Various NC/PLC interface

signals and functions

A2

Axis monitoring,
protection zones

A3

Continuouspath Mode,
Exact Stop, LookAhead

B1

Acceleration

B2

Diagnostic tools

D1

Basic Functions

Travel to fixed stop

F1

Function Manual

Velocities, Setpoint/ActualValue Systems, Closed-Loop

Control

G2

Auxiliary Function Output

to PLC

H2

Mode Group, Channel,

Program Operation,
Reset Response

K1

Axis Types, Coordinate

Systems, Frames

K2

Emergency Stop

N2

Transverse axes

P1

PLC Basic program

powerline

P3
pl

PLC basic program

solution line

P3
sl

Reference point approach

R1

Spindles

S1

Feeds

V1

Tool compensation

W1

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

Valid for

Control

SINUMERIK 840D sl/840DE sl

SINUMERIK 840Di sl/840DiE sl
SINUMERIK 840D powerline/840DE powerline
SINUMERIK 840Di powerline/840DiE powerline
SINUMERIK 810D powerline/810DE powerline

Software

NCU system software for 840D sl/840DE sl

NCU system software for 840Di sl/DiE sl
NCU system software for 840D/840DE
NCU system software for 840Di/840DiE
NCU system software for 810D/810DE
03/2006 Edition

Version

1.3
1.0
7.4
3.3
7.4

6FC5397-0BP10-1BA0

NC/PLC interface signals

Z1

Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
Danger
indicates that death or severe personal injury will result if proper precautions are not taken.
Warning
indicates that death or severe personal injury may result if proper precautions are not taken.
Caution
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
Notice
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.

Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage
Note the following:
Warning
This device may only be used for the applications described in the catalog or the technical description and only in
connection with devices or components from other manufacturers which have been approved or recommended by
Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly
as well as careful operation and maintenance.

Trademarks
All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.

Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG
Automation and Drives
Postfach 48 48
90437 NRNBERG
GERMANY

Order No.: 6FC5397-0BP10-1BA0

Edition 05/2006

Copyright Siemens AG Fehler!

Unbekannter Name fr
Dokument-Eigenschaft..
Technical data subject to change

Foreword
SINUMERIK Documentation
The SINUMERIK documentation is organized in 3 parts:
General documentation
User documentation
Manufacturer/service documentation
A monthly updated publications overview with respective available languages can be found
in the Internet under:
http://www.siemens.com/motioncontrol
Select the menu items "Support" "Technical Documentation" "Overview of
Publications".
The Internet version of DOConCD (DOConWEB) is available under:
http://www.automation.siemens.com/doconweb
Information about training courses and FAQs (Frequently Asked Questions) can be found
in internet under:
http://www.siemens.com/motioncontrol under menu option "Support"

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.

Basic Functions
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

iii

Foreword

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.

Structure of the Function Manual

Structure of this Function Manual:
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 function descriptions.
The description of each function is a separate book.
Appendix with list of abbreviations and terms.
An overview of the functions described in this Function Manual is on the third page. The
functions are listed in alphanumeric order of their abbreviations (e.g. A2, A3, etc.). The
Descriptions of Functions are also contained in this order in the Function Manual.
A Description of Functions contains the following chapters:
Brief description
Detailed description
Constraints
Examples
Data lists

Note
Detailed descriptions regarding data and alarms are provided for:
machine and setting data:
Electronic only on DOConCD or DOConWEB
NC/PLC interface signals:
/FB1/ NC/PLC interface signals (Z1)
/FB2/ NC/PLC interface signals (Z2)
/FB3/ NC/PLC interface signals (Z3)
alarms:
/DA/ Diagnostics Manual

iv

Basic Functions
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Foreword

Technical information
The following notation is used in this documentation:
Signal/Data

Notation

Example

NC/PLC interface
signals

... NC/PLC interface signal:

When the new gear step is engaged, the following NC/PLC

interface signals are set by the PLC program:

Signal data (signal name)

DB31, ... DBX16.0-16.2 (current gear step A to C)

DB31, ... DBX16.3 (gear is changed)

Machine data

Setting Data

... machine data:

Master spindle is the spindle stored in the machine data:

<Type><Number> <Complete
Designator> (<Meaning>)

MD20090 $MC_SPIND_DEF_MASTER_SPIND (Position of

deletion of the master spindle in the channel).

... Setting data:

The logical master spindle is contained in the setting data:

<Type><Number> <Complete
Designator> (<Meaning>)

SD42800 $SC_SPIND_ASSIGN_TAB[0] (Spindle number

converter).

Data types
The following elementary data types are used in the control system:
Type

Meaning

Value range

INT

Signed integers

(231 - 1)

REAL

Figures with decimal point acc. to IEEE

(10-300 10+300)

BOOL

Boolean values: TRUE/FALSE

TRUE 0; FALSE = 0

CHAR

1 ASCII character corresponding to the code

0 255

STRING

Character string, number of characters in [...], maximum of

200 characters

Sequence of values with 0 ... 255

AXIS

Axis identifier

Axis identifier for all channel axes

FRAME

Geometrical parameters for translation, rotation, scaling,

and mirroring

Arrays can only be formed from similar elementary data types. Up to two-dimensional arrays are possible.

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

Basic Functions
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Foreword

Technical Support
If you have any questions, please contact the following hotline:
European and African time zone
A&D Technical Support
Tel.:

+49 (0) 180 / 5050 - 222

Fax:

+49 (0) 180 / 5050 - 223

Internet: http://www.siemens.com/automation/support-request
Email:

mailto:[email protected]

Asian and Australian time zone

A&D Technical Support
Tel.:

+86 1064 719 990

Fax:

+86 1064 747 474

Internet: http://www.siemens.com/automation/support-request
Email:

mailto:[email protected]

American time zone

A&D Technical Support
Tel.:

+1 423 262 2522

Fax:

+1 423 262 2289

Internet: http://www.siemens.com/automation/support-request
Email:

mailto:[email protected]

Note
Country specific telephone numbers for technical support are provided under the following
Internet address:
http://www.siemens.com/automation/service&support

vi

Basic Functions
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Foreword

Questions about the Manual

If you have any queries (suggestions, corrections) in relation to this documentation, please
send a fax or e-mail to the following address:
Fax:

+49 (0) 9131 / 98 - 63315

Email:

mailto:[email protected]

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

SINUMERIK Internet address

http://www.siemens.com/sinumerik

EC declaration of conformity
The EC Declaration of Conformity for the EMC Directive can be found/obtained
in the internet:
http://www.ad.siemens.de/csinfo
under product/order no. 15257461
with the relevant branch office of the A&D MC group of Siemens AG.

Basic Functions
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

vii

Foreword

viii

Basic Functions
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

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

Various NC/PLC interface signals and functions (A2)

1
Brief description
______________
2
Detailed description
______________

SINUMERIK
840D sl/840Di sl/840D/840Di/810D
Various NC/PLC interface signals
and functions (A2)
Function Manual

Valid for

Control

SINUMERIK 840D sl/840DE sl

SINUMERIK 840Di sl/840DiE sl
SINUMERIK 840D powerline/840DE powerline
SINUMERIK 840Di powerline/840DiE powerline
SINUMERIK 810D powerline/810DE powerline

Software

NCU System Software for 840D sl/840DE sl

NCU system software for 840D sl/DiE sl
NCU system software for 840D/840DE
NCU system software for 840Di/840DiE
NCU system software for 810D/810DE
03/2006 Edition
6FC5397-0BP10-1BA0

Version
1.3
1.0
7.4
3.3
7.4

3
Supplementary conditions
______________
4
Example
______________
5
Data lists
______________

Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
Danger
indicates that death or severe personal injury will result if proper precautions are not taken.
Warning
indicates that death or severe personal injury may result if proper precautions are not taken.
Caution
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
Notice
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.

Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage
Note the following:
Warning
This device may only be used for the applications described in the catalog or the technical description and only in
connection with devices or components from other manufacturers which have been approved or recommended by
Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly
as well as careful operation and maintenance.

Trademarks
All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.

Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG
Automation and Drives
Postfach 48 48
90437 NRNBERG
GERMANY

Order No.: 6FC5397-0BP10-1BA0

Edition 05/2006

Copyright Siemens AG 2006.

Technical data subject to change

Table of contents
1

Brief description ...................................................................................................................................... 1-1

Detailed description ................................................................................................................................ 2-1

2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.1.7
2.1.8
2.1.9
2.1.10

NC/PLC interface signals........................................................................................................... 2-1

General ...................................................................................................................................... 2-1
Ready signals to PLC ................................................................................................................ 2-3
Alarm signals to PLC ................................................................................................................. 2-4
SINUMERIK 840Di-specific interface signals ............................................................................ 2-4
Signals to/from panel front ......................................................................................................... 2-5
Signals to channel...................................................................................................................... 2-7
Signals to axis/spindle ............................................................................................................... 2-7
Signals from axis/spindle ......................................................................................................... 2-17
Signals to axis/spindle (digital drives)...................................................................................... 2-18
Signals from axis/spindle (digital drives).................................................................................. 2-20

2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.5.1
2.2.5.2
2.2.5.3
2.2.5.4

Functions.................................................................................................................................. 2-23
Screen settings ........................................................................................................................ 2-23
Settings for involute interpolation............................................................................................. 2-25
Activate DEFAULT memory..................................................................................................... 2-28
Read/write PLC variable .......................................................................................................... 2-28
Access protection via password and keyswitch....................................................................... 2-32
Access protection via password and keyswitch....................................................................... 2-32
Password ................................................................................................................................. 2-34
Keyswitch settings (DB10, DBX56.4 to 7) ............................................................................... 2-35
Parameterizable protection levels............................................................................................ 2-36

Supplementary conditions ...................................................................................................................... 3-1

Example.................................................................................................................................................. 4-1

Data lists................................................................................................................................................. 5-1

5.1
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5

Machine data.............................................................................................................................. 5-1

Drive-specific machine data....................................................................................................... 5-1
Memory specific machine data .................................................................................................. 5-2
NC-specific machine data .......................................................................................................... 5-4
Channelspecific machine data ................................................................................................... 5-4
Axis/spindlespecific machine data ............................................................................................. 5-5

5.2

System variables........................................................................................................................ 5-5

5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.3.8

Signals ....................................................................................................................................... 5-5

Signals to NC ............................................................................................................................. 5-5
Signals from NC......................................................................................................................... 5-6
Signals to operator panel front................................................................................................... 5-7
Signals from operator panel front .............................................................................................. 5-8
Signals to channel...................................................................................................................... 5-8
Signals from channel ................................................................................................................. 5-9
Signals to axis/spindle ............................................................................................................... 5-9
Signals from axis/spindle ......................................................................................................... 5-10

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

iii

Table of contents
Index................................................................................................................................................ Index-1

iv

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Brief description

Content
The PLC/NCK interface comprises a data interface on one side and a function interface on
the other. The data interface contains status and control signals, auxiliary functions and G
functions, while the function interface is used to transfer jobs from the PLC to the NCK.
This Description describes the functionality of interface signals, which are of general
relevance but are not included in the Descriptions of Functions.
Asynchronous events
Status signals
PLC variable (read and write)

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

1-1

Brief description

1-2

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1

2.1.1

2.1

NC/PLC interface signals

General

NC/PLC interface
The NC/PLC interface comprises the following parts:
Data interface
Function interface

Data interface
The data interface is used for component coordination:
PLC user program
NC
HMI (operator components)
MCP (Machine Control Panel)
Data exchange is organized by the basic PLC program.

Cyclic signal exchange

The following interface signals are transferred cyclically, i.e. in the clock grid of the OB1, by
the basic PLC program:
NC and operator-panel-front-specific signals
Mode groupspecific signals
Channelspecific signals
Axis/spindlespecific signals

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-1

Detailed description
2.1 NC/PLC interface signals

NC and operator-panel-front-specific signals (DB10)

PLC to NC:
Signals for influencing the CNC inputs and outputs
Keyswitch signals (and password)
NC to PLC:
Actual values of CNC inputs
Setpoints of CNC outputs
Ready signals from NC and HMI
NC status signals (alarm signals)

Channel-specific signals (DB21, ...)

PLC to NC:
Control signal "Delete distancetogo"
NC to PLC:
NC status signals (NCK alarm active)

Axis/spindle-specific signals (DB31, etc.)

PLC to NC:
Control signals to axis/spindle (e.g. followup mode, servo enable, etc.)
Control signals to drive (bytes 20, 21)
NC to PLC:
Status signals from axis/spindle (e.g. position controller active, current controller active,
etc.)
Control signals from drive (bytes 93, 94)

Function interface
The function interface is generated by function blocks (FB) and function calls (FC). Function
requests, e.g. to traverse axes, are sent from the PLC to the NC via the function interface.

2-2

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1 NC/PLC interface signals

References
For detailed information about the following subject areas, please refer to:
Description of the basic PLC program:
/FB1/ Function Manual, Basic Functions; Basic PLC Program (P3)
Description of event-controlled signal exchange (auxiliary and G functions):
/FB1/ Function Manual, Basic Functions; Auxiliary Function Output to PLC (H2)
Overview of all interface signals, function blocks and data blocks:
/LIS/Lists

2.1.2

Ready signals to PLC

DB10, DBX104.7 (NC CPU Ready)

The NC CPU is ready and registers itself cyclically with the PLC.

DB10,DBX108.1 (HMI CPU2 Ready)

HMI CPU2 is ready and registers itself cyclically to NC.
References:
/FB2/ Function Manual, Expansion Functions; Several Control Panels on Multiple NCUs,
Decentralized Systems (B3)

DB10, DBX108.2 (HMI CPU1 Ready, HMI to MPI)

The HMI CPU1 is ready and registers itself cyclically with the NC. Operator unit connection
via MPI interface.

DB10, DBX108.3 (HMI CPU1 Ready, HMI to OPI)

The HMI CPU1 is ready and registers itself cyclically with the NC. Operator unit connection
via OPI interface.

DB10, DBX108.6 (611D Ready)

Group signal: All available SIMODRIVE 611D drives ready.
Condition: Readiness of all machine axes
DB31,... DBX93.5 (Drive Ready) = 1
611D Ready is only output in conjunction with SIMODRIVE 611D drives.

DB10, DBX108.6 (NC Ready)

The NC is ready.

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-3

Detailed description
2.1 NC/PLC interface signals

2.1.3

Alarm signals to PLC

DB10, DBX103.0 (HMI alarm pending)

The HMI component signals that at least one HMI alarm is pending.

DB10, DBX109.6 (ambient temperature alarm)

The ambient temperature or fan monitoring function has responded.

DB10, DBX109.7 (NCK battery alarm)

The battery voltage has dropped below the lower limit value. The control can still be
operated. A control system shutdown or failure of the supply voltage will lead to loss of data.

DB10, DBX109.0 (NCK alarm pending)

The NC signals that at least one NC alarm is pending. The channelspecific interface can be
scanned to see which channels are involved and whether this will cause a processing stop.

DB21, ... DBX36.6 (channelspecific NCK alarm pending)

The NC sends this signal to the PLC to indicate that at least one NC alarm is pending for the
affected channel. See also: DB21, ... DBX36.6 (NCK alarm with processing stop pending)

DB21, ... DBX36.6 (NCK alarm with processing stop present)

The NC sends this signal to the PLC to indicate that at least one NCK alarm, which has
interrupted or aborted the current program run (processing stop), is pending for the affected
channel.

2.1.4

SINUMERIK 840Di-specific interface signals

For a detailed description of the SINUMERIK 840Di-specific interface signals, please refer
to:
References:
/HBI/ SINUMERIK 840Di Manual

2-4

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1 NC/PLC interface signals

2.1.5

Signals to/from panel front

DB19, DBX0.0 (operator panel inhibit)

All inputs via operator components on the operator panel front are inhibited.

DB19, DBX0.1 (darken screen)

The operator panel screen is darkened or lightened.
If the interface signal is used to actively darken the screen:
It is no longer possible to switch the screen bright again on the keyboard (see below).
The first keystroke on the operator panel already triggers an operator action.

Note
In order to prevent accidental operator actions when the screen is darkened via the
interface signal, we recommend disabling the keyboard at the same time.
DB19, DBX0.1 = 1 AND DB19, DBX0.2 = 1 (key disable)

Screen darkening via keyboard/automatic screen saver

If no buttons are pressed on the operator panel front within the assigned time (default = 3
minutes):
MD9006 $MM_DISPLAY_BLACK_TIME
(time for screen darkening), the screen is automatically darkened.
The screen lights up again the first time a button is pressed following darkening. Pressing a
button to lighten the screen will not generate an operator action.
Parameterization
DB19, DBX0.1 = 0
MD9006 $MM_DISPLAY_BLACK_TIME > 0

DB19, DBX0.2 (key disable)

All inputs via the connected keyboard are inhibited.

DB19, DBX 0.3 / 0.4 (delete cancel alarms / delete recall alarms)
Request to delete all currently pending alarms with Cancel or Recall delete criterion. Deletion
of the alarms is acknowledged via the following interface signals.
DB19, DBX20.3 (cancel alarm deleted)
DB19, DBX20.4 (recall alarm deleted)

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-5

Detailed description
2.1 NC/PLC interface signals

DB19, DBX0.7 (actual value in WCS, 0=MCS)

Switching over of actual-value display between machine and workpiece coordinate system:
DB19, DBX0.7 = 0: Machine coordinate system (MCS)
DB19, DBX0.7 = 1: Workpiece coordinate system (WCS)

DB19, DBB12 (control of V24 interface) (HMI Embedded only)

Job interface to control RS-232C. The jobs relate to the user control files in the interface
signals:
DB19, DBB14 (control of V24 interface).
DB19, DBB15 (control of V24 interface).

DB19, DBB13 (control of file transfer via hard disk) (HMI Advanced only)
Job byte to control file transfer via hard disk. The jobs relate to the user control file in the
interface signals:
DB19, DBB16 (parts program handling: Number of the control file for user file names)
DB19, DBB17 (parts program handling: Index of the file from the user list to be transmitted).

DB19, DBB14 (control of V24 interface) (HMI Embedded only)

Description byte to specify the PLC index of the axis, channel or TO number for the standard
control file. The standard control file is processed in accordance with the job in the interface
signal:
DB19, DBB12.

DB19, DBB15 (control of V24 interface) (HMI Embedded only)

Description byte to specify the line in the standard/user control file in which the file to be
transferred is stored.

DB19, DBB16 (control of file transfer via hard disk) (HMI Advanced only)
Control byte for file transfer via hard disk to define the index for the control file (job list). This
file is handled according to the job in the interface signal:
DB19, DBB13.

DB19, DBB17 (control of file transfer via hard disk) (HMI Advanced only)
Control byte for file transfer via hard disk to indicate the line in the user control file in which
the control file to be transferred is stored

DB19, DBB24 (control of V24 interface) (HMI Embedded only)

Status byte for current status of data transfer for "RS-232 ON", "RS-232 OFF", "RS-232
EXTERNAL", "RS-232 STOP", etc., or if an error occurred during data transfer.

2-6

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2.1 NC/PLC interface signals

DB19, DBB25 (control of V24 interface) (HMI Embedded only)

Output byte for RS-232 data transmission error values.

DB19, DBB26 (control of file transfer via hard disk) (HMI Advanced only)
Status byte for current status of data transfer for "select", "load" or "unload", or if an error
occurred during data transmission.

DB19, DBB27 (control of file transfer via hard disk) (HMI Advanced only)
Output byte for error values for data transfer via hard disk.

2.1.6

Signals to channel

DB21, ... DBX6.2 (delete distance-to-go)

The rising edge on the interface signal generates a stop on the programmed path in the
corresponding NC channel with the currently active path acceleration. The path distance-togo is then deleted and the block change to the next part-program block is enabled.

2.1.7

Signals to axis/spindle

DB31, ... DBX1.0 (drive-test travel enable)

If machine axes are traversed by special test functions such as "function generator", an
explicit drive-test-specific enable is requested for the movement:
DB31, ... DBX61.0 = 1 (drive test travel request)
The movement is carried out once the movement is enabled:
DB31, ... DBX1.0 == 1 (drive test travel enable)

Notice
It is the sole responsibility of the machine manufacturer/system startup engineer to take
suitable action/carry out appropriate tests to ensure that the machine axis can be traversed
during the drive test without putting personnel or machinery at risk.

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2.1 NC/PLC interface signals

DB31, ... DBX1.3 (axis/spindle disable)

Axis disable when machine axis is at rest
No traversing request (manual or automatic) is carried out for a machine axis at rest and
NC/PLC interface signal:
DB31, ... DBX1.3 == 1 (Axis/spindle disable).
The traversing request is maintained. If the axis disable is canceled when a traversing
request is pending DB31, ... DBX1.3 = 0 the traversing movement is carried out.
Axis disable when machine axis in motion
When machine axis is in motion and NC/PLC interface signal DB31, ... DBX1.3 == 1 the
movement of the machine axis is decelerated to a standstill via the axis-specific brake
characteristics currently active or, if it is part of an interpolated path movement or coupling, it
is decelerated on a path or coupling-specific basis.
The movement is continued if the axis disable is canceled by another pending traversing
request: DB31, ... DBX1.3 = 0.
Spindle disable
The response is determined by the current spindle mode:
Control mode: Speed setpoint = 0
Positioning mode: See above "Axis disable".

DB31, ... DBX1.4 (follow-up mode)

"Follow-up mode" is only effective in conjunction with the NC/PLC interface signal:
DB31, ... DBX2.1 (servo enable)
DB31, ... DBX2.1

DB31, ... DBX1.4

Function

Ineffective

Normal operation (machine axis in closed-loop control

mode)

Followup

Hold

Function: Follow-up
During follow-up, the setpoint position of the machine axis is continuously corrected to the
actual position (setpoint position = actual position).
The following interface signals have to be set for the follow-up function:
DB31, ... DBX2.1 = 0 (servo enable)
DB31, ... DBX1.4 = 1 (follow-up mode)
Feedback:
DB31, ... DBX61.3 = 1 (follow-up mode active)

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2.1 NC/PLC interface signals

Note
When the servo enable is set from follow-up mode, if the part program is active, the last
programmed position is approached again internally in the NC (REPOSA: Approach along line
on all axes). In all other cases, all subsequent movements start at the current actual position.

During "follow-up", clamping or zero-speed monitoring are not active.

Function: Holding
The hold function does not correct the setpoint position of the machine axis to the actual
position. If the machine axis moves away from the setpoint position, a following error
(difference between setpoint and actual position) is generated. This error is corrected
"suddenly" when the servo enable is set by the position controller, without observing the
axial acceleration characteristic.
The following interface signals have to be set for the hold function:
DB31, ... DBX2.1 = 0 (servo enable)
DB31, ... DBX1.4 = 0 (follow-up mode)
Feedback:
DB31, ... DBX61.3 = 0 (follow-up mode active)
During "hold", clamping or zero-speed monitoring are active.

Notice
With the "hold" function, once the servo enable has been set, the setpoint/actual-value
difference is corrected: directly by the position controller, i.e., without following the axial
acceleration characteristic.

Application example
Positioning response of machine axis Y following clamping when "servo enable" set.
Clamping pushed the machine axis from the actual position Y1 to the clamping position Yk.

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Detailed description
2.1 NC/PLC interface signals

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2-10

Trajectory for clamping and "hold"

Various NC/PLC interface signals and functions (A2)

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Detailed description
2.1 NC/PLC interface signals

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Drives with analog setpoint interface

A drive with an analog setpoint interface is capable of traversing the machine axis with an
external setpoint. If "follow-up mode" is set for the machine axis, the actual position
continues to be acquired. Once follow-up mode has been cancelled, homing is not required.
The following procedure is recommended:
1. Activate follow-up mode:
DB31, ... DBX2.1 = 0 (servo enable)
DB31, ... DBX1.4 = 1 (follow-up mode) (in the same or preceding OB1 cycle)
The axis/spindle is operating in followup mode
2. Deactivate external servo enable and external speed setpoint
Axis/spindle moves with external setpoint
NC continues to detect the actual position and corrects the setpoint position to the
actual position
3. Deactivate external servo enable and cancel external speed setpoint
Axis/spindle stops
4. Canceling followup mode
DB31, ... DBX2.1 = 1 (servo enable)
DB31, ... DBX1.4 = 0 (follow-up mode)
NC synchronizes to current actual position. The next traversing movement begins at
this position.

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Detailed description
2.1 NC/PLC interface signals

Note
"Followup mode" does not have to be canceled because it only has an effect in
combination with "servo enable".

Canceling followup mode

Once follow-up mode has been canceled, the machine axis does not have to be homed
again if the maximum permissible encoder limit frequency of the active measuring system
was not exceeded during follow-up mode. If the encoder limit frequency is exceeded, the
controller will detect this:
DB31, ... DBX60.4 / 60.5 = 0 (homed/synchronized 1 / 2)
Alarm: "21610 Encoder frequency exceeded"

Note
If "follow-up mode" is deactivated for a machine axis, which is part of an active
transformation (e.g. TRANSMIT), this can generate movements as part of repositioning
(REPOS) other machine axes involved in the transformation.

Monitoring
If a machine axis is in follow-up mode, the following monitoring mechanisms will not act:
Zero-speed monitoring
Clamping monitoring
Positioning monitoring
Effects on other interface signals:
DB31, ... DBX60.7 = 0 (position reached with exact stop fine)
DB31, ... DBX60.6 = 0 (position reached with exact stop coarse)

DB31, ... DBX1.5 / 1.6 (position measuring system 1 / 2)

2 measuring systems can be connected to one machine axis, e.g.,
Indirect motor measuring system
Direct measuring system on load
Only one measuring system can be active at any one time. All closed-loop control,
positioning operations, etc. involving the machine axis always relate to the active measuring
system.

2-12

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2.1 NC/PLC interface signals

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The table below shows the functionality of the interface signals in conjunction with the "servo
enable".
DB31, ... DBX1.5

DB31, ... DBX1.6

DB31, ... DBX2.1

Function

0 (or 1)

Position measuring system 1 active

Position measuring system 2 active

"Parking" active

Spindle without position measuring system (speedcontrolled)

1 -> 0

0 -> 1

Switchover: Position measuring system 1 2

0 -> 1

1 -> 0

Switchover: Position measuring system 2 1

DB31, ... DBX2.1 (servo enable)

Setting the servo enable closes the machine axis position control loop. The machine axis is
in position control mode.
DB31, ... DBX2.1 == 1
Canceling the servo enable opens the machine axis position control loop and, subject to a
delay, the machine axis speed control loop:
DB31, ... DBX2.1 == 0

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Detailed description
2.1 NC/PLC interface signals

Activation methods
The closed-loop servo enable for a machine axis is influenced by:
PLC user program by means of the following NC/PLC interface signals:
DB31, ... DBX2.1 (servo enable)
DB31, ... DBX21.7 (pulse enable)
DB31, ... DBX93.5 (drive ready)
DB10, DBX56.1 (EMERGENCY STOP)
NCK-internal
Alarms that trigger cancellation of the servo enable on the machine axes. Alarms, which
cancel the servo enable, are described in:
References:
/DA/ Diagnostics Manual
Canceling the servo enable when the machine axis is at standstill:
The machine axis position control loop opens
DB31, ... DBX61.5 = 0 (position controller active)
Canceling the servo enable when the machine axis is in motion:
If a machine axis is part of an interpolatory path movement or coupling and the servo enable
for this is canceled, all axes involved are stopped with a fast stop (speed setpoint = 0) and
an alarm is displayed:
Alarm: "21612 Servo enable reset during movement"
The machine axis is decelerated taking into account the parameterized temporal duration
of the brake ramp for error states with a fast stop (speed setpoint = 0):
MD36610 $MA_AX_EMERGENCY_STOP_TIME
An alarm is displayed:
Alarm: "21612 Servo enable reset during movement"

Note
The servo enable is canceled at the latest when the cutout time expires:
MD36610 $MA_AX_EMERGENCY_STOP_TIME

The machine axis position control loop opens. Interface signal:

DB31, ... DBX61.5 = 0 (position controller active).
The time for the parameterized cut-off delay of the servo enable is started by the machine
data:
MD36620 $MA_SERVO_DISABLE_DELAY_TIME.
As soon as the actual speed has reached the zero speed range, the drive servo enable is
canceled. Interface signal:
DB31, ... DBX61.6 = 0 (speed controller active).

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Detailed description
2.1 NC/PLC interface signals
The position actual value of the machine axis continues to be acquired by the control.
At the end of the braking operation, the machine axis is switched to follow-up mode,
regardless of the corresponding NC/PLC interface signal. Zero-speed and clamping
monitoring are not effective. See the description above for the interface signal:
DB31, ... DBX1.4 (follow-up mode).
Synchronizing the actual value (homing)
Once the servo enable has been set, the actual position of the machine axis does not need
to be synchronized again (homing) if the maximum permissible limit frequency of the
measuring system was not exceeded during the time in which the machine axis was not in
position-control mode.

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Detailed description
2.1 NC/PLC interface signals

DB31, ... DBX2.2 (Delete distance-to-go/Spindle reset (axis-/spindle-specific))

"Delete distance-to-go" is effective in AUTOMATIC and MDA modes only in conjunction with
positioning axes. The positioning axis is decelerated to standstill following the current brake
characteristic. The distance-to-go of the axis is deleted.
Spindle reset
A detailed description of the spindle reset can be found in:
References:
/FB1/ Function Manual Basic Functions, Spindles (S1)

DB31, ... DBX9.0 / 9.1 / 9.2 (controller parameter set selection)

The PLC user program sends a binary code request via the "controller parameter set
selection" to activate the corresponding parameter set with that of the NC.
DBX9.2

DBX9.1

DBX9

Parameter-set number

Parameter-set changeover must be enabled via the machine data (not required for spindles):
MD35590 $MA_PARAMSET_CHANGE_ENABLE = 1 or 2
For detailed information about parameter-set changeover, please refer to:
References:
/FB1/ Function Manual Basic Functions, Spindles (S1)
Chapter: Spindle modes > axis mode;
Chapter: Programmable Gears > Gear Stages for Spindles and Gear Change

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2.1 NC/PLC interface signals

Parameter set changeover when machine axis is in motion

The response to a parameter-set changeover depends on the consequential change in the
closed-loop control circuit gain factor Kv:
MD32200 $MA_POSCTRL_GAIN (KV factor)
"Identical servo gain factors" or "position control not active":
The NC responds immediately to the parameter-set changeover. The parameter set is
also changed during the movement.
"Non-identical servo gain factors" or "position control active":
In order to effect a changeover as smoothly as possible, changeover is not activated until
the axis "is stationary", i.e. once the parameterized zero speed has been reached or
undershot:
DB31, ... DBX61.4 = 1 (axis/spindle stationary)
MD36060 $MA_STANDSTILL_VELO_TOL (threshold velocity/speed 'axis/spindle
stationary')
Parameter set changeover from the parts program
For parameter-set changeover from the parts program, the user (machine manufacturer)
must define corresponding user-specific auxiliary functions and evaluate them in the PLC
user program. The PLC user program will then set the changeover request on the
corresponding parameter set.
For detailed information about auxiliary function output, please refer to:
References:
/FB1/ Function Manual Basic Functions, Auxiliary Function Output (H2)

DB31, ... DBX9.3 (disable parameter-set default setting by NC)

Parameter-set changeover request will be ignored.

2.1.8

Signals from axis/spindle

DB31, ... DBX61.0 (drive test travel request)

If machine axes are traversed by special test functions such as "function generator", an
explicit drive-test-specific enable is requested for the movement:
DB31, ... DBX61.0 == 1 (drive test travel request)
The movement is carried out once the movement is enabled:
DB31, ... DBX1.0 == 1 (drive test travel enable)

DB31, ... DBX61.3 (follow-up mode active)

The machine axis is in follow-up mode.

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2.1 NC/PLC interface signals

DB31, ... DBX61.4 (axis/spindle stationary)

"Axis/spindle stationary" is set by the NC if:
No new setpoints are to be output AND
The actual speed of the machine axis is lower than the parameterized zero speed:
MD36060 $MA_STANDSTILL_VELO_TOL (threshold velocity axis stationary)

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

The machine axis position control loop is closed and position control is active.

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

The machine axis speed control loop is closed and speed control is active.

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

The machine axis current control loop is closed and current control is active.

DB31, ...DBX69.0 / 69.1 / 69.2 (controller parameter set)

Active parameter set Coding accordingly:
DB31, ... DBX9.0 / 9.1 / 9.2 (controller parameter set selection)

DB31, ... DBX76.0 (lubrication pulse)

Following a control POWER ON/RESET, the signal status is 0 (FALSE).
The "lubrication pulse" is inverted (edge change) as soon as the machine axis completes a
distance longer than the parameterized traversing distance for lubrication.
MD33050 $MA_LUBRICATION_DIST (distance for lubrication by PLC)

2.1.9

Signals to axis/spindle (digital drives)

DB31, ... DBX20.1 (ramp-function-generator fast stop) (not on 810D)

A "fast stop" is requested for the drive. The drive is then stopped without a ramp function
(speed setpoint 0). Servo enable is maintained.

DB31, ... DBX20.2 (torque limit 2) (not on 810D)

Request for torque limit 2. The limit value is specified in the drive parameters.

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2.1 NC/PLC interface signals

DB31, ... DBX20.3 (speed setpoint smoothing) (not on 810D)

Request to smooth the speed setpoint.

DB31, ... DBX21.0 / 21.1 / 21.2 (drive parameter set selection A, B, C)

Request to change over drive parameter set:
DBX 21.2

DBX 21.1

DBX21.0

Parameter-set number

The feedback signal is sent via the interface signals:

DB31, ... DBX93.0,1 / 93.2 (active drive parameter set)

DB31, ... DBX21.3 / 21.4 (motor selection A, B) (not on 810D)

Selection of motor/operating mode.
DBX 21.4

DBX 21.3

Motor number

Operating mode

3 1)

4 1)

1) Can only be used on SIMODRIVE 611D Performance2 control module and SIMODRIVE
611U
Only operating modes 1 and 2 are valid on main spindle drive:
Operating modes 1: Star
Operating modes 2: Delta

DB31, ... DBX21.5 (motor selection made) (not on 810D)

The PLC user program sends this signal to the drive to indicate successful motor selection.
For example, in the case of star/delta switchover on the SIMODRIVE 611D or 611U, a
message or signal must be provided when the motor contactor has switched. The pulses are
then enabled by the drive.

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DB31, ... DBX21.6 (integrator disable n-controller) (not on 810D)

The PLC user program inhibits the integrator of the speed controller for the drive. The speed
controller is thus switched from PI to P controller.
Note
If the speed controller integrator disable is activated, compensations might take place in
certain applications (e.g., if the integrator was already holding a load while stationary).
Feedback via the interface signal:
DB31, ... DBX93.6 = 1 (integrator n-controller disabled)

DB31, ... DBX21.7 (pulse enable)

The pulse enable for the drive module is only requested if all enable signals (hardware and
software) are pending:
Trigger equipment enable
Servo and pulse enable (terminal 63)
Pulse enable (safe operational stop) (terminal 663)
Stored hardware input
Setpoint enable (terminal 64)
"Status ready for traverse" (terminal 72/73)
No 611D drive alarm (DClink1 error)
DC link connected
Ramp-up completed
See also:
DB31, ... DBX93.7 (pulses enabled)

2.1.10

Signals from axis/spindle (digital drives)

DB31, ... DBX92.0 (setup mode active)

On the drive, "setup mode" is active.

DB31, ... DBX92.1 (ramp-function-generator fast stop active) (not on 810D)

The drive signals back to the PLC that ramp-function-generator fast stop is active. The drive
is thus brought to a standstill without the ramp function (with speed setpoint 0).

DB31, ... DBX92.2 (torque limit 2 active) (not on 810D)

The drive signals back to the PLC that torque limit 2 is active for the axis/spindle. The torque
limit value is defined with the drive parameters.

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2.1 NC/PLC interface signals

DB31, ... DBX92.3 (speed-setpoint smoothing active) (not on 810D)

The PLC user program requests speed-setpoint smoothing filter for the axis/spindle. The
smoothing is activated in the drive module only under certain conditions.

DB31, ... DBX93.0, 1, 2 (active drive parameter set A, B, C)

The drive module sends this checkback to the PLC to indicate which drive parameter set is
currently active. With bit combination A, B, C, eight different drive parameter sets can be
selected by the PLC for the SIMODRIVE 611D.

DB31, ... DBX93.3, 4 (active motor A, B)

The drive module (MSD) sends this checkback to the PLC to indicate which of the 4 motor
types or motor operating modes is active.
The following selections can be made on the main spindle drive:
Star mode (A=0, B=0)
Delta mode (A=1, B=0)
On the 611D with Performance2 controller module and 611U, combinations A = 0, B = 1 and
A = 1, B = 1 may also be selected.

DB31, ... DBX93.5 (DRIVE ready)

Checkback signal indicating that the drive is ready. The conditions required for traversing the
axis/spindle are fulfilled.

DB31, ... DBX93.6 (integrator n-controller disabled) (not on 810D)

The speed-controller integrator is disabled. The speed controller has thus been switched
from PI to P controller.

DB31, ... DBX93.7 (pulses enabled)

The pulse enable for the drive module is available. The axis/spindle can now be traversed.

DB31, ... DBX94.0 (motor temperature prewarning)

The motor temperature has exceeded the warning threshold. If the motor temperature
remains at this level, the drive will be stopped after a defined time (drive MD) and the pulse
enable removed.

DB31, ... DBX94.1 (heat-sink temperature prewarning)

The heat-sink temperature has exceeded the warning threshold. The pulse enable will be
removed for the drive module in question after 20 seconds.

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2.1 NC/PLC interface signals

DB31, ... DBX94.2 (ramp-up function completed)

This signal indicates that the actual speed value has reached the new setpoint allowing for
the tolerance band set in drive machine data:
MD1426 $MD_SPEED_DES_EQ_ACT_TOL
The acceleration procedure is thus completed. Any subsequent speed fluctuations due to
load changes will not affect the interface signal.

DB31, ... DBX94.3 (|Md| < Mdx)

This signal indicates that the current torque |Md| is lower than the parameterized threshold
torque Mdx:
MD1428 $MD_TORQUE_THRESHOLD_X.
The threshold torque is entered as a percentage of the current speeddependent torque
limitation.

DB31, ... DBX94.4 (|nact| < nmin)

This signal indicates that the actual speed |nact| is lower than the set minimum speed nmin:
MD1418 $MD_SPEED_THRESHOLD_MIN

DB31, ... DBX94.5 (|nact| < nix)

This signal indicates that the actual speed |nact| is lower than the set threshold speed nx:
MD1417 $MD_SPEED_THRESHOLD_X

DB31, ... DBX94.6 (nact = nsetp)

An indication on the the PLC states that the actual speed nact has reached the new setpoint
allowing for the tolerance band set in drive machine data:
MD1426 $MD_SPEED_DES_EQ_ACT_TOL.
and that it is within the tolerance band.

DB31, ... DBX94.7 (variable signaling function) (not 810D)

Using the variable signaling function, it is possible to monitor digitally for any axis any
variable from SIMODRIVE 611 to check if it violates a certain threshold and to signal as an
interface signal to the PLC.
The variable to be monitored is specified with 611D machine data.

DB31, ... DBX95.0 (DC link voltage < warning level)

The drive signals to the PLC that the DC link voltage UDC link has fallen below the DC link
undervoltage warning threshold:
MD1604 $MD_LINK_VOLTAGE_WARN_LIMIT

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2.2 Functions

DB31, ... DBX95.7 (i2t monitoring) (not 810D)

The variable signaling function can be used to protect the power section of the SIMODRIVE
611 universal and SIMODRIVE 611 digital drives against continuous overload. The PLC is
signaled for each axis indicating whether the i2t monitoring has been initiated.
The variable to be monitored is specified with 611D machine data.

2.2

2.2.1

2.2

Functions

Screen settings
Contrast, monitor type, foreground language, and display resolution to take effect after
system startup can be set in the operator panel machine data.

Contrast
MD9000 $MM_LCD_CONTRAST (contrast)
For slimline operator panels with a monochrome LCD, the contrast to be applied following
system startup can be set.
There are 16 different contrast settings (0: dark, 15: light).

Monitor type
MD9001 $MM_DISPLAY_TYPE (monitor type)
Indicate the relevant monitor type for optimum color matching.

Foreground language
MD9003 $MM_FIRST_LANGUAGE (foreground language)
On SINUMERIK 840D/840Di/810D, 2 languages are available simultaneously. The
foreground language can be used to set the language to be displayed following control rampup.
The language can be changed in the DIAGNOSTICS operating area on the HMI user
interface. Once the control has ramped up, the foreground language will be restored.

Display resolution
MD9004 $MM_DISPLAY_RESOLUTION (display resolution)
The number of places after the decimal point for the position display of the axes is defined in
the display resolution. The position display consists of max. 12 characters including sign and
decimal point. The number of digits after the decimal point can be set to between 0 and 5.
The default setting for the number of digits after the decimal point is 3, corresponding to a
display resolution of 103 [mm] or [degrees].

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Detailed description
2.2 Functions

REFRESH suppression
MD10131 $MN_SUPPRESS_SCREEN_REFRESH (screen refresh in case of overload)
Default setting for screen-refresh strategy with high NC utilization:
Value 0: Refresh of current values is suppressed in all channels.
Value 1: Refresh of current values is suppressed in time-critical channels.
Value 2: Refresh of current values is never suppressed.

2.2.2

Settings for involute interpolation

Introduction
The involute of the circle is a curve traced out from the end point on a "piece of string"
unwinding from the curve. Involute interpolation allows trajectories along an involute.
<

;<

%DVHFLUFOHFHQWHU;  < 
6WDUWSRLQW
5

%DVHFLUFOH

(QGSRLQW

Figure 2-6

2-24

Involute (unwound from base circle)

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Detailed description
2.2 Functions

Programming
A general description of how to program involute interpolation can be found in:
References:
/PG/ Fundamentals Programming Guide
In addition to the programmed parameters, machine data are relevant in two instances of
involute interpolation; these data may need to be set by the machine manufacturer/end user.

Accuracy
If the programmed end point does not lie exactly on the involute defined by the starting point,
interpolation takes place between the two involutes defined by the starting and end points
(see illustration below).
The maximum deviation of the end point is determined by the machine data:
MD21015 $MC_INVOLUTE_RADIUS_DELTA

6WDUWSRLQW

%DVHFLUFOH

(QGSRLQW

0D[GHYLDWLRQ

Figure 2-7

MD21015 specifies the max. permissible deviation

Limit angle
If AR is used to program an involute leading to the base circle with an angle of rotation that is
greater than the maximum possible value, an alarm is output and program execution
aborted.

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Detailed description
2.2 Functions

$5PD[

$5

6WDUWSRLQW

Figure 2-8

Limited angle of rotation towards base circle

The alarm display can be suppressed using the following parameter settings:
MD21016 $MC_INVOLUTE_AUTO_ANGLE_LIMIT = TRUE
The programmed angle of rotation is then also limited automatically and the interpolated path
ends at the point at which the involute meets the base circle. This, for example, makes it
easier to program an involute, which starts at a point outside the base circle and ends
directly on it.

Tool radius compensation

2 1/2 D tool-radius compensation is the only tool-radius compensation function permitted for
involutes. If 3D tool-radius compensation is active (both circumferential and face milling),
when an involute is programmed, machining is interrupted with alarm 10782.
With 2 1/2 D tool-radius compensation, the plane of the involute must lie in the compensation
plane. or else alarm 10781 will be generated. It is however permissible to program an
additional helical component for an involute in the compensation plane.

Dynamic response
Involutes that begin or end on the base circle have an infinite curvature at this point. To
ensure that the velocity is adequately limited at this point when tool-radius compensation is
active, without reducing it too far at other points, the "Velocity limitation profile" function must
be activated:
MD28530 $MC_MM_PATH_VELO_SEGMENTS > 1
A setting of 5 is recommended. This setting need not be made if only involute sections are
used, which have radii of curvature that change over a relatively small area.

2-26

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Detailed description
2.2 Functions

2.2.3

Activate DEFAULT memory

GUD start values

The DEF... / REDEF... NC commands can be used to assign default settings to global user
data (GUD). These default settings must be permanently stored in the system if they are to
be available after certain system states (e.g. RESET).
The memory space for this is taken from the memory area that was assigned via the
machine data:
MD18150 $MM_GUD_VALUES_MEM.
The setting for activating the stored default values is made in machine data:
MD11270 $MN_DEFAULT_VALUES_MEM_MASK.
References:
/FB1/Function Manual Basic Functions, S7: "Memory Configuration"
/PGA/ Programming Guide Advanced

2.2.4

Read/write PLC variable

High-speed data channel

For highspeed exchange of information between the PLC and NC, a memory area is
reserved in the communications buffer on these modules (dualport RAM). Variables of any
type (I/O, DB, DW, flags) may be exchanged within this memory area.
The PLC accesses this memory using 'Function Calls' (FC) while the NCK uses '$ variables'.

Organization of memory area

The user's programming engineer (NCK and PLC) is responsible for organizing (structuring)
this memory area.
Every storage position in the memory can be addressed provided that the limit is selected
according to the appropriate data format (i.e., a DWORD for a 4byte limit, a WORD for a 2byte limit, etc.).
The memory is accessed via the data type and the position offset within the memory area.

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Detailed description
2.2 Functions

Access from NC
To allow the NC to access PLC variables (from a part program) quickly, $ variables are
provided in the NCK. The PLC uses a function call (FC) to read and write $ variables. Data
are transferred to and from the NCK immediately.
$ variables can be accessed (by the NCK) during preprocessing and in synchronized
actions.
Data type information is determined by the $ variable data type, the position index is
specified as an array index (in bytes).
The following $ variables are available:
$A_DBB

Data byte (8 bits)

$A_DBW

Data word (16 bits)

$A_DBD

Data double word (32 bits)

$A_DBR

Real data (32 bits)

$A_DBB(n)

<= x <= 255

$A_DBW(n)

-32768 <= x <= 3276

$A_DBD(n)

-2147483648 <= x <= 2147483647

Ranges of values

Access from PLC

The PLC uses function calls (FC) to access the memory. These FCs ensure that data are
read and written in the DPR immediately, i.e., not just at the beginning of the PLC cycle. FCs
receive data type information and the position offset as parameters.

2-28

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Detailed description
2.2 Functions

1&

3/&

3/&'$7$ $B'%'>@

&$//)&

'DWDW\SH'ZRUGE\WHV
3RVLWLRQRIIVHW[



Figure 2-9

Communications buffer (DPR) for NC/PLC communication

Supplementary conditions
The user's programming engineer (NCK and PLC) is responsible for organizing the DPR
memory area. No checks are made for inconsistencies in the configuration.
A total of 1024 bytes are available in the input and output directions.
Singlebit operations are not supported and must be linked back to byte operations by the
user (programming engineer).
Since the contents of variables are manipulated directly in the communications buffer, the
user must remember that intermediate changes in values occur as a result of multiple
access operations where a variable is evaluated several times or when variables are
linked (i.e., it may be necessary to store values temporarily in local variables or R
parameters or to set up a semaphore).
The user's programming engineer is responsible for coordinating access operations to the
communications buffer from different channels.
Data consistency can be guaranteed only for access operations up to 16 bits (byte and
word). The user's programming engineer is responsible for ensuring consistent
transmission of 32bit variables (double and real). A simple semaphore mechanism is
provided in the PLC for this purpose.
The PLC stores data in 'Little Endian' format in the DPR.
Values transferred with $A_DBR are subject to data conversion and hence to loss of
accuracy. The data format for floatingpoint numbers is DOUBLE (64 bits) on the NCK, but
only FLOAT (32 bits) on the PLC. The format used for storage in the dualport RAM is
FLOAT. Conversion takes place respectively before/after storage in the dualport RAM.
If a read/write access is made from the NCK to a variable in the dualport RAM, the
conversion is performed twice. It is impossible to prevent differences between read and
written values because the data are stored in both formats.

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Detailed description
2.2 Functions

Example
Bypassing the problem by means of comparison on "EPSILON" (minor deviation)
Block
number

Program code

N10

DEF REAL DBR

N12

DEF REAL EPSILON = 0.00001

N20

$A_DBR[0]=145.145

N30

G4 F2

N40

STOPRE

N50

DBR=$A_DBR[0]

N60

IF ( ABS(DBR/145.145-1.0) < EPSILON ) GOTOF ENDE

N70

MSG ( "error" )

N80

M0

N90

END:

N99

M30

Activation
The maximum number of output variables that can be written to simultaneously can be set
with:
MD28150 $MC_MM_NUM_VDIVAR_ELEMENTS

Example
A WORD is to be transferred from the PLC to the NC.
The position offset within the NCK input (PLC output area) should be the fourth byte. The
position offset must be a whole-number multiple of the data width.
Writing from PLC:
Program code (extract)

Comment

. . .
CALL FC21 (
Enable :=M10.0,

;if TRUE, then FC21 active

Funct :=B#16#4,
S7Var :=P#M 104.0 WORD1,
IVAR1 :=04,
IVAR2 :=-1,
Error :=M10.1,
ErrCode :=MW12);
. . .
)

Reading in part program

Program code (extract)

Comment

. . .
PLCDATA = $A_DBW[4];

// Read a word

. . .

2-30

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Detailed description
2.2 Functions

Behavior during POWER ON, block search

The DPR communications buffer is initialized during "POWER ON".
During a "block search", the PLC variable outputs are collected and transferred to the DPR
communications buffer with the approach block (analogous to writing of analog and digital
outputs).
Other status transitions have no effect in this respect.

2.2.5

Access protection via password and keyswitch

2.2.5.1

Access protection via password and keyswitch

Access authorization
Access to functions, programs and data is useroriented and controlled via 8 hierarchical
protection levels. These are subdivided into:
Password levels for Siemens, machine manufacturer and end user
Keyswitch positions for end user

Multi-level security concept

A multi-level security concept to regulate access rights is available in the form of password
levels and keyswitch settings.
Protection
level

Type

Users

Password

Siemens

All functions, programs and data

Password

Machine manufacturer:
Development

Defined functions, programs and data;

e.g.,: entering options

Password

Machine manufacturer:
Start-up engineer

Defined functions, programs and data;

e.g.,: Bulk of machine data

Password

End user:
Servicing

Assigned functions, programs and data

Keyswitch position 3

End user: Programmer,

machine setter

Lower than protection level

0 to 3; defined by machine manufacturer or end user

Keyswitch position 2

End user: Skilled operator

without programming
knowledge

Lower than protection level

0 to 3; defined by end user

Keyswitch position 1

End user: Trained operator

without programming
knowledge

Example:
Program selection only, tool-wear entries, and workoffset entries

Keyswitch position 0

End user: Semi-skilled

operator

Example:
No entries and program selection possible,
only the machine control panel can be operated

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Detailed description
2.2 Functions

Access features
Protection level 0 provides the greatest number of access rights, protection level 7 the
least.
If certain access rights are granted to a protection level, these protection rights
automatically apply to any higher protection levels.
Conversely, protection rights for a certain protection level can only be altered from a
higher protection level.
Access rights for protection levels 0 to 3 are permanently assigned by Siemens and
cannot be altered (default).
Access rights can be set by querying the current keyswitch positions and comparing the
passwords entered. When a password is entered it overwrites the access rights of the
keyswitch position.
Options can be protected on each protection level. However, option data can only be
entered in protection levels 0 and 1.
Access rights for protection levels 4 to 7 are only suggestions and can be altered by the
machine tool manufacturer or end user.

2.2.5.2

Password

Set password
The password for a protection level (0 3) is entered via the HMI user interface.
Example: HMI Advanced
DIAGNOSTICS operation area, softkey: SET PASSWORD
References:
/BAD/ Operator's Guide HMI Advanced

Delete password
Access rights assigned by means of setting a password remain effective until they are
explicitly revoked by deleting the password.
Example: HMI Advanced
DIAGNOSTICS operation area, softkey: DELETE PASSWORD
References:
/BAD/ Operator's Guide HMI Advanced
Note
Access rights and password status (set/deleted) are not affected by POWER OFF/ON!

Maximum number of characters

A password may contain up to eight characters. We recommend that you confine yourself to
the characters available on the operator panel when defining the password. Where a
password consists of less than eight characters, the additional characters are interpreted as
blanks.

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Detailed description
2.2 Functions

Defaults
The following default passwords are defined for protection levels 1 to 3:
Protection level 1: SUNRISE
Protection level 2: EVENING
Protection level 3: CUSTOMER

Note
Following NC-CPU ramp-up in commissioning mode (NCK commissioning switch:
position 1) the passwords for protection levels 1 3 are reset to the default settings. For
reasons of data protection, we strongly recommend that you change the default settings.

2.2.5.3

Keyswitch settings (DB10, DBX56.4 to 7)

Key switch
The keyswitch has four positions, to which protection levels 4 to 7 are assigned. The
keyswitch comprises a number of keys in a variety of colors, which can be set to different
switch positions.

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Figure 2-10

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RU
EODFN
.H\

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3RVLWLRQ

RURU
JUHHQNH\

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RURU
RU
UHGNH\

%LW

Switch positions 0 to 3

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Detailed description
2.2 Functions

Switch positions
Switch position 0 has the most restricted access rights. Switch position 3 has the least
restricted access rights.
DB10, DBX56.4 / .5 / .6 / .7 (switch positions 0 / 1 / 2 / 3)
Machine-specific enables for access to programs, data and functions can be assigned to the
switch positions. For detailed information, please refer to:
References:
/IAM/ Installation & Startup Guide HMI/MMC; Access Protection

Default settings via the PLC user program

The keyswitch switch positions are transferred to the NC/PLC interface via the basic PLC
program. The corresponding interface signals can be modified via the PLC user program. In
this context, from the point of view of the NC, only one switch position should ever be active,
i.e,. the corresponding interface signal set to 1. If, from the point of view of the NC, a number
of switch positions are active at the same time, switch position 3, i.e., the keyswitch position
with the least restricted access rights, will be activated internally by the NC.

2.2.5.4

Parameterizable protection levels

Parameterizable protection level

The parameter level can be freely parameterized for a variety of functions and data areas.
The protection level is set via operator-panel machine data, designated as follows:
$MM_USER_CLASS_<Function_DataArea>
Examples:
$MM_USER_CLASS_READ_TOA

Read tool offsets

$MM_USER_CLASS_WRITE_TOA

Write tool offsets

$MM_USER_CLASS_READ_PROGRAM

Read part programs

$MM_USER_CLASS_WRITE_PROGRAM

Write/edit part programs

Default values
On delivery or following standard commissioning, with very few exceptions, the default value
for the protection level will be set to 7, i.e., the lowest protection level.

2-34

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Supplementary conditions

There are no supplementary conditions to note.

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3-1

Supplementary conditions

3-2

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Example
Parameter set changeover

A parameter-set changeover is performed to change the position-control gain (servo gain

factor) for machine axis X1 from v = 4.0 to Kv = 0.5.

Prerequisites
Parameter-set changeover must be enabled:
MD35590 $MA_PARAMSET_CHANGE_ENABLE [AX1] = 1 or 2
The 1st parameter set for machine axis X1 is set, in accordance with machine data with
index "0" NC/PLC interface:
DB31, DBB9.0 DBB9.2 = 0

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4-1

Example

Parameter-set-dependent machine data

Parameter-set-dependent machine data are set as follows:
Machine data

Remarks

MD32200 $MA_POSCTRL_GAIN [0, AX1] = 4.0

Servo gain setting for parameter set 1

MD32200 $MA_POSCTRL_GAIN [1, AX1] = 2.0

Servo gain setting for parameter set 2

MD32200 $MA_POSCTRL_GAIN [2, AX1] = 1.0

Servo gain setting for parameter set 3

MD32200 $MA_POSCTRL_GAIN [3, AX1] = 0.5

Servo gain setting for parameter set 4

MD32200 $MA_POSCTRL_GAIN [4, AX1] = 0.25

Servo gain setting for parameter set 5

MD32200 $MA_POSCTRL_GAIN [5, AX1] = 0.125

Servo gain setting for parameter set 6

MD31050 $MA_DRIVE_AX_RATIO_DENOM [0, AX1] = 3

Denominator load gearbox for parameter set 1

MD31050 $MA_DRIVE_AX_RATIO_DENOM [1, AX1] = 3

Denominator load gearbox for parameter set 2

MD31050 $MA_DRIVE_AX_RATIO_DENOM [2, AX1] = 3

Denominator load gearbox for parameter set 3

MD31050 $MA_DRIVE_AX_RATIO_DENOM [3, AX1] = 3

Denominator load gearbox for parameter set 4

MD31050 $MA_DRIVE_AX_RATIO_DENOM [4, AX1] = 3

Denominator load gearbox for parameter set 5

MD31050 $MA_DRIVE_AX_RATIO_DENOM [5, AX1] = 3

Denominator load gearbox for parameter set 6

MD31060 $MA_DRIVE_AX_RATIO_NUMERA [0, AX1] = 5

Counter load gearbox for parameter set 1

MD31060 $MA_DRIVE_AX_RATIO_NUMERA [1, AX1] = 5

Counter load gearbox for parameter set 2

MD31060 $MA_DRIVE_AX_RATIO_NUMERA [2, AX1] = 5

Counter load gearbox for parameter set 3

MD31060 $MA_DRIVE_AX_RATIO_NUMERA [3, AX1] = 5

Counter load gearbox for parameter set 4

MD31060 $MA_DRIVE_AX_RATIO_NUMERA [4, AX1] = 5

Counter load gearbox for parameter set 5

MD31060 $MA_DRIVE_AX_RATIO_NUMERA [5, AX1] = 5

Counter load gearbox for parameter set 6

MD35130 $MA_AX_VELO_LIMIT [0...5, AX1]

Setting for each parameter set*)

MD32800 $MA_EQUIV_CURRCTRL_TIME [0..5, AX1]

Setting for each parameter set*)

MD32810 $MA_EQUIV_SPEEDCTRL_TIME [0..5, AX1]

Setting for each parameter set*)

MD32910 $MA_DYN_MATCH_TIME [0...5, AX1]

Setting for each parameter set*)

*) The appropriate line must be specified separately for each parameter set according to the applicable syntax rules.

Changeover
In order to switch over the position-control gain, the PLC user program selects the 4th
parameter set for machine axis X1.
Requirement by PLC user program:
DB31, DBB9.0 DBB9.2 = 3
A request to change over to the 4th parameter set is sent for machine axis AX1.
The parameter set is changed over once a delay has elapsed.
Parameter set 4 is now active, in accordance with machine data with index "3"
Feedback by NC:
DB31, DBB69.0 DBB69.2 = 3
The NC confirms/acknowledges the parameter-set changeover.

4-2

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Data lists
5.1

5.1.1

5.1

Machine data

Drive-specific machine data

Number

Identifier: $MD_

Description

1403

PULSE_SUPPRESSION_SPEED

Shutoff speed for pulse suppression

1404

PULSE_SUPPRESSION_DELAY

Time for pulse suppression

1417

SPEED_THRESHOLD_X

nx for nact < nsetp signal

1418

SPEED_THRESHOLD_MIN

nmin for nact < nsetp signal

1426

SPEED_DES_EQ_ACT_TOL

Tolerance band for nset = nact signal

1427

SPEED_DES_EQ_ACT_DELAY

Delay time nset = nact signal

1428

TORQUE_THRESHOLD_X

Threshold torque

1429

TORQUE_THRESHOLD_X_DELAY

Delay time nd < ndx signal

1602

MOTOR_TEMP_WARN_LIMIT

Maximum motor temperature

1603

MOTOR_TEMP_ALARM_TIME

Time for motor temperature alarm

1604

LINK_VOLTAGE_WARN_LIMIT

DC link under voltage warning threshold

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Data lists
5.1 Machine data

5.1.2

Memory specific machine data

Number
HMI
Advanced

Identifier: $MM_

Description

HMI
Embedded

9000

9000

LCD_CONTRAST

Contrast

9001

9001

DISPLAY_TYPE

Monitor type

9002

DISPLAY_MODE

external monitor (1: black and white, 2: color)

9003

FIRST_LANGUAGE

Foreground language

9004

DISPLAY_RESOLUTION

Display resolution

9005

PRG_DEFAULT_DIR

Basic setting Program directory

9006

DISPLAY_BLACK_TIME

Time setting for screen saver

9007

TABULATOR_SIZE

Tabulator length

9004

9008

9008

KEYBOARD_TYPE

Keyboard type (0: OP, 1: MFII/QWERTY)

9009

9009

KEYBOARD_STATE

Shift behavior of keyboard during booting

SPIND_DISPLAY_RESOLUTION

Display resolution for spindle values

9010
9011

9011

DISPLAY_RESOLUTION_INCH

Display resolution for INCH_system of units

9012

9012

ACTION_LOG_MODE

Set action mode for action log

9013

SYS_CLOCK_SYNC_TIME

System clock synchronizing time

9020

TECHNOLOGY

Basic configuration for simulation and free

contour programming

9030

EXPONENT_LIMIT

Number of places to be displayed without

exponent

9031

EXPONENT_SCIENCE

Technical exponent representation in three

steps

9180

USER_CLASS_READ_TCARR

Protection level read tool carrier offsets

general

9181

USER_CLASS_WRITE_TCARR

Protection level write tool carrier offsets

general

9200

USER_CLASS_READ_TOA

Protection level read tool offsets general

9020

9200
9201

9201

USER_CLASS_WRITE_TOA_GEO

Protection level write tool geometry

9202

9202

USER_CLASS_WRITE_TOA_WEAR

Protection level write tool wear data

9203

9203

USER_CLASS_WRITE_FINE

Protection level write fine

9204

USER_CLASS_WRITE_TOA_SC

Protection level change total tool offsets

9205

USER_CLASS_WRITE_TOA_EC

Protection level change tool setup offsets

9206

USER_CLASS_WRITE_TOA_SUPVIS

Protection level change tool-monitoring limit

values

9207

USER_CLASS_WRITE_TOA_ASSDNO

Change D No. assigned to a tool edge

9208

USER_CLASS_WRITE_MAG_WGROUP

change wear group magazine location/mag.

9209

9209

USER_CLASS_WRITE_TOA_ADAPT

Protection level write tool adapter data

9210

9210

USER_CLASS_WRITE_ZOA

Protection level write settable zero offset

9211

9211

USER_CLASS_READ_GUD_LUD

Protection level read user variables

5-2

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Data lists
5.1 Machine data
Number

Identifier: $MM_

Description

9212

9212

USER_CLASS_WRITE_GUD_LUD

Protection level write user variables

9213

9213

USER_CLASS_OVERSTORE_HIGH

Protection level extended overstore

9214

9214

USER_CLASS_WRITE_PRG_CONDIT

Protection level program control

9215

9215

USER_CLASS_WRITE_SEA

Protection level write setting data

9216

USER_CLASS_READ_PROGRAM

Protection level read part program

9217

USER_CLASS_WRITE_PROGRAM

Protection level enter part program

9218

USER_CLASS_SELECT_PROGRAM

Protection level part program selection

9218
9219

9219

USER_CLASS_TEACH_IN

Protection level TEACH IN

9220

9220

USER_CLASS_PRESET

Protection level PRESET

9221

9221

USER_CLASS_CLEAR_RPA

Protection level delete R parameters

9222

9222

USER_CLASS_WRITE_RPA

Protection level write R parameters

9223

USER_CLASS_SET_V24

Protection level for RS232C interface

parameterization

9224

USER_CLASS_READ_IN

Protection level for import data

9225

USER_CLASS_READ_CST

Protection level standard cycles

9226

USER_CLASS_READ_CUS

Protection level user cycles

9227

USER_CLASS_SHOW_SBL2

Skip single block2 (SBL2)

9228

USER_CLASS_READ_SYF

Access level select directory SYF

9229

USER_CLASS_READ_DEF

Access level select directory DEF

9230

USER_CLASS_READ_BD

Access level select directory BD

USER_CLASS_WRITE_RPA_1

Write protection for first RPA area

9232

USER_BEGIN_WRITE_RPA_1

Start of the first RPA area

9233

USER_END_WRITE_RPA_1

End of the first RPA area

9234

USER_CLASS_WRITE_RPA_2

Write protection for second RPA area

9235

USER_BEGIN_WRITE_RPA_2

Start of the second RPA area

9236

USER_END_WRITE_RPA_2

End of the second RPA area

9237

USER_CLASS_WRITE_RPA_3

Write protection for third RPA area

9238

USER_BEGIN_WRITE_RPA_3

Start of the third RPA area

9239

USER_END_WRITE_RPA_3

End of the third RPA area

9240

USER_CLASS_WRITE_TOA_NAME

Change tool designation and duplo

9241

USER_CLASS_WRITE_TOA_Type

Change tool type

9460

PROGRAMM_SETTINGS

Resetproof data storage for settings in the

PROGRAM operating area

9461

CONTOUR_END_TEXT

String to be added to end of contour on

completion of input

9478

TO_OPTION_MASK

Variants of tool offsets

9500

NC_PROPERTIES

NC_properties: Bit 0: Digital drives,

Bit 1: Software startup switch

9510

USER_CLASS_DIRECTORY1_P

Protection level for network drive 1 for

PROGRAM operating area

9511

USER_CLASS_DIRECTORY2_P

Protection level for network drive 2 for

PROGRAM operating area

9512

USER_CLASS_DIRECTORY3_P

Protection level for network drive 3 for

PROGRAM operating area

9231

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

5-3

Data lists
5.1 Machine data
Number

Identifier: $MM_

Description

9513

USER_CLASS_DIRECTORY4_P

Protection level for network drive 4 for

PROGRAM operating area

9516

USER_CLASS_DIRECTORY1_M

Protection level for network drive 1 for

MACHINE operating area

9517

USER_CLASS_DIRECTORY2_M

Protection level for network drive 2 for

MACHINE operating area

9518

USER_CLASS_DIRECTORY3_M

Protection level for network drive 3 for

MACHINE operating area

9519

USER_CLASS_DIRECTORY4_M

Protection level for network drive 4 for

MACHINE operating area

5.1.3

NC-specific machine data

Number

Identifier: $MN_

Description

10350

FASTIO_DIG_NUM_INPUTS

Number of active digital NCK input bytes

10360

FASTIO_DIG_NUM_OUTPUTS

Number of active digital NCK output bytes

10361

FASTIO_DIG_SHORT_CIRCUIT

Short-circuit digital inputs and outputs

11120

LUD_EXTENDED_SCOPE

Activate programglobal variables (PUD)

11270

DEFAULT_VALUES_MEM_MSK

Activ.
Function: Save DEFAULT values of GUD.

18150

MM_GUD_VALUES_MEM

Reserve memory space for GUD

5.1.4

Channelspecific machine data

Number

Identifier: $MC_

Description

21015

INVOLUTE_RADIUS_DELTA

NC start disable without reference point

21016

INVOLUTE_AUTO_ANGLE_LIMIT

Automatic angle limitation for involute interpolation

27800

TECHNOLOGY_MODE

Technology in channel

28150

MM_NUM_VDIVAR_ELEMENTS

Number of write elements for PLC variables

28530

MM_PATH_VELO_SEGMENTS

Number of storage elements for limiting path velocity

in block

5-4

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Data lists
5.2 System variables

5.1.5

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

30350

SIMU_AX_VDI_OUTPUT

Output of axis signals for simulation axes

33050

LUBRICATION_DIST

Lubrication pulse distance

35590

PARAMSET_CHANGE_ENABLE

Parameter set definition possible from PLC

36060

STANDSTILL_VELO_TOL

Maximum velocity/speed when axis/spindle stationary

36610

AX_EMERGENCY_STOP_TIME

Length of the braking ramp for error states

36620

SERVO_DISABLE_DELAY_TIME

Cutout delay servo enable

5.2

5.2

System variables

Names

Description

$P_FUMB

Unassigned part program memory (Free User Memory Buffer)

$A_DBB[n]

Data on PLC (data type BYTE)

$A_DBW[n]

Data on PLC (WORD type data)

$A_DBD[n]

Data on PLC (DWORD type data)

$A_DBR[n]

Data on PLC (REAL type data)

5.3

5.3.1

5.3

Signals

Signals to NC

DB number

Byte.Bit

Description

10

56.7

Keyswitch setting 0 to 3

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

5-5

Data lists
5.3 Signals

5.3.2

Signals from NC

DB number

Byte.Bit

Description

10

103.0

Remote diagnostics (MMC alarm is active)

10

103.5

AT box ready

10

103.6

MMC temperature limit

10

103.7

MMC battery alarm

10

104.7

NCK CPU Ready

10

108.1

MMCCPU2Ready (MMC to OPI or MPI)

10

108.2

MMC CPU1 Ready (MMC to MPI)

10

108.3

MMC CPU1 Ready (MMC to OPI, standard link)

10

108.6

Drive Ready

10

108.7

NC Ready

10

109.0

NCK alarm is active

10

109.5

NCU573 heat-sink temperature alarm

10

109.6

Air temperature alarm

10

109.7

NCK battery alarm

5-6

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Data lists
5.3 Signals

5.3.3

Signals to operator panel front

DB number

Byte.Bit

Description

19

0.0

Screen bright

19

0.1

Darken screen

19

0.2

Key disable

19

0.3

Delete Cancel alarms (HMI Advanced only)

19

0.4

Delete Recall alarms (HMI Advanced only)

19

0.7

Actual value in WCS

19

10.0

Programming area selection

19

10.1

Alarm area selection

19

10.2

Tool offset selection

19

10.7

ShopMill control signal

19

12.2

COM2 active (job byte of PLC)

19

12.3

COM1 active (job byte of PLC)

19

12.4

RS232 stop (job byte of PLC)

19

12.5

RS232 external (job byte of PLC)

19

12.6

RS232 OFF (job byte of PLC)

19

12.7

RS232 ON (job byte of PLC)

19

13.5

Unload part program

19

13.6

Load part program

19

13.7

Part program selection

19

14.7

File system active/passive (for HMI Embedded, always active)

19

16.7

File system active/passive (for HMI Advanced, always passive)

19

44.0

Mode change disable

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

5-7

Data lists
5.3 Signals

5.3.4

Signals from operator panel front

DB number

Byte.Bit

Description

19

20.1

Screen is dark

19

20.7

Switch over MCS/WCS

19

24.0

Error (Acknowledgment byte for current RS232 status)

19

24.1

O.K. (Acknowledgment byte for current RS232 status)

19

24.2

COM2 active (Acknowledgment byte for current RS232 status)

19

24.3

COM1 active (Acknowledgment byte for current RS232 status)

19

24.4

RS232 stop (Acknowledgment byte for current RS232 status)

19

24.5

RS232 External (Acknowledgment byte for current RS232C status)

19

24.6

RS232 OFF (Acknowledgment byte for current RS232 status)

19

24.7

RS232 ON (Acknowledgment byte for current RS232 status)

19

26.0

Error (Part program handling status)

19

26.1

O.K. (Part program handling status)

19

26.3

Active (Part program handling status)

19

26.5

Unload (Part program handling status)

19

26.6

Load (Part program handling status)

19

26.7

Select (Part program handling status)

19

42.0

FC9: Measure in JOG mode

19

45.0

FC9 Out: Active

19

45.1

FC9 Out: Done

19

45.2

FC9 Out: Error

19

45.3

FC9 Out: StartErr

5.3.5

Signals to channel

DB number

Byte.Bit

Description

21, ...

6.2

Delete distancetogo (channelspecific)

5.3.6

Signals from channel

DB number

Byte.Bit

Description

21, ...

36.6

Channelspecific NCK alarm is active

21, ...

36.7

NCK alarm with processing stop present

21, ...

318.7

Overstore active

5-8

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Data lists
5.3 Signals

5.3.7

Signals to axis/spindle

DB number

Byte.Bit

Description

31, ...

1.3

Axis/spindle disable

31, ...

1.4

Follow-up mode

31, ...

1.5

Position measuring system 1

31, ...

1.6

Position measuring system 2

31, ...

2.1

Controller enable

31, ...

2.2

Delete distancetogo (axisspecific)/Spindle reset

31, ...

1, 2

Parameter set switchover (request)

31, ...

20.0

Rampup times

31, ...

20.1

Rampfunction-generator fast stop

31, ...

20.2

Torque limit 2

31, ...

20.3

Speed setpoint smoothing

31, ...

21.2

Drive parameter set selection A, B, C

31, ...

21.4

Motor selection A, B

31, ...

21.5

Motor selection to follow

31, ...

21.6

Speed controller integrator disable

31, ...

21.7

Pulse enable

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

5-9

Data lists
5.3 Signals

5.3.8

Signals from axis/spindle

DB number

Byte.Bit

Description

31, ...

60.4 / 60.5

Referenced, synchronized 1 / Referenced, synchronized 2

31, ...

61.3

Followup mode active

31, ...

64.6 / 64.7

Traverse command minus / plus

31, ...

61.3

Followup mode active

31, ...

61.4

Axis/spindle stops

31, ...

61.5

Position controller active

31, ...

61.6

Speed control loop active

31, ...

61.7

Current controller active

31, ...

1, 2

Parameter set switchover (feedback)

31, ...

76.0

Lubrication pulse

31, ...

92.0

Setup mode active

31, ...

92.1

Rampfunction-generator fast stop active

31, ...

92.2

Torque limit 2 active

31, ...

92.3

Speed setpoint smoothing active

31, ...

93.2

Active drive parameter set A, B, C

31, ...

93.4

Active motor A, B

31, ...

93.5

Drive Ready

31, ...

93.6

Speed controller integrator disabled

31, ...

93.7

Pulses enabled

31, ...

94.0

Motor temperature prewarning

31, ...

94.1

Heat-sink temperature prewarning

31, ...

94.2

Ramp-up function completed

31, ...

94.3

|Md| < Mdx

31, ...

94.4

|nact| < nmin

31, ...

94.5

|nact| < nx

31, ...

94.6

nact = nset

31, ...

94.7

Variable signaling function

31, ...

95.0

UDC link<warning threshold

5-10

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Index
6
611D Ready, 2-3

A
Access authorization, 2-32
Access features, 2-33
Access security, 2-32
Actual value synchronization, 2-15
Actual value in workpiece coordinate system, 2-6
Air temperature alarm, 2-4
Axis disable, 2-8
Axis/spindle stops, 2-18

C
Cancel alarms, 2-5
Channelspecific NCK alarm is active, 2-4
Contrast, 2-23
Controller parameter set switchover, 4-1
Current controller active, 2-18
Cyclic signal exchange, 2-1

D
Darken screen, 2-5
Data channel
high-speed, 2-28
DB10
DBX103.0, 2-4
DBX104.7, 2-3
DBX108.1, 2-3
DBX108.2, 2-3
DBX108.3, 2-3
DBX108.6, 2-3
DBX108.7, 2-3
DBX109.0, 2-4
DBX109.6, 2-4
DBX109.7, 2-4
DBX56.1, 2-14
DBX56.4, 2-36

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

DBX56.5, 2-36
DBX56.6, 2-36
DBX56.7, 2-36
DB19
DBB12, 2-6
DBB13, 2-6
DBB14, 2-6
DBB15, 2-6
DBB16, 2-6
DBB17, 2-6
DBB24, 2-7
DBB25, 2-7
DBB26, 2-7
DBB27, 2-7
DBX 0.3, 2-5
DBX 0.4, 2-5
DBX0.0, 2-5
DBX0.1, 2-5
DBX0.2, 2-5
DBX0.7, 2-6
DBX20.3, 2-5
DBX20.4, 2-6
DB21, ...
DBX36.6, 2-4
DBX36.7, 2-4
DBX6.2, 2-7
DB31
DBB69.0, 4-2
DBB69.1, 4-2
DBB69.2, 4-2
DBB9.0, 4-1, 4-2
DBB9.1, 4-1, 4-2
DBB9.2, 4-1, 4-2
DB31, ...
DBX1.0, 2-7, 2-17
DBX1.3, 2-8
DBX1.4, 2-8, 2-9, 2-11, 2-15
DBX1.5, 2-12
DBX1.6, 2-12
DBX2.1, 2-8, 2-9, 2-11, 2-13, 2-14
DBX2.2, 2-16
DBX20.1, 2-18
DBX20.2, 2-18
DBX20.3, 2-19
DBX21.0, 2-19

Index-1

Index
DBX21.1, 2-19
DBX21.2, 2-19
DBX21.3, 2-19
DBX21.4, 2-19
DBX21.5, 2-19
DBX21.6, 2-20
DBX21.7, 2-14, 2-20
DBX60.4, 2-12
DBX60.6, 2-12
DBX60.7, 2-12
DBX61.0, 2-7, 2-17
DBX61.3, 2-8, 2-9, 2-17
DBX61.4, 2-17, 2-18
DBX61.5, 2-14, 2-18
DBX61.6, 2-14, 2-18
DBX61.7, 2-18
DBX69.0, 2-18
DBX76.0, 2-18
DBX9.0, 2-16, 2-18
DBX9.1, 2-16, 2-18
DBX9.2, 2-16, 2-18
DBX9.3, 2-17
DBX92.0, 2-20
DBX92.1, 2-20
DBX92.2, 2-20
DBX92.3, 2-21
DBX93.0, 2-19, 2-21
DBX93.1, 2-19, 2-21
DBX93.2, 2-19, 2-21
DBX93.3, 2-21
DBX93.4, 2-21
DBX93.5, 2-14, 2-21
DBX93.6, 2-20, 2-21
DBX93.7, 2-20, 2-21
DBX94.0, 2-21
DBX94.1, 2-21
DBX94.2, 2-22
DBX94.3, 2-22
DBX94.4, 2-22
DBX94.5, 2-22
DBX94.6, 2-22
DBX94.7, 2-22
DBX95.0, 2-23
DBX95.7, 2-23
DB31, ...
DBX69.1, 2-18
DB31, ... DBX60.5, 2-12
DB31, ... DBX69.2, 2-18
DB31,...
DBX93.5, 2-3
DC link undervoltage warning threshold, 2-23
DC link voltage, 2-23
DClink, 2-23
Default passwords, 2-35

Index-2

Delete distance-to-go, 2-7

Display resolution, 2-24
Drive-test travel enable, 2-7
Drive-test travel request, 2-17

F
Followup mode active, 2-17
Foreground language, 2-23

H
High-speed data channel, 2-28
HMI alarms, 2-4
HMI CPU1 Ready, 2-3
HMI CPU2 Ready, 2-3

I
Interface signals
for operator panel, 2-5
Interface signals (A2), 1-1
Interface signals from and to channel, 2-7
Interface signals|Spindle reset, 2-16
Interpolatory axis grouping, 2-14

K
Key disable, 2-5
Key switch, 2-35

L
Lockable data areas, 2-36
Lubrication pulse, 2-18

M
Machine coordinate system, 2-6
MCS, 2-6
Md
|Md| < Mdx, 2-22
MD10131, 2-24
MD11270, 2-28
MD1417, 2-22
MD1418, 2-22
MD1426, 2-22
MD1428, 2-22
MD1604, 2-23
MD18150, 2-28
MD21015, 2-26

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Index
MD21016, 2-27
MD28150, 2-31
MD28530, 2-27
MD31050 $MA_DRIVE_AX_RATIO_DENOM, 4-1
MD31060 $MA_DRIVE_AX_RATIO_NUMERA, 4-1
MD32200, 2-17
MD32200 $MA_POSCTRL_GAIN, 4-1
MD32800 $MA_EQUIV_CURRCTRL_TIME, 4-1
MD32810 $MA_EQUIV_SPEEDCTRL_TIME, 4-2
MD32910 $MA_DYN_MATCH_TIME, 4-2
MD33050, 2-18
MD35130 $MA_AX_VELO_LIMIT, 4-1
MD35590, 2-16
MD35590 $MA_PARAMSET_CHANGE_ENABLE, 4-1
MD36060, 2-17, 2-18
MD36610, 2-14
MD36620, 2-14
MD9000, 2-23
MD9001, 2-23
MD9003, 2-23
MD9004, 2-24
MD9006, 2-5
Monitor type, 2-23

N
nact
|nact| < nmin, 2-22
|nact| < nx, 2-22
nact = nsetp, 2-22
NCK alarm is active, 2-4
NCK alarm with processing stop, 2-4
NCK battery alarm, 2-4
NCK CPU Ready, 2-3

P
Password, 2-34

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

resetting, 2-34
setting, 2-34
PLC/NCK interface, 2-1
Position controller active, 2-18
Position measuring system, 2-12
Protection levels, 2-36

R
Ramp-up function completed, 2-22
Read/write PLC variable, 2-28
Recall alarms, 2-5

S
Servo enable, 2-13
Signals
Alarm signals, 2-4
Axis/spindle-specific (DB31, ...), 2-2
Channel-specific (DB21, ...), 2-2
Ready signals, 2-3
Speed control loop active, 2-18
Spindle disable, 2-8
Spindle reset, 2-16

U
Undervoltage threshold, 2-23

V
Variable signaling function, 2-22

W
WCS, 2-6
Workpiece coordinate system, 2-6

Index-3

Various NC/PLC interface signals and functions (A2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Index-4

1
Brief Description
______________

SINUMERIK 840D sl/840Di sl/840D/840Di/810D Axis monitoring, protection zones (A3)

2
Detailed description
______________
SINUMERIK
840D sl/840Di sl/840D/840Di/810D
Axis monitoring, protection zones
(A3)
Function Manual

Valid for

Control

SINUMERIK 840D sl/840DE sl

SINUMERIK 840Di sl/840DiE sl
SINUMERIK 840D powerline/840DE powerline
SINUMERIK 840Di powerline/840DiE powerline
SINUMERIK 810D powerline/810DE powerline

Software

Version

NCU System Software for 840D sl/840DE sl

NCU system software for 840Di sl/DiE sl
NCU system software for 840D/840DE
NCU system software for 840Di/840DiE
NCU system software for 810D/810DE
03/2006 Edition
6FC5397-0BP10-1BA0

1.3
1.0
7.4
3.3
7.4

3
Supplementary conditions
______________
4
Examples
______________
5
Data lists
______________

Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
Danger
indicates that death or severe personal injury will result if proper precautions are not taken.
Warning
indicates that death or severe personal injury may result if proper precautions are not taken.
Caution
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
Notice
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.

Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage
Note the following:
Warning
This device may only be used for the applications described in the catalog or the technical description and only in
connection with devices or components from other manufacturers which have been approved or recommended by
Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly
as well as careful operation and maintenance.

Trademarks
All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.

Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG
Automation and Drives
Postfach 48 48
90437 NRNBERG
GERMANY

Order No.: 6FC5397-0BP10-1BA0

Edition 05/2006

Copyright Siemens AG 2006.

Technical data subject to change

Table of contents
1

Brief Description ..................................................................................................................................... 1-1

1.1

Axis monitoring functions ........................................................................................................... 1-1

1.2

Protection zones ........................................................................................................................ 1-2

Detailed description ................................................................................................................................ 2-1

2.1
2.1.1
2.1.1.1
2.1.1.2
2.1.2
2.1.2.1
2.1.2.2
2.1.2.3
2.1.2.4
2.1.2.5
2.1.3
2.1.4

Motion monitoring functions ....................................................................................................... 2-1

Contour monitoring .................................................................................................................... 2-1
Contour error.............................................................................................................................. 2-1
Following Error Monitoring ......................................................................................................... 2-2
Positioning, zero speed and clamping monitoring ..................................................................... 2-4
Correlation between positioning, zero-speed and clamping monitoring .................................... 2-4
Positioning monitoring................................................................................................................ 2-5
Zero speed monitoring ............................................................................................................... 2-6
Exact stop and standstill tolerance dependent on the parameter set........................................ 2-7
Clamping monitoring .................................................................................................................. 2-7
Speed-setpoint monitoring ....................................................................................................... 2-14
Actual velocity monitoring ........................................................................................................ 2-16

2.2
2.2.1
2.2.2
2.2.2.1
2.2.2.2
2.2.2.3
2.2.2.4
2.2.3

Measuring-system monitoring (systems with SIMODRIVE 611D)........................................... 2-17

Encoder-limit-frequency monitoring ......................................................................................... 2-17
Zero-mark monitoring............................................................................................................... 2-19
General .................................................................................................................................... 2-19
Zero-mark monitoring for incremental encoders...................................................................... 2-20
Zero-mark monitoring for absolute encoders........................................................................... 2-21
Customized error reactions...................................................................................................... 2-23
Monitoring hardware faults....................................................................................................... 2-25

2.3

Measuring-system monitoring (systems with PROFIBUS drives) ........................................... 2-25

2.4
2.4.1
2.4.2
2.4.3
2.4.4

Monitoring of static limits.......................................................................................................... 2-26

Overview of the limit switch monitoring.................................................................................... 2-26
Hardware limit switches ........................................................................................................... 2-27
Software limit switch ................................................................................................................ 2-28
Working area limitation ............................................................................................................ 2-30

2.5
2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
2.5.6
2.5.7

Protection zones ...................................................................................................................... 2-33

General .................................................................................................................................... 2-33
Types of protection zone.......................................................................................................... 2-34
Definition via part program instruction ..................................................................................... 2-37
Definition via system variable .................................................................................................. 2-41
Activation and deactivation of protection zones....................................................................... 2-43
Protection-zone violation and temporary enabling of individual protection zones................... 2-47
Restrictions in protection zones ............................................................................................... 2-53

Supplementary conditions ...................................................................................................................... 3-1

3.1

Axis monitoring functions ........................................................................................................... 3-1

Axis monitoring, protection zones (A3)

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iii

Table of contents
4

Examples................................................................................................................................................ 4-1
4.1

Definition and activation of protection zones ............................................................................. 4-1

Data lists................................................................................................................................................. 5-1

5.1
5.1.1
5.1.2
5.1.3

Machine data.............................................................................................................................. 5-1

NC-specific machine data .......................................................................................................... 5-1
Channelspecific machine data ................................................................................................... 5-1
Axis/spindlespecific machine data ............................................................................................. 5-2

5.2
5.2.1

Setting data ................................................................................................................................ 5-3

Axis/spindlespecific setting data ................................................................................................ 5-3

5.3
5.3.1
5.3.2
5.3.3

Signals........................................................................................................................................ 5-4
Signals to channel...................................................................................................................... 5-4
Signals from channel.................................................................................................................. 5-4
Signals to axis/spindle................................................................................................................ 5-5

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

iv

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Brief Description
1.1

1.1

Axis monitoring functions

Function
Comprehensive monitoring functions are present in the control for protection of people and
machines:
Motion monitoring functions
Contour monitoring
Position monitoring
Zero-speed monitoring
Clamping monitoring
Speed-setpoint monitoring
Actual-velocity monitoring
Encoder Monitoring
Monitoring of static limits
Limit-switch monitoring
Working-area limitation

Axis monitoring, protection zones (A3)

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1-1

Brief Description
1.2 Protection zones

1.2

1.2

Protection zones

Function
With the help of protection zones, elements of the machine (e.g. spindle chuck, tool changer,
tool holder, tailstock, movable probe, etc.) and the workpiece can be protected against
collisions.
During automatic execution of part programs in the AUTOMATIC or MDI mode, the NC
checks at the start of every part-program block whether a collision between protection zones
can occur upon moving along the programmed path.
After manual deactivation of an active protection zone, the zone can be entered. After
leaving the protection zone, the protection zone automatically becomes active again.
The definition, activation and deactivation of protection zones takes place via part program
instructions.

1-2

Axis monitoring, protection zones (A3)

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Detailed description
2.1

2.1

Motion monitoring functions

2.1.1

Contour monitoring

2.1.1.1

Contour error
Contour errors are caused by signal distortions in the position control loop.
Signal distortions can be linear or nonlinear.

Linear signal distortions

Linear signal distortions are caused by:
Speed and position controller not being set optimally
Different servo gain factors of the feed axes involved in creating the path
With the same servo gain factor for two linear-interpolated axes, the actual position
follows the set position along the same path but with a time delay. With different servo
gain factors, a parallel offset arises between the set and actual path.
Unequal dynamic response of the feed drives
Unequal drive dynamic responses lead to path deviations especially on contour changes.
Circles are distorted into ellipses by unequal dynamic responses of the two feed drives.

Axis monitoring, protection zones (A3)

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2-1

Detailed description
2.1 Motion monitoring functions

Nonlinear signal distortions

Nonlinear signal distortions are caused by:
Activation of the current limitation within the machining area
Activation of the limitation of the set speed
Backlash within and/or outside the position control loop
When traversing a circular path, contour errors occur primarily due to the reversal error
and friction.
During movement along straight lines, a contour error arises due to a reversal error
outside the position control loop, e.g., due to a tilting milling spindle. This causes a
parallel offset between the actual and the set contour. The shallower the gradient of the
straight line, the larger the offset.
Nonlinear friction behavior of slide guides

2.1.1.2

Following Error Monitoring

Function
In control engineering terms, traversing along a machine axis always produces a certain
following error, i.e., a difference between the set and actual position.
The following error that arises depends on:
Position control loop gain
MD32200 $MA_POSCTRL_GAIN (servo gain factor)
Maximum acceleration
MD32300 $MA_MAX_AX_ACCEL (Maximum axis acceleration)
Maximum velocity
MD32000 $MA_MAX_AX_VELO (maximum axis velocity)
With activated feedforward control: Precision of the path model and the parameters:
MD32610 $MA_VELO_FFW_WEIGHT (factor for the velocity 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)
In the acceleration phase, the following error initially increases when traversing along a
machine axis. After a time depending on the parameterization of the position control loop,
the following error then remains constant in the ideal case. Due to external influences, more
or less large fluctuations in the following error always arise during a machining process. To
prevent these fluctuations in the following error from triggering an alarm, a tolerance range
within which the following error may change must be defined for the following-error
monitoring:
MD36400 $MA_CONTOUR_TOL (Contour monitoring tolerance range)

2-2

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1 Motion monitoring functions

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Following-Error Monitoring

Effectivity
The following-error monitoring only operates with active position control and the following
axis types:
Linear axes with and without feedforward control
Rotary axes with and without feedforward control
Position-controlled spindles

Fault
If the configured tolerance limit is exceeded, the following alarm appears:
25050 "Axis <Axis identifier> Contour monitoring"
The affected axis/spindle is stopped via the configured braking ramp in follow-up mode:
MD36610 $MA_AX_EMERGENCY_STOP_TIME
(Maximum time for braking ramp when an error occurs)

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-3

Detailed description
2.1 Motion monitoring functions

2.1.2

Positioning, zero speed and clamping monitoring

2.1.2.1

Correlation between positioning, zero-speed and clamping monitoring

Overview
The following overview shows the correlation between the positioning, zero speed and
clamping monitoring functions:

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2-4

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1 Motion monitoring functions

2.1.2.2

Positioning monitoring

Function
At the end of a positioning operation:
Set velocity = 0 AND
DB31, ... DBX64.6/64.7 (motion command minus/plus) = 0
checks the position monitoring to ensure that the following error of every participating
machine axis is smaller than the exact-stop fine tolerance during the delay time.
MD36010 $MA_STOP_LIMIT_FINE (exact stop fine)
MD36020 $MA_POSITIONING_TIME (delay time exact stop fine)
After reaching "Exact stop fine", the position monitoring is deactivated.

Note
The smaller the exact stop fine tolerance is, the longer the positioning operation takes and
the longer the time until block change.

Rules for MD setting

MD36010 $MA_STOP_LIMIT_FINE

MD36020 $MA_POSITIONING_TIME

large

can be selected relatively short

small

must be selected relatively long

MD32200 $MA_POSCTRL_GAIN
(servo gain factor)

MD36020 $MA_POSITIONING_TIME

small

must be selected relatively long

large

can be selected relatively short

Effectivity
The position monitoring only operates with active position control and the following axis
types:
Linear axes
Rotary axes
Position-controlled spindles

Axis monitoring, protection zones (A3)

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Detailed description
2.1 Motion monitoring functions

Fault
If the configured position-monitoring time is exceeded, the following alarm appears:
25080 "Axis <Axis identifier> Position monitoring"
The affected axis is stopped via the configured braking ramp in follow-up mode:
MD36610 $MA_AX_EMERGENCY_STOP_TIME
(Maximum time for braking ramp when an error occurs)

2.1.2.3

Zero speed monitoring

Function
At the end of a positioning operation:
Set velocity = 0 AND
DB31, ... DBX64.6/64.7 (motion command minus/plus) = 0
checks the zero-speed monitoring to ensure that the following error of every participating
machine axis is smaller than the standstill tolerance during the delay time.
MD36040 $MA_STANDSTILL_DELAY_TIME (Zero-speed monitoring delay time)
MD36030 $MA_STANDSTILL_POS_TOL (standstill tolerance)
After reaching the required exact-stop state, the positioning operation is completed:
DB31, ... DBX60.6/60.7 (position reached with exact stop coarse/fine) = 1
The position-monitoring function is deactivated and is replaced by the zero-speed
monitoring.
Zero-speed monitoring monitors the adherence to the standstill tolerance. If no new travel
request is received, the machine axis must not depart from the standstill tolerance.

Effectivity
The zero-speed monitoring only operates with active position control and the following axis
types:
Linear axes
Rotary axes
Position-controlled spindles

2-6

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1 Motion monitoring functions

Fault
If the delay time and/or the standstill tolerance is exceeded, the following alarm appears:
25040 "Axis <Axis identifier> Zero-speed monitoring"
The affected axis is stopped via the configured braking ramp in follow-up mode:
MD36610 $MA_AX_EMERGENCY_STOP_TIME
(Maximum time for braking ramp when an error occurs)

2.1.2.4

Exact stop and standstill tolerance dependent on the parameter set

Common factor for position tolerances

For adaptation to different machining situations and/or axis dynamics, e.g.,:
Operating state A: High precision, long machining time
Operating state B: Lower precision, shorter machining time
Changing of the mass relationships after gear change
the positioning tolerances:
MD36000 $MA_STOP_LIMIT_COARSE (exact stop coarse)
MD36010 $MA_STOP_LIMIT_FINE (exact stop fine)
MD36030 $MA_STANDSTILL_POS_TOL (standstill tolerance)
can be weighted with a common factor depending on the parameter set:
MD36012 $MA_STOP_LIMIT_FACTOR (exact stop coarse/fine and standstill factor)
Because the factor applies in common for all three position tolerances, the relationship
between the values remains constant.

2.1.2.5

Clamping monitoring

Clamping monitoring
For machine axes that are mechanically clamped upon completion of a positioning operation,
larger motions can result from the clamping process (> standstill tolerance). As a result,
zero-speed monitoring is replaced by clamping monitoring during the clamping process.
Clamping monitoring monitors the adherence to the configured clamping tolerance:
MD36050 $MA_CLAMP_POS_TOL (Clamping tolerance)

Activation
The clamping monitoring is activated by the following interface signal:
DB31, ... DBX2.3 (clamping in progress)

Axis monitoring, protection zones (A3)

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2-7

Detailed description
2.1 Motion monitoring functions

Note
The clamping monitoring is not active in "follow-up mode" (DB31, ... DBX1.4 = 1).

Fault
If the clamping tolerance is exceeded, the following alarm appears:
26000 "Clamping monitoring"
The affected axis is stopped via the configured braking ramp in follow-up mode:
MD36610 $MA_AX_EMERGENCY_STOP_TIME
(Maximum time for braking ramp when an error occurs)

Automatic stopping for removal of the clamp

If a clamped axis must be traversed again in continuous-path mode, the NC stops the path
motion for Look Ahead at the start of the motion block of the clamped axis until the clamped
axis can once again be traversed. If the clamping is released before stopping, the path
motion is not stopped.
Parameterization:
MD36052 $MA_STOP_ON_CLAMPING = 'H01' (Special function for clamped axis)

Note
The NC detects whether an axis is clamped based on the "servo enable" state of the axis:
DB31, ... DBX2.2 = 0: no servo enable axis is clamped
DB31, ... DBX2.2 = 1: servo enable axis is not clamped

Prerequisites for the PLC user program

The axis is always removed from the clamp when a travel command is pending.
The following is always valid for the axis:
DB31, ... DBX2.2 (servo enable) = 0: Axis is clamped.
DB31, ... DBX2.2 (servo enable) = 1: Axis is not clamped.
The following image shows an example of the interface signals and states upon releasing of
the axis clamp:

2-8

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1 Motion monitoring functions

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Release axis clamp if MD36052 $MA_STOP_ON_CLAMPING = 'H01'

The part-program blocks N310 and N410 refer to the following programming example:
N100

G0 X0 Y0 Z0 A0 G90 G54 F500

N101

G641 ADIS=.1 ADISPOS=5

N210

G1 X10

N220

G1 X5 Y20

N310

G0 Z50

N410

G0 A90

; Turn rotary table

N510

G0 X100

; Approach

N520

G0 Z2

N610

G1 Z-4

N620

G1 X0 Y-20

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

; Edit
; Retract

; Edit

2-9

Detailed description
2.1 Motion monitoring functions

Optimized releasing of the axis clamp via travel command

If a clamped axis is to be traversed in continuous-path mode, a travel command is issued for
the clamped axis in the rapid traverse blocks (G0) immediately before the traversing block of
the clamped axis. This way, the PLC user program can release the axis clamp again in time.
(The travel command is set a maximum of two rapid travers blocks prior (including
intermediate blocks) to retain the reference to the initiating part program block).
Parameterization:
MD36052 $MA_STOP_ON_CLAMPING = 'H03' (Special function for clamped axis)
Prerequisites for the PLC user program
The axis is removed from the clamp as soon as a travel command is pending.
The axis may be removed from the clamp even if only during positioning (G0).
The following image shows an example of the interface signals and states upon releasing of
the axis clamp:

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2-10

Release axis clamp if MD36052 $MA_STOP_ON_CLAMPING = 'H03'

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1 Motion monitoring functions

Automatic stopping for setting of the clamp

If an axis is to be clamped in continuous-path mode, the NC stops the path motion before the
next "Non-rapid traverse block" if the axis has not been clamped by then, i.e., the PLC has
set the feedrate override value to zero.
Parameterization:
MD36052 $MA_STOP_ON_CLAMPING = 'H04' (Special function for clamped axis)
Prerequisites for the PLC user program
The axis is always clamped when no travel command is pending.
The axis does not have to be clamped during positioning of the other axes.
It can be seen whether the axes are being positioned depending on whether rapid
traverse (G0) is programmed.
The stop command is therefore not set immediately at the beginning of the block
containing the axis, but at the beginning of the next machining block (traversing block,
that is not traversed with rapid traverse).
The axis is clamped if the feed rate override of a machining block is not equal to 0.
If the axis is clamped before the next machining block, i.e., the feedrate override is other
than 0 again, no stop is generated.
The following image shows an example of the interface signals and states upon setting of
the axis clamp. The part program blocks N410, N510, N520 and N610 refer to the schematic
example under certain boundary conditions.

Axis monitoring, protection zones (A3)

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2-11

Detailed description
2.1 Motion monitoring functions

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Set axis clamp if MD36052 $MA_STOP_ON_CLAMPING = 'H04'

Constraints
Continuous-path mode
For the above-mentioned functions:
Automatic stopping for removal of the clamp
Optimized releasing of the axis clamp via travel command
Automatic stopping for setting of the clamp
the "Look Ahead" function must be active.
Part-program blocks without path motion (e.g., M82/M83) interrupt continuouspath mode and
thus also the "Look Ahead" function.

2-12

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1 Motion monitoring functions

Example:
The part-program blocks N320 and N420 are inserted in the programming example used.
N100

G0 X0 Y0 Z0 A0 G90 G54 F500

N101

G641 ADIS=.1 ADISPOS=5

N210

G1 X10

N220

G1 X5 Y20

N310

G0 Z50

; Retraction

N320

M82

; no path motion

N410

G0 A90

; Turn rotary table

N420

M83

; no path motion

N510

G0 X100

; Approach

N520

G0 Z2

N610

G1 Z-4

N620

G1 X0 Y-20

; Edit

; Edit

The function behaves as follows:

MD36052 $MA_STOP_ON_CLAMPING = 'H03'
No longer has an effect.
The travel command is set in Look Ahead mode only for blocks with active continuouspath mode. M82 generates a stop and thus interrupts the continuouspath mode. The Look
Ahead stopping on N410 would not be necessary because stopping occurs anyway.
MD36052 $MA_STOP_ON_CLAMPING = 'H04'
Generates a stop irrespective of M83, which is executed as a function of "feedrate
override 0%". The axis is thus stopped before the first machining block.

Note
MD36052 $MA_STOP_ON_CLAMPING = 'H01' or 'H04'
Both functions can be used irrespective of the clamping of axes:
MD36052 $MA_STOP_ON_CLAMPING = 'H01'
Generates a Look Ahead stop for the path motion if no servo enable signal is active
for the relevant axis.
MD36052 $MA_STOP_ON_CLAMPING = 'H04'
Generates a Look Ahead stop for the path motion if the feed rate overrate = 0% at the
transition from the part-program blocks with rapid traverse to part-program blocks
without rapid traverse.
Both functions ensure that the path motion in continuous-path mode is already stopped
before the start of the relevant part-program block and not just within the part-program
block.

Axis monitoring, protection zones (A3)

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2-13

Detailed description
2.1 Motion monitoring functions

Block-change criterion: Clamping tolerance

After activation of clamp monitoring:(DB31, ... DBX2.3 = 1) the block-change criterion for
traversing blocks, in which the axis stops at the end of the block, no longer acts as the
corresponding exact-stop condition but the configured clamping tolerance:
MD36050 $MA_CLAMP_POS_TOL (clamping tolerance with interface signal "Clamping
active")

Behavior upon releasing of the clamp

If the axis was moved by the clamping process, it is returned by the NC to the position
setpoint after releasing of the clamp and setting of the servo enable state. Repositioning
depends on whether "Follow-up mode" was activated for the axis:
Without follow-up mode:

Repositioning by position controller

With follow-up mode:

Repositioning by interpolator

See also interface signal:

DB31, ... DBX1.4 (follow-up mode)

Note
The following interface signals can be evaluated by the PLC user program as the criterion for
activation of the "Follow-up mode":
DB31, ... DBX60.6 / 60.7 (position reached with exact stop coarse / fine)

2.1.3

Speed-setpoint monitoring

Function
The speed setpoint comprises:
Speed setpoint of the position controller
Speed setpoint portion of the feedforward control (with active feedforward control only)
Dift compensation (only for drives with analog setpoint interface)

2-14

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1 Motion monitoring functions

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Speed setpoint calculation

The speed-setpoint monitoring ensures by limiting the control or output signal (10V for
analog setpoint interface or rated speed for digital drives) that the physical limitations of the
drives are not exceeded:
MD36210 $MA_CTRLOUT_LIMIT (Maximum speed setpoint)

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Speed setpoint limitation

Speed-setpoint monitoring delay

To prevent an error reaction from occurring in every speed-limitation instance, a delay time
can be configured:
MD36220 $MA_CTRLOUT_LIMIT_TIME (Speed-setpoint monitoring delay)
Only if the speed limitation is required for longer than the configured time does the
corresponding error reaction occur.

Axis monitoring, protection zones (A3)

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Detailed description
2.1 Motion monitoring functions

Effectivity
The speed-setpoint monitoring is only active for closed-loop position-controlled axes and
cannot be deactivated.

Fault
If the configured delay time is exceeded, the following alarm appears:
25060 "Axis <Axis identifier> Speed-setpoint monitoring"
The affected axis is stopped via the configured braking ramp in follow-up mode:
MD36610 $MA_AX_EMERGENCY_STOP_TIME
(Maximum time for braking ramp when an error occurs)

Note
Upon reaching the speed-setpoint monitoring, the position feedback loop of the axis
becomes non-linear due to the limitation. Contour errors result if the axis is involved in
generating the contour.

2.1.4

Actual velocity monitoring

Function
The actual-velocity monitoring checks that the current actual velocity of a machine
axis/spindle does not exceed the configured threshold:
MD36200 $MA_AX_VELO_LIMIT (velocity-monitoring threshold)
The threshold should be 10-15% above the configured maximum velocity.
For axes:
MD32000 $MA_MAX_AX_VELO (maximum axis velocity)
For spindles:
MD35110 $MA_GEAR_STEP_MAX_VELO_LIMIT[n] (maximum speed of gear stage)
If you use this setting the speed will not normally exceed the velocity-monitoring threshold
(exception: drive error).

Activation
The actual-velocity monitoring is activated as soon as the active measuring system returns
valid actual values (encoder limit frequency not exceeded):
DB31, ... DBX1.5/1.6 (position measuring system 1/2)

2-16

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Detailed description
2.2 Measuring-system monitoring (systems with SIMODRIVE 611D)

Effectivity
The actual-velocity monitoring only operates with active position control and the following
axis types:
Linear axes
Rotary axes
Open loop controlled and position controlled spindles.

Fault
If the threshold is exceeded, the following alarm appears:
25030 "Axis <Axis identifier> Actual-velocity alarm limit"
The affected axis is stopped via the configured braking ramp in follow-up mode:
MD36610 $MA_AX_EMERGENCY_STOP_TIME
(Maximum time for braking ramp when an error occurs)

2.2

2.2.1

2.2

Measuring-system monitoring (systems with SIMODRIVE 611D)

Encoder-limit-frequency monitoring

Function
The encoder-limit-frequency monitoring checks that the encoder frequency does not exceed
the configured encoder limit frequency.
MD36300 $MA_ENC_FREQ_LIMIT (encoder limit frequency)
Encoder-limit-frequency monitoring always refers to the active measuring system selected in
the NC/PLC interface:
DB31, ... DBX1.5/1.6 (position measuring system 1/2)

Effectivity
The encoder limit frequency is operative for:
Linear axes
Rotary axes
Open loop controlled and position controlled spindles.

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Detailed description
2.2 Measuring-system monitoring (systems with SIMODRIVE 611D)

Fault
Upon exceeding of the encoder limit frequency, the following occurs:
Message to the PLC:
DB31, ... DBX60.2 or 60.3 = 1 (encoder limit frequency exceeded 1 or 2)
Spindles
Spindles are not stopped but continue to turn with speed control.
If the spindle speed is reduced so much that the encoder frequency passes below the
encoder limit frequency, the actual value system of the spindle is automatically
resynchronized.
Axes
The following alarm is displayed:
21610 "Channel <Channel number> Axis <Axis identifier> Encoder <Encoder number >
Frequency exceeded"
The affected axis is stopped via the configured braking ramp in follow-up mode:
MD36610 $MA_AX_EMERGENCY_STOP_TIME
(Maximum time for braking ramp when an error occurs)

Note
If the encoder limit frequency is exceeded, the position-controlled machine axis must be
re-referenced.
References:
/FB1/Function Manual, Basic Functions; Reference Point Approach (R1)

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Detailed description
2.2 Measuring-system monitoring (systems with SIMODRIVE 611D)

2.2.2

Zero-mark monitoring

2.2.2.1

General

Function
Zero-mark monitoring serves as a plausibility check for the actual values of the relevant
machine axis.

Note
The zero-mark monitoring is only active beneath the configured encoder limit frequency:
MD36302 $MA_ENC_FREQ_LIMIT_LOW (encoder limit frequency for encoder
resynchronization)

The type of zero-mark monitoring depends on the type of encoder used:

MD30240 $MA_ENC_TYPE (encoder type of actual-value acquisition)
Encoder
type

Meaning

Simulation

Raw signal generators (voltage, current, EXE etc.) High resolution

Rectangular signal encoder (standard, no. of PPRs quadrupled)

Reserved

Absolute encoder with EnDat interface

Absolute encoder with SSI interface

Activation/Deactivation
The function is activated/deactivated with machine data:
MD36310 $MA_ENC_ZERO_MONITORING (Zero-mark monitoring)
MD36310

Meaning

No zero-mark monitoring.

>0

Zero-mark monitoring active.

100

No zero-mark monitoring and all encoder alarms concealed.

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2.2 Measuring-system monitoring (systems with SIMODRIVE 611D)

2.2.2.2

Zero-mark monitoring for incremental encoders

Function
Incremental encoders with one or more zero marks use the zero-mark signals to check the
plausibility of the actual values.
Monitoring starts with the first zero-mark signal once the encoder has been switched on
(fault counter = 0). The function checks whether the number of incremental signals is
plausible after each zero mark (if equidistant zero marks) or after every second zero mark (if
distance-coded zero marks). This is the case, for example, if the number of incremental
signals from straight-line axis motions matches the value required for the distance between
two relevant zero marks. In the event of a non-plausible deviation, the fault counter
increases by 1. The zero-mark monitoring is tripped (alarm) if several non-plausible
deviations occur in direct sequence and the fault counter exceeds the configured permissible
number of deviations:
MD36310 $MA_ENC_ZERO_MONITORING (Zero-mark monitoring)
If a plausible value is recorded before this threshold is reached, the fault counter is reset to
0. This ensures that the non-plausible deviations only trigger an alarm if they occur in direct
sequence and in a non-tolerable number.

Note
If using external zero marks (BERO) instead of encoder zero marks, you must deactivate
zero-mark monitoring:
MD36310 $MA_ENC_ZERO_MONITORING = 0

Fault
Alarm 25020
If zero-mark monitoring is tripped in the active measuring system, alarm 25020 appears:
"Axis <Axis identifier> Zero-mark monitoring of active encoder"
The affected axis is stopped via the configured braking ramp in follow-up mode:
MD36610 $MA_AX_EMERGENCY_STOP_TIME
(Maximum time for braking ramp when an error occurs)
Alarm 25021
If zero-mark monitoring is tripped in the passive measuring system alarm 25021 appears:
"Axis <Axis identifier> Zero-mark monitoring of passive encoder"
There is no further alarm response.

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2.2 Measuring-system monitoring (systems with SIMODRIVE 611D)

2.2.2.3

Zero-mark monitoring for absolute encoders

Function
Absolute encoders use the absolute values supplied by the measuring system to check the
plausibility of the actual value.
During the check, the NC compares the cyclic position value held in the position control cycle
clock based on the incremental information from the encoder with a new position value
generated directly from the absolute and incremental information and checks that the
calculated position difference does not exceed the configured permissible deviation.
MD36310 $MA_ENC_ZERO_MONITORING
The permissible deviation is indicated in 1/2 rough lines. It is generally sufficient to enter a
1/2 rough line.

Note
The "zero-mark monitoring" of absolute encoders specifically detects all deviations caused
by dirt on the absolute track or by faults when transferring the absolute value. However,
small errors in the incremental track (burst interference, impulse errors) are not detected. In
such instances the zero-mark monitoring only responds to deviations in the millimeter range.
This form of monitoring should therefore serve as additional monitoring to assist the
diagnosis of absolute-position faults.

Fault
Alarm 25020
If zero-mark monitoring is tripped in the active measuring system, alarm 25020 appears:
"Axis <Axis identifier> Zero-mark monitoring of active encoder"
The affected axis is stopped via the configured braking ramp in follow-up mode:
MD36610 $MA_AX_EMERGENCY_STOP_TIME
(Maximum time for braking ramp when an error occurs)
Alarm 25021
If zero-mark monitoring is tripped in the passive measuring system alarm 25021 appears:
"Axis <Axis identifier> Zero-mark monitoring of passive encoder"
There is no further alarm response.
Alarm 25022
If the absolute value transfer is interrupted, alarm 25022 appears:
"Axis <Axis identifier> Encoder <Encoder number> Warning <Error fine identification>
There is no further alarm response.

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2.2 Measuring-system monitoring (systems with SIMODRIVE 611D)

Note
In the event of a fault, the adjustment of the absolute encoder is lost and the axis is no
longer referenced. The absolute encoder must be readjusted.
References:
/FB1/Function Manual, Basic Functions; Reference Point Approach (R1);
Chapter: Referencing with absolute encoders

Notice
Errors in the incremental track that cannot be detected with amplitude monitoring can cause
position deviations in the millimeter range. The deviation depends on the lattice pitch/line
count and the traversing velocity of the axis when the error occurs.
Complete position monitoring is only possible through redundancy, i.e., through comparison
with an independent second measuring system.

2.2.2.4

Customized error reactions

Customized zero-mark monitoring

You can customize the default alarm and reaction behavior of zero-mark monitoring using
system variables. This allows you to perform your own monitoring using a synchronized
action or OEM application and to use all of the reaction options available in this application,
e.g.:
Transmit alarm
Use cycles (e.g., approach tool-change position)
...
Example:
Users can adjust the alarm and reaction behavior so that when machining an expensive
workpiece, which could be damaged if the axis is stopped as a result of an alarm, machining
stops before the machining quality of the workpiece is assessed using appropriate
synchronized action commands.

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2.2 Measuring-system monitoring (systems with SIMODRIVE 611D)

Effectivity
Customized monitoring can be activated in parallel to or as an alternative to standard zeromark monitoring, depending on the setting in machine data:
MD36310 $MA_ENC_ZERO_MONITORING (Zero-mark monitoring)
MD36310

Meaning

Customized monitoring is active, standard zero-mark monitoring is deactivated.

>0

Customized monitoring and standard zero-mark monitoring operate in parallel.

100

All encoder monitoring functions are deactivated.

If both monitoring functions are active (MD36310 > 0), you can perform cascaded
monitoring.
Example:
If a value falls below the threshold specified in MD36310, customized monitoring triggers a
prewarning; standard zero-marking monitoring will only detect a fault if the threshold is
exceeded and will then deactivate automatically.

System variables
You can implement customized error reactions using the following system variables:
Measuring systems with incremental encoders
System variable

Meaning

$VA_ENC_ZERO_MON_ERR_CNT[n,ax]

Contains the current number of detected zero-mark

errors.
Power on and the selection/deselection of parking
positions triggers a zero reset; reset does not reset
the counter.

n:

Encoder number

ax:

Machine axis

Measuring systems with absolute encoders

System variable

Meaning

$VA_ENC_ZERO_MON_ERR_CNT[n,ax]

Contains the current position difference between the

cyclic position value held in the position control cycle
clock based on the incremental information from the
encoder and a new position value generated from the
encoder's absolute and incremental information.
Power on and the selection/deselection of parking

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2.2 Measuring-system monitoring (systems with SIMODRIVE 611D)
System variable

Meaning
positions triggers a zero reset; reset does not reset
the counter.

$VA_ABSOLUTE_ENC_ERR_CNT[n,ax]

Contains the current number of errors detected when

transferring the absolute values. Monitors the
reliability of the absolute value transfer process.
Power on and the selection/deselection of parking
positions triggers a zero reset; reset does not reset
the counter.

$VA_ABSOLUTE_ENC_STATE[n,ax]

2.2.3

n:

Encoder number

ax:

Machine axis

Determines the last error status of the absoluteencoder interface.

Monitoring hardware faults

Function
This monitoring function monitors the measuring systems of a machine axis for hardware
faults (e.g., measuring system failure, open circuit).

Fault
Alarm 25000
If a hardware fault is detected in the active measuring system, alarm 25000 appears:
"Axis <Axis identifier> Hardware fault active encoder"
The affected axis is stopped via the configured braking ramp in follow-up mode:
MD36610 $MA_AX_EMERGENCY_STOP_TIME
(Maximum time for braking ramp when an error occurs)
Alarm 25001
If a hardware fault is detected in the passive measuring system alarm, 25001 appears:
"Axis <Axis identifier> Hardware fault passive encoder"
There is no further alarm response.

Notice
For hardware faults, the referencing status of the machine axis is reset:
DB31, ... DBX60.4 / 60.5 = 0 (referenced/synchronized 1 / 2)

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Detailed description
2.3 Measuring-system monitoring (systems with PROFIBUS drives)

2.3

2.3

Measuring-system monitoring (systems with PROFIBUS drives)

The NC has no direct access to the measuring-system hardware for systems with
PROFIBUS drives and therefore measuring-system monitoring is mainly performed by the
drive software.
References:
Drive Functions SINAMICS S120
/FBU/SIMODRIVE 611 universal Function Manual

Encoder-limit-frequency monitoring
In the case of systems with PROFIBUS drives, encoder-limit-frequency monitoring is also
performed in the NCK.

Zero-mark monitoring
PROFIBUS drives with incremental encoders
Zero-mark monitoring is performed by the drive software.
PROFIBUS drives with absolute encoders
The drive software performs the monitoring function, while the plausibility check is carried
out in the NCK (as for SIMODRIVE 611D systems).

2.4

2.4.1

2.4

Monitoring of static limits

Overview of the limit switch monitoring

Overview of possible limit switch monitoring functions:

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2.4 Monitoring of static limits

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Travel limits

Hardware limit switches

Function
A hardware limit switch is normally installed at the end of the traversing range of a machine
axis. It serves to protect against accidental overtravelling of the maximum traversing range of
the machine axis while the machine axis is not yet referenced.
If the hardware limit switch is triggered, the PLC user program created by the machine
manufacturer sets the corresponding interface signal:
DB31, ... DBX12.0 / 12.1 = 1 (hardware limit switch minus / plus)

Braking behavior
The braking behavior of the machine axis upon reaching the hardware limit switch is
configurable via:
MD36600 $MA_BRAKE_MODE_CHOICE = (Braking behavior)
Braking behavior:
0: Braking with the configured axial acceleration
1: Rapid stop (set velocity = 0)

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2.4 Monitoring of static limits

Effectivity
The hardware limit-switch monitoring is active after the control has ramped up in all modes.

Effect
Upon reaching the hardware limit switch, the following occurs:
Alarm: "21614 Channel <Channel number> Axis <Axis identifier> Hardware limit switch
<Direction>"
The machine axis is braked according to the configured braking behavior.
If the axis/spindle is involved in interpolation with other axes/spindles, these are also
braked according to their configured braking behavior.
The traversing keys of the affected machine axis are blocked based on the direction.

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2.4 Monitoring of static limits

2.4.3

Software limit switch

Function
Software limit switches serve to limit the traversing range of a machine axis. Per machine
axis and per traversing direction, two (1st and 2nd) software limit switches are available:
MD36110 POS_LIMIT_PLUS (1st software limit switch plus)
MD36110 POS_LIMIT_MINUS (1st software limit switch minus)
MD36130 POS_LIMIT_PLUS (2nd software limit switch plus)
MD36120 POS_LIMIT_MINUS (2nd software limit switch minus)
By default, the 1st software limit switch is active. The 2nd software limit switch can be
activated for a specific direction with the PLC user program.
DB31, ... DBX12.2 / 12.3 (2nd software limit switch minus / plus)

Effectivity
Immediately after the successful referencing of the machine axis.
In all operating modes.

Constraints
The software limit switches refer to the machine coordinate system.
The software limit switches must be inside the range of the hardware limit switches.
The machine axis can be moved to the position of the active software limit switch.
PRESET
After use of the function PRESET, the software limit-switch monitoring is no longer active.
The machine must first be re-referenced.
Endlessly rotating rotary axes
No software limit-switch monitoring takes place for endlessly rotating rotary axes:
MD30310 $MA_ROT_IS_MODULO == 1 (Modulo conversion for rotary axis and spindle).

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2.4 Monitoring of static limits

Effect
Automatic operating modes (AUTOMATIC, MDI)
1. Without transformation, without overlaid movement, unchanged software limit switch:
A part program block with a programmed traversing motion that would lead to
overrunning of the software limit switch is not started.
2. With transformation:
Different reactions occur depending on the transformation type.
Behavior as under 1.
or
The part program block with a programmed traversing motion that would lead to
overrunning of the software limit switch is started. The affected machine axis stops at
the active software limit switch. The other machine axes participating in the traversing
motion are braked. The programmed contour is left during this process.
3. With overlaid motion
The part program block with a programmed traversing motion that would lead to
overrunning of the software limit switch is started. Machine axes that are traveling with
overlaid motion or have traveled with overlaid motion stop at the active software limit
switch in question. The other machine axes participating in the traversing motion are
braked. The programmed contour is left during this process.
Manual operating modes
1. JOG without transformation
The machine axis stops at the software limit switch position.
2. JOG with transformation
The machine axis stops at the software limit switch position. Other machine axes
participating in the traversing motion are braked. The preset path is left during this
process.
General
Changing of the software limit switch (1st 2nd software limit switch)
If the actual position of the machine axis after changing lies behind the software limit
switch, it is stopped with the maximum permissible acceleration.
Overrunning the software limit switch in JOG mode
If the position of the software limit switch is reached and renewed pressing of the
traversing button should cause further travel in this direction, an alarm is displayed and
the axis is not traversed farther:
Alarm: "10621 Channel <Channel number> Axis <Axis identifier> is at the software limit
switch <Direction>"

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2.4 Monitoring of static limits

2.4.4

Working area limitation

Function
Working-area limitation via setting data
The working-area limitation serves to limit the traversing range of a geometry or special axis
with respect to the basic coordinate system.
The dimensions of the working-area limitation are configured via immediately effective
setting data:
SD43420 $SA_WORKAREA_LIMIT_PLUS (Working-area limitation plus)
SD43430 $SA_WORKAREA_LIMIT_MINUS (Working-area limitation minus)
Programmable working-area limitation
The working-area limitation is programmable via the part program instructions G25 / G26
(lower / upper working-area limitation). The programmed working-area limitation has priority
over the working-area limitation set in the settings data. It overwrites the value entered in the
setting date and is retained even after NC-RESET and program end.
Working-area limitation and tool data
For traversing motions with an active tool, not only the position of the axis but also the
position of the tool tip P is monitored.
Consideration of the tool radius must be activated separately:
MD21020 $MC_WORKAREA_WITH_TOOL_RADIUS (Consideration of the tool radius in the
working-area limitation)

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Detailed description
2.4 Monitoring of static limits

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References:
/PG/Programming Manual Fundamentals

Effectivity
Immediately after the successful referencing of the machine axis.
In all operating modes.

Activation
Working-area limitation via setting data
The activation/deactivation of the working-area limitation takes place direction-specifically via
the immediately effective setting data:
SD43400 $SA_WORKAREA_PLUS_ENABLE (Working-area limitation active in the
positive direction)
SD43410 $SA_WORKAREA_MINUS_ENABLE (Working-area limitation active in the
negative direction)

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2.4 Monitoring of static limits

Programmable working-area limitation

The activation/deactivation of the programmable working-area limitation takes place via the
part program instructions:
WALIMON (Working-area limitation ON)
WALIMOF (Working-area limitation OFF)

Changing the working-area limitation

Working-area limitation via setting data
HMI user interface: Operating area "Parameter"
Automatic modes: Changes are possible only in the RESET state; effectivity:
immediately
Manual operating modes: Changes are always possible, effectivity: at the start of the
next traversing motion.
Programmable working-area limitation
Reprogramming the working-area limitation using G25/G26 <Axis identifier><Value>
Changes are immediately effective.

Constraints
The working-area limitation refers to the basic coordinate system.
The working-area limitation must lie within the range of the software limit switch.
PRESET
After use of the function PRESET, the software limit-switch monitoring is no longer active.
The machine must first be re-referenced.
The RESET position with regard to WALIMON / WALIMOF is configurable via:
MD20150 $MC_GCODE_RESET_VALUES (RESET position of G groups)
Endlessly rotating rotary axes
No software limit-switch monitoring takes place for endlessly rotating rotary axes:
MD30310 $MA_ROT_IS_MODULO == 1 (Modulo conversion for rotary axis and spindle)

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2.4 Monitoring of static limits

Effect
Automatic operating modes
1. With / without transformation
The part program block with a programmed traversing motion that would lead to
overrunning of the working-area limitation is not started.
2. With overlaid motion
The part program block with a programmed traversing motion that would lead to
overrunning of the working-area limitation is started. Axes that are traversed with overlaid
motion stop at the working-area limitation.
Manual operating modes
1. JOG with / without transformation
The axis is positioned at the working-area limitation and then stopped. Other machine
axes participating in the traversing motion are braked. The preset path is left during this
process.

General
Activation of the working-area limitation
If the actual position of an axis after activation is located outside of the working-area
limitation, it is stopped with the maximum permissible acceleration.
Overrunning of the working-area limitation in JOG mode
If the position of the working-area limitation is reached and renewed pressing of the
traversing button should cause further travel in this direction, an alarm is displayed and
the axis is not moved farther:
Alarm: "10631 Channel <Channel number> Axis <Axis identifier> is at the working-area
limitation <Direction>"

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2.5 Protection zones

2.5

2.5.1

2.5

Protection zones

General

Function
Protection zones are static or moveable in 2- or 3-dimensional ranges within a machine to
protect machine elements against collisions.
The following elements can be protected:
Permanent parts of the machine and attachments (e.g. toolholding magazine, swiveling
probe). Only the elements that can be reached by possible axis constellations are
relevant.
Moving parts belonging to the tool (e.g. tool, toolholder)
Moving parts belonging to the workpiece (e.g. parts of the workpiece, clamping table,
clamping shoe, spindle chuck, tailstock).
Protection zones are defined via part program instructions or system variables so that they
completely surround the element to be protected. The activation and deactivation of
protection zones also takes place via part program instructions.
Protection-zone monitoring by the NC is channelspecific, i.e. all the active protection zones
of a channel monitor one another for collisions.

Definition of a protection zone

It is possible to define 2dimensional or 3dimensional protection zones as polygons with a
maximum of ten corner points. The protection zones can also contain arc contour elements.
Polygons are defined in a previously defined plane.
Expansion in the third dimension can be limited between -1 and +1.
The following four cases are possible:
Dimension of the protection zone from -1 to +1
Dimension of the protection zone from -1 to upper limit
Dimension of the protection zone from lower limit to +1
Dimension of protection zone from lower limit to upper limit.

Coordinate system
The definition of a protection zone takes place with reference to the geometric axis of a
channel in the basic coordinate system.

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2.5 Protection zones

Referenc
Tool-related protection zones
Coordinates for toolrelated protection zones must be given as absolute values referred to
the tool carrier reference point F.
Workpiece-related protection zones
Coordinates for workpiecerelated protection zones must be given as absolute values
referred to the zero point of the basic coordinate system.

Orientation
The orientation of the protection zones is determined by the plane definition
(abscissa/ordinate), in which the contour is described, and the axis perpendicular to the
contour (vertical axis).
The orientation of the protection zones must be the same for the tool and workpiecerelated
protection zones.

Note
During machining in operating modes JOG, MDI and AUTOMATIC, the control checks
whether the tool (or its protection zones) violate the protection zones of the workpiece.

2.5.2

Types of protection zone

Protection zones relating to machine or channel

Machine-related protection zone
A machine-related protection zone is taken into account by all channels of the NC.
Channel-related protection zones
A channel-related protection zone is taken into account within one channel only.

Example: Doubleslide turning machine

The toolrelated protection zones are assigned to channel 1 or 2.
The workpiecerelated protection zones are assigned to the machine.
The coordinate system must be identical for both channels.

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2.5 Protection zones

Maximum number of protection areas

The maximum definable number of machine- and channel-related protection zones is set via:
MD18190 $MM_NUM_PROTECT_AREA_NCK (Number of files for machine-related
protection zones)
MD28200 $MM_NUM_PROTECT_AREA_CHAN (Number of files for channel-specific
protection zones)

Absolute and relative protection zones

The coordinates of a protection zone must always be programmed as absolute values with
respect to the reference point of the protection zone. When the protection zone is activated
via the part program it is possible to apply a relative offset to the reference point of the
protection zone.

Examples
Below are a few examples of protection zones
Toolrelated protection zone
Workpiece-related protection zone
3-dimensional protection zone
Relative protection zone

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2-36

Example of application on turning machine

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Detailed description
2.5 Protection zones

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Example of a turning machine with relative protection zone for tailstock

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Detailed description
2.5 Protection zones

2.5.3

Definition via part program instruction

General
A protection-zone definition must contain the following information:
Protection zone type (workpiece- or tool-related)
Orientation of protection zone
Type of limitation in the third dimension
Upper and lower limit of the protection zone in the third dimension
Activation type ("Protection zone immediately active": only possible via system variable)
Contour elements

Definition of protection zones

The following systematics must be maintained in the definition of channel-specific protection
zones:
Definition of the working plane: G17, G18 or G19
Definition beginning
Channel-specific protection zones: CPROTDEF(...)
Machine or NC-specific protection zone: NPROTDEF(...)
Contour description for protection zone
End of definition: EXECUTE(...)

Definition of the working plane

The desired working plane to which the contour description of the protection zone refers
must be selected with G17, G18, G19 before start of the definition. It may not be changed
before the end of the definition. Programming of the applicate is not permitted between start
and end of the definition.

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2.5 Protection zones

Definition beginning
The definition start is defined by the corresponding subroutine:
CPROTDEF(n, t, applim, appplus, appminus)
NPROTDEF(n, t, applim, appplus, appminus)
Parameters Type
n
INT

Description

Tool-related protection zone

BOOL

Number of the defined protection zone

TRUE: Tool-oriented protection zone
FALSE: Workpiece-related protection zone

applim

INT

Type of limitation in the third dimension

0: No limitation
1: Limit in plus direction
2: Limit in minus direction
3: Limit in positive and negative direction

appminus

REAL

Value of the limit in the negative direction in the 3rd dimension 1)

appplus

REAL

Value of the limit in the negative direction in the 3rd dimension 1)

1) The following must be true: appplus > appminus

Contour description for protection zone

The contour of a protection zone is described with traversing motions. These are not
executed and have no connection to previous or subsequent geometry descriptions. They
only define the protection zone.
The contour of a protection zones is specified with up to eleven traversing movements in the
selected working plane. The first traversing movement is the movement to the contour. The
last point in the contour description must always coincide with the first point of the contour
description. In the case of rotationsymmetrical contours (e.g. spindle chuck), the whole
contour must be described (not merely the contour to the turning center).
The valid protection zone is the zone left of the contour.
Internal protection zone
The contour of an internal protection zone must described in the counterclockwise
direction.
External protection zones (permitted only for workpiece-related protection zones)
The contour of an external protection zone must be described in the clockwise direction.

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2.5 Protection zones

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Examples: External and internal protection zone

Toolrelated protection zones must be convex. If a concave protection zone is required, the
protection zone must be divided up into several convex protection zones.
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2-40

Examples: convex and concave tool-related protection zones

Axis monitoring, protection zones (A3)

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Detailed description
2.5 Protection zones

Contour elements
The following contour elements are permissible:
G0, G1 for straight contour elements
G2 for circle segments in the clockwise direction
Permissible only for workpiece-related protection zones.
Not permissible for tool-related protection zones because they must be convex.
G3 for circular segments in the counterclockwise direction
A protection zone cannot be described by a complete circle. A complete circle must be
divided into two half circles.
The sequence G2, G3 or G3, G2 is not permitted. A short G1 block must be inserted
between the two circular blocks.

Constraints
During the definition of a protection zone, the following functions must not be active or used:
Tool radius compensation (cutter radius compensation, tool nose radius compensation)
Transformation,
Reference point approach (G74)
Fixed point approach (G75)
Dwell time (G4)
Block search stop (STOPRE)
End of program (M17, M30)
M functions: M0, M1, M2
Programmable frames (TRANS, ROT, SCALE, MIRROR) and configurable frames (G54 to G57)
are ineffective.
Inch/metric switchovers with G70/G71 or G700/G710 are effective.

End of definition
The end of definition is defined by the following subroutine:
EXECUTE(NOT_USED)
Parameters Type
NOT_USED INT

Description
Error variable has no effect in protection zones with EXECUTE.

The definition of a machine or channel-related protection zone is completed with the

subroutine EXECUTE(n).

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Detailed description
2.5 Protection zones

2.5.4

Definition via system variable

General
If the protection zones are defined with part program instructions (see Chapter: Definition by
means of part program instructions), the protection zone data are stored in system variables.
The system variables can also be written directly so that the definition of protection areas
can also be performed directly in the system variables.
The same supplementary conditions apply for the definition of the contour of a protection
zone as for a protection-zone definition via part program instructions.

System variable
The protection-zone definitions include the following system variables:
System variable
$SN_PA_ACTIV_IMMED[n]
$SC_PA_ACTIV_IMMED[n]

2-42

Type
BOOL

Meaning
Activation type
The protection zone is active immediately after power up of
the control and referencing of the axes.
FALSE: not immediately active
TRUE: immediately active

$SN_PA_T_W[n]
$SC_PA_T_W[n]

INT

Protection zone type

0: Workpiece-related protection zone
1: Reserved
2: Reserved
3: Tool-related protection zone

$SN_PA_ORI[n]
$SC_PA_ORI[n]

INT

Orientation of the protection zone, i.e. polygon definition in

the plane of:
0: 1. and 2nd geometry axis
1: 3. and 1st geometry axis
2: 2. and 3ard geometry axis

$SN_PA_LIM_3DIM[n]
$SC_PA_LIM_3DIM[n]

INT

Type of limitation in the third dimension

0: No limit
1: Limit in positive direction
2: Limit in negative direction
3: Limit in positive and negative direction

$SN_PA_PLUS_LIM[n]
$SC_PA_PLUS_LIM[n]

REAL

Value of the limit in the positive direction in the 3rd

dimension

$SN_PA_MINUS_LIM[n]
$SC_PA_MINUS_LIM[n]

REAL

Value of the limit in the negative direction in the 3rd

dimension

$SN_PA_CONT_NUM[n]
$SC_PA_CONT_NUM[n]

INT

Number of valid contour elements

$SN_PA_CONT_TYP[n, i]
$SC_PA_CONT_TYP[n, i]

INT

Contour type[i], contour type (G1, G2, G3) of the nth contour
element

$SN_PA_CONT_ABS[n, i]
$SC_PA_CONT_ABS[n, i]

REAL

End point of the contour[i], abscissa value

$SN_PA_CONT_ORD[n, i]
$SC_PA_CONT_ORD[n, i]

REAL

End point of the contour[i], ordinate value

$SN_PA_CENT_ABS[n, i]
$SC_PA_CENT_ABS[n, i]

REAL

Center point of the circular contour[i], absolute abscissa

value

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Detailed description
2.5 Protection zones
System variable
$SN_PA_CENT_ORD[n, i]
$SC_PA_CENT_ORD[n, i]

Type
REAL

Meaning
Center point of the circular contour[i], absolute ordinate
value

$SN_... are system variables for NC and machine-specific protection zones.

$SC_... are system variables for channel-specific protection zones.
The index "n" corresponds to the number of the protection zone: 0 = 1. Protection zone
The index "i" corresponds to the number of the contour element: 0 = 1. Contour element
The contour elements must be defined in ascending order.

Note
The system variables of the protection-zone definitions are not restored with REORG.

Data of the protection-zone definitions

data storage
The protection-zone definitions are stored in the following files:
File

Blocks

_N_NCK_PRO

Data block for NCspecific protection zones

_N_CHAN1_PRO

Data block for channelspecific protection zones in channel 1

_N_CHAN2_PRO

Data block for channelspecific protection zones in channel 2

Data backup
The protection-zone definitions are saved in the following files:
File

Blocks

_N_INITIAL_INI

All data blocks of the protection zones

_N_COMPLETE_PRO

All data blocks of the protection zones

_N_CHAN_PRO

All data blocks of the channelspecific protection zones

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Detailed description
2.5 Protection zones

2.5.5

Activation and deactivation of protection zones

General
The activation status of a protection zone is:
Preactivated
Preactivated with conditional stop
Enabled
Disabled
A protection zone is monitored for violation only when it is activated.
Activation
The activation of a protection zone can take place through:
Part program instruction
Automatically after the control powers up
PLC user program
For activation through the PLC user program, the protection zone must be first
preactivated via a part program.
The preactivation, deactivation and activation of all protection zones always takes place
channel-specifically. A protection zone can also be active in multiple channels
simultaneously (application example: Double-slide single-spindle machine with one quill and
two machining slides. Machine-related protection zones are automatically activated in all
channels after the control powers up.
An activated protection zone is only taken into account after the successful referencing of all
participating geometry axes.
Preactivation
Only preactivated protection zones can be activated from the PLC user program.

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2-44

Example: Turning machine with preactivated protection zone for a sensor.

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Detailed description
2.5 Protection zones
Deactivation
A protection zone can be deactivated from a part program only.
RESET response
The activation status of a protection zone is retained even after NC-RESET and program end.

Memory requirements
The memory requirements with regard to protection zones are defined with the following
parameters:
Maximum number of protection zones that can be simultaneously activated in the
channel:
MD28210 $MC_MM_NUM_PROTECT_AREA_ACTIVE
Maximum number of contour elements that can be defined per protection zone:
MD28212 $MC_MM_NUM_PROTECT_AREA_CONTUR

Deactivation, preactivation, activation via part program

The activation status of a channel- or machine-specific protection zone is defined by the
corresponding subroutine:
Channel-specific protection zone:
CPROT (n, state, xMov, yMov, zMov)
Machine or NC-specific protection zone:
NPROT (n, state, xMov, yMov, zMov)
Parameters
n

Type
INT

Description

state

INT

Activation status

Number of the protection zone

0: deactivated
1: Preactivated
2: Enabled

xMov,
REAL
yMov, zMov

Offset values of the previously defined protection zone in the geometry axes

Offsets
During preactivation or activation of the protection zone, an offset can be entered in 0 to 3
dimensions. The offset refers to:
Workpiece-specific protection zones: Machine zero
Tool-specific protection zones: Tool holder reference point F

Note
A protection zone cannot be activated in a single channel with different offsets
simultaneously.

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Detailed description
2.5 Protection zones

Activation via PLC user program

A protection zone preactivated in the part program can be activated in the PLC user
program.
Preactivated protection zones
The NC indicates the preactivated protection zones:
DB21, ... DBX272.0 to 273.1 (machine-related protection zone 1 - 10 preactivated)
DB21, ... DBX274.0 to 275.1 (channel-specific protection zone 1 - 10 preactivated)
Protection-zone violation
Activated and preactivated protection zones that are or would be violated by the
programmed traversing motions of the current part-program block if the PLC user program
would activate the preactivated protection zone:
DB21, ... DBX276.0 to DBX277.1 (machine-related protection zone 1 - 10 violated).
DB21, ... DBX278.0 to DBX279.1 (channel-specific protection zone 1 - 10 violated).
Activate
The preactivated protection zones can be activated from the PLC user program:
DB21, ... DBX8.0 to DBX9.1 (activate machine-related protection zone 1 - 10).
DB21, ... DBX10.0 to DBX11.1 (activate channel-specific protection range 1 - 10).
Deactivation
Protection zones activated from the part program cannot be deactivated by the PLC user
program.

Note
It follows from the rules listed above that protection zones that should be activated via the
PLC user program are intended specially for this. Preactivation in the part program is only
useful for these protection zones.
For protection zones that are known only in the part program and not in the PLC user
program, only activation in the part program makes sense.

2-46

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Detailed description
2.5 Protection zones

Automatic activation after the control powers up

The configuration for automatic activation of a protection zone after the control powers up is
performed via the following system variable:
Channel-specific protection zone:
$SC_PA_ACTIV_IMMED[ n ]
Machine or NC-specific protection zone:
$SN_PA_ACTIV_IMMED[ n ]
With automatic activation, no relative offset of the protection zone is possible.

Note
If no toolrelated protection zone is active, the tool path is checked against the workpiecerelated protection zones.
If no workpiece-oriented protection zone is active, protection-zone monitoring does not take
place.

Block search with calculation

For block search with calculation, the last programmed activation state of a protection zone
is always taken into account.

Program test
In automatic modes, activated and preactivated protection zones are monitored even during
program control: PROGRAM TEST.

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Detailed description
2.5 Protection zones

2.5.6

Protection-zone violation and temporary enabling of individual protection zones

Function
Workpiece and toolrelated protection zones that are activated or deactivated are monitored
for collision. If a protection-zone violation is detected, behavior in the individual operating
modes is as follows.
Terminating temporary enabling
Temporary enabling of a protection zone is terminated after the following events:
after NC RESET
Operating modes AUTOMATIC or MDA End of block is outside the protection zone
Manual operating modes: End of movement is outside the protection zone
Activating a protection zone
On NC RESET all the enabled protection zones become active again. If the part program or
jog mode is started again, the protection zones must be reenabled. If the current position lies
within a protection zone that becomes active again after NC RESET, this protection zone
must be enabled again on the first path movement.
Preactivated protection zones
Protection zones can be preactivated with part programs. To make them fully operative, they
must also be set to the "operative" state by the PLC.
In contrast to AUTOMATIC mode, a change in the NC/PLC interface signals "Make
preactivated protection zones operative" only has an effect on stationary axes in the
geometry system. This means: If an inoperative protection zone is made "operative" once a
motion has been started, it is not evaluated until the axes have stopped, possibly resulting in
the output of an alarm.
If a preactivated protection zone is made "operative" during traversing, the alarm 10704
"Protection-zone monitoring is not guaranteed" and the PLC interface signal are set:
DB31, ... DBX39.0 (protection-zone monitoring not guaranteed).
Deactivation of toolrelated protection zones
Toolrelated protection zones can be deactivated only in the part program or, if they have
been preactivated, by being rendered "inoperative" by the PLC.

2-48

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Detailed description
2.5 Protection zones

Geo-axis replacement
Machine data can be used to configure protection zones and working-area limitations for
geo-axis replacement:
Protection zones can be activated with:
MD10618 PROTAREA_GEOAX_CHANGE_MODE, Bit 1 = 1 (Protection zone for
switchover of geo axes).
Working-area limitations can be activated with:
MD10604 WALIM_GEOAX_CHANGE_MODE, Bit 0 = 1 (Working-area limitations for
switchover of geo axes).
If functions such as protection zone or working-area limitation are deactivated during
geometry axis replacement, the bits should be set to zero.
For information about frames for switchover of geo axes, see:
References:
/FB1/Function Manual Basic Functions; Axes, Coordinate Systems, Frames (K2)
Transformation changeover
Protection zones can also be activated during transformation changeover using machine
data:
MD10618 PROTAREA_GEOAX_CHANGE_MODE, Bit 0 = 1 (Protection zone for switchover
of geo axes).
Bit 0 = 0 deactivates this function.
Monitoring of overlaid motion
Axes that have been assigned to another channel are not taken into account. The last
position to be approached is taken to be the end position. It is not taken into account whether
the axis has traversed after changing channels.

Behavior in the AUTOMATIC and MDI operating modes

Protection zones are not overrun in Automatic modes:
If the movement in a block is from outside into the protection zone (N30), deceleration is
executed toward the end of the previous block (N20) and the movement is stopped.
If the protection zone is preactivated but not activated by the PLC, machining is
continued (case 1).
If the protection zone is activated or preactivated and activated by the PLC, machining
is stopped (case 2).
If the starting point of the block is inside the protection zone, the movement is not started.
If a protection zone is violated, alarm 10700 "NCK protection zone violated in v or MDI" or
10701 "Channel-specific protection zone violated in AUTOMATIC or MDI" is signaled for the
workpiece-related protection zone.

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2-49

Detailed description
2.5 Protection zones

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Behavior of the path velocity when entering a protection zone

Overlaying several axis motions

Overlaid motions of external ZO (zero offsets) or DRF are taken into account if they are
executed at a sufficiently early point in time.
If an overlaid motion occurs while a protection zone is active or operative, an alarm is output
as a warning. This alarm has no effect on the machining operation and resets itself if the
transferred motion has been fully taken into account. The PLC interface signal is set at the
same time as alarm 10704:
DB31, ... DBX39.0 (protection-zone monitoring not guaranteed).
Enabling of workpiece-related protection zones
When a workpiece-related protection zone has been violated, the operator can enable it
temporarily with NC start in the AUTOMATIC and JOG modes so that it can be traversed.
This clears the alarm and travels into the protection zone in the AUTOMATIC and MDI
operating modes.
Only workpiecerelated protection zones can be enabled temporarily with NC start and
traversed by all toolrelated protection zones including the programmed path.
If on NC-START the preactivated tool or workpiecerelated protection zone is deactivated by
the PLC after the alarm, machining is continued without the protection zone being enabled
temporarily.
If a fully operative, preactivated protection zone causes a machining interruption and the
output of an alarm owing to protection-zone violation, machining can be resumed on NC start
if the PLC makes the zone inoperative again.
If enabling of a protection zone is to be safeguarded better than with a simple NC start, NC
start must be disabled or made dependent on other conditions in the PLC user program
when this alarm is triggered.
If the user does not want to permit overrunning the protection zone, he can terminate the
traversing movement with NC RESET.
If several protection zones are violated at the same time by the movement, acknowledgment
is required for each of these protection zones. With NC start the individual protection zones
can then be enabled one after the other.

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Detailed description
2.5 Protection zones

Application for temporary enabling:

Drilling a turned part: The drill is allowed to enter the protection zone of the spindle chuck.
Monitoring of overlaid motion
On preparation of the NC blocks, part of the offsets of geometry axes resulting from the
overlaid motions are taken into account.
If further offsets occur that could not be taken into account on preparation of the blocks, the
channelspecific PLC interface signal is set.
DB31, ... DBX39.0 (protection-zone monitoring not guaranteed).
This signal is set while offsets are active that cannot be taken into account. The signal can
be set and reset within a block.
Simultaneously with the PLC interface signal, a selfcanceling alarm 10704 "Protection-zone
monitoring is not guaranteed" is output.
The following overlaid motions of geometry axes are taken into account in the preparation of
blocks:
1. DRF offsets
2. Work offsets external
3. Fine tool offsets
4. Rapid retraction
5. Offsets generated by compile cycles
6. Oscillation
7. Concurrent positioning axes
8. Positioning axes
The alarm is canceled or the PLC interface signal reset when the offsets from the overlaid
motions are taken into account again or when the offsets are reduced to zero again.

Note
The end position for positioning axes is taken to be a position in the whole block. This means
that the alarm 10704 "Protection zones not guaranteed" is output when the positioning axis
starts to move. The overlaid motions themselves are not limited, nor is there any intervention
in processing of the program.

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Detailed description
2.5 Protection zones

Behavior in JOG mode

Overlaying several axis motions
In JOG mode traversing can be performed simultaneously in several geometry axes even
when protection zones are active. However, safe monitoring of protection zones can then no
longer be guaranteed. This is indicated as follows:
Alarm: " 10704 Protection-zone monitoring is not guaranteed"
DB31, ... DBX39.0 = 1 (protection-zone monitoring not guaranteed)
The traversing range of the geometry axes is limited in all directions by the protection zones
with the same effect as they had at the start point.

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Figure 2-16

Motion boundaries of axes

When the geometry axes have completed their movements (end of interpolation), the alarm
is automatically reset and the final position checked to see whether it is within one or several
protection zones.
There are three possible situations in this case:
1. If the position is outside all active protection zones, the next traversing motion can be
started normally. The appropriate PLC interface signals "Machinespecific or channelspecific protection zone violated" are set for the protection zones that are enabled or just
preactivated, but not yet operative.
2. If the position is within an active protection zone, the alarm "Protection zone violated in
JOG" is generated, thereby disabling any traversing motions. The appropriate PLC
interface signals "Machinespecific or channelspecific protection zone violated" are also
set.
The alarm is reset by:
Temporary enabling of the affected protection zones
Deactivation of the relevant protection zones if they are preactivated
Deactivation of the protection zone in MDI
3. If the position is on the protection zone limitation (position is still valid), no alarm is
generated.

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Detailed description
2.5 Protection zones

Note
While any one axis in the geometry system is still oscillating, the status "Motions of axes
in geometry system completed" cannot be reached.
The warning remains active, the other axes in the geometry system can continue to
traverse.
The alarm "Protection zone reached in JOG" is not output if the motion of the first axis to
be started is terminated by the limitation determined prior to the motion.

Monitoring (pre)activated protection zones

(Pre)activated protection zones are also monitored in manual modes (JOG, INC,
handwheel).
Limitation of traversing motion of an axis
Axis motions are limited in JOG mode by means of software limit switches or the workingarea limitation. The protection zones are an additional limiting element on the traversing
motion of the geometry axes.
If the traversing motion of an axis is limited because it has reached a protection zone, then a
selfresetting alarm "Protection zone reached in JOG" is generated. The alarm text specifies
the violated protection zone and the relevant axis. It is assured that no protection zone will
be violated when one axis is traversing in JOG. (This response is analogous to approaching
software limit switches or a working-area limitation).
The alarm is reset:
when an axis is traversed along a path that does not lead into the protection zone
when the protection zone is enabled
on NC RESET.
If an axis starts to move towards a protection zone when it is at a protection zone limit, then
a selfresetting alarm "Protection zone reached in JOG" is output and the motion is not
started.
Enabling of workpiece-related protection zones
When a workpiecerelated protection zone has been violated, the operator can also enable it
temporarily in JOG mode so that it can be traversed. This resets the alarm and the motion is
started in the manual operating modes after a new travel command.

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Detailed description
2.5 Protection zones

Temporary enabling of protection zones

Protection zones can be enabled in JOG mode when:
1. the current position is within a protection zone (alarm active)
2. a motion is to be started on the protection zone limit (alarm active)
A protection zone is enabled when:
a positive signal edge arrives at the PLC interface "Temporary enabling of protection
zones" (this enable resets the active alarm).
if the axis then starts to move again into the same protection zone.
Start of the motion causes:
the protection zone to be enabled
the appropriate PLC interface signals "Machinespecific or channelspecific protection zone
violated" to be set.
the axis to start moving.
The enabling signal is canceled if a motion is started that does not lead into the enabled
protection zone.
If the current position is located in other active protection zones or the limit for other
protection zones must be crossed with the motion that has been started, then alarms 10702,
10703 or 10706, 10707 are output. The PLC interface signal "Temporary enabling of
protection zones" can be set again to enable the protection zone for which an alarm is
output.
The enabling signals for the individual protection zones are still valid on switchover to
operating modes AUTOMATIC or MDA, and vice versa, the enabling signals of protection
zones that were output in AUTOMATIC and MDA remain valid.
If the end position is located outside the relevant protection zone the next time the axes in
the geometry system stop:

the enabling signals of the individual protection zones are canceled

the appropriate PLC interface signal "Machinespecific or channelspecific protection zone

violated" is reset.

2.5.7

Restrictions in protection zones

Restrictions in protection-zone monitoring

No protection-zone monitoring is possible under the following conditions:
Orientation axes
Protection-zone monitoring for fixed machine-related protection zones with transmit or
peripheral surface transformation.
Exception: Protection zones defined with rotation symmetry around the spindle axis.
Here, no DRF offset must be active.
Mutual monitoring of tool-related protection zones

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Detailed description
2.5 Protection zones

Positioning axes
For positioning axes, only the programmed block end point is monitored.
An alarm is displayed during the traversing motion of the positioning axes:
Alarm: "10704 Protection-zone monitoring is not guaranteed".

Axis exchange
If an axis is not active in a channel because of an axis replacement, the position of the axis
last approached in the channel is taken as the current position. If this axis has not yet been
traversed in the channel, zero is taken as the position.

Machine-related protection zones

A machine-related protection zone or its contour is defined using the geometry axis, i.e. with
reference to the basic coordinate system (BCS) of a channel. In order that correct protectionzone monitoring can take place in all channels in which the machine-related protection zone
is active, the basic coordinate system (BCS) of all affected channels must be identical
(position of the coordinate point of origin with respect to the machine zero point and
orientation of the coordinate axes).

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Detailed description
2.5 Protection zones

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Supplementary conditions
3.1

3.1

Axis monitoring functions

Settings
For correct operation of the monitoring, the following settings must be made or checked, in
addition to the machine data mentioned:
General
MD31030 $MA_LEADSCREW_PITCH (Leadscrew pitch)
MD31050 $MA_DRIVE_AX_RATIO_DENOM (Denominator load gearbox)
MD31060 $MA_DRIVE_AX_RATIO_NUMERA (Numerator load gearbox)
MD31070 $MA_DRIVE_ENC_RATIO_DENOM (Denominator measuring gearbox)
MD31080 $MA_DRIVE_ENC_RATIO_NUMERA (Numerator measuring gearbox)
MD32810 $MA_EQUIV_SPEEDCTRL_TIME (equivalent time constant speed control loop
for feedforward control)
Encoder resolution
The corresponding machine data is described in:
References:
/FB1/ Function Manual, Basic Functions; Velocities, Setpoint/Actual Value Systems,
Closed-Loop Control (G2)
Only drives with analog speed setpoint interface
MD32260 $MA_RATED_VELO (Nominal motor speed)
MD32250 $MA_RATED_OUTVAL (Nominal output voltage)

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3-1

Supplementary conditions
3.1 Axis monitoring functions

3-2

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Examples
4.1

4.1

Definition and activation of protection zones

Requirement
The following internal protection zones are to be defined for a turning machine:
One machine- and workpiecerelated protection zone for the spindle chuck, without
limitation in the third dimension
One channelspecific protection zone for the workpiece, without limitation in the third
dimension
One channelspecific, toolrelated protection zone for the toolholder, without limitation in
the third dimension
The workpiece zero is placed on the machine zero to define the protection zone for the
workpiece.
When activated, the protection zone is then offset by 100mm in the Z axis in the positive
direction.

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4-1

Examples
4.1 Definition and activation of protection zones




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Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Examples
4.1 Definition and activation of protection zones

Protection-zone definition in the part program

Table 4-1

Part program excerpt for protection-zone definition:

DEF INT AB
G18

Definition of the working plane

NPROTDEF(1,FALSE,0,0,0)

Definition beginning: Protection zone

for spindle chuck

G01 X100 Z0

Contour description: 1. Contour

element

G01 X-100 Z0

Contour description: 2. Contour

element

G01 X-100 Z110

Contour description: 3. Contour

element

G01 X100 Z110

Contour description: 4. Contour

element

G01 X100 Z0

Contour description: 5. Contour

element

EXECUTE(AB)

End of definition: Protection zone for

spindle chuck

CPROTDEF(1,FALSE,0,0,0)

Definition beginning: Protection zone

for workpiece

G01 X80 Z0

Contour description: 1. Contour

element

G01 X-80 Z0

Contour description: 2. Contour

element

G01 X-80 Z40

Contour description: 3. Contour

element

G01 X80 Z40

Contour description: 4. Contour

element

G01 X80 Z0

Contour description: 5. Contour

element

EXECUTE(AB)

End of definition: Protection zone for

workpiece

CPROTDEF(2,TRUE,0,0,0)

Definition beginning: Protection zone

for tool holder

G01 X0 Z-50

Contour description: 1. Contour

element

G01 X-190 Z-50

Contour description: 2. Contour

element

G03 X-210 Z-30 I-20

Contour description: 3. Contour

element

G01 X-210 Z20

Contour description: 4. Contour

element

G01 X0 Z50

Contour description: 5. Contour

element

G01 X0 Z-50

Contour description: 6. Contour

element

EXECUTE(AB)

End of definition: Protection zone for

tool holder

NPROTDEF(0,FALSE,0,0,0)

Axis monitoring, protection zones (A3)

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4-3

Examples
4.1 Definition and activation of protection zones

Protection-zone definition with system variables

Table 4-2

4-4

Protection zone: Spindle chuck

System variable

Valu
e

Comment

$SN_PA_ACTIV_IMMED[0]

; Protection zone for spindle chuck not immediately active

$SN_PA_T_W[0]

""

; Machine-related protection zone for spindle chuck

$SN_PA_ORI[0]

; Orientation of the protection zone: 1= 3. and 1st geometry

axis

$SN_PA_LIM_3DIM[0]

; Type of limitation in the third dimension: 0 = No limit

$SN_PA_PLUS_LIM[0]

; Value of the limit in the positive direction in the 3rd

dimension

$SN_PA_MINUS_LIM[0]

; Value of the limitation in the negative direction in the 3rd

dimension

$SN_PA_CONT_NUM[0]

; Number of valid contour elements

$SN_PA_CONT_TYP[0,0]

; Contour type[i] : 1 = G1 for even,

; Protection zone for spindle chuck, contour element 0

$SN_PA_CONT_TYP[0,1]

; Contour type[i] : 1 = G1 for even,

; Protection zone for spindle chuck, contour element 1

$SN_PA_CONT_TYP[0,2]

; Contour type[i] : 1 = G1 for even,

; Protection zone for spindle chuck, contour element 2

$SN_PA_CONT_TYP[0,3]

; Contour type[i] : 1 = G1 for even,

; Protection zone for spindle chuck, contour element 3

$SN_PA_CONT_TYP[0,4]

; Contour type[i] : 0 = not defined,

; Protection zone for spindle chuck, contour element 4

$SN_PA_CONT_TYP[0,5]

; Contour type[i] : 0 = not defined,

; Protection zone for spindle chuck, contour element 5

$SN_PA_CONT_TYP[0,6]

; Contour type[i] : 0 = not defined,

; Protection zone for spindle chuck, contour element 6

$SN_PA_CONT_TYP[0,7]

; Contour type[i] : 0 = not defined,

; Protection zone for spindle chuck, contour element 7

$SN_PA_CONT_TYP[0,8]

; Contour type[i] : 0 = not defined,

; Protection zone for spindle chuck, contour element 8

$SN_PA_CONT_TYP[0,9]

; Contour type[i] : 0 = not defined,

; Protection zone for spindle chuck, contour element 9

$SN_PA_CONT_ORD[0,0]

-100

; Endpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 0

$SN_PA_CONT_ORD[0,1]

-100

; Endpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 1

$SN_PA_CONT_ORD[0,2]

100

; Endpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 2

$SN_PA_CONT_ORD[0,3]

100

; Endpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 3

$SN_PA_CONT_ORD[0,4]

; Endpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 4

$SN_PA_CONT_ORD[0,5]

; Endpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 5

$SN_PA_CONT_ORD[0,6]

; Endpoint of contour[i], ordinate value

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Examples
4.1 Definition and activation of protection zones
; Protection zone for spindle chuck, contour element 6
$SN_PA_CONT_ORD[0,7]

; Endpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 7

$SN_PA_CONT_ORD[0,8]

; Endpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 8

$SN_PA_CONT_ORD[0,9]

; Endpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 9

$SN_PA_CONT_ABS[0,0]

; Endpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 0

$SN_PA_CONT_ABS[0,1]

110

; Endpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 1

$SN_PA_CONT_ABS[0,2]

110

; Endpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 2

$SN_PA_CONT_ABS[0,3]

; Endpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 3

$SN_PA_CONT_ABS[0,4]

; Endpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 4

$SN_PA_CONT_ABS[0,5]

; Endpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 5

$SN_PA_CONT_ABS[0,6]

; Endpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 6

$SN_PA_CONT_ABS[0,7]

; Endpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 7

$SN_PA_CONT_ABS[0,8]

; Endpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 8

$SN_PA_CONT_ABS[0,9]

; Endpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 9

$SN_PA_CENT_ORD[0,0]

; Midpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 0

$SN_PA_CENT_ORD[0.1]

; Midpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 1

$SN_PA_CENT_ORD[0,2]

; Midpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 2

$SN_PA_CENT_ORD[0,3]

; Midpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 3

$SN_PA_CENT_ORD[0,4]

; Midpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 4

$SN_PA_CENT_ORD[0,5]

; Midpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 5

$SN_PA_CENT_ORD[0,6]

; Midpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 6

$SN_PA_CENT_ORD[0,7]

; Midpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 7

$SN_PA_CENT_ORD[0,8]

; Midpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 8

$SN_PA_CENT_ORD[0,9]

; Midpoint of contour[i], ordinate value

; Protection zone for spindle chuck, contour element 9

$SN_PA_CENT_ABS[0,0]

; Midpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 0

Axis monitoring, protection zones (A3)

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4-5

Examples
4.1 Definition and activation of protection zones
$SN_PA_CENT_ABS[0.1]

; Midpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 1

$SN_PA_CENT_ABS[0,2]

; Midpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 2

$SN_PA_CENT_ABS[0,3]

; Midpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 3

$SN_PA_CENT_ABS[0,4]

; Midpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 4

$SN_PA_CENT_ABS[0,5]

; Midpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 5

$SN_PA_CENT_ABS[0,6]

; Midpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 6

$SN_PA_CENT_ABS[0,7]

; Midpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 7

$SN_PA_CENT_ABS[0,8]

; Midpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 8

$SN_PA_CENT_ABS[0,9]

; Midpoint of contour[i], abscissa value

; Protection zone for spindle chuck, contour element 9

Table 4-3

4-6

Protection zone: Workpiece and tool holder

System variable

Valu
e

Comment

$SN_PA_ACTIV_IMMED[0]

; Protection zone for workpiece not immediately active

$SN_PA_ACTIV_IMMED[1]

; Protection zone for tool holder not immediately active

$SC_PA_TW[0]

""

; Protection zone for workpiece, channel-specific

$SC_PA_TW[1]

'H01' ; Protection zone for toolholder, channel-specific

$SC_PA_ORI[0]

; Orientation of the protection zone: 1= 3. and first geometry

axis
; Protection zone for workpiece

$SC_PA_ORI[1]

; Orientation of the protection zone: 1= 3. and first geometry

axis
; Protection zone for tool holder

$SC_PA_LIM_3DIM[0]

; Type of limitation in the third dimension: 0 = no limitation

; Protection zone for workpiece tool holder 0

$SC_PA_LIM_3DIM[1]

; Type of limitation in the third dimension: 0 = no limitation

; Protection zone for tool holder

$SC_PA_PLUS_LIM[0]

; Value of limitation in positive direction in the third dimension

; Protection zone for workpiece

$SC_PA_PLUS_LIM[1]

; Value of limitation in positive direction in the third dimension

; Protection zone for tool holder

$SC_PA_MINUS_LIM[0]

; Value of limitation in negative direction in the third dimension

; Protection zone for workpiece

$SC_PA_MINUS_LIM[1]

; Value of limitation in negative direction in the third dimension

; Protection zone for tool holder

$SC_PA_CONT_NUM[0]

; Number of valid contour elements,

; Protection zone for workpiece

$SC_PA_CONT_NUM[1]

; Number of valid contour elements,

; Protection zone for tool holder 1

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Examples
4.1 Definition and activation of protection zones
$SN_PA_CONT_TYP[0,0]

; Contour type[i] : 1 = G1 for even,

; Protection zone for workpiece, contour element 0

$SN_PA_CONT_TYP[0,1]

; Contour type[i] : 1 = G1 for even,

; Protection zone for workpiece, contour element 1

$SN_PA_CONT_TYP[0,2]

; Contour type[i] : 1 = G1 for even,

; Protection zone for workpiece, contour element 2

$SN_PA_CONT_TYP[0,3]

; Contour type[i] : 1 = G1 for even,

; Protection zone for workpiece, contour element 3

$SN_PA_CONT_TYP[0,4]

; Contour type[i] : 1 = G1 for even,

; Protection zone for workpiece, contour element 4

$SN_PA_CONT_TYP[0,5]

; Contour type[i] : 0 = not defined,

; Protection zone for workpiece, contour element 5

$SN_PA_CONT_TYP[0,6]

; Contour type[i] : 0 = not defined,

; Protection zone for workpiece, contour element 6

$SN_PA_CONT_TYP[0,7]

; Contour type[i] : 0 = not defined,

; Protection zone for workpiece, contour element 7

$SN_PA_CONT_TYP[0,8]

; Contour type[i] : 0 = not defined,

; Protection zone for workpiece, contour element 8

$SN_PA_CONT_TYP[0,9]

; Contour type[i] : 0 = not defined,

; Protection zone for workpiece, contour element 9

$SN_PA_CONT_TYP[1,0]

; Contour type[i] : 1 = G1 for even,

; Protection zone for tool holder, contour element 0

$SN_PA_CONT_TYP[1,1]

; Contour type[i] : 3 = G3 f. Circuit element, counter-clockwise,

; Protection zone for tool holder, contour element 1

$SN_PA_CONT_TYP[1,2]

; Contour type[i] : 1 = G1 for even,

; Protection zone for tool holder, contour element 2

$SN_PA_CONT_TYP[1,3]

; Contour type[i] : 1 = G1 for even,

; Protection zone for tool holder, contour element 3

$SN_PA_CONT_TYP[1,4]

; Contour type[i] : 1 = G1 for even,

; Protection zone for tool holder, contour element 4

$SN_PA_CONT_TYP[1,5]

; Contour type[i] : 0 = not defined,

; Protection zone for tool holder, contour element 5

$SN_PA_CONT_TYP[1,6]

; Contour type[i] : 0 = not defined,

; Protection zone for tool holder, contour element 6

$SN_PA_CONT_TYP[1,7]

; Contour type[i] : 0 = not defined,

; Protection zone for tool holder, contour element 7

$SN_PA_CONT_TYP[1,8]

; Contour type[i] : 0 = not defined,

; Protection zone for tool holder, contour element 8

$SN_PA_CONT_TYP[1,9]

; Contour type[i] : 0 = not defined,

; Protection zone for tool holder, contour element 9

$SN_PA_CONT_ORD[0,0]

-80

; Endpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 0

$SN_PA_CONT_ORD[0,1]

-80

; Endpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 1

$SN_PA_CONT_ORD[0,2]

80

; Endpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 2

$SN_PA_CONT_ORD[0,3]

80

; Endpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 3

$SN_PA_CONT_ORD[0,4]

; Endpoint of contour[i], ordinate value

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

4-7

Examples
4.1 Definition and activation of protection zones
; Protection zone for workpiece, contour element 4

4-8

$SN_PA_CONT_ORD[0,5]

; Endpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 5

$SN_PA_CONT_ORD[0,6]

; Endpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 6

$SN_PA_CONT_ORD[0,7]

; Endpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 7

$SN_PA_CONT_ORD[0,8]

; Endpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 8

$SN_PA_CONT_ORD[0,9]

; Endpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 9

$SN_PA_CONT_ORD[1,0]

-190

; Endpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 0

$SN_PA_CONT_ORD[1,1]

-210

; Endpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 1

$SN_PA_CONT_ORD[1,2]

-210

; Endpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 2

$SN_PA_CONT_ORD[1,3]

; Endpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 3

$SN_PA_CONT_ORD[1,4]

; Endpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 4

$SN_PA_CONT_ORD[1,5]

; Endpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 5

$SN_PA_CONT_ORD[1,6]

; Endpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 6

$SN_PA_CONT_ORD[1,7]

; Endpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 7

$SN_PA_CONT_ORD[1,8]

; Endpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 8

$SN_PA_CONT_ORD[1,9]

; Endpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 9

$SN_PA_CONT_ABS[0,0]

; Endpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 0

$SN_PA_CONT_ABS[0,1]

40

; Endpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 1

$SN_PA_CONT_ABS[0,2]

40

; Endpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 2

$SN_PA_CONT_ABS[0,3]

; Endpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 3

$SN_PA_CONT_ABS[0,4]

-50

; Endpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 4

$SN_PA_CONT_ABS[0,5]

; Endpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 5

$SN_PA_CONT_ABS[0,6]

; Endpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 6

$SN_PA_CONT_ABS[0,7]

; Endpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 7

$SN_PA_CONT_ABS[0,8]

; Endpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 8

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Examples
4.1 Definition and activation of protection zones
$SN_PA_CONT_ABS[0,9]

; Endpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 9

$SN_PA_CONT_ABS[1,0]

-50

; Endpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 0

$SN_PA_CONT_ABS[1,1]

-30

; Endpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 1

$SN_PA_CONT_ABS[1,2]

20

; Endpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 2

$SN_PA_CONT_ABS[1,3]

50

; Endpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 3

$SN_PA_CONT_ABS[1,4]

-50

; Endpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 4

$SN_PA_CONT_ABS[1,5]

; Endpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 5

$SN_PA_CONT_ABS[1,6]

; Endpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 6

$SN_PA_CONT_ABS[1,7]

; Endpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 7

$SN_PA_CONT_ABS[1,8]

; Endpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 8

$SN_PA_CONT_ABS[1,9]

; Endpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 9

$SN_PA_CENT_ORD[0,0]

; Midpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 0

$SN_PA_CENT_ORD[0.1]

-190

; Midpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 1

$SN_PA_CENT_ORD[0,2]

; Midpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 2

$SN_PA_CENT_ORD[0,3]

; Midpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 3

$SN_PA_CENT_ORD[0,4]

; Midpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 4

$SN_PA_CENT_ORD[0,5]

; Midpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 5

$SN_PA_CENT_ORD[0,6]

; Midpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 6

$SN_PA_CENT_ORD[0,7]

; Midpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 7

$SN_PA_CENT_ORD[0,8]

; Midpoint of contour[i], ordinate value

; Protection zone for workpiece, contour element 8

$SN_PA_CENT_ORD[0,9]

; Midpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 9

$SN_PA_CENT_ORD[1.0]

; Midpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 0

$SN_PA_CENT_ORD[1.1]

-190

; Midpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 1

$SN_PA_CENT_ORD[1.2]

; Midpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 2

$SN_PA_CENT_ORD[1.3]

; Midpoint of contour[i], ordinate value

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

4-9

Examples
4.1 Definition and activation of protection zones
; Protection zone for tool holder, contour element 3

4-10

$SN_PA_CENT_ORD[1.4]

; Midpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 4

$SN_PA_CENT_ORD[1.5]

; Midpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 5

$SN_PA_CENT_ORD[1.6]

; Midpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 6

$SN_PA_CENT_ORD[1.7]

; Midpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 7

$SN_PA_CENT_ORD[1.8]

; Midpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 8

$SN_PA_CENT_ORD[1.9]

; Midpoint of contour[i], ordinate value

; Protection zone for tool holder, contour element 9

$SN_PA_CENT_ABS[0,0]

; Midpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 0

$SN_PA_CENT_ABS[0.1]

-30

; Midpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 1

$SN_PA_CENT_ABS[0,2]

; Midpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 2

$SN_PA_CENT_ABS[0,3]

; Midpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 3

$SN_PA_CENT_ABS[0,4]

; Midpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 4

$SN_PA_CENT_ABS[0,5]

; Midpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 5

$SN_PA_CENT_ABS[0,6]

; Midpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 6

$SN_PA_CENT_ABS[0,7]

; Midpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 7

$SN_PA_CENT_ABS[0,8]

; Midpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 8

$SN_PA_CENT_ABS[0,9]

; Midpoint of contour[i], abscissa value

; Protection zone for workpiece, contour element 9

$SN_PA_CENT_ABS[1.0]

; Midpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 0

$SN_PA_CENT_ABS[1.1]

-30

; Midpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 1

$SN_PA_CENT_ABS[1.2]

; Midpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 2

$SN_PA_CENT_ABS[1.3]

; Midpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 3

$SN_PA_CENT_ABS[1.4]

; Midpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 4

$SN_PA_CENT_ABS[1.5]

; Midpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 5

$SN_PA_CENT_ABS[1.6]

; Midpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 6

$SN_PA_CENT_ABS[1.7]

; Midpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 7

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Examples
4.1 Definition and activation of protection zones
$SN_PA_CENT_ABS[1.8]

; Midpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 8

$SN_PA_CENT_ABS[1.9]

; Midpoint of contour[i], abscissa value

; Protection zone for tool holder, contour element 9

Activation
Table 4-4

Part program excerpt for activating the three protection zones for spindle chuck,
workpiece, and toolholder:

NPROT(1, 2, 0, 0, 0)

; Protection zone: Spindle chuck

CPROT(1, 2, 0, 0, 100)

; Protection zone: Workpiece with 100mm offset in the Z

axis.

CPROT(2, 2, 0, 0, 0)

; Protection zone: Toolholder

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

4-11

Examples
4.1 Definition and activation of protection zones

4-12

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Data lists
5.1

5.1.1

5.1

Machine data

NC-specific machine data

Axis monitoring functions

None

Protection zones
Number

Identifier: $MN_

Description

10604

WALIM_GEOAX_CHANGE_MODE

Working-area limitation during switchover of geometry

axes

10618

PROTAREA_GEOAX_CHANGE_MODE

Protection zone for switchover of geo axes

18190

MM_NUM_PROTECT_AREA_NCK

Number of files for machinerelated protection zones

5.1.2

Channelspecific machine data

Axis monitoring functions

Number

Identifier: $MC_

Description

20150

GCODE_RESET_VALUES[n]

Reset G groups

21020

WORKAREA_WITH_TOOL_RADIUS

Allowance for tool radius with working-area limitation

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

5-1

Data lists
5.1 Machine data

Protection zones
Number

Identifier: $MC_

Description

28200

MM_NUM_PROTECT_AREA_CHAN

Number of files for channelspecific protection zones

28210

MM_NUM_PROTECT_AREA_ACTIVE

Number of simultaneously active protection zones in

one channel

28212

MM_NUM_PROTECT_AREA_CONTUR

Elements for active protection zones (DRAM)

5.1.3

Axis/spindlespecific machine data

Axis monitoring functions

Number

Identifier: $MA_

Description

30310

ROT_IS_MODULO

Modulo conversion for rotary axis and spindle

32200

POSCTRL_GAIN [n]

Servo gain factor

32250

RATED_OUTVAL

Rated output voltage

32260

RATED_VELO

Rated motor speed

32300

MAX_AX_ACCEL

Axis acceleration

32800

EQUIV_CURRCTRL_TIME

Equivalent time constant current control loop for feedforward control

32810

EQUIV_SPEEDCTRL_TIME

Equivalent time constant speed control loop for feedforward control

32910

DYN_MATCH_TIME [n]

Time constant for dynamic matching

35160

SPIND_EXTERN_VELO_LIMIT

Spindle speed limitation via PLCC

36000

STOP_LIMIT_COARSE

Exact stop coarse

36010

STOP_LIMIT_FINE

Exact stop fine

36020

POSITIONING_TIME

Time delay exact stop fine

36030

STANDSTILL_POS_TOL

Zero speed tolerance

36040

STANDSTILL_DELAY_TIME

Delay time zero-speed monitoring

36050

CLAMP_POS_TOL

Clamping tolerance with IS "Clamping active"

36052

STOP_ON_CLAMPING

Special functions for clamped axis

36060

STANDSTILL_VELO_TOL

Maximum velocity/speed "Axis/spindle stationary"

36100

POS_LIMIT_MINUS

software limit switch minus

36110

POS_LIMIT_PLUS

Software limit switch plus

36120

POS_LIMIT_MINUS2

software limit switch minus

36130

POS_LIMIT_PLUS2

Software limit switch plus

36610

AX_EMERGENCY_STOP_TIME

Length of the braking ramp for error states

36200

AX_VELO_LIMIT

Threshold value for velocity monitoring

36210

CTRLOUT_LIMIT

Maximum speed setpoint

36220

CTRLOUT_LIMIT_TIME

Delay time for speed-setpoint monitoring

36300

ENC_FREQ_LIMIT

Encoder limit frequency

5-2

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Data lists
5.2 Setting data
Number

Identifier: $MA_

Description

36302

ENC_FREQ_LIMIT_LOW

Encoder limit frequency resynchronization

36310

ENC_ZERO_MONITORING

Zero-mark monitoring

36400

CONTOUR_TOL

Tolerance band contour monitoring

36500

ENC_CHANGE_TOL

Maximum tolerance for position actual value switchover

36510

ENC_DIFF_TOL

Measuring system synchronism tolerance

36600

BRAKE_MODE_CHOICE

Deceleration behavior on hardware limit switch

36620

SERVO_DISABLE_DELAY_TIME

Cutout delay servo enable

Protection zones
Number

Identifier: $MA_

Description

30800

WORK_AREA_CHECK_TYPE

Type of checking of working area limits

5.2

5.2.1

5.2

Setting data

Axis/spindlespecific setting data

Axis monitoring functions

Number

Identifier: $SA_

Description

43400

WORKAREA_PLUS_ENABLE

Working-area limitation active in positive direction

43410

WORKAREA_MINUS_ENABLE

Working-area limitation active in negative direction

43420

WORKAREA_LIMIT_PLUS

Working-area limitation plus

43430

WORKAREA_LIMIT_MINUS

Working-area limitation minus

Protection zones
None

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

5-3

Data lists
5.3 Signals

5.3

5.3.1

5.3

Signals

Signals to channel

Axis monitoring functions

None

Protection zones
DB number

Byte.Bit

Description

21, ...

1.1

Enable protection zones

21, ...

4.7

Feed override

21, ...

6.0

Feed disable

21, ...

8.0

Activate machinerelated protection zone 1

21, ...

8.7

Activate machinerelated protection zone 8

21, ...

9.0

Activate machinerelated protection zone 9

21, ...

9.1

Activate machinerelated protection zone 10

21, ...

10.0

Activate channelspecific protection zone 1

21, ...

10.7

Activate channelspecific protection zone 8

21, ...

11.0

Activate channelspecific protection zone 9

21, ...

11.1

Activate channelspecific protection zone 10

5.3.2

Signals from channel

Axis monitoring functions

None

Protection zones
DB number

Byte.Bit

Description

21, ...

272.0

Machinerelated protection zone 1 preactivated

21, ...

272.7

Machinerelated protection zone 8 preactivated

21, ...

273.0

Machinerelated protection zone 9 preactivated

21, ...

273.1

Machinerelated protection zone 10 preactivated

5-4

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Data lists
5.3 Signals
DB number

Byte.Bit

Description

21, ...

274.0

Channelspecific protection zone 1 preactivated

21, ...

274.7

Channelspecific protection zone 8 preactivated

21, ...

275.0

Channelspecific protection zone 9 preactivated

21, ...

275.1

Channelspecific protection zone 10 preactivated

21, ...

276.0

Machinerelated protection zone 1 violated

21, ...

276.7

Machinerelated protection zone 8 violated

21, ...

277.0

Machinerelated protection zone 9 violated

21, ...

277.1

Machinerelated protection zone 10 violated

21, ...

278.0

Channelspecific protection zone 1 violated

21, ...

278.7

Channelspecific protection zone 8 violated

21, ...

279.0

Channelspecific protection zone 9 violated

21, ...

279.1

Channelspecific protection zone 10 violated

5.3.3

Signals to axis/spindle

Axis monitoring functions

DB number

Byte.Bit

Description

31, ...

1.4

Follow up operation

31, ...

1.5 / 1.6

Position measuring system 1 / 2

31, ...

2.1

Servo enable

31, ...

2.3

Clamping in progress

31, ...

3.6

Velocity/spindle speed limitation

31, ...

4.3

Feed stop

31, ...

12.0 / 12.1

Hardware limit switch minus/Hardware limit switch plus

31, ...

12.2 / 12.3

Software limit switch minus / 2nd software limit switch plus

31, ...

60.2 / 60.3

Encoder limit frequency exceeded 1 / 2

31, ...

60.4 / 60.5

Referenced/synchronized 1 / 2

31, ...

64.6 / 64.7

Traverse command minus / plus

Protection zones
None

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

5-5

Data lists
5.3 Signals

5-6

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Index
A
Activation of protection zones
Example, 4-11
Axis clamping
Operations, optimized, 2-7
Axis monitoring functions, 1-1
Actual velocity, 2-16
Axis/spindlespecific machine data, 5-2
Axis/spindlespecific setting data, 5-3
Channelspecific machine data, 5-1
Constraints, 3-1
Following error, 2-2
Speed setpoint, 2-14
Zero speed, 2-6

C
Contour error, 2-1
Coordinate system, 2-33

D
DB 31, ...
DBX1.4, 2-8, 2-14
DBX1.5, 2-16, 2-17
DBX1.6, 2-16, 2-17
DBX12.0, 2-27
DBX12.1, 2-27
DBX12.2, 2-28
DBX12.3, 2-28
DBX2.2, 2-8
DBX2.3, 2-8, 2-14
DBX39.0, 2-47, 2-49, 2-50, 2-51
DBX60.2, 2-18
DBX60.3, 2-18
DBX60.4, 2-25
DBX60.5, 2-25
DBX60.6, 2-6, 2-14
DBX60.7, 2-6, 2-14
DBX64.6, 2-6
DBX64.7, 2-6
DB21, ...
Axis monitoring, protection zones (A3)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

DBX10.0 to DBX11.1, 2-45

DBX272.0 to 273.1, 2-45
DBX274.0 to 275.1, 2-45
DBX276.0 to DBX277.1, 2-45
DBX278.0 to DBX279.1, 2-45
DBX8.0 to DBX9.1, 2-45
Dirt deposits, 2-25

E
Encoder monitoring functions, 2-17
Encoder frequency, 2-17
Encoder type, 2-19
Zero marks, 2-19, 2-20

H
Hardware faults, 2-25
Hardware limit switches, 2-27

I
Interface signals|Table, 5-4

L
Limit switch monitoring, 2-26
Linear signal distortions, 2-1

M
MD10604, 2-48
MD10618, 2-48
MD18190, 2-35
MD20150, 2-32
MD21020, 2-30
MD28200, 2-35
MD28210, 2-44
MD28212, 2-44
MD30240, 2-19
MD30310, 2-28, 2-32
MD31030, 3-1
MD31050, 3-1

Index-1

Index
MD31060, 3-1
MD31070, 3-1
MD31080, 3-1
MD32000, 2-2
MD32200, 2-2
MD32200, 2-5
MD32250, 3-1
MD32260, 3-1
MD32300, 2-2
MD32610, 2-2
MD32800, 2-2
MD32810, 2-2, 3-1
MD36000, 2-7
MD36010, 2-5, 2-7
MD36012, 2-7
MD36020, 2-5
MD36030, 2-6, 2-7
MD36040, 2-6
MD36050, 2-7, 2-14
MD36052, 2-8, 2-10, 2-11, 2-13
MD36100, 2-28
MD36110, 2-28
MD36120, 2-28
MD36130, 2-28
MD36200, 2-16
MD36210, 2-15
MD36220, 2-15
MD36300, 2-17
MD36302, 2-19
MD36310, 2-19, 2-20, 2-21
MD36400, 2-2
MD36600, 2-27
MD36610, 2-3, 2-6, 2-7, 2-8, 2-16, 2-17, 2-18, 2-20,
2-22, 2-25
Monitoring of static limits, 2-26

O
Orientation, 2-34

P
Protection zone
Activate, 2-43
Deactivation, 2-43
Definition, 2-37, 2-41
Enable, 2-47
Restrictions, 2-53
Protection zones, 1-2, 2-33
Channelspecific machine data, 5-2
data storage, 2-42
General machine data, 5-1
Protection-zone definition
Example, 4-1
Protection-zone definition with system variables, 2-41
Protection-zone violation, 2-47

S
SD43400, 2-31
SD43410, 2-31
SD43420, 2-30
SD43430, 2-30
Servo gain factor, 2-1
Signal distortions, 2-1
Software limit switch, 2-28
Spindle speed
Control, 2-18

W
Working-area limitation, 2-30

Nonlinear signal distortions, 2-2

Index-2

Axis monitoring, protection zones (A3)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

SINUMERIK 840D sl/840Di sl/840D/840Di/810D Continuouspath Mode, Exact Stop, LookAhead (B1)

1
Brief Description
______________
2
Detailed description
______________

SINUMERIK
840D sl/840Di sl/840D/840Di/810D
Continuouspath Mode, Exact Stop,
LookAhead (B1)
Function Manual

Valid for

Control

SINUMERIK 840D sl/840DE sl

SINUMERIK 840Di sl/840DiE sl
SINUMERIK 840D powerline/840DE powerline
SINUMERIK 840Di powerline/840DiE powerline
SINUMERIK 810D powerline/810DE powerline

Software

NCU System Software for 840D sl/840DE sl

NCU system software for 840D sl/DiE sl
NCU system software for 840D/840DE
NCU system software for 840Di/840DiE
NCU system software for 810D/810DE

03/2006 Edition
6FC5397-0BP10-1BA0

Version
1.3
1.0
7.4
3.3
7.4

3
Supplementary conditions
______________
4
Examples
______________
5
Data lists
______________

Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
Danger
indicates that death or severe personal injury will result if proper precautions are not taken.
Warning
indicates that death or severe personal injury may result if proper precautions are not taken.
Caution
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
Notice
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.

Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage
Note the following:
Warning
This device may only be used for the applications described in the catalog or the technical description and only in
connection with devices or components from other manufacturers which have been approved or recommended by
Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly
as well as careful operation and maintenance.

Trademarks
All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.

Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG
Automation and Drives
Postfach 48 48
90437 NRNBERG
GERMANY

Order No.: 6FC5397-0BP10-1BA0

Edition 05/2006

Copyright Siemens AG 2006.

Technical data subject to change

Table of contents
1

Brief Description ..................................................................................................................................... 1-1

Detailed description ................................................................................................................................ 2-1

2.1
2.1.1
2.1.2
2.1.3

General ...................................................................................................................................... 2-1

Parameterization of the reset response..................................................................................... 2-1
Block change and positioning axes ........................................................................................... 2-1
Block change delay.................................................................................................................... 2-1

2.2

Exact stop .................................................................................................................................. 2-2

2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7

Continuous-path mode............................................................................................................... 2-6

General ...................................................................................................................................... 2-6
Velocity reduction according to overload factor ......................................................................... 2-9
Rounding according to path criterion ....................................................................................... 2-11
Rounding with maximum possible dynamic response on each axis........................................ 2-19
Smoothing the path velocity..................................................................................................... 2-21
Dynamic response adaptation ................................................................................................. 2-25
Technology G group ................................................................................................................ 2-34

2.4

LookAhead ............................................................................................................................... 2-37

2.5

NC block compressor COMPON, COMPCURV, -CAD ........................................................... 2-43

Supplementary conditions ...................................................................................................................... 3-1

3.1

Rounding and repositioning (REPOS) ....................................................................................... 3-1

3.2

Smoothing the path velocity....................................................................................................... 3-2

Examples................................................................................................................................................ 4-1
4.1

Example of jerk limitation on the path........................................................................................ 4-1

Data lists................................................................................................................................................. 5-1

5.1
5.1.1
5.1.2
5.1.3

Machine data.............................................................................................................................. 5-1

General machine data................................................................................................................ 5-1
Channelspecific machine data ................................................................................................... 5-1
Axis/spindlespecific machine data ............................................................................................. 5-2

5.2
5.2.1

Setting data ................................................................................................................................ 5-3

Channelspecific setting data ...................................................................................................... 5-3

5.3
5.3.1
5.3.2

Signals ....................................................................................................................................... 5-3

Signals from channel ................................................................................................................. 5-3
Signals to axis/spindle ............................................................................................................... 5-3

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

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

iii

Table of contents

iv

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Brief Description

Continuous-path mode
In continuous-path mode, the NC attempts to keep the programmed path velocity as
constant as possible. In particular, deceleration of the path axes at the block limits of the part
program is to be avoided.

Exact stop mode

In exact stop traversing mode, all axes involved in the traversing motion (except axes of
modal traversing modes) are decelerated at the end of each block until they come to a
standstill. The transition to the next block occurs only when all axes involved in the traversing
motion have reached their programmed target position in accordance with the selected exact
stop criterion.
Exact stop
Exact stop is a state of a machine axis that refers to the position difference relative to its
setpoint position at the end of the traversing motion. The machine axis reaches the "exact
stop" state as soon as its following error is less than the specified position difference (exact
stop limit).

Look ahead
"Look ahead" is a function for optimizing continuous path mode.
Smooth machining of workpieces is necessary to ensure a high-quality surface finish. For
this reason, path velocity variations should be avoided during machining whenever possible.
Without "Look Ahead", the NC only takes into consideration the block immediately following
the current block to determine the possible path velocity. If the following block contains only
a short path, the NC must reduce the path velocity (decelerate in the current block) to be
able to stop in time at the end of the next block, if necessary.
When the NC "looks ahead" over an parameterizable number of blocks following the current
block, a much higher path velocity can be attained under certain circumstances because the
NC now has more blocks and more path available for calculation.
This results in the following advantages:
Machining with higher path velocities on average
Improved surface quality by avoiding deceleration and acceleration processes

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

1-1

Brief Description

Smoothing the path velocity

"Smoothing the path velocity" is a function especially for applications (such as high speed
milling in mold and die production) that require an extremely steady path velocity.
Deceleration and acceleration processes that would cause high-frequency excitations of
machine resonances are avoided with the "Smoothing the path velocity" function.
This results in the following advantages:
Improved surface quality and machining time by avoiding excitation of machine
resonances.
Constant profile of path velocity and cutting rates by avoiding "unnecessary" acceleration
processes, i.e., acceleration processes that do not greatly improve the program run time.

Dynamic response adaptation

In addition to the "Smoothing the path velocity" function, "Dynamic response adaptation" is
another function for avoiding high-frequency excitations of machine resonances while
optimizing the dynamic path response. To this end, highly frequent changes in path velocity
are automatically executed with lower jerk or acceleration values than the dynamic response
limit value parameters assigned in the machine data.
Thus, with low-frequency changes in path velocity, the full dynamic response limit values
apply, whereas with high-frequency changes, only the reduced dynamic response limit
values act due to the automatic dynamic response adaptation.

NC block compressor
When a workpiece design is completed with a CAD/CAM system, the CAD/CAM system
generally also compiles the corresponding part program to create the workpiece surface. To
do so, most CAD/CAM systems use linear blocks to describe even curved sections of the
workpiece surface. Many interpolation points are generally necessary to maintain the
required contour accuracy. This results in many linear blocks, typically with very short paths.
The "NC block compressor" function uses polynomial blocks to perform a subsequent
approximation of the contour specified by the linear blocks. During this process, an
assignable number of linear blocks is replaced by a polynomial block. Furthermore, the
number of linear blocks that can be replaced by a polynomial block also depends on the
specified maximum permissible contour deviation and the contour profile.
Use of polynomial blocks provides the following advantages:
Fewer part program blocks to describe the workpiece contour
Higher maximum path velocities

1-2

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1

2.1.1

2.1

General

Parameterization of the reset response

The channel-specific basic position is activated via a reset:
MD20150 $MC_GCODE_RESET_VALUES (RESET position of G groups)
The initial setting can be specified for exact stop and continuous path modes and exact stop
criterion.
Detailed information on basic settings can be found in:
References:
/FB1/Function Manual, Basic Functions; Mode Group, Channel, Program Operation, Reset
Response (K1)

2.1.2

Block change and positioning axes

If path axes are traversed in continuous path mode in a part program, traversing positioning
axes can also simultaneously affect both the response of the path axes and the block
change. For a detailed description of positioning axes, refer to:
References:
/FB2/ Function Manual, Extended Functions; Positioning Axes (P2)

2.1.3

Block change delay

Even if all path axes and special axes traversing in the part program block have satisfied
their specific block transition criteria, the block change can still be delayed due to other
unsatisfied conditions and/or active functions:
Missing auxiliary function acknowledgement by the PLC
Non-existent following blocks
Active function: "Empty buffer"

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-1

Detailed description
2.2 Exact stop

Effects
If a block change cannot be executed in continuous path mode, all axes programmed in this
part program block (except cross-block traversing special axes) are stopped. In this case,
contour errors do not occur. The stopping of the path axes during machining can cause
undercuts on the workpiece surface.

2.2

2.2

Exact stop

Exact stop or exact stop mode

In contrast to continuous path mode, in exact stop or exact stop mode, all path axes and
non-modal special axes involved in the traversing motion are decelerated until they reach a
standstill at the end of each block. The transition to the next block occurs only when all axes
involved in the traversing motion have reached their programmed target position with subject
to the selected exact stop criterion.
This results in the following response:
All path axes and non-modal special axes involved in the traversing motion are
decelerated at the end of the block until they reach a standstill.
By decelerating the axes and via the waiting period until the state is reached: "exact stop"
for all the machine axes involved, the program run time becomes considerably longer
compared to the continuous-path mode.
In exact stop mode, undercuts can occur on the workpiece surface during machining.

Use
Exact stop mode should always be used when the programmed contour must be executed
exactly.

Activation of exact stop mode

Exact stop mode is activated in the part program by programming the following G-functions:
G60 - Exact stop on, modal
G09 - Exact stop on, non-modal

Exact stop criteria: "Exact stop coarse" and "Exact stop fine"
The two exact stop criteria "Exact stop coarse" and "Exact stop fine" are used to specify the
applicable tolerance window for reaching the state: "exact stop" of a machine axis.
Machine axis state
The state of a machine axis that refers to the position difference relative its setpoint position
at the end of a traversing motion is also designated as an exact stop. The machine axis
reaches the "exact stop" state as soon as its following error is less than the specified position
difference (exact stop criterion).

2-2

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.2 Exact stop

Parameterization
The tolerance windows of the exact stop criteria are specified with the following machine
data:
MD36010 STOP_LIMIT_FINE (exact stop fine)
MD36000 STOP_LIMIT_COARSE (exact stop coarse)

Note
Tolerance window
The tolerance windows of the exact stop criteria "Exact stop coarse" and "Exact stop fine"
should be assigned such that the following applies: "Exact stop coarse" > "Exact stop
fine"

([DFWVWRSILQH

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QBQHJDWLYH

Figure 2-1

6(7326,7,21

([DFWBVWRSBF
RDUVH

$[LVBGLUHFWLRQBS
RVLWLYH
$&78$/326,7,21

Tolerance windows of exact stop criteria

Exact stop criterion: "Interpolator end"

With exact stop criterion "Interpolator end", the block change to the next block takes place as
soon as all path axes and non-modal special axes involved in the traversing motion have
reached the position programmed in the block in terms of the setpoint value. That is, the
interpolator has executed the block.
The actual position or the following error of the machine axes involved, for exact stop criteria,
are: "Interpolator end" not considered. Depending on the dynamics of the machine axes, this
can lead to greater smoothing of the contour at the block transitions in comparison to the
exact stop criteria: "exact stop coarse" and "exact stop fine."

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-3

Detailed description
2.2 Exact stop

Block change depending on exact-stop criteria

The figure below illustrates the block change timing in terms of the selected exact stop
criterion.

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%ORFNFKDQJH
$FWXDO
YDOXH

ZLWK*
ZLWK*
ZLWK*

6HWSRLQW

Figure 2-2

Block change accordance to selected exact stop criterion

Activation of an exact stop criterion

An exact stop criterion is activated in the part program by programming the following Gfunctions:
G601 - Exact stop fine
G602 - Exact stop coarse
G603 - Interpolator end

Evaluation factor for exact stop criteria

A parameter set-dependent evaluation of the exact stop criteria can be specified via the
following axis-specific machine data:
MD36012 $MA_STOP_LIMIT_FACTOR (exact stop coarse/fine and standstill factor)
Applications
Adaptation of the positioning response to different mass ratios, such as after a gearshift
Reduction in positioning time, depending on various machining states, such as roughing
and finishing

2-4

Continuouspath Mode, Exact Stop, LookAhead (B1)

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Detailed description
2.2 Exact stop

Assignable specification of the active exact stop criterion

The active exact stop criterion can be permanently specified for the part program commands
of the first G-group irrespective of the exact stop criterion programmed in the part program.
This specification can be made independently for each of the following part program
commands:
Rapid traverse: G0
Machining commands: G1, G2, G3, CIP, ASPLINE, BSPLINE, CSPLINE,
POLY, G33, G34, G35, G331, G332, OEMIPO01, OEMIPO02, CT
The setting is done in a channel-specific manner via the following machine data:
MD20550 $MC_EXACT_POS_MODE (exact stop conditions for G00 and G01)
Coding
Each exact stop criterion is location-coded:
Ones position E: Rapid traverse
Tens position Z: all other part program commands in the first G-group
MD20550 $MC_EXACT_POS_MODE = < ZE >
Z or E

Active exact stop criterion

Programmed exact stop criterion

G601 (Exact stop window fine)

G602 (Exact stop window coarse)

G603 (Interpolator end)

Example
MD20550 $MC_EXACT_POS_MODE = 02
Ones position = 2:
With rapid traverse, exact stop criterion G602 (exact stop window coarse) is always active,
irrespective of any programming in the part program.
Tens digit = 0:
For traversing with all other part program commands of the first G-group, the exact stop
criterion programmed in the part program is active.

Continuouspath Mode, Exact Stop, LookAhead (B1)

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2-5

Detailed description
2.3 Continuous-path mode

Assignable exact stop criterion for rapid traverse transitions in continuous path mode
The behavior at the block transition of part program blocks before and after rapid traverse
blocks can be parameterized via the following channel-specific machine data:
MD20552 $MC_EXACT_POS_MODE_G0_TO_G1 = < value > (exact stop condition for G00G01 transition)

2.3

2.3.1

2.3

Value

Meaning

No additional stop at the block change

Stop at block change: response, as appropriate Behavior according to G601 (Exact stop
window fine)

Stop at block transition: Same behavior as G602 (positioning window coarse).

Stop at block transition: Same behavior as G603 (interpolator end).

Like 0; in addition, the override of the next non-G00 block is taken into account with Look
ahead in the G00 block during the transition from G00 to non-G00.

Like 0; in addition, the override of the next block is taken into account with Look ahead
during the transition from G00 to non-G00 and non-G00 to G00.

Continuous-path mode

General

Continuous-path mode
In continuouspath mode, the path velocity is not decelerated for the block change in order to
permit the fulfillment of an exact-stop criterion.
The objective of this mode is to avoid rapid deceleration of the path axes at the block-change
point so that the axis velocity remains as constant as possible when the program moves to
the next block.
To achieve this objective, the "LookAhead" function is also activated when continuouspath
mode is selected.
Continuouspath mode causes the smoothing and tangential shaping of angular block
transitions by local changes in the programmed contour. The extent of the change relative to
the programmed contour can be limited by specifying the overload factor or rounding criteria.
Continuouspath operation causes:
Contour rounding
Shorter machining times through elimination of braking and acceleration processes that
are required to comply with the exact-stop criterion
Improved cutting conditions because of the more constant velocity

2-6

Continuouspath Mode, Exact Stop, LookAhead (B1)

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Detailed description
2.3 Continuous-path mode
Continuouspath mode is suitable if:
A contour must be traversed as quickly as possible (e.g., with rapid traverse).
The exact contour may deviate from the programmed contour within a specific tolerance
for the purpose of obtaining a continuous contour.
Continuous-path mode is suitable if:
A contour is to be traversed precisely.
An absolutely constant velocity is required.

Implicit exact stop

In some cases, an exact stop needs to be generated in continuouspath mode to allow the
execution of subsequent actions. In such situations, the path velocity is reduced to zero.
If auxiliary functions are output before the traverse motion, the previous block is only
terminated when the selected exact-stop criterion is fulfilled.
If auxiliary functions are to be output after the traverse motion, they are output after the
interpolator end of the block.
If an executable block (e.g., starting a positioning axis) contains no travel information for
the path axes, the previous block is terminated on reaching the selected exact-stop
criterion.
If a positioning axis is declared to be the geometry axis, the previous block is terminated
at the interpolator end when the geometry axis is programmed.
If a synchronized axis is programmed that was last programmed as a positioning axis or
spindle (initial setting of the special axis is positioning axis), the previous block is ended
at the interpolator end.
If the transformation is changed, the block previously processed is terminated with the
active exact-stop criterion.
A block is terminated on interpolator end if the following block contains the switchover of
the acceleration profile BRISK/SOFT.
Additional information on BRISK and SOFT:
References:
/FB1/ Function Manual, Basic Function; Acceleration (B2)
If the "empty buffer" function is programmed, the previous block is terminated when the
selected exact-stop criterion is reached.

Velocity = 0 in continuouspath mode

Regardless of the implicit exact-stop response, the path motion is braked down to zero
velocity at the end of the block in cases where:
Positioning axes have been programmed with syntax POS and have a travel time that
exceeds that of the path axes. Block change occurs when the "exact stop fine" of the
positioning axes is reached.
The time taken to position a spindle programmed with syntax SPOS is longer than the
travel time of the path axes. The block change is carried out when the "exact stop fine" of
the positioning spindle is reached.

Continuouspath Mode, Exact Stop, LookAhead (B1)

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2-7

Detailed description
2.3 Continuous-path mode
The current block contains traversing commands for geometry axes and the following
block traversing commands for synchronized axes or, alternatively, the current block
contains traversing commands for synchronized axes and the subsequent block
traversing commands for geometry axes.
Synchronization is required

Auxiliary function output during traversal

In continuous-path mode with auxiliary-function output during motion and short traversing
blocks, the path velocity is decelerated prior to PLC acknowledgment of the auxiliary
functions.
The axes are decelerated to standstill respecting the acceleration limits at the end of the
block. At the end of the block acknowledgment is awaited before motion can continue.
Acknowledgment during deceleration
Acknowledgment during deceleration accelerates the velocity back to the programmed path
velocity.
In order to prevent this happening in continuous-path mode, the following machine data can
be used to set a time for the CNC during which the PLC will safely acknowledge the auxiliary
functions for the CNC:
MD10110 PLC_CYCLE_TIME_AVERAGE (average PLC acknowledgement time)
Acknowledgment outside of travel time
The path velocity for the block ahead is reduced to the point that the block duration
corresponds to the specified time if the traversing time is less than the time specified in the
machine data MD10110 based on the programmed path length and velocity of the block with
auxiliary function output.
If acknowledgment is not received within the time, the following prepared block cannot be
processed and the axes are braked to standstill with setpoint = 0 without considering the
acceleration limits.
Acknowledgment not received by end of block
If the acknowledgment is not received by the end of the block in long blocks in which the
velocity has not needed to be reduced on account of the PLC acknowledgment time, the
velocity is maintained until the end of the block and then reduced as described above.
Acknowledgment during braking
If the acknowledgment arrives while the axis is decelerating, the axis is not accelerated back
up to the requested velocity.

MD10110
The machine data is not evaluated:
MD10110 PLC_CYCLE_TIME_AVERAGE (average PLC acknowledgement time)

2-8

Continuouspath Mode, Exact Stop, LookAhead (B1)

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Detailed description
2.3 Continuous-path mode

2.3.2

Velocity reduction according to overload factor

Velocity reduction according to overload factor

The function lowers the path velocity in continuouspath mode until the nontangential block
transition can be traversed in one interpolation cycle while respecting the deceleration limit
and taking and overload factor into account.
With the reduced velocity, axial jumps in velocity are produced with a nontangential contour
at the block transition. These jumps in velocity are also performed by the coupled motion
synchronized axes. The jump in velocity prevents the path velocity dropping to zero.
This jump is performed if the axial velocity was reduced with the axial acceleration to a
velocity from which the new setpoint can be reached with the jump. The magnitude of the
setpoint jump can be limited using an overload factor. Because the magnitude of the jump is
axial, the minimum jump of the path axes which are active during the block change is
considered during block transition. With a practically tangential block transition, the path
velocity is not reduced if the permissible axial accelerations are not exceeded. In this way,
very small angular changes in the contour can be overtraveled directly.

Overload factor
The overload factor restricts step changes in the machine axis velocity at block ends. So that
the velocity jump does not exceed the maximum load on the axis, the jump is derived from
the acceleration of the axis.
The overload factor indicates the extent by which the acceleration of the machine axis, which
is set in machine data, may be exceeded for an IPO cycle:
MD32300 MAX_AX_ACCEL (axis acceleration).
The velocity jump is the product of the axial acceleration * (overload factor -1) * interpolator
cycle.
The factor is stored in the machine data:
MD32210 MAX_ACCEL_OVL_FACTOR (overload factor for axial jumps in velocity).
Factor 1.0 means that only tangential transitions with finite velocity can be traversed. For all
other transitions, the velocity is reduced to zero by changing the setpoint. This behavior is
equivalent to the function "Exact stop with interpolator end". This is undesirable for
continuouspath mode, so the factor must be set to greater than 1.0.
For startup and installation, please note that the factor must be reduced if the machine is
likely to be subject to vibrations during angular block transitions and rounding is not to be
used.
The block transitions are always rounded irrespective of the set overload factor by setting the
machine data:
MD20490 IGNORE_OVL_FACTOR_FOR_ADIS (G641/G642 irrespective of the overload
factor).

Continuouspath Mode, Exact Stop, LookAhead (B1)

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2-9

Detailed description
2.3 Continuous-path mode

Selection and deselection of velocity reduction

Continuouspath mode with velocity reduction according to overload factor can be selected
modally in every NC part program block by means of program code G64.
Continuouspath mode G64 can be
Interrupted non-modally by selecting exact stop G09
Deselected by selecting exact stop G60
Deselected by selecting rounding G641

Implicit continuouspath mode

If it is not possible to insert approximate positioning blocks due to the very short block path
lengths (e.g., zeroclocked blocks) in continuouspath mode with rounding G641, the mode is
switched over to continuouspath mode G64.
The figure below shows how the function velocity drops according to an overload factor.

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Figure 2-3

2-10

Axial velocity change on block transition

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.3 Continuous-path mode

2.3.3

Rounding according to path criterion

Blending
Rounding means that an angular block transition is changed to a tangential block transition
by a local change to the programmed feedrate.
Rounding replaces the area in the vicinity of the original angular block transition (including
transitions between blocks inserted by the CNC) by a continuous contour. In this case, it is
not only the geometry axes that are taken into account, but all machine axes, which are
traversing synchronously. The rounding function therefore smoothes the traversing path of
orientation axes as well as general velocity step changes in synchronized axes.

Note
Rounding cannot and should not replace the functions for defined smoothing: RND, RNDM,
ASPLINE, BSPLINE, CSPLINE.
If a rounding movement initiated by G641, G642, G643, G644 is interrupted, the corner point
of the original contour will be used for subsequent repositioning, rather than the interruption
point.

Rounding is initiated by shortening discontinuously adjoining blocks and inserting one or two
intermediate blocks at this point. The original block boundary is removed and can no longer
be used for synchronization conditions (e.g., auxiliary function output parallel to motion, stop
at end of block).
With rounding, all synchronization conditions are best referred to the end of the shortened
first block and not to the end of the intermediate rounding block. The following block is thus
not started and with a stop at end of block, the contour of the following block can still be
changed.
Rounding is only performed if the block transition is to be traveled with finite velocity. The
maximum path speed is influenced by the curvature. The maximum acceleration values of
the axes are not exceeded. A block without traverse information for the path axes requires
velocity "zero" and therefore no rounding.
Rounding is also used if the traversal of the block transition requires a velocity that lies below
the permissible velocity at the end of the block according to G64 (see overload factor). This
means that very small knees in the contour (e.g., 0.5 degrees) can be overtraveled directly.

Continuouspath Mode, Exact Stop, LookAhead (B1)

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2-11

Detailed description
2.3 Continuous-path mode

No intermediate rounding blocks

An intermediate rounding block is not inserted in the following situations:
1

The axis stops between the two blocks. This occurs when ...
1

The auxiliary function output is programmed before the movement in the following block.

The following block does not contain a path movement.

An axis, which was previously a positioning axis traverses as a path axis for the first time
in the following block.

An axis, which was previously a path axis traverses as a positioning axis for the first time
in the following block.

The previous block moves geometry axes and the following block does not.

The following block moves geometry axes and the previous block does not.

Prior to thread cutting: The following block uses G33 as a preparatory function and the
previous block does not.

A change is made between BRISK and SOFT.

Axes involved in the transformation are not completely assigned to the path motion (e.g.,
for oscillation, positioning axes)

The rounding block would slow down part program execution. This occurs when ...
1

A rounding block is inserted between very short blocks. Since each block requires at
least one interpolation cycle, the added intermediate block would double the machining
time.

A block transition G64 (continuous-path mode without rounding) can be traversed

without speed reduction. Rounding would increase the machining time.

2-12

Rounding is not parameterized. This occurs when ...

1

ADISPOS == 0 in G0 blocks. (default!)

ADIS == 0 in non-G0 blocks. (default!)

On transition from G0 to non-G0 or non-G0 to G0 respectively, the smaller value from

ADISPOS and ADIS applies.

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.3 Continuous-path mode

Synchronized axes
If a number of paths need to be synchronized (e.g., contour, special axis), then every path
must always have its own rounding area.
There are no practical means of achieving this exactly. Therefore, on the basis of the specific
meaning of the contour (geometry axis), the following procedure is applied:
Rounding behavior with synchronized paths
Original path for

Result for

Geometry axes

Orientation axis/
synchronized axis

rounding path

Smooth

Smooth

Defined path is traversed exactly

Smooth

Angular path

Intermediate blocks,the geometry axes follow the

path exactly, all orientation/synchronized axis paths
are smoothed

Angular path

Smooth

Intermediate block,the geometry axes perform

rounding, all orientation/synchronized axis paths are
smoothed

Angular path

Angular path

intermediate block,the geometry axes perform

rounding, all orientation/synchronized axis paths are
smoothed

Path criterion
The size of the rounding area can be controlled by path criteria ADIS and ADISPOS. These
are the precoincidences for the block change. ADIS and ADISPOS describe the distance,
which the rounding block may begin, at the earliest, before the end of the block or the
distance after the end of block within which the rounding block must be terminated.

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Example for rounding an angular block transition

Acute angles produce rounding curves with a large degree of curvature and therefore cause
a corresponding reduction in velocity.

Continuouspath Mode, Exact Stop, LookAhead (B1)

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2-13

Detailed description
2.3 Continuous-path mode

Parameterization of the path criterion

ADISPOS is programmed in the same way as ADIS, but must be used specifically for
movements in rapid traverse mode (G00).
ADIS and ADISPOS are preset in the part program.
For example, ADIS = 0.3 indicates a path criterion with a rounding distance of 0.3 mm
(ADISPOS is the same).

Scope of the path criterion

ADIS or ADISPOS must be programmed. If the default is "zero", G641 behaves like G64.
If only one of the blocks involved is rapid traverse G00, the smaller rounding distance
applies.
If a very small value is used for ADIS, the control must make sure that every interpolated
block, even an intermediate rounding block, contains at least one interpolation point. The
maximum path velocity is thereby limited to ADIS/interpolation cycle.
Irrespective of ADIS and ADISPOS, the rounding area is limited by the block length.

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Figure 2-5

2-14

YESDWK1

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Path with limitation of ADIS

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.3 Continuous-path mode

Programming example
N1 G641Y50 F10 ADIS = 0.5
N2 X50
N3 X50.7
N4 Y50.7
N5 Y51.4
N6 Y51.0
N7 X52.1

In blocks with short distances (distance < 4*ADIS and < 4 * ADISPOS respectively), the
rounding distance is reduced so that a traversable part of the original block is retained. The
remaining length depends on the axis path and is approximately 60% of the distance still to
be traversed in the block.
ADIS or ADISPOS is therefore reduced to the remaining 40% of the distance to be traversed.
This algorithm prevents a rounding block being inserted for a very small change in contour.
In this case, switchover to continuouspath mode G64 is automatic until rounding blocks can
be inserted again.

Selection and deselection of rounding blocks

Program code G641 can be inserted in any NC part program block to modally select
rounding according to a path criterion. Before or on selection, the path criteria
ADIS/ADISPOS must be specified.
Continuouspath mode G641 can be
Interrupted non-modally by selecting exact stop G09
Deselected by selecting exact stop G60
Deselected by selecting velocity drop G64

Rounding with axial tolerances

In addition to rounding using the command G641, rounding with axial tolerances enabled
modally using G642 is possible.
In this case, instead of rounding being performed within a defined ADIS range, the axial
tolerances defined with the following machine data are used.
MD33100 COMPRESS_POS_TOL (maximum tolerance with compression).
The mode of operation is otherwise identical to G641.
References:
/PG/Programming Manual Fundamentals

Continuouspath Mode, Exact Stop, LookAhead (B1)

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Detailed description
2.3 Continuous-path mode

Extensions
G643 is not used to generate a separate rounding block, but axisspecific blockinternal
rounding movements are inserted.
The expansions described below refine the response with G642 and G643 and "rounding
with contour tolerance" is introduced.
When rounding with G642 and G643, the maximum permissible deviations of each axis are
normally specified.
Rounding with G642 and G643 can be configured with the following machine data such that
instead of the axis-specific tolerances, a contour tolerance and an orientation tolerance can
be specified.
MD20480 SMOOTHING_MODE (rounding behavior with G64x)
In this case, the tolerance of the contour and of the orientation is set using two independent
setting data, which can be programmed in the NC program. This means that different setting
data can be specified for each block transition.

Contour tolerance
A contour tolerance is specified using the setting data:
SD42465 SMOOTH_CONTUR_TOL (maximum contour tolerance when rounding)
This setting data defines the maximum rounding tolerance for the contour.

Orientation tolerance
To specify an orientation tolerance, the setting data:
SD42466 SMOOTH_ORI_TOL (max. tolerance of the tool orientation for rounding)
This setting data defines the maximum rounding tolerance for the tool orientation The data
determines the maximum permissible angular deviation of the orientation of the tool. This
data is only effective if an orientation transformation is active.

2-16

Continuouspath Mode, Exact Stop, LookAhead (B1)

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Detailed description
2.3 Continuous-path mode

Possible combinations
The following table indicates for G642 and G643 the effect of axis tolerances in the following
machine data:
MD33100 COMPRESS_POS_TOL (maximum tolerance with compression).
It also applies to the setting data given above.
MD20480 SMOOTHING_MODE must be loaded with two decimal places as follows:
G642

G643

Setting the value in the tens digit of the

machine data:

(Setting the value in the ones digit of the

machine data:

MD20480 SMOOTHING_MODE (rounding

behavior with G64x)

MD20480 SMOOTHING_MODE (rounding

behavior with G64x)

Axis-specific tolerances are used for G642.

These are set using the axis-specific
machine data: MD33100 (default value).

Axis-specific tolerances are used for G643.

These are set using the axis-specific
machine data: MD33100 (default value).

When rounding geometry axes with G642,

the following contour tolerance is used:

When rounding geometry axes with G643,

the following contour tolerance is used:

SD42465 SMOOTH_CONTUR_TOL
(maximum contour tolerance when
rounding)

SD42465 SMOOTH_CONTUR_TOL
(maximum contour tolerance when
rounding).

The remaining axes are rounded using the

axisspecific tolerances in the machine data:
MD33100.

The remaining axes are rounded using the

axisspecific tolerances in the machine data:
MD33100.

The orientation movement with G642 is

rounded using the angle tolerance:

The orientation movement with G463 is

rounded using the angle tolerance:

SD42466 SMOOTH_ORI_TOL (max.

tolerance of the tool orientation for
rounding).

SD42466 SMOOTH_ORI_TOL (max.

tolerance of the tool orientation for rounding)

Value

All the other axes use the axis-specific

tolerances in the machine data: MD33100.
3

All the other axes use the axis-specific

tolerances in the machine data: MD33100.

Combination of the two options 1x and 2x.

i.e., the following tolerances are used for
G642: SD42465 and SD42466.

Combination of the two options 1x and 2x.

i.e., the following tolerances are used for
G643: SD42465 and SD42466.

Further axes are rounded using the axisspecific tolerance.

Further axes are rounded using the axisspecific tolerance.

The rounding length programmed with

ADIS= or ADISPOS= is used for G642.

The rounding length programmed with

ADIS= or ADISPOS= is used for G643.

Any axis-specific tolerance or contour and

orientation tolerance specifications are
ignored.

Any axis-specific tolerance or contour and

orientation tolerance specifications are
ignored.

Continuouspath Mode, Exact Stop, LookAhead (B1)

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Detailed description
2.3 Continuous-path mode

Differences between G642 - G643

With regard to their rounding behavior, commands G642 ad G643 differ as follows:
G642

G643

With G642, the rounding travel is determined

based on the shortest rounding travel of all axes.
This value is taken into account when generating
a rounding block.

In the case of G643, the rounding travel of each

axis can be different. The rounding travels are
taken into account axisspecifically and blockinternally.

With G642, the rounding area results from the

smallest tolerance setting.

Very different specifications for the contour

tolerance and the tolerance of the tool orientation
can only have effect with G643.

Constraints
Expansion to include contour tolerance and orientation tolerance exists only in systems with
options for polynomial interpolation. The orientation-transformation option is also required for
rounding orientations with angular tolerance specification.
Restriction for protection zones with active radius compensation and tool orientation:
Although tool radius compensation is applied for a tool orientation, which is not perpendicular
to one of the three datum planes of the basic coordinate system, the protection zones are
not rotated onto the corresponding plane.
For G643 the following must apply in the machine data:
MD28530 MM_PATH_VELO_SEGMENTS > 0 (Number of memory elements for limiting the
path velocity)
If this condition is met, the following machine data must apply to all the axes:
MD35240 ACCEL_TYPE_DRIVE = FALSE (acceleration characteristic line DRIVE for axes
ON/OFF)

Expansion
Rounding with G642 and G643 has been extended so that the length of the rounding
distance can be specified directly instead of entering the maximum tolerances.
As with G641, the language commands ADIS = ... for G01 and ADISPOS = ... for G00 are
used respectively for this purpose.
Whether or not G642, G643 are specified with the maximum tolerances or the rounding
length, is set with the machine data:
MD20480 SMOOTHING_MODE (rounding behavior with G64x)
The following applies:

2-18

SMOOTHING_MODE = x4

G643 with ADIS or ADISPOS

SMOOTHING_MODE = 4x

G642 with ADIS or ADISPOS

Continuouspath Mode, Exact Stop, LookAhead (B1)

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Detailed description
2.3 Continuous-path mode

Profile for limit velocity

The use of a velocity profile can be controlled during rounding using the hundreds digit in the
machine data:
MD20480 SMOOTHING_MODE (rounding behavior with G64x)
Hundred's place:
< 100:

A profile of the limit velocity is calculated within the rounding area, based on the
defined maximum values for acceleration and jerk on the participating axes or
path.
This can lead to an increase in the path velocity in the rounding area and
therefore to the acceleration of the participating axes.

100:

A profile of the limit velocity is not calculated for rounding blocks with
G641/G642. A constant velocity limit is specified instead.
This prevents the participating axes being accelerated into the rounding area
during rounding with G641/G642. However, in certain cases, this setting can
cause the rounding blocks to be traversed too slowly, especially in large
rounding areas.

1xx:

No velocity profile for G641

2xx:

No velocity profile for G642

Note
See also:
MD28530 MM_PATH_VELO_SEGMENTS (number of memory elements for limiting the path
velocity)

2.3.4

Rounding with maximum possible dynamic response on each axis

How this type of rounding differs from existing types

Unlike existing rounding types, which are activated with G codes G641, G642 and G643, in
this case, the maximum possible dynamic response on each axis takes priority.

Activation
This type of rounding is activated by G code G644. Further information needs to be
programmed and/or entered in the machine data, depending on the setting.

Note
G644 is not available with an active kinematic transformation. The system switches internally
to G642.

Continuouspath Mode, Exact Stop, LookAhead (B1)

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Detailed description
2.3 Continuous-path mode

Configuration
The rounding is configured with G644 using the following machine data:
MD20480 SMOOTHING_MODE (comparison of the rounding with G64x)
The following options are available (the values should be entered in the thousand's place of
the machine data):
Thousand's place:
0xxx:

When rounding with G644, the maximum deviations of each axis specified with
the following machine data are used:
MD33100 COMPRESS_POS_TOL (maximum tolerance with compression).

1xxx:

Input the maximum rounding path by programming ADIS=... or ADISPOS=...(as

for G641)

2xxx:

Input the maximum possible frequencies of each axis in the rounding area using
the machine data:
MD32440 LOOKAH_FREQUENCY (smoothing frequency for Look Ahead)
The rounding area is defined so that no frequencies in excess of the specified
maximum can occur while the rounding motion is in progress.

3xxx:

Any axis that has a velocity jump at a corner traverses around the corner with the
maximum possible dynamic response (maximum acceleration and maximum
jerk).
SOFT: The jerk is limited.
BRISK: When BRISK is active, only the acceleration is limited to its maximum
value.
With this setting, neither the maximum deviations nor the rounding distance are
checked.
The resulting deviations or rounding distances are determined exclusively by the
dynamic limits of the respective axis and the current path velocity.

While, with 3xxx, the rounding distance results exclusively from the dynamic response data
of the respective axis, in the other cases the distance to the corner at which the rounding
motion begins is checked. In the first two cases, the possible rounding distance is limited to a
maximum value, which results either from the defined maximum deviation or a direct
programming command.
In contrast, in the case of 2xxx, the rounding distance is limited to a minimum value, which
results from the maximum permissible excitation frequency and the current path velocity.

Additional limitation
Any further limitations are also effective in addition to this rounding distance limitation. The
rounding distance cannot exceed half the length of the original participating blocks.
The smoothing of the velocity jump on each axis and thus the shape of the rounding path
depends on whether an interpolation is performed with or without jerk limitation.
Consequently, a different velocity characteristic is produced for each axis, depending on
whether BRISK or SOFT is active.

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2.3 Continuous-path mode

BRISK
With BRISK, no jerk limitation is active; the acceleration of each axis reaches its maximum
value in the entire rounding area.

SOFT
With SOFT, the jerk of each axis is limited to its maximum value within the rounding area.
The rounding motion thus generally consists of 3 phases:
Phase 1
During phase 1, each axis builds up its maximum acceleration. The jerk is constant and
equal to the maximum possible jerk on the respective axis.
Phase 2
During phase 2, the maximum permissible acceleration is applied.
Phase 3
During phase 3, which is the last phase, the acceleration of each axis is reduced back to
zero with the maximum permissible jerk (see figure below).

2.3.5

Smoothing the path velocity

Application
In some applications in mold making, especially in the case of high speed cutting, it is
desirable to achieve a constant path velocity.

Response without smoothing

The velocity control function utilizes the specified axial dynamic response. If the programmed
feedrate cannot be achieved, the path velocity is brought to the parameterized axial limit
values and the limit values of the path (velocity, acceleration, jerk). This can lead to repeated
braking and acceleration on the path.
If a short acceleration takes place during a machining function with high path velocity, and is
thus followed almost immediately by braking, the reduction in the machining time is only
minimal. Acceleration of this kind can, however, have undesirable effects if, for example, it
results in machine resonance.

Solution: Smoothing
In some cases, it can therefore be reasonable to sacrifice transient acceleration processes in
favor of a smoother tool path velocity. The following sections describe the conditions and
possible settings to avoid less effective accelerations/decelerations.

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2.3 Continuous-path mode

Advantages
The following improvements are possible:
Avoidance of excitations of possible machine resonance due to continuous, transient
braking and acceleration processes (in the area of less IPO cycles).
Avoiding of constantly varying cutting rates due to acceleration which brings no significant
shortening of the program running time.

Smoother path movement

If the velocity is controlled smoother and not every acceleration process is carried out, both
advantages can be achieved without any undesired extended machining time.

Decision-making criteria
The control system makes a decision based on:
Smoothing frequency for the tool path velocity (MD)
Tolerable loss in productivity when suppressing accelerations/decelerations (MD).

Setting parameters for path smoothing

The user can define the following parameters to set the path smoothing:
Extending the processing time by means of machine data:
MD20460 LOOKAH_SMOOTH_FACTOR (smoothing factor for Look Ahead)
If the velocity is not accelerated, it will take longer to process this part program (see
example).
Use of the machine data to input the resonance frequencies of the participating axes:
MD32440 LOOKAH_FREQUENCY (smoothing frequency for Look Ahead)
Only accelerations in velocity, which clearly excite machine resonances, should be
removed.
Use of machine data to take into account the programmed feedrate for smoothing:
MD20462 LOOKAH_SMOOTH_WITH_FEED (path smoothing with programmed feedrate)

MD20460
A percentage value corresponding to the permissible extension must be specified in machine
data:
MD20460 LOOKAH_SMOOTH_FACTOR (smoothing factor for Look Ahead)
The percentage value defines how much longer a machining step without accelerations may
be than the corresponding step when performing the accelerations/decelerations.
This would be a "worst-case" value, if all accelerations within the part program, except the
initial approach motion, were smoothed.

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2.3 Continuous-path mode
The actual extension will always be smaller, and may even be 0, if the criterion is not met by
any of the accelerations.
Values between 50 and 100% may also be entered without significantly increasing the
machining time.

MD20462
Whether the programmed feedrate should also be taken into consideration during the
smoothing is determined by the machine data:
MD20462 LOOKAH_SMOOTH_WITH_FEED (path smoothing with programmed feedrate)
If the MD is set to 1 (default), the smoothing factor is observed with particular precision if the
override is set to 100%.

MD32440
The following machine data contains a smoothing frequency for LookAhead:
MD32440 LOOKAH_FREQUENCY (smoothing frequency for Look Ahead)
Acceleration and braking processes running at a frequency higher than parameterized in this
MD are smoothed or reduced in their dynamic response depending on their parameterization
in the machine data:
MD20460 LOOKAH_SMOOTH_FACTOR (smoothing factor for Look Ahead)
MD20465 ADAPT_PATH_DYNAMIC (adaptation of the path dynamics)
The minimum value for all axes involved in the path is always calculated.
If vibration is excited in the mechanical system of this axis and if the corresponding
frequency is known, this MD should be set to a value smaller than this frequency.
The required resonance frequencies, for example, can be calculated using the built-in
measuring functions.
The minimum value for this MD32440 is calculated as fPath on the basis of the axis involved
in the path.
For the smoothing, only those acceleration processes in which the start and end velocity of
this motion are reached within the time below are taken into consideration:
t = t2-t1 = 2/fPath

Note
The smoothing of the path velocity does not lead to contour errors. Variations in axis velocity
due to curvatures in the contour at constant path velocity may continue to occur and are not
reduced at this point.
Variations in path velocity due to the input of a new feedrate are not changed either. This
remains the responsibility of the programmer of the subprogram.

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2.3 Continuous-path mode

Activation
The smoothing of the path velocity is activated with machine data, which is active with
NewConfig:
MD20460 LOOKAH_SMOOTH_FACTOR
With the default value 0, the function is deactivated.

Example
The following parameters are assumed:
MD20460 LOOKAH_SMOOTH_FACTOR = 10% (smoothing factor for Look Ahead)
MD32440 LOOKAH_FREQUENCY[AX1] = 20Hz (smoothing frequency for Look Ahead)
MD32440 LOOKAH_FREQUENCY[AX2] = 20Hz
MD32440 LOOKAH_FREQUENCY[AX3] = 10Hz
The path involves the 3 axes X = AX1, Y = AX2, Z = AX3.
The minimum value of MD32440 for these 3 axes is thus 10 Hz. This means that any
acceleration, which is completed within a period of t2-t1 = 2/10Hz = 200 ms, is examined.
The time t2 is the time after which, following acceleration from velocity v1, the velocity
returns to this velocity v1. The extending of the execution time is also only considered within
this range.
A time t2-t1 in excess of 200 ms or additional program processing time t3-t2 greater than
10% (= MD20460) of t2-t1, produces the following time characteristic:

Y
Y
Y

W

Figure 2-6

W

Characteristic of time-optimum path velocity (without smoothing)

However, a time t2-t1 below 200 ms and additional program processing time t3-t2 no greater
than 10% of t2-t1 produces this time characteristic:

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2.3 Continuous-path mode

Y
Y
Y

W
W

Figure 2-7

2.3.6

W

Characteristic of the smoothed path velocity

Dynamic response adaptation

Key statement
Highly dynamic acceleration and deceleration processes during machining can cause
excitation of mechanical vibrations of machine elements and consequently a reduction of the
surface quality of the workpiece. The function: "Dynamic response adaptation" therefore
provides the option of adapting the dynamic response of acceleration and deceleration
processes to the machine conditions by means of the following parameters:
Adaptation factor of the dynamic path response
Via the adaptation factor of the dynamic path response, temporary changes in the path
velocity are executed with smaller dynamic response limit values. This adaptation factor
can be set for each channel for traversing motions with acceleration without (BRISK) and
with (SOFT) jerk limiting:
Traversing motions with acceleration without jerk limiting:
MD20465 $MC_ADAPT_PATH_DYNAMIC[ 0 ] (adaptation of the dynamic path
response)
The adaptation factor acts on the acceleration.
Traversing motions with acceleration with jerk limiting:
MD20465 $MC_ADAPT_PATH_DYNAMIC[ 1 ]
The adaptation factor acts on the jerk.
Excitation frequency
The dynamic response limiting should only be active during deceleration and acceleration
processes that trigger mechanical vibrations larger than a specific limiting frequency, thus
causing excitation of machine resonances. This excitation frequency, after which the
dynamic response limiting activates, can be axis-specifically specified via the machine
data:
MD32440 $MA_LOOKAH_FREQUENCY (smoothing frequency for Look Ahead)
During the processing, the NC cyclically determines, for all the axes in the path, the
minimum value of their excitation frequencies as the limiting frequency for the adaptation
of the dynamic response.
Continuouspath Mode, Exact Stop, LookAhead (B1)
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Detailed description
2.3 Continuous-path mode

Constraints
The dynamic response adaptation considers only the resulting path and not the deceleration
and acceleration processes of the individual axes involved in the path. For this reason,
critical deceleration and acceleration processes of the axes with respect to the excitation of
mechanical vibrations can occur due to discontinuous contour profiles or kinematic
transformations, even with a constant path velocity profile.

Activation
The dynamic response adaptation is only active during path motions:
Continuous-path mode (G64, G64x)
In continuous-path mode, the optimal effect of the dynamic response adaptation is
attained with an active 100% override. Considerable deviations from this value or
functions that cause the path axes to decelerate (e.g. auxiliary function outputs to the
PLC) greatly reduce the desired action.
Exact stop (G60)
In addition, the dynamic response adaptation is not active under the following boundary
conditions:
Programmed rapid traverse (G0)
Changes in the override value
Stop requests during motion, e.g NC-STOP, NC-RESET
Active function: "Velocity-related path acceleration" (DRIVE)

Activation
The dynamic response adaptation is activated by an adaptation factor greater than 1:
MD20465 $MC_ADAPT_PATH_DYNAMIC > 1 (adaptation of the dynamic path response)
Automatic activation of the "Smoothing the path velocity" function
When the dynamic response adaptation is activated in continuous path mode, the
"Smoothing the path velocity" function is always activated as well. For a parameterized
smoothing factor of 0% (presetting: deactivated), a smoothing factor of 100% is used. For a
smoothing factor other than 0%, the parameterized value is used:
MD20460 $MC_LOOKAH_SMOOTH_FACTOR (smoothing factor for Look Ahead)

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2.3 Continuous-path mode

Adaptations
In order to clarify the adaptation processes sketched below, please note the following basic
principles:
The size of the time window is tadapt = 1 / f.
1. The time needed to change the velocity is less than tadapt:
The acceleration rates are reduced by a factor greater than 1 and less than the value
written in machine data:
MD20465 ADAPT_PATH_DYNAMIC (adaptation of the path dynamics)
The reduction in acceleration rate increases the time taken to change the velocity.
The following cases are different:
The acceleration rate is reduced with a value less than MD20465 so that the process
lasts for tadapt [s]. The permitted reduction does not need to be fully utilized.
The acceleration time is reduced with the value written in MD20465. The process lasts
less than tadapt despite the reduced acceleration. The permitted reduction was fully
utilized.
2. The time needed to change the velocity is greater than tadapt:
No dynamic response adaptation is required.

Example 1: Effect of dynamic response adaptation; acceleration mode: BRISK

Parameter assignment
Machine data
$MC_ADAPT_PATH_DYNAMIC[0] = 1.5
$MC_LOOKAH_SMOOTH_FACTOR = 1.0

See note

$MA_LOOKAH_FREQUENCY[AX1] = 20 Hz

TAX1 = 1/20 Hz = 50 ms

$MA_LOOKAH_FREQUENCY[AX2] = 10 Hz

TAX2 = 1/10 Hz = 100 ms

$MA_LOOKAH_FREQUENCY[AX3] = 20 Hz

TAX3 = 1/20 Hz = 50 ms

Note
A smoothing factor other than 0% prevents the default value of 100% from being used to
smooth the path velocity. To illustrate this effect, in contrast to Example 2 the smoothing of
the path velocity is practically deactivated.
AX2
For path motions in which axis AX2 is involved, all deceleration and acceleration processes
that would last less than TAX2 are adapted.
AX1, AX3
If only axes AX1 and/or AX3 are involved in path motions, all deceleration and acceleration
processes that would last less than TAX1 = TAX3 are adapted. This time is designated tadaptxy in
the following diagrams:

Continuouspath Mode, Exact Stop, LookAhead (B1)

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Detailed description
2.3 Continuous-path mode

%
WDGDSW

WDGDSW

Y
WDGDSW

W

WDGDSW

W

Figure 2-8

W

W

W

W

W

W

Path velocity profile optimized for time without smoothing or dynamic adaptation
response

Y
%
WDGDSW

Y

WDGDSW

WDGDSW

W

Figure 2-9

W

W

W

W

W

W

W

Path velocity profile with adaptation of dynamic response

Interval: t0 - t1 and t2 - t3
The acceleration process between t0 - t1 and the deceleration process between t2 - t3
are lengthened in time due to an adaptation of the acceleration to time tadapt01 or tadapt23.
Interval: t4 - t5
The acceleration process between t4 - t5 is executed with an acceleration reduced by the
maximum adaptation factor of 1.5. However, the acceleration process is completed
before time tadapt45.
Interval: t6 - t7
The deceleration process between t6 - t7 remains unchanged, as it lasts longer than
tadapt67.

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Detailed description
2.3 Continuous-path mode

Example 2: Effect of smoothing the path velocity and dynamic response adaptation: acceleration
mode: BRISK
Parameter assignment
Machine data
$MC_ADAPT_PATH_DYNAMIC[0] = 3
$MC_LOOKAH_SMOOTH_FACTOR = 80%
$MA_LOOKAH_FREQUENCY[AX1] = 20 Hz

TAX1 = 1/20 Hz = 50 ms

$MA_LOOKAH_FREQUENCY[AX2] = 20 Hz

TAX2 = 1/20 Hz = 50 ms

$MA_LOOKAH_FREQUENCY[AX3] = 20 Hz

TAX3 = 1/20 Hz = 50 ms

Y
Y

Figure 2-10

W

W

W

W

W

Path velocity profile optimized for time without smoothing or dynamic adaptation
response

Y
%

Y

W

Figure 2-11

W

W

W

W

Path velocity profile with path smoothing and adaptation of dynamic response

Continuouspath Mode, Exact Stop, LookAhead (B1)

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Detailed description
2.3 Continuous-path mode
Effects of path smoothing
Interval: t1 - t2
The acceleration and deceleration process between t1 - t2 does not take place because
the lengthening of the machining time without the acceleration process to v12 is less than
the resulting time if a smoothing factor of 80% is applied.
Interval: t3 - t5
The acceleration and braking profile between t3 and t5 does not fulfill this condition or
takes longer the parameterized smoothing time: TAXn = 2/20 Hz = 100 ms.
Effects of the dynamic response adaptation
Interval: t3 - t4
The acceleration process between t3 - t4 is shorter than MIN(TAXn) =1/20 Hz = 50 ms and
is therefore executed with an acceleration reduced by an adaptation factor of 3.
Interval: up to t1
The acceleration up to t1 left over after path smoothing is stretched to the time period up
to t1' by the dynamic response adaptation.
Conclusion
This example shows the interaction of path smoothing and dynamic response adaptation in
continuous-path mode. Only those acceleration or deceleration processes that were not
eliminated by the path smoothing are subsequently optimized by the dynamic response
adaptation. For this reason, both functions should always be activated, if possible.

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Detailed description
2.3 Continuous-path mode

Example 3: Effect of adaptation and smoothing the path velocity; acceleration mode: BRISK
Parameter assignment
$MC_ADAPT_PATH_DYNAMIC[1] = 4
$MC_LOOKAH_SMOOTH_FACTOR = 100%
$MA_LOOKAH_FREQUENCY[AX1] = 10 Hz

TAX1 = 1/10 Hz = 100 ms

$MA_LOOKAH_FREQUENCY[AX2] = 10 Hz

TAX2 = 1/10 Hz = 100 ms

$MA_LOOKAH_FREQUENCY[AX3] = 20 Hz

TAX3 = 1/20 Hz = 50 ms

Without path dynamic response adaptation or path smoothing

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The path-velocity characteristic has been obtained through deselection of path dynamic
response adaptation and path smoothing.
This corresponds to the following parameter settings:
$MC_ADAPT_PATH_DYNAMIC[1] = 1
$MC_LOOKAH_SMOOTH_FACTOR = 0%

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2.3 Continuous-path mode

With path dynamic response adaptation, without path smoothing

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The path-velocity characteristic has been obtained through selection of path dynamic
response adaptation with minimum, and thus virtually inactive, path smoothing.
The following parameter settings were made:
$MC_ADAPT_PATH_DYNAMIC[1] = 4
$MC_LOOKAH_SMOOTH_FACTOR = 1%

With path dynamic response adaptation and path smoothing

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The path-velocity characteristic has been obtained through selection of path dynamic
response adaptation and path smoothing.
The standard path rounding parameter settings for deselected path smoothing and active
path dynamic response adaptation were selected:

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2.3 Continuous-path mode

$MC_ADAPT_PATH_DYNAMIC[1] = 4
$MC_LOOKAH_SMOOTH_FACTOR = 0%
(same meaning as $MC_LOOKAH_SMOOTH_FACTOR = 100%)

Installation and startup

The basic prerequisites for starting up the path dynamic response adaptation function are as
follows:
Determination of the natural frequency of the path axes for parameter assignment of
dynamic response adaptation:
MD32440 $MA_LOOKAH_FREQUENCY (smoothing frequency for Look Ahead)
Determination of the dynamic response limiting values: Velocity, acceleration, and jerk
Determination of the dynamic response limiting values
The determination of the dynamic response limiting values for the traversing of path axes by
means of acceleration with jerk limiting (SOFT) is described below. This procedure can be
transferred analogously to the case of acceleration without jerk limiting (BRISK).
1. Deactivate the dynamic response adaptation:
MD20465 $MC_ADAPT_PATH_DYNAMIC[1] = 1 (adaptation of the path dynamic
response)
2. Observe the positioning behavior of each path axis at different traversing velocities.
When doing so, set the jerk such that the desired positioning tolerance is maintained.
Note
The higher the traversing velocity from which the positioning process is started, the
higher in general the jerk can be set.
3. Use the maximum permissible jerk determined for the least critical traversing velocity:
MD32431 $MA_MAX_AX_JERK (maximum jerk)
4. Determine the FAPD factor for all of the path axes using:
FAPD = (largest determined jerk) / (smallest determined jerk)
Note
The smallest determined jerk is the value for the jerk during the most critical traversing
velocity.
5. Enter the largest FAPD factor that was determined via all the path axes as the value for the
dynamic response adaptation:
MD20465 $MC_ADAPT_PATH_DYNAMIC[ 1 ] = FAPD

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2.3 Continuous-path mode

2.3.7

Technology G group

Dynamic response settings for technology G groups

Different settings can be stored and programmed for five different machining sections, e.g.
tapping, roughing, smoothing, and smooth-finishing. So, for example, roughing can be
performed optimized for time and smoothing, optimized for surface.
With machine data:
MD20150: GCODE_RESET_VALUES
, the basic setting Technology G group after RESET can be set.
Only the dynamic response of the path axes is determined when the technology group G
code is activated. This has no effect on:
Positioning axes
PLC axes
Command axes
Movements based on axis coupling
Overlaid movements with handwheel
JOG movements
Reference point approach (G74)
Fixed point travel (G75)
Rapid traverse movements (G0)
The dynamic response for these axis movements is still derived from the machine data of the
DYNNORM default setting.

Technology G group
Five dynamic response settings are available in G code group 59 technology:
DYNORM for standard dynamic response
DYNPOS for positioning mode, tapping
DYNROUGH for roughing
DYNSEMIFIN for finishing
DYNFINISH for smooth-finishing
For further information about programming, please refer to
References:
/PG/ Programming Guide Fundamentals, Path traversing behavior.

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2.3 Continuous-path mode

Enabling selected dynamics groups only

Some G codes can be deactivated by the machine manufacturer. If deactivated G codes are
programmed alarm 14011 is output. G codes DYNPOS for positioning mode and
DYNSEMIFIN for finishing, for example, can be deactivated with the following setting.
MD10712: NC_USER_CODE_CONF_NAME_TAB[0]="DYNPOS"
MD10712: NC_USER_CODE_CONF_NAME_TAB[1]=" "
MD10712: NC_USER_CODE_CONF_NAME_TAB[2]="DYNSEMIFIN"
MD10712: NC_USER_CODE_CONF_NAME_TAB[3]=" "

Configuring the dynamic response values.

The values for each technology group are stored in the following machine data:
Axis
MD32300: MAX_AX_ACCEL[n]
MD32431: MAX_AX_JERK[n]
MD20600: MAX_PATH_JERK[n]
MD32432: PATH_TRANS_JERK_LIM[n]
MD32310: MAX_ACCEL_OVL_FACTOR[n]
MD32433: SOFT_ACCEL_FACTOR[n]
Path
MD20602: CURV_EFFECT_ON_PATH_ACCEL[n]
MD20603: CURV_EFFECT_ON_PATH_JERK[n]
Value frange for index n = 0 to 4
Example of programming with index:
MD32300: MAX_AX_ACCEL[3, AX1]=1
R1=MD20602: CURV_EFECT_ON_PATH_ACCEL[4]

Notice
Writing the machine data without an index places the same value in all field elements of the
machine data in question.
Reading the machine data without an index always supplies the value of the field with index
0.
These constellations can occur:
1. Write from part program MD32300: MAX_AX_ACCEL[AX1]=1 sets all five field elements to
value 1 (unit of measurement metric or inch depending on axis type and reference system).
2. Read in archive files from software versions earlier than SW 7.2.

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Activate parameter sets for dynamic response

By programming G codes, the machine data affecting dynamics are activated and assigned
as follows:
Active parameter set

G CODE of group 59 technology:

Index 0: Value for:

DYNNORM

Index 1: Value for:

DYNPOS

Index 2: Value for:

DYNROUGH

Index 3: Value for:

DYNSEMIFIN

Index 4: Value for:

DYNFINISH

Note
We recommend suppressingG codes that are not used
with MD10712: NC_USER_CODE_CONF_NAME_TAB[n]. This will prevent these G codes
from being programmed accidentally and activating unconfigured machine data.

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2.4 LookAhead

2.4

2.4

LookAhead

Function
LookAhead is a procedure in continuouspath mode (G64, G641) that achieves velocity
control with LookAhead over several NC part program blocks beyond the current block.
If the program blocks only contain very small paths, a velocity per block is achieved that
permits deceleration of the axes at the block end point without violating acceleration limits.
This means that the programmed velocity was not actually reached although a sufficient
number of prepared blocks with virtually tangential path transitions was available.
With the LookAhead function it is possible to plan the acceleration and deceleration phase
with approximately tangential path transitions in order to achieve a higher feedrate with
shorter distances. Deceleration to velocity limits is possible with LookAhead such that
violation of the acceleration and velocity limit is prevented.

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Comparison of velocity response with exact stop G60 and continuouspath mode G64
with LookAhead with short traversing paths.

LookAhead takes plannable velocity limits into consideration such as:

Exact stop at block end
Velocity limit in the block
Acceleration limit in the block
Velocity limit on block transition
Synchronization with block change at block transition.

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2.4 LookAhead

Scope
The LookAhead function is only available for path axes and not for spindles and positioning
axes.
LookAhead carries out a block-specific analysis of velocity limits and specifies the required
brake ramp profile based on this information. LookAhead is adapted automatically to block
length, braking capacity and permissible path velocity.
For safety reasons, the velocity at the end of the last prepared block must initially be
assumed to be zero because the next block might be very small or be an exact-stop block
and the axes must have been stopped by the end of the block.
With a series of blocks with high set velocity and very short paths, the speed can be
increased in each block depending on the velocity value currently calculated by the
LookAhead function in order to achieve the required set velocity. After this it can be reduced
so that the velocity at the end of the last block considered by the LookAhead function can be
zero.
This results in a serrated velocity profile (see the following fig.) which can be avoided by
reducing the set velocity or increasing the number of blocks considered by the LookAhead
function.

Number of blocks
To achieve reliable axis traversal in continuouspath mode, the feedrate must be adapted
over several blocks. The number of blocks considered by the LookAhead function is
calculated automatically and can, if required, be limited by a machine data. The standard
setting is 1, which means that LookAhead only considers the following block for velocity
control.
Because LookAhead is especially important for short blocks (relative to the deceleration
path), the number of blocks required is of interest for LookAhead braking (see fig. below). It
is enough to consider the path length to be equal to the deceleration path that is required to
brake from maximum velocity to standstill.
For a machine with a low axial acceleration of a = 1m/s2 and a high feedrate of vpath = 10
m/min, the following number of blocks for the control is obtained with an attainable block
cycle time of the control of TB = 10 ms.
nLookAhead= Deceleration path/Block length = ( vpath2 / (2a)) / (vpath * TB) = 9
Considering these aspects, it is advisable to adapt the feedrate over 10 blocks. The number
of blocks entered for the LookAhead function forecast does not change the LookAhead
algorithm and memory requirement.
As, in a program, the machining velocity is very often set to a lower value than the maximum
velocity, more blocks than are required would be predicted, overloading the processor
unnecessarily. The number of blocks required is therefore derived from the velocity, which is
calculated by multiplying the programmed speed by the value of machine data:
MD12100 OVR_FACTOR_LIMIT_BIN
(limit of binary-coded override switch)
or by the 31st override value of machine data:
MD12030 OVR_FACTOR_FEEDRATE
(analysis of path feedrate override switch).

2-38

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.4 LookAhead
The 31st override value must tally with the override factor most frequently used.
The number of blocks considered by the LookAhead function is limited by the possible
number of NC blocks in the IPO buffer.

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1

Figure 2-13

1

1

1

1 1

Example for modal velocity control (number of blocks considered by the LookAhead
function = 2)

Velocity profiles
In addition to the fixed, plannable velocity limitations, LookAhead can also take account of
the programmed velocity. This makes it possible to achieve a lower velocity by applying
LookAhead beyond the current block.

Following block velocity

One possible velocity profile contains the determination of the following block velocity. Using
information from the current and the following NC block, a velocity profile is calculated from
which, in turn, the required velocity reduction for the current override is derived.
The calculated maximum value of the velocity profile is limited by the maximum path velocity.
With this function it is possible to initiate a speed reduction in the current block taking
override into account such that the lower velocity of the following block can be achieved. If
the reduction in velocity takes longer than the travel time of the current block, the velocity is
further reduced in the following block. Velocity control is only ever considered for the
following block.
This function is activated using machine data:
MD20400 LOOKAH_USE_VELO_NEXT_BLOCK
(LookAhead for following block velocity).

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-39

Detailed description
2.4 LookAhead

Override points
If the velocity profile of the following block velocity is not sufficient because, for example,
very high override values, e.g., 200%, or constant cutting rate G96/G961 are being used,
with the result that the velocity must be further reduced in the following block, LookAhead
provides a way of reducing the programmed velocity over several NC blocks.
By defining override points, LookAhead then calculates a limiting velocity profile for each
value. The required velocity reductions for the current override are derived from these
profiles.
The calculated maximum value of the velocity profile is limited by the maximum path velocity.
The higher value must take account of the velocity range reached by the maximum value of
machine data:
MD12030 OVR_FACTOR_FEEDRATE
(analysis of path feedrate override switch)
or the value of machine data:
MD12100 OVR_FACTOR_LIMIT_BIN
(limit of binary-coded override switch)
respectively.
In this way, a reduction of the velocity continuing into the block in which it is programmed
can be avoided. If velocity reductions across block boundaries are required already at 100%
override, a point must be set in the lower override range as well.
The number of override points used for each channel is specified in machine data:
MD20430 LOOKAH_NUM_OVR_POINTS
(number of override switch points for LookAhead).
The corresponding points are written to machine data:
MD20440 LOOKAH_OVR_POINTS
(override switch points for LookAhead).
A combination of both procedures can be used to calculate the velocity profile and is
generally recommended, because the preset machine data for these functions already takes
the widest range of override-specific velocity limits into account.
Plannable velocity limits restrict override-specific velocity limits.
If neither of the two procedures has been activated, the setpoint velocity is always applied in
the current block.

2-40

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.4 LookAhead

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1

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Example for limiting velocity characteristics with number of LookAhead blocks = 4

... and the following settings:

MD20430 LOOKAH_NUM_OVR_POINTS = 2
MD20440 LOOKAH_OVR_POINTS = 1.5, 0.5
MD20400 LOOKAH_USE_VELO_NEXT_BLOCK = 1

Block cycle problem

Block cycle problems are encountered in cases where the traversing distances of the NC
blocks to be processed are so short that the LookAhead function has to reduce the machine
velocity to provide enough time for block processing. In this situation, constant braking and
acceleration of path motion may occur.
Machine data:
MD20450 LOOKAH_RELIEVE_BLOCK_CYCLE
(relief factor for the block cycle time)
can be set to smooth such velocity fluctuations.

Selection and deselection of LookAhead

The LookAhead function is selected and deselected with continuouspath mode (G64 or G641
respectively).

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-41

Detailed description
2.4 LookAhead

Special cases of LookAhead

Axis-specific feed stop and axis-specific axis disable are ignored by LookAhead.
If an axis is to be interpolated that should on the other hand be made stationary by axisspecific feed stop or axis disable, LookAhead does not stop path movement before the block
in question but decelerates in the block itself.
If this response is not wanted, an axis-specific feed stop can be transferred to a channel via
the PLC to stop the path immediately.
See also: /FB1/, A3, Axis clamping.

2-42

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.5 NC block compressor COMPON, COMPCURV, -CAD

2.5

2.5

NC block compressor COMPON, COMPCURV, -CAD

COMPON, COMPCURV
The modal G code COMPON or COMPCURV can be used to activate an "NC block
compressor".
This function collects a series of linear blocks during linear interpolation (the number is
limited to 10) and approximates them within a tolerance specified in machine data via a 3rd
degree (COMPON) or 5th degree (COMPCURV) polynomial.
One larger traversing block is processed by the NC instead of a large number of small
blocks.

COMPCAD
The COMPCAD G code can be used to select a further compression, which optimizes the
surface quality and velocity. The interpolation accuracy can again be specified in machine
data.
COMPCAD is processor and memoryintensive. It should only be used if surface quality
enhancement measures cannot be incorporated in the CAD/CAM program.
The programming procedure is described in:
References:
/PGA/ Programming Guide, Advanced.
The compressor for orientation transformation is described in:
References:
/FB3/ Description of Functions, Special Functions; 3 to 5-axis transformation (F2).
The following three machine data are available for the compressor function:
MD20170 COMPRESS_BLOCK_PATH_LIMIT

This MD specifies the maximum path length for

block compression. Longer blocks are not
compressed.

MD33100 COMPRESS_POS_TOL

A tolerance can be specified for each axis.

This value specifies the maximum deviation of
the generated spline curve from the
programmed end points.
The higher the values, the more blocks can be
compressed.

MD20172 COMPRESS_VELO_TOL

The maximum permissible deviation of the path

feedrate while the compressor is active in
conjunction with FLIN and FCUB can be
specified here (does not apply to the COMPCAD
command).

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-43

Detailed description
2.5 NC block compressor COMPON, COMPCURV, -CAD

Recommendation for MD settings

The following machine data affect the compressor function and should contain the following
values (specified in mm):
Machine data

Recommended value

MD18360 MM_EXT_PROG_BUFFER_SIZE

100

MD28520 MM_MAX_AXISPOLY_PER_BLOCK

MD28530 MM_PATH_VELO_SEGMENTS

MD28540 MM_ARCLENGTH_SEGMENTS

10

MD28070 MM_NUM_BLOCKS_IN_PREP

60

MD28060 MM_IPO_BUFFER_SIZE

100

SD42470 CRIT_SPLINE_ANGLE

36

MD20170 COMPRESS_BLOCK_PATH_LIMIT

20

MD20172 COMPRESS_VELO_TOL

100

MD32310 MAX_ACCEL_OVL_FACTOR[AX1]

<Value for G64 operation>

MD32310 MAX_ACCEL_OVL_FACTOR[AX2]

Value for G64 operation

MD32310 MAX_ACCEL_OVL_FACTOR[AX3]

<Value for G64 operation>

MD20490 IGNORE_OVL_FACTOR_FOR_ADIS

A tolerance can be specified for each axis: This value specifies the maximum deviation of
the generated spline curve from the programmed end points. The higher the values, the
more blocks can be compressed.
Experience has shown that a value of 0.01 is suitable for most applications:
MD33100 COMPRESS_POS_TOL[AX1] = 0.01
MD33100 COMPRESS_POS_TOL[AX2] = 0.01
MD33100 COMPRESS_POS_TOL[AX3] = 0.01

If not, the value can be increased to 0.02, for example:

MD33100 COMPRESS_POS_TOL[AX1] = 0.02
MD33100 COMPRESS_POS_TOL[AX2] = 0.02
MD33100 COMPRESS_POS_TOL[AX3] = 0.02
NewConfig

2-44

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.5 NC block compressor COMPON, COMPCURV, -CAD

Activating the MD values

The new values are activated after the NewConfig command.
The rounding function G642 and jerk limitation SOFT can be used to achieve further
improvements in surface quality. These commands must be entered at the start of the
program:
COMPCAD SOFT G642
COMPOF terminates the compressor function.
All blocks are compressed for which a simple syntax is sufficient:
N... G1X... Y... Z... F...
where "..." is a number and X, Y, Z are axis names.
Blocks with e.g., extended addresses such as C=100 or A=AC(100) or blocks with auxiliary
functions are also compressed.

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-45

Detailed description
2.5 NC block compressor COMPON, COMPCURV, -CAD

2-46

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Supplementary conditions
3.1

3.1

Rounding and repositioning (REPOS)

Repositioning within the rounding area

If the traversing motion of the path axes within the corner rounding area is interrupted for
traversing blocks with programmed rounding (part program command G641, G642, G643 or
G644), repositioning occurs as follows in the event of a subsequent REPOS operation,
depending on the current REPOS mode:
REPOS mode
RMB
Block start of interrupted traversing block
RMI
Block end of interrupted traversing block
RME

Block end of interrupted traversing block

RMN

Block end of interrupted traversing block

Example
Two traversing blocks N10 and N20 with programmed rounding G641. In the rounding area,
the traversing motion is interrupted and the axes are subsequently traversed, e.g., manually
to the REPOS starting point. Repositioning on the contour takes place differently, depending
on the active REPOS mode.

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

3-1

Supplementary conditions
3.2 Smoothing the path velocity

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3.2

3.2

Example of Rounding and REPOS

Smoothing the path velocity

Several blocks with SOFT and BRISK

Smoothing of the path velocity is only effective in continuouspath mode with LookAhead over
several blocks with SOFT and BRISK, but not with G0.
The cycle times of the control must be parameterized such that the preprocessing is
provided with enough blocks to be able to analyze an acceleration process.

3-2

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Examples
4.1

4.1

Example of jerk limitation on the path

...
N1000 G64 SOFT

; Continuous-path mode with SOFT acceleration

characteristics

N1004 G0 X-20 Y10

N1005 G1 X-20 Y0

; Straight

N1010 G3 X-10 Y-10 I10

; Block transition with jump in path curvature

(straight - circular)

N1011 G3 X0 Y0 J10

; Block transition with continuous path curvature

N1020 G2 X5 Y5 I5

; Block transition with jump in path curvature

(circular - circular)

N1021 G2 X10 Y0 J-5

...

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

4-1

Examples
4.1 Example of jerk limitation on the path

4-2

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Data lists
5.1

5.1.1

5.1

Machine data

General machine data

Number

Identifier: $MN_

Description

10110

PLC_CYCLE_TIME_AVERAGE

Maximum PLC acknowledgment time

18360

MM_EXT_PROG_BUFFER_SIZE

FIFO buffer size for processing from external

5.1.2

Channelspecific machine data

Number

Identifier: $MC_

Description

20170

COMPRESS_BLOCK_PATH_LIMIT

Maximum traversing length of NC block for

compression

20400

LOOKAH_USE_VELO_NEXT_BLOCK

Look Ahead for constant acceleration velocity control

20430

LOOKAH_NUM_OVR_POINTS

Number of override switch points for Look Ahead

20440

LOOKAH_OVR_POINTS

Override switch points for LookAhead

20450

LOOKAH_RELIEVE_BLOCK_CYCLE

Relief factor for the block cycle time

20460

LOOKAH_SMOOTH_FACTOR

Smoothing factor for LookAhead

20462

LOOKAH_SMOOTH_WITH_FEED

Smoothing takes feedrate into account

20465

ADAPT_PATH_DYNAMIC

Adaptation of path dynamic response

20480

SMOOTHING_MODE

Rounding behavior with G642, G643, G644

20490

IGNORE_OVL_FACTOR_FOR_ADIS

G641/G642 irrespective of overload factor

20550

EXACT_POS_MODE

Exact-stop conditions with G0/G1

20602

CURV_EFFECT_ON_PATH_ACCEL

Influence of path curvature on path dynamic response

20603

CURV_EFFECT_ON_PATH_JERK

Influence of path curvature on path jerk

28060

MM_IPO_BUFFER_SIZE

Number of NC blocks in IPO buffer (DRAM)

28070

MM_NUM_BLOCKS_IN_PREP

Number of NC blocks for block preparation (DRAM)

28520

MM_MAX_AXISPOLY_PER_BLOCK

Maximum number of axis polynomials per block

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

5-1

Data lists
5.1 Machine data
Number

Identifier: $MC_

Description

28530

MM_PATH_VELO_SEGMENTS

Number of storage elements for limiting path velocity

in block

28540

MM_ARCLENGTH_SEGMENTS

Number of storage elements for arc length function

representation per block

5.1.3

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

32310

MAX_ACCEL_OVL_FACTOR

Overload factor for velocity jump

32431

MAX_AX_JERK

Maximum axis jerk for path motion

32432

PATH_TRANS_JERK_LIM

Maximum axial jerk of a geometry axis at block

boundary

32433

SOFT_ACCEL_FACTOR

Scaling of acceleration limitation for SOFT

32434

G00_ACCEL_FACTOR

Scaling of acceleration limitation for G00

32435

G00_JERK_FACTOR

Scaling of axial jerk limitation for G00

32440

LOOKAH_FREQUENCY

Smoothing limit frequency for LookAhead

33100

COMPRESS_POS_TOL

Maximum deviation with compensation

36000

STOP_LIMIT_COARSE

Exact stop coarse

36010

STOP_LIMIT_FINE

Exact stop fine

36012

STOP_LIMIT_FACTOR

Exact stop coarse/fine factor and zero speed

monitoring

36020

POSITIONING_TIME

Delay time exact stop fine

5-2

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Data lists
5.2 Setting data

5.2

5.2

5.2.1

Setting data

Channelspecific setting data

Number

Identifier: $SC_

Description

42465

SMOOTH_CONTUR_TOL

Max. contour deviation on rounding

42466

SMOOTH_ORI_TOL

Max. deviation of the tool orientation on rounding

42470

CRIT_SPLINE_ANGLE

Limit angle for spline and polynomial interpolation and

compressor

5.3

5.3.1

5.3

Signals

Signals from channel

DB number

Byte.Bit

Description

21, ...

36.3

All axes stationary

5.3.2

Signals to axis/spindle

DB number

Byte.Bit

Description

31, ...

60.6

Position reached with exact stop coarse

31, ...

60.7

Position reached with exact stop fine

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

5-3

Data lists
5.3 Signals

5-4

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Index
Following block velocity, 2-39
Number of blocks, 2-38
Override, 2-40
Selection and deselection, 2-41
Velocity profiles, 2-39

A
Adaptation
Dynamic Response, 1-2
Auxiliary function output, 2-8

M
B
Blending, 2-11
Block-change point, 2-6

C
COMPCAD, 2-43
COMPCURV, 2-43
COMPON, 2-43
Compressor for orientation transformation, 2-43
Continuous-path mode, 2-6

E
Exact stop criteria, 2-2, 2-3, 2-4
Exact-stop criteria
Exact stop coarse, 2-4
Exact stop fine, 2-4
Exact-stop criterion, 2-6

G
Geometry axes, 2-7, 2-11

I
Implicit continuouspath mode, 2-10
Implicit exact stop, 2-7
Interpolator end, 2-4

L
LookAhead, 2-6, 2-37
Block cycle problem, 2-41
Continuouspath Mode, Exact Stop, LookAhead (B1)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

MD settings
NC block compressor, 2-44
MD10110, 2-8
MD12030, 2-39, 2-40
MD12100, 2-39, 2-40
MD18360, 2-44
MD20150, 2-1, 2-34
MD20170, 2-43, 2-44
MD20172, 2-43, 2-44
MD20400, 2-39
MD20430, 2-40
MD20440, 2-40
MD20450, 2-41
MD20460, 2-22, 2-23, 2-24, 2-26
MD20462, 2-22, 2-23
MD20465, 2-23, 2-25, 2-26, 2-27, 2-33
MD20480, 2-16, 2-17, 2-18, 2-19, 2-20
MD20490, 2-9, 2-44
MD20550, 2-5
MD20552, 2-5
MD28060, 2-44
MD28070, 2-44
MD28520, 2-44
MD28530, 2-18, 2-19, 2-44
MD28540, 2-44
MD32210, 2-9
MD32300, 2-9
MD32310, 2-44
MD32431, 2-33
MD32440, 2-20, 2-22, 2-23, 2-24, 2-25, 2-33
MD33100, 2-15, 2-17, 2-20, 2-43, 2-44
MD35240, 2-18
MD36000, 2-3
MD36010, 2-3
MD36012, 2-4

Index-1

Index

NC block compressor
COMPON, COMPCURV, COMCAD, 2-43

Rounding with contour tolerance, 2-16

O
Orientation axes, 2-11
Overload factor, 2-9

P
Path criterion, 2-13
POS, 2-7

Index-2

S
SD42465, 2-16, 2-17
SD42466, 2-16, 2-17
SD42470, 2-44
SPOS, 2-7
Synchronized axes, 2-7, 2-13

V
Velocity reduction according to overload factor, 2-9

Continuouspath Mode, Exact Stop, LookAhead (B1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

1
Brief description
______________

SINUMERIK 840D sl/840Di sl/840D/840Di/810D Acceleration (B2)

2
Functions
______________
SINUMERIK
840D sl/840Di sl/840D/840Di/810D
Acceleration (B2)

Valid for

Control

SINUMERIK 840D sl/840DE sl

SINUMERIK 840Di sl/840DiE sl
SINUMERIK 840D powerline/840DE powerline
SINUMERIK 840Di powerline/840DiE powerline
SINUMERIK 810D powerline/810DE powerline
NCU System Software for 840D sl/840DE sl
NCU system software for 840Di sl/DiE sl
NCU system software for 840D/840DE
NCU system software for 840Di/840DiE
NCU system software for 810D/810DE

03/2006 Edition
6FC5397-0BP10-1BA0

4
Examples
______________
5
Data lists
______________

Function Manual

Software

3
Supplementary conditions
______________

Version
1.3
1.0
7.4
3.3
7.4

Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
Danger
indicates that death or severe personal injury will result if proper precautions are not taken.
Warning
indicates that death or severe personal injury may result if proper precautions are not taken.
Caution
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
Notice
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.

Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage
Note the following:
Warning
This device may only be used for the applications described in the catalog or the technical description and only in
connection with devices or components from other manufacturers which have been approved or recommended by
Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly
as well as careful operation and maintenance.

Trademarks
All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.

Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG
Automation and Drives
Postfach 48 48
90437 NRNBERG
GERMANY

Order No.: 6FC5397-0BP10-1BA0

Edition 05/2006

Copyright Siemens AG 2006.

Technical data subject to change

Table of contents
1

Brief description ...................................................................................................................................... 1-1

1.1

Customer benefit........................................................................................................................ 1-1

1.2

Features ..................................................................................................................................... 1-1

1.3

Requirements............................................................................................................................. 1-2

Functions ................................................................................................................................................ 2-1

2.1
2.1.1
2.1.1.1
2.1.1.2
2.1.2
2.1.2.1
2.1.3
2.1.3.1
2.1.3.2

Acceleration without jerk limitation (BRISK/BRISKA) (channel-/axis-specific) .......................... 2-1

Detailed Description................................................................................................................... 2-1
General Information ................................................................................................................... 2-1
Programmable maximum value (axis-specific) .......................................................................... 2-3
Activation.................................................................................................................................... 2-3
Parameterization ........................................................................................................................ 2-3
Programming.............................................................................................................................. 2-3
Path acceleration without jerk limitation (BRISK) ...................................................................... 2-3
Single-axis acceleration without jerk limitation (BRISKA).......................................................... 2-4

2.2
2.2.1
2.2.1.1
2.2.2
2.2.2.1
2.2.3

Constant travel time (channel-specific)...................................................................................... 2-5

Detailed Description................................................................................................................... 2-5
General Information ................................................................................................................... 2-5
Activation.................................................................................................................................... 2-6
Parameterization ........................................................................................................................ 2-6
Programming.............................................................................................................................. 2-6

2.3
2.3.1
2.3.1.1
2.3.2
2.3.3

Acceleration matching (ACC) (axis-specific) ............................................................................. 2-7

Detailed Description................................................................................................................... 2-7
General Information ................................................................................................................... 2-7
Activation.................................................................................................................................... 2-7
Programming.............................................................................................................................. 2-7

2.4
2.4.1
2.4.1.1
2.4.2
2.4.2.1
2.4.3

Acceleration margin (channel-specific)...................................................................................... 2-8

Detailed Description................................................................................................................... 2-8
General Information ................................................................................................................... 2-8
Activation.................................................................................................................................... 2-9
Parameterization ........................................................................................................................ 2-9
Programming.............................................................................................................................. 2-9

2.5
2.5.1
2.5.1.1
2.5.2
2.5.2.1
2.5.3
2.5.3.1
2.5.3.2

Path-acceleration limitation (channel-specific) .......................................................................... 2-9

Detailed Description................................................................................................................... 2-9
General Information ................................................................................................................... 2-9
Activation.................................................................................................................................. 2-10
Parameterization ...................................................................................................................... 2-10
Programming............................................................................................................................ 2-10
Limit value ................................................................................................................................ 2-10
Switch ON/OFF ........................................................................................................................ 2-10

2.6
2.6.1
2.6.1.1

Path acceleration for real-time events (channel-specific)........................................................ 2-11

Detailed Description................................................................................................................. 2-11
General Information ................................................................................................................. 2-11

Acceleration (B2)
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iv

2.6.2
2.6.3

Activation.................................................................................................................................. 2-12
Programming............................................................................................................................ 2-12

2.7
2.7.1
2.7.1.1
2.7.2
2.7.2.1
2.7.3

Acceleration with programmed rapid traverse (G00) (axis-specific) ........................................ 2-13

Detailed Description ................................................................................................................. 2-13
General Information ................................................................................................................. 2-13
Activation.................................................................................................................................. 2-14
Parameterization ...................................................................................................................... 2-14
Programming............................................................................................................................ 2-14

2.8
2.8.1
2.8.1.1
2.8.2
2.8.2.1
2.8.3

Acceleration with active jerk limitation (SOFT/SOFTA) (axis-specific) .................................... 2-14

Detailed Description ................................................................................................................. 2-14
General Information ................................................................................................................. 2-14
Activation.................................................................................................................................. 2-15
Parameterization ...................................................................................................................... 2-15
Programming............................................................................................................................ 2-15

2.9
2.9.1
2.9.1.1
2.9.2
2.9.2.1
2.9.3

Excessive acceleration for non-tangential block transitions (axis-specific) ............................. 2-16

Detailed Description ................................................................................................................. 2-16
General Information ................................................................................................................. 2-16
Activation.................................................................................................................................. 2-16
Parameterization ...................................................................................................................... 2-16
Programming............................................................................................................................ 2-17

2.10
2.10.1
2.10.1.1
2.10.2
2.10.3

Acceleration margin for radial acceleration (channel-specific) ................................................ 2-17

Detailed Description ................................................................................................................. 2-17
General Information ................................................................................................................. 2-17
Activation.................................................................................................................................. 2-19
Programming............................................................................................................................ 2-19

2.11
2.11.1
2.11.1.1
2.11.1.2
2.11.1.3
2.11.2
2.11.2.1
2.11.3

Jerk limitation with path interpolation (SOFT) (channel-specific)............................................. 2-19

Detailed Description ................................................................................................................. 2-19
General Information ................................................................................................................. 2-19
Maximum jerk value (axis-specific) .......................................................................................... 2-21
Maximum jerk value (channel-specific).................................................................................... 2-21
Activation.................................................................................................................................. 2-21
Parameterization ...................................................................................................................... 2-21
Programming............................................................................................................................ 2-22

2.12
2.12.1
2.12.1.1
2.12.2
2.12.2.1
2.12.3

Jerk limitation with single-axis interpolation (SOFTA) (axis-specific) ...................................... 2-22

Detailed Description ................................................................................................................. 2-22
General Information ................................................................................................................. 2-22
Activation.................................................................................................................................. 2-23
Parameterization ...................................................................................................................... 2-23
Programming............................................................................................................................ 2-23

2.13
2.13.1
2.13.1.1
2.13.2
2.13.2.1
2.13.3
2.13.3.1
2.13.3.2

Path-jerk limitation (channel-specific) ...................................................................................... 2-24

Detailed Description ................................................................................................................. 2-24
General Information ................................................................................................................. 2-24
Activation.................................................................................................................................. 2-24
Parameterization ...................................................................................................................... 2-24
Programming............................................................................................................................ 2-25
Maximum path jerk................................................................................................................... 2-25
Switch ON/OFF ........................................................................................................................ 2-25

2.14
2.14.1
2.14.1.1
2.14.2
2.14.3

Path jerk for real-time events (channel-specific)...................................................................... 2-26

Detailed Description ................................................................................................................. 2-26
General Information ................................................................................................................. 2-26
Activation.................................................................................................................................. 2-27
Programming............................................................................................................................ 2-27

Acceleration (B2)
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2.15
2.15.1
2.15.1.1
2.15.2
2.15.2.1
2.15.3

Jerk with programmed rapid traverse (G00) (axis-specific)..................................................... 2-28

Detailed Description................................................................................................................. 2-28
General Information ................................................................................................................. 2-28
Activation.................................................................................................................................. 2-28
Parameterization ...................................................................................................................... 2-28
Programming............................................................................................................................ 2-29

2.16
2.16.1
2.16.1.1
2.16.2
2.16.2.1
2.16.3

Excessive jerk for block transitions without constant curvature (axis-specific) ....................... 2-29
Detailed Description................................................................................................................. 2-29
General Information ................................................................................................................. 2-29
Activation.................................................................................................................................. 2-29
Parameterization ...................................................................................................................... 2-29
Programming............................................................................................................................ 2-30

2.17
2.17.1
2.17.1.1
2.17.2
2.17.2.1
2.17.3

Jerk filter (axis-specific) ........................................................................................................... 2-30

Detailed Description................................................................................................................. 2-30
General Information ................................................................................................................. 2-30
Activation.................................................................................................................................. 2-33
Parameterization ...................................................................................................................... 2-33
Programming............................................................................................................................ 2-34

2.18
2.18.1
2.18.1.1
2.18.1.2
2.18.1.3
2.18.2
2.18.2.1
2.18.2.2
2.18.3
2.18.3.1
2.18.3.2

Kneeshaped acceleration characteristic curve ........................................................................ 2-34

Detailed Description................................................................................................................. 2-34
Adaptation to the motor characteristic curve ........................................................................... 2-34
Effects on path acceleration..................................................................................................... 2-36
Substitute characteristic curve ................................................................................................. 2-37
Activation.................................................................................................................................. 2-39
Parameterization ...................................................................................................................... 2-39
Commissioning......................................................................................................................... 2-40
Programming............................................................................................................................ 2-40
Channel-specific activation (DRIVE)........................................................................................ 2-40
Axis-specific activation (DRIVEA) ............................................................................................ 2-41

Supplementary conditions ...................................................................................................................... 3-1

3.1

Acceleration and jerk ................................................................................................................. 3-1

3.2
3.2.1

Kneeshaped acceleration characteristic curve .......................................................................... 3-1

Active kinematic transformation ................................................................................................. 3-1

Examples................................................................................................................................................ 4-1
4.1
4.1.1

Acceleration ............................................................................................................................... 4-1

Path velocity characteristic ........................................................................................................ 4-1

4.2
4.2.1

Jerk ............................................................................................................................................ 4-2

Path velocity characteristic ........................................................................................................ 4-2

4.3

Acceleration and jerk ................................................................................................................. 4-4

4.4
4.4.1

Kneeshaped acceleration characteristic curve .......................................................................... 4-5

Activation.................................................................................................................................... 4-5

Data lists................................................................................................................................................. 5-1

5.1
5.1.1
5.1.2

Machine data.............................................................................................................................. 5-1

Channelspecific machine data ................................................................................................... 5-1
Axis/spindlespecific machine data ............................................................................................. 5-1

5.2
5.2.1

Setting data ................................................................................................................................ 5-2

Channelspecific setting data ...................................................................................................... 5-2

5.3

System variables........................................................................................................................ 5-2

Index................................................................................................................................................ Index-1
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Acceleration (B2)
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Brief description
1.1

1.1

Customer benefit

Scope of functions
The Description of Functions covers the following sub-functions:
Acceleration
Jerk
Kneeshaped acceleration characteristic
Acceleration and jerk
The effective acceleration and jerk can be optimally matched to the machine and machining
situation concerned using axis- and channel-specific programmable maximum values,
programmable acceleration profiles in part programs and synchronized actions, and dynamic
adaptations and limitations.
Kneeshaped acceleration characteristic
The knee-shaped acceleration characteristic means that, in the case of machine axes
featuring a motor (in particular stepper motors) with a torque characteristic that is highly
dependent upon speed, acceleration can be set at the level required to ensure optimum
utilization of the motor whilst at the same time protecting it against overload.

1.2

1.2

Features

Acceleration
Axis-specific functions:
Programmable maximum acceleration value
Acceleration profile that can be selected via part-program instruction:
Acceleration without jerk limitation (BRISKA)
Setting of maximum value using part-program instruction (ACC)
Specific maximum value for programmed rapid traverse (G00).
Specific maximum value for traverse with active jerk limitation
Excessive acceleration for non-tangential block transitions

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Brief description
1.3 Requirements

Channel-specific functions:
Acceleration profile that can be selected via part-program instruction:
Acceleration without jerk limitation (BRISK)
Programmable constant travel time for the purpose of avoiding extreme sudden
acceleration
Programmable acceleration margin for overlaid traversing
Adjustable acceleration limitation
Adjustable acceleration for specific real-time events
Programmable acceleration margin for radial acceleration

Jerk
Axis-specific functions:
Acceleration profile that can be selected via part-program instruction:
Acceleration with jerk limitation (SOFTA)
Programmable maximum jerk value for single-axis interpolation
Programmable maximum jerk value for path interpolation
Channel-specific functions:
Acceleration profile that can be selected via part-program instruction:
Acceleration with jerk limitation (SOFT)
Adjustable jerk limitation
Adjustable path jerk for specific real-time events
Specific maximum value for programmed rapid traverse (G00)
Excessive jerk for block transitions without constant curvature

Kneeshaped acceleration characteristic

A knee-shaped acceleration characteristic is parameterized using the following characteristic
data:
Maximum velocity vmax
Maximum acceleration amax
Creep velocity vred
Creep acceleration ared
Nature of the acceleration reduction (constant, hyperbolic, linear)

1.3

1.3

Requirements
There are no specific requirements to be met.

1-2

Acceleration (B2)
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Functions
2.1

2.1

Acceleration without jerk limitation (BRISK/BRISKA) (channel-/axisspecific)

2.1.1

Detailed Description

2.1.1.1

General Information

General Information
In the case of acceleration without jerk limitation (jerk = infinite) the maximum value is
applied for acceleration immediately. As regards acceleration with jerk limitation, it differs in
the following respects:
Advantages
Shorter processing times with the same maximum values for velocity and acceleration.
Disadvantages
Increased load on the machine's mechanical components and risk of inducing highfrequency and difficult-to-control mechanical vibrations.

Acceleration (B2)
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2-1

Functions
2.1 Acceleration without jerk limitation (BRISK/BRISKA) (channel-/axis-specific)

Acceleration profile

D
DPD[

DPD[
Y
YPD[

W

Figure 2-1

amax:

W

W

Velocity and acceleration schematic for stepped acceleration profile

Maximum acceleration value

vmax:

Maximum velocity value

t:

Time

The following features of the acceleration profile can be identified from the figure above:
Time: t0
Sudden acceleration from 0 to +amax
Interval: t0 - t1
Constant acceleration with +amax; linear increase in velocity
Time: t1
Sudden acceleration from 2 * amax with immediate switchover from acceleration to braking

Note
The sudden acceleration can normally be avoided by specifying a constant velocity time
(see Section: "Sudden acceleration with constant velocity phase").

Interval: t1 - t2
Constant acceleration with -amax; linear decrease in velocity

2-2

Acceleration (B2)
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Functions
2.1 Acceleration without jerk limitation (BRISK/BRISKA) (channel-/axis-specific)

2.1.1.2

Programmable maximum value (axis-specific)

Function
The maximum acceleration value can be set for each specific machine axis:
MD32300 $MA_MAX_AX_ACCEL (maximum axis acceleration)
The path parameters are calculated by the path planning component during preprocessing
so that the programmed maximum values of the machine axes that are of relevance for the
path are not exceeded.

Exceeding of maximum value

It is possible for the maximum value to be exceeded in connection with specific machining
situations (see Section: Acceleration matching (ACC) and System variable
($AC_PATHACC)).

2.1.2

Activation

2.1.2.1

Parameterization

Programming
The maximum values are parameterized for specific axes using machine data:
MD32300 $MA_MAX_AX_ACCEL (maximum axis acceleration)

2.1.3

Programming

2.1.3.1

Path acceleration without jerk limitation (BRISK)

Syntax
BRISK

Functionality
The BRISK part-program instruction is used to select the "without jerk limitation" acceleration
profile for the purpose of path acceleration.
G group: 21
Effective: Modal

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Functions
2.1 Acceleration without jerk limitation (BRISK/BRISKA) (channel-/axis-specific)

Reset response
The channel-specific initial setting is activated via a reset:
MD20150 $MC_GCODE_RESET_VALUES[20]

Supplementary conditions
If the acceleration profile is changed in a part program during machining (BRISK/SOFT) an
exact stop is performed at the end of the block.

2.1.3.2

Single-axis acceleration without jerk limitation (BRISKA)

Syntax
BRISKA (axis{,axis})

Function
The BRISKA part-program instruction is used to select the "without jerk limitation"
acceleration profile for single-axis movements (JOG, JOG/INC, positioning axis,
reciprocating axis, etc.).
G group: Effective: Modal

Axis:
Value range: Axis identifier for channel axes

Axis-specific initial setting

Acceleration without jerk limitation can be set as the axis-specific initial setting for single-axis
movements:
MD32420 $MA_JOG_AND_POS_JERK_ENABLE = FALSE

Reset response
The axis-specific initial setting is activated via a reset:
MD32420 $MA_JOG_AND_POS_ENABLE

2-4

Acceleration (B2)
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Functions
2.2 Constant travel time (channel-specific)

2.2

2.2

Constant travel time (channel-specific)

2.2.1

Detailed Description

2.2.1.1

General Information

Overview
In the case of acceleration without jerk limitation, sudden acceleration of 2 * amax occurs on
switchover between acceleration and braking. In order to avoid this sudden acceleration, a
channel-specific constant travel time can be programmed. The constant travel time defines
the time taken to traverse between the acceleration and braking phases at constant velocity:
MD20500 $MC_CONST_VELO_MIN_TIME (minimum time with constant velocity)

Note
The constant travel time is ineffective:
Active function: Look Ahead
In traversing blocks with a travel time that is less or equal to the interpolation cycle time.

D

DPD[

W
DPD[
Y
YPD[

W

Figure 2-2

W

W

W

W

W

Schematic for abrupt acceleration

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Functions
2.2 Constant travel time (channel-specific)

1:

Characteristic with constant travel time

2:

Characteristic without constant travel time

amax:

Maximum acceleration value

vmax:

Maximum velocity value

t:

Time

The effect of the constant travel time can be seen from the figure above:
Time: t1
End of acceleration phase with sudden acceleration 1 * amax
Interval: t1 - t2
Acceleration 0; constant velocity using the parameterized constant travel time
Time: t2
Start of braking phase with sudden acceleration 1 * amax
The times t0, t1' and t2' indicate the characteristic that would have been produced had no
constant travel time been defined.

2.2.2

Activation

2.2.2.1

Parameterization

Function
The constant travel time is parameterized for specific channels using machine data:
MD20500 $MC_CONST_VELO_MIN_TIME
(minimum time with constant velocity)

2.2.3

Programming

Key statement
The function is not programmable.

2-6

Acceleration (B2)
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Functions
2.3 Acceleration matching (ACC) (axis-specific)

2.3

2.3

Acceleration matching (ACC) (axis-specific)

2.3.1

Detailed Description

2.3.1.1

General Information

Function
A part-program instruction (ACC) can be used to match the acceleration of specific axes to
the current machining situation. The range used for this purpose is anywhere between
greater than 0% and less than or equal to 200% of the maximum value programmed in the
machine data.

Effective
Effective

Acceleration matching is effective for all types of interpolation in AUTOMATIC and

MDA operating modes as well as with dry-run feed.

Ineffective

Acceleration matching is ineffective in JOG and JOG/REF (reference point

approach) operating modes.
Acceleration matching is also ineffective if the machine axes have been brought to a
standstill via a quick stop due to the detection of a fault (setpoint = 0).

2.3.2

Activation

Function
The function does not need to be activated.

2.3.3

Programming

Syntax
ACC[axis] = adjustment factor

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Functions
2.4 Acceleration margin (channel-specific)

Functionality
The ACC part-program instruction is used to adjust the maximum acceleration value of a
machine axis.
Axis:
Value range: Axis identifier for the channel's machine axes
Adjustment factor:
Value range: 0 < adjustment factor 200
Unit: Per cent
Deactivate: ACC[axis] = 100
Effective: Modal

Reset response
The behavior during channel RESET or M30 can be controlled via MD 32320
DYN_LIMIT_RESET_MASK:
Bit 0: 0 The programmed ACC value is reset to 100% with channel RESET/M30.
Bit 0: 1 The programmed ACC value is retained beyond channel RESET/M30.

2.4

2.4

Acceleration margin (channel-specific)

2.4.1

Detailed Description

2.4.1.1

General Information

General information
Under normal circumstances, preprocessing makes maximum use of the parameterized
maximum values of the machine axes for the purpose of path acceleration. In order that an
acceleration margin may be set aside for overlaid movements, e.g., within the context of the
"Rapid lift away from the contour" function, path acceleration can be reduced by a
programmable factor. When, for example, a factor of 0.2 is applied, preprocessing will only
use 80% of the maximum possible path acceleration. 20% is set aside as an acceleration
margin for overlaid movements.

2-8

Acceleration (B2)
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Functions
2.5 Path-acceleration limitation (channel-specific)

2.4.2

Activation

2.4.2.1

Parameterization

Parameterization
Parameters for the acceleration margin are assigned for each channel by means of machine
datum:
MD20610 $MC_ADD_MOVE_ACCEL_RESERVE
(acceleration margin for overlaid motions)

2.4.3

Programming

The function is not programmable.

2.5

2.5

Path-acceleration limitation (channel-specific)

2.5.1

Detailed Description

2.5.1.1

General Information

General Information
To enable a flexible response to the machining situations concerned, setting data can be
used to limit the path acceleration calculated during preprocessing for specific channels:
SD42500 $SC_SD_MAX_PATH_ACCEL (maximum path acceleration)
The value specified in the setting data is only taken into account if it is smaller than the path
acceleration calculated during preprocessing.
The limitation must be activated for specific channels using setting data:
SD42502 $SC_IS_SD_MAX_PATH_ACCEL = TRUE

Acceleration (B2)
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Functions
2.5 Path-acceleration limitation (channel-specific)

2.5.2

Activation

2.5.2.1

Parameterization

Parameterization
Parameterization is carried out for specific channels using setting data:
SD42500 $SC_SD_MAX_PATH_ACCEL (maximum path acceleration)
SD42502 $SC_IS_SD_MAX_PATH_ACCEL (activation of path-acceleration limitation)

2.5.3

Programming

2.5.3.1

Limit value

Syntax
$SC_SD_MAX_PATH_ACCEL = limit value

Functionality
The path-acceleration limitation can be adjusted for the situation by programming the setting
data.

Limit value:
Value range: 0
Unit: m/s2
Application:
Part program
Static synchronized action

2.5.3.2

Switch ON/OFF

Syntax
$SC_IS_SD_MAX_PATH_ACCEL = value

2-10

Acceleration (B2)
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Functions
2.6 Path acceleration for real-time events (channel-specific)

Functionality
The path-acceleration limitation can be activated/deactivated by programming the setting
data.
Parameter: Value
Value range: TRUE, FALSE
Application:
Part program
Static synchronized action

2.6

2.6

Path acceleration for real-time events (channel-specific)

2.6.1

Detailed Description

2.6.1.1

General Information

General Information
So that no compromise has to be made between machining-optimized acceleration on the
one hand and time-optimized acceleration in connection with the following real-time events
on the other:
NC-STOP/NC-START
Feedrate override modifications
Modification of the velocity default for "safely reduced velocity" within the context of the
"Safely Integrated" function
the path acceleration can be set for the real-time events specified above using a channelspecific system variable:
$AC_PATHACC = path acceleration
Real-time event acceleration will only be active for the duration of the change in velocity in
respect of one of the real-time events specified above.

Limitation
If the specified path acceleration exceeds the capabilities of the machine axes that are of
relevance for the path, a limit will be imposed on the path acceleration within the control so
that the resulting axial acceleration (ares) is restricted to less than 2x the parameterized
maximum axial value (amax).
ares = 2 * amax, mit amax = MD32300 $MA_MAX_AX_ACCEL

Acceleration (B2)
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Functions
2.6 Path acceleration for real-time events (channel-specific)

Note
Real-time-event path acceleration is enabled, irrespective of the radial acceleration.

Effective
Effective

Real-time event acceleration is only enabled in AUTOMATIC and MDA operating

modes in conjunction with the following real-time events:
NC-STOP/NC-START
Override modifications
Modification of the velocity default for "safely reduced velocity" within the context
of the "Safely Integrated" function

Ineffective

Path acceleration for real-time events is ineffective for changes in path velocity that
are attributable to path planning during preprocessing for the channel, such as
contour curvatures, corners, kinematic transformation limitations, etc.
Real-time-event path acceleration is ineffective if the programmed value is smaller
than the path acceleration calculated during preprocessing for the path section
concerned.

Programming
For information about programming system variables in the part program or synchronized
actions, see Chapter: Programming.

2.6.2

Activation

Start-up (commissioning)
The function does not need to be activated.

2.6.3

Programming

Syntax
$AC_PATHACC = path acceleration

2-12

Acceleration (B2)
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Functions
2.7 Acceleration with programmed rapid traverse (G00) (axis-specific)

Functionality
Real-time-event path acceleration is set via the channel-specific system variables.
Parameter: Path acceleration
Value range: Path acceleration 0
Unit: m/s2
Deactivation: $AC_PATHACC = 0
Application:
Part program
Static synchronized action

Reset response
Real-time-event path acceleration is deactivated on reset.

Supplementary conditions
Programming $AC_PATHACC in the part program automatically triggers a preprocessing
stop with REORG (STOPRE).

2.7

2.7

Acceleration with programmed rapid traverse (G00) (axis-specific)

2.7.1

Detailed Description

2.7.1.1

General Information

Frequently, the acceleration for the machine axes involved in the machining process must be
set lower than the machine's performance capability officially allows because of the
supplementary conditions associated with the specific process concerned.
For time-optimized traversing of the machine axes with programmed rapid traverse (partprogram instruction G00), a specific maximum value can be programmed for the axis-specific
acceleration.

JOG setup mode

This function does not affect acceleration in respect of a rapid traverse override in JOG
setup mode.

Acceleration (B2)
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Functions
2.8 Acceleration with active jerk limitation (SOFT/SOFTA) (axis-specific)

2.7.2

Activation

2.7.2.1

Parameterization

The maximum value for axis-specific acceleration with programmed rapid traverse is
parameterized (G00) using the axis-specific machine data:
MD32434 $MA_G00_ACCEL_FACTOR
(scaling of the acceleration limitation with G00)
This is used to generate the maximum value for axis-specific acceleration with programmed
rapid traverse (G00) that is taken into account by the path planning component during
preprocessing:
Acceleration[axis] =
MD32300 $MA_MAX_AX_ACCEL * MD32434 $MA_G00_ACCEL_FACTOR

2.7.3

Programming

The function is not programmable.

2.8

2.8

Acceleration with active jerk limitation (SOFT/SOFTA) (axis-specific)

2.8.1

Detailed Description

2.8.1.1

General Information

Function
Compared with acceleration without jerk limitation, acceleration with jerk limitation results in
a certain degree of time loss, even when the same maximum acceleration value is used. To
compensate for this time loss, a specific maximum value can be programmed for the axisspecific acceleration as far as traversing of the machine axes with active jerk limitation
(SOFT/SOFTA) is concerned.

2-14

Acceleration (B2)
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Functions
2.8 Acceleration with active jerk limitation (SOFT/SOFTA) (axis-specific)

The maximum value for acceleration with active jerk limitation is parameterized using a
factor calculated in relation to the axis-specific maximum value. This is used to generate the
maximum value for axis-specific acceleration with active jerk limitation that is taken into
account by the path planning component during preprocessing:
Acceleration[axis] =
MD32300 $MA_MAX_AX_ACCEL * MD32433 $MA_SOFT_ACCEL_FACTOR

2.8.2

Activation

2.8.2.1

Parameterization

Function
The maximum value for acceleration with active jerk limitation (SOFT/SOFTA) is
parameterized using the axis-specific machine data:
MD32434 $MA_SOFT_ACCEL_FACTOR
(scaling of the acceleration limitation with SOFT)

2.8.3

Programming

The function is not programmable.

Acceleration (B2)
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Functions
2.9 Excessive acceleration for non-tangential block transitions (axis-specific)

2.9

2.9

Excessive acceleration for non-tangential block transitions (axisspecific)

2.9.1

Detailed Description

2.9.1.1

General Information

Function
In the case of non-tangential block transitions (corners), the programmable controller may
have to decelerate the geometry axes significantly in order to ensure compliance with the
parameterized axis dynamics. For the purpose of reducing/avoiding deceleration in
connection with non-tangential block transitions, a higher level of axis-specific acceleration
can be enabled.
Excessive acceleration is parameterized using a factor calculated in relation to the axisspecific maximum value. This is used to generate the maximum value for axis-specific
acceleration with non-tangential block transitions that is taken into account by the path
planning component during preprocessing:
Acceleration[axis] =
MD32300 $MA_MAX_AX_ACCEL * MD32310 $MA_MAX_ACCEL_OVL_FACTOR

2.9.2

Activation

2.9.2.1

Parameterization

Function
Excessive acceleration for non-tangential block transitions is parameterized using the axisspecific machine data:
MD32310 $MA_MAX_ACCEL_OVL_FACTOR
(overload factor for velocity jumps)

2-16

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Functions
2.10 Acceleration margin for radial acceleration (channel-specific)

2.9.3

Programming

Programmability
The function is not programmable.

2.10

2.10

Acceleration margin for radial acceleration (channel-specific)

2.10.1

Detailed Description

2.10.1.1

General Information

Overview
In addition to the path acceleration (tangential acceleration), radial acceleration also has an
effect on curved contours. If this is not taken into account during parameterization of the path
parameters, the effective axial acceleration during acceleration and deceleration on the
curved contour can, for a short time, reach 2x the maximum value.
Effective axial acceleration =
Path acceleration + radial acceleration =
2 * ( MD32300 $MA_MAX_AX_ACCEL )

1
1
DSDWK
DUDGLDO

1

Figure 2-3

Radial and path acceleration on curved contours

The channel-specific machine data:

MD20602 $MC_CURV_EFFECT_ON_PATH_ACCEL
(influence of path curvature on dynamic path response)
can be used to set the proportion of the axis-specific acceleration that is to be taken into
account for radial acceleration.

Acceleration (B2)
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Functions
2.10 Acceleration margin for radial acceleration (channel-specific)

When, for example, a value of 0.75 is applied, 75% of the axis-specific acceleration will be
made available for radial acceleration and 25% for path acceleration.
The corresponding maximum values are generally calculated as follows:
Radial acceleration =
MD20602 $MC_CURV_EFFECT_ON_PATH_ACCEL * MD32300 $MA_MAX_AX_ACCEL

Path acceleration =
(1 - MD20602 $MC_CURV_EFFECT_ON_PATH_ACCEL) * MD32300
$MA_MAX_AX_ACCEL

Example
The following machine parameters apply:
MD32300 $MA_MAX_AX_ACCEL for all geometry axes: 3 m/s
Maximum path velocity with a path radius of 10 mm due to mechanical constraints of the
machine: 5 m/min.
The radial acceleration is calculated as follows:

D UDGLDO 

Y SDWK >PPLQ@



U>PP@ >PV @

 

PV

The acceleration margin is set as follows:

0'0&B&859B())(&7B21B3$7+B$&&(/ 
D UDGLDO >PV @



0'0$B0$;B$;B$&&(/ >PV  @

 

Linear motions
The acceleration margin referred to above is ineffective in the case of linear motions (linear
interpolation) without active kinematic transformation.

2-18

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Functions
2.11 Jerk limitation with path interpolation (SOFT) (channel-specific)

2.10.2

Activation

2.10.3

Programming

Programmability
The function is not programmable.

2.11

2.11

Jerk limitation with path interpolation (SOFT) (channel-specific)

2.11.1

Detailed Description

2.11.1.1

General Information

Overview
As far as the functionality described in the rest of this document is concerned, constant
acceleration, i.e., acceleration with jerk limitation (jerk = infinite value), is the assumed
acceleration profile. In the case of acceleration with jerk limitation, linear interpolation is
applied in respect of acceleration from 0 to the maximum value.

Advantages
Minimal load on the machine's mechanical components and low risk of high-frequency and
difficult-to-control mechanical vibrations thanks to constant excessive acceleration.

Disadvantages
Longer machining times compared with stepped acceleration profile when the same
maximum velocity and acceleration values are used.

Acceleration (B2)
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Functions
2.11 Jerk limitation with path interpolation (SOFT) (channel-specific)

Acceleration profile

U
UPD[

W
UPD[
D
DPD[
W
DPD[
Y
YPD[

W

Figure 2-4

W

W

W

W

W

W

Jerk, acceleration and velocity schematic with jerk limitation acceleration profile

rmax:

Maximum jerk value

amax:

Maximum acceleration value

vmax:

Maximum velocity value

t:

Time

The following features of the acceleration profile can be identified from the figure above:
Interval: t0 - t1
Constant jerk with +rmax; linear increase in acceleration; quadratic increase in velocity
Interval: t1 - t2
Constant acceleration with +amax; linear increase in velocity
Interval: t2 - t3
Constant jerk with -rmax; linear decrease in acceleration; quadratic decrease in excessive
velocity until maximum value +vmax is reached
Interval: t3 - t4
Constant jerk with +rmax; linear increase in braking acceleration; quadratic decrease in
velocity

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2.11 Jerk limitation with path interpolation (SOFT) (channel-specific)

Interval: t4 - t5
Constant braking acceleration with -amax; linear decrease in velocity
Interval: t5 - t6
Constant jerk with -rmax; linear decrease in braking acceleration; quadratic decrease in
velocity reduction until zero velocity is reached v = 0

2.11.1.2

Maximum jerk value (axis-specific)

Function
The maximum jerk value can be set for each specific machine axis using the following
machine data:
MD32431 $MA_MAX_AX_JERK (maximum axis jerk)
The path parameters are calculated by the path planning component during preprocessing
so that the programmed maximum values of the machine axes that are of relevance for the
path are not exceeded.

Exceeding of maximum value

It is possible for the maximum value to be exceeded in connection with specific machining
situations (see following Section: System variable ($AC_PATHJERK)).

2.11.1.3

Maximum jerk value (channel-specific)

Function
As well as it being possible to set the maximum jerk value for specific axes, it can also be
assigned as a channel-specific path parameter using the following machine data:
MD20600 $MC_MAX_PATH_JERK (path-related maximum jerk)
To prevent the axis and channel-specific maximum jerk values interfering with one another,
the channel-specific value must be set to a value greater then the maximum axial values.

2.11.2

Activation

2.11.2.1

Parameterization

Function
The axis- and channel-specific maximum values are parameterized using the following
machine data:
MD32431 $MA_MAX_AX_JERK (maximum axis jerk)
MD20600 $MC_MAX_PATH_JERK (path-related maximum jerk)
Acceleration (B2)
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Functions
2.12 Jerk limitation with single-axis interpolation (SOFTA) (axis-specific)

2.11.3

Programming

Syntax
SOFT

Functionality
The SOFT part-program instruction is used to select the acceleration profile with jerk
limitation for the traversing operations of geometry axes in the channel.
G group: 21
Effective: Modal

Reset response
The channel-specific initial setting is activated via a reset:
MD20150 $MC_GCODE_RESET_VALUES[20]

Supplementary conditions
If the acceleration mode is changed in a part program during machining (BRISK SOFT), a
block change is performed at the point of transition with an exact stop at the end of the block,
even in continuous-path mode.

2.12

2.12

Jerk limitation with single-axis interpolation (SOFTA) (axis-specific)

2.12.1

Detailed Description

2.12.1.1

General Information

Overview
The maximum jerk value can be set for each specific machine axis for single-axis
movements (setup modes e.g. JOG, JOG/INC, positioning axis, reciprocating axis, etc.):
MD32430 $MA_JOG_AND_POS_MAX_JERK (maximum axis jerk)

Initial setting
Acceleration with jerk limitation can be set as the axial initial setting:
MD32420 $MA_JOG_AND_POS_JERK_ENABLE
(initial setting of axial jerk limitation)

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Functions
2.12 Jerk limitation with single-axis interpolation (SOFTA) (axis-specific)

2.12.2

Activation

2.12.2.1

Parameterization

Function
The function's initial setting and the maximum values are parameterized for specific axes
using machine data:
MD32420 $MA_JOG_AND_POS_JERK_ENABLE
(initial setting of axial jerk limitation)
MD32430 $MA_JOG_AND_POS_MAX_JERK (maximum axis jerk)

2.12.3

Programming

Syntax
SOFTA (axis{,axis})

Functionality
The SOFTA part-program instruction is used to select acceleration with jerk limitation for
single-axis movements (positioning axis, reciprocating axis, etc.)
G group: Effective: Modal

Axis:
Value range: Axis identifier for channel axes

Axis-specific initial setting

Acceleration with jerk limitation can be set as the axis-specific initial setting for single-axis
movements:
MD32420 $MA_JOG_AND_POS_JERK_ENABLE = TRUE

Reset response
The axis-specific initial setting is activated via a reset:
MD32420 $MA_JOG_AND_POS_ENABLE

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Functions
2.13 Path-jerk limitation (channel-specific)

2.13

2.13

Path-jerk limitation (channel-specific)

2.13.1

Detailed Description

2.13.1.1

General Information

Overview
To enable a flexible response to the machining situations concerned, setting data can be
used to limit the path jerk calculated during preprocessing for specific channels:
SD42510 $SC_SD_MAX_PATH_JERK (maximum path jerk)
The value specified in the setting data is only taken into account in the channel if it is smaller
than the path jerk calculated during preprocessing.
The limitation must be activated for specific channels using setting data:
SD42512 $SC_IS_SD_MAX_PATH_JERK = TRUE

2.13.2

Activation

2.13.2.1

Parameterization

Function
Parameterization is carried out for specific channels using setting data:
SD42510 $SC_SD_MAX_PATH_JERK (maximum path jerk)
SD42512 $SC_IS_SD_MAX_PATH_JERK
(activation of path-jerk limitation)

2-24

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Functions
2.13 Path-jerk limitation (channel-specific)

2.13.3

Programming

2.13.3.1

Maximum path jerk

Syntax
$SC_SD_MAX_PATH_JERK = jerk value

Functionality
The path-jerk limitation can be adjusted for the situation by programming the setting data.

Jerk value:
Value range: 0
Unit: m/s3
Application:
Part program
Static synchronized action

2.13.3.2

Switch ON/OFF

Syntax
$SC_IS_SD_MAX_PATH_JERK = value

Functionality
The path-jerk limitation can be activated/deactivated by programming the setting data.
Parameter: Value
Value range: TRUE, FALSE
Application:
Part program
Static synchronized action

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2.14 Path jerk for real-time events (channel-specific)

2.14

2.14

Path jerk for real-time events (channel-specific)

2.14.1

Detailed Description

2.14.1.1

General Information

Overview
So that no compromise has to be made between machining-optimized jerk on the one hand
and time-optimized jerk in connection with the following real-time events on the other:
NC-STOP/NC-START
Feedrate override modifications
Modification of the velocity default for "safely reduced velocity" within the context of the
"Safely Integrated" function
the path jerk can be set for the real-time events specified above using a channel-specific
system variable:
$AC_PATHJERK = path jerk
Path jerk for real-time events will only be active for the duration of the change in velocity in
respect of one of the real-time events specified above.

Limitation
As the jerk is not a physical variable of any relevance to the drive, no limit is imposed on the
jerk set.

Effective
Effective

Path jerk for real-time events is only enabled in AUTOMATIC and MDA operating
modes in conjunction with the following real-time events:
NC-STOP/NC-START
Override modifications
Modification of the velocity default for "safely reduced velocity" within the context
of the "Safely Integrated" function

Ineffective

Path jerk for real-time events is ineffective for changes in the path velocity that are
attributable to path planning during preprocessing for the channel, such as contour
curvatures, corners, kinematic transformation limitations, etc.
Path jerk for real-time events is ineffective if the programmed value is smaller than
the path jerk calculated during preprocessing for the path section concerned.

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2.14 Path jerk for real-time events (channel-specific)

Programming
For the purpose of setting the jerk for real-time events in accordance with the acceleration,
the system variables can be set as follows:
$AC_PATHJERK = $AC_PATHACC/smoothing time
$AC_PATHACC: Path acceleration [m/s2]
Smoothing time: Freely selectable, e.g., 0.02 s
For information about programming system variables in the part program or synchronized
actions, see Chapter: Programming.

2.14.2

Activation

Function
The function does not need to be activated.

2.14.3

Programming

Syntax
$AC_PATHJERK = path jerk

Functionality
The path jerk for real-time events is set via the channel-specific system variables.

Jerk value:
Value range: Path jerk 0
Unit: m/s3
Application:
Part program
Static synchronized action

Reset response
The function is deactivated on reset.

Supplementary conditions
Programming $AC_PATHJERK in the part program automatically triggers a preprocessing
stop with REORG (STOPRE).

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Functions
2.15 Jerk with programmed rapid traverse (G00) (axis-specific)

2.15

2.15

Jerk with programmed rapid traverse (G00) (axis-specific)

2.15.1

Detailed Description

2.15.1.1

General Information

Overview
Frequently, the maximum jerk for the machine axes involved in the machining process must
be set lower than the machine's performance capability officially allows because of the
supplementary conditions associated with the specific process concerned.
For time-optimized traversing of the machine axes with programmed rapid traverse (partprogram instruction G00), a specific maximum value can be programmed for the axisspecific jerk.

JOG setup mode

This function does not affect jerk in respect of a rapid traverse override in JOG setup mode.

2.15.2

Activation

2.15.2.1

Parameterization

Function
The maximum value for axis-specific jerk with programmed rapid traverse is parameterized
(G00) using the axis-specific machine data:
MD32434 $MA_G00_ACCEL_FACTOR
(scaling of the acceleration limitation with G00)
This is used to generate the maximum value for axis-specific jerk with programmed rapid
traverse (G00) that is taken into account by the path planning component during
preprocessing:
Jerk[axis] =
MD32431 $MA_MAX_AX_JERK * MD32435 $MA_G00_JERK_FACTOR

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2.16 Excessive jerk for block transitions without constant curvature (axis-specific)

2.15.3

Programming

Programmability
The function is not programmable.

2.16

2.16

Excessive jerk for block transitions without constant curvature (axisspecific)

2.16.1

Detailed Description

2.16.1.1

General Information

Overview
In the case of block transitions without constant curvature (e.g. straight line > circle), the
programmable controller has to decelerate movement of the geometry axes significantly in
order to ensure compliance with the parameterized axis dynamics. For the purpose of
reducing/avoiding deceleration in connection with block transitions without constant
curvature, a higher level of axis-specific jerk can be enabled.
The excessive jerk is parameterized using a dedicated axis-specific maximum value.

2.16.2

Activation

2.16.2.1

Parameterization

Function
The excessive jerk for block transitions without constant curvature is parameterized using
the axis-specific machine data:
MD32432 $MA_PATH_TRANS_JERK_LIM
(excessive jerk for block transitions without constant curvature)

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2.17 Jerk filter (axis-specific)

2.16.3

Programming

Programmability
The function is not programmable.

2.17

2.17

Jerk filter (axis-specific)

2.17.1

Detailed Description

2.17.1.1

General Information

Overview
In certain application scenarios, e.g.,when milling free-form surfaces, it may be beneficial to
smooth the position setpoint characteristics of the machine axes. This enables surface
quality to be improved by reducing the mechanical vibrations generated in the machine.
For the purpose of smoothing the position setpoint characteristic of a machine axis, a jerk
filter can be activated at position controller level, independently of the channel- and axisspecific jerk limitations taken into account at interpolator level.
The effect of the jerk filter must be as strong as possible without having an unacceptable
impact on contour accuracy. The filter should also have as "balanced" a smoothing effect as
possible, i.e., if the same contour is traversed forwards and backwards, the contour
smoothed by the filter should be as similar as possible in both directions.
To enable the jerk filter to be optimally matched to the machine conditions, various filter
modes are available:
2nd-order filter (PT2)
Sliding mean value generation
Bandstop filter

Mode: 2nd-order filter

Owing to the fact that it is a simple low-pass filter, "2nd-order filter" mode can only meet the
requirements specified above where relatively small filter time constants (around 10 ms) are
concerned. When used in conjunction with larger time constants, impermissible contour
deviations are soon manifest. The effect of the filter is relatively limited.
This filter mode offers advantages if very large filter time constants are needed and contour
accuracy is only of secondary importance (e.g. positioning axes).
For historical reasons, this filter mode is set as the default.

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Functions
2.17 Jerk filter (axis-specific)

Mode: Sliding mean value generation

Where minimal contour deviations are required, filter time constants within the range of 2040 ms can be set using the "sliding mean value generation" filter mode. The smoothing effect
is largely symmetrical.
The display of the calculated servo gain factor (KV factor), e.g. in the HMI Advanced "Axis"
service screen, shows smaller values than would normally be expected for the filter. The
contour accuracy is in fact higher than the displayed KV filter appears to suggest.
When changing from "2nd-order filter" to "sliding mean value generation" filter mode, the
displayed KV factor may, therefore, drop (with identical filter time constant), even though
there is an improvement in contour accuracy.

Mode: Bandstop filter

The bandstop filter is a 2nd-order filter in terms of numerator and denominator:

+V

V
  I=

V
  I1

 V ' =
  I=
 V ' 1
  I1

where:
fZ:

Numerator natural freq.

fN:

Denominator natural freq.

DZ:

Numerator damping

DN:

Denominator damping

Since a vibration-capable filter setting is not expected to yield useful results in any case, as
with the jerk filter's "2nd-order filter" (PT2) low-pass filter (PT2) mode there is no setting
option for the denominator damping DN. The denominator damping DN is permanently set to
1.
The bandstop filter can be parameterized in 2 different ways:
Real bandstop filter
Bandstop filter with additional amplitude response increase/decrease at high frequencies
Real bandstop filter
The real bandstop filter is applied when identical numerator and denominator natural
frequencies are selected:
fZ = fN = fblock (blocking frequency)
If numerator damping setting = 0 is selected, the blocking frequency is equivalent to
complete attenuation. In this case the 3 dB bandwidth is calculated as follows:
f3 dB bandwidth = 2 * fblock
If instead of complete attenuation, a reduction by a factor of k is all that is required, then
numerator damping should be selected in accordance with k. In this case the above formula
for calculating the 3 dB bandwidth no longer applies.

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Functions
2.17 Jerk filter (axis-specific)
Bandstop filter with additional amplitude response increase/decrease at high frequencies
In this case, the numerator and denominator natural frequencies are set to different values.
The numerator natural frequency determines the blocking frequency.
By selecting a lower/higher denominator natural frequency than the numerator natural
frequency, you can increase/decrease the amplitude response at high frequencies. An
amplitude response increase at high frequencies can be justified in most cases, as the
controlled system generally possesses a lowpass characteristic itself, i.e., the amplitude
response drops at high frequencies anyway.
Supplementary conditions
If too high a numerator natural frequency is selected, the filter is disabled. In this case the
limiting frequency fZmax depends on the position-control cycle:

I =PD[ 


  7
=PLQ

6KDQQRQ7KHRUHP
  7
3RVLWLRQFRQWUROF\FOH

The limitation is enabled for specific axes using machine data:

MD32400 $MA_AX_JERK_ENABLE (axial jerk limitation)
and set with time specifications for the smoothing filter using machine data:
MD32410 $MA_AX_JERK_TIME (time constants for the axial return filter)
.
With SW 5.1 and higher, it is also possible to control the jerk limitation in the position
controller with a new filter based on a smoothing method that incurs few contour errors:
MD32402 AX_JERK_MODE = 1

2nd-order filter (default)

corresponds to SW 1 to SW 4.4

MD32402 AX_JERK_MODE = 2

Sliding mean value generation

MD32402 AX_JERK_MODE = 3

Bandstop filter with SW 6.3 and higher

(New jerk filter with SW 5.1 and higher).

Modus 2 requires a bit more computation time, but with the same smoothing effect, it results
in lower contour errors or, with the same accuracy, in a smoother contour with smoother
movements. Mode 2 is recommended. Mode 1 is the default mode in SW 1 to SW 4.4 for
compatibility reasons.
For more information about how the jerk filter available with SW 5.1 and higher works
(balancing filter for improving the position setpoints of the position controller), please refer to:
References:
/FB1/ Manual of Functions, Basic Functions; Velocities, Setpoint/Actual-Value Systems,
Regulatory Control (G2), Chapter: "Control Optimization"

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2.17 Jerk filter (axis-specific)

Mode 3
There are 2 parameterization options for the bandstop filter:
"Real bandstop filter":
When identical numerator and denominator natural frequencies are selected (=blocking
frequency). If you select (numerator) damping setting zero, the blocking frequency is
equivalent to complete attenuation.
In this case the 3 dB bandwidth is determined on the following basis:
fbandwidth = 2 * fblock.
If instead of complete attenuation, a reduction by a factor of k is all that is required, then
the numerator damping should be selected in accordance with k.
"Bandstop filter with additional amplitude response increase/decrease at high
frequencies":
In this case, the numerator and denominator natural frequencies are set to different
values. The numerator natural frequency determines the blocking frequency. By selecting
a lower (higher) denominator natural frequency than the numerator natural frequency,
you can increase (decrease) the amplitude response at high frequencies. An amplitude
response increase at high frequencies can be justified in most cases, as the controlled
system generally possesses a lowpass characteristic itself, i.e., the amplitude response
drops at high frequencies anyway.

2.17.2

Activation

2.17.2.1

Parameterization

Activation
The jerk filter is activated using the machine data:
MD32400 $MA_AX_JERK_ENABLE = TRUE
The jerk filter is active in all operating modes and with all types of interpolation.

Filter mode
The mode is selected using the machine data:
MD32402 $MA_AX_JERK_MODE = mode
Mode = 1

(2nd-order filter)

Mode = 2

(Sliding mean value generation)

Mode = 3

(Bandstop filter)

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Functions
2.18 Kneeshaped acceleration characteristic curve

2.17.3

Programming

Programmability
The function is not programmable.

2.18

2.18

Kneeshaped acceleration characteristic curve

2.18.1

Detailed Description

2.18.1.1

Adaptation to the motor characteristic curve

Function
Various types of motor, particularly stepper motors, have a torque characteristic that is highly
dependent upon speed and shows a steep decrease in torque in the upper speed range. To
ensure optimum utilization of the motor characteristic curve, it is necessary to reduce the
acceleration once a certain speed is reached.

0>1P@
0PD[

0UHG


Figure 2-5

2-34


QUHG





  
QPD[

Q>@

Torque characteristic curve of a motor with torque characteristic that is highly dependent
upon speed

1:

Torque decrease zone

nred:

Speed above which reduced torque has to be assumed

nmax:

Maximum speed

Mmax:

Max. torque

Mred:

Torque at nmax (corresponds to creep acceleration)

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Functions
2.18 Kneeshaped acceleration characteristic curve

Simulation of torque characteristic

For the purpose of simulating the torque characteristic of the motor characteristic curve, the
machine data:
MD35242 $MA_ACCEL_REDUCTION_TYPE = characteristic
can be used to select various types of characteristic curve:
0

= Constant characteristic

= Hyperbolic characteristic

= Linear characteristic

The following figures show typical velocity and acceleration characteristic curves for the
respective types of characteristic:
Constant characteristic

YPD[
DPD[
YUHG

DUHG

YUHG

Figure 2-6

YPD[

Acceleration and velocity characteristic with acceleration reduction: 0 = constant

Hyperbolic characteristic

YPD[
DPD[
YUHG

DUHG

YUHG

Figure 2-7

YPD[ Y

Acceleration and velocity characteristic with acceleration reduction: 1 = hyperbolic

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Functions
2.18 Kneeshaped acceleration characteristic curve
Linear characteristic

Y
YPD[

DPD[
YUHG

DUHG

YUHG

Figure 2-8

YPD[ Y

Acceleration and velocity characteristic with acceleration reduction: 2 = linear

The key data for the characteristic curves equate to:

vmax

2.18.1.2

= $MA_MAX_AX_VELO

vred

= $MA_ACCEL_REDUCTION_SPEED_POINT * $MA_MAX_AX_VELO

amax

= $MA_MAX_AX_ACCEL

ared

= (1 - $MA_ACCEL_REDUCTION_FACTOR) * $MA_MAX_AX_ACCEL

Effects on path acceleration

Function
The path acceleration characteristic curve is generated on the basis of the types of
characteristic for the axes that are of relevance for the path. If axes with different types of
characteristic curve are interpolated together, the acceleration profile for the path
acceleration will be determined on the basis of the reduction type that is most restrictive.
The following order of priorities applies, whereby 1 = top priority:
1. Acceleration reduction: 0 = constant characteristic
2. Acceleration reduction: 1 = hyperbolic characteristic
3. Acceleration reduction: 2 = linear characteristic
4. No acceleration reduction effective
A situation, whereby no acceleration reduction is active, arises for example when:
MD35220 $MA_ACCEL_REDUCTION_SPEED_POINT = 1
and/or
MD35230 $MA_ACCEL_REDUCTION_FACTOR = 0

2-36

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Functions
2.18 Kneeshaped acceleration characteristic curve

Note
Machine axes featuring stepper motor and DC drive can be interpolated together.

2.18.1.3

Substitute characteristic curve

Function
If the programmed path cannot be traversed using the parameterized acceleration
characteristic curve (e.g., active kinematic transformation), a substitute characteristic curve
is generated by reducing the dynamic limit values. The dynamic limit values are calculated to
ensure that the substitute characteristic curve provides the best possible compromise
between maximum velocity and constant acceleration.

Substitute characteristic curve with linear path sections

Limitation to this value is applied if the programmed path velocity is greater than that at
which 15% of the maximum acceleration capacity is still available (v15%a). Consequently,
15% of the maximum acceleration capacity/motor torque always remains available, whatever
the machining situation.
D
DPD[

DHUV

D
/RFNHG]RQH
DUHG
YUHG

Figure 2-9

YSURJ

YD

YPD[

Substitute path characteristic curve: Linear path

aers:

Substitute characteristic curve constant acceleration

a15%:

Minimal constant acceleration

vers:

Substitute characteristic curve velocity

vprog:

Programmed velocity

v15%a:

Velocity at a15%

a15% = 0.15 @ (amax - ared) + ared

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-37

Functions
2.18 Kneeshaped acceleration characteristic curve

Substitute characteristic curve with curved path sections

In the case of curved path sections, normal and tangential acceleration are considered
together. The path velocity is reduced so that only up to 25% of the speed-dependent
acceleration capacity of the axes is required for normal acceleration. The remaining 75% of
the acceleration capacity is set aside for the tangential acceleration, i.e.,
deceleration/acceleration on the path.
D
DPD[
D1

DHUV

Y
U

$[LDOFKDUDFWHULVWLFDY

DUHG
YUHG

Figure 2-10

YHUV

YPD[

Substitute path characteristic curve: Curved path

aN:

Normal acceleration

aers:

Substitute characteristic curve constant acceleration

vers:

Substitute characteristic curve velocity

r:

Path radius

Block transitions with continuous-path mode

If continuous-path mode is active, non-tangential block transitions result in axial velocity
jumps when the programmed path velocity is used for traversing.
As a result, the path velocity is controlled in such a way that prevents any axial velocity
proportion from exceeding the creep velocity vred at the time of the block transition.

Deceleration ramp with continuous-path mode and LookAhead

In the case of consecutive part program blocks with short paths, an acceleration or
deceleration operation may be spread over several part program blocks.
In such a situation LookAhead also takes into account the parameterized speed-dependent
acceleration characteristic.

2-38

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Functions
2.18 Kneeshaped acceleration characteristic curve

YPD[

YUHG

1

Figure 2-11

1

Brake application point

2:

Torque decrease zone

3:

Maximum torque zone

vred:

Creep velocity

vmax:

Maximum velocity

Nxy:

Part program block with block number Nxy

Activation

2.18.2.1

Parameterization

1

1

1

Deceleration with LookAhead

1:

2.18.2

1

Function
The knee-shaped acceleration characteristic curve is parameterized for specific axes using
the following machine data:
MD32000 $MA_MAX_AX_VELO (maximum axis velocity)
MD35220 $MA_ACCEL_REDUCTION_SPEED_POINT
(speed for reduced acceleration)
MD35230 $MA_ACCEL_REDUCTION_FACTOR (reduced acceleration)
MD32300 $MA_MAX_AX_ACCEL (Maximum axis acceleration)
MD35242 $MA_ACCEL_REDUCTION_TYPE
(type of acceleration reduction: 0 = constant, 1 = hyperbolic, 2 = linear)

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-39

Functions
2.18 Kneeshaped acceleration characteristic curve

2.18.2.2

Commissioning

Function
The knee-shaped acceleration characteristic curve is activated for a specific machine axis
using the machine data:
MD35240 $MA_ACCEL_TYPE_DRIVE = TRUE

Single-axis interpolation
As soon as the knee-shaped acceleration characteristic curve is activated, in the case of
single-axis interpolations (positioning axis, reciprocating axis, manual travel, etc.), traversing
is performed exclusively in DRIVEA mode.
Switching of the acceleration profile via the part-program instructions:
Abrupt acceleration changes (BRISKA)
Acceleration with jerk limitation (SOFTA)
is not possible.

Path interpolation
If the knee-shaped acceleration characteristic curve is parameterized for a machine axis that
is of relevance for a programmed path, but the DRIVE part-program instruction has not
been activated, then a substitute characteristic curve with lower dynamic limit values is
generated for the path.

2.18.3

Programming

2.18.3.1

Channel-specific activation (DRIVE)

Syntax
DRIVE

Functionality
The knee-shaped characteristic curve is activated for path acceleration using the DRIVE
part-program instruction.
G group: 21
Effective: Modal

Reset response
The channel-specific default setting is activated via a reset:
MD20150 $MC_GCODE_RESET_VALUES[20]

2-40

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Functions
2.18 Kneeshaped acceleration characteristic curve

Dependencies
If the knee-shaped acceleration characteristic curve is parameterized for a machine axis,
then this becomes the default acceleration profile for all traversing operations.
If the effective acceleration profile is changed for a specific path section using the SOFT or
BRISK part-program instructions, then an appropriate substitute characteristic curve with
lower dynamic limit values is used in place of the knee-shaped acceleration characteristic
curve.
The knee-shaped acceleration characteristic curve can be reactivated by reprogramming
DRIVE.

2.18.3.2

Axis-specific activation (DRIVEA)

Syntax
DRIVEA (axis{,axis})

Functionality
The knee-shaped characteristic curve is activated for all single-axis interpolations
(positioning axis, reciprocating axis, etc.) for specific axes using the part-program instruction.
G group: Effective: Modal

Axis:
Value range: Axis identifier for the channel axes

Reset response
The channel-specific default setting is activated via a reset:
MD20150 $MC_GCODE_RESET_VALUES[20]

Dependencies
If the knee-shaped acceleration characteristic curve is parameterized for a machine axis,
then this becomes the default acceleration profile for all traversing operations.
If the effective acceleration profile is changed for a specific axis using the SOFTA or BRISKA
part-program instructions, then an appropriate substitute characteristic curve is used in place
of the knee-shaped acceleration characteristic curve.
It is possible to switch back to the knee-shaped acceleration characteristic curve for a
specific axis by programming DRIVEA.

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-41

Functions
2.18 Kneeshaped acceleration characteristic curve

2-42

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Supplementary conditions
3.1

3.1

Acceleration and jerk

There are no other supplementary conditions to note.

3.2

3.2.1

3.2

Kneeshaped acceleration characteristic curve

Active kinematic transformation

Key statement
The knee-shaped acceleration characteristic curve is not taken into account in connection
with an active kinematic transformation. The control switches to acceleration without jerk
limitation (BRISK) and a substitute characteristic curve is adopted for path acceleration.

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

3-1

Supplementary conditions
3.2 Kneeshaped acceleration characteristic curve

3-2

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Examples
4.1

4.1.1

4.1

Acceleration

Path velocity characteristic

Key statement
An excerpt from a part program is provided below, together with the associated acceleration
characteristic, by way of an example. These are used to illustrate how the path velocity can
be adapted to take account of various events and the resulting change in acceleration.

Part program (excerpt, schematic)

; Acceleration selection in accordance with fast input 1 ($A_IN[1]):
N53 ID=1 WHEN $A_IN[1] == 1 DO $AC_PATHACC = 2.*$MA_MAX_AX_ACCEL[X]
; Test override profile (simulates external intervention):
N54 ID=2 WHENEVER ($AC_TIMEC > 16) DO $AC_OVR=10
N55 ID=3 WHENEVER ($AC_TIMEC > 30) DO $AC_OVR=100
;Approach
N1000 G0 X0 Y0 BRISK
N1100 TRANS Y=-50
N1200 AROT Z=30 G642
; Contour
N2100 X0 Y0
N2200 X = 70 G1 F10000 RNDM=10 ACC[X]=30 ACC[Y]=30
N2300 Y = 70
N2400 X0
N2500 Y0
M30

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

4-1

Examples
4.2 Jerk

Y>PV@


$&B295 

$&B295 
W>PV@
1

Figure 4-1

1

Switching between path acceleration specified during preprocessing and real-time acceleration

Acceleration profile: BRISK

1:

Accelerate to 100% of path velocity (F10000) in accordance with acceleration default: ACC (N2200...)

2:

Brake to 10% of path velocity as a result of override modification ($AC_OVR) in accordance with real-time
acceleration $AC_PATHACC (N53/N54...)

3:

Accelerate to 100% of path velocity as a result of override modification ($AC_OVR) in accordance with real-time
acceleration $AC_PATHACC (N53/N55...)

4:

Brake to block end velocity for intermediate smoothing block in accordance with acceleration default: ACC
(N2200...)

5:

Speed limitation as a result of smoothing (see 9)

6:

Accelerate to 100% of path velocity ($AC_OVR) in accordance with acceleration default: ACC (N2300...)

7:

Decelerate as a result of override modification at a rate of acceleration that is in accordance with real-time
acceleration $AC_PATHACC (N53/N54...)

8:

Accelerate to 100% of path velocity as a result of override modification ($AC_OVR) in accordance with real-time
acceleration $AC_PATHACC (N53/N55...)

9:

Intermediate block inserted within the control as a result of the programmed smoothing (RNDM) (N2200...)

4.2

4.2.1

4.2

Jerk

Path velocity characteristic

Key statement
An excerpt from a part program is provided below, together with the associated acceleration
characteristic, by way of an example. These are used to illustrate how the path velocity can
be adapted to take account of various events and the resulting change in jerk.

4-2

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Examples
4.2 Jerk

Part program (excerpt, schematic)

; Setting of path acceleration and path jerk in the event of external intervention:
N0100 $AC_PATHACC = 0.
N0200 $AC_PATHJERK = 4. * ($MA_MAX_AX_JERK[X] + $MA_MAX_AX_JERK[Y]) / 2.
; Synchronized actions for the purpose of varying the override (simulates external
intervention):
N53 ID=1 WHENEVER ($AC_TIMEC > 16) DO $AC_OVR=10
N54 ID=2 WHENEVER ($AC_TIMEC > 30) DO $AC_OVR=100
;Approach
N1000 G0 X0 Y0 SOFT
N1100 TRANS Y=-50
N1200 AROT Z=30 G642
; Contour
N2100 X0 Y0
N2200 X = 70 G1 F10000 RNDM=10
N2300 Y = 70
N2400 X0
N2500 Y0
M30

Y>PV@

295 

295 

295 

W>PV@
1

1
51'0 

Figure 4-2

51'0

Switching between path jerk specified during preprocessing and $AC_PATHJERK

Acceleration profile: SOFT

1:

Jerk according to $MA_MAX_AX_JERK[..]

2:

Jerk according to $AC_PATHJERK

3:

Jerk according to $MA_MAX_AX_JERK[..] (approach block end velocity)

4:

Velocity limit due to arc

5:

Jerk according to $AC_PATHJERK

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

4-3

Examples
4.3 Acceleration and jerk

4.3

4.3

Acceleration and jerk

Key statement
In the following example a short part program is used to illustrate the velocity and
acceleration characteristic for the X-axis. It also shows the connection between specific
velocity and acceleration-related machine data and the contour sections they influence.

Part program
N90 F5000 SOFT G64

; Continuous-path mode, acceleration with jerk

limitation

N100 G0 X0 Y0 Z0

; Rapid traverse

N110 G1 X10

;Straight line

N120 G3 CR=5 X15 Y5

; Circular arc, radius 5 mm, block transition:

tangential

N130 G3 CR=10 X5 Y15

; Circular arc, radius 10 mm, block transition:

tangential

N140 G1 X-5 Y17.679

; straight, 15o bend

N200 M30

\
1

1



1


Figure 4-3

4-4

1




Part program contour

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Examples
4.4 Kneeshaped acceleration characteristic curve

0$;B$;B$&&(/>;@ 62)7B$&&(/B)$&725>;@
0'0$;B$&&(/B29/B)$&725>;@
0'0$;B$;B-(5.>;@

1

1

1

1

$[LVDFFHOHUDWLRQ
$[LVYHORFLW\

Figure 4-4

4.4

4.4.1

0'3$7+B75$16B-(5.B/,0>;@

X axis: Velocity and acceleration characteristic

4.4

Kneeshaped acceleration characteristic curve

Activation

Key statement
The example given illustrates how the knee-shaped acceleration characteristic curve is
activated on the basis of:
Machine data
Part program instruction

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

4-5

Examples
4.4 Kneeshaped acceleration characteristic curve

Machine data
Parameterizing the characteristic curve (example only)
X axis
MD35220 $MA_ACCEL_REDUCTION_SPEED_POINT[X] = 0.4
MD35230 $MA_ACCEL_REDUCTION_FACTOR[X] = 0.85
MD35242 $MA_ACCEL_REDUCTION_TYPE[X] = 2
MD35240 $MA_ACCEL_TYPE_DRIVE[X] = TRUE
Y axis
MD35220 $MA_ACCEL_REDUCTION_SPEED_POINT[Y] = 0.0
MD35230 $MA_ACCEL_REDUCTION_FACTOR[Y] = 0.6
MD35242 $MA_ACCEL_REDUCTION_TYPE[Y] = 1
MD35240 $MA_ACCEL_TYPE_DRIVE[Y] = TRUE
Z axis
MD35220 $MA_ACCEL_REDUCTION_SPEED_POINT[Z] = 0.6
MD35230 $MA_ACCEL_REDUCTION_FACTOR[Z] = 0.4
MD35242 $MA_ACCEL_REDUCTION_TYPE[Z] = 0
MD35240 $MA_ACCEL_TYPE_DRIVE[Z] = FALSE

Activation by setting as the channel-specific default setting

MC_GCODE_RESET_VALUE[20] = 3 (DRIVE)

Part program (excerpt)

N10 G1 X100 Y50 Z50 F700

Path motion (X,Y, Z) with DRIVE

N15 Z20

Path motion (Z) with DRIVE

N20 BRISK

Switchover to BRISK

N25 G1 X120 Y70

Path motion (Y, Z) with substitute

characteristic curve

N30 Z100

Path motion (Z) with BRISK

N35 POS[X] = 200 FA[X] = 500

Positioning motion (X) with DRIVEA

N40 BRISKA(Z)

Activate BRISKA for Z

N40 POS[Z] = 50 FA[Z] = 200

Positioning motion (Z) with BRISKA

N45 DRIVEA(Z)

Activate DRIVEA for Z

N50 POS[Z] = 100

Positioning motion (Z) with DRIVE

N55 BRISKA(X)

results in error message

...

4-6

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Data lists
5.1

5.1.1

5.1

Machine data

Channelspecific machine data

Number

Identifier: $MC_

Description

20150

GCODE_RESET_VALUES

Initial setting of G groups

20500

CONST_VELO_MIN_TIME

Minimum time with constant velocity

20600

MAX_PATH_JERK

Pathrelated maximum jerk

20602

CURV_EFFECT_ON_PATH_ACCEL

Influence of path curvature on dynamic path response

20610

ADD_MOVE_ACCEL_RESERVE

Acceleration reserve for overlaid movements

5.1.2

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

32000

MAX_AX_VELO

Maximum axis velocity

32300

MAX_AX_ACCEL

Maximum axis acceleration

32310

MAX_ACCEL_OVL_FACTOR

Overload factor for velocity jump

32320

DYN_LIMIT_RESET_MASK

Reset behavior of dynamic limits

32400

AX_JERK_ENABLE

Axial jerk limitation

32402

AX_JERK_MODE

Filter type for axial jerk limitation

32410

AX_JERK_TIME

Time constant for axial jerk filter

32420

JOG_AND_POS_JERK_ENABLE

Enabling axial jerk limitation

32430

JOG_AND_POS_MAX_JERK

Max. axial jerk for JOG and POS

32431

MAX_AX_JERK

Maximum axis jerk for path motion

32432

PATH_TRANS_JERK_LIM

Max. axial jerk of a geometry axis at block boundary

32433

SOFT_ACCEL_FACTOR

Scaling of acceleration limitation for SOFT

32434

G00_ACCEL_FACTOR

Scaling of acceleration limitation for G00

32435

G00_JERK_FACTOR

Scaling of axial jerk limitation for G00

35220

ACCEL_REDUCTION_SPEED_POINT

Speed for reduced acceleration

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

5-1

Data lists
5.2 Setting data
Number

Identifier: $MA_

Description

35230

ACCEL_REDUCTION_FACTOR

Acceleration reduction factor

35240

ACCEL_TYPE_DRIVE

"DRIVE" acceleration characteristic curve: ON/OFF

35242

ACCEL_REDUCTION_TYPE

Type of acceleration reduction

5.2

5.2

5.2.1
Number

Setting data

Channelspecific setting data

Identifier: $SC_

Description

42500

SD_MAX_PATH_ACCEL

Max. path acceleration

42502

IS_SD_MAX_PATH_ACCEL

Analysis of SD 42500: ON/OFF

42510

SD_MAX_PATH_JERK

Max. path-related jerk

42512

IS_SD_MAX_PATH_JERK

Analysis of SD 42510: ON/OFF

5.3

5.3

System variables

Identifier

Description

$AC_PATHACC

Path acceleration for real-time events

$AC_PATHJERK

Path jerk for real-time events

5-2

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Index
$

$AC_PATHACC, 2-12, 2-27

$AC_PATHJERK, 2-26, 2-27
$SC_IS_SD_MAX_PATH_ACCEL, 2-10
$SC_IS_SD_MAX_PATH_JERK, 2-25
$SC_SD_MAX_PATH_ACCEL, 2-10
$SC_SD_MAX_PATH_JERK, 2-25

MD20150, 2-4, 2-22, 2-40, 2-41

MD20500, 2-5, 2-6
MD20600, 2-21
MD20602, 2-17, 2-18
MD20610, 2-9
MD32000, 2-39
MD32300, 2-3, 2-14, 2-15, 2-16, 2-17, 2-18, 2-39
MD32310, 2-16
MD32400, 2-32, 2-33
MD32402, 2-33
MD32410, 2-32
MD32420, 2-4, 2-22, 2-23
MD32430, 2-22, 2-23
MD32431, 2-21, 2-28
MD32432, 2-29
MD32433, 2-15
MD32434, 2-14, 2-15, 2-28
MD32435, 2-28
MD35220, 2-36, 2-39
MD35230, 2-36, 2-39
MD35240, 2-40
MD35242, 2-35, 2-39

A
ACC[axis], 2-7

B
BRISK, 2-3
BRISKA, 2-4

D
DRIVE, 2-40
DRIVEA, 2-41

J
Jerk limiting
Smoothing method, 2-32

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

S
SD42500, 2-9, 2-10
SD42502, 2-9, 2-10
SD42510, 2-24
SD42512, 2-24
SOFT, 2-22
SOFTA, 2-23

Index-1

Index

Index-2

Acceleration (B2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

1
Brief description
______________

SINUMERIK 840D sl/840Di sl/840D/840Di/810D Diagnostic tools (D1)

2
Detailed description
______________
SINUMERIK
840D sl/840Di sl/840D/840Di/810D
Diagnostic tools (D1)

Valid for

Control

SINUMERIK 840D sl/840DE sl

SINUMERIK 840Di sl/840DiE sl
SINUMERIK 840D powerline/840DE powerline
SINUMERIK 840Di powerline/840DiE powerline
SINUMERIK 810D powerline/810DE powerline
NCU System Software for 840D sl/840DE sl
NCU system software for 840D sl/DiE sl
NCU system software for 840D/840DE
NCU system software for 840Di/840DiE
NCU system software for 810D/810DE
03/2006 Edition
6FC5397-0BP10-1BA0

4
Examples
______________
5
Data lists
______________

Function Manual

Software

3
Constraints
______________

Version
1.3
1.0
7.4
3.3
7.4

Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
Danger
indicates that death or severe personal injury will result if proper precautions are not taken.
Warning
indicates that death or severe personal injury may result if proper precautions are not taken.
Caution
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
Notice
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.

Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage
Note the following:
Warning
This device may only be used for the applications described in the catalog or the technical description and only in
connection with devices or components from other manufacturers which have been approved or recommended by
Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly
as well as careful operation and maintenance.

Trademarks
All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.

Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG
Automation and Drives
Postfach 48 48
90437 NRNBERG
GERMANY

Order No.: 6FC5397-0BP10-1BA0

Edition 05/2006

Copyright Siemens AG 2006.

Technical data subject to change

Table of contents
1

Brief description ...................................................................................................................................... 1-1

Detailed description ................................................................................................................................ 2-1

2.1

Description of diagnostic tools ................................................................................................... 2-1

2.2

Service displays ......................................................................................................................... 2-4

2.3

Axis/spindle service display ....................................................................................................... 2-5

2.4

Drive service display (for digital drives only)............................................................................ 2-15

2.5

Service display PROFIBUS DP 840Di..................................................................................... 2-26

2.6

Communication log .................................................................................................................. 2-29

2.7

PLC status................................................................................................................................ 2-30

2.8

Other diagnostics tools ............................................................................................................ 2-31

2.9

Identifying defective drive modules.......................................................................................... 2-32

Constraints ............................................................................................................................................. 3-1

Examples................................................................................................................................................ 4-1

Data lists................................................................................................................................................. 5-1

5.1
5.1.1
5.1.2
5.1.3

Machine data.............................................................................................................................. 5-1

Drive-specific machine data....................................................................................................... 5-1
NC-specific machine data .......................................................................................................... 5-2
Axis/spindlespecific machine data ............................................................................................. 5-2

5.2
5.2.1

Setting data ................................................................................................................................ 5-3

Axis/spindle-specific setting data ............................................................................................... 5-3

5.3
5.3.1
5.3.2

Signals ....................................................................................................................................... 5-3

Signals to axis/spindle ............................................................................................................... 5-3
Signals from axis/spindle ........................................................................................................... 5-4

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

Diagnostic tools (D1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

iii

Table of contents

iv

Diagnostic tools (D1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Brief description

Diagnostic tools
Integrated and external diagnostic tools are available for operating the SINUMERIK control.
In addition, the NC assists with error delimitation for drive problems by providing the option
of simulating the drive interface of machine axes.

Integrated diagnostic tools

The following information is displayed via the HMI user interface:
Display of alarms and messages from the control system or drives in plaintext
Status displays for:
Interface signals from NC, HMI, PLC and I/O modules
Data blocks
PLC flags, timers and counters
Inputs and outputs of the PLC.
Service displays
Nominal values, actual values and status data for axes/spindles
Communication error log for NC, PLC and HMI
Logbook
Display showing version of system software installed

Diagnostic tools (D1)

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1-1

Brief description

External diagnostic tools

The 611D commissioning software (to be installed on an external computer) is used to
configure and set parameters for SIMODRIVE 611-D drives.
The 611D commissioning software provides the following functions:
First commissioning through direct input of drive parameters
Commissioning by transferring standard data records that are derived from motor/power
section combinations
Automatic controller setting (self-optimization)
Measurement functions for evaluating speed and position control loops and regulating
torque in the time and frequency range without external measurement equipment.
Fast Fourier Transformation (FFT) for analysis of the control loop setting and machine
kinematics
Circularity test
Archiving drive and control data
By means of the DAC configuration, the 611D drive modules enable the output of all
important control loop variables of the position, speed and torque levels to external
measurement devices (e.g. oscilloscope, signal plotter) via measuring sockets.

References
A detailed description of the 611D commissioning software can be found in:
/FBA/ Function Manual, Drive Functions, Speed Control Loop (DD2)
A detailed description of the circularity test can be found in:
/FB2/ Function Manual, Extended Functions, Compensations (K3)

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Detailed description
2.1

2.1

Description of diagnostic tools

Scope
The Function Manual deals with displays of the user interface, system functions, procedures
for determining system statuses and, if necessary, measures for avoiding undesirable
conditions for the NC control, PLC and drives.

General
Alarm and signal status displays
The currently active or not yet acknowledged alarms and messages are displayed in the
Diagnostics operating area.

Alarm log
The alarm log contains the alarms that have occurred and the time. Detailed information on
the individual alarms can be found in:
References: /DA/ Diagnostics Manual, or in the case of systems with HMI Advanced see
Online Help.

Note
The corresponding explanations for alarms and messages which the machine tool
manufacturer issues (range of values ......),
can be found in the machine tool manufacturer's documentation.

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Detailed description
2.1 Description of diagnostic tools

Alarm handler
Application
The alarm handler provides an infrastructure for activating and managing alarms on the
NCK.

Functions
Buffering of a maximum of 16 alarms that have been activated since system powerup and
which have not yet been reset.
Alarm reactions can be programmed as channelspecific, modegroupspecific or NCKspecific reactions.
The "NoReady" alarm reaction can also be programmed as a channelspecific reaction.

Activation
The alarm handler is activated when an error status is detected in the NCK, causing an
alarm to be output.
It is possible to trigger an alarm in a part program using the SETAL command.
Reference: /PGA/Programming Manual Advanced

Note
The currently active alarms in the NCK are read via the operator panel interface.
It is not possible to set alarms externally in the NCK.

Alarms with an alarm ID in the 60000 to 60999 range can be activated in a part program.

Data backup
On Power ON , the alarm-handler data are reinitialized completely, since they are not
stored in the buffered SRAM.

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Detailed description
2.1 Description of diagnostic tools

Compatibility
As of SW 4
As of SW 4.1 and later, it is possible to set the channelspecific signal CHANNEL_NOREADY
in the VDI interface in response to alarms.
Up to SW 3.x
Machine data:
MD11412 $MN_ALARM_REACTION_CHAN_NOREADY
controls whether the channel-specific signal CHANNEL_NOREADY function is used. This
ensures that earlier PLC versions remain compatible.
Default setting: CHANNEL_NOREADY signal is not used.
Alarms that have specified a channelspecific NOREADY signal are reconfigured to the
modegroupspecific NOREADY signal.

Clearing criterion
For each alarm, you must specify how the alarm can be cleared again. The following clearing
criteria are possible:
POWERONCLEAR
The alarm is cleared by switching the control off and then on again.
RESETCLEAR
When the Reset key is pressed, the alarm is cleared in the channel in which it occurred.
CANCELCLEAR
The alarm is cleared in any channel when the Cancel key is pressed. The alarm can also
be cleared by means of an NC start or Reset.
NCSTARTCLEAR
The alarm is cleared in the channel in which the alarm occurred by starting a program.
The alarm can also be cleared by means of a Reset.
CLEARHIMSELF
The alarm is not cleared by an operator input or action, but explicitly by a "clearAlarm"
programmed in the NCK source code.
BAGRESETCLEAR
The alarm is cleared by a "BAGRESETCLEAR" command or by executing a Reset in
every channel of this mode group.
NCKRESETCLEAR
The alarm is cleared by an "NCKRESETCLEAR" command or by executing a Reset in
every channel.

Alarm display control

The scope of the alarm outputs can be modified using machine data.
MD11410 $MN_SUPPRESS_ALARM_MASK (mask for suppressing special alarm
outputs)
MD11411 $MN_ENABLE_ALARM_MASK (mask for enabling special alarm outputs)
For details of this machine data, please refer to chapter 4.

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Detailed description
2.2 Service displays

2.2

2.2

Service displays

Conditions of use
Conditions for the use of service displays are specified. Service displays are differentiated
between in terms of axis/spindle, drive and profibus DP

Operation
For how to operate the service displays see:
References:
/BAD/ "HMI Advanced Operator's Guide"
/BEM/ "HMI Embedded Operator's Guide"

Note
On HMI Advanced, it is possible to switch between the displays using the vertical soft key for
Part view/Overall view. The data in the partial view are updated at significantly shorter
intervals.

General
In principle, the following service displays are available:
Axis/spindle service displays
Drive service displays
Profibus-DP service displays

Note
System dependencies
The availability of individual service displays depends on the particular system, e.g.:
Drive service displays: for digital drives only
Profibus-DP service displays: for SINUMERIK 840Di only

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Detailed description
2.3 Axis/spindle service display

2.3

2.3

Axis/spindle service display

Values and statuses

Displays showing values and statuses on the control's user interface allow the operating
status of the axes and spindles to be evaluated.

Accessing the diagnostic options

For the purposes of commissioning and diagnosing
axes and
spindles,
the information shown in the following figure can be called up for each axis/spindle in the
"Diagnostics" operating area via the operator panel.
This information is used for
checking the setpoint branch
(e.g. position setpoint, speed setpoint, spindle speed setpoint prog.)
checking the actual value branch
(e.g. actual position value measuring system 1/2, actual speed value)
optimizing the position control loop
(e.g. following error, control deviation, servo gain factor)
checking the whole control loop of the axis
(e.g. by comparing the position setpoint and the actual position value, speed setpoint and
the actual speed value)
checking hardware errors
(e.g. by checking the encoder: If the axis is physically moved, a change in the actual
position value must result)
setting and checking axis monitoring functions.
Descriptions on how to select and operate the "Diagnostics" area can be found in:
References:
/BAD/ "HMI Advanced Operator's Guide"
/BEM/ "HMI Embedded Operator's Guide"

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Detailed description
2.3 Axis/spindle service display

Figure 2-1

Example for service axis/spindle HMI Advanced

Following error
The difference between the position setpoint and the actual position value of active
measuring system 1 or 2.
Unit: mm, inch or degrees

Error signal
The difference between the position setpoint at the position controller input and the actual
position value of active measuring system 1 or 2.
Unit: mm, inch or degrees

Contour deviation
The current contour deviation is displayed with this value (variations of the following error
caused by settling operations on the speed controller due to load changes).
The contour deviation results from the difference between an actual position pre-calculated
from the position setpoint and the actual position value of active measuring system 1 or 2.
Unit: mm, inch or degrees

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Detailed description
2.3 Axis/spindle service display

Servo gain factor (calculated)

The servo gain factor in the display is calculated by the NC according to the following
equation:

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Velocity setpoint = setpoint currently being output to the axis/spindle.

References:
/FB1/ Function Manual, Basic Functions; Velocities, Setpoint/Actual Value Systems, Control
Loop Control (G2)

Active meas. system

This line indicates whether measuring system 1 or 2 is active.

Position actual value measuring system 1/2

The actual position of the axis as measured via measuring system 1/2. The position is
displayed in the machine coordinate system (no work offsets or tool offsets included).
Unit: mm, inches or degrees

Position reference value

Specified position transferred from the interpolator to the position control.
Unit: mm, inches or degrees

compensation value meas. system 1 or 2

Display of absolute compensation value for measuring system 1 or 2.
The compensation value consists of the sum of backlash and leadscrew error compensation
for the actual axis position
Unit: mm, inches or degrees

Sag and temperature compensation

Display of the compensation value calculated for the current axis position based on the total
of the sag and temperature compensations.
Unit: mm, inches or degrees

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Detailed description
2.3 Axis/spindle service display

Velocity actual value of active encoder (only 840Di)

Display of velocity actual value of the currently active encoder.

Velocity setpoint of drive (only 840Di)

Display of velocity setpoint of drive.

Speed actual value

The pulses supplied by the encoder are evaluated by the NC and displayed.
Unit: %
100% means maximum speed (corresponds to 10 V for analog interface; maximum speed
for SIMODRIVE 611 digital, specified by machine data:
MD1401 $MD_MOTOR_MAX_SPEED (speed for maximum useful motor speed).

Speed setpoint
Speed setpoint transferred to the drive (= speed setpoint from position controller and feed
forward control).
Unit: %
100% corresponds to the maximum speed setpoint (10 V for an analog interface, maximum
speed for SIMODRIVE 611 digital).

Spindle speed setpoint prog.

Speed setpoint programmed by the user.
Unit: rpm
e.g.: Input: S1000; display: 1000 rpm
Display applies to spindles only.

Spindle speed setpoint current

Current active speed setpoint with correct sign, including calculated compensation value and
any operative speed limitation (programmed by means of setting or machine data).
Unit: rpm
Display applies to spindles only.

Override
The effective correction factor of the feed or spindle correction switch is displayed.
Unit: %

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Detailed description
2.3 Axis/spindle service display

Position offset for master axis/spindle actual value

The currently applicable position offset value is displayed here (relative to the actual value) if
such a position offset (angular offset between master and slave axes) has been programmed
for the "Synchronous spindle" function.
Unit: mm, inches, degrees
References:
/FB2/ Function Manual, Extended Functions; Synchronous Spindle (S3)

Position offset for master axis/spindle setpoint value

The currently applicable position offset value is displayed here (relative to the setpoint) if
such a position offset (angular offset between master and slave axes) has been programmed
for the "Synchronous spindle" function.
Unit: mm, inches, degrees
References:
/FB2/Function Manual, Extended Functions; Synchronous Spindle (S3)

Current gear stage

The current actual gear stage is displayed here.
With axes, this is only displayed if a spindle is assigned to the axis. This display corresponds
to IS DB31, ... DBX16.0 to 16.2 ("Actual gear stage").
References
/FB1/ Function Manual, Basic Functions; Spindles (S1)
Displays which of the 6 parameter sets of the position controller is active. A parameter set
changeover takes place, for example, with a gear shift.
References:
/FB1/ Function Manual, Basic Functions; Velocities, Setpoint/Actual-Value Systems, ClosedLoop Control (G2)

Controller mode
Displays the current controller modes.
0:

Position Control

1:

Speed Control

2:

Stopping

3:

Parking

4:

Followup

5:

Braking

For a more detailed description of controller modes, refer to:

References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

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Detailed description
2.3 Axis/spindle service display

"Referenced" status display

Status display for reference point approach (axis).
Bit0=Status 0:

The machine axis is not cross-referenced using position measurement

system 1 or 2.

Bit0=Status 1:

The machine axis has reached the reference point (incremental

measuring system) and/or target point (length measuring system with
distance coded reference marks) during reference point approach.

Bit1=Status 0:

No obligation to cross-reference (NC start possible without crossreferencing this axis)

Bit1=Status 1:

There is no obligation to cross-reference for the NC start.

Depending on machine data:

MD34110 $MA_REFP_CYCLE_NR
and
MD20700 $MC_REFP_NC_START_LOCK
Display corresponds to
IS DB31, ... DBX60.4 and 60.5 ("Referenced/synchronized 1 or 2").
References:
/FB1/ Function Manual, Basic Functions; Reference Point Approach (R1)

QEC learning active

Indicates whether or not the learning process for quadrant error compensation for the axis is
active.

Fixed stop reached

Indicates whether or not the axis has fulfilled the conditions for "Fixed stop reached" when
the "Travel to fixed stop" function is active (IS DB31..., DBX62.5).
References:
/FB1/ Function Manual, Basic Functions; Travel to Fixed Stop (F1)

Torque limitation value

Indicates the value programmed by means of
FXST[x] or
SD43510 $SA_FIXED_STOP_TORQUE
or the value defined with machine datum:
MD37010 $MA_FIXED_STOP_TORQUE_DEF
for the clamping torque for "Travel to fixed stop".
Unit: % of maximum torque
References:
/FB1/ Function Manual, Basic Functions; Travel to Fixed Stop (F1)

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Detailed description
2.3 Axis/spindle service display

Safe actual position of the axis

Displays the current actual axis position that has been measured via the NC. This actual
position should correspond in value to "Safe actual position of drive".
References:
/FBSI/ Description of Functions, Safety Integrated

Safe actual position of drive

Displays the current actual axis position that has been measured via the drive. This actual
position should correspond in value to "Safe actual position of axis".
References:
/FBSI/ Description of Functions, Safety Integrated

Safe input signals of the axis

Displays the safe input signals of the PLC defined for the "Safety Integrated" function. The
status of these input signals should correspond to the "Safe input signals of drive" status.
References:
/FBSI/ Description of Functions, Safety Integrated

Safe input signals of the drive

Displays the safe input signals of the drive (DMP on drive bus) defined for the "Safety
Integrated" function. The status of these input signals should correspond to the "Safe input
signals of axis" status.
References:
/FBSI/ Description of Functions, Safety Integrated

Safe output signals of the axis

Displays the safe output signals of the PLC defined for the "Safety Integrated" function. The
status of these output signals should correspond to the "Safe output signals of drive" status.
References:
/FBSI/ Description of Functions, Safety Integrated

Safe output signals of the drive

Displays the safe output signals of the drive (DMP on drive bus) defined for the "Safety
Integrated" function. The status of these output signals should correspond to the "Safe
output signals of axis" status.
References:
/FBSI/ Description of Functions, Safety Integrated
The following description contains more information on problems and questions that may
arise.

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Detailed description
2.3 Axis/spindle service display

Control technology concept

The figure below shows at which points in the controlloop the axis and spindle information is
read off.

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2-12

Overview diagram of axis and spindle information

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Detailed description
2.3 Axis/spindle service display

Checks
Check of the position controller setting
The position controller settings can be easily managed via the service axis display.
The number 1 (corresponds to servo gain = 1) should be entered in machine data:
MD32200 $MA_POSCTRL_GAIN [n] (servo gain factor).
The change takes effect immediately.
Because the servo gain factor is defined as

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a following error of 1 mm must be measured (with KV = 1 and constant velocity) at a

feedrate of 1 m/min.
If the desired servo gain (KV) factor does not correspond to the actual factor, the possible
causes and remedial optimization options are as follows:
Speed or torque feedforward control is activated. A higher servo gain factor is displayed
than was set with machine data:
MD32200 $MA_POSCTRL_GAIN [n] (servo gain factor)
.
Filter for jerk limitation or dynamic response adaptation is activated. A lower servo gain
factor is displayed than was set with machine data:
MD32200 $MA_POSCTRL_GAIN [n] (servo gain factor)
.

Diagnostics for alarms

This information is also provided as a diagnostic tool for diagnosing the causes of alarms
such as:
"Standstill monitoring"
following error >
MD36030 $MA_STANDSTILL_POS_TOL (standstill tolerance)
"Contour monitoring"
contour deviation >
MD36400 $MA_CONTOUR_TOL (tolerance band for contour monitoring)
"Speed setpoint limiting"
Speed setpoint >
MD36210 $MA_CTRLOUT_LIMIT
(maximum speed setpoint)

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Detailed description
2.3 Axis/spindle service display

"Positioning monitoring"
following error >
MD36010 $MA_STOP_LIMIT_FINE
(exact stop fine)
"Measuring system changeover not available
difference between actual position value measuring system 1 and 2 >
MD36500 $MA_ENC_CHANGE_TOL
(maximum tolerance for actual position value measurement)
"Clamping monitoring"
following error >
MD36050 $MA_CLAMP_POS_TOL
(clamping tolerance for "Clamping active" interface signal)
For details on the behavior of the NC control in response to individual alarms, and remedial
action, please refer to:
References:
/DA/ Diagnostics Manual

Diagnostics of operational state errors

The following information is also provided to assist in the analysis of operational state errors
such as:
Despite an active motion command, the axis does not move.
Check whether controller is enabled. In controller mode, position control or speed
control (with spindle control) must be activated.
Occurrence of feed fluctuations.
Detection via following error or actual speed value.
Incorrect positioning.
Compare position setpoint with actual position value of measuring system 1/2 and
absolute compensation value of measuring system 1 or 2.
The cam is not detected by the PLC during referencing.
Check status display "referenced"
An incorrect reference point value was displayed.
The wrong measuring system may have been used for referencing.
Large fluctuations in the actual speed value are occurring in the main spindle drive.
The selected actual speed range for encoders is too high or the machine datum:
MD36300 $MA_ENC_FREQ_LIMIT [n] (encoder limiting frequency)
is set higher than specified in the encoder data sheet.
Incorrect spindle positioning occurs.
The wrong measuring system may be selected or synchronization may have been
performed with the wrong zero mark.

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Detailed description
2.4 Drive service display (for digital drives only)

2.4

2.4

Drive service display (for digital drives only)

Displays
Displays on the control's user interface that show values and statuses allow for evaluation of
the operating statuses of the digital drives.

Access
Accessing diagnostic options:
For the purposes of commissioning and diagnosing
feed drives (FDD) and
main spindle drives (MSD)
the information shown in the following figure can be called up for each axis/spindle in the
"Diagnostics" operating area via the operator panel.

Note
The parameters in the "Drive" service display are not necessary for connecting drives via the
PROFIBUS DP. For SINUMERIK 840Di, the drives are defined as PROFIBUS nodes. The
appropriate service data is displayed in 840DiStartup in the menu Diagnostics -->
PROFIBUS.

Application
The diagnostic options are used for:
checking the status of enabling and control signals
(e.g. pulse enable, drive enable, motor selection, setpoint parameter set)
checking the status of FDD/MSD operating modes
(e.g. setup mode, parking axis)
displaying temperature warnings
checking the current setpoint/actual value display
(e.g. actual position value measuring system 1/2, speed setpoint, actual speed value)
checking the drive status (drive ready)
displaying the current ramp-up phase
displaying the group error message (message status class 1)
displaying the drive status messages
(e.g. threshold torque not reached, minimum speed not reached, actual speed = set
speed)

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Detailed description
2.4 Drive service display (for digital drives only)

Service HMI Advanced Drive

Descriptions on how to select and operate the "Diagnostics" area can be found in:
References:
/BAD/ Operator's Guide HMI Advanced
/BEM/ Operator's Guide HMI Embedded
Note
The individual status displays, warnings, messages, etc., are explained in the following
sections. For HMI SW 6 and higher, the status is shown in plain text as "yes" or "no" instead
of "0" and "1".
For additional information, refer to:
References:
/IAD/Installation Guide

Explanations/Terms
Drive enable (terminal 64/63)
The display corresponds to the status of terminal 64/63 on the SIMODRIVE611 digital
infeed/regenerative feedback unit.
State 1: Central drive enable
State 0 : Central drive disable
Display corresponds to machine datum:
MD1700 $MD_TERMINAL_STATE
(status of binary inputs).

Pulse enable (terminal 63/48)

The display corresponds to the status of terminal 63/48 on the SIMODRIVE611 digital
infeed/regenerative feedback unit.
State 1: Central pulse enable
State 0 : Central pulse disable
Display corresponds to machine datum:
MD1700 $MD_TERMINAL_STATE
(status of binary inputs).

Pulse enable (terminal 663)

The display corresponds to the status of terminal 663 (relay: safe operational stop) on the
drive module.
State 1: Module-specific pulse enable
State 0 : module-specific pulse disable
Display corresponds to machine datum:
MD1700 $MD_TERMINAL_STATE
(status of binary inputs).

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Detailed description
2.4 Drive service display (for digital drives only)

Setup mode (terminal 112) HMI SW 6.3 and later

The display corresponds to the status of terminal 112 on the SIMODRIVE 611 digital
infeed/regenerative feedback unit.
State 1: Central drive disable for setup mode
State 0 : Central drive enable, no setup mode
Display corresponds to machine datum:
MD1700 $MD_TERMINAL_STATE
(status of binary inputs).

PLC pulse enable

Indicates whether the pulse enable from the PLC is available for the drive.
State 1: The pulses for the drive module have been disabled by the PLC.
State 0: Pulse enable for this drive is activated by the PLC.
Display corresponds to IS DB31, ... DBX21.7 ("Pulse enable")
References:
/FB1/Function Manual, Basic Functions; Various Interface Signals (A2)

Speed controller enable NC

This display indicates whether the speed controller for the drive has been enabled by the
NC.
State 1: Speed controller enable = OFF
State 0: Speed controller enable = ON

Rampup function generator quick stop

Status display for rampup function generator quick stop.
State 1:

Ramp-up function generator quick stop is not active for the drive.

State 0:

Ramp-up function generator quick stop is active. The drive is stopped without
a ramp function with speed setpoint = 0 and without pulse suppression.

Display corresponds to IS DB31, ... DBX92.1 ("Rampfunction generator rapid stop").

References:
/FB1/Function Manual, Basic Functions; Various Interface Signals (A2)

DC link state (on/off)

The display contains the following drive warning:
State 0: DC link voltage = ON
State 1: DC link voltage is below warning threshold.
The warning threshold corresponds to machine datum:
MD1604 $MD_LINK_VOLTAGE_WARN_LIMIT (DC link undervoltage warning threshold).

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Detailed description
2.4 Drive service display (for digital drives only)

Enable pulses
Message indicating whether the drive pulses have been enabled.
State 0:

The drive module pulses are suppressed. The axis/spindle can therefore not
be traversed.

State 1:

The drive module pulses are enabled. The axis/spindle can now be traversed.

Display corresponds to IS DB31, ... DBX93.7 ("Enable pulses").

References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2).

Drive ready
Display of the current status of the selected drive.
State 0: The drive is not ready.
State 1: The drive is ready.
Display corresponds to IS DB31, ... DBX93.5 ("Drive Ready").
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)
Display indicating the current rampup phase of the selected drive.
Meaning:

CRC error
Display of communications errors detected in hardware between NC and drive.

Note
If the display shows a value other than "0", please contact your SIEMENS Regional Office!

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Detailed description
2.4 Drive service display (for digital drives only)

ZK1 Messages
Display indicates whether messages of status class 1 are active.
State 0: No status class 1 message is active.
State 1: One or several status class 1 messages are active.
Status class 1 messages are alarms with the following characteristics:
They cause internal responses
(e.g. regenerative braking, immediate pulse suppression)
They are modal.

DC link voltage
Indicates the current DC link voltage level within the drive grouping.
Unit: Volts

Speed setpoint
The displayed speed setpoint represents the unfiltered total setpoint value. It is made up of
the position controller output component and the speed feed forward branch.
Unit: rpm
Display corresponds to machine datum:
MD1706 $MD_DESIRED_SPEED (desired speed).

Speed actual value

The actual value displayed represents the unfiltered actual speed value.
Unit: rpm
Display corresponds to machine datum:
MD1707 $MD_ACTUAL_SPEED (actual speed value).

Smoothed actual current value

Display of the smoothed actual current value. The torquegenerating actual current value is
smoothed by a PT1 element with parameterizable time constant.
Unit: %
100 % corresponds to the maximum current of the power section.
Display corresponds to machine datum:
MD1708 $MD_ACTUAL_CURRENT (smoothed actual current value).

Motor temperature
Display of motor temperature measured via temperature sensors.
Unit: Degrees Celsius
Display corresponds to machine datum:
MD1702 $MD_MOTOR_TEMPERATURE (motor temperature).

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2.4 Drive service display (for digital drives only)

Speed setpoint filter 1

Status display of speed setpoint smoothing function.
State 0:

No speed setpoint smoothing is active.

State 1:

Smoothing of the speed setpoint as requested by the PLC using IS DB31, ...
DBX20.3
("Speed setpoint smoothing") takes effect because speed setpoint filter 1 is
configured as the low pass.

Display corresponds to IS DB31, ... DBX92.3 ("Speed setpoint smoothing active") and is
shown in an updated form as of software version 6.3 and later.
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

2. Torque Limit
Display of active torque limit
State 0: Torque limit 1 is active.
State 1: Torque limit 2 is active.
Display corresponds to IS DB31, ... DBX92.2
("Torque limit 2 active").
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

Integrator disabling
This display indicates whether the speed controller integrator is active.
State 0:

The integrator of the speed controller is enabled. The speed controller

functions as a PI controller.

State 1:

Deactivation of the speed-controller integrator as requested by the PLC using

IS DB 31, ... DBX 21.6
("Integrator disable speed controller") is active for the drive module. The
speed controller has therefore switched from a PI to a P controller.

Display corresponds to IS DB31, ... DBX93.6 ("Speed-controller integrator disabled").

References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

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2.4 Drive service display (for digital drives only)

Setup mode
Mode display of the SIMODRIVE 611 digital.
State 0: Normal mode is active for the drive.
State 1: Setup mode is active for the drive.
Display corresponds to IS DB31, ... DBX92.0
("Setup mode active").
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

Parking axis
Mode display of the SIMODRIVE 611 digital.
State 0:

Axis/spindle in normal mode

State 1:

Axis/spindle in parking position, i.e. all encoder-specific monitoring and

evaluating functions are disabled. This allows the encoder to be withdrawn
without initiating an alarm.

Setpoint parameter set (drive)

Indicates which of the 8 drive parameter sets of the SIMODRIVE 611 digital are to be
activated by the PLC.
Display corresponds to IS DB31, ... DBX21.0 to 21.2 ("Parameter set selection A,B,C").
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

Actual parameter set (drive)

Display indicating which of the 8 drive parameter sets of the SIMODRIVE 611 digital is
currently active.
Display corresponds to IS DB31, ... DBX93.0 to 93.2
("Active parameter set A,B,C").
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals

Operating mode
Display indicating whether the motor is operating as a feed drive or main spindle drive.

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2.4 Drive service display (for digital drives only)

Motor selection (star/delta)

Display indicating which motor data set is to be activated by the PLC. At the moment the
motor data record is used for the star/delta switchover on main spindle drives.
The following assignment applies:
Motor selection

Application

Coding

Motor 1

MSD: Star mode

Motor 2

MSD: Delta mode

Motor 3

Reserved

Motor 4

Reserved

The display applies only to MSD drives.

The display corresponds to IS DB31, ... DBX21.3 to 21.4
("Motor selection A,B").
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

Actual motor (star/delta)

Display indicating which of the motor data sets is currently active. At the moment the motor
data record is used for the star/delta switchover on main spindle drives.
The following assignment applies:
Motor selection

Application

Coding

Motor 1

MSD: Star mode

Motor 2

MSD: Delta mode

Motor 3

Reserved

Motor 4

Reserved

The display applies only to MSD drives.

The display corresponds to IS DB31, ... DBX93.3 to 93.4
("Active motor A,B").
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

Position actual value measuring system 1/2

The actual position of the axis as measured via measuring system 1/2. The position is
displayed in the machine coordinate system (no work offsets or tool offsets included).
Unit: mm, inches or degrees

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2.4 Drive service display (for digital drives only)

Power section in it limitation HMI SW 6.3 and later

Limitation for protecting the power section against continuous overloading of the
SIMODRIVE 611 drives.
State 1: i2t power section limitation has responded
State 0 : i2t power section limitation has not responded
The display applies to SIMODRIVE universal and SIMODRIVE digital drives.
The display corresponds to IS DB31, ... DBX95.7
("i2t monitoring).
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

Heatsink temperature warning

Warning signal output by drive:
State 0: The heatsink temperature monitoring has not responded.
State 1: The heatsink temperature monitoring has responded.
Display corresponds to IS DB31, ... DBX94.1
("Heatsink temperature prewarning").
References:
/FB1/Function Manual, Basic Functions; Various Interface Signals (A2)

Motor temperature warning

Warning signal output by drive:
State 0: The motor temperature is below the warning threshold.
State 1: The motor temperature has exceeded the defined warning threshold.
The warning threshold corresponds to machine datum:
MD1602 $MD_MOTOR_TEMP_WARN_LIMIT (maximum motor temperature).
Display corresponds to IS DB31, ... DBX94.0
("Motor temperature prewarning").
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

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2.4 Drive service display (for digital drives only)

Ramp-up function completed

Status display of drive.
State 0:

The ramp-up function has not yet been completed after a new speed setpoint
was defined.

State 1:

The actual speed value has reached the speed tolerance band after a new
speed setpoint was defined.

The speed tolerance band corresponds to machine datum:

MD1426 $MD_SPEED_DES_EQ_ACT_TOL (tolerance band for 'ndesired-nactual' message).
Display corresponds to IS DB31, ... DBX94.2
("Ramp-up function completed").
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

Torque lower than threshold setting

Status display of drive.
State 0:

In the stationary condition (i.e. ramp-up procedure completed), the torque

setpoint is greater than the threshold torque.

State 1:

In the stationary condition, the torque setpoint has not reached the threshold
torque.

The threshold torque corresponds to machine datum:

MD1428 $MD_TORQUE_THRESHOLD_X (threshold torque).
Display corresponds to IS DB31, ... DBX94.3 ("Md< Mdx").
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

Speed lower than minimum setting

Status display of drive.
State 0: The actual speed value is greater than the minimum speed.
Status 1: The actual speed value is smaller than the minimum speed.
The minimum speed corresponds to machine datum:
MD1418 $MD_SPEED_THRESHOLD_MIN (nmin for 'nactual < nmin' message).
Display corresponds to IS DB31, ... DBX94.4
"|nactual|< nmin").
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

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2.4 Drive service display (for digital drives only)

Speed lower than threshold setting

Status display of drive.
State 0: The actual speed value is greater than the threshold speed.
Status 1: The actual speed value is smaller than the threshold speed.
The threshold speed corresponds to machine datum:
MD1417 $MD_SPEED_THRESHOLD_X
(nx for 'nactual < nx' message).
Display corresponds to IS DB31, ... DBX94.5
"|nactual|< nx").
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

Actual speed = set speed

Status display of drive.
State 0:

The actual speed value is outside the speed tolerance band after a
new speed setpoint was defined.

State 1:

The actual speed value has reached the speed tolerance band after a new
speed setpoint was defined.

The speed tolerance band corresponds to machine datum:

MD1426 $MD_SPEED_DES_EQ_ACT_TOL (tolerance band for 'nset-nactual' message).
Display corresponds to IS DB31, ... DBX94.6
("|nactual|= nset").
References:
/FB1/ Function Manual, Basic Functions; Various Interface Signals (A2)

Variable signal 1
Status display of 611D variable signaling function.
With the variable signaling function, any memory location can be monitored to see whether a
definable threshold is exceeded. In addition to the threshold, a tolerance band can be
defined which is also taken into account when scanning for violation of the threshold value.
The signal can be combined with an ON delay or OFF delay time.
State 0: Threshold value not reached
State 1: Threshold value exceeded
Parameters for the variable signal function are set using the following 611D machine data:

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2.4 Drive service display (for digital drives only)

MD1620 $MD_PROG_SIGNAL_FLAGS

(Bits variable signal function)

MD1621 $MD_PROG_SIGNAL_NR

(Signal number variable signal function)

MD1622 $MD_PROG_SIGNAL_ADDRESS

(Address variable signal function)

MD1623 $MD_PROG_SIGNAL_THRESHOLD

(Threshold variable signal function)

MD1624 $MD_PROG_SIGNAL_HYSTERESIS

(Hysteresis variable signal function)

MD1625 $MD_PROG_SIGNAL_ON_DELAY

(ON Delay variable signal function)

MD1626 $MD_PROG_SIGNAL_OFF_DELAY

(OFF Delay variable signal function)

Diagnostics for alarms

This information is also provided as a diagnostic tool for diagnosing the causes of alarms
such as:
"Ramp-up error"
Check the ramp-up phase to see which ramp-up phase the drive has reached.
"Drive malfunction"
Message ZK1 is set.
check specified parameter set, motor selection, DC link status.
Check following alarms 300500 to 300515.
"Zero speed monitoring",
25050 "Contour monitoring",
25060 "Speed setpoint limitation"
25080 "Positioning monitoring"
The enabling for the drive may have been omitted (e.g. pulse enable, drive enable,
pulse enable for PLC not available); this leads to display pulses enabled = off.
"Motor temperature exceeded"
Check the current motor temperature.
For details on the behavior of the NC control in response to individual alarms, and remedial
action, please refer to:
References:
/DA/ Diagnostics Manual

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Detailed description
2.5 Service display PROFIBUS DP 840Di

2.5

2.5

Service display PROFIBUS DP 840Di

The user interface 840Di StartUp provides diagnostic screen forms for PROFIBUS DP and
its nodes. . These diagnostic screens are only intended for information. You cannot modify
them.
The following detailed information is displayed:
PROFIBUS configuration
Information on the slaves regarding their assignment to PLC/NC
Detailed information on the slaves and the corresponding slots
Information on the axes.
To obtain a quick overview, the current states of certain functions are represented by
colored lamps. The following general conventions are used for the meaning of the individual
colors:
Green: Function is OK.
Red: Failure or no communication at the moment
Gray: Function is not available for the present communication.
Diagnostic screen PROFIBUS DP Configuration
The diagnostic screen PROFIBUS Configuration provides general information on PROFIBUS
DP.
The following parameters are displayed:

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2.5 Service display PROFIBUS DP 840Di

Table 2-1

Diagnostic screen PROFIBUS Configuration

Function/subfunction

Explanation/meaning

Bus configuration
Baud rate in MBd

Data transfer rate

Cycle time in msec

Configured bus cycle time; also defines the position controller cycle

Synchronous portion
(TDX) in msec

Configured time for cyclic data exchange within a PROFIBUS DP cycle

Status
Configuration OK.

Status of configuration
Green lamp: DP master has powered up.
Red lamp: Failure or no communication.

Bus status

Current bus status is displayed in this field. Each bus status is explained in the screen form in
brief. Possible states are:
POWER_ON
OFFLINE
CLEAR
OPERATE
ERROR

Diagnostic screen of the DP slaves

These diagnostic screen forms provide an overview of the DP slaves configured and
detected on the bus.
The following information is provided:
Table 2-2

Diagnostic screen Information on the slaves

Function/subfunction

Explanation/meaning

Slave No. [DP address]

Configured DP address of DP slave

Assignment

It is displayed whether the DP slave is assigned to the NC or to the PLC.

NC: e.g. one or several drives controlled by the NC.
PLC: e.g. I/O modules or an axis controlled by the PLC.

Active on the bus

Displays whether the DP slave has been detected on the bus

Green lamp: DP slave has been detected on PROFIBUS DP and the data exchange with the
assigned component (NC or PLC) operates.
Red lamp: Failure or no communication.

Sync. with NC

Displays whether DP slave operates on the bus synchronously to the NC.

Green lamp: DP slave operates on PROFIBUS DP synchronously to the NC, i.e. the
equidistant data exchange takes place.
Gray lamp: DP slave is not assigned to the NC, but to the PLC.
Red lamp: Failure or no communication.

Number of slots

Number of configured slots within DP slave

Details

Pressing this button will open another diagnostic screen that provides detailed information on
the corresponding DP slave.

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Detailed description
2.5 Service display PROFIBUS DP 840Di

Detailed information of the slots within a slave

The Details button opens the diagnostics dialog box Detailed information on the slave. This
screen form provides detailed information on the slots assigned to the DP slave.
In addition, the Slave dialog box displays important information on the DP slave currently
selected.
The following information is displayed for the slots:
Table 2-3

Diagnostic screen Detailed information on the slave

Function/subfunction

Explanation/meaning

Slaves
Slave No. [DP address]

Configured DP address of DP slave

Assignment

Displays whether the DP slave is assigned to the NC or to the PLC.

NC: e.g. one or several drives controlled by the NC.
PLC: e.g. I/O modules or an axis controlled by the PLC.

Active on the bus

Displays whether the DP slave has been detected on the bus

Green lamp: DP slave has been detected on PROFIBUS DP and the data exchange with the
assigned component (NC or PLC) operates.
Red lamp: Failure or no communication.

Synchr.

Displays whether DP slave operates on the bus synchronously to the NC.

Green lamp: DP slave operates on PROFIBUS DP synchronously to the NC, i.e. the
equidistant data exchange takes place.
Gray lamp: DP slave is not assigned to the NC, but to the PLC.
Red lamp: Failure or no communication.

Slots
No.

Slot number within DP slave

I/O address

I/O address in the I/O address space of the PLC assigned to this slot. For NC axes, setpoint and
actual value must always be configured using the same I/O address.

Logical drive no.

Drive number assigned for the appropriate axis in the NC machine data.

Length [bytes]

Length of the I/O area in the STEP7 I/O address space, which is reserved for the slot

Type

Specification whether the slot is an input, output or diagnostic slot. If the slot is assigned to an
NC axis, an output is always designated as a setpoint and an input always as an actual value.

Machine axes

Display of the name defined for this slot in the machine data. If the slot is not assigned to any
NC axis, "No NC axis" is displayed.

Message frame type

Message frame type configured in the NC machine data. If the slot is not assigned to any NC
axis, the message frame type will not be occupied (-).

Status

Current slot status is only displayed for NC axes

Green: Slot is used by the NC; communication active
Gray: No NC axis
Red: Slot is used by the NC; communication currently not active

Diagnostic screen for the axes

The diagnostic screen AxisInfo displays axisspecific detailed information. The diagnostic
screen provides an NCoriented view of the axis information.
The following information is displayed for the axes:

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2.6 Communication log
Table 2-4

Diagnostic screen AxisInfo

Function/subfunction

Explanation/meaning

Machine axes

Name of the axis defined in the NC machine data

Output
Slave/slot

Configured assignment

Status

Current slot status

Green lamp: Cyclic communication
Red lamp: No cyclic communication (as yet).

Message frame failures

The display shows the number of message frame failures since the NC was booted.
This value indicates the quality (fault susceptibility) of the PROFIBUS DP line.

Encoder 1
Slave/slot

Configurable assignment

Status

Current slot status

Green lamp: Cyclic communication
Red lamp: No cyclic communication (as yet).

Message frame failures

Type

The display shows the number of message frame failures since the NC was booted.
This value indicates the quality (fault susceptibility) of the PROFIBUS DP line.
Display of encoder type configured in the NC machine data
ABS: Absolute encoder
INC: Incrementalvalue encoder

Encoder 2

2.6

(If configured, the same display as for encoder 1)

2.6

Communication log

Log assistance
In event of a fault and when developing OEM applications, control logs may assist with the
analysis.

Logs and version

Communication log
The communication errors which have occurred between the HMI and NC are displayed in
chronological order via the soft key Comm. log in the "Diagnostics" operating area This error
list assists developers of OEM applications in localizing sporadic errors. The list has no
relevance for normal operation.

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Detailed description
2.7 PLC status

Logbook
The logbook display selected by means of soft key Logbook in the "Diagnostics" operating
area automatically lists details of all alterations to the control that are relevant for the system
(e.g., changes in access level).
For SINUMERIK 840Di, the logbook is displayed in 840Di StartUp.

Version
The version of the MMC or NC software installed can be read from this display
("Diagnostics" operating area via soft key Version) by service personnel.
The software version of each software module is also displayed in a list.

2.7

2.7

PLC status

PLC status signals can be checked and altered via the operator panel in the "Diagnostics"
operating area.

Application
The end customer or service personnel can use this function on site without a programming
device to do the following:
Check the input and output signals of the PLC I/Os.
Carry out limited troubleshooting
Check the interface signals for diagnostic purposes.

Operation
For information about status display operation and changing PLC signals, refer to the
Operator's Guide for the relevant HMI software.

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2.8 Other diagnostics tools

Status display
The status of the following data can be displayed on the operator panel.
Interface signals from the machine control panel
Interface signals to the machine control panel
Interface signals between the NCK and PLC
Interface signals between the HMI and PLC
Data blocks (DB 0-127)
Flags (FB 0-255)
Timers (T 0-127)
Counters (C 0-63)
Inputs (IB 0-127)
Outputs (QB 0-127)
For a breakdown of the interface signals (DBx, DBBy), refer to:
References:
/LIS2/ Lists (Manual 2)

Change in status
The status of the above signals can be changed for test purposes. Signal combinations are
also possible. A maximum of ten operands can be altered at any one time.

2.8

2.8

Other diagnostics tools

611D commissioning tool

Using the 611D commissioning tool and archiving software, the control can be evaluated and
the control status can be saved.

611D commissioning tool

One of the functions of this program is to provide a tool
for evaluating the most important values for the position, speed and current control
for archiving drive and control data, and
for analyzing the stated physical properties.
For handling and complete range of functions see:
References:
/IAD/ Installation Guide

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2.9 Identifying defective drive modules

Archiving of data
The PCIN software package can be used to archive machine data, setting data, part
programs, etc.
A description of how to use this can be found in the associated documentation:
References:
/PI/ PCIN 4.3

840Di StartUp
For diagnosing the SINUMERIK 840Di, the WINDOWS program 840Di StartUp can be used.
This provides information, e.g. on the current operating mode and the nodes of PROFIBUS
DP.

2.9

2.9

Identifying defective drive modules

Deactivate drives
Drives can be removed from the NC configuration using a piece of machine data.
Troubleshooting may involve a situation where a drive module (SIMODRIVE 611 digital)
displayed in an alarm text needs to be removed from the bus in order to determine whether
this module has caused the displayed error.
With machine datum:
MD13030 $MN_DRIVE_MODULE_TYPE
individual modules can be removed from the NC-side drive bus configuration (the affected
axes are switched to simulation).

Note
You must remove the desired module from the drive bus configuration (SIMODRIVE 611
digital) before you activate the function. To do this, connect the drive so as to exclude the
module.
Since this internal modification to the machine configuration can result in damage to the
machine if implemented incorrectly, the axes are prevented from moving.
If Safety Integrated has been activated for the modules concerned, you must disable it
manually (safety, logged, EMERGENCY STOP scheme).

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2.9 Identifying defective drive modules

Remove drive module at NC end

A drive module (SIMODRIVE 611 digital) specified in an alarm text must be removed from
the bus:
1. Remove the module from the drive bus network
2. Set entries of the drive module in machine datum:
MD13030 $MN_DRIVE_MODULE_TYPE
to zero (zero-axis module).
3. Perform an NC RESET.
The axes which were controlled by the removed drive modules are now replaced by
simulated axes. The 611D bus with its drive modules is now in a state in which it could
normally move axes, but axis traversal has been disabled internally.
Alarm 300020 "Drive %1 removed for diagnostics" is displayed to indicate this status to the
operator.

Restoring the initial configuration

After completing the diagnostics, the initial configuration on the drive bus must be restored:
1. Replace or re-install the removed drive module.
2. Change entries of the drive module in machine datum:
MD13030 $MN_DRIVE_MODULE_TYPE
back to the original values.
3. Perform an NC RESET.

Example
The 2axis module with drive numbers "1" and "2" must be removed from a drive grouping.

Note
Before activating the function, the module in question must be removed from the drive bus
configuration
(SIMODRIVE 611 digital). To do this, connect the drive bus so as to exclude the module.
If Safety Integrated has been activated for the modules concerned, you must disable it
manually (safety, logged, EMERGENCY STOP scheme).

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2.9 Identifying defective drive modules

Table 2-5

Bus configuration example

Module

Drive no.

Active

Type

Module type

Power section code

10

ARM/MSD

Axis

Left

SRM/FDD

Axis

14
14

Right

SRM/FDD

Axis

Left

HLA

Axis

Right

ANA

Axis

12

SLM

Axis

11

PER

DMPC

11

Module "2" must now be removed:

Machine datum:
MD13030 $MN_DRIVE_MODULE_TYPE
is to be selected on the "General MD" MD screen.
DRIVE_MODULE_TYPE[0] = 1
DRIVE_MODULE_TYPE[1] = 2 <- set this entry to zero
DRIVE_MODULE_TYPE[2] = 2 <- set this entry to zero
DRIVE_MODULE_TYPE[3] = 2
DRIVE_MODULE_TYPE[4] = 2
DRIVE_MODULE_TYPE[5] = 1
DRIVE_MODULE_TYPE[6] = 9
After the changes, the table looks like this:
DRIVE_MODULE_TYPE[0] = 1
DRIVE_MODULE_TYPE[1] = 0
DRIVE_MODULE_TYPE[2] = 0
DRIVE_MODULE_TYPE[3] = 2
DRIVE_MODULE_TYPE[4] = 2
DRIVE_MODULE_TYPE[5] = 1
DRIVE_MODULE_TYPE[6] = 9
Alarms 300020 "Drive 1 removed for diagnostics" and 300020 "Drive 2 removed for
diagnostics" are displayed.
Internally simulated drives are used for all axes which had settings on the removed drive
numbers. If the controller is engaged for the drives that are still installed, these drives
operate in the normal way. Interpolative traversal of all axes is disabled.

Note
If alarm 300003 "Axis xx drive yy incorrect module type zz" appears, then you have removed
only one part of a 2axis module. In this case, you should check the module type in the drive
configuration display. "NO" axis type is shown for removed modules.

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2.9 Identifying defective drive modules

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Constraints

No supplementary conditions apply.

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3-1

Constraints

3-2

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Examples
No examples are available.

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Examples

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Data lists
5.1

5.1.1

5.1

Machine data

Drive-specific machine data

Number

Identifier: $MD_

Description

1401

MOTOR_MAX_SPEED

Speed for max. useful motor speed

1417

SPEED_THRESHOLD_X

nx for 'nact < nx' signal

1418

SPEED_THRESHOLD_MIN

nmin for 'nact < nmin' signal

1426

SPEED_DES_EQ_ACT_TOL

Tolerance band for 'nset-nact' signal

1428

TORQUE_THRESHOLD_X

Threshold torque

1602

MOTOR_TEMP_WARN_LIMIT

Maximum motor temperature

1604

LINK_VOLTAGE_WARN_LIMIT

DC link under voltage warning threshold

1620

PROG_SIGNAL_FLAGS

Bits variable signal function

1621

PROG_SIGNAL_NR

Signal number variable signal function

1622

PROG_SIGNAL_ADDRESS

Address variable signal function

1623

PROG_SIGNAL_THRESHOLD

Threshold variable signal function

1624

PROG_SIGNAL_HYSTERESIS

Hysteresis variable signal function

1625

PROG_SIGNAL_ON_DELAY

ON Delay variable signal function

1626

PROG_SIGNAL_OFF_DELAY

OFF Delay variable signal function

1700

TERMINAL_STATE

Status of binary inputs

1702

MOTOR_TEMPERATURE

Motor temperature

1706

DESIRED_SPEED

Speed setpoint

1707

ACTUAL_SPEED

Speed actual value

1708

ACTUAL_CURRENT

Smoothed current actual value

Diagnostic tools (D1)

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5-1

Data lists
5.2 Setting data

5.1.2

NC-specific machine data

Number

Identifier: $MN_

Description

11410

SUPPRESS_ALARM_MASK

Mask for suppressing special alarms

11411

ENABLE_ALARM_MASK

Activation of special alarms

11412

ALARM_REACTION_CHAN_NOREADY

Alarm reaction CHAN_NOREADY permitted

11413

ALARM_PAR_DISPLAY_TEXT

Texts as alarm parameters (Siemens Rights)

11420

LEN_PROTOCOL_FILEX

File size for protocol files (KB)

13030

DRIVE_MODULE_TYPE

Module identifier (SIMODRIVE 611 digital)

5.1.3
Number

Axis/spindlespecific machine data

Identifier: $MA_

Description

32200

POSCTRL_GAIN [n]

Servo gain factor

32250

RATED_OUTVAL

Rated output voltage

32260

RATED_VELO

Rated motor speed

36010

STOP_LIMIT_FINE

Exact stop fine

36030

STANDSTILL_POS_TOL

Zero speed tolerance

36050

CLAMP_POS_TOL

Clamping tolerance

36210

CTRLOUT_LIMIT

Maximum speed setpoint

36300

ENC_FREQ_LIMIT[n]

Encoder limit frequency

36400

CONTOUR_TOL

Tolerance band contour monitoring

36500

ENC_CHANGE_TOL

Max. tolerance for actual position value acquisition

37010

FIXED_STOP_TORQUE_DEF

Clamping torque

43510

FIXED_STOP_TORQUE

Fixed stop clamping torque

5.2

5.2.1

5.2

Setting data

Axis/spindle-specific setting data

Number

Identifier: $SA_

Description

43510

FIXED_STOP_TORQUE

Fixed stop clamping torque

5-2

Diagnostic tools (D1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Data lists
5.3 Signals

5.3

5.3.1

5.3

Signals

Signals to axis/spindle

DB number

Byte.Bit

Description

31, ...

16.0 - 16.2

Actual gear stages A, B, C

31, ...

21.0 - 21.2

Parameter set selection A, B, C

31, ...

21.3 - 21.4

Motor selection A, B

31, ...

21.7

Pulse enable

5.3.2

Signals from axis/spindle

DB number

Byte.Bit

Description

31, ...

60.4

Referenced/synchronized 1

31, ...

60.5

Referenced/synchronized 2

31, ...

62.5

Fixed stop reached

31, ...

92.0

Setup mode active

31, ...

92.1

Rampup function generator quick stop

31, ...

92.2

Torque limit 2 active

31, ...

92.3

Speed setpoint smoothing active

31, ...

93.0 - 93.2

Active parameter set A, B, C

31, ...

93.3 - 93.4

Active motor A, B

31, ...

93.5

Drive Ready

31, ...

93.6

Speed controller integrator disabled

31, ...

93.7

Pulses enabled

31, ...

94.0

Motor temperature prewarning

31, ...

94.1

Heat-sink temperature prewarning

31, ...

94.2

Ramp-up function completed

31, ...

94.3

_'Md_'< Mdx

31, ...

94.4

_'nact_'< nmin

31, ...

94.5

_'nact_'< nx

31, ...

94.6

_'nact_'= nset

Diagnostic tools (D1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

5-3

Data lists
5.3 Signals

5-4

Diagnostic tools (D1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Index
6
611D commissioning tool, 2-31

A
Axis/spindle service display, 2-5

C
Communication log, 2-29

D
DB31, ...
DBX16.0, 2-9
DBX16.1, 2-9
DBX16.2, 2-9
DBX20.3, 2-20
DBX21.0, 2-21
DBX21.1, 2-21
DBX21.2, 2-21
DBX21.3, 2-22
DBX21.4, 2-22
DBX21.7, 2-17
DBX60.4, 2-10
DBX60.5, 2-10
DBX62.5, 2-10
DBX92.0, 2-21
DBX92.1, 2-17
DBX92.2, 2-20
DBX92.3, 2-20
DBX93.0, 2-21
DBX93.1, 2-21
DBX93.2, 2-21
DBX93.3, 2-22
DBX93.4, 2-22
DBX93.5, 2-18
DBX93.6, 2-20
DBX93.7, 2-18
DBX94.0, 2-23
DBX94.1, 2-23

Diagnostic tools (D1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

DBX94.2, 2-23
DBX94.3, 2-24
DBX94.4, 2-24
DBX94.5, 2-24
DBX95.7, 2-23
DB31, ... DBX94.6, 2-25
Diagnostic tools (D1), 1-1
Interrupts, 2-1
Diagnostics, 2-5
Drive service display, 2-15

L
Logbook, 2-30

M
MD11412, 2-3
MD13030, 2-32, 2-33, 2-34
MD1401, 2-8
MD1417 $MD_SPEED_THRESHOLD_X, 2-24
MD1418 $MD_SPEED_THRESHOLD_MIN, 2-24
MD1426 $MD_SPEED_DES_EQ_ACT_TOL, 2-23, 225
MD1428 $MD_TORQUE_THRESHOLD_X, 2-24
MD1604, 2-18
MD1620 $MD_PROG_SIGNAL_FLAGS, 2-25
MD1621 $MD_PROG_SIGNAL_NR, 2-25
MD1622 $MD_PROG_SIGNAL_ADDRESS, 2-25
MD1623 $MD_PROG_SIGNAL_THRESHOLD, 2-25
MD1624 $MD_PROG_SIGNAL_HYSTERESIS, 2-25
MD1625 $MD_PROG_SIGNAL_ON_DELAY, 2-25
MD1626 $MD_PROG_SIGNAL_OFF_DELAY, 2-25
MD1700, 2-16, 2-17
MD1702 $MD_MOTOR_TEMPERATURE, 2-19
MD1706, 2-19
MD1707, 2-19
MD1708, 2-19
MD20700, 2-10
MD32200, 2-13
MD34110, 2-10
MD36010 $MA_STOP_LIMIT_FINE, 2-14
MD36030 $MA_STANDSTILL_POS_TOL, 2-13
MD36050 $MA_CLAMP_POS_TOL, 2-14

Index-1

Index
MD36210 $MA_CTRLOUT_LIMIT, 2-13
MD36300 $MA_ENC_FREQ_LIMIT, 2-14
MD36400 $MA_CONTOUR_TOL, 2-13
MD36500 $MA_ENC_CHANGE_TOL, 2-14
MD37010 $MA_FIXED_STOP_TORQUE_DEF, 2-10

R
Ramp-up phase, 2-25

S
Service display PROFIBUS DP, 2-26
Servo gain factor (Kv), 2-13

NCK alarm handler, 2-2

V
O
of defective drive modules
Identification, 2-32

Version, 2-30

Z
ZK1 Messages, 2-25

PCIN, 2-32
PLC status, 2-30

Index-2

Diagnostic tools (D1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

1
Brief Description
______________

SINUMERIK 840D sl/840Di sl/840D/840Di/810D Travel to fixed stop (F1)

2
Detailed Description
______________
SINUMERIK
840D sl/840Di sl/840D/840Di/810D
Travel to fixed stop (F1)

Valid for

Control

SINUMERIK 840D sl/840DE sl

SINUMERIK 840Di sl/840DiE sl
SINUMERIK 840D powerline/840DE powerline
SINUMERIK 840Di powerline/840DiE powerline
SINUMERIK 810D powerline/810DE powerline
NCU System Software for 840D sl/840DE sl
NCU system software for 840Di sl/DiE sl
NCU system software for 840D/840DE
NCU system software for 840Di/840DiE
NCU system software for 810D/810DE
03/2006 Edition
6FC5397-0BP10-1BA0

4
Examples
______________
5
Data lists
______________

Function Manual

Software

3
Supplementary conditions
______________

Version
1.3
1.0
7.4
3.3
7.4

Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
Danger
indicates that death or severe personal injury will result if proper precautions are not taken.
Warning
indicates that death or severe personal injury may result if proper precautions are not taken.
Caution
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
Notice
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.

Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage
Note the following:
Warning
This device may only be used for the applications described in the catalog or the technical description and only in
connection with devices or components from other manufacturers which have been approved or recommended by
Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly
as well as careful operation and maintenance.

Trademarks
All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.

Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG
Automation and Drives
Postfach 48 48
90437 NRNBERG
GERMANY

Order No.: 6FC5397-0BP10-1BA0

Edition 05/2006

Copyright Siemens AG 2006.

Technical data subject to change

Table of contents
1

Brief Description ..................................................................................................................................... 1-1

Detailed Description................................................................................................................................ 2-1

2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6

General functionality .................................................................................................................. 2-1

Functional sequence, programming, parameterization ............................................................. 2-1
Response to RESET and function abort.................................................................................... 2-8
Block search response............................................................................................................... 2-9
Miscellaneous .......................................................................................................................... 2-14
Supplementary conditions for expansions ............................................................................... 2-17
Travel with limited moment/force FOC: ................................................................................... 2-19

2.2
2.2.1
2.2.2

Travel to fixed stop with analog drives..................................................................................... 2-22

SIMODRIVE 611 digital (VSA/HSA) ........................................................................................ 2-22
Travel to fixed stop with hydraulic drives SIMODRIVE 611 digital (HLA module)................... 2-26

2.3
2.3.1
2.3.2
2.3.3

Travel to fixed stop with analog drives..................................................................................... 2-26

SIMODRIVE 611 analog (FDD) ............................................................................................... 2-26
SIMODRIVE 611 analog (FDD) ............................................................................................... 2-29
Diagrams for travel to fixed stop with analog drives ................................................................ 2-32

Supplementary conditions ...................................................................................................................... 3-1

Examples................................................................................................................................................ 4-1

Data lists................................................................................................................................................. 5-1

5.1
5.1.1

Machine data.............................................................................................................................. 5-1

Axis/spindlespecific machine data ............................................................................................. 5-1

5.2
5.2.1

Setting data ................................................................................................................................ 5-2

Axis/spindle-specific setting data ............................................................................................... 5-2

5.3
5.3.1
5.3.2

Signals ....................................................................................................................................... 5-2

Signals to axis/spindle ............................................................................................................... 5-2
Signals from axis/spindle ........................................................................................................... 5-3

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

Travel to fixed stop (F1)

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iii

Table of contents

iv

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Brief Description

Customer benefit
The "Travel to fixed stop" function can be used for operations such as traversing tailstocks or
sleeves to an end limit position in order to clamp workpieces.

Features
The clamping torque and a fixed stop monitoring window can be programmed in the parts
program and can also be altered via setting data once the fixed stop has been reached.
The "travel to fixed stop" function can be implemented for axes as well as for spindles
with axistraversing capability.
The function can be implemented for several axes simultaneously and parallel to the
motion of other axes.
Torques or the power can be adjusted to a specific setting.
Travel with limited torque/power (Force Control, FOC) can be activated.
The "travel to fixed stop" functions can be enabled from synchronized actions.
Block search with calculation, multichannel (SERUPRO).
Move axes with FXS and FOC in simulation mode.
Vertical axes can also be moved with FXS to a fixed stop.
With SW 6.4 and higher, VDI signals can be used to set a REPOS offset for each axis and
display the FXS status currently active on the machine after the search target has been
located.

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

1-1

Brief Description

1-2

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed Description
2.1

2.1.1

2.1

General functionality

Functional sequence, programming, parameterization

Programming
Travel to fixed stop is selected or deselected with the following commands:
FXS[Machine axis identifier]=1 (selected)
FXS[Machine axis identifier]=0 (deselected)
The commands are modal.
The clamp torque is set with the command:
FXST[Machine axis identifier] = <torque>
.
It is entered in % of the static torque for feed spindle drives:
(MD1118 MOTOR_STANDSTILL_CURRENT)
or in % of motor torque for main spindle drives:
(MD1103 MOTOR_NOMINAL_POWER)
.
The command is used for setting the width of the fixed stop monitoring window.
FXSW[machine axis identifier] = monitoring window
The unit is dependent on the default setting: mm, inch or degrees.

Channel axis identifier

Instead of the machine axis identifiers, it is also possible to use channel axis identifiers if the
channel axis identifiers are assigned exactly to one machine axis.
Restrictions:
Channel identifiers may not be used (option disabled) for machine axes which have an active
transformation or frame.
If the machine axis is a coupled axis (e.g. following axis), programming is prevented and
alarm 14092 "Incorrect axis type" is displayed.
The movement to the destination point can be described as a path or positioning axis
movement. With positioning axes, the function FXS can be performed across block
boundaries. The function may also be selected for several machine axes simultaneously.

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-1

Detailed Description
2.1 General functionality
The FXST and FXSW commands are optional.
The travel path and the command which activates that function must be programmed in one
block (exception: Synchronized actions).

Examples
With machine axis identifiers:
X250 Y100 F100 FXS[X1]=1
X250 Y100 F100 FXS[X1]=1 FXST[X1]=12.3
X250 Y100 F100 FXS[X1]=1 FXST[X1]=12.3 FXSW[X1]=2

; mm

X250 Y100 F100 FXS[X1]=1 FXSW[X1]=2

; mm

References:
/PG/ "Programming Guide: Fundamentals"

Channel axis identifier with unambiguous machine axis assignment:

For the purpose of illustrating the differences in programming, chanel axis X is programmed
as the image of machine axis AX1 [or X1 (Name in machine parameter:
MD10000 $MN_AXCONF_MACHAX_NAME_TAB)]
.
Programming with machine axis identifiers
FXS[X1] = 1

; Selecting X1

FXST[X1] = 10

; New torque for X1

FXSW[X1] = 5

; New window for X1

Programming with channel axis identifiers

FXS[X] = 1

; Selecting X1 ->X1

FXST[X] = 10

; New torque X1 ->X1

FXSW[X] = 5

; New window for X -> X1

All four of the following programming lines have the same effect when the channel axis X is
imaged on the machine axis AX1, X1:
Z250 F100 FXS[AX1]=1 FXST[AX1]=12.3 FXSW[AX1]=2000
Z250 F100 FXS[X1]=1 FXST[X1]=12.3 FXSW[X1]=2000
Z250 F100 FXS[X]=1 FXST[X]=12.3 FXSW[X]=2000
Z250 F100 FXS[X]=1 FXST[X1]=12.3 FXSW[AX1]=2000

2-2

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed Description
2.1 General functionality

Functional sequence
The function is explained by the example below (sleeve is pressed onto workpiece).

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WRIL[HGVWRS

3URJU(QG
SRVLWLRQ

Figure 2-1

)L[HGVWRS
6WDUWSRVLWLRQ
PRQLWRULQJZLQGRZ

Example of travel to fixed stop

Selection
The NC recognizes the "Travel to fixed stop" function selection using command FXS[x]=1
and reports to the PLC using IS DB31, ... DBX62.4 ("Activate travel to fixed stop") to indicate
that the function has been selected.
If the machine data:
MD37060 FIXED_STOP_ACKN_MASK
(observation of PLC acknowledgements for travel to fixed stop)
is set accordingly, PLC acknowledgement via IS DB31, ... DBX3.1 ("Enable travel to fixed
stop") is waited for.
The programmed target position is then approached from the start position at the
programmed velocity. The fixed stop must be located between the start and target positions
of the axis/spindle. A programmed torque limit is effective from the start of the block, i.e. the
fixed stop is also approached with reduced torque. Allowance for this limitation is made in
the NC through an automatic reduction in the acceleration rate.
If no torque has been programmed in the block or has not been programmed since the start
of the program, the value entered in the axis-specific machine data:
MD37010 $MA_FIXED_STOP_TORQUE_DEF
(presetting for terminal torque)
applies.

Travel to fixed stop (F1)

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2-3

Detailed Description
2.1 General functionality

Fixed stop reached

As soon as the axis comes into contact with the mechanical fixed stop (workpiece), the
closedloop control in the drive raises the torque so that the axis can move on. The torque
rises up to the programmed limit value and then remains constant.
The "Fixed point reached" status can be calculated as follows depending on the machine
data:
MD37040 $MA_FIXED_STOP_BY_SENSOR (fixed stop recognition by sensor)
:
FIXED_STOP_BY_SENSOR = 0
The "Fixed point reached" status is present when the axial contour variance (= difference
between actual and expected following error) has exceeded the machine data value:
MD37030 $MA_FIXED_STOP_THRESHOLD (threshold for fixed stop recognition)
.
FIXED_STOP_BY_SENSOR = 1
External sensor provides NC via the PLC, using IS DB31, ... DBX1.2 ("Sensor fixed
stop"), with the status "Fixed stop reached".
FIXED_STOP_BY_SENSOR = 2
The "Fixed stop reached" status is active either when the status has been detected by the
contour monitoring function or when the external sensor signals this status by a signal
change from 0 " 1 to (DB31,...DBX 1.2).
The axial contour variance is explained in:
References:
/FB1/ Function Manual, Basic Function; Diagnostics Tools (D1)

Internal processes
Once the NC has detected the "Fixed stop reached" status, it deletes the distancetogo and
the position setpoint is made to follow. The controller enabling command remains active.
The PLC is then informed using IS DB31, ... DBX62.5 ("Fixed stop reached").
If the machine data:
MD37060 $MA_FIXED_STOP_ACKN_MASK
is set accordingly, PLC acknowledgement using IS DB31, ... DBX1.1 ("Acknowledge fixed
stop reached") is waited for.
The NC then executes a block change or considers the positioning motion to be completed,
but still leaves a setpoint applied to the drive actuator to allow the clamping torque to take
effect.
The fixed stop monitoring function is activated as soon as the stop position is reached.

2-4

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed Description
2.1 General functionality

Monitoring window
If a fixed stop monitoring window has not been programmed in the block or has not been
programmed since the start of the program, the value entered in the machine data:
MD37020 $MA_FIXED_STOP_WINDOW_DEF
(presetting for fixed stop monitoring window)
applies.
If the axis leaves the position it was in when the fixed stop was detected, then alarm 20093
"Fixed stop monitoring has responded" is displayed and the "Travel to fixed stop" function
deselected.
The window must be selected by the user such that the alarm is activated only when the axis
leaves the fixed stop position.

Enabling the fixed stop alarms

Definitions for enabling the fixed stop alarms can be set as follows using machine data:
MD37050 $MA_FIXED_STOP_ALARM_MASK
:
MD 37050 = 0

Fixed stop not reached (suppress Alarm 20091)

MD 37050 = 2

Fixed stop not reached (suppress alarm 20091) and fixed stop aborted
(suppress alarm 20094)

MD 37050 = 3

Fixed stop aborted (suppress alarm 20094)

All other permissible values of 7 or less do not suppress any alarms.

Using the parts program command NEWCONF a new setting can be activated.

Fixed stop is not reached

If the programmed limit position is reached without the "Fixed point reached" status having
been recognized, alarm 20091 "Fixed point not reached" is output depending on the status of
machine data:
MD37050 $MA_FIXED_STOP_ALARM_MASK (enable fixed stop alarms)

Function abort
If the "Travel to fixed stop" function is aborted due to the occurence of a pulse disable,
cancelation of PLC acknowledgements or a reset in the starting block, alarm 20094 can be
controlled (display or suppression) using machine data:
MD37050m $MA_FIXED_STOP_ALARM_MASK

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-5

Detailed Description
2.1 General functionality

Abort without alarm

Travel to fixed stop can be aborted by the PLC in the starting block without triggering an
alarm (for example, when the operator presses a button) if alarm 20094 is suppressed in
machine data:
MD37050 $MA_FIXED_STOP_ALARM_MASK
.
The Travel to fixed stop function is deselected in response to both "Fixed stop not reached"
and "Fixed stop aborted".

Interrupts
If the fixed stop position is not reached when the function is active, alarm 20091 "Fixed stop
not reached" is output and a block change executed.
If a travel request (e.g. from the part program, the PLC, from compile cycles or from the
operator panel) is provided for an axis after the fixed stop has been reached, the alarm
20092 "Travel to fixed stop still active" is output and the axis is not moved.
If after reaching the fixed stop an axis is pushed out of position more than the indicated value
in
SD FIXED_STOP_WINDOW (fixed stop monitoring window)
, the alarm 20093 "fixed stop monitoring has responded" is output; the "travel to fixed stop"
function is then deselected for this axis and system variable $AA_FXS[x] is set to 2.

No termination during alarm

"Travel to fixed stop" remains active during alarms
if the bit values in machine data:
MD37052 $MA_FIXED_STOP_ALARM_REACTION
have been set.
IS "Mode group ready" (DB11, ... DBX6.3) remains active.

Alarm suppression after new programming

Travel to fixed stop can be used for simple measuring processes.
For example, it is possible to carry out a check for tool breakage by measuring the tool
length by traversing onto a defined obstacle. To do so, the fixed stop alarm must be
suppressed. When the function for clamping workpieces is then used "normally," the alarm
can be activated using parts program commands.

Sequence in case of a fault or abnormal termination

IS DB31, ... DBX62.4 ("Activate travel to fixed stop") is reset.
Depending on machine data:
MD37060 $MA_FIXED_STOP_ACKN_MASK
, PLC acknowledgement is expected by resetting the IS
DB31, ... DBX3.1 ("Enable travel to fixed stop") is waited for.
The torque limitation is then canceled and a block change executed.

2-6

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed Description
2.1 General functionality

Deselection
The NC recognizes the function deselection via programming of the command FXS[x]=0.
Then an advance stop (STOPRE) is internally released, since it can't be forseen where the
axis will be after deselection.
The torque limitation and the monitoring of the fixed stop monitoring window is cancelled.
The IS DB31, ... DBX62.4 ("Activate travel to fixed stop") and DB31, ... DBX62.5 ("Fixed stop
reached") are reset.
Depending on machine data:
MD37060 $MA_FIXED_STOP_ACKN_MASK
, PLC acknowledgement is waited for by resetting the IS
DB31, ... DBX3.1 ("Enable travel to fixed stop") and/or
DB31, ... DBX1.1 ("Acknowledge fixed stop reached").
The axis will then change to position control. The followup mode of the position setpoints is
ended and a synchronization to the new actual position is carried out.
A programmed traverse motion can then be executed. This motion must lead away from the
fixed stop or else the stop or even the machine may sustain damage.
A block change is executed after the target position has been reached.

Multiple selection
A selection may only be carried out once. If the function is called once more due to faulty
programming (FXS[Axis]=1) the alarm 20092 "Travel to fixed stop still active" is initiated.

Blockrelated synchronized actions

By programming a blockrelated synchronized action, travel to fixed stop can be connected
during an approach motion.
Programming example:
N10 G0 G90 X0 Y0
N20 WHEN $AA_IW[X]>17 DO FXS[X]=1

; If X reaches a position greater

N30 G1 F200 X100 Y110

; 17mm FXS is activated

Changing the clamping torque and fixed stop monitoring window

The clamping torque and the monitoring window can be changed with the commands
FXST[x] and FXSW[x]. The changes take effect before traversing movements in the same
block.
Programming of a new fixed stop monitoring window causes a change not only in the
window width but also in the reference point for the center of the window if the axis has
moved prior to reprogramming. The actual position of the machine axis when the window is
changed is the new window center point.

Travel to fixed stop (F1)

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Detailed Description
2.1 General functionality

Terminal 663 with MD37002 controllable

With the machine data:
MD37002 $MA_FIXED_STOP_CONTROL
the response to pulse disabling on the stop is controllable.
Deleting the pulses via terminal 663 or the ("Pulse enable") IS DBX31, ...DBX21.7 will not
abort the function. As a result, the drive will press against the fixed stop again without any
further operating action when the machine is restarted.
The rise time of the torque corresponds to the time needed by the current controller of the
drive to reach the limitation again.
If the pulses are deleted when a deselection is active (waiting for PLC acknowledgments),
the torque limit will be reduced to zero. If the pulses are reactivated during this phase, torque
is no longer built up. Once the deselection has been completed, you can continue traversing
as normally.

FXS commands programmable in synchronized actions

The parts program commands FXS, FXST and FXSW can be programmed in synchronized
actions/technology cycles.
The function FXS[x]=1 can also be activated without movement; the torque is limited
immediately. As soon as the axis is moved via a setpoint, the limit stop monitor is activated.
In static and blockrelated synchronized actions, the same commands FXS, FXST, FXSW can
be used as in the normal parts program run. The values assigned can result from a
calculation.

Ramp for torque limitation with MD37012

A ramp has been implemented so that the setting of a torque limit is not to jerky.
For this purpose, the amount
of time required to reach the new torque limit is specified in the machine data:
MD37012 $MA_FIXED_STOP_TORQUE_RAMP_TIME.

2.1.2

Response to RESET and function abort

Response to RESET
During selection (fixed stop not yet reached) the function FXS can be aborted with RESET.
The termination is carried out such that an "almost achieved" fixed stop (setpoint already
beyond the fixed stop, but still within the threshold for the fixed stop detection) will not result
in damage.
This is achieved by synchronizing the position setpoint to the new actual position. As soon
as the fixed stop is reached, the function remains operative even after RESET.

2-8

Travel to fixed stop (F1)

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Detailed Description
2.1 General functionality

Function abort
A function abort can be triggered by the following events:
EMERGENCY STOP:
With an 840D control, the NC and drive are disconnected from the supply after
EMERGENCY STOP, i.e. the PLC must react.
With an 840Di control, the NC and drive are disconnected from the supply after
EMERGENCY STOP, i.e. the PLC must react.

Caution
Make sure that after canceling the function
"travel to fixed stop" by "EMERGENCY STOP," no dangerous machine situation
(MD37002 $MA_FIXED_STOP_CONTROL e.g. canceling pulse disable) can arise.

The fixed stop monitoring function responds in the case of:

Exit from fixed stop position by axis
Tool breakage
Pulse disable

2.1.3

Block search response

Block search with calculation

The response is as follows:
If the target block is located in a program section in which the axis must stop at a fixed
limit, then the fixed stop is approached if it has not yet been reached.
If the target block is located in the program section in which the axis must not stop at a
fixed limit, then the axis leaves the fixed stop if it is still positioned there.
If the desired fixed stop status is reached, alarm message 10208 "press NC Start to
continue the program" is output. The program can be continued after pressing NC Start to
acknowledge.
At the start of the target block, FXST[x] and FXSW[x] are set to the same value as they
would have during normal program processing.

Travel to fixed stop (F1)

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Detailed Description
2.1 General functionality

Block search without calculation

The commands FXS, FXST and FXSW are ignored.

FOC
FOCON/FOCOF is activated modally. It is already active in the approach block.

SERUPRO
Block search with calculation, multichannel
The block search in program test mode is designated SERUPRO and is derived from the
"Search-Run by Program test." This search mode allows the user a multichannel block
search with calculation of all required status data from the previous history.
The PLC interface is updated in this block search and matching processes, which cover the
interaction of several channels executed within the framework of this block search correctly.

Search process with FXS and FOC

The user selects FXS or FOC in a program area of the searched target block in order to
acquire all states and functions of this machining last valid. The NC will start the selected
program in Program test mode automatically. After the target block has been found, the NC
stops at the beginning of the target block, deselects Program test internally again and
displays the Stop condition "Search target found" in its block display.
If FXS "travel to fixed stop" is located between the beginning of the program and the search
target, the instruction is not really executed by the NC. The motion is only simulated up to
the programmed end point.

Caution
SERUPRO approach does not really take the statementFXS into account. The approach to
the programmed end position of the FXS block is only simulated without torque limitation.

The user can log the turning on and turning off of FXS in the parts program. If necessary, the
user can start an ASUB in order to activate or deactivate FXS in this SERUPRO-ASUP.

2-10

Travel to fixed stop (F1)

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Detailed Description
2.1 General functionality

$AA_FXS and $VA_FXS

In SW 6.2 and higher, the meaning of system variable $AA_FXS is redefined for SERUPRO
only and completely replaced by variable $VA_FXS. Variables $AA_FXS and $VA_FXS have
the same values continuously outside the SERUPRO function.
Description

NCK Variables

Axis not at fixed stop

$AA_FXS = 0 and $VA_FXS = 0

Fixed stop successfully approached

$AA_FXS = 1 and $VA_FXS = 1

Approach to fixed stop failed

$AA_FXS = 2 and $VA_FXS = 2

Travel to fixed stop selection active

$AA_FXS = 3 and $VA_FXS = 3

Fixed stop detected

$AA_FXS = 4 and $VA_FXS = 4

Travel to fixed stop deselection active

$AA_FXS = 5 and $VA_FXS = 5

Course of values
Course of values of system variables $VA_FXS[ ] with values 1 to 5

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,6$FWLYDWHWUDYHOWRIL[HGHQGVWRS
7HUPLQDOFODPSDFWLYH
,6(QDEOHWUDYHOWRIL[HGVWRS
,6)L[HGVWRSUHDFKHG
7HUPLQDOFODPSDFWLYH

,6$FNQRZOHGJHIL[HGVWRSUHDFKHG
6HWYHORFLW\

7DUJHWSRVLWLRQGHVHOHFWHGUHFRUG
5HFRUGFKDQJH

DFFHOHUDWLRQDFFRUGLQJWR0'0$;B$;B$&&(/
7HUPLQDOFODPSLVVWLOODFWLYHZLWKRXWFKDQJHRYHURIWHUPLQDOFODPS

Figure 2-2

Diagram for FXS with a digital drive (611 digital)

Travel to fixed stop (F1)

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Detailed Description
2.1 General functionality

$AA_FXS Simulate axis traversal

System variable $AA_FXS displays the current status of program simulation "programsensitive system variable."

Example:
If in the SERUPRO process axis Y traversal is simulated with FXS[Y]=1, then $AA_FXS has
a value of 3.
If in the SERUPRO process axis Y traversal is simulated with FXS[Y]=0, then $AA_FXS has
a value of 0.
During simulation with SERUPRO, $AA_FXS cannot have the values 1, 2, 4, 5, since the
actual status of $VA_FXS "travel to fixed stop" can never be detected.

Note
The state $AA_FXS = 1 is never reached during the SERUPRO operation. This means that
other program branches can be processed which will produce different results due to the
simulation.

If after the SERUPRO process axis Y is traversed again, then variables $AA_FXS and
$VA_FXS are assigned the same values again.

$VA_FXS Real machine status

Variable $VA_FXS always describes the real machine status.
In this way, the actual existing machine status of the corresponding axis with $VA_FXS is
displayed.

Setpoint/actual status comparison

The two system variables $AA_FXS and $VA_FXS can be used to compare the setpoint and
actual states in the parts program. The SERUPRO ASUB routine is then as follows:
SERUPRO ASUP
Asup fxsSeruproAsup.mpf
The setpoint and actual states are compared for the
;REPOSA block FXS to correspondingly activate or deactivate.
N1000 WHEN ($AA_FXS[X]==3) AND ($VA_FXS[X]==0) DO FXS[X]=1
N2000 WHEN ($AA_FXS[X]==0) AND ($VA_FXS[X]==1) DO FXS[X]=0
N1020 REPOSA

2-12

Travel to fixed stop (F1)

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Detailed Description
2.1 General functionality

REPOS display Offset

Once the search target has been found, the FXS status active on the machine is displayed
for each axis via the axial VDI signals:
IS DB31, ... DBX62.4 ("Activate travel to fixed stop")
and
IS DB31, ... DBX62.5 ("Fixed stop reached")
.

Example:
If the machine is at the fixed stop and the block search has reached a block after deselection
of FXS , the new target position is displayed via IS DB31, ... DBX62.5 ("Fixed stop reached")
as the REPOS offset.

FXS fully automatically in REPOS

With REPOS the functionality of FXS is repeated automatically and designated FXS-REPOS
below. This sequence is comparable to the program "fxsSeruproAsup.mpf." Every axis is
taken into account and the torque last programmed before the search target is applied.
The user can treat FXS separately in a SERUPRO-ASUP.
The following then applies:
Every FXS action in SERUPRO-ASUP automatically ensures
$AA_FXS[X] == $VA_FXS[X].
This deactivates FXS-REPOS for axis X.

Deactivate FXS REPOS

FXS-REPOS is deactivated by:
an FXS synchronous action which refers to REPOSA
Or
$AA_FXS[X] == $VA_FXS[X] in SERUPRO_ASUP.

Note
A SERUPRO-ASUP without FXS handling or no SERUPRO-ASUP results in fully
automatic FXS-REPOS.

Travel to fixed stop (F1)

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Detailed Description
2.1 General functionality

Caution
FXS-REPOS moves all path axes in a path grouping to the target position. Axes with and
without FXS treatment thus traverse together with the G code and feedrate valid at the
time the target block is processed. As a result, the fixed stop may be approached in rapid
traverse(G0) or higher velocity.

FOC fully automatically in REPOS

The FOC-REPOS function behaves analogously to the FXS-REPOS function.

Note
A continuously changing torque characteristic cannot be implemented with FOC-REPOS.

Example:
A program moves axis X from 0 to 100 and activates FOC every 20 millimeters for 10
millimeters at a time. This torque characteristic is generated with nonmodal FOC and
therefore cannot be traced by FOC-REPOS. FOC-REPOS will traverse axis X from 0 to 100
with or without FOC.
For programming examples of FXS "travel to fixed stop," please see:
References:
/FB1/ Function Manual Basic Functions; Mode Group, Channel, Program Operation (K1);
Section: Program test

2.1.4

Miscellaneous

Setting data
The following axisspecific setting data are provided for the "Travel to fixed stop" function:
SD43500 $SA_FIXED_STOP_SWITCH (selection of travel to fixed stop)
SD43510 $SA_FIXED_STOP_TORQUE (clamping torque for travel to fixed stop)
SD43520 $SA_FIXED_STOP_WINDOW (fixed stop monitoring window)
The setting data are effective only when the axis has reached the fixed stop.
The status of the setting data is displayed via the operator panel in the "Parameters" area.
The commands FXS[x], FXST[x] and FXSW[x] effect a blocksynchronous change in
these setting data.

2-14

Travel to fixed stop (F1)

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Detailed Description
2.1 General functionality

If FXST[x] and FXSW[x] are not programmed, the default settings from the machine data:
MD37010 $MA_FIXED_STOP_TORQUE_DEF
and
MD37020 $MA_FIXED_STOP_WINDOW_DEF
are taken over in the corresponding setting dates if "travel to fixed stop" is activated.
The setting data for clamping torque and fixed stop monitoring window can be changed by
the operator and via the PLC. It is thus possible to specify a higher or lower clamping torque
or a modified fixed stop monitoring window after the fixed stop has been reached.

Changing the clamping torque using the ramp and values greater than 100%
A clamping torque change is transferred to the drive steplike. It is possible to specify a ramp
for always reaching a changed torque limit via the machine data:
MD37012 $MA_FIXED_STOP_TORQUE_RAMP_TIME
.

Clamping torque greater than 100%

Values greater than 100% for the setting data:
SD43510 $SA_FIXED_STOP_TORQUE
are only practical for a short time.
Irrespectively, the maximum torque is limited by the drive.
The drive machine dates have a limiting effect, i.e.:
MD1103 Motor current
MD1104 maximum motor current
MD1105 Reduction in max. motor current
MD1230/1231 torque limiting value 1/2
For further information, please refer to the Planning Guide SIMODRIVE ThreePhase Motors
for Feed and Main Spindle Drives and to the appropriate document regarding the hydraulic
module /FBHLA/.
References:
/FBHLA/ Description of functions HLA-Module

Status query in the parts program

System variable $AA_FXS[x] indicates the status of the "travel to fixed stop" function.
It has the following coding:
$AA_FXS=0

Axis not at fixed stop.

$AA_FXS=1

Fixed stop has been approached successfully

(axis is within fixed stop monitoring window).

$AA_FXS=2

Approach to fixed stop has failed

(axis is not at fixed stop).

$AA_FXS=3

Travel to fixed stop activated.

$AA_FXS=4

Fixed stop detected.

$AA_FXS=5

Travel to fixed stop is deselected. The deselection is not yet completed.

Travel to fixed stop (F1)

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Detailed Description
2.1 General functionality
Query of the system variable in the parts program initiates a block search stop.
As a result of the status query in the parts program, it is possible, for example, to react to an
erroneous operational sequence of the "Travel to fixed stop" function.
The following example applies:
MD37050 $MA_FIXED_STOP_ALARM_MASK = 0
an alarm is not generated in the error scenario, and a block change therefore takes place
and the error scenario can be evaluated via the system variable.

Example
X300 Y500 F200 FXS[X1]=1 FXST[X1]=25 FXSW[X1]=5
IF $AA_FXS[X1]=2 GOTOF FXS_ERROR
G01 X400 Y200

Inoperative IS signals
The following IS signals (PLC ! NCK) are inoperative for axes at the fixed stop until the
function is deselected (incl. traversing motion):
IS DB31, ... DBX1.3 ("axis/spindle disable")
IS DB31, ... DBX2.1 ("controller enable")

Actual position at fixed stop

System variable $AA_IM[x] can determine the actual position of the machine axis, e.g. for
test purposes after successful "travel to fixed stop."

Combination with other functions

"Measure with deletion of distance to go" (command MEAS) and "travel to fixed stop" cannot
be programmed at the same time in one block.
Exception:
One function is acting on a path axis while the other is acting on a positioning axis or both
functions are acting on positioning axes.

Contour monitoring
The axis contour monitoring function is inoperative while "Travel to fixed stop" is active.

Positioning axes
When "Travel to fixed stop" is applied toPOSA axes, block changes are made independently
of the fixed stop motion.

2-16

Travel to fixed stop (F1)

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Detailed Description
2.1 General functionality

Vertical axes
The "Travel to fixed stop" function can be used for vertical axes even when alarms are
active.
Should the traversal of vertical axes be aborted as a result of an FXS alarm, the relevant
drives are not disconnected from the supply via the VDI interface.
This functionality has the same effect on vertical axes as an electronic weight compensation
and can be configured via machine data:
MD37052 $MA_FIXED_STOP_ALARM_REACTION
.

Note
For further details about adaptations for SIMODRIVE 611 digital or digital (HLA module),
please see:
References:
/FB2/ Function Manual Extension Functions; Compensation (K3); Section: Electronic weight
compensation

MD37052
The machine data:
MD37052 $MA_FIXED_STOP_ALARM_REACTION
the drive is not disconnected from the power supply by setting the bits, even when an alarm
is generated, while IS DB11, ... DBX6.3 ("Mode group ready") remains active.
Bit value=0:
The alarms have an effect on FXS (drive becomes disconnected as previously).
IS DB11, ... DBX6.3 ("Mode group ready") is canceled.
Bit value=0:
The alarms have no effect on FXS. IS DB11, ... DBX6.3
("Mode group ready") remains active.
Bit 0: Alarm 20090

Travel to fixed stop cannot be programmed

Bit1: Alarm 20091

Fixed stop is not reached.

Bit 2: Alarm 20092

Travel to a fixed stop active.

Bit 3: Alarm 20093

Standstill monitoring on fixed stop is triggered.

Bit 4: Alarm 20094

Travel to fixed stop aborted.

Travel to fixed stop (F1)

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2.1.5

Supplementary conditions for expansions

Response to pulse blocking

The cancellation of the pulse enable, either by terminal 663 or by IS DB31, ... DBX21.7
("Pulse enable") is hereafter called a pulse disable.
The machine parameter:
MD37002 $MA_FIXED_STOP_CONTROL
can be used to influence the interaction of "travel to fixed stop" and pulse disable.
Bit 0: Response in case of pulse blocking at stop as follows:
Bit 0 = 0

Travel to fixed stop aborted.

Bit 0 = 1

Travel to fixed stop is aborted,

i.e., the drive becomes weak.

Once the pulse blocking is canceled again, the drive will press at the limited torque again.
The torque is actuated steplike.
At the fixed stop, the drive can be controlled either via:
IS DB31, ... DBX21.7 ("Pulse enable")
Or
Drive monitor 663 pulse enable
The NC evaluates IS DB31, ... DBX21.7 ("Pulse enable") itself.
Depending on the drive machine data:
MD1012 $MD_FUNC_SWITCH
the NC reacts with FXS to a change in the status of terminal 663 as follows:
Bit 2 = 0

The NC does not receive the status of terminal 663.

Bit 2 = 1

The NC does not receive the status of terminal 663.

Terminal 663
When pulse enabling is canceled by terminal 663, the drive is deenergized and coasts to a
standstill immediately.
With:
MD1012 $MD_FUNC_SWITCH, Bit 2 = 0
, this is not signaled to NC.
The status can be checked in the line "Pulse enable" (terminal 663) in service display service
drive.

2-18

Travel to fixed stop (F1)

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Detailed Description
2.1 General functionality

Note
Travel to fixed stop can be canceled by disabling pulses from IS " DB31, ... DBX21.7 ("Pulse
enable") or Terminal 663, if:
MD37002 $MA_FIXED_STOP_CONTROL, Bit 0 = 0
and
MD1012 $MD_FUNC_SWITCH, Bit 2 = 1
are fulfilled.
Both interrupting FXS and stopping "travel to fixed stop" is achieved by the following settings:
MD37002 $MA_FIXED_STOP_CONTROL, Bit 0 = 0
and
MD1012 $MD_FUNC_SWITCH, Bit 2 = 0.

Programming FXS in synchronized actions

The function is not available for analog axes (PLC acknowledgment cannot be awaited).
Select FXS[ ]=1:
The following signal interfaces are set:
Reporting to PLC:
IS DB31, ... DBX62.4 ("Activate travel to fixed stop")
The FXS selection command can only be used in systems with digital drives (VSA, HSA,
HLA).
The following condition mustbe observed:
MD37060 $MA_FIXED_STOP_ACKN_MASK, Bit 0 = 0
Bit 0 = 1 (waiting for PLC acknowledgement) must not be set, otherwise, an interpolator
stop would be required to acknowledge the signal, interrupting the movement.
Deselect FXS[ ]=0:
The following signal interfaces are reset:
Reporting to PLC:
IS DB31, ... DBX62.4 ("Activate travel to fixed stop")
The machine parameter:
MD37060 $MA_FIXED_STOP_ACKN_MASK
must have the value null for signal deselection without motion stop.

Without ramp
The torque limit is changed without taking into account the ramp if:
FXS is activated with (FXS[]=1), to make sure that the reduction is activated
immediately (especially for synchronized actions).
The drive needs to be de-energized as quickly as possible in the event of a fault.

Travel to fixed stop (F1)

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Detailed Description
2.1 General functionality

Selection of FXS with G64

In the machine data:
MD37060 $MA_FIXED_STOP_ACKN_MASK
bit 0 must = 0 (do not wait for PLC input signal "travel to fixed stop active"), since the
selection of FXS must not be allowed to initiate a motion stop.

Modify the torque FXST

The clamping torque can already be modified when approaching the stop.
The torque limit FXST acts in addition to the acceleration limitation with ACC.
The new torque in consideration of the ramp
(MD37012 $MA_FIXED_STOP_TORQUE_RAMP_TIME)
interpolation cycle takes effect after the change in the drive.
A change of the effective torque can be checked by reading the synchronized action variable
$VA_TORQUE[axis].

2.1.6

Travel with limited moment/force FOC:

Function
For applications in which torque or force are to be changed dynamically depending on the
travel or on the time or on other parameters (e.g. pressing), the following functionalityFOC
(Force Control) is provided.
Force/travel or force/time profiles are thus possible using the "Interpolation cycle" resolution.
The function allows torque/force to be modified at any time using synchronized actions.
The function can be activated modally or blockrelated.

Modal activation (FOCON/FOCOF)

The activation of the function after POWER_ON and RESET is determined by the machine
data:
MD37080 $MA_FOC_ACTIVATION_MODE
Table 2-1
Bit 0
Bit 1

Controlling the initial setting of the modal limitation of torque/force

After
Power On
RESET

Value
0

Effect
FOCOF

FOCON

FOCOF

FOCON

FOCON: Activation of the modally effective torque/force limitation

FOCOF: Disable torque/force limitation
The modal activation acts beyond the program end.If already programmed, it is effective with
FXST set torque/force. FXST can be programmed irrespectively of FOCON; it comes into
effect, however, only after the function has been activated.

2-20

Travel to fixed stop (F1)

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Detailed Description
2.1 General functionality

Programming
The programming of the axis is carried out in square brackets.
The following are permissible:
Geometry axis identifiers
Channel axis identifiers
Machine axis identifiers
Example:
N10 FOCON[X]

; Modal activation of the torque limit

N20 X100 Y200 FXST[X]=15

; X travels with reduced torque (15%)

N30 FXST[X]=75 X20

; Changing the torque to 75%.

; X travels with this reduced torque.

N40 FOCOF[X]

; Disable torque limit

Block-related limit (FOC)

The parts program command FOC activates the torque limit for a block.
An activation from a synchronized action takes effect up to the end of the current parts
program block.

Priority FXS/FOC
An activation of FXS with FOC active has priority, i.e. FXS is executed.
A deselection of FXS will cancel the clamping.
A modal torque/force limitation remains active.
After PowerOn, the machine data:
MD37010 $MA_FIXED_STOP_TORQUE_DEF. is in effect in an activation.
This torque can be modified at any time by programmingFXST.

Synchronized actions
The language commands FOC, FOCON, FOCOF can also be programmed in synchronized
actions as the commands for "travel to fixed stop."

Determine FOC status

The activation status can be read at any time via the status variable $AA_FOC.
If FXS is also activated, the status is not changed.
0:

FOC not active

1:

FOC modal active

2:

FOC block-related active

Travel to fixed stop (F1)

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Detailed Description
2.1 General functionality

Determine torque limit status

The system variables $VA_TORQUE_AT_LIMIT can be used at any time to read in systems
with digital drives (FDD, MSD, HLA) whether the currently active torque corresponds to the
given torque limit.
0:

Effective torque less than torque limit value

1:

Effective torque has reached the torque limit value

Restrictions
The function FOC is subject to the following restrictions:
The change of the torque/force limitation representing itself as an acceleration limitation
is only taken into account in the traversing movement at block limits (see command ACC).
Only FOC:
No monitoring is possible from the VDI interface to check that the active torque limit has
been reached.
If the acceleration limitation is not adapted accordingly, an increase of the drag distance
during the traversing motion occurs.
If the acceleration limitation is not adapted accordingly, the end-of-block position is
possibly reached later than specified in:
MD36040 $MA_STANDSTILL_DELAY_TIME
.
The machine data:
MD36042 $MA_FOC_STANDSTILL_DELAY_TIME
is introduced for this and monitored in this status.

Possible application link and container axes

All axes that can be traversed in a channel, i.e. also link axes and container axes, can be
traversed to fixed stop.
References:
/FB2/ Function Manual, Extension Functions; Several Control Panels on Multiple NCUs,
Distributed Systems (B3)
The status of the machine axis is kept in the case of a container switch, i.e. a clamped
machine axis remains at the stop.
If a modal torque limitation has been activated with FOCON, this is kept for the machine axis
even after a container switch.

2-22

Travel to fixed stop (F1)

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Detailed Description
2.2 Travel to fixed stop with analog drives

2.2

2.2.1

2.2

Travel to fixed stop with analog drives

SIMODRIVE 611 digital (VSA/HSA)

Selection
The NC recognizes the "Travel to fixed stop" function selection using command FXS[x]=1
and reports to the PLC using interface signal DB31, ... DBX62.4 ("Activate travel to fixed
stop") to indicate that the function has been selected.
If the machine data:
MD37050 FIXED_STOP_ACKN_MASK
is set accordingly, PLC acknowledgement using IS
DB31, ... DBX3.1 ("Enable travel to fixed stop") is waited for
and the function is then started.
This acknowledgment is not required by the NC for digital drives.
The axis now traverses to the target position at the programmed velocity. At the same time,
the clamping torque (specified via FXST[x]) is transferred to the drive via the digital
interface, and this limits its effective torque. In addition, the acceleration is reduced
accordingly in the NC automatically acc. to FXST[x]).

Fixed stop reached

As soon as the axis reaches the fixed stop, the axial contour deviation increases.
If the threshold entered in the machine data:
MD37030 FIXED_STOP_THRESHOLD
is exceeded or the NST signal DB31, ... DBX1.2 ("Sensor fixed stop"), is set, the control
recognizes that the fixed stop has been reached.
The NC will then delete the distance to go and will synchronize the position setpoint to the
current actual position value. The controller enabling command remains active.
The NC then outputs IS DB31, ... DBX62.5 ("Fixed stop reached") to the PLC.
If the machine data:
MD37060 FIXED_STOP_ACKN_MASK
is set accordingly, PLC acknowledgement via IS DB31, ... DBX1.1 ("Acknowledge fixed stop
reached") is waited for.
This acknowledgment is not required by the NC for digital drives.
A block change is executed. The clamping torque continues to be applied.

Travel to fixed stop (F1)

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2-23

Detailed Description
2.2 Travel to fixed stop with analog drives

Fixed stop is not reached

If the programmed end position is reached without the "Fixed stop reached" status being
recognized, then the torque limitation in the drive is canceled via the digital interface and IS
DB31, ... DBX62.4 ("Activate travel to fixed stop") reset.
Depending on machine data:
MD37060 FIXED_STOP_ACKN_MASK
, PLC acknowledgement is waited for by resetting the IS
DB31, ... DBX3.1 ("Enable travel to fixed stop")
and the block change is then carried out.

Deselection
The NC recognizes the function deselection via programming of the command FXS[x]=0.
Then an advance stop (STOPRE) is internally released, since it can't be forseen where the
axis will be after deselection.
The torque limitation and monitoring of the fixed stop monitoring window are canceled.
IS DB31, ... DBX62.4 ("Activate travel to fixed stop") and DB31, ... DBX62.5 ("Fixed stop
reached") are reset.
Depending on machine data:
MD37060 FIXED_STOP_ACKN_MASK
, PLC acknowledgement is waited for by resetting the IS
DB31, ... DBX3.1 ("Enable travel to fixed stop") and/or
DB31, ... DBX1.1 ("Acknowledge fixed stop reached").
The axis will then change to position control. The followup mode of the position setpoints is
ended and a synchronization to the new actual position is carried out.
A programmed traverse motion can then be executed. This motion must lead away from the
fixed stop or else the stop or even the machine may sustain damage.
A block change is executed after the target position has been reached.

Enabling the fixed stop alarms

The machine parameter:
MD37050 FIXED_STOP_ALARM_MASK
:can be used to set the enabling of the fixed stop alarms as follows:
MD 37050 = 0

Fixed stop not reached (suppress Alarm 20091)

MD 37050 = 2

Fixed stop not reached ( suppress alarm 20091) and fixed stop aborted
(suppress alarm 20094)

MD 37050 = 3

Fixed stop aborted (suppress alarm 20094)

All other permissible values of 7 or less do not suppress any alarms.

Using the parts program command NEWCONF a new setting can be activated.

2-24

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed Description
2.2 Travel to fixed stop with analog drives

Terminal 663 with MD37002 controllable

With the machine parameter:
MD37002 FIXED_STOP_CONTROL
the response to pulse blocking on the fixed stop is controllable.
Deleting the pulses by terminal 663 or the "Pulse enable" IS DBX31, ...DBX21.7 will not
abort the function. As a result, the drive will press against the fixed stop again without any
further operating action when the machine is restarted.
The rise time of the torque corresponds to the time needed by the current controller of the
drive to reach the limitation again.
If the pulses are deleted when a deselection is active (waiting for PLC acknowledgments),
the torque limit will be reduced to zero. If the pulses are reactivated during this phase, torque
is no longer built up. Once the deselection has been completed, you can continue traversing
as normally.

Diagram
The following diagram shows the progress of the motor current, the following error and IS
signals for DB31, ... DBX62.4 ("Activate travel to fixed stop") and DB31, ... DBX62.5 ("Fixed
stop reached") with digital drive (SIMODRIVE 611 digital).

Travel to fixed stop (F1)

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2-25

Detailed Description
2.2 Travel to fixed stop with analog drives

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2-26

> 10 ms with 611-A (VSA)

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Diagram for FXS with a digital drive (611 digital)

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed Description
2.3 Travel to fixed stop with analog drives

2.2.2

Travel to fixed stop with hydraulic drives SIMODRIVE 611 digital (HLA module)

Velocity/force control
If the function FXS (FXS[x]=1) is activated for the hydraulic module 611 digital (HLA
module), only a change from velocity control to force control takes place. Positioning from
the NC is no longer possible in this case.

NC
When traveling to fixed stop, the NC evaluates a torque/force limit acting in addition to the
limits set on the drive:
Current
Force/torque,
Power, pullout power
Setup mode

Note
For a description of velocity and force control and special information about the
adjustments on SIMODRIVE 611 digital or digital (HLA module), please refer to:
References:
/FBHLA/, Function Manual HLA Module; Drive Functions Firmware
/FB2/, Description of Functions Extension Functions; Compensation (K3); Section:
Electronic weight compensation

2.3

2.3.1

2.3

Travel to fixed stop with analog drives

SIMODRIVE 611 analog (FDD)

Current/torque control
With the 611 analog (FDD), the torque control and torque limitation
611 analog (VSA) has been realized as a current control/current limitation.

Fixed clamping torque

A fixed current limitation is preset in the drive actuator by means of a resistor circuit (or via
R12). This current limitation is activated by the control via a PLC output (which acts on
terminal 96 of the actuator), thus ensuring that a fixed clamping torque is available on the
axis. Setpoints can be injected via terminals 56/14 or 24/20.

Travel to fixed stop (F1)

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2-27

Detailed Description
2.3 Travel to fixed stop with analog drives

Programmable clamping torque

In this case, the PLC switches the drive actuator from speedcontrolled into currentcontrolled
operation as soon as the fixed stop is reached.
Activation of terminal 22 causes the voltage level applied to terminals 20/24 to take effect as
a current setpoint rather than a speed setpoint.
The NC is thus able to specify a variable clamping torque.
Setpoints must be injected via terminals 24/20.
References:
/IAA/ Installation and start-up guide SIMODRIVE 611 analog System

Selection
The NC detects that the function "travel to fixed stop" is selected via the command
FXS[x]=1 and signals the PLC via the IS "Activate travel to fixed stop" (DB31, ... DBX62.4)
that the function has been selected.
The PLC must then activate the current limitation on the actuator (terminal 96).
If the machine paramete:
MD37060 FIXED_STOP_ACKN_MASK
is set accordingly, then the IS waits for acknowledgment by the PLC in the form of IS
"Activate travel to fixed stop" (DB31, ... DBX3.1)
and then the function is started.

Note
(This acknowledgment should always be programmed for analog drives for safety reasons,
i.e. so that the motion is not started before the torque has been limited).

The NC then internally sets the torque limit to the value specified via the machine parameter:
MD37070 FIXED_STOP_ANA_TORQUE
(torque limit on fixed stop approach for analog drives)
.
This value must correspond to the torque limit value activated via terminal 96.
In addition, the acceleration is automatically reduced in the NC according to the value in the
machine parameter:
MD37070 FIXED_STOP_ANA_TORQUE
The axis now traverses to the target position at the programmed velocity.

2-28

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed Description
2.3 Travel to fixed stop with analog drives

Fixed stop reached

As soon as the axis reaches the fixed stop, the axial contour deviation increases.
If the recorded threshold in the machine parameter:
MD37030 FIXED_STOP_THRESHOLD
is exceeded or the IS signal
"Sensor fixed stop" (DB31, ... DBX1.2) is set,
the controller recognizes that the fixed stop has been reached.
The position controller then responds by outputting a speed setpoint corresponding to the
value set in the machine parameter:
MD37070 FIXED_STOP_ANA_TORQUE
.
The speed controller's output is limited by terminal 96, forcing the drive to the current limit by
means of this continuously applied setpoint.
The NC then deletes the remaining distancetogo and forces the position setpoint to follow.
The controller enabling command remains active.
The NC then outputs IS "Fixed stop reached" (DB31 , ... DBX62.5) to the PLC.
If a programmable clamping torque input (via FXST[x] or setting data), is required from the
NC, then the PLC must switch the drive over from speed controlled to current controlled
operation.
To do so, it activates terminal 22 and switches off the current limitation (terminal 96) after a
period of 10 ms.
As a result, the torque now takes effect on the drive from the machine parameter:
MD37070 FIXED_STOP_ANA_TORQUE
.
If the machine parameter:
MD37060 FIXED_STOP_ACKN_MASK
is set accordingly, then the IS waits for acknowledgment by the PLC in the form of IS
"Acknowledge fixed stop reached" (DB31, ... DBX1.1) and then suddenly transfers the
required clamping torque from the selection block to the drive.
A block change is executed. The clamping torque continues to be applied.

Fixed stop is not reached

If the programmed end position is reached without the "fixed stop reached" status being
recognized, then the internal torque limit in the machine parameter:
MD37070 FIXED_STOP_ANA_TORQUE
is cancelled and the IS signal "activate travel to fixed stop"
(DB31, ... DBX62.4).
The PLC must then deactivate the current limitation (terminal 96).
Depending on the machine parameter:
MD37060 FIXED_STOP_ACKN_MASK
the NC waits for the PLC to acknowledge by resetting IS
"Activate travel to fixed stop" (DB31, ... DBX3.1)
and then the block change is performed.

Travel to fixed stop (F1)

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2-29

Detailed Description
2.3 Travel to fixed stop with analog drives

Deselection
The NC detects that the function has been deselected on the basis of commandFXS[x]=0
and specifies a speed or current setpoint of "0," i.e. zero clamping torque.
The NC then resets IS "Activate travel to fixed stop" (DB31, ... DBX62.4) and "Fixed stop
reached" (DB31, ... DBX62.5).
If currentcontrolled operation is activated, the PLC must first switch on the current limitation
(terminal 96) and switch the drive over to speedcontrolled operation (terminal 22) (a speed
setpoint of "0" is applied by NC).
Then current limitation must then be deactivated (terminal 96).
Depending on the machine parameter:
MD37060 FIXED_STOP_ACKN_MASK
the NC waits for the PLC to acknowledge by resetting IS
"Activate travel to fixed stop" (DB31, ... DBX3.1) and/or
"Acknowledge fixed stop reached" (DB31, ... DBX1.1).
The axis then switches over to position control mode (followup mode is terminated) and
synchronization with the new actual position takes place.
The programmed travel motion is then executed.
A block change is executed after the target position has been reached.

2.3.2

SIMODRIVE 611 analog (FDD)

Fixed clamping torque

A fixed clamping torque is implemented by entering a fixed torque limitation in a free gear
stage in the drive actuator (setting parameter 039). When the "Travel to fixed stop function"
is selected, the PLC switches over to the unassigned gear stage of the drive actuator, thus
activating the torque limitation.
Setpoints must be injected via terminals 56/14.

Programmable clamping torque

In this case, the PLC switches the drive actuator from speedcontrolled into torquecontrolled
operation after the fixed stop is reached. The NC can therefore input a variable clamping
torque.
Setpoints must be injected via terminals 56/14.
References:
/IAA/ Installation and start-up guide SIMODRIVE 611 analog System

Caxis operation
The control system has to switch the spindle into C-axis mode before the "Travel to fixed
stop" function is selected. The PLC does this by activating one of the programmable
terminals E1-D9 (e.g. terminal E1) of the drive actuator.

2-30

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed Description
2.3 Travel to fixed stop with analog drives

Selection
The NC detects that the function "travel to fixed stop" is selected via the command
FXS[x]=1 and signals the PLC via the IS "Activate travel to fixed stop" (DB31, ... DBX62.4)
that the function has been selected.
As a result, the PLC activates the unassigned gear stage, in which the torque limitation is
effective, by means of programmable terminals E1 - E9 of the drive actuator. It then switches
the speed controller monitor off (one terminal (E1-E9) to deactivate error F11 of drive
actuator).
If the machine paramete:
MD37060 FIXED_STOP_ACKN_MASK
is set accordingly, then the IS waits for acknowledgment by the PLC in the form of IS
"Activate travel to fixed stop" (DB31, ... DBX3.1) and then the function is started.

Note
(This acknowledgment should always be programmed for analog drives for safety reasons,
i.e. so that the motion is not started before the torque has been limited).

The NC then internally sets the torque limit to the value specified via the machine parameter:
MD37070 FIXED_STOP_ANA_TORQUE
(torque limit on fixed stop approach for analog drives)
This value must correspond to the torque limit value set in the actuator.
In addition, the acceleration is automatically reduced in the NC according to the value in the
machine parameter:
MD37070 FIXED_STOP_ANA_TORQUE
The rotary axis now traverses to the target position at the programmed velocity.

Fixed stop reached

As soon as the Caxis reaches the fixed stop, the axial contour deviation increases.
If the recorded threshold in the machine parameter:
MD37030 FIXED_STOP_THRESHOLD
is exceeded or the IS signal
"Sensor fixed stop" (DB31, ... DBX1.2) is set,
the controller recognizes that the fixed stop has been reached.
The position controller then responds by outputting a speed setpoint corresponding to the
value set in the machine parameter:
MD37070 FIXED_STOP_ANA_TORQUE
.
The speed controller forces the drive to the torque limit by means of this continuously applied
setpoint.
The NC then deletes the remaining distancetogo and forces the position setpoint to follow.
The controller enabling command remains active.
The NC then outputs IS "Fixed stop reached" (DB31 , ... DBX62.5) to the PLC.

Travel to fixed stop (F1)

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2-31

Detailed Description
2.3 Travel to fixed stop with analog drives
If a programmable clamping torque input (via FXST[x] or setting parameter) is required
from the NC, then the PLC must switch the drive over from speed controlled to current
controlled operation. To do so, it activates one of the programmable terminals E1 - E9 (e.g.
terminal E5) and switches off the torque limitation after a period of 80 ms by selecting the
preceding gear stage.
As a result, the torque now takes effect on the drive from the machine parameter:
MD37070 FIXED_STOP_ANA_TORQUE
If the machine parameter:
MD37060 FIXED_STOP_ACKN_ASK
is set accordingly, then the IS waits for acknowledgment by the PLC in the form of IS
"Acknowledge fixed stop reached" (DB31, ... DBX1.1) and then suddenly transfers the
required clamping torque from the selection block to the drive.
A block change is executed. The clamping torque continues to be applied.

Fixed stop is not reached

If the programmed end position is reached,
without the "fixed stop reached" status being detected,
then the internal torque limit in the machine parameter:
MD37070 FIXED_STOP_ANA_TORQUE
is cancelled and the IS signal "activate travel to fixed stop"
(DB31, ... DBX62.4).
The PLC then activates the preceding gear stage, thus deactivating the torque limitation. It
also switches on the speed control monitoring function again.
Depending on the machine parameter:
MD37060 FIXED_STOP_ACKN_MASK
the NC waits for the PLC to acknowledge by resetting IS
"Activate travel to fixed stop" (DB31, ... DBX3.1)
and then the block change is performed.

Deselection
The NC detects that the function has been deselected on the basis of command FXS[x]=0
and specifies a speed or torque setpoint of "0," i.e. zero clamping torque.
The NC then resets IS "Activate travel to fixed stop"
(DB31, ... DBX62.4) and "Fixed stop reached" (DB31, ... DBX62.5).
If torquecontrolled operation is activated, the PLC must first select the unassigned gear
stage in which the torque limitation is effective and switch the drive over to speedcontrolled
operation (a speed setpoint of "0" is applied by NC). The PLC must also deactivate the
speed controller monitoring function.
The PLC then activates the preceding gear stage, thus deactivating the torque limitation. It
also switches on the speed control monitoring function again.

2-32

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed Description
2.3 Travel to fixed stop with analog drives

Depending on the machine parameter:

MD37060 FIXED_STOP_ACKN_MASK
the NC waits for the PLC to acknowledge by resetting IS
"Activate travel to fixed stop" (DB31, ... DBX3.1) and/or
"Acknowledge fixed stop reached" (DB31, ... DBX1.1).
The C-axis then switches over to position control mode (followup mode is terminated) and
synchronization with the new actual position takes place.
The programmed travel motion is then executed.
A block change is executed after the target position has been reached.

2.3.3

Diagrams for travel to fixed stop with analog drives

FXS selection (fixed stop is reached)

The following diagram shows the sequence of the following error and interface signals for
"FXS selection" (fixed stop is reached) on analog drives.

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Figure 2-4

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Diagram for FXS selection (fixed stop is reached) with analog drive

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-33

Detailed Description
2.3 Travel to fixed stop with analog drives

FXS selection (fixed stop is not reached)

The following diagram shows the sequence of the following error and interface signals for
"FXS selection" (fixed stop is not reached) on analog drives.

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Figure 2-5

2-34

Diagram for FXS selection (fixed stop is not reached) with analog drive

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed Description
2.3 Travel to fixed stop with analog drives

FXS deselection
The following diagram shows the sequence of the following error and interface signals for
"FXS Deselection" on analog drives.

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Figure 2-6

Diagram for FXS deselection with analog drive

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-35

Detailed Description
2.3 Travel to fixed stop with analog drives

2-36

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Supplementary conditions

There are no supplementary conditions to note.

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

3-1

Supplementary conditions

3-2

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Examples
Static synchronized actions
Travel to fixed stop (FXS), initiated by a synchronized action.
N10 IDS=1 WHENEVER

; Activate static synchronized action:

(($R1==1) AND

; By the setting of $R1=1

($AA_FXS[Y]==0)) DO

; for

$R1=0 FXS[Y]=1

; the axis Y FXS is activated

FXST[Y]=10

; the active torque is reduced to 10%

FA[Y]=200

; and a travel motion to

POS[Y]=150

; direction of the stop started

N11 IDS=2 WHENEVER

; once the stop has been recognized

($AA_FXS[Y]==4) DO

; ($AA_FXS[Y]==4), the torque is

FXST[Y]=30

; increased to 30%

N12 IDS=3 WHENEVER

; after reaching the stop

($AA_FXS[Y]==1) DO

; the torque becomes dependent

FXST[Y]=$R0

; on R0 controlled

N13 IDS=4 WHENEVER

; deselection in dependence

(($R3==1) AND

; on R3 and

($AA_FXS[Y]==1)) DO

; reverse

FXS[Y]=0
FA[Y]=1000 POS[Y]=0
N20 FXS[Y]= 0

; normal program run:

G0 G90 X0 Y0
N30 RELEASE(Y)

; axis Y for the movement to

; activate synchronized action

N40 G1 F1000 X100

; Movement of another axis

N50 ......
N60 GET(Y)

; Include axis Y again in the

; pathgroup

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

4-1

Examples

Multiple selection
A selection may only be carried out once. If the function is called once more due to faulty
programming (FXS[Axis]=1) the alarm 20092 "Travel to fixed stop still active" is initiated.
Programming code that scans $AA_FXS[] or a separate flag (here R1) in the condition will
ensure that the function is not activated more than once.

programming example (parts program fragment):

N10 R1=0
N20 IDS=1 WHENEVER ($R1 == 0 AND $AA_IW[AX3]>7) DO R1=1 FXS[AX1]=1
FXST[AX1] = 12

Blockrelated synchronized actions

By programming a blockrelated synchronized action, travel to fixed stop can be connected
during an approach motion.
Programming example:
N10 G0 G90 X0 Y0

4-2

N20 WHEN $AA_IW[X]>17 DO FXS[X]=1

; If X reaches a position greater

N30 G1 F200 X100 Y110

; 17mm FXS is activated

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Data lists
5.1

5.1.1

5.1

Machine data

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

36042

FOC_STANDSTILL_DELAY_TIME

Delay time 0 monitoring with FOC and FXS

37000

FIXED_STOP_MODE

Travel to fixed stop mode

37002

FIXED_STOP_CONTROL

Special function when traveling to fixed stop

37010

FIXED_STOP_TORQUE_DEF

Default setting for clamping torque

37012

FIXED_STOP_TORQUE_RAMP_TIME

Virtual time until reaching the new clamping torque

when traveling to fixed stop

37020

FIXED_STOP_WINDOW_DEF

Default for fixed stop monitoring window

37030

FIXED_STOP_THRESHOLD

Threshold for fixed stop detection

37040

FIXED_STOP_BY_SENSOR

Fixed stop detection via sensor

37050

FIXED_STOP_ALARM_MASK

Enabling the fixed stop alarms

37052

FIXED_STOP_ALARM_REACTION

Reaction to fixed stop alarms

37060

FIXED_STOP_ACKN_MASK

Monitoring of PLC acknowledgments for travel to fixed

stop

37070

FIXED_STOP_ANA_TORQUE

Torque limit on fixed stop approach for analog drives

37080

FOC_ACTIVATION_MODE.

Status of activation of the modal function FOC

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

5-1

Data lists
5.2 Setting data

5.2

5.2

5.2.1

Setting data

Axis/spindle-specific setting data

Number

Identifier: $SA_

Description

43500

FIXED_STOP_SWITCH

Selection of travel to fixed stop

43510

FIXED_STOP_WINDOW

Clamping torque when traveling to fixed stop

extended to a torque greater than 100%

43520

FIXED_STOP_TORQUE

Fixed stop monitoring window

5.3

5.3.1

5.3

Signals

Signals to axis/spindle

DB number

Byte.Bit

Description

31, ...

1.1

Acknowledge fixed stop reached

31, ...

1.2

Sensor for fixed stop

31, ...

1.3

Axis/spindle disable

31, ...

2.1

Controller enable

31, ...

3.1

Enable travel to fixed stop

5-2

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Data lists
5.3 Signals

5.3.2

Signals from axis/spindle

DB number

Byte.Bit

Description

31, ...

60.4

Referenced/synchronized 1

31, ...

60.5

Referenced/synchronized 2

31, ...

62.5

Fixed stop reached

31, ...

92.0

Setup mode active

31, ...

92.1

Rampup function generator quick stop

31, ...

92.2

Torque limit 2 active

31, ...

92.3

Speed setpoint smoothing active

31, ...

93.0 - 93.2

Active parameter set A, B, C

31, ...

93.3 - 93.4

Active motor A, B

31, ...

93.5

Drive Ready

31, ...

93.6

Speed controller integrator disabled

31, ...

93.7

Pulses enabled

31, ...

94.0

Motor temperature prewarning

31, ...

94.1

Heat-sink temperature prewarning

31, ...

94.2

Ramp-up function completed

31, ...

94.3

_'Md_'< Mdx

31, ...

94.4

_'nact_'< nmin

31, ...

94.5

_'nact_'< nx

31, ...

94.6

_'nact_'= nset

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

5-3

Data lists
5.3 Signals

5-4

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Index
B

Block-related limit (FOC), 2-20

SD43500, 2-14
SD43510, 2-14
SD43520, 2-14
SERUPRO, 2-9
SERUPRO ASUP, 2-12

C
Channel axis identifiers with FXS, 2-1

F
FXS REPOS, 2-13

M
MD1012, 2-17, 2-18
MD1103, 2-15
MD1104, 2-15
MD1105, 2-15
MD1118, 2-1
MD1130:, 2-1
MD1230/1231, 2-15
MD36040:, 2-21
MD36042, 2-21
MD37002, 2-7, 2-8, 2-17, 2-18, 2-24
MD37010, 2-3, 2-14, 2-20
MD37012, 2-8, 2-14, 2-19
MD37020, 2-4, 2-14
MD37030, 2-4, 2-22, 2-28, 2-30
MD37040, 2-4
MD37050, 2-5, 2-15, 2-22, 2-23
MD37052, 2-6, 2-16
MD37060, 2-3, 2-4, 2-6, 2-7, 2-18, 2-19, 2-23, 2-27,
2-28, 2-29, 2-30, 2-31
MD37070, 2-27, 2-28, 2-30, 2-31
MD37080, 2-19
Modal activation (FOCON/FOCOF), 2-19

T
Travel to fixed stop
Analog drives, 2-26
Analog drives, diagrams, 2-32
Analog drives, FXS deselection, 2-34
Analog drives, FXS selection, 2-32
analog drives, SIMODRIVE 611A (FDD), 2-26
analog drives, SIMODRIVE 611A (MSD), 2-29
Block search, 2-9
Contour monitoring, 2-16
Customer benefit, 1-1
Deselection, 2-6
Function abort, 2-8
Functional sequence, 2-3
Monitoring window, 2-4
Positioning axes, 2-16
Programming, 2-1
RESET, 2-8
Selection, 2-3
Setting data, 2-14, 2-23
Status query, 2-15
Travel to fixed stop (F1)
Interrupts, 2-6
Setting data, 2-5

V
Vertical axes, 2-16

R
REPOS Offset, 2-12

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Index-1

Index

Index-2

Travel to fixed stop (F1)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

SINUMERIK 840D sl/840Di sl/840D/840Di/810D Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)

1
Brief description
______________
2
Detailed description
______________

SINUMERIK
840D sl/840Di sl/840D/840Di/810D
Velocities, Setpoint/Actual-Value
Systems, Closed-Loop Control (G2)
Function Manual

Valid for

Control

SINUMERIK 840D sl/840DE sl

SINUMERIK 840Di sl/840DiE sl
SINUMERIK 840D powerline/840DE powerline
SINUMERIK 840Di powerline/840DiE powerline
SINUMERIK 810D powerline/810DE powerline

Software

NCU System Software for 840D sl/840DE sl

NCU system software for 840D sl/DiE sl
NCU system software for 840D/840DE
NCU system software for 840Di/840DiE
NCU system software for 810D/810DE

03/2006 Edition
6FC5397-0BP10-1BA0

Version
1.3
1.0
7.4
3.3
7.4

3
Supplementary conditions
______________
4
Examples
______________
5
Data lists
______________

Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
Danger
indicates that death or severe personal injury will result if proper precautions are not taken.
Warning
indicates that death or severe personal injury may result if proper precautions are not taken.
Caution
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
Notice
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.

Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage
Note the following:
Warning
This device may only be used for the applications described in the catalog or the technical description and only in
connection with devices or components from other manufacturers which have been approved or recommended by
Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly
as well as careful operation and maintenance.

Trademarks
All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.

Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG
Automation and Drives
Postfach 48 48
90437 NRNBERG
GERMANY

Order No.: 6FC5397-0BP10-1BA0

Edition 05/2006

Copyright Siemens AG 2006.

Technical data subject to change

Table of contents
1

Brief description ...................................................................................................................................... 1-1

Detailed description ................................................................................................................................ 2-1

2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6

Velocities, traversing ranges, accuracies .................................................................................. 2-1

Velocities.................................................................................................................................... 2-1
Traversing ranges ...................................................................................................................... 2-3
Positioning accuracy of the control system................................................................................ 2-4
Block diagram of resolutions and scaling values ....................................................................... 2-5
Input/display resolution, computational resolution ..................................................................... 2-6
Scaling of physical quantities of machine and setting data ....................................................... 2-7

2.2
2.2.1
2.2.2
2.2.3
2.2.4

Metric/inch measuring system ................................................................................................. 2-11

General .................................................................................................................................... 2-11
Conversion of basic system by parts program......................................................................... 2-12
Manual switchover of the basic system ................................................................................... 2-16
FGROUP and FGREF ............................................................................................................. 2-20

2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7

Setpoint/actual-value system ................................................................................................... 2-22

General .................................................................................................................................... 2-22
Speed setpoint and actual-value routing ................................................................................. 2-25
Configuration of drives ............................................................................................................. 2-31
Adapting the motor/load ratios ................................................................................................. 2-32
Speed setpoint output .............................................................................................................. 2-35
Actual-value processing........................................................................................................... 2-38
Adjustments to actual-value resolution .................................................................................... 2-41

2.4
2.4.1
2.4.2
2.4.3

Closed-loop control .................................................................................................................. 2-47

General .................................................................................................................................... 2-47
Parameter sets of the position controller ................................................................................. 2-52
Extending the parameter set.................................................................................................... 2-53

2.5
2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
2.5.6

Optimization of the control ....................................................................................................... 2-57

Position controller: injection of positional deviation ................................................................. 2-57
Position controller position setpoint filter: New balancing filter................................................ 2-58
Position controller position setpoint filter: new jerk filter .......................................................... 2-65
Position control with proportional-plus-integral-action controller ............................................. 2-67
System variable for status of pulse enable .............................................................................. 2-70
Expansions for "deceleration axes" ......................................................................................... 2-71

Supplementary conditions ...................................................................................................................... 3-1

Examples................................................................................................................................................ 4-1

Data lists................................................................................................................................................. 5-1

5.1
5.1.1
5.1.2
5.1.3
5.1.4

Machine data.............................................................................................................................. 5-1

Memory specific machine data .................................................................................................. 5-1
NC-specific machine data .......................................................................................................... 5-1
Channelspecific machine data ................................................................................................... 5-2
Axis/spindlespecific machine data ............................................................................................. 5-2

Index................................................................................................................................................ Index-1
Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)
Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

iii

Table of contents

iv

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Brief description

The description of functions explains how to parameterize a machine axis in relation to:
Actual-value/measuring systems
Setpoint system
Operating accuracy
Travel ranges
Axis velocities
Control parameters

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

1-1

Brief description

1-2

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1

2.1.1

2.1

Velocities, traversing ranges, accuracies

Velocities

Maximum path and axis velocities and spindle speed

The maximum path and axis velocities and spindle speed are influenced by the machine
design, the dynamic response of the drive and the limit frequency of the actual-value
acquisition (encoder limit frequency).
The maximum axis velocity is defined in machine data:
MD32000 $MA_MAX_AX_VELO (maximum axis velocity).
The maximum permissible spindle speed is defined via machine data:
MD35100 $MA_SPIND_VELO_LIMIT (maximum spindle speed).
For more information, see:
References:
/FB1/ Function Manual, Basic Functions; Spindles (S1)
As well as limiting using MD32000, the control limits the maximum path velocity in relation to
the situation and according to the following formula:

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Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0


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2-1

Detailed description
2.1 Velocities, traversing ranges, accuracies
For setting the interpolation cycle, see:
References:
/FB3/ Function Manual, Special Functions; Cycle Times (G3)
With a high feedrate (resulting from programmed feedrates and feedrate override), the
maximum path velocity is limited to Vmax.
This automatic feedrate limiting can lead to a drop in velocity over several blocks with
programs generated by CAD systems with extremely short blocks.

Example:
Interpolation cycle = 12 ms
N10 G0 X0 Y0; [mm]
N20 G0 X100 Y100; [mm]
Path length programmed in block = 141.42 mm
Vmax = (141.42 mm/12 ms) * 0.9 = 10606.6 mm/s = 636.39 m/min
The following restriction applies to the minimum path or axis velocity:

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The computational resolution is defined via machine data:

MD10200 $MN_INT_INCR_PER_MM (computational resolution for linear positions)
or
MD10210 $MN_INT_INCR_PER_DEG (computational resolution for angular positions):
If Vmin is not reached, no traversing is carried out.

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Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1 Velocities, traversing ranges, accuracies

Example:
MD10200 $MN_INT_INCR_PER_MM = 1000 [incr. /mm];
Interpolation cycle = 12 ms;
Vmin = 10 -3/(1000 incr/mm x 12 ms) = 0.005 mm/min;
The value range of the feed rates depends on the selected computational resolution
When the machine data:
MD10200 $MN_INT_INCR_PER_MM
(computational resolution for linear positions) (1000 incr./mm)
or
MD10210 $MN_INT_INCR_PER_DEG
(computational resolution for angular positions) (1000 incr./degree)
is assigned its default values, the following range of values can be programmed with the
specified resolution:
Range of values for path feedrate F and geometry axes:
Metric system:

Inch system:

0.001 F 999,999.999

0.001 F 399,999.999 [inch/min, inch/rev]

[mm/min, mm/rev, degrees/min, degrees/rev]

Range of values for feedrate for positioning axes:
Metric system:

Inch system:

0.001 FA 999,999.999

0.001 FA 399,999.999

[mm/min, mm/rev, degrees/min, degrees/rev]

[inch/min, inch/rev]

Range of values for spindle speed S:

0.001 S 999,999.999 [rpm]

If the computational resolution is increased/decreased by a factor of 10, the ranges of values

change accordingly.

2.1.2

Traversing ranges

Range of values of the traversing ranges

The range of values of the traversing range depends on the computational resolution
selected.
If machine data:
MD10200 $MN_INT_INCR_PER_MM
(computational resolution for linear positions) (1000 incr./mm)
or
MD10210 $MN_INT_INCR_PER_DEG
(computational resolution for angular positions) (1000 incr./degree)
are assigned their default values, the following range of values can be programmed with the
input resolution:

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-3

Detailed description
2.1 Velocities, traversing ranges, accuracies
Table 2-1

Traversing ranges of axes

G71 [mm, degrees]

G70 [inch, degrees]

Range

Range

Linear axes X, Y, Z, etc.

999.999,999

399.999,999

Rotary axes A, B, C, etc.

999.999,999

999.999,999

Interpolation parameters I, J, K

999.999,999

399.999,999

The unit of measurement of rotary axes is always degrees.

If the computational resolution is increased/decreased by a factor of 10, the ranges of values
change accordingly.
The traversing range can be limited by software limit switches and working areas.
References:
/FB1/Function Manual, Basic Functions; Axis Monitoring, Protection Zones (A3)
The traversing range for rotary axes can be limited via machine data.
References:
/FB2/Function Manual, Extended Functions; Rotary Axes (R2)
For special features of linear and rotary axes with a large traversing range, see:
References:
/FB1/ Function Manual, Basic Functions; Reference Point Approach (R1)

2.1.3

Positioning accuracy of the control system

Actual-value resolution and computational resolution

The positioning accuracy of the control depends on the actual-value resolution (=encoder
increments/(mm or degrees)) and the computational resolution (=internal increments/(mm or
degrees)).
The coarse resolution of these two values determines the positioning accuracy of the control.
The input resolution, interpolator and position-control cycle selections have no effect on this
accuracy.

2-4

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1 Velocities, traversing ranges, accuracies

2.1.4

Block diagram of resolutions and scaling values

Block diagram of units and resolutions

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Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-5

Detailed description
2.1 Velocities, traversing ranges, accuracies

This diagram shows how input values are converted into internal units.
It also shows the following conversion to internal increments/(mm or degrees), which can
cause loss of decimal places if the computational resolution was selected to be coarser than
the input resolution.
In addition, it provides an overview of the following topics:
Selection of measuring system (metric/inch)
Scaling of physical quantities of machine and setting data
Conversion of basic system
Setting of computational resolution
One example is the conversion of a physical quantity
(MD36110 $MA_POS_LIMIT_PLUS)
depending on the machine data parameterization
(MD10230 $MN_SCALING_FACTORS_USER_DEF,
MD10220 $MN_SCALING_USER_DEF_MASK).

2.1.5

Input/display resolution, computational resolution

Resolutions: Differences
Resolutions, e.g. resolutions of linear and angular positions, velocities, accelerations and
jerk, must be differentiated as follows:
Input resolution
Data is input via the control panel or parts programs.
Display resolution
Data is displayed via the control panel.
Computational resolution
Data input via the control panel or parts program is displayed internally.
The input and display resolution is defined via the control panel being used, whereby the
display resolution of position values can be changed with machine data:
MD9004 $MM_DISPLAY_RESOLUTION
.
Machine data:
MD9011 $MM_DISPLAY_RESOLUTION_INCH
can be used to configure the display resolution of position values using the inch system.
This allows you to display up to six decimal places with the inch setting.
For the programming of parts programs, the input resolutions listed in the Programming
Guide apply.
The desired computational resolution is defined via machine data:
MD10200 $MN_INT_INCR_PER_MM (computational resolution for linear positions)
or
MD10210 $MN_INT_INCR_PER_DEG (computational resolution for angular positions).

2-6

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

Detailed description
2.1 Velocities, traversing ranges, accuracies

It is independent of the input/display resolution but should have at least the same resolution.
The maximum number of places after the decimal point for position values, velocities, etc., in
the parts program and the number of places after the decimal point for tool offsets, zero
offsets, etc. (and therefore also for the maximum possible accuracy). is defined by the
computational resolution.
The accuracy of angle and linear positions is limited to the computational resolution by
rounding the product of the programmed value with the computational resolution to an
integer number.
To make the rounding clear, powers of 10 should be used for the computational resolution.

Example of rounding:
Computational resolution: 1000 increments/mm
Programmed path: 97.3786 mm
Effective value = 97.379 mm

Example of programming in the 1/10 m range:

All the linear axes of a machine are to be programmed and traversed within the range of
values 0.1 to 1000 m.
In order to position accurately to 0.1 m, the computational resolution must be set to 104
incr./mm.
MD10200 $MN_INT_INCR_PER_MM = 10000 [incr./mm]:
Example of related parts program:

2.1.6

N20 G0 X 1.0000 Y 1.0000

Traverse axes to position

X=1.0000 mm, Y=1.0000 mm

N25 G0 X 5.0002 Y 2.0003

Traverse axes to position

X=5.0002 mm, Y=2.0003 mm

Scaling of physical quantities of machine and setting data

Input/output units
Machine and setting data that possess a physical quantity are interpreted in the input/output
units below depending on whether the metric or inch system is selected:
Physical quantity:

Input/output units for standard basic system:

Metric

Inch

Linear position

1 mm

1 inch

Angular position

1 degree

1 degree

Linear velocity

1 mm/min

1 inch/min

Angular velocity

1 rpm

1 rpm

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)

Function Manual, 03/2006 Edition, 6FC5397-0BP10-1BA0

2-7

Detailed description
2.1 Velocities, traversing ranges, accuracies
Physical quantity:

Input/output units for standard basic system:

Metric

Inch

Linear acceleration

m/s2

1 inch/s2

Angular acceleration

1 rev./s2

1 rev./s2

Linear jerk

1 m/s3

1 inch/s3

rev./s3

Angular jerk

1 rev./s3

<