0 Z0 F5000
N20 T1 D1 ; Radius=5
N30 TRAORI(1) ; Transformation selection
N40 CUT3DC ; 3D TRC selection (circumferential milling)
N50 G42 X10 Y10 ; TRC selection
N60 X60
N70 ...

Intermediate blocks
Intermediate blocks are permitted when 3D TRC is active. The specifications for 2D TRC apply
equally to 3D TRC.

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23.5 Constraints

23.4.2 Deselection of 3D TRC

Deselection
The 3D tool radius compensation function is deselected in a linear block G0/G1 with geometry
axes by means of G40.
Example:

Program code Comment

N10 A0 B0 X0 Y0 Z0 F500
N20 T1 D1 ; Radius=5
N30 TRAORI(1) ; Transformation selection
N40 CUT3DC ; 3D TRC selection
N50 G42 X10 Y10 ; TRC selection
N60 X60
N70 G40 X100 Y0 Z20 ; 3D TRC deselection
N80 ...

Note
D0 is programmed via active tool radius compensation, so there is no selection. If no geometry
axis is programmed for the current plane in the block with the selection, no selection takes
place.

23.5 Constraints

Face milling
The following boundary conditions must be observed for the "3D tool radius compensation"
for face milling:
● Functions with higher-order geometry information cannot be used (e.g. compressor,
polynomial or spline interpolation).
● A "bottleneck detection" is not possible, and therefore the user is solely responsible.
● For traversing motion in the orientation direction of the tool, and alarm is displayed and
machining stopped.

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23.6 Examples

23.6 Examples
Example program for 3D circumferential milling:

Program code Comment

; Definition of tool D1
$TC_DP1[1,1]=120 ; Type (end mill)
$TC_DP3[1,1] = ; Length offset vector
$TC_DP6[1.1] =8 ; Radius
N10 X0 Y0 Z0 T1 D1 F12000 ; Selection of the tool
N20 TRAORI(1) ; Activate transformation
N30 G42 ORIC ISD=10 CUT3DC G64 X30 ; Activate 3D circumferential milling,
; Orientation changes at outside corners
; Constant, 10 mm insertion depth.
N40 ORIWKS A30 B15 ; Change of orientation at a corner
; by specification of axis positions.
N50 Y20 A3=1 C3=1 ; Traversing block with change in orientation, specifica-
tion
; of the orientation with direction vectors
N60 X50 Y30 ; Traversing block with constant orientation
N70 Y50 A3=0.5 B3=1 C3=5 ; Traversing block with change in orientation
N80 M63 ; Block without traversing information
N90 X0 ISD=20 ; Traversing block with change of the insertion depth
N100 G40 Y0 ; Deactivating the tool radius compensation
N110 M30

Example program for 3D face milling:

Program code Comment

N10 ; Definition of tool D1
N20 $TC_DP1[1,1] = 121 ; Tool type (torus cutter)
N30 $TC_DP3[1,1]=20 ; Tool length offset
N40 $TC_DP6[1,1]=5 ; Radius
N60
N70
N50 $TC_DP7[1,1]=3 ; Smoothing radius
N80 X0 Y0 Z0 A0 B0 C0 G17 T1 D1 F12000 ; Selection of the tool
N90 TRAORI(1)
N100 B4=-1 C4=1 ; Plane definition
N110 G41 ORID CUT3DF G64 X10 Y0 Z0 ; Activate tool offset
N120 X30
N130 Y20 A4=1 C4=1 ; Outside corner, new plane definition
N140 B3=1 C3=5 ; Change in orientation with ORID
N150 B3=1 C3=1 ; Change in orientation with ORID
N160 X-10 A5=1 C5=2 ORIC

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23.7 Data lists

Program code Comment

N170 A3=-2 C3=1 ; Change in orientation with ORIC
N180 A3=-1 C3=1 ; Change in orientation with ORIC
N190 Y-10 A4=-1 C4=3 ; New plane definition
N200 X-20 Y-20 Z10 ; Inside corner with previous block
N210 X-30 Y10 A4=1 C4=1 ; Inside corner, new plane definition
N220 A3=1 B3=0.5 C3=1.7 ; Change in orientation with ORIC
N230 X-20 Y30 A4=1 B4=-2 C4=3 ORID
N240 A3 = 0.5 B3=-0.5 C3=1 ; Change in orientation
N250 X0 Y30 C4=1 ; Path movement, new plane,
; Orientation
; With relative programming
N260 BSPLINE X20 Z15 ; Spline onset, relative programming
N270 X30 Y25 Z18 ; of the orientation remains during
N280 X40 Y20 Z13 ; Spline active
N290 X45 Y0 PR=2 Z8
N300 Y-20
N310 G2 ORIMKS A30 B45 i-20 X25 Y-40 Z0 ; Helix, orientation with axis program
N320 G1 X0 A3=-0.123 B3=0.456 C3 =2.789 B4=-1 C4=5 ; Path movement, orientation, non-constant plane
B5=-1 C5=2
N330 X-20 G40 ; Deactivation of the tool offset
N340 M30

23.7 Data lists

23.7.1 General machine data

Number Identifier: $MN_ Description

18094 MM_NUM_CC_TDA_PARAM Number of TDA data
18096 MM_NUM_CC_TOA_PARAM Number of TOA data, which can be set up per tool and
evaluated by the CC
18100 MM_NUM_CUTTING_EDGES_IN_TOA Tool offsets per TOA module
18110 MM_NUM_TOA_MODULES Number of TOA modules

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23.7 Data lists

23.7.2 Channelspecific machine data

Number Identifier: $MC_ Description

20110 RESET_MODE_MASK Definition of control basic setting after powerup and RE‐
SET / part program end
20120 TOOL_RESET_VALUE Definition of tool for which tool length compensation is
selected during powerup or on reset or parts program
end as a function of MD 20110
20130 CUTTING_EDGE_RESET_VALUE Definition of tool cutting edge for which tool length com‐
pensation is selected during powerup or on reset or
parts program end as a function of MD20110
20140 TRAFO_RESET_VALUE Definition of transformation block which is selected dur‐
ing powerup and or RESET or parts program end as a
function of MD20110
20210 CUTCOM_CORNER_LIMIT Max. angle for intersection calculation with tool radius
compensation
20220 CUTCOM_MAX_DISC Maximum value for tool radius compensation
20230 CUTCOM_CURVE_INSERT_LIMIT Minimum value for intersection calculation with tool ra‐
dius compensation
20240 CUTCOM_MAXNUM_CHECK_BLOCKS Blocks for predictive contour calculation with tool radius
compensation
20250 CUTCOM_MAXNUM_DUMMY_BLOCKS Max. no. of dummy blocks with no traversing movements
20270 CUTTING_EDGE_DEFAULT Selected cutting edge after tool change
20610 ADD_MOVE_ACCEL_RESERVE Acceleration reserve for overlaid movements
21080 CUTCOM_PARALLEL_ORI_LIMIT Limit angle between path tangent and tool orientation
with 3D tool radius compensation
21082 CUTCOM_PLANE_ORI_LIMIT Minimum angle between surface normal and tool orien‐
tation with side angle not equal to 0
21084 CUTCOM_PLANE_PATH_LIMIT Minimum angle between surface normal vector and path
tangent vector, for 3D face milling
22550 TOOL_CHANGE_MODE New tool offsets with M function
22560 TOOL_CHANGE_M_CODE M function for tool change

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24.1 Brief description

Function
With the "Path length evaluation" function, the NCK specific machine axis data is made
available as the system and OPI variables, with whose help it is possible to assess the strain
on the machine axes and thereby make an evaluation on the state of the machine's
maintenance.

Recorded data
The following data is recorded:
● Total traverse path
● Total travel time
● Total travel count
● Total traverse path at high axis speeds
● Total travel time at high axis speeds
● Travel count at high axis speeds
● Total sum of jerks
● Axis travel time with jerk
● Travel count with jerk

Evaluation
When the function is activated, the selected control data is automatically sent and made
available via the system and OPI variables for evaluation in the part program or synchronized
actions, as with user-specified HMI functions.

Meaning
The data remains saved in the control, so that it may continue to be used after POWER OFF /
ON. Consequently, the actual value of a data item represents the sum of all measured values
since the function was activated.

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24.3 Parameterization

24.2 Data
The following data is available:

System variable 1) OPI variable Meaning

$AA_TRAVEL_DIST aaTravelDist Total traverse path:
sum of all set position changes in MCS 2) in [mm] or [deg.].
$AA_TRAVEL_TIME aaTravelTime Total travel time:
sum of IPO clock cycles from set position changes in MCS 2) in [s]
(solution: 1 IPO clock cycle)
$AA_TRAVEL_COUNT aaTravelCount Total travel count:
a complete machine axis trip is defined by the following succession of
states, as based on set position: standstill > traversing > standstill
$AA_TRAVEL_DIST_HS aaTravelDistHS Total traversing distance at high axis velocities 3)
$AA_TRAVEL_TIME_HS aaTravelTimeHS Total traversing time at high axis velocities 3)
$AA_TRAVEL_COUNT_HS aaTravelCountHS Total number of traversing operations at high axis velocities 3)
$AA_JERK_TOT aaJerkTotal Total sum of axis jerks:
Sum of all jerk setpoints in [m/s3] or [deg./ s3].
$AA_JERK_TIME aaJerkTime Total travel time with jerk:
sum of IPO clock cycles from jerk setpoint changes in [s] (solution: 1
IPO clock cycle)
$AA_JERK_COUNT aaJerkCount Total number of traversing operations with jerk
1)
System variables can be read from part programs and synchronized actions
2
) MCS: Machine coordinate system
3)
Actual machine axis velocity ≥ 80% of the maximum parameterized axis velocity (MD32000 MAX_AX_VELO)

24.3 Parameterization

24.3.1 General activation

The function is generally activated via the NCK-specific machine data:
MD18860 $MN_MM_MAINTENANCE_MON (Activate recording of maintenance data)

24.3.2 Data groups

The data has been collected into data groups.
The data groups are activated via the axis-specific machine data:

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24.4 Examples

MD33060 $MA_MAINTENANCE_DATA (configuration to record maintenance data)

Bit Value Activation of the following data: System variable / OPI variable
0 1 ● Total traverse path: $AA_TRAVEL_DIST / aaTravelDist
● Total travel time: $AA_TRAVEL_TIME / aaTravelTime
● Total travel count: $AA_TRAVEL_COUNT / aaTravelCount
1 1 ● Total traversing distance for high velocities:
$AA_TRAVEL_DIST_HS / aaTravelDistHS
● Total traversing time for high velocities:
$AA_TRAVEL_TIME_HS / aaTravelTimeHS
● Total number of traversing operations at high velocities:
$AA_TRAVEL_COUNT_HS / aaTravelCountHS
2 1 ● Total sum of jerks: $AA_JERK_TOT / aaJerkTotal
● Travel time with jerk: $AA_JERK_TIME / aaJerkTime
● Total travel count with jerk:
$AA_JERK_COUNT / aaJerkCount

24.4 Examples

24.4.1 Traversal per part program

Three geometry axes AX1, AX2 and AX3 exist in a machine. For geometry axis AX1, the part
program-driven total traverse path, total travel time and travel count should be calculated.

Parameter assignment
Activation of the overall function:
MD18860 $MN_MM_MAINTENANCE_MON = TRUE
Group activation: "Total travel distance, total travel time and number of travel operations" for
geometry axis AX1:
MD33060 $MA_MAINTENANCE_DATA[AX1] = 1

Programming
To determine the values referred to the part program, the actual value of the system variables
at the beginning of the part program must be saved in a calculation variable. The difference is
acquired at the end of the part program.
Part program (extract):

Program code Comment

...
; Current values:

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24.5 Data lists

Program code Comment

R10=$AA_TRAVEL_DIST[AX1] ; Total traversing distance AX1
R11=$AA_TRAVEL_TIME[AX1] ; Total traversing time AX1
R12=$AA_TRAVEL_COUNT[AX1] ; Number of traversing operations AX1

... ; Traversing motion of axes

; Generating the difference:

R10=R10-$AA_TRAVEL_DIST[AX1] ; Traversing distance AX1 in the part pro-
gram
R11=R11-$AA_TRAVEL_TIME[AX1] ; Traversing time AX1 in the part program
R12=R12-$AA_TRAVEL_COUNT[AX1] ; Number of traversing operations AX1 in
the part program

24.5 Data lists

24.5.1 Machine data

24.5.1.1 NC-specific machine data

Number Identifier: $MN_ Description

18860 MM_MAINTENANCE_MON Activate recording of maintenance data

24.5.1.2 Axis/spindlespecific machine data

Number Identifier: $MA_ Description

33060 MAINTENANCE_DATA Configuration, recording maintenance data

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25.1 F2: 3 to 5-axis transformation

25.1.1 Signals from channel (DB21, ...)

DB21, ...
DBX29.4 activate PTP traversal
Edge evaluation: Yes Signal(s) updated:
Signal state 1 or edge activate PTP traversal.
change 0 → 1
Signal state 0 or edge Activate CP traversal.
change 1 → 0
Signal irrelevant for ... No handling transformations active.
Additional references Function Manual, Special Functions; 3-Axis to 5-Axis Transformation (F2)

DB21, ...
DBX33.6 Transformation active
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge Active transformation.
change 0 → 1
Signal state 0 or edge Transformation not (no longer) active.
change 1 → 0
Signal irrelevant for ... No transformation used.
Additional references Programming Manual, Fundamentals

DB21, ...
DBB232 Number of active G function of G function group 25 (tool orientation reference)
Edge evaluation: Signal(s) updated:
Signal state 1 or edge ORIWKS: The tool orientation is implemented in a workpiece coordinate system and is thus
change 0 → 1 not dependent on the machine kinematics. This is the default setting.
Signal state 0 or edge ORIMKS: The tool orientation is defined in the machine coordinate system and is thus depend‐
change 1 → 0 ent on the machine kinematics. This is the default setting.

DB21, …
DBX317.6 PTP traversal active
Edge evaluation: Yes Signal(s) updated:
Signal state 1 or edge PTP traversal active.
change 0 → 1

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25.1 F2: 3 to 5-axis transformation

DB21, …
DBX317.6 PTP traversal active
Signal state 0 or edge CP traversal active.
change 1 → 0
Signal irrelevant for ... No handling transformations active.
Additional references Function Manual, Special Functions; 3-Axis to 5-Axis Transformation (F2)

DB21, …
DBX318.2 TOFF active
Edge evaluation: Yes Signal(s) updated:
Signal state 1 or edge Activate online tool length offset.
change 0 → 1
Signal state 0 or edge Reset online tool length offset.
change 1 → 0
Signal irrelevant for ... The "generic 5-axis transformation" option is not available and no handling transformations
are active.
Additional references Function Manual, Special Functions; 3-Axis to 5-Axis Transformation (F2)

DB21, …
DBX318.3 TOFF motion active
Edge evaluation: Yes Signal(s) updated:
Signal state 1 or edge Activate offset motion.
change 0 → 1
Signal state 0 or edge Deactivate offset motion.
change 1 → 0
Signal irrelevant for ... The "generic 5-axis transformation" option is not available and no handling transformations
are active.
Additional references Function Manual, Special Functions; 3-Axis to 5-Axis Transformation (F2)

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25.2 G1: Gantry axes

25.2 G1: Gantry axes

25.2.1 Signals to axis/spindle (DB31, ...)

DB31, ...
DBX29.4 Start gantry synchronization
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge Request from PLC user program to synchronize the leading axis with the assigned synchron‐
change 0 → 1 ized axes:
MD37100 $MA_GANTRY_AXIS_TYPE (gantry axis definition)
(i.e. all gantry axes approach the reference position of the gantry grouping in the decoupled
state).
Synchronization of the gantry axes can be started only under the following conditions:
● REF machine function must be active
● DB11, ... DBX5.2 (REF active machine function) = 1
● DB31, ... DBX101.5 (gantry grouping is synchronized) = 0
● DB31, ... DBX101.4 (gantry synchronization ready to start) = 1
● No axis is being referenced in the appropriate NC channel:
DB21, … DBX33.0 (referencing active) = 0
Signal state 0 or edge The PLC user program can then, for example, reset the interface signal to signal state "0" on
change 1 → 0 completion of gantry synchronization (DB31, ... DBX101.5 = 1).
If the IS is set continuously to "1", the gantry synchronization run would be started automatically
as soon as the above conditions are fulfilled.
Signal irrelevant for ... Gantry synchronized axis
Application example(s) If the deviation between the position actual values and the reference position is greater than
the gantry warning threshold after referencing of the gantry axes, automatic gantry synchroni‐
zation is not started and IS "Gantry synchronization ready to start" is set to "1".
Synchronization of the gantry axes can be started by the user or the PLC user program with
IS "Start gantry synchronization".
Corresponding DB31, ... DBX101.5 (gantry grouping is synchronized)
to .... DB31, ... DBX101.4 (gantry synchronization ready to start)
DB11, ... DBX5.2 (REF active machine function)
DB21, ... DBX33.0 (referencing active)

DB31, ...
DBX29.5 Disable automatic synchronization
Edge evaluation: No Signal(s) updated:
Signal state 1 or edge No automatic synchronization.
change 0 → 1
Signal state 0 or edge The automatic synchronization process is active.
change 1 → 0

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25.2 G1: Gantry axes

DB31, ...
DBX29.5 Disable automatic synchronization
Signal irrelevant for ... Gantry synchronized axis
Application example(s) The automatic synchronization process can be disabled by sending a VDI signal to the axial
PLC → NC interface of the master axis. This always makes sense when the axes are not
activated by default. In this case, the synchronization process should also be started explicitly.

25.2.2 Signals from axis/spindle (DB31, ...)

DB31, ...
DBX101.2 Gantry trip limit exceeded
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge The difference between the position actual values of the leading and synchronized axes has
change 0 → 1 exceeded the maximum permissible limit value. The axes in the gantry grouping are shut down
internally in the control. Alarm 10653 "Error limit exceeded" is also output.
The monitored limit value is derived from the following machine data:
● MD37120 $MA_GANTRY_POS_TOL_ERROR (gantry trip limit)
... if gantry grouping is synchronized.
● MD37130 $MA_GANTRY_POS_TOL_REF (gantry trip limit for referencing)
... if gantry grouping is not yet synchronized.
Note:
IS "Gantry trip limit exceeded" is output to the PLC via the PLC interface of the synchronized
axis.
Signal state 0 or edge The difference between the position actual values of the leading and synchronized axes is still
change 1 → 0 within the permissible tolerance range.
Signal irrelevant for ... Gantry leading axis
Corresponding to .... MD37120 $MA_GANTRY_POS_TOL_ERROR (gantry trip limit)
MD37130 $MA_GANTRY_POS_TOL_REF (gantry trip limit for referencing)
DB31, ... DBX101.5 (gantry grouping is synchronized)

DB31, ...
DBX101.3 Gantry warning limit exceeded
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge The difference between the position actual values of the leading and synchronized axes has
change 0 → 1 exceeded the limit value defined by the following machine data:
MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit)
The message "Warning limit exceeded" is also output.
Note:
IS "Gantry warning limit exceeded" is output to the PLC via the PLC interface of the synchron‐
ized axis.
Signal state 0 or edge The difference between the position actual values of the leading and synchronized axes is less
change 1 → 0 than the limit value defined with machine data:
MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit)
Signal irrelevant for ... Gantry leading axis

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25.2 G1: Gantry axes

DB31, ...
DBX101.3 Gantry warning limit exceeded
Application example(s) When the gantry warning limit is exceeded, the necessary measures (e.g. program interruption
at block end) can be initiated by the PLC user program.
Special cases, errors, ... Warning limit monitoring is rendered inactive when the value 0 is input in the following machine
data:
MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit)
Corresponding to .... MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit)

DB31, ...
DBX101.4 Gantry synchronization ready to start
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge After gantry axis referencing, the monitoring function has detected that the position actual value
change 0 → 1 deviation between the leading and synchronized axes is greater than the gantry warning limit:
MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit)
It is therefore not possible to start the automatic synchronization compensatory motion of the
gantry axes internally in the control.
The compensatory motion must be started by the user or the PLC user program (IS "Start
gantry synchronization"). The signal is processed for the gantry leading axis only.
Signal state 0 or edge After the synchronization compensatory motion has been started by the PLC user program (IS
change 1 → 0 "Start gantry synchronization" = "1").
Signal irrelevant for ... Gantry synchronized axis
Corresponding to .... MD37110 $MA_GANTRY_POS_TOL_WARNING (gantry warning limit)
DB31, ... DBX29.4 (gantry synchronization ready to start)
DB31, ...DBX60.4 and 60.5 (referenced / synchronized 1/2)

DB31, ...
DBX101.5 Gantry grouping is synchronized
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge The gantry axis grouping defined with the following machine data is synchronized:
change 0 → 1 MD37100 $MA_GANTRY_AXIS_TYPE (gantry axis definition)
Any existing misalignment between the leading and synchronized axes (e.g. after start-up of
the machine) is eliminated by gantry axis synchronization (see Section "Start-up of gantry
axes (Page 162)").
The synchronization process is initiated either automatically once the gantry axes have been
referenced or via the PLC user program (IS "Start gantry synchronization").
The compensation values for temperature and sag do not become effective internally in the
control until the gantry grouping is synchronized.
Note:
IS "Gantry grouping is synchronized" is output to the PLC via the PLC interface of the leading
axis.

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25.2 G1: Gantry axes

DB31, ...
DBX101.5 Gantry grouping is synchronized
Signal state 0 or edge The gantry axis grouping defined with the following machine data is not synchronized:
change 1 → 0 MD37100 $MA_GANTRY_AXIS_TYPE (gantry axis definition)
which means that the positions of the leading and synchronized axes may not be ideally aligned
(e.g. gantry misalignment).
Workpiece machining with a non-synchronized gantry axis grouping will result in impaired ma‐
chining accuracy or mechanical damage to the machine.
The gantry grouping becomes desynchronized if:
● The gantry axes were in "Follow-up" mode
● The reference position of a gantry axis is no longer valid or the axis is referenced again (IS
"Referenced/Synchronized")
● The gantry grouping has been invalidated via the following machine data:
MD37140 $MA_GANTRY_BREAK_UP (invalidate gantry axis grouping)
Signal irrelevant for ... Gantry synchronized axis
Application example(s) Machining should be enabled only if the gantry axes are already synchronized. This can be
implemented in the PLC user program by combining NC Start with IS "Gantry grouping is
synchronized".
Corresponding to .... DB31, ... DBX29.4 (gantry synchronization ready to start)
DB31, ... DBX60.4 and 60.5 (referenced/synchronized 1 / 2)
MD37140 $MA_GANTRY_BREAK_UP (invalidate gantry axis grouping)

DB31, ...
DBX101.6 Gantry leading axis
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge The axis is defined as the leading axis within a gantry axis grouping (see MD37100).
change 0 → 1 Note:
The following interface signals are evaluated or output to the PLC via the PLC interface of the
gantry leading axis:
DB31, ... DBX29.4 (gantry synchronization ready to start)
DB31, ... DBX101.5 (gantry grouping is synchronized)
Signal state 0 or edge The axis is defined as the synchronized axis within a gantry axis grouping (see MD37100).
change 1 → 0 It is not possible to traverse a synchronized axis directly by hand (in JOG mode) or to program
it in a part program.
Note:
The following interface signals are output to the PLC via the PLC interface of the gantry
synchronized axis:
DB31, ... DBX101.3 (warning limit exceeded)
DB31, ... DBX101.2 (gantry trip limit exceeded)
The NCK does not evaluate individual axial PLC interface signals for the synchronized axis.
Corresponding to .... MD37100 $MA_GANTRY_AXIS_TYPE (gantry axis definition)
DB31, ...DBX101.7 (gantry axis)

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25.3 K9: Collision avoidance

DB31, ...
DBX101.7 Gantry axis
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge The axis is defined as a gantry axis within a gantry axis grouping (see MD37100).
change 0 → 1 The PLC user program can read IS "Gantry leading axis" to detect whether the axis has been
declared as a leading or synchronized axis.
Signal state 0 or edge The axis is not defined as a gantry axis (see MD37100).
change 1 → 0
Corresponding to .... MD37100 $MA_GANTRY_AXIS_TYPE (gantry axis definition)
DB31, ... DBX101.6 (gantry leading axis)

25.3 K9: Collision avoidance

25.3.1 Signals from PLC to NC (DB10)

DB10
DBX58.0 - 7 Collision avoidance: Deactivate protection area group
Edge evaluation: No Signal(s) updated: Cyclically
Signal state 1 The deactivation of all protection areas in the selected operating mode and the
selected protection area type is requested.
Bit Operating mode Protection area type 1)
0 AUTOMATIC MACHINE
1 AUTOMATIC TOOL
2 --- ---
3 --- ---
4 JOG MACHINE
5 JOG TOOL
6 --- ---
7 --- ---
Signal state 0 The deactivation of all protection areas in the selected operating mode and the
selected protection area type is not requested.

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25.3 K9: Collision avoidance

DB10
DBX58.0 - 7 Collision avoidance: Deactivate protection area group
Remark 1) Type of a protection area: System variable $NP_PROT_TYPE (Page 236)
Note
● The protection area groups can be deactivated through the SINUMERIK
Operate user interface. Machine basic display AUTOMATIC, JOG or MDI >
"ETC key (">")" > "Settings" > "Collision avoidance" > "Switch collision
avoidance on and off"
● If manual traversing has been enabled in AUTOMATIC mode:
MD10735 $MN_JOG_MODE_MASK, bit 0 == 1 (Enable Jog in Automatic
mode)
the settings for the JOG mode also apply in AUTOMATIC mode during
manual traversing.
Additional references Turning and/or Milling Operating Manual respectively: "Collision avoidance" sec‐
tion

DB10
DBX234.0 - DBX241.7 Collision avoidance: Activate protection area
Edge evaluation: No Signal(s) updated: Cyclically
Signal state 1 Request to activate the protection areas that are connected with the interface
signal.
Signal state 0 Request to deactivate the protection areas that are connected with the interface
signal.
Remark A protection area is connected with the interface signal via parameter assign‐
ment of the Bit number corresponding with the interface signal, in the system
variables $NP_BIT_NO (Page 240) of the protection area.
Assignment: Bit number ↔ interface signal
Bit number Interface signal
0, 1, 2, ... 62, 63 DBX234.0, DBX234.1, DBX234.2, ... DBX241.6,
DBX241.7
corresponding DB10, DBX226.0 - DBX233.7 (collision avoidance: protection area active)
with ...

25.3.2 Signals from the NC to the PLC (DB10)

DB10
DBX226.0 - DBX233.7 Collision avoidance: Protection area active
Edge evaluation: No Signal(s) updated: Cyclically
Signal state 1 The protection area connected to the interface signal 1) is active.
If several protection areas are connected to the interface signal 1): All protection
areas are active.
Signal state 0 The protection area connected to the interface signal 1) is not active.
If several protection areas are connected to the interface signal 1): At least one
protection area is not active.

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25.3 K9: Collision avoidance

DB10
DBX226.0 - DBX233.7 Collision avoidance: Protection area active
Remark A protection area is connected with the interface signal via parameter assign‐
ment of the Bit number corresponding with the interface signal, in the system
variables $NP_BIT_NO (Page 240) of the protection area.
Assignment: Bit number ↔ interface signal
Bit number Interface signal
0, 1, 2, ... 62, 63 DBX226.0, DBX226.1, DBX226.2, ... DBX233.6,
DBX233.7
corresponding DB10, DBX234.0 - DBX241.7 (collision avoidance: activate protection area)
with ...

25.3.3 Signals from channel (DB21)

DB21, ...
DBX377.0 Collision avoidance: Stop
Edge evaluation: No Signal(s) updated: Cyclically
Signal state 1 The collision avoidance has triggered a stop of the traversing motions in the
channel.
Signal state 0 The collision avoidance has not triggered a stop of the traversing motions in the
channel.

25.3.4 Signals from axis (DB31)

DB31, ... Collision avoidance: Velocity reduction

DBX77.0
Edge evaluation: No Signal(s) updated: Cyclically
Signal state 1 The traversing velocity of the axis is reduced by the collision avoidance.
Signal state 0 The traversing velocity of the axis is not reduced by the collision avoidance.

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25.4 M3: Axis couplings

25.4 M3: Axis couplings

25.4.1 Signals to axis (DB31, ...)

DB31, …
DBX26.4 Active following axis overlay

Edge evaluation: No Signal(s) updated: Cyclic

Signal state 1 or edge An additional traversing motion can be overlaid on the following axis.
change 0 → 1 This signal is required for the flying synchronization of master and slave axes. Until the "enable
following axis overlay" signal stays set at 1, the following axis selected with EGONSYN will travel
to synchronization in the EG coupling.
Modulo axes included in the EG coupling reduce their position values in the modulo, thereby
ensuring that they approach the next possible synchronization.
Signal state 0 or edge The following axis cannot be overlaid and traversed.
change 1 → 0 If the "enable following axis overlay" signal has not been set for the following axis, the axis
will not travel to synchronization. Instead, the program is stopped at the EGONSYN block and
the self-clearing alarm 16771 is issued until the "enable following axis overlay" signal is set to
1.

25.4.2 Signals from axis (DB31, ...)

DB31, …
DBX98.5 Velocity warning threshold
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge When the following axis velocity in the axis grouping of the electronic gear (set in machine
change 0 → 1 data MD32000) reaches or exceeds the velocity % block entered in machine data MD37550,
the signal is set to 1.
Signal state 0 or edge The following axis velocity in the axis grouping of the electronic gear is less than the threshold
change 1 → 0 value described above.
Signal irrelevant ... Without electronic gear.
Corresponding to ... the following machine data:
MD37550 $MA_EG_VEL_WARNING (threshold value velocity alarm threshold)
MD32000 $MA_MAX_AX_VELO (maximum axis velocity)

DB31, …
DBX98.6 Acceleration warning threshold
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge When the following axis acceleration in the axis grouping of the electronic gear (set in machine
change 0 → 1 data MD32300) reaches or exceeds the acceleration % block entered in machine data
MD37550, the signal is set to 1.
Signal state 0 or edge The following axis acceleration in the axis grouping of the electronic gear is less than the
change 1 → 0 threshold value described above.

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 Z3: NC/PLC interface signals
25.5 R3: Extended stop and retract

DB31, …
DBX98.6 Acceleration warning threshold
Signal irrelevant ... Without electronic gear.
Corresponding to ... The following machine data:
MD37550 $MA_EG_VEL_WARNING (threshold value velocity alarm threshold)
MD32300 $MA_MAX_AX_ACCEL (axis acceleration)

DB31, …
DBX99.3 Axis accelerated
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge When the following axis acceleration in the axis grouping of the electronic gear (set in machine
change 0 → 1 data MD32300) reaches or exceeds the acceleration % block entered in machine data
MD37560, the signal is set to 1.
Signal state 0 or edge The following axis acceleration in the axis grouping of the electronic gear is less than the
change 1 → 0 operating value described above.
Signal irrelevant ... Without electronic gear.
Corresponding to ... The following machine data:
MD37560 $MA_EG_ACC_TOL (threshold value for "Accelerate axis")
MD32300 $MA_MAX_AX_ACCEL (axis acceleration)

25.5 R3: Extended stop and retract

25.5.1 Signals from axis/spindle (DB31, ...)

DB31, ...
DBX95.1 ESR: DC link undervoltage
Edge evaluation: No Signal(s) updated: Cyclically
Signal state 1 The drive signals that the DC link voltage VDC link is less than the lower DC link voltage threshold set
with parameter p1248.
Signal state 0 The drive signals that the DC link voltage VDC link is greater than the lower DC link voltage threshold
set with parameter p1248.
Application exam‐ The PLC user program can initiate measures in order to safely end machining and/or to buffer the
ple(s) DC link voltage, e.g. initiate a drive-autonomous and/or control-managed extended stop and retract
(ESR).
Corresponding to .... ● Drive parameter p1248 (lower DC link voltage threshold)
● Drive telegram MELDW.Bit 4
Additional references Commissioning Manual IBN CNC: NCK, PLC, Drive

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Z3: NC/PLC interface signals
25.6 S9: Setpoint changeover

DB31, ...
DBX95.2 ESR: Reaction triggered or generator operation active
Edge evaluation: No Signal(s) updated: Cyclically
Signal state 1 The drive signals that the configured ESR response has been triggered or generator operation is
active.
Signal state 0 The drive signals that neither the configured ESR response has been triggered nor that generator
operation is active.
Corresponding to .... Drive telegram MELDW.Bit 9
Additional references Commissioning Manual IBN CNC: NCK, PLC, Drive

DB31, ...
DBX95.3 Generator operation – minimum speed fallen below
Edge evaluation: No Signal(s) updated: Cyclically
Signal state 1 The axis is parameterized as generator axis. The drive signals that the actual speed is less than the
minimum speed set using parameter p2161 (speed threshold value 3).
Signal state 0 The axis is parameterized as generator axis. The drive signals that the actual speed is greater than
the minimum speed set using parameter p2161 (speed threshold value 3).
Application exam‐ The PLC user program can initiate measures in order to safely end machining and/or to buffer the
ple(s) DC link voltage, e.g. initiate a drive-autonomous and/or control-managed extended stop and retract
(ESR).
Corresponding to .... ● Drive parameter p2161 (speed threshold value 3)
● Drive telegram MELDW.Bit2
Additional references Commissioning Manual IBN CNC: NCK, PLC, Drive

25.6 S9: Setpoint changeover

25.6.1 Signals to axis/spindle (DB31, ...)

DB31, ...
DBX24.5 Activate setpoint exchange
Edge evaluation: No Signal(s) updated: Cyclic
Signal state = 1 Request to axis to take over drive control.
Signal state = 0 Request to axis to relinquish drive control.

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 Z3: NC/PLC interface signals
25.8 TE1: Clearance control

25.6.2 Signals from axis/spindle (DB31, ...)

DB31, ...
DBX96.5 Status of setpoint exchange
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 The axis has taken over control of the drive.
Signal state 0 The axis has relinquished control of the drive.
Signal relevant for ... All axes involved in setpoint exchange.

25.7 T3: Tangential control

25.7.1 Special response to signals

The movement of the axis under tangential follow-up control to compensate for a tangent jump
at a corner of the path (defined by the movements of the leading axis) can be stopped by the
following signals (e.g. for test purposes):
● NC Stop and override = 0
● Removal of the axis-specific feed enable
The signals are described in:
Reference:
Lists (Book 2)

25.8 TE1: Clearance control

25.8.1 Signals to channel (DB21, ...)

Table 25-1

DB21, ...
DBX1.4 CLC stop
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or Clearance control is deactivated in the same way as the part program command
edge change 0 → 1 CLC_GAIN=0.0.
Signal state 0 or Clearance control is enabled.
edge change 1 → 0

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25.8 TE1: Clearance control

DB21, ...
DBX1.5 CLC_Override
Edge evaluation: no Signal(s) updated: Cyclic
Signal state 1 or The channel-specific override DB21, … DBB4 (feed rate override) also applies to the clearance
edge change 0 → 1 control
Override settings < 100% reduce corresponding to the velocity limitation for the overriding
motion, as defined in the following machine data:
MD62516 $MC_CLC_SENSOR_VELO_LIMIT (velocity of clearance control motion)
Override settings > 100% apply the limitation from the machine data.
Signal state 0 or The maximum velocity of the control motion is not dependent on the override setting
edge change 1 → 0
Application example The difference for the operator is particularly dependent on whether the sensor motion is stop‐
ped or not with a 0 override.
Corresponding to .... channel-specific override settings:
DB21, ... DBB4 (feed rate override)
DB21, ... DBX6.7 (feed rate override active)

25.8.2 Signals from channel (DB21, ...)

DB21, ...
DBX37.3 CLC is active
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or Clearance control is activated.
edge change 0 → 1
Signal state 0 or Clearance control is deactivated.
edge change 1 → 0

DB21, ...
DBX37.4 CLC motion at lower motion limit
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or The traversing movement of the clearance-controlled axes based on clearance control has
edge change 0 → 1 been stopped at the upper movement limit set in
MD62505 $MC_CLC_SENSOR_LOWER_LIMIT (lower clearance control motion limit)
or programmed with CLC_LIM(..).
Note:
The following signal is set at the same time:
DB21, … DBX37.5 (CLC-stopped upper limit)
→ see "CLC motion has stopped" signal.
Signal state 0 or Clearance control has left the lower limitation.
edge change 1 → 0

Special functions
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 Z3: NC/PLC interface signals
25.8 TE1: Clearance control

DB21, ...
DBX37.5 CLC motion at upper motion limit
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or The traversing movement of the clearance-controlled axes based on clearance control has
edge change 0 → 1 been stopped at the upper movement limit set in
MD62506 $MC_CLC_SENSOR_UPPER_LIMIT (upper clearance control motion limit)
or programmed with CLC_LIM(..).
Note:
The following signal is set at the same time:
DB21, … DBX37.4 (CLC-stopped lower limit)
→ see "CLC motion has stopped" signal.
Signal state 0 or Clearance control has left the upper limitation.
edge change 1 → 0

DB21, ...
DBX37.4-5 CLC motion has stopped
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or The traversing movement of the clearance-controlled axes based on clearance control is at a
edge change 0 → 1 standstill. The following conditions will set the signal:
The standstill conditions set in the following machine data are met:
MD62520 $MC_CLC_SENSOR_STOP_POS_TOL (positional tolerance for status message
"Clearance control zero speed")
MD62521 $MC_CLC_SENSOR_STOP_DWELL_TIME (wait time for status message "Clear‐
ance control zero speed")
Programming of CLC_GAIN=0.0
PLC interface signal:
DB21, … DBX1.4 (stop CLC motion)
Note:
The "CLC motion at standstill" signal is only set if bits 4 and 5 are set at the same time. If only
one of the two bits is set → see below.
Signal state 0 or Clearance control generates traversing movements directly in the clearance-controlled axes.
edge change 1 → 0 As long as the axes are traversing due to clearance control, the axial interface signals cannot
be set:
DB31, … DBX60.6/7 (position reached with exact stop coarse/fine)
Corresponding to .... DB3x DBX30.6/7 "Position reached, exact stop coarse/fine"

Special functions
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Z3: NC/PLC interface signals
25.9 TE3: Speed/torque coupling, master-slave

25.9 TE3: Speed/torque coupling, master-slave

25.9.1 Signals to axis/spindle (DB31, ...)

DB31, ...
DBX24.4 Torque compensatory controller on
Edge evaluation: Yes Signal(s) updated: Cyclically
Signal state 1 or edge Torque compensatory controller is to be activated.
change 0 → 1 The following conditions must be fulfilled for activation:
DB31, ... DBX96.2 ("fine" differential speed reached)
Signal state 0 or edge Torque compensatory controller is to be deactivated.
change 1 → 0

DB31, ...
DBX24.7 Master/slave on
Edge evaluation: Yes Signal(s) updated: Cyclic
Signal state 1 or edge Master-slave coupling should be activated.
change 0 → 1
Signal state 0 or edge Master-slave coupling should be deactivated.
change 1 → 0 The following conditions must be fulfilled for activation and deactivation:
● Leading and following axes under position control (DB31, ... DBX61.5)
● Leading and following axes are at standstill (DB31, ... DBX61.4)
● The channels of the leading and following axes are in the reset state (DB21, ... DBX35.7)
If a condition is not fulfilled, the coupling will not be activated or deactivated. No alarm appears
and the status of the coupling remains the same.
If, at a later point, all conditions are fulfilled, the coupling will be activated or deactivated
depending on the status of the signal.
The signal for the following axis of a coupling is relevant.

25.9.2 Signals from axis/spindle (DB31, ...)

DB31, ...
DBX96.2 Master/slave fine
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge The differential speed is in the range defined by the following machine data:
change 0 → 1 MD37272 $MA_MS_VELO_TOL_FINE
Signal state 0 or edge The differential speed has not reached the range defined in MD37272.
change 1 → 0

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 Z3: NC/PLC interface signals
25.10 TE4: Transformation package, handling

DB31, ...
DBX96.3 Master/slave coarse
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge The differential speed is in the range defined by the following item of machine data:
change 0 → 1 MD37270 $MA_MS_VELO_TOL_COARSE
Signal state 0 or edge The differential speed has not reached the range defined in MD37270.
change 1 → 0

DB31, ...
DBX96.4 Master/slave compensatory cont. active
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge Torque compensatory control is active.
change 0 → 1
Signal state 0 or edge Torque compensatory control is not active.
change 1 → 0 The signal at the slave axis of a coupling is relevant.

DB31, ...
DBX96.7 Master/slave active
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or edge Master-slave coupling is active.
change 0 → 1
Signal state 0 or edge Master-slave coupling is not active.
change 1 → 0 The signal at the following axis of a coupling is relevant.

25.10 TE4: Transformation package, handling

25.10.1 Signals from channel (DB21, ...)

DB21, ...
DBX29.4 Activate PTP traversal
Edge evaluation: Yes Signal(s) updated:
Signal state 1 or Activate PTP traversal.
edge change 0 → 1
Signal state 0 or Activate CP traversal.
edge change 1 → 0
Signal irrelevant No handling transformations active.
for ...
Additional references Function Manual, Special Functions; 3-Axis to 5-Axis Transformation (F2)

Special functions
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Z3: NC/PLC interface signals
25.11 TE6: MCS coupling

DB21, ...
DBX33.6 Transformation active
Edge evaluation: Yes Signal(s) updated:
Signal state 1 or edge Active transformation.
change 0 → 1
Signal state 0 or edge Transformation not (no longer) active.
change 1 → 0
Signal irrelevant for ... No transformation used.
Additional references Function Manual, Special Functions; 3-Axis to 5-Axis Transformation (F2)

DB21, ...
DBB232 Number of active G function of G function group 25 (tool orientation reference)
Edge evaluation: Signal(s) updated:
Meaning 1 ORIWKS: The tool orientation is implemented in a workpiece coordinate system and is thus not de‐
pendent on the machine kinematics.
Meaning 2 ORIMKS: The tool orientation is defined in the machine coordinate system and is thus dependent on
the machine kinematics. This is the default setting.
Meaning 3 ORIPATH: The tool orientation is implemented with the programmed lead and side angles relative to
the path tangent and surface normal vector.

DB21, ...
DBX317.6 PTP traversal active
Edge evaluation: Yes Signal(s) updated:
Signal state 1 or edge PTP traversal active.
change 0 → 1
Signal state 0 or edge CP traversal active.
change 1 → 0
Signal irrelevant for ... No handling transformations active.
Additional references Function Manual, Special Functions; 3-Axis to 5-Axis Transformation (F2)

25.11 TE6: MCS coupling

25.11.1 Signals to axis/spindle (DB31, ...)

DB31, …
DBX24.2 Deactivate or disable coupling
Edge evaluation: No Signal(s) updated:
Signal state 1 An active coupling is not deactivated until the relevant axes are stationary. If CC_COPON is
programmed for this axis, no error message is generated.
Signal state 0 Coupling may be activated

Special functions
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 Z3: NC/PLC interface signals
25.11 TE6: MCS coupling

DB31, …
DBX24.2 Deactivate or disable coupling
Signal irrelevant for ...
Application example(s) Evaluated only on the CC_Slave axis.

DB31, …
DBX24.3 Switch on collision protection
Edge evaluation: Yes Signal(s) updated:
Signal state 1 Collision protection ON
Signal state 0 Collision protection OFF
Signal irrelevant for ... This signal is processed only if collision protection is not activated via machine data:
MD65543 $MA_CC_PROTECT_OPTIONS
Application example(s) Evaluated only on the PSlave axis.

25.11.2 Signals from axis/spindle (DB31, ...)

DB31, …
DBX66.0 Activate monitor
Edge evaluation: No Signal(s) updated:
Signal state 1 Monitoring is active.
This readout must be activated by the PSlave axis in the the following machine data:
MD63543 $MD_CC_PROTECT_OPTIONS
Note:
Conflicts may occur in connection with customer-specific compile cycles.
Signal state 0 Monitor is not active.

DB31, …
DBX97.0 Axis is a slave axis
Edge evaluation: No Signal(s) updated:
Signal state 1 Axis is a CC_Slave axis.
The associated CC_Master axis can be found in the machine data.
Signal state 0 Axis is not a CC_Slave axis

DB31, …
DBX97.1 Activate coupling
Edge evaluation: No Signal(s) updated:
Signal state 1 Coupling active
Signal state 0 Coupling not active
Signal irrelevant for ...
Application example(s) Displayed only for the CC_Slave axis.

Special functions
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Z3: NC/PLC interface signals
25.12 TE7: Continue machining at the contour – retrace support

DB31, …
DBX97.2 Activate mirroring
Edge evaluation: No Signal(s) updated:
Signal state 1 Mirroring active (1:-1)
Signal state 0 1:1 coupling active
Signal irrelevant for ... Relevant only if coupling is active (DBX97.1 = 1)
Application example(s) Displayed only for the CC_Slave axis.

DB31, …
DBX97.3 Offset after point of activation
Edge evaluation: Yes Signal(s) updated:
Signal state 1 New offset after point of activation.
This bit is set to 1 if a particular event (SW/HW limit switch on CC_Slave axis) causes a change
in the offset between CC_Master and CC_Slave stored when the coupling was activated.
Signal state 0 No new offset since activation.
Signal irrelevant for ... The bit is not set in the RESET phase.
Application example(s) Displayed only for the CC_Slave axis.

25.12 TE7: Continue machining at the contour – retrace support

25.12.1 Signals to channel

DB21, ...
DBX0.1 Reverse/Forward
Edge evaluation: Yes Signal(s) updated:
Signal state 1 or edge Activate reverse travel.
change 0 → 1 The RESU main program CC_RESU.MPF is generated from the traversing blocks recorded in the
RESU-internal block buffer in order to initiate travel back along the contour on the next NC START.
Edge change 1 → 0 Activate forward travel.
The RESU main program CC_RESU.MPF is generated from the traversing blocks recorded in the
RESU-internal block buffer in order to initiate travel forwards along the contour on the next NC
START.
Signal state 0 Not relevant.
Signal irrelevant for ... RESU technological function not loaded or not activated.

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 Z3: NC/PLC interface signals
25.12 TE7: Continue machining at the contour – retrace support

DB21, ...
DBX0.2 Start retrace support
Edge evaluation: No Signal(s) updated:
Signal state 1 Start retrace support:
The original machining program is reselected and a block search is carried out to locate the program
continuation point.
Signal state 0 Not relevant.
Signal irrelevant for ... The NC is not in Retrace mode or RESU is not active.

25.12.2 Signals from channel

DB21, ...
DBX32.1 Retrace mode active
Edge evaluation: No Signal(s) updated:
Signal state 1 The "Retrace mode active" signal is active as long as the control is in Retrace mode. This is the case
from initial activation of the "reverse/forward" signal until activation of the "start retrace support"
signal.
Signal state 0 The machining program is executed.
Signal irrelevant for ... RESU technological function not active.

DB21, ...
DBX32.2 Retrace support active
Edge evaluation: No Signal(s) updated:
Signal state 1 The "retrace support active" signal is set as soon as signal state 1 is detected for the "start retrace
support" signal. The "retrace support active" signal is reset at the end of retrace support once the
last action block has been completed.
Signal state 0 Retrace support not active
Signal irrelevant for ... RESU technological function not active.

Special functions
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Z3: NC/PLC interface signals
25.12 TE7: Continue machining at the contour – retrace support

Special functions
848 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
Appendix A
A.1 List of abbreviations

A
O Output
ADI4 (Analog drive interface for 4 axes)
AC Adaptive Control
ALM Active Line Module
ARM Rotating induction motor
AS Automation system
ASCII American Standard Code for Information Interchange: American coding standard for
the exchange of information
ASIC Application-Specific Integrated Circuit: User switching circuit
ASUB Asynchronous subprogram
AUXFU Auxiliary function: Auxiliary function
STL Statement List
UP User Program

B
OP Operating Mode
BAG Mode group
BCD Binary Coded Decimals: Decimal numbers encoded in binary code
BERO Contact-less proximity switch
BI Binector Input
BICO Binector Connector
BIN BINary files: Binary files
BIOS Basic Input Output System
BCS Basic Coordinate System
BO Binector Output
OPI Operator Panel Interface

C
CAD Computer-Aided Design
CAM Computer-Aided Manufacturing
CC Compile Cycle: Compile cycles
CI Connector Input
CF Card Compact Flash Card
CNC Computerized Numerical Control: Computer-Supported Numerical Control

Special functions
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Appendix
A.1 List of abbreviations

C
CO Connector Output
CoL Certificate of License
COM Communication
CPA Compiler Projecting Data: Configuring data of the compiler
CRT Cathode Ray Tube: picture tube
CSB Central Service Board: PLC module
CU Control Unit
CP Communication Processor
CPU Central Processing Unit: Central processing unit
CR Carriage Return
CTS Clear To Send: Ready to send signal for serial data interfaces
CUTCOM Cutter radius Compensation: Tool radius compensation

D
DAC Digital-to-Analog Converter
DB Data Block (PLC)
DBB Data Block Byte (PLC)
DBD Data Block Double word (PLC)
DBW Data Block Word (PLC)
DBX Data block bit (PLC)
DDE Dynamic Data Exchange
DDS Drive Data Set: Drive data set
DIN Deutsche Industrie Norm
DIO Data Input/Output: Data transfer display
DIR Directory: Directory
DLL Dynamic Link Library
DO Drive Object
DPM Dual Port Memory
DPR Dual Port RAM
DRAM Dynamic memory (non-buffered)
DRF Differential Resolver Function: Differential revolver function (handwheel)
DRIVE-CLiQ Drive Component Link with IQ
DRY Dry Run: Dry run feedrate
DSB Decoding Single Block: Decoding single block
DSC Dynamic Servo Control / Dynamic Stiffness Control
DW Data Word
DWORD Double Word (currently 32 bits)

E
I Input
EES Execution from External Storage

Special functions
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 Appendix
A.1 List of abbreviations

E
I/O Input/Output
ENC Encoder: Actual value encoder
EFP Compact I/O module (PLC I/O module)
ESD Electrostatic Sensitive Devices
EMC ElectroMagnetic Compatibility
EN European standard
ENC Encoder: Actual value encoder
EnDat Encoder interface
EPROM Erasable Programmable Read Only Memory: Erasable, electrically programmable
read-only memory
ePS Network Services Services for Internet-based remote machine maintenance
EQN Designation for an absolute encoder with 2048 sine signals per revolution
ES Engineering System
ESR Extended Stop and Retract
ETC ETC key ">"; softkey bar extension in the same menu

F
FB Function Block (PLC)
FC Function Call: Function Block (PLC)
FEPROM Flash EPROM: Read and write memory
FIFO First In First Out: Memory that works without address specification and whose data is
read in the same order in which they was stored
FIPO Fine interpolator
FPU Floating Point Unit: Floating Point Unit
CRC Cutter Radius Compensation
FST Feed Stop: Feedrate stop
FBD Function Block Diagram (PLC programming method)
FW Firmware

G
GC Global Control (PROFIBUS: Broadcast telegram)
GDIR Global part program memory
GEO Geometry, e.g. geometry axis
GIA Gear Interpolation dAta: Gear interpolation data
GND Signal Ground
GP Basic program (PLC)
GS Gear Stage
GSD Device master file for describing a PROFIBUS slave
GSDML Generic Station Description Markup Language: XML-based description language for
creating a GSD file
GUD Global User Data: Global user data

Special functions
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Appendix
A.1 List of abbreviations

H
HEX Abbreviation for hexadecimal number
AuxF Auxiliary function
HLA Hydraulic linear drive
HMI Human Machine Interface: SINUMERIK user interface
MSD Main Spindle Drive
HW Hardware

I
IBN Commissioning
ICA Interpolatory compensation
IM Interface Module: Interconnection module
IMR Interface Module Receive: Interface module for receiving data
IMS Interface Module Send: Interface module for sending data
INC Increment: Increment
INI Initializing Data: Initializing data
IPO Interpolator
ISA Industry Standard Architecture
ISO International Standardization Organization

J
JOG Jogging: Setup mode

K
KV Gain factor of control loop
Kp Proportional gain
KÜ Transformation ratio
LAD Ladder Diagram (PLC programming method)

L
LAI Logic Machine Axis Image: Logical machine axes image
LAN Local Area Network
LCD Liquid Crystal Display: Liquid crystal display
LED Light Emitting Diode: Light-emitting diode
LF Line Feed
PMS Position Measuring System
LR Position controller
LSB Least Significant Bit: Least significant bit
LUD Local User Data: User data (local)

Special functions
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 Appendix
A.1 List of abbreviations

M
MAC Media Access Control
MAIN Main program: Main program (OB1, PLC)
MB Megabyte
MCI Motion Control Interface
MCIS Motion Control Information System
MCP Machine Control Panel: Machine control panel
MD Machine Data
MDA Manual Data Automatic: Manual input
MDS Motor Data Set: Motor data set
MSGW Message Word
MCS Machine Coordinate System
MM Motor Module
MPF Main Program File: Main program (NC)
MCP Machine control panel

N
NC Numerical Control: Numerical Control
NCK Numerical Control Kernel: NC kernel with block preparation, traversing range, etc.
NCU Numerical Control Unit: NCK hardware unit
NRK Name for the operating system of the NCK
IS Interface Signal
NURBS Non-Uniform Rational B-Spline
WO Work Offset
NX Numerical Extension: Axis expansion board

O
OB Organization block in the PLC
OEM Original Equipment Manufacturer
OP Operator Panel: Operating equipment
OPI Operator Panel Interface: Interface for connection to the operator panel
OPT Options: Options
OLP Optical Link Plug: Fiber optic bus connector
OSI Open Systems Interconnection: Standard for computer communications

P
PIQ Process Image Output
PII Process Image Input
PC Personal Computer
PCIN Name of the SW for data exchange with the control

Special functions
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Appendix
A.1 List of abbreviations

P
PCMCIA Personal Computer Memory Card International Association:
Plug-in memory card standardization
PCU PC Unit: PC box (computer unit)
PG Programming device
PKE Parameter identification: Part of a PIV
PIV Parameter identification: Value (parameterizing part of a PPO)
PLC Programmable Logic Control: Adaptation control
PN PROFINET
PNO PROFIBUS user organization
PO POWER ON
POU Program Organization Unit
POS Position/positioning
POSMO A Positioning Motor Actuator: Positioning motor
POSMO CA Positioning Motor Compact AC: Complete drive unit with integrated power and control
module as well as positioning unit and program memory; AC infeed
POSMO CD Positioning Motor Compact DC: Like CA but with DC infeed
POSMO SI Positioning Motor Servo Integrated: Positioning motor, DC infeed
PPO Parameter Process data Object: Cyclic data telegram for PROFIBUS DP transmission
and "Variable speed drives" profile
PPU Panel Processing Unit (central hardware for a panel-based CNC, e.g SINUMERIK
828D)
PROFIBUS Process Field Bus: Serial data bus
PRT Program Test
PSW Program control word
PTP Point-To-Point: Point-To-Point
PUD Program global User Data: Program-global user variables
PZD Process data: Process data part of a PPO

Q
QEC Quadrant Error Compensation

R
RAM Random Access Memory: Read/write memory
REF REFerence point approach function
REPOS REPOSition function
RISC Reduced Instruction Set Computer: Type of processor with small instruction set and
ability to process instructions at high speed
ROV Rapid Override: Input correction
RP R Parameter, arithmetic parameter, predefined user variable
RPA R Parameter Active: Memory area on the NCK for R parameter numbers
RPY Roll Pitch Yaw: Rotation type of a coordinate system
RTLI Rapid Traverse Linear Interpolation: Linear interpolation during rapid traverse motion

Special functions
854 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 Appendix
A.1 List of abbreviations

R
RTS Request To Send: Control signal of serial data interfaces
RTCP Real Time Control Protocol

S
SA Synchronized Action
SBC Safe Brake Control: Safe Brake Control
SBL Single Block: Single block
SBR Subroutine: Subprogram (PLC)
SD Setting Data
SDB System Data Block
SEA Setting Data Active: Identifier (file type) for setting data
SERUPRO SEarch RUn by PROgram test: Search run by program test
SFB System Function Block
SFC System Function Call
SGE Safety-related input
SGA Safety-related output
SH Safe standstill
SIM Single in Line Module
SK Softkey
SKP Skip: Function for skipping a part program block
SLM Synchronous Linear Motor
SM Stepper Motor
SMC Sensor Module Cabinet Mounted
SME Sensor Module Externally Mounted
SMI Sensor Module Integrated
SPF Sub Routine File: Subprogram (NC)
PLC Programmable Logic Controller
SRAM Static RAM (non-volatile)
TNRC Tool Nose Radius Compensation
SRM Synchronous Rotary Motor
LEC Leadscrew Error Compensation
SSI Serial Synchronous Interface: Synchronous serial interface
SSL Block search
STW Control word
GWPS Grinding Wheel Peripheral Speed
SW Software
SYF System Files: System files
SYNACT SYNchronized ACTion: Synchronized Action

Special functions
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Appendix
A.1 List of abbreviations

T
TB Terminal Board (SINAMICS)
TCP Tool Center Point: Tool tip
TCP/IP Transport Control Protocol / Internet Protocol
TCU Thin Client Unit
TEA Testing Data Active: Identifier for machine data
TIA Totally Integrated Automation
TM Terminal Module (SINAMICS)
TO Tool Offset: Tool offset
TOA Tool Offset Active: Identifier (file type) for tool offsets
TRANSMIT Transform Milling Into Turning: Coordination transformation for milling operations on
a lathe
TTL Transistor-Transistor Logic (interface type)
TZ Technology cycle

U
UFR User Frame: Work offset
SR Subprogram
USB Universal Serial Bus
UPS Uninterruptible Power Supply

V
VDI Internal communication interface between NCK and PLC
VDI Verein Deutscher Ingenieure [Association of German Engineers]
VDE Verband Deutscher Elektrotechniker [Association of German Electrical Engineers]
VI Voltage Input
VO Voltage Output
FDD Feed Drive

W
SAR Smooth Approach and Retraction
WCS Workpiece Coordinate System
T Tool
TLC Tool Length Compensation
WOP Workshop-Oriented Programming
WPD Workpiece Directory: Workpiece directory
TRC Tool Radius Compensation
T Tool
TO Tool Offset
TM Tool Management
TC Tool change

Special functions
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 Appendix
A.1 List of abbreviations

X
XML Extensible Markup Language

Z
WOA Work Offset Active: Identifier for work offsets
ZSW Status word (of drive)

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 857
Appendix
A.2 Overview

A.2 Overview

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Special functions
858 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
Glossary

Absolute dimensions
A destination for an axis motion is defined by a dimension that refers to the origin of the currently
valid coordinate system. See → Incremental dimension

Acceleration with jerk limitation

In order to optimize the acceleration response of the machine whilst simultaneously protecting
the mechanical components, it is possible to switch over in the machining program between
abrupt acceleration and continuous (jerk-free) acceleration.

Address
An address is the identifier for a certain operand or operand range, e.g. input, output, etc.

Alarms
All → messages and alarms are displayed on the operator panel in plain text with date and time
and the corresponding symbol for the deletion criterion. Alarms and messages are displayed
separately.
1. Alarms and messages in the part program:
Alarms and messages can be displayed in plain text directly from the part program.
2. Alarms and messages from the PLC:
Alarms and messages for the machine can be displayed in plain text from the PLC program.
No additional function block packages are required for this purpose.

Archiving
Reading out of files and/or directories on an external memory device.

Asynchronous subprogram
Part program that can be started asynchronously to (independently of) the current program
status using an interrupt signal (e.g. "Rapid NC input" signal).

Automatic
Operating mode of the controller (block sequence operation according to DIN): Operating
mode for NC systems in which a → subprogram is selected and executed continuously.

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 859
Glossary

Auxiliary functions
Auxiliary functions enable → part programs to transfer → parameters to the → PLC, which then
trigger reactions defined by the machine manufacturer.

Axes
In accordance with their functional scope, the CNC axes are subdivided into:
● Axes: Interpolating path axes
● Auxiliary axes: Non-interpolating feed and positioning axes with an axis-specific feedrate.
Auxiliary axes are not involved in actual machining, e.g. tool feeder, tool magazine.

Axis address
See → Axis name

Axis name
To ensure clear identification, all channel and → machine axes of the control system must be
designated with unique names in the channel and control system. The → geometry axes are
called X, Y, Z. The rotary axes rotating around the geometry axes → are called A, B, C.

Backlash compensation
Compensation for a mechanical machine backlash, e.g. backlash on reversal for ball screws.
Backlash compensation can be entered separately for each axis.

Backup battery
The backup battery ensures that the → user program in the → CPU is stored so that it is safe
from power failure and so that specified data areas and bit memory, timers and counters are
stored retentively.

Basic axis
Axis whose setpoint or actual value position forms the basis of the calculation of a
compensation value.

Basic Coordinate System

Cartesian coordinate system which is mapped by transformation onto the machine coordinate
system.
The programmer uses axis names of the basic coordinate system in the → part program. The
basic coordinate system exists parallel to the → machine coordinate system if no
→ transformation is active. The difference lies in the → axis names.

Special functions
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 Glossary

Baud rate
Rate of data transfer (bits/s).

Blank
Workpiece as it is before it is machined.

Block
"Block" is the term given to any files required for creating and processing programs.

Block search
For debugging purposes or following a program abort, the "Block search" function can be used
to select any location in the part program at which the program is to be started or resumed.

Booting
Loading the system program after power ON.

C axis
Axis around which the tool spindle describes a controlled rotational and positioning motion.

C spline
The C spline is the most well-known and widely used spline. The transitions at the interpolation
points are continuous, both tangentially and in terms of curvature. Polynomials of the
3rd degree are used.

Channel
A channel is characterized by the fact that it can process a → part program independently of
other channels. A channel exclusively controls the axes and spindles assigned to it. Part
program runs of different channels can be coordinated through → synchronization.

Circular interpolation
The → tool moves on a circle between specified points on the contour at a given feedrate, and
the workpiece is thereby machined.

CNC
See → NC
Computerized Numerical Control: includes the components → NCK, → PLC, HMI, → COM.

Special functions
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Glossary

CNC
See → NC
Computerized Numerical Control: includes the components → NCK, → PLC, HMI, → COM.

COM
Component of the NC for the implementation and coordination of communication.

Compensation axis
Axis with a setpoint or actual value modified by the compensation value

Compensation table
Table containing interpolation points. It provides the compensation values of the compensation
axis for selected positions on the basic axis.

Compensation value
Difference between the axis position measured by the encoder and the desired, programmed
axis position.

Continuous-path mode
The objective of continuous-path mode is to avoid substantial deceleration of the → path axes
at the part program block boundaries and to change to the next block at as close to the same
path velocity as possible.

Contour
Contour of the → workpiece

Contour monitoring
The following error is monitored within a definable tolerance band as a measure of contour
accuracy. An unacceptably high following error can cause the drive to become overloaded, for
example. In such cases, an alarm is output and the axes are stopped.

Coordinate system
See → Machine coordinate system, → Workpiece coordinate system

CPU
Central processing unit, see → PLC

Special functions
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 Glossary

CU
Transformation ratio

Curvature
The curvature k of a contour is the inverse of radius r of the nestling circle in a contour point
(k = 1/r).

Cycles
Protected subprograms for execution of repetitive machining operations on the → workpiece.

Data block
1. Data unit of the → PLC that → HIGHSTEP programs can access.
2. Data unit of the → NC: Data blocks contain data definitions for global user data. This data
can be initialized directly when it is defined.

Data word
Two-byte data unit within a → data block.

Diagnostics
1. Operating area of the control.
2. The control has a self-diagnostics program as well as test functions for servicing purposes:
status, alarm, and service displays

Dimensions specification, metric and inches

Position and pitch values can be programmed in inches in the machining program. Irrespective
of the programmable dimensions (G70/G71), the control is set to a basic system.

DRF
Differential Resolver Function: NC function which generates an incremental work offset in
Automatic mode in conjunction with an electronic handwheel.

Drive
The drive is the unit of the CNC that performs the speed and torque control based on the
settings of the NC.

Special functions
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Glossary

Dynamic feedforward control

Inaccuracies in the → contour due to following errors can be practically eliminated using
dynamic, acceleration-dependent feedforward control. This results in excellent machining
accuracy even at high → path velocities. Feedforward control can be selected and deselected
on an axis-specific basis via the → part program.

Editor
The editor makes it possible to create, edit, extend, join, and import programs / texts / program
blocks.

Exact stop
When an exact stop statement is programmed, the position specified in a block is approached
exactly and, if necessary, very slowly. To reduce the approach time, → exact stop limits are
defined for rapid traverse and feed.

Exact stop limit

When all path axes reach their exact stop limits, the control responds as if it had reached its
precise destination point. A block advance of the → part program occurs.

External work offset

Work offset specified by the → PLC.

Fast retraction from the contour

When an interrupt occurs, a motion can be initiated via the CNC machining program, enabling
the tool to be quickly retracted from the workpiece contour that is currently being machined.
The retraction angle and the distance retracted can also be parameterized. An interrupt routine
can also be executed following the fast retraction.

Feed override
The programmed velocity is overriden by the current velocity setting made via the → machine
control panel or from the → PLC (0 to 200%). The feedrate can also be corrected by a
programmable percentage factor (1 to 200%) in the machining program.

Finished-part contour
Contour of the finished workpiece. See → Raw part.

Fixed machine point

Point that is uniquely defined by the machine tool, e.g. machine reference point.

Special functions
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 Glossary

Fixed-point approach
Machine tools can approach fixed points such as a tool change point, loading point, pallet
change point, etc. in a defined way. The coordinates of these points are stored in the control.
The control moves the relevant axes in → rapid traverse, whenever possible.

Frame
A frame is an arithmetic rule that transforms one Cartesian coordinate system into another
Cartesian coordinate system. A frame contains the following components: → work offset,
→ rotation, → scaling, → mirroring.

Geometry
Description of a → workpiece in the → workpiece coordinate system.

Geometry axis
The geometry axes form the 2 or 3-dimensional → workpiece coordinate system in which, in
→ part programs, the geometry of the workpiece is programmed.

Ground
Ground is taken as the total of all linked inactive parts of a device which will not become live
with a dangerous contact voltage even in the event of a malfunction.

Helical interpolation
The helical interpolation function is ideal for machining internal and external threads using form
milling cutters and for milling lubrication grooves.
The helix comprises two motions:
● Circular motion in one plane
● A linear motion perpendicular to this plane

High-level CNC language

The high-level language is used to write NC programs, → synchronized actions, and → cycles.
It provides: control structures → user-defined variables, → system variables, → macro
programming.

High-speed digital inputs/outputs

The digital inputs can be used for example to start fast CNC program routines (interrupt
routines). High-speed, program-driven switching functions can be initiated via the digital CNC
outputs

Special functions
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Glossary

HIGHSTEP
Summary of programming options for → PLCs of the AS300/AS400 system.

HW Config
SIMATIC S7 tool for the configuration and parameterization of hardware components within
an S7 project

Identifier
In accordance with DIN 66025, words are supplemented using identifiers (names) for variables
(arithmetic variables, system variables, user variables), subprograms, key words, and words
with multiple address letters. These supplements have the same meaning as the words with
respect to block format. Identifiers must be unique. It is not permissible to use the same
identifier for different objects.

Inch measuring system

Measuring system which defines distances in inches and fractions of inches.

Inclined surface machining

Drilling and milling operations on workpiece surfaces that do not lie in the coordinate planes
of the machine can be performed easily using the function "inclined-surface machining".

Increment
Travel path length specification based on number of increments. The number of increments
can be stored as → setting data or be selected by means of a suitably labeled key (i.e. 10, 100,
1000, 10000).

Incremental dimension
Incremental dimension: A destination for axis traversal is defined by a distance to be covered
and a direction referenced to a point already reached. See → Absolute dimension.

Intermediate blocks
Motions with selected → tool offset (G41/G42) may be interrupted by a limited number of
intermediate blocks (blocks without axis motions in the offset plane), whereby the tool offset
can still be correctly compensated for. The permissible number of intermediate blocks which
the controller reads ahead can be set in system parameters.

Interpolator
Logic unit of the → NCK that defines intermediate values for the motions to be carried out in
individual axes based on information on the end positions specified in the part program.

Special functions
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 Glossary

Interpolatory compensation
Mechanical deviations of the machine are compensated for by means of interpolatory
compensation functions, such as → leadscrew error, sag, angularity, and temperature
compensation.

Interrupt routine
Interrupt routines are special → subprograms that can be started by events (external signals)
in the machining process. A part program block which is currently being worked through is
interrupted and the position of the axes at the point of interruption is automatically saved.

Inverse-time feedrate
The time required for the path of a block to be traversed can also be programmed for the axis
motion instead of the feed velocity (G93).

JOG
Operating mode of the control (setup mode): The machine can be set up in JOG mode.
Individual axes and spindles can be traversed in JOG mode by means of the direction keys.
Additional functions in JOG mode include: → Reference point approach, → Repos, and → Preset
(set actual value).

Key switch
The key switch on the → machine control panel has four positions that are assigned functions
by the operating system of the controller. The key switch has three different colored keys that
can be removed in the specified positions.

Keywords
Words with specified notation that have a defined meaning in the programming language for
→ part programs.

KV
Servo gain factor, a control variable in a control loop.

Leading axis
The leading axis is the → gantry axis that exists from the point of view of the operator and
programmer and, thus, can be influenced like a standard NC axis.

Leadscrew error compensation

Compensation for the mechanical inaccuracies of a leadscrew participating in the feed. The
controller uses stored deviation values for the compensation.

Special functions
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Glossary

Limit speed
Maximum/minimum (spindle) speed: The maximum speed of a spindle can be limited by
specifying machine data, the → PLC or → setting data.

Linear axis
In contrast to a rotary axis, a linear axis describes a straight line.

Linear interpolation
The tool travels along a straight line to the destination point while machining the workpiece.

Load memory
The load memory is the same as the → working memory for the CPU 314 of the → PLC.

Look Ahead
The Look Ahead function is used to achieve an optimal machining speed by looking ahead
over an assignable number of traversing blocks.

Machine axes
Physically existent axes on the machine tool.

Machine control panel

An operator panel on a machine tool with operating elements such as keys, rotary switches,
etc., and simple indicators such as LEDs. It is used to directly influence the machine tool via
the PLC.

Machine coordinate system

A coordinate system, which is related to the axes of the machine tool.

Machine zero
Fixed point of the machine tool to which all (derived) measuring systems can be traced back.

Machining channel
A channel structure can be used to shorten idle times by means of parallel motion sequences,
e.g. moving a loading gantry simultaneously with machining. Here, a CNC channel must be
regarded as a separate CNC control system with decoding, block preparation and interpolation.

Special functions
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 Glossary

Macro techniques
Grouping of a set of statements under a single identifier. The identifier represents the set of
consolidated statements in the program.

Main block
A block preceded with ":" that contains all information to start the operating sequence in a
→ part program.

Main program
The term "main program" has its origins during the time when part programs were split strictly
into main and → subprograms. This strict division no longer exists with today's SINUMERIK
NC language. In principle, any part program in the channel can be selected and started. It then
runs through in → program level 0 (main program level). Further part programs or → cycles as
subprograms can be called up in the main program.

MDI
Operating mode of the control: Manual Data Input. In the MDI mode, individual program blocks
or block sequences with no reference to a main program or subprogram can be input and
executed immediately afterwards through actuation of the NC start key.

Messages
All messages programmed in the part program and → alarms detected by the system are
displayed on the operator panel in plain text with date and time and the corresponding symbol
for the deletion criterion. Alarms and messages are displayed separately.

Metric measuring system

Standardized system of units: For length, e.g. mm (millimeters), m (meters).

Mirroring
Mirroring reverses the signs of the coordinate values of a contour, with respect to an axis. It
is possible to mirror with respect to more than one axis at a time.

Mode
An operating concept on a SINUMERIK control The following modes are defined: → Jog, → MDI,
→ Automatic.

Mode group
Axes and spindles that are technologically related can be combined into one mode group.
Axes/spindles of a mode group can be controlled by one or more → channels. The same
→ mode type is always assigned to the channels of the mode group.

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 869
Glossary

NC
Numerical Control component of the → CNC that executes the → part programs and coordinates
the movements of the machine tool.

Network
A network is the connection of multiple S7-300 and other end devices, e.g. a programming
device via a → connecting cable. A data exchange takes place over the network between the
connected devices.

NRK
Numeric robotic kernel (operating system of → NCK)

NURBS
The motion control and path interpolation that occurs within the control is performed based on
NURBS (Non Uniform Rational B-Splines). This provides a uniform procedure for all internal
interpolations.

OEM
The scope for implementing individual solutions (OEM applications) has been provided for
machine manufacturers, who wish to create their own user interface or integrate technology-
specific functions in the control.

Offset memory
Data range in the control, in which the tool offset data is stored.

Oriented spindle stop

Stops the workpiece spindle in a specified angular position, e.g. in order to perform additional
machining at a particular location.

Overall reset
In the event of an overall reset, the following memories of the → CPU are deleted:
● → Working memory
● Read/write area of → load memory
● → System memory
● → Backup memory

Special functions
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 Glossary

Override
Manual or programmable possibility of intervention that enables the user to override
programmed feedrates or speeds in order to adapt them to a specific workpiece or material.

Part program
Series of statements to the NC that act in concert to produce a particular → workpiece. Likewise,
this term applies to execution of a particular machining operation on a given → raw part.

Part program block

Part of a → part program that is demarcated by a line feed. There are two types: → main blocks
and → subblocks.

Part program management

Part program management can be organized by → workpieces. The size of the user memory
determines the number of programs and the amount of data that can be managed. Each file
(programs and data) can be given a name consisting of a maximum of 24 alphanumeric
characters.

Path axis
Path axes include all machining axes of the → channel that are controlled by the → interpolator
in such a way that they start, accelerate, stop, and reach their end point simultaneously.

Path feedrate
Path feedrate affects → path axes. It represents the geometric sum of the feedrates of the
→ geometry axes involved.

Path velocity
The maximum programmable path velocity depends on the input resolution. For example, with
a resolution of 0.1 mm the maximum programmable path velocity is 1000 m/min.

PCIN data transfer program

PCIN is a utility program for sending and receiving CNC user data (e.g. part programs, tool
offsets) via the serial interface. The PCIN program can run under MS-DOS on standard
industrial PCs.

Peripheral module
I/O modules represent the link between the CPU and the process.

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 871
Glossary

I/O modules are:

● → Digital input/output modules
● → Analog input/output modules
● → Simulator modules

PLC
Programmable Logic Controller: → Programmable logic controller. Component of → NC:
Programmable control for processing the control logic of the machine tool.

PLC program memory

SINUMERIK 840D sl: The PLC user program, the user data and the basic PLC program are
stored together in the PLC user memory.

PLC programming
The PLC is programmed using the STEP 7 software. The STEP 7 programming software is
based on the WINDOWS standard operating system and contains the STEP 5 programming
functions with innovative enhancements.

Polar coordinates
A coordinate system which defines the position of a point on a plane in terms of its distance
from the origin and the angle formed by the radius vector with a defined axis.

Polynomial interpolation
Polynomial interpolation enables a wide variety of curve characteristics to be generated, such
as straight line, parabolic, exponential functions (SINUMERIK 840D sl).

Positioning axis
Axis that performs an auxiliary motion on a machine tool (e.g. tool magazine, pallet transport).
Positioning axes are axes that do not interpolate with → path axes.

Pre-coincidence
Block change occurs already when the path distance approaches an amount equal to a
specifiable delta of the end position.

Program block
Program blocks contain the main program and subprograms of → part programs.

Special functions
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 Glossary

Program level
A part program started in the channel runs as a → main program on program level 0 (main
program level). Any part program called up in the main program runs as a → subprogram on
a program level 1 ... n of its own.

Programmable frames
Programmable → frames enable dynamic definition of new coordinate system output points
while the part program is being executed. A distinction is made between absolute definition
using a new frame and additive definition with reference to an existing starting point.

Programmable logic controller

Programmable logic controllers (PLCs) are electronic controllers, the function of which is stored
as a program in the control unit. This means that the layout and wiring of the device do not
depend on the function of the controller. The programmable logic control has the same
structure as a computer; it consists of a CPU (central module) with memory, input/output
modules and an internal bus system. The peripherals and the programming language are
matched to the requirements of the control technology.

Programmable working area limitation

Limitation of the motion space of the tool to a space defined by programmed limitations.

Programming key
Characters and character strings that have a defined meaning in the programming language
for → part programs.

Protection zone
Three-dimensional zone within the → working area into which the tool tip must not pass.

Quadrant error compensation

Contour errors at quadrant transitions, which arise as a result of changing friction conditions
on the guideways, can be virtually entirely eliminated with the quadrant error compensation.
Parameterization of the quadrant error compensation is performed by means of a circuit test.

R parameters
Arithmetic parameter that can be set or queried by the programmer of the → part program for
any purpose in the program.

Rapid traverse
The highest traverse velocity of an axis. It is used, for example, when the tool approaches the
→ workpiece contour from a resting position or when the tool is retracted from the workpiece

Special functions
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Glossary

contour. The rapid traverse velocity is set on a machine-specific basis using a machine data
item.

Reference point
Machine tool position that the measuring system of the → machine axes references.

Rotary axis
Rotary axes apply a workpiece or tool rotation to a defined angular position.

Rotation
Component of a → frame that defines a rotation of the coordinate system around a particular
angle.

Rounding axis
Rounding axes rotate a workpiece or tool to an angular position corresponding to an indexing
grid. When a grid index is reached, the rounding axis is "in position".

RS-232-C
Serial interface for data input/output. Machining programs as well as manufacturer and user
data can be loaded and saved via this interface.

Safety functions
The controller is equipped with permanently active monitoring functions that detect faults in
the → CNC, the → PLC, and the machine in a timely manner so that damage to the workpiece,
tool, or machine is largely prevented. In the event of a fault, the machining operation is
interrupted and the drives stopped. The cause of the malfunction is logged and output as an
alarm. At the same time, the PLC is notified that a CNC alarm has been triggered.

Scaling
Component of a → frame that implements axis-specific scale modifications.

Setting data
Data which communicates the properties of the machine tool to the NC as defined by the
system software.

Softkey
A key, whose name appears on an area of the screen. The choice of softkeys displayed is
dynamically adapted to the operating situation. The freely assignable function keys (softkeys)
are assigned defined functions in the software.

Special functions
874 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 Glossary

Software limit switch

Software limit switches limit the traversing range of an axis and prevent an abrupt stop of the
slide at the hardware limit switch. Two value pairs can be specified for each axis and activated
separately by means of the → PLC.

Spline interpolation
With spline interpolation, the controller can generate a smooth curve characteristic from only
a few specified interpolation points of a set contour.

Standard cycles
Standard cycles are provided for machining operations which are frequently repeated:
● For the drilling/milling technology
● For turning technology
The available cycles are listed in the "Cycle support" menu in the "Program" operating area.
Once the desired machining cycle has been selected, the parameters required for assigning
values are displayed in plain text.

Subblock
Block preceded by "N" containing information for a sequence, e.g. positional data.

Subprogram
The term "subprogram" has its origins during the time when part programs were split strictly
into →main and subprograms. This strict division no longer exists with today's SINUMERIK NC
language. In principle, any part program or any → cycle can be called up as a subprogram
within another part program. It then runs through in the next → program level (x+1) (subprogram
level (x+1)).

Synchronization
Statements in → part programs for coordination of sequences in different → channels at certain
machining points.

Synchronized actions
1. Auxiliary function output
During workpiece machining, technological functions (→ auxiliary functions) can be output
from the CNC program to the PLC. For example, these auxiliary functions are used to
control additional equipment for the machine tool, such as quills, grabbers, clamping
chucks, etc.
2. Fast auxiliary function output
For time-critical switching functions, the acknowledgement times for the → auxiliary
functions can be minimized and unnecessary hold points in the machining process can be
avoided.

Special functions
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Glossary

Synchronized axes
Synchronized axes take the same time to traverse their path as the geometry axes take for
their path.

Synchronized axis
A synchronized axis is the → gantry axis whose set position is continuously derived from the
motion of the → leading axis and is, thus, moved synchronously with the leading axis. From
the point of view of the programmer and operator, the synchronized axis "does not exist".

System memory
The system memory is a memory in the CPU in which the following data is stored:
● Data required by the operating system
● The operands timers, counters, markers

System variable
A variable that exists without any input from the programmer of a → part program. It is defined
by a data type and the variable name preceded by the character $. See → User-defined variable.

Tapping without compensating chuck

This function allows threads to be tapped without a compensating chuck. By using the
interpolating method of the spindle as a rotary axis and the drilling axis, threads can be cut to
a precise final drilling depth, e.g. for blind hole threads (requirement: spindles in axis operation).

Text editor
See → Editor

TOA area
The TOA area includes all tool and magazine data. By default, this area coincides with the
→ channel area with regard to the access of the data. However, machine data can be used to
specify that multiple channels share one → TOA unit so that common tool management data
is then available to these channels.

TOA unit
Each → TOA area can have more than one TOA unit. The number of possible TOA units is
limited by the maximum number of active → channels. A TOA unit includes exactly one tool
data block and one magazine data block. In addition, a TOA unit can also contain a toolholder
data block (optional).

Special functions
876 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 Glossary

Tool
Active part on the machine tool that implements machining (e.g. turning tool, milling tool, drill,
LASER beam, etc.).

Tool nose radius compensation

Contour programming assumes that the tool is pointed. Because this is not actually the case
in practice, the curvature radius of the tool used must be communicated to the controller which
then takes it into account. The curvature center is maintained equidistantly around the contour,
offset by the curvature radius.

Tool offset
Consideration of the tool dimensions in calculating the path.

Tool radius compensation

To directly program a desired → workpiece contour, the control must traverse an equistant path
to the programmed contour taking into account the radius of the tool that is being used (G41/
G42).

Transformation
Additive or absolute zero offset of an axis.

Travel range
The maximum permissible travel range for linear axes is ± 9 decades. The absolute value
depends on the selected input and position control resolution and the unit of measurement
(inch or metric).

User interface
The user interface (UI) is the display medium for a CNC in the form of a screen. It features
horizontal and vertical softkeys.

User memory
All programs and data, such as part programs, subprograms, comments, tool offsets, and work
offsets / frames, as well as channel and program user data, can be stored in the shared CNC
user memory.

User program
User programs for the S7-300 automation systems are created using the programming
language STEP 7. The user program has a modular layout and consists of individual blocks.

Special functions
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Glossary

The basic block types are:

● Code blocks
These blocks contain the STEP 7 commands.
● Data blocks
These blocks contain constants and variables for the STEP 7 program.

User-defined variable
Users can declare their own variables for any purpose in the → part program or data block
(global user data). A definition contains a data type specification and the variable name. See
→ System variable.

Variable definition
A variable definition includes the specification of a data type and a variable name. The variable
names can be used to access the value of the variables.

Velocity control
In order to achieve an acceptable traverse rate in the case of very slight motions per block, an
anticipatory evaluation over several blocks (→ Look Ahead) can be specified.

WinSCP
WinSCP is a freely available open source program for Windows for the transfer of files.

Work offset
Specifies a new reference point for a coordinate system through reference to an existing zero
point and a → frame.
1. Settable
A configurable number of settable work offsets are available for each CNC axis. The offsets
- which are selected by means of G commands - take effect alternatively.
2. External
In addition to all the offsets which define the position of the workpiece zero, an external
work offset can be overridden by means of the handwheel (DRF offset) or from the PLC.
3. Programmable
Work offsets can be programmed for all path and positioning axes using the TRANS
statement.

Working area
Three-dimensional zone into which the tool tip can be moved on account of the physical design
of the machine tool. See → Protection zone.

Special functions
878 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 Glossary

Working area limitation

With the aid of the working area limitation, the traversing range of the axes can be further
restricted in addition to the limit switches. One value pair per axis may be used to describe the
protected working area.

Working memory
The working memory is a RAM in the → CPU that the processor accesses when processing
the application program.

Workpiece
Part to be made/machined by the machine tool.

Workpiece contour
Set contour of the → workpiece to be created or machined.

Workpiece coordinate system

The workpiece coordinate system has its starting point in the → workpiece zero-point. In
machining operations programmed in the workpiece coordinate system, the dimensions and
directions refer to this system.

Workpiece zero
The workpiece zero is the starting point for the → workpiece coordinate system. It is defined
in terms of distances to the → machine zero.

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 879
Glossary

Special functions
880 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
Index
$AC_TOOLR_END, 104
$AN_ACTIVATE_COLL_CHECK, 285
$ $AN_COLL_CHECK_OFF, 285
$AN_COLL_IPO_ACTIVE, 285
$AA_BRAKE_CONDB, 442
$AN_COLL_IPO_LIMIT, 285
$AA_BRAKE_CONDM, 442
$AN_COLL_LOAD, 285
$AA_BRAKE_STATE, 442
$AN_COLL_MEM_AVAILABLE, 286
$AA_COLLPOS, 285
$AN_COLL_MEM_USE_ACT, 286
$AA_COUP_ACT, 314
$AN_COLL_MEM_USE_MAX, 286
$AA_COUP_CORR, 450
$AN_COLL_MEM_USE_MIN, 286
$AA_COUP_CORR_DIST, 451
$AN_COLL_STATE, 285
$AA_DTBREB, 286
$AN_COLL_STATE_COND, 285
$AA_DTBREB_CMD, 286
$AN_ESR_TRIGGER, 494
$AA_DTBREB_CORR, 286
$NK_A_OFF, 200, 204, 206
$AA_DTBREB_DEP, 286
$NK_AXIS, 200, 203
$AA_DTBREM, 287
$NK_NAME, 195
$AA_DTBREM_CMD, 287
$NK_NEXT, 196
$AA_DTBREM_CORR, 287
$NK_OFF_DIR, 198, 202, 205, 207
$AA_DTBREM_DEP, 287
$NK_PARALLEL, 196
$AA_ESR_ENABLE, 494
$NK_SWITCH, 211
$AA_IN_SYNC, 348
$NK_SWITCH_INDEX, 208
$AA_JERK_COUNT, 824
$NK_SWITCH_POS, 210
$AA_JERK_TIME, 824
$NK_TYPE, 198
$AA_JERK_TOT, 824
$NP_1ST_PROT, 237
$AA_LEAD_P, 348
$NP_BIT_NO, 241
$AA_LEAD_P_TURN, 348
$NP_CHAIN_ELEM, 235
$AA_LEAD_SP, 348
$NP_COLL_PAIR, 261, 282
$AA_LEAD_SV, 348
$NP_COLOR, 249
$AA_LEAD_V, 348
$NP_D_LEVEL, 250
$AA_MASL_STAT, 652
$NP_DIR, 259
$AA_SYNC, 348, 416
$NP_FILENAME, 256
$AA_SYNCDIFF, 415
$NP_INDEX, 243
$AA_TRAVEL_COUNT, 824
$NP_INIT_STAT, 240, 242
$AA_TRAVEL_COUNT_HS, 824
$NP_NAME, 245
$AA_TRAVEL_DIST, 824
$NP_NEXT, 247
$AA_TRAVEL_DIST_HS, 824
$NP_NEXTP, 248
$AA_TRAVEL_TIME, 824
$NP_OFF, 258
$AA_TRAVEL_TIME_HS, 824
$NP_PARA, 257
$AC_COLLPOS, 285
$NP_PROT_COLOR, 239
$AC_TOOL_O_ACT, 105
$NP_PROT_D_LEVEL, 240
$AC_TOOL_O_DIFF, 105
$NP_PROT_NAME, 234
$AC_TOOL_O_END, 105
$NP_PROT_TYPE, 236
$AC_TOOL_R_ACT, 106
$NP_SAFETY_DIST, 284
$AC_TOOL_R_DIFF, 106
$NP_TYPE, 255
$AC_TOOL_R_END, 106
$NP_USAGE, 251
$AC_TOOLO_ACT, 104
$P_PROG_EVENT, 652
$AC_TOOLO_DIFF, 104
$P_SEARCH_MASLC, 652
$AC_TOOLO_END, 104
$P_SEARCH_MASLD, 652
$AC_TOOLR_ACT, 104
$P_TOOL_O, 105
$AC_TOOLR_DIFF, 105

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 881
Index

$P_TOOL_R, 105
$P_TOOLROT, 104
$VA_STOPSI, 501 A
$VA_SYNCDIFF, 415
aaJerkCount, 824
$VC_TOOL_O, 105
aaJerkTime, 824
$VC_TOOL_O_DIFF, 105
aaJerkTotal, 824
$VC_TOOL_R, 106
aaTravelCount, 824
$VC_TOOL_R_DIFF, 106
aaTravelCountHS, 824
$VC_TOOLO, 104
aaTravelDist, 824
$VC_TOOLO_DIFF, 104
aaTravelDistHS, 824
$VC_TOOLO_STAT, 104
aaTravelTime, 824
$VC_TOOLR, 105
aaTravelTimeHS, 824
$VC_TOOLR_DIFF, 105
Acceleration
$VC_TOOLR_STAT, 105
Channel-specific, 776
Function-specific, 776
Acceleration mode, 459
2 Acceleration warning threshold, 836, 837
2-axis swivel head, 86 Access rights, 786
ACCLIMA[FA], 458
Activate coupling, 845
3 Activate master-slave coupling, 842
Activate mirroring, 846
3-axis and 4-axis transformation, 35
Activate monitor, 845
3-axis and 4-axis transformations, 55
activate PTP traversal, 827
3-axis kinematics, 85
Activate PTP traversal, 843
3-axis to 5-axis transformation
Activate setpoint exchange, 838
Call and application, 66
Activate torque compensatory controller, 842
3-axis transformations, 69
Activation, 67
Activation of rotation, 120
Activation/Deactivation, 785
4 Actual value display, 351
4-axis kinematics, 85 Alarm 10653, 150
4-axis Transformation, 35 Alarm texts, 579
4-axis transformations, 69 Angle of rotation, 123
ASUB enable, 734
Automatic synchronization, 829, 830
5 AXCTSWED, 777
Axis accelerated, 837
5-axis kinematics, 84
Axis assignment, 328
5-axis transformation
Axis container, 776
Configuration of a machine, 43
Axis container rotation, 776
Geometry of the machine, 44
Axis identifier, 790
Machine types, 42
Axis is a slave axis, 845
Singular positions, 52
Axis replacement, 437, 749
Tool orientation, 49

B
7
Basic orientation, 87
7-axis transformation, 78
Behavior at inside corners, 815
Example, 140
Behavior at outer corners, 814
Kinematics, 79
Behavior at pole, 53

Special functions
882 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 Index

Block change criterion, 400 Software version, 578

Block search SW version, 578
Master-slave, speed coupling, 652 Compile cycles, 574
Boundary conditions, 790 Compiling, 786
Compression mode, 91
Compressor, 90
C Continue machining ASUB, 740
Contour accuracy
Call condition, 789
Programmable, 182
Cardan milling head, 62
Contour tunnel
Applications, 62
-radius, 181
JOG, 65
Control dynamics, 351
Cartesian manual travel, 40
Coordinate reference, 399
CC_COPOFF, 715
Coordinate system, 309
CC_COPON, 715
Coupled axes, 308
CC_COPONM, 715
Coupled axis grouping, 308
CC_FASTOFF, 764
Deactivating, 312
CC_FASTON, 762
Definition and switch on, 312
CC_FASTON_CONT, 763
Coupled motion, 307
CC_PREPRE, 725, 735
Activating/deactivating, 310
CC_RESU.MPF, 737
Control system dynamics, 316
CC_RESU_ASUP.SPF, 741
Distance-to-go, 311
CC_RESU_BS_ASUP.SPF, 740
Dynamics limit, 315
CC_RESU_END.SPF, 740
Interface signals, 313
CC_RESU_INI.SPF, 738
Programming, 312
Change in orientation, 123, 801, 815
Coupled motion axis as leading axis, 309
Change insertion depth, 806
coupling
Circumferential milling, 798
Deactivating, 393
CLC_RESU_LENGTH_BS_BUFFER, 746
Coupling factor, 396
Clearance control, 589
Counter, 397
Collision monitoring, 597
Denominator, 397
Compensation vector, 593
Coupling module, 384
Control dynamics, 589
Creating, 388
Control loop structure, 592
Delete, 389
Detailed description, 588
Coupling reference, 398, 399
Programming, 604
Coupling rule, 384, 396
Signal descriptions, 839
Coupling type, 347
Startup, 598
Coupling types, 431
Supplementary conditions, 621
CP-BASIC, 380
Technological features, 596
CPBC, 401
Velocity feedforward control, 591
CP-COMFORT, 380
Collision avoidance
CPDEF, 389
Fundamentals example, 217, 292
CPDEF+CPLA, 390
Collision avoidance: Activate protection area, 834
CPDEL, 389
Collision avoidance: Deactivate protection area
CPDEL+CPLA, 392
group, 833, 834
CP-EXPERT, 380
Collision avoidance: Protection area active, 834, 835
CPFMOF, 407
Collision avoidance: Stop, 835
CPFMON, 406
Collision avoidance: Velocity reduction, 835
CPFMSON, 404
Collision pairs, 282
CPFPOS, 402
Collision tolerance, 269
CPFRS, 400
Compile cycle
CPLDEF, 390
Interface version, 576

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 883
Index

CPLDEL, 391 CUT3DFS, 818

CPLDEN, 397 Cutter shapes, 809
CPLINSC, 413 CYCLE750, 534
CPLINTR, 413 CYCLE751
CPLNUM, 397 External programming, 535
CPLOF, 395 CYCLE752
CPLON, 394 External programming, 536
CPLOUTSC, 414 CYCLE753
CPLOUTTR, 413 External programming, 539
CPLPOS, 403 CYCLE754
CPLSETVAL, 399 External programming, 540
CPMALARM, 428 CYCLE755
CPMBRAKE, 423 External programming, 541
CPMPRT, 411 CYCLE756
CPMRESET, 409 External programming, 542
CPMSTART, 410 CYCLE757
CPMVDI, 424 External programming, 544
CPOF, 394 CYCLE758
CPOF+CPFPOS, 408 External programming, 547
CPON, 393 CYCLE759
CPRECOF, 184 External programming, 548
CPRECON, 184
CPRES, 436
CPSETTYPE, 431 D
CP-STATIC, 380
DB 31, ...
CPSYNCOP, 417
DBX1.4, 159
CPSYNCOP2, 420
DBX101.3, 830, 831
CPSYNCOV, 418
DBX101.5, 158, 831, 832
CPSYNFIP, 417
DBX2.1, 159
CPSYNFIP2, 420
DBX24.3, 845
CPSYNFIV, 418
DBX24.5, 842
CTOL, 184
DBX29.5, 159, 173
Curve segment, 318
DBX66.0, 845
Curve table, 398
DBX96.7, 843
Curve tables, 317
DBX97.0, 845
Activation, 333
DBX97.1, 845
Behavior in operating modes, 334
DBX97.2, 846
Deactivation, 333
DBX97.3, 846
Delete, 321
DB10
Insufficient memory, 320
DBB0, 623
Interface signals, 335
DBB146, 623
Memory optimization, 320
DBX226.0 - DBX233.7, 240, 834, 835
Memory type, 319
DBX234.0 - DBX241.7, 240, 834
Multiple use, 334
DBX58.0-7, 833, 834
Overwrite, 321
DB11, ...
Programming, 323
DBX5.2, 156
Standard memory type, 322
DB11, …
Tool radius compensation, 319
DBX0.7, 734
Transformations, 339
DB21
CUT3DC, 818
DBX377.0, 835
CUT3DF, 818
DB21, ...
CUT3DFF, 818
DBB232, 827, 844

Special functions
884 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 Index

DBX0.1, 846 DBX0.2, 313

DBX0.2, 847 DBX0.3, 313
DBX0.3, 313 DBX0.4, 313
DBX1.4, 839 DBX0.5, 313
DBX1.5, 840 DBX0.6, 313
DBX29.4, 827, 843 DBX0.7, 313
DBX317.6, 844 DBX1.3, 313
DBX318.2, 127, 128 DBX1.4, 168, 314
DBX318.3, 127 DBX1.5, 159, 168, 314, 335, 351
DBX32.1, 847 DBX1.6, 159, 168, 314, 335, 351
DBX32.2, 847 DBX101.2, 149, 167, 830
DBX33.6, 827, 844 DBX101.3, 149, 167
DBX37.3, 840 DBX101.4, 156, 167, 831
DBX37.4, 840, 841 DBX101.5, 150, 156, 167, 169
DBX37.5, 841 DBX101.6, 167, 832
DBX6.7, 840 DBX101.7, 167, 833
DBX7.3, 622 DBX103.0, 450
DBX7.4, 622 DBX103.4, 421
DB21, … DBX103.5, 421
DBB4, 840 DBX2.1, 168, 313, 314
DBX0.1, 726, 734, 737, 741 DBX24.2, 844, 845
DBX0.2, 727, 734, 742 DBX24.5, 838
DBX1.0, 160 DBX24.7, 656, 842
DBX1.4, 841 DBX26.4, 360, 363
DBX317.6, 827, 828 DBX29.4, 157, 167, 173, 175, 829
DBX318.0, 744 DBX29.5, 157, 167, 829, 830
DBX318.2, 828 DBX31.6, 448
DBX318.3, 828 DBX31.7, 452
DBX32.1, 742 DBX4.0, 313
DBX32.2, 734 DBX4.1, 313
DBX32.6, 727 DBX4.2, 313
DBX33.0, 156 DBX4.3, 313, 357
DBX33.4, 744 DBX4.7/4.6, 152
DBX33.6, 66, 704 DBX60.4, 168
DBX37.4, 841 DBX60.5, 168
DBX37.5, 840 DBX61.5, 656
DBX7.7, 734 DBX61.6, 656
DB31 DBX61.7, 656
DBX77.0, 835 DBX64.6, 168
DB31, ... DBX64.7, 168
DBB101.4, 173, 174 DBX95.1, 837
DBB101.6, 173, 174 DBX95.2, 838
DBB101.7, 173, 174 DBX95.3, 838
DBB102.2, 175 DBX96.2, 842
DBB102.3, 175 DBX96.3, 843
DBB102.4, 175 DBX96.4, 843
DBB102.5, 175 DBX96.5, 839
DBB102.6, 175 DBX96.7, 656
DBB102.7, 175 DBX97.1, 715
DBX 99.1, 359 DBX97.2, 715
DBX0.0, 313 DBX98.0, 358, 359, 416, 446
DBX0.1, 313 DBX98.1, 358, 359, 416, 446

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 885
Index

DBX98.4, 360
DBX98.5, 360
DBX98.6, 360 E
DBX98.7, 488
Effects on orientations, 70
DBX99.0, 314
EG axis group
DBX99.1, 314
- activating, 362
DBX99.2, 451
- Deactivating, 367
DBX99.3, 360
- defining, 361
DBX99.4, 348, 358, 359
- delete, 367
DB31, ... DBX1.4, 314
EG axis groupings, 355
DB31, …
Electronic gearbox, 352, 353
DBX24.2, 715
System variables, 369
DBX24.3, 717
Element, 188
DBX26.4, 836
Enable, 770
DBX60.6, 841
Enable following axis overlay, 836
DBX60.7, 841
End orientation, 121
DBX66.0, 718
END program, 740
DBX97.0, 714
ESR, 470
DBX97.3, 716
Gating logic, 480
DBX98.5, 836
Trigger sources, 479, 480
DBX98.6, 836, 837
Euler angles, 49
DBX99.3, 837
Example
DB31, ... DBB20, 513
Tangential control, 654
DB31, ... DBB21, 513
Extended interpolation of orientation axes, 121
DB31, ... DBB92, 512
Extended monitoring
DB31, ... DBB93, 512
Gantry axes, 150
DB31, ... DBB94, 512
DB31, ... DBB95, 512
DBX31, …
DBX1.5, 607
F
DBX2.1, 607 Face milling, 809
DBX21.7, 607 Following axis overlay, 385
DC Link Following axis/spindle module, 390
Energy balance, 483 Functionality, 784
Deactivate or disable coupling, 844, 845
Definition
EG axis group, 361 G
Definition of an axis pair, 771
G0 edge change, 754
DELOBJ, 213
G450, 800
Dependent coupled motion axis, 309
G451, 804
Detailed description, 783
G91 extension
Diagnosing and optimizing utilization of
Zero offset, 113
resources, 335
Gantry axes
Differential speed "Coarse", 843
Differences in comparison with coupled
Differential speed "Fine", 842
motion, 171
Direction of rotation, 123
Gantry axis, 833
Direction vector, 122
Gantry grouping is synchronized, 831, 832
Disable, 761
Gantry leading axis, 832
Distance vector
Gantry synchronization ready to start, 831
Maximum, 781
Gantry trip limit exceeded, 830
Dynamic limits, 457
Gantry warning limit exceeded, 830, 831

Special functions
886 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 Index

Gear stage change with activated master-slave Large circle interpolation, 81

coupling, 650 Laser cutting
General functionality, 783 Clearance control, 588
General information, 783 Leading axes
Generator operation, 470, 484 Defining, 390
Generic 5-axis transformation and variants, 67 Delete, 391
Generic orientation transformation variants, 69 Leading axis
GUD variables, 746 Activating, 394
Switch off, 395
Limit angle for the fifth axis, 53
H Linear axis, 771
Logging, 351
Hardware requirements, 383

M
I
Machine kinematics, 68
I/Os, 753, 760
Machine types, 42, 44, 71
Identification of axis sequence, 44
5-axis transformation, 68
Independent coupled motion axis, 309
6-axis transformation, 75
INI program, 738
Main program, 737
Insertion depth (ISD), 798
Master value
Integrated outputs, 753
-coupling, 341
Interface signals
-object, 341
ESR reaction is triggered, 838
Offset, 412
Generator operation – minimum speed fallen
Scaling, 412
below, 838
Master value coupling
VDC link lower than alarm threshold, 837
Behavior in operating modes, 349
Interface versions, 577
Interface signals, 351
Intermediate blocks, 818
Switch off, 346
Intermediate orientation, 123
Switch on, 345
Interpolation, 351
Master/slave coarse, 843
Interpolation of the angle of rotation, 118
Master/slave compensatory cont. active, 843
Interpolation of the rotation vector, 119
Master/slave fine, 842
Interpolation type and selection, 114
Master-slave coupling active, 843
Interruption point, 726
Maximum axis acceleration, 458
Intersection procedure for 3D compensation, 804
Maximum axis velocity, 458
ISD, 798
Maximum switching frequency, 757
MD10000, 33, 777
MD10002, 777
K MD10089, 500
Keywords, 385 MD10300, 599
Kinematic chains, 188 MD10320, 603
Kinematic structure, 187 MD10350, 599
Kinematic transformation, 41 MD10360, 760
Kinematics MD10362, 599, 602
Swiveling linear axis, 36 MD10366, 599, 602
Kinematics of machines, 42 MD10619, 279
MD10620, 49, 700
MD10622, 279
L MD10640, 49, 700
MD10674, 114
Language scope, 790
MD10700, 783, 785, 787

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 887
Index

MD10712, 601 MD20900, 322, 328

MD11410, 310, 428 MD20905, 322, 325, 327, 336
MD11410 $MN_SUPPRESS_ALARM_MASK MD21050, 181
Bit31, 358 MD21060, 181
MD11450, 653 MD21070, 182
MD11602, 653, 734 MD21084, 811
MD11604, 653, 734 MD21094, 98, 100, 102
MD11660 $MN_NUM_EG, 355 MD21100, 49, 109, 118, 700
MD12701, 777 MD21102, 109
MD12750, 777 MD21104, 110, 700
MD16800, 193 MD21106, 82
MD18114, 78 MD21108, 54
MD18170, 785 MD21120, 84, 106
MD18180, 785 MD21130, 84
MD18242, 786 MD21150, 108
MD18351, 732, 785 MD21155, 108
MD18400, 318, 321 MD21160, 108
MD18402, 318, 321 MD21165, 108
MD18403, 318, 321 MD21180, 90, 141
MD18404, 318, 321 MD21186, 112
MD18406, 318, 321 MD21190, 126, 127
MD18408, 318, 321 MD21194, 127
MD18409, 318, 321 MD21380, 470, 504
MD18410, 318, 321 MD21380 $MC_DELAY_TIME1, 473
MD18450, 383 MD21380 $MC_ESR_DELAY_TIME1, 473, 474, 475
MD18452, 383 MD21381, 504
MD18860, 824 MD21381 $MC_ESR_DELAY_TIME2, 473, 475
MD18880, 193 MD22410, 460
MD18882, 193 MD24100, 44, 48, 71, 72, 73, 74, 75, 664, 705, 707,
MD18890, 232, 280 708
MD18892, 232, 280 MD24110, 44, 72, 76, 107, 664
MD18893, 232 MD24120, 664, 708, 735
MD18894, 232, 280 MD24200, 71, 74, 75
MD18895, 232, 280 MD24210, 72
MD18896, 280 MD24410, 107
MD18897, 232 MD24432, 107
MD18898, 281 MD24460, 705
MD18899, 233 MD24462, 107
MD19610, 770 MD24480, 44, 48
MD19830, 279 MD24482, 44
MD20050, 735, 761 MD24500, 45, 73, 74, 76
MD20060, 33, 790 MD24510, 45, 72
MD20080, 33, 790 MD24520, 48, 73
MD20105, 653 MD24530, 53
MD20110, 66, 185, 311, 344, 346, 349, 350, 705 MD24540, 53, 85
MD20112, 185, 311, 344, 346, 349, 350 MD24550, 73, 74, 76
MD20140, 705 MD24558, 74, 76
MD20150, 51, 700 MD24560, 45, 73, 74, 76
MD20178, 96 MD24561, 76
MD20470, 183 MD24567, 77
MD20482, 92 MD2457, 70
MD20610, 127 MD24570, 68, 72

Special functions
888 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 Index

MD24572, 69, 72 MD33060, 825

MD24573, 76 MD33100, 91
MD24574, 70, 72, 76 MD34040, 154
MD24576, 76 MD34070, 154
MD24580, 107 MD34080, 158, 164, 174
MD24582, 71 MD34090, 158, 164, 174
MD24585, 107, 108 MD34100, 152, 154, 156, 158, 160, 175
MD24590, 111 MD34110, 160
MD24620, 48, 73 MD34330, 154, 158, 160
MD24630, 53 MD36000, 601
MD24640, 53, 85 MD36010, 601
MD24670, 70 MD36012, 159
MD24674, 72 MD36020, 601
MD24680, 107 MD36030, 159
MD24682, 71, 74 MD36040, 602
MD24690, 111 MD36060, 602
MD28010, 786 MD36100, 623
MD28020, 786 MD36110, 623
MD28040, 786 MD36120, 623
MD28090, 598, 716, 730, 760 MD36130, 623
MD28100, 598, 716, 730, 760 MD36500, 160, 181
MD28105, 731 MD36600, 445
MD28590, 95 MD36954, 500
MD30110, 510 MD36955, 500
MD30130, 342, 345, 347 MD37014, 649
MD30132, 342, 624 MD37100, 164, 172, 623, 829
MD30230, 510 MD37110, 149, 154, 165, 172, 175, 176
MD30450, 170 MD37120, 149, 162, 172, 175, 176, 830
MD30455, 442, 449 MD37130, 149, 162, 172, 176, 830
MD30552, 714 MD37135, 150
MD32000, 457, 600 MD37140, 152, 157, 169, 170
MD32000 $MA_MAX_AX_VELO, 360 MD37150, 150, 158
MD32100, 162 MD37160, 335, 344
MD32200, 163, 600 MD37200, 417
MD32230, 600 MD37200
MD32300, 457, 717 $MA_COUPLE_POS_TOL_COARSE, 358, 370
$MA_MAX_AX_ACCEL, 360 MD37200
MD32300 $MA_MAX_AX_ACCEL, 360 $MN_COUPLE_POS_TOL_COARSE, 358, 359
MD32400, 163 MD37202, 419
MD32410, 163, 591 MD37210, 417
MD32415, 184 MD37210 $MA COUPLE_POS_TOL_FINE, 359
MD32420, 163 MD37210 $MA_COUPLE_POS_TOL_FINE, 358,
MD32430, 163 370
MD32434, 721 MD37212, 420
MD32610, 163, 591 MD37220, 417
MD32620, 163 MD37230, 417
MD32650, 163 MD37262, 655
MD32800, 163 MD37268, 648
MD32810, 163, 164 MD37400, 518
MD32900, 164 MD37500, 503
MD32910, 164 MD37500 $MA_ESR_REACTION, 474
MD33000, 163 MD37550 $MA_EG_VEL_WARNING, 360

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 889
Index

MD37560 $MA_EG_ACC_TOL, 360 MD62615, 708

MD43108, 376 MD62616, 669, 692, 708
MD51160, 281 MD62617, 675, 678, 685, 691, 709
MD51161, 281 MD62618, 674, 678, 685, 691, 708
MD51162, 281 MD62620, 673, 678, 685, 691, 708
MD60900+i, 730 MD62629, 676
MD60940, 598 MD62630, 676
MD60948, 760, 762 MD62631, 676
MD60972, 771, 777 MD62632, 677
MD61516, 771, 777 MD62636, 703
MD61517, 772, 777 MD62637, 703
MD61518, 772 MD63514, 776
MD61519, 773 MD63540, 714
MD61532, 773 MD63541, 716
MD62500, 601 MD63542, 717
MD62502, 601 MD63543, 717
MD62504, 597, 601, 606 MD63544, 717
MD62505, 603, 611, 612, 840 MD63545, 717
MD62506, 603, 611, 612, 841 MD65520, 600
MD62508, 603, 623 MD65530, 600
MD62510, 610, 617 MELDW
MD62511, 603, 610, 617 Bit9, 495
MD62512, 610, 617 Memory configuration
MD62513, 603, 610, 617 Curve tables, 318
MD62516, 840 Generic coupling, 383
MD62520, 841 Memory requirements, 786
MD62521, 841 Minimum switching position clearance, 757
MD62522, 603, 616 Modulo display, 112
MD62523, 614 Modulo leading axis, 334
MD62524, 605 Monitoring
MD62528, 600 Synchronous operation, 415
MD62560, 761
MD62571, 732
MD62572, 732 N
MD62574, 733
NAMETOINT, 216
MD62575, 745
NC block compressor, 90
MD62580, 730
NC-controlled extended stop, 473
MD62600, 660, 677, 685, 691, 695, 708
Number of active G function of G function group
MD62601, 675, 678, 685, 691
25, 844
MD62602, 695, 696, 697, 698, 708
Number of active G function of G function group 25
MD62603, 666, 678, 685, 691, 708
(tool orientation reference), 827
MD62604, 668, 678, 685, 691, 708
MD62605, 672, 677, 685, 691, 708
MD62606, 668, 685, 691, 708
MD62607, 667, 678, 685, 691, 708
O
MD62608, 668, 686, 692 Offset, 80
MD62609, 668, 686, 692 of a lead value, 412
MD62610, 668, 678, 690, 692 Offset after point of activation, 846
MD62611, 668, 678, 685, 690, 692 Offset vector, 772
MD62612, 666, 678, 686, 691 Online tool length offset, 125
MD62613, 666, 678, 686, 691 Opening angle, 123
MD62614, 692, 708 Opening angle of the cone, 122

Special functions
890 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 Index

Operating modes Pole, 53

JOG, 82 Polynomial interpolation, 115
Option, 770 Orientation vector, 113
ORIC, 801, 815 Polynomial of the 5th degree, 119
ORICONCCW, 122, 124 Polynomials for 2 angles, 115
ORICONCW, 122, 124 POLYPATH, 114
ORICONIO, 123, 124 Position of the orientation coordinate system
ORICONTO, 123 Generic transformation with 6 axes, 77
ORICURVE, 123 Program continuation point, 726
ORID, 803 Program handling, 785
Orientation, 81, 87 Programming
Orientation axes, 39, 106 Cartesian position, 81
Modulo display, 113 Orientation, 81
Orientation direction, 117 Polynomial, 113
Orientation direction and rotation, 118 PROTA, 289
Orientation in TCS and MCS, 49 PROTD, 291
Orientation motion Protection window, 773
with axis limits, 89 PROTS, 290
Orientation of the machine axes, 773 PTP traversal active, 827, 828, 844
Orientation programming, 49
Orientation relative to the path, 97
Orientation transformation, 41 R
Programming, 109
r9721, 502
Orientation transformation and orientable tool
r9723, 502
holders, 112
Rapid stop, 445
Orientation vector, 114
Reaction to Stop, 344
Orientation with axis interpolation, 81
RESET response, 736
ORIMKS, 49
Restrictions, 327
ORIPLANE, 122, 124
Restrictions for kinematics and interpolation, 84
ORISOF, 96
RESU ASUB, 741
ORISON, 95, 96
RESU main program, 737
ORIWKS, 49, 79
RESU working plane, 730
Outside corners/inside corners, 799
RESU-specific part programs
Overview, 736
Retrace mode active, 847
P Retrace support active, 847
p0888, 489, 491, 492 Retraceable contour range, 726
p0890, 502 Retract, 469, 470
p0891, 490, 491 Retraction direction, 772
p0892, 490, 491 Reverse/Forward, 846
p0893, 491 Rotary axis, 771
p1240, 492 Rotary axis of the cone, 121
p1248, 493 Rotary axis position
p1414, 592 calculating, 89
p2161, 493 Rotation of the orientation vector, 117, 118
p9554, 500, 502 RPY angles, 49
p9555, 501 Runtime optimization, 784
p9580, 501, 502
p9697, 501, 502
Parallel subchains, 189 S
PI controller, 459
Safety clearance, 269
Plane, 730

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 891
Index

Scaling swiveled linear axis

of a lead value, 412 Pole, 57
SD42450, 184 Swiveling linear axis, 36
SD42460, 184 Synchronism
SD42475, 91 Correction, 450
SD42476, 91 Synchronism difference, 358
SD42477, 91 - scanning, 360
SD42650, 82 Synchronization, 459
SD42660, 83 Following axis, 353
SD42670, 100 Synchronization mode, 404
SD42672, 100 Synchronous operation
SD42678, 96 Deviation, 446
SD42680, 96 -difference, 415
SD42970, 127 -monitoring, 415
SD42974, 72 Synchronous operation monitoring
SD43100, 347 stage 2, 419
SD43102, 342 Synchronous position
SD43104, 342 Following axis, 402
SD43106, 342 Leading axis, 403
SD43108, 342 Syntax check, 789
Series machine startup, 733 System variables, 388
Setup for orientation, 34
Collision avoidance, 267
Shutting down, 469
Extended, 470 T
Siemens compile cycles, 574
TANG, 519
Simulated master value, 342
TANGDEL, 524
Singular positions, 52
Tangential control, 517
Singularities, 85
Examples, 654
Slot, 776
TANGOF, 523
Smoothing
TANGON, 522
of the orientation characteristic, 96
Technology functions, 573
the orientation characteristic, 95
Activate, 579
Special functions, 573
Temporary curve table, 320
Spindle
TLIFT, 521
in master value coupling, 344
TOFF active, 828
Start, 789
TOFF motion active, 828
Start gantry synchronization, 829
Tool offsets, 751
Start orientation, 121
Tool orientation, 39
Start retrace support, 847
Tool orientation using orientation vectors, 52, 85
Starting value, 328
Tool tip at a fixed point in space, 49
States
Toolholder, with orientation capability
Protection areas, 268
Programming, 85
Status of coupling, 314, 351
Torque compensatory controller active, 843
Status of setpoint exchange, 839
TRAANG, 339
SW version, 578
TRAILOF, 312
Switch on collision protection, 845
TRAILON, 312
Switching criteria, 754
Transformation, 750
Switching instants, 757
Transformation active, 66, 827, 844
Switching position, 754
Transformation inactive, 66
Switching position offset, 758, 759
Transformation types, 48
Two-axis swivel head, 42

Special functions
892 Function Manual, 10/2015, 6FC5397-2BP40-5BA3
 Index

U
Universal milling head, 38

V
V2 preprocessing
Brief description, 783
Velocity threshold value, 755
Velocity warning threshold, 836
VELOLIMA[FA], 458
Versions, 380
Virtual leading axis, 342

W
WAITC, 401
World coordinate system, 190

Special functions
Function Manual, 10/2015, 6FC5397-2BP40-5BA3 893
Index

Special functions
894 Function Manual, 10/2015, 6FC5397-2BP40-5BA3