SINUMERIK 810D/840D powerline Turning with ShopTurn

SINUMERIK 810D/840D powerline Turning with ShopTurn
Preface
Introduction
1
SINUMERIK
System overview
2
810D/840D powerline
Turning with ShopTurn
Graphical program input
3
DIN/ISO programming
4
Setup functions
5
Tool management
6
Program management, user
memory
7
Simulation
8
Complete machining
9
In-process measuring
10
PC software
11
Automatic mode
12
Velocity control
13
Option list for the
SINUMERIK package
14
Summary of unique selling
points
15
Control system overview
for machine tools' sales people
05/2007
Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
WARNING
This device may only be used for the applications described in the catalog or the technical description and only
in connection with devices or components from other manufacturers which have been approved or
recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage,
positioning and assembly as well as careful operation and maintenance.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Automation and Drives
Postfach 48 48
90437 NÜRNBERG
GERMANY
Ⓟ 05/2007
Copyright © Siemens AG 2007.
Technical data subject to change
Preface
Scope of validity
This document provides you with an overview of the functional range of ShopTurn version
6.4, in use with the SINUMERIK 810D powerline or SINUMERIK 840D powerline.
The document is oriented towards vendors and dealers of machine tools.
Organization of information
● Of the varied functional possibilities of this SINUMERIK product, we only designate those
qualities which are of direct value to the machine's user.
● All functions contained in the machine's basic configuration will be identified as follows:
☑ Basic configuration
● All functions not contained in the machine's basic configuration will be identified as
follows:
☑ Option: ...
● A summary of the unique selling points of ShopTurn in comparison with competitors may
be found in chapter "Summary of unique selling points".
● For information on marketing options through the machine manufacturer, please see the
technical description of each machine.
Subject to change without prior notice
Contact person at machine manufacturer
Sales
Phone:
+49 xxx xxx
Fax:
+49 xxx xxx
E-mail:
xxx@maschinenhersteller.com
Web:
http://www.maschinenhersteller.com
Servicing
Phone:
+49 xxx xxx
Fax:
+49 xxx xxx
E-mail:
xxx@maschinenhersteller.com
Web:
http://www.maschinenhersteller.com
Homepage:
http://www.maschinenhersteller.com
Turning with ShopTurn
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3
Preface
Contact person at Siemens
Sales & Marketing / Specialist Support
Phone:
+49 xxx xxx
Fax:
+49 xxx xxx
Web:
http://www4.ad.siemens.de (worldwide)
Servicing
Phone:
+49 xxx xxx
Fax:
+49 xxx xxx
Web:
http://www4.ad.siemens.de (worldwide)
Homepage:
Visit the JobShop internet portal:
http://www.siemens.de/jobshop
4
Turning with ShopTurn
Control system overview for machine tools' sales people, 05/2007
Table of contents
Preface ...................................................................................................................................................... 3
1
2
3
4
Introduction................................................................................................................................................ 9
1.1
Application......................................................................................................................................9
1.2
Machine spectrum..........................................................................................................................9
System overview...................................................................................................................................... 11
2.1
SINUMERIK 810D powerline .......................................................................................................11
2.2
SINUMERIK 840D powerline .......................................................................................................12
2.3
Operator panel fronts ...................................................................................................................13
2.4
Operator panel equipment ...........................................................................................................17
2.5
Handwheel ...................................................................................................................................18
Graphical program input .......................................................................................................................... 19
3.1
Introduction ..................................................................................................................................19
3.2
Dynamic broken-line graphics......................................................................................................20
3.3
Online help ...................................................................................................................................21
3.4
Standard machining steps ...........................................................................................................22
3.5
Example Thread-cutting...............................................................................................................23
3.6
Example Repair thread ................................................................................................................23
3.7
Contour calculator (graphical programming) ...............................................................................24
3.8
Contour stock removal cycle........................................................................................................25
3.9
Residual material detection, segmental processing ....................................................................26
3.10
Contour slots, contour spigots .....................................................................................................27
3.11
Detection of residual material when milling .................................................................................27
3.12
Path Milling Cycle ........................................................................................................................28
DIN/ISO programming ............................................................................................................................. 29
4.1
DIN/ISO language........................................................................................................................29
4.2
DIN/ISO editor / G code editor .....................................................................................................30
4.3
Machining cycles..........................................................................................................................31
4.4
Contour calculator (DIN/ISO) .......................................................................................................32
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Table of contents
5
6
7
Setup functions ........................................................................................................................................ 33
5.1
Measure workpiece ..................................................................................................................... 33
5.2
Zero/work offset .......................................................................................................................... 34
5.3
Measure tool ............................................................................................................................... 34
5.4
TSM universal cycle .................................................................................................................... 35
5.5
Positioning cycle ......................................................................................................................... 35
5.6
Stock removal ............................................................................................................................. 36
Tool management.................................................................................................................................... 37
6.1
Tool table..................................................................................................................................... 37
6.2
Tool monitoring, sister tools ........................................................................................................ 38
Program management, user memory ...................................................................................................... 39
7.1
Program manager ....................................................................................................................... 39
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
User memory and data management ......................................................................................... 40
Buffered CNC work memory ....................................................................................................... 40
USB memory stick....................................................................................................................... 40
CompactFlash card ..................................................................................................................... 41
Ethernet networking .................................................................................................................... 41
Hard disk drive ............................................................................................................................ 42
Disk drive..................................................................................................................................... 42
8
Simulation................................................................................................................................................ 43
9
Complete machining ................................................................................................................................ 45
9.1
Counterspindle ............................................................................................................................ 45
9.2
Counterspindle machining........................................................................................................... 46
9.3
Additional components................................................................................................................ 47
9.4
Front surface machining.............................................................................................................. 48
9.5
Peripheral surface machining...................................................................................................... 49
10
In-process measuring .............................................................................................................................. 51
11
PC software ............................................................................................................................................. 53
12
6
11.1
CAD reader for PC ...................................................................................................................... 53
11.2
ShopTurn on PC, SinuTrain ........................................................................................................ 54
11.3
ShopTurn for self-learning........................................................................................................... 54
Automatic mode....................................................................................................................................... 55
12.1
Program control........................................................................................................................... 55
12.2
Simultaneous recording .............................................................................................................. 56
12.3
Block search................................................................................................................................ 57
12.4
Basic block display...................................................................................................................... 58
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Table of contents
13
Velocity control ........................................................................................................................................ 59
13.1
Jerk limitation ...............................................................................................................................59
13.2
Dynamic feedforward control .......................................................................................................60
14
Option list for the SINUMERIK package .................................................................................................. 61
15
Summary of unique selling points ............................................................................................................ 63
Index........................................................................................................................................................ 65
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1
Introduction
1.1
Application
ShopTurn is a customized technology package for all standard single-slide CNC turning
machines used worldwide.
ShopTurn enables the simple operation of machine tools, supporting all operator actions with
graphic help displays.
The functions in the manual mode enable a quick, practical machine set-up. More
specifically, this consists of calculating the workpiece position in the machine, as well as the
maintenance and measuring of the tools in use.
ShopTurn offers two options for programming:
The DIN/ISO editor is used to create DIN/ISO programs on the machine and correct
externally created DIN/ISO programs.
The work plan editor is used for graphic programming on the machine. Here are the typical
applications for finishing individual parts and small series. For example, DIN/ISO sections
may be flexibly inserted for complex part machining steps.
ShopTurn offers a uniform control configuration which covers all required areas of
application without additional start-up and training costs:
● Easy-to-use interface for all machine functions
● DIN/ISO programming on the machine or offline via CAD/CAM system
● Graphical programming
● Complete machining
● Measuring functions for workpieces and tools
1.2
Machine spectrum
ShopTurn is especially well-suited for the following types of machine:
1. Single-slide turning machines with X and Z axes
– Turning
– Centric drilling on the end face
2. Like 1.) with rotating tools (C axis mode)
– Any drilling or milling on the end face and outer surface
3. Like 1.) or 2.) with additional Y axis
– Any drilling or milling on the end face and outer surface
4. Like 1.) or 2.) or 3.) with additional counterspindle for front and rear machining
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2
System overview
2.1
SINUMERIK 810D powerline
The SINUMERIK 810D powerline is a fully digital CNC controller for standard machine tools
and handling tasks.
● Three integrated power modules (optionally expandable to 6 power modules)
● Digital drive control
● Up to 6 axes, including a maximum of 1 spindle and 1 auxiliary spindle
● Up to 2 machining channels
● NC interpreter for DIN and high-level language elements
● Intelligent control functions for complex machining tasks
You can find further information in catalog NC 60
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Highlights
● Cost-effective thanks to integrated power modules
● Very dynamic due to digital drive control
● Can be used for a wide variety of applications due to the use of a large number of CNC
functions
● Space-saving design for even the smallest control cabinets
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System overview
2.2 SINUMERIK 840D powerline
2.2
SINUMERIK 840D powerline
The SINUMERIK 840D powerline is a modular CNC for complex machine tools, mold
making, rotary indexing machines and transfer lines.
● Digital drive controller
● Modular design for drive controller and power unit
● Up to 31 axes/spindles in up to 10 processing channels
● NC interpreter for DIN and high-level language elements
● Intelligent control functions meeting the highest standards of machining technology
You can find further information in catalog NC 61
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Highlights
● Flexible application and guaranteed future through modular drive design and
comprehensive CNC functions
● Extremely high dynamics, precision and surface quality through use of
high performance processors
● High degree of expandability for complex production machines
12
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System overview
2.3 Operator panel fronts
2.3
Operator panel fronts
These operator panel fronts have an integrated CNC keyboard. We offer matched machine
control panels for the version with mechanical keys (protection class IP54) and the version
with membrane keys (protection class IP65). You have two choices:
OP 010C
Operator panel 483mm wide, 10.4" display, integrated CNC keyboard,
with frontal USB port for memory stick,
version with mechanical keys,
separate machine control panel
Highlights
● All relevant functions at a glance, thanks to horizontal and vertical softkeys
● Brilliant color display, balanced and high-quality design of operator components
● Simple data handling with easily accessible USB memory stick
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System overview
2.3 Operator panel fronts
OP 010
Operator panel 483mm wide, 10.4" display, integrated CNC keyboard,
with frontal USB port for memory stick,
version with membrane-type keys,
separate machine control panel
Highlights
● All relevant functions at a glance, thanks to horizontal and vertical softkeys
● Brilliant color display, balanced and high-quality design of operator components
● Simple data handling with easily accessible USB memory stick
14
Turning with ShopTurn
Control system overview for machine tools' sales people, 05/2007
System overview
2.3 Operator panel fronts
OP 010S
Operator panel 310mm wide, 10.4" display, mechanical keyboard,
with frontal USB port for memory stick,
separate CNC keyboard and machine control panel
Highlights
● Option of especially slim design
● All relevant functions at a glance, thanks to horizontal and vertical softkeys
● Brilliant color display, balanced and high-quality design of operator components
● Simple data handling with easily accessible USB memory stick
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System overview
2.3 Operator panel fronts
OP 015
Operator panel 483mm wide, 15" display, membrane keys,
with frontal USB port for memory stick,
separate CNC keyboard and machine control panel
Highlight
● Option of especially large display for better readability and graphic display for high-class
machines
● All relevant functions at a glance, thanks to horizontal and vertical softkeys
● Brilliant color display, balanced and high-quality design of operator components
● Simple data handling with easily accessible USB memory stick
16
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System overview
2.4 Operator panel equipment
2.4
Operator panel equipment
The ShopTurn user interface can be installed on either of the following PC modules
PCU20
● Fewer parts for specifically flat design
● Competitive purchase price and inexpensive replacement parts
● CNC memory expandable using Compact Flash cards
Highlights
● Rugged and cost-optimized solution, as there is no hard disk
PCU50
For customers who require a hard disk and a Windows operating system, we offer
the PCU 50.
● Windows XP operating system
● Additional CNC memory through hard disk
● Additional PCI slots on board
Highlights
● Flexible software expansion on Windows platform
● Flexible hardware expansion via PCI slots
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System overview
2.5 Handwheel
2.5
Handwheel
A handwheel can be connected for machine setup:
● magnetic latching for precise incremental movement
● Signals generated by the encoder correspond to rotation of the manually activated wheel
- the axis selected by the controller is paraxial positioned.
18
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Graphical program input
3.1
Introduction
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50 ☑ Option: Machining step programming
The graphical programming is done via a graphic, interactive work plan editor. Each program
line represents a machining step (ex.: Stock removal, groove, thread cutting) or geometric
data required for the machining steps (turning / milling contours or position patterns).
Machining steps belonging together are linked to each another. The interlinked machining
steps are performed consecutively at the appropriate contours or position patterns.
Graphical programming offers, in comparison to DIN/ISO programming, a compact and
easily comprehensible program overview.
Entering individual machining steps requires no knowledge of DIN/ISO. All required technical
and geometric parameters are entered in screen forms.
Simple and intuitive programming with machining steps can always be flexibly expanded via
entry of DIN/ISO blocks and control functions.
Highlights
● Intuitive program input, without knowledge of DIN/ISO or Operator Manual
● Thanks to the interlinking of maching steps, the position patterns and contours need only
be entered or changed once, offering benefits in time and security.
● Compact, clearly arranged machining programs
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Graphical program input
3.2 Dynamic broken-line graphics
3.2
Dynamic broken-line graphics
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50 ☑ Option: Machining step programming
While programming, the previously entered machining steps will be continuously displayed to
scale. A simulation is not required for this.
● Turning display
● End face and outer surface
Highlight
● More certainty during program input thanks to quick review of the resulting contour
20
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Control system overview for machine tools' sales people, 05/2007
Graphical program input
3.3 Online help
3.3
Online help
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50 ☑ Option: Machining step programming
All input parameters are clarified with dynamic help displays. In addition, explanatory cursor
text is displayed. This enables creation of programs on the machine without a programmer
handbook.
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Toggles between the work plan and programming graphics as well as between
the parameterization screen form with programming graphics and the
parameterization screen form with the help display.
Highlight
● Programming on the machine without a handbook
● Help key to toggle between help displays
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Graphical program input
3.4 Standard machining steps
3.4
Standard machining steps
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50 ☑ Option: Machining step programming
A number of different machining operations are available in the work plan editor:
• Turning operations
– Face turning
– Stock removal, groove, threading
– Undercut form E, F, thread undercuts
– Longitudinal / face / taper threads,
thread re-machining
– Plunge-turning
– Plunge-cutting
• Drilling and milling operations
– Centric drilling and threading
– Centering, drilling, boring, reaming,
deep-hole drilling
– Threading, thread milling
– Circular and rectangular slots /
spigots
– Longitudinal / circular groove
– Multiple edge
• Engraving cycle
– Any text with special characters
• Position pattern
– Position list
– Line / pitch circle / full circle / grid
• Basic elements
– Straight / circle / helix
• Miscellaneous
– Marks / repetitions
– Offset, rotation, scaling, mirroring
Drilling and milling operations may be linked any way with position patterns.
Highlights
● Time saving through program input completely by dialog; complete with tool, feedrate and
spindle speed or cutting rate
● Expanded selection of ready-made machining operations, including the innovative plunge
turning
22
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Control system overview for machine tools' sales people, 05/2007
Graphical program input
3.5 Example Thread-cutting
3.5
Example Thread-cutting
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50 ☑ Option: Machining step programming
A threading cycle is available in the work plan editor:
The following threads can be generated:
• Longitudinal thread
• Face thread
• Tapered thread
• Linked threads via DIN/ISO cycle
The following parameters can be specified:
• Outer / inner thread
• Roughing, finishing, roughing & finishing
• Linear / degressive infeed
• Thread pitch in mm/rev, inch/rev, gear/inch, module
• Variable pitch
• Infeed at one or changing edge
• Number of non-cuts
• Start angle offset
• Multiple threads (up to 6)
Highlight
● All popular thread forms possible
3.6
Example Repair thread
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50 ☑ Option: Machining step programming
By positioning the threading tool in the recutting thread, the synchronization point (starting
angle) of the thread can be determined.
Then the thread can be remachined following the thread-cutting cycle.
Highlight
● Support for thread repair as standard
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Graphical program input
3.7 Contour calculator (graphical programming)
3.7
Contour calculator (graphical programming)
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50 ☑ Option: Machining step programming
A contour calculator is available in the work plan editor.
The following contours may be generated with this geometry calculator:
● Blank and finished-part contours for turning
● Contours for milling on the end face and outer surface
The contour calculator provides the following possibilities:
● Up to 250 geometry elements programmable
● Automatic calculation of only partly defined elements
● Chamfer or radius programmable in contour transitions
● Chamfer or radius programmable as the contour start or end element
● Definition of undercuts (form E, F, thread undercut) directly in the contour
● Polar geometry for milling contours on the end face and outer surface
● Separate feedrate for individual contour elements; chamfer and radius programmable
● Separate grinding allowance for contour elements programmable
● Direct entry of fitting measurements (ex.: F60H7)
● Conversion of contours and position patterns in DXF format with CAD Reader for PC;
continued processing with the contour calculator in the control
Highlights
● Easy input of workpiece geometry: "Drawing dot to dot"
● Determination of contours with many unknown intermediate values is possible
● Speedy and certain from drawing to finished workpiece
24
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Graphical program input
3.8 Contour stock removal cycle
3.8
Contour stock removal cycle
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50 ☑ Option: Machining step programming
With the intelligent contour stock removal cycle, free contours can be processed in a variety
of ways:
● Processing any contour calculator geometry
● Cylindrical blank, freely-defined blank, blank as allowance of finished-part contour
● Longitudinal / face / contour-parallel roughing on outside and inside
● Processing sloping contours (relief cuts)
● Consideration of tool's setting and plate angle
● Grooving any contours on outside, inside or end face
● Plunge turn any contours on outside, inside or end face
● Finishing with negative allowances (for machining electrodes)
● Roughing with feed interruption to reduce flow chips
● Optional number of cutting passes with orientation to workpiece edges
● Finishing with alternating cutting depth for longer tool life
● Arbitrary limitation to the machining segment with automatic blank actualization
Highlights
● Effective processing through orientation to the actually existing material
● Lower risk of accident and better chip disposal through feed interruption
● Reduced machining time through selectable cut segmentation
● Save on tool costs through finishing with alternating cutting depth
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Graphical program input
3.9 Residual material detection, segmental processing
3.9
Residual material detection, segmental processing
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Option: Residual material
detection and machining
Identification of residual material
Contour regions which do not permit machining by tools with large plate angles are
automatically recognized in the stock removal cycle. The operator can rework these regions
using a suitable tool with a smaller plate angle.
Segmental processing
The contour stock removal cycle allows any segmentation of the desired machining region.
This enables individual segments to be processed with the technically suitable tools and
cutting values.
Application examples:
● Inside machining first with small tools, then with larger and more stable tools
● A degressive infeed avoids an overly high cutting pressure for small workpiece diameters
A variety of stock removal strategies may be used here, such as longitudinal turning, contour
grooving, plunge turning or any combination of these. The current machining procedure
automatically actualizes the blank contour for the following step, so that programming time is
kept to a minimum.
Highlights
● Detection of residual material: Time saving through avoiding idle cuts during residual
stock removal
● Segmentation: Limit the machining process to always apply the optimum tool and cutting
values
26
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Graphical program input
3.10 Contour slots, contour spigots
3.10
Contour slots, contour spigots
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50 ☑ Option: Machining step programming
ShopTurn offers stock removal for processing contour slots and spigots on the end face and
outer surface. Up to 12 islands can be considered for each slot. The slot and island contours
can be entered with the contour calculator directly into the control.
The following operations are available:
• Emptying, edge / base finishing
• Direct or helical plunging
• Manual or automatic allocation
of plunging point
• Optional predrilling at plunging point
Highlight
● Also program and machine complex contour slots within a short time
3.11
Detection of residual material when milling
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Option: Residual material
detection and machining
Contour regions which do not permit milling with large diameter tools are automatically
recognized in the contour slots cycle. The operator can rework these regions using a smaller
tool.
Highlight
● Shorter machining times through automatic detection of residual material
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Graphical program input
3.12 Path Milling Cycle
3.12
Path Milling Cycle
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50 ☑ Option: Machining step programming
A path milling cycle is available for path machining of milling contours:
• Milling with or without radius compensation
• Traversing in quarter circle, half circle or straight
• Grooving on parallel walls of the outer surface
Highlight
● Soft approach and retraction on any milling contour
28
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4
DIN/ISO programming
4.1
DIN/ISO language
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
The SINUMERIK controller's CNC interpreter can also process more complex CNC
commands, in addition to DIN 66025 standard commands. The commands are presented in
clearly readable form.
The following commands are available:
● G Functions
G0, G1, G2, G71, etc.
● Language commands (extended G functions)
CIP, DIAMON, SOFT, BRISK, FFWON, etc.
● Frame operations (programmable work offsets)
The workpiece coordinate system can be shifted, scaled, mirrored or rotated with the
commands TRANS, SCALE, MIRROR, ROT.
● Arithmetic operations
Arithmetic operations are available to combine the variables:
– Arithmetic operations + - * / sin cos exp etc.
– Logical operations == <> >= etc.
● User data
The user can define his/her own variables by name and type.
● R parameters (calculation parameters)
100 predefined R parameters are available as arithmetic parameters (floating comma
format).
● System variables
System variables can be read / written in all programs. They enable access to zero
offsets, tool offsets, axis positions, measurement values, control conditions etc.
● Program control structures
BASIC-style language commands are available for flexible programming of the user
cycles: IF-ELSE-ENDIF, FOR, CASE etc.
Highlights
● Unbeatable range of language commands for flexible and time-optimzed part programs
● Better program overview via user variables in plaintext format
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DIN/ISO programming
4.2 DIN/ISO editor / G code editor
4.2
DIN/ISO editor / G code editor
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
ShopTurn can accept direct input of DIN/ISO programs.
To this end, a line-oriented DIN/ISO editor is available.
The DIN/ISO editor enables one to directly enter or edit CNC language commands. Thereby,
the complete range of CNC functions are available for the most complex machining.
The following possibilities arise:
● Creation of DIN/ISO programs at the control
● Edit externally rendered DIN/ISO programs (ex.: CAD/CAM programs)
The following functions are included in the DIN/ISO editor:
● Contour calculator
● Tool selection directly from tool list
● Support screens for standard machining and measuring cycles
● "Copy", "Insert" and "Cut" key group
● "Find", "Replace" and "Replace All" character string
● Renumber program
● Direct execution from any NC program block (block search)
● Jump to program start and program end
Highlight
● Save time by programming with efficient DIN/ISO editor
30
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Control system overview for machine tools' sales people, 05/2007
DIN/ISO programming
4.3 Machining cycles
4.3
Machining cycles
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
Machining cycles for standard machining, turning, milling and drilling may be started from the
DIN/ISO editor. Input screens with dynamic help displays are available for the convenient
input of machining parameters.
The following machining cycles are available:
● Turning
Face turning, stock removal, groove, undercut (form A, B, C, D, E, F), thread cutting,
thread chaining
● Drilling
Centering, drilling, boring, reaming, deep-hole drilling, threading
● Position pattern
Line, circle, grid
● Milling
Face milling, elongated holes, circumferential slot, slot milling, path milling, engraving,
circular pockets and spigots, rectangular pockets and spigots, contour slot
Highlight
● Graphical support of cycles as an expansion of the highly flexible DIN/ISO programing
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DIN/ISO programming
4.4 Contour calculator (DIN/ISO)
4.4
Contour calculator (DIN/ISO)
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
A contour calculator is available in the DIN/ISO editor.
The following contours may be generated with this geometry calculator:
● Contours for turning
● Contours for milling on the end face and outer surface
The contour calculator provides the following possibilities:
● Up to 250 geometry elements programmable
● Automatic calculation of unknown elements ("drawing dot to dot")
● Chamfer or radius programmable in contour transitions
● Open DIN/ISO input field (e.g. for element-based feedrates)
● Conversion of contours and position patterns in DXF format with CAD Reader for PC;
continued processing with the contour calculator in the control
Highlights
● Easy input of workpiece geometry: Drawing dot to dot
● Determination of contours with many unknown intermediate values is possible
● Speedy and certain from drawing to finished workpiece
32
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5
Setup functions
5.1
Measure workpiece
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
The workpiece can be measured as follows:
• Reference tool
Highlight
● Fast zero point definition by dialog
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Setup functions
5.2 Zero/work offset
5.2
Zero/work offset
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
The following settable work offsets are available in ShopTurn:
• A basic offset
• Maximum of 99 work offsets
(G54, G55 ...)
• Each work offset with its own
fine offset
Highlight
● Flexible machining due to great number of settable work offsets
5.3
Measure tool
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
The tool compensation value can be directly determined
in the machine set-up.
The following variants are available:
• Determine lengths via reference diameter
• Tool measuring probe (tooleye) or magnifier
Highlight
● Save time by determining the tool measurements directly in the machine
34
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Setup functions
5.4 TSM universal cycle
5.4
TSM universal cycle
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
A universal cycle is available in the setup for the most commonly used machine functions:
● Tool change with direct access via the tool table (T)
● Spindle speed and direction (S)
● M functions (M)
● Activation of work offsets
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Highlight
● Take-over and change-in tools directly from the tool table
5.5
Positioning cycle
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
The machine axes can be positioned directly
via input screens in the setup:
• Linear axes / spindles
• Feedrate / rapid traverse
Highlight
● Simple axis positioning without manual input, directly over the dialog screen
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35
Setup functions
5.6 Stock removal
5.6
Stock removal
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
Stock removal is conveniently available in
the set-up. Soft collet chucks can, for
example, be turned with this cycle.
The following parameters can be specified:
• Roughing or finishing
• Undercut for soft collet chucks
Highlight
● Preparation of workpiece or collet chuck without having to create a part program
36
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6
Tool management
6.1
Tool table
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
Tools with their complete information may be managed in the tool list. The cutting plate
geometry is displayed to scale.
(The maximum number of tools is defined by the machine manufacturer.)
Tools are assigned to the desired turret positions with the load function. With the unload
function, you may remove tools from the turret but retain the tool data.
The following data can be stored for each tool:
● Tool type (rougher, finisher, engraver, drilling and milling tools ....)
● Tool name in plaintext (ex.: "ROUGHING_80")
● Max. of 9 cutting edges per tool
● Tool length and cutting plate geometry
● Nose angle for drills or number of teeth for milling tools
● Direction of spindle rotation and coolant (level 1 and 2)
Highlights
● All tool data at a glance
● Simple and secure handling via unmistakable tool names
● Take over tools directly from the list to the program
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Tool management
6.2 Tool monitoring, sister tools
6.2
Tool monitoring, sister tools
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
ShopTurn offers efficient tool management for the activation of replacement tools.
● Monitor cutting time (T) or number of exchanges (C)
● Prewarning limit for timely preparation of new tools
● Automatic exchange of sister tools for automatic operation possible (duplo number DP)
Highlights
● Reduction of machine standstill times via tool monitoring
● Support of tool life monitoring or job time monitoring as standard
38
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7
Program management, user memory
7.1
Program manager
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
The program manager supports plaintext file names up to 24 characters.
Part programs can be saved complete with set-up data like tool data and zero points.
Highlights
● Part programs can be created, retrieved and saved within a very short time
● User-friendly data handling in typical PC style with copying, pasting, renaming, etc.
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Program management, user memory
7.2 User memory and data management
7.2
User memory and data management
7.2.1
Buffered CNC work memory
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
SINUMERIK 810D powerline
Basic configuration: 0.5 MB, expandable to 2.5 MB
SINUMERIK 840D powerline
NCU 571.5, NCU572.5, NCU 573.5
Basic configuration: 3 MB, expandable to 6 MB
Highlight
● Exceptionally large storage space in basic configuration already
7.2.2
USB memory stick
☑ 810D
☑ 840D
☐ PCU 20 ☑ PCU 50
☑ Basic configuration
(USB memory stick required)
A USB memory stick can be used on the front side of the operator panel.
User data stored on the PC can be quickly transferred to the
internal CNC memory. For security reasons executing from the
USB memory stick is not possible. In this regard use the possibility
of execution from the hard disk.
Highlights
● User-friendly solution, as memory slot is located at front
● Extremely cost-efficient, as no software option required
40
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Control system overview for machine tools' sales people, 05/2007
Program management, user memory
7.2 User memory and data management
7.2.3
CompactFlash card
☑ 810D
☑ 840D
☑ PCU 20 ☐ PCU 50
☑ Option: Management of network
and disk drives
A CompactFlash card can be used to expand the CNC memory of the PCU20.
The amount of additional memory capacity depends on the CompactFlash Card used
(maximum 1 GB).
The CompactFlash Card is not included in the PCU20 scope of delivery!
Highlight
● All of the relevant user data is available immediately
7.2.4
Ethernet networking
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Option: Management of network
and disk drive
The PCU20 and PCU50 come ready for Ethernet (RJ45
connection). The data transfer rate is 10 / 100 Mbit/s.
Access to the network drive is available directly from the
ShopTurn program manager. No additional software is
required on the server.
Highlight
● Easy and economical connection via Ethernet (TCP/IP) to Windows PCs or Unix
workstations
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Program management, user memory
7.2 User memory and data management
7.2.5
Hard disk drive
☑ 810D
☑ 840D
☐ PCU 20 ☑ PCU 50
☑ Basic configuration
A hard disk with 12GB of user memory is available on the PCU 50 for expansion of the CNC
memory.
Highlights
● Hard disk can still be used as a data carrier
7.2.6
Disk drive
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Option: Management of network
and disk drive
PCU 20 and PCU 50 are prepared for
connection to a USB disk drive as standard.
Access to the disk drive is available directly
from the ShopTurn program manager.
The disk drive is not supplied with the
product.
Highlight
● Diskette can still be used as a data carrier
42
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8
Simulation
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
The simulation integrated in ShopTurn offers an optimal process reliability. This is
guaranteed as it is calculating with exactly the same tool geometry as for the actual
machining process.
The simulation can be controlled by start, stop and reset softkeys. For critical machining, the
simulation can be operated in single block mode. The current data for axis position,
machining block, tool and feedrate will be displayed.
The ShopTurn simulation allows the display of the following programs:
● DIN/ISO program, also with machining cycles
● Sequence program, counterspindle machining also included
The following displays are possible:
● 3-window view in the standard, with PCU 50 small volume model directly with in the 3window view
● Single block operation and start / stop possible at any time
● Simulation velocity adjustable with the feedrate override of the machine control panel
● The required machining time is automatically calculated and displayed in the simulation
☑ Option: 3D simulation of the finished part
● 3D volume model of the finished part with section planes and detailed view
3-window view
volume model
Highlight
● Simulation as real assistance for programming and offer calculation
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9
Complete machining
9.1
Counterspindle
☐ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Option: Synchronous spindle
☑ Option: Travel to fixed stop
The SINUMERIK 840D powerline enables the use of a fully-fledged counterspindle. The
main spindle and counterspindle can be operated under conditions of angular synchronism.
DIN/ISO programming
The commands for spindle synchronization and the axis movements for workpiece transfer
can be programmed as DIN/ISO language commands.
Machining step programming
A counterspindle cycle is conveniently available for spindle synchronization and axis
movements for workpiece transfer.
Highlights
● Simple and secure programming of all counterspindle functions
● High quality of workpieces by workpiece transfer in synchronous spindle mode
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45
Complete machining
9.2 Counterspindle machining
9.2
Counterspindle machining
☐ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50 ☑ Option: Machining step programming
A control cycle for counterspindle machining is available in the work plan editor with the
following functions.
• Gripping
Gripping the workpiece with
counterspindle in synchronous mode
• Pulling
Pulling long workpieces with the
counterspindle
• Rear side
Machining the rear side of the workpiece
in the counterspindle.
The programming is the same as with
machining the main spindle. The Z axis
value is mirrored.
• Front
Switchover from counterspindle
machining to main spindle machining for
bar stock
• Complete
Gripping, pulling, threading and
counterspindle machining with bar stock
All main spindle machining steps are supported by the counterspindle.
Highlights
● Easy programming of complete machining process by dialog
● Security while programming the counterspindle machining via familiar cycle support; Z
axis value is mirrored
46
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Complete machining
9.3 Additional components
9.3
Additional components
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
Control cycles and input screens for the DIN/ISO and machining step programming are
available for the following additional components: bar loaders, parts grippers and tailstocks.
The control cycles and input screens must be adjusted by the machine manufacturer to the
machine's actual conditions.
Highlight
● Simple programming of additional components
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47
Complete machining
9.4 Front surface machining
9.4
Front surface machining
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Option: TRANSMIT and
peripheral surface transformation
Drilling and milling can be performed on the front surface of workpieces in the main and
counterspindle with ShopTurn.
The part program is easily created in a right-angle coordinate system with the front surface
transformation TRANSMIT (C axis mode) .
The path movements are conducted with the
linear axes X / Z and the rotary axis C.
Machine without Y axis
• Machining with TRANSMIT
Machine with Y axis
• Machining with Y axis
• Machining with TRANSMIT
Highlights
● Full functional range for drilling and milling on the front surface
● Reduction of set-up times by complete machining on one machine
48
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Complete machining
9.5 Peripheral surface machining
9.5
Peripheral surface machining
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Option: TRANSMIT and
peripheral surface transformation
Drilling and milling can be performed on the outer surface of workpieces in the main and
counterspindle with ShopTurn and the outer surface transformation TRACYL.
Machine without Y axis
• Any drill holes on the outer surface
• Any milling without slot wall offset on the
outer surface
Machine with Y axis
• Any drill holes on the outer surface
• Any milling without slot wall offset on the
outer surface
• Any milling with slot wall offset on the
outer surface
• Grooving on parallel walls of the outer
surface with milling radius correction
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Highlights
● Full functional range for drilling and milling on the outer surface
● Reduction of set-up times by complete machining on one machine
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49
10
In-process measuring
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Option: Measuring cycles
Measuring cycles are available in the DIN/ISO editor for measuring tasks in automatic mode.
Input screens with dynamic help displays are used for convenient entry of the measuring
parameters.
The following measuring variants are available:
● Calibrate workpiece and tool measuring inputs
● Tool measurement with tool measuring input
● Single-point workpiece measurement with reversal
● Two-point workpiece measurement
The following measuring tasks can be made:
● Automatic value correction for tool geometry or work offset
● Display measurement results
● Log measurement results
Highlights
● Reliable quality of the manufactured parts by automatic measurement in the machine
● Easy adjustment via input displays with graphic support
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11
PC software
11.1
CAD reader for PC
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Option: CAD reader for PC
Contours and position patterns can be converted on the PC from DXF files into a format
understandable to the control with the software package "CAD Reader for PC". The contours
can be reworked in the contour calculator on the controller.
Highlight
● Time saving with conversion of contours and position patterns from DXF files
● Work preparation and training at the PC without occupying the machine
● Further editing at the controller using the contour calculator possible at any time
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PC software
11.2 ShopTurn on PC, SinuTrain
11.2
ShopTurn on PC, SinuTrain
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Option: SinuTrain ShopTurn
Controller-identical PC system for work
preparation and CNC training
• Full functional range of ShopTurn
• Networking of several student and trainer
units possible
Highlight
● PC software for training and work preparation without occupying the machine
11.3
ShopTurn for self-learning
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Option: ShopTurn for
self-learning
Multimedia introduction to turning technology with ShopTurn.
● Programming exercises with directed examples
Highlight
● Graphically supported instruction software for beginners
54
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12
Automatic mode
12.1
Program control
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
Single block
Single block mode can be activated for startup of the program. For this purpose a program
stop occurs after each traversing block.
Work plan programs offer the alternative of halting processing after each plane infeed.
Program test
Programs can be checked before processing in a program test mode. The program is
executed to completion with stationary axes.
Program editing
In machine status STOP, the program can be edited directly at the location of the fault, e.g.
erroneous DIN/ISO blocks or falsely parameterized machining steps. After editing of the
program, the machining process can be directly continued (a block search is carried out for
machining step programs).
Repositioning to the contour
In machine status STOP, the machining axes can be moved to and away from the workpiece
surface during machining using the handwheel or the direction keys.
Highlights
● Secure startup of new part programs
● Continue machining quickly after interruptions
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55
Automatic mode
12.2 Simultaneous recording
12.2
Simultaneous recording
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Option: Simultaneous recording
(simulation of current machining)
The tool paths can be simultaneously
recorded on the control screen while
machining.
• Workpiece graphics and views
correspond to the graphic simulation
• Color-coordinated differentiation of rapid
traverse and feedrate
Highlights
● Machining can also be monitored in a complex machine room
56
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Automatic mode
12.3 Block search
12.3
Block search
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
A block search may be performed in machine condition RESET, e.g. after a program
interruption or to search for a resume point. The program data will be readied so as all
relevant parameters (tool, zero offsets, M functions, etc.) are available upon continuation of
the program.
The following search variants are available:
● To the interruption point
● To any CNC block in a DIN/ISO program
● To any subroutine levels in DIN/ISO programs
● To any sequence in work plan programs
● To any position in the position patterns for the work plan programming
Highlights
● Time-saving and secure re-start at any program point, as no editing of the part program is
required
● Highlight: Direct continuation from an individual position of a position pattern during work
plan programming is possible, providing huge savings in time
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Automatic mode
12.4 Basic block display
12.4
Basic block display
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
The individual traversing blocks are displayed as DIN/ISO commands during execution of
machining steps or machining cycles.
The basic block display guarantees an especially high process security while running-in
programs in single block mode.
Highlights
● Optimal control of the program execution, as well in complex sequences or machining
cycles, especially in single block mode
58
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13
Velocity control
13.1
Jerk limitation
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
The control calculates a steady acceleration profile instead of jumps in acceleration. This
enables jerk-free velocity characteristics for the involved path axes. The jerk limitation can
also be directly activated in the part program with the »SOFT« NC language command.
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Highlights
● Longer machine lifespan through protection of the mechanical components
● Higher path accuracy through softer acceleration
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59
Velocity control
13.2 Dynamic feedforward control
13.2
Dynamic feedforward control
☑ 810D
☑ 840D
☑ PCU 20 ☑ PCU 50
☑ Basic configuration
Inaccuracies in the resulting workpiece contour due to following errors can practically be
eliminated using dynamic feedforward control FFWON. The result is excellent machining
precision even at high tool path feedrates. This is clarified with a circularity test on the
machine.
Example:
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FRQWRXU
$FWXDOJHQHUDWHG
FRQWRXU
3URJUDPPHGFRQWRXU
3URJUDPPHGFRQWRXU
Highlight
● Higher path accuracy through compensation of contouring errors
60
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14
Option list for the SINUMERIK package
The basic options and their Siemens order numbers are listed in the following:
ShopTurn additional functions
Machining step programming
6FC5463-0GA21-0AA0
Residual material detection and machining
6FC5463-0GA10-0AA0
3D simulation of the finished part (volume model)
6FC5463-0GA11-0AA0
Simultaneous recording (real-time simulation of current
machining)
6FC5463-0GA12-0AA0
Memory expansion and networking
CNC user memory in NCU expanded by 2 MB each 1)
6FC5251-0AD02-0AA0
Network drive management via Ethernet
6FC5463-0FA03-0AA0
Hard disk PCU50 instead of PCU20
1)
1), 2)
Disk drive 1), 2)
CNC additional functions
TRANSMIT and peripheral surface transformation when using
driven tools 1)
6FC5251-0AB01-0AA0
Travel to fixed stop and synchronous spindle when using counterspindle 1), 2)
Turning, drilling and milling measuring cycles for workpiece
and tool measurement 1)
6FC5250-0BX00-0AB0
PC software
SinuTrain ShopTurn, without CAD Reader
(CD-ROM)
6FC5463-0GA50-0AG0
SinuTrain ShopTurn, with CAD Reader
(CD-ROM)
6FC5463-0GA51-0AG0
CAD reader for PC (CD-ROM)
6FC5260-0AY00-0AG0
ShopTurn for self-learning (CD-ROM)
6FC5095-0AB00-0BG0
1) Notice: Commissioning expense required.
2) Please discuss with machine manufacturer.
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61
Summary of unique selling points
15
The control and drive package which Siemens offers in the SINUMERIK 810 powerline /
SINUMERIK 840D powerline and ShopTurn has the following prominent characteristics.
Especially in comparison to European control providers:
● Increased productivity
– Blank contours with path optimization avoid idle cuts and reduce the machining time
for pre-formed parts, e.g. castings.
– Stock removal with orientation to workpiece edges instead of a uniform number of
cutting passes avoids an unfavorable minimum infeed and thereby raises the quality of
the workpiece.
● Better result for workpieces
– Programmable jerk limiting and velocity feedforward control provide for a better
workpiece surface in conjunction with extremely dynamic drives.
– Reliable parts quality through in-process measuring with automatic correction of the
tool data or work offsets
● More flexibility with DIN/ISO programming
– Unbeatable command range with G codes, variables and HLL elements
And in further comparison to Asian control providers:
● User-friendlier interface
– Plaintext descriptions for part programs and tools offer greater transparency.
– Take-over or change-in tools directly from the tool list to the program.
– Machining step programming complete with specifications for the tool, feedrate and
spindle speed or cutting rate; no entries required in DIN/ISO
● Greater guarantee for the future via intelligent control functions
– Residual material detection and engraving cycle save time for programming and
machining.
– Chaining of machining steps avoids multiple entry of contours/pattern positions.
● PC software enabling the machine more time available for production
– Conversion of contours and position patterns in DXF format with CAD Reader for PC;
continued processing with the contour calculator in the control
– Controller-identical PC software SinuTrain for training and work preparation
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63
Index
A
E
Additional components, 47
Application, 9
Application Memory, 40
Arithmetic operations, 29
Arithmetic parameters, 29
Engraving cycle, 22
Ethernet, 41
B
Bar loader, 47
Basic block display, 58
Blank actualization, 26
Block search, 57
Broken-line graphics, 20
C
CAD Reader, 53
CNC memory, 40
CompactFlash Card, 41
Contour calculator (DIN/ISO), 32
Contour calculator (graphical programming), 24
Contour slots, 27
Contour spigots, 27
Contour stock removal cycle, 25
Contour-grooving, 25
Control structures, 29
Counterspindle machining, 46
D
Detection of residual material when milling, 27
DIN/ISO editor, 30
DIN/ISO language, 29
DIN/ISO programming, 29, 30
disk drive, 42
Disk drive, 42
DXF converter, 53
DXF import, 24
F
Feed interruption, 25
Feedforward control, 60
Flashcard, 41
Floppy disk drive, 42
FRAMES, 29
Front surface machining, 48
G
G code editor, 30
G Functions, 29
Graphical programming, 19
H
Handwheel, 18
Hard disk, 42
M
Machine spectrum, 9
Machining Cycles, 31
Machining steps, 19
Measure tool, 34
Measure workpiece, 33
Measuring cycles, 51
N
Networking, 41
O
Operator panel equipment, 17
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65
Index
Operator panel fronts, 13
Operator Panels, 13
Option list, 61
P
Parts gripper, 47
Path milling cycle, 28
PC software, 53
PCU 20, 17
PCU 50, 17
Peripheral surface machining, 49
Plunge-turning, 25
Positioning cycle, 35
Program control, 55
Program editing, 55
Program manager, 39
Program test, 55
Programmable work offsets, 29
R
Repair thread, 23
Replacement tools, 38
Repositioning to the contour, 55
Residual material detection turning, 26
SINUMERIK 840D powerline, 12
SinuTrain, 54
Standard cycles, 31
Standard machining steps, 22
Stock removal, 36
System variables, 29
T
Tailstock, 47
TCP/IP, 41
Thread-cutting, 23
Tool life monitoring, 38
Tool management, 37
TRACYL, 49
Training CD, 54
TRANSMIT, 48
TSM universal cycle, 35
U
Unique selling points, 63
User data, 29
V
Velocity control, 59
S
Segmental processing, 26
ShopTurn on PC, 54
Simultaneous recording, 56
Single block, 55
SINUMERIK 810D powerline, 11
66
W
Work offsets, 34
Turning with ShopTurn
Control system overview for machine tools' sales people, 05/2007
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