Académique Documents
Professionnel Documents
Culture Documents
June 2016
Uniformly digital
2
Contents
The iTNC 530...
The iTNC 530 is versatile. It adapts The iTNC 530 is flexible. Do you prefer to graphic aids including practice-oriented
optimally to the needs of your company work at the machine or at a programming fixed cycles. For simple worksuch as
regardless of whether you are station? Both are simple with the iTNC 530 face millingyou need not write a
manufacturing single parts or batches, as youll be impressed by their workshop- program, since it is easy to operate the
simple or complex parts, whether your oriented programmability just as by their machine manually with the iTNC 530.
shop works on call or is centrally external program creation: The iTNC 530 can be programmed
organized. You can program your own conventional remotely just as wellfor example on a
milling, drilling, and boring operations at CAM system or at a HEIDENHAIN
the machine in dialog with the control. programming station. Its Ethernet interface
The iTNC 530 gives you optimal support guarantees very short transfer times, even
with smarT.NC or Klartextthe of long programs.
conversational guidance from
HEIDENHAINas well as with numerous
Universal milling machine High speed milling Five-axis machining with swivel head
Shop-floor programming in HEIDENHAIN Fast block processing and rotary table
conversational format or with smarT.NC Short control-loop cycle time Offline programming away from the
Upwardly compatible programs Motion control with smoothed jerk machine: the iTNC 530 automatically
Fast presetting with HEIDENHAIN 3-D High spindle speed takes the machine geometry into
touch probe Fast data transfer account
Electronic handwheel Tilting the working plane
Cylinder surface machining
Tool Center Point Management (TCPM)
3-D tool compensation
Fast, accurate contour execution through
short block processing times
4
The iTNC 530 is universal. Its broad and
complex range of applications proves it.
Whether on simple 3-axis universal milling
machines in tool and mold making, or on
machining centers in interlinked
productionin either case, the iTNC 530 is
the right control. And it offers the
applicable features both necessary and
helpful.
For 5-axis machining on very large Boring mill Machining centers and automated
machines Cycles for drilling, boring and spindle machining
Inspecting and optimizing machine alignment Tool management
accuracy with KinematicsOpt Drilling oblique holes Pallet management
Global program settings for Control of quills (parallel axes) Tool-oriented machining
superimposition of various functions Controlled presetting
Procedure with handwheel Datum management
superimposition in the virtual tool axis Automatic workpiece measurement with
HEIDENHAIN 3-D touch probes
Automatic tool measurement and
breakage inspection
Connection with host computer
5
Well designed and user friendly
The iTNC 530 in dialog with the user
The screen
The large 19-inch TFT color flat-panel
display shows a clear overview of all
relevant information for programming,
operating and inspecting the machine tool
and control, such as program blocks,
comments and error messages. More
information is provided through graphic
support during program entry, test run and
actual machining.
The keyboard
As with all TNCs from HEIDENHAIN, the
operating panel is oriented to the
programming process. The well-thought-
out arrangement of keys in a clear division
into function groups, i.e. programming
modes, machining modes, management/
TNC functions and navigation, supports
you during program input. Simple key
assignment, easily understandable
symbols or abbreviations clearly indicate
each keys function.
6
Ergonomic and elegant, state-of-the-art
and field-provenHEIDENHAIN controls
in a new design. Judge for yourself:
The screen content includes two
operating modes, the program, graphics Durable
and the machine status The high-quality stainless steel design of
the iTNC 530 features a special protection
coating and is therefore highly resistant to
PLC function keys (soft keys) for machine
soiling and wear.
functions
Smooth
The rectangular, slightly rounded keys are
Keys for screen management (screen
pleasant to the touch and reliable in
layout), operating mode and switching
operation. Their inscriptions do not wear
between soft-key rows
off, even under extreme workshop
conditions.
Reliable
The elevated key bed of the machine
Alphanumeric keyboard for comments or operating panel prevents accidental
DIN/ISO programs and a set of PC keys for actuation. LEDs serve for status display of
controlling the operating system functions. each key by clearly indicating the active
machine functions.
Versatile
USB port for additional data storage or
Soft keys both for the programming and
pointing devices
the machine functions always show only
the currently available selections.
7
Consistently upward compatible
A promising future with HEIDENHAIN contouring controls
8
2012: TNC 640 for
milling/turning
machines
Old programs also run on newer TNC Familiar function keys take on new
controls tasks
Part programs from your NC program Of course, many innovations and
archive that were written on older TNC improvements have been included in the
contouring controls can also be run on an iTNC 530but the fundamental
iTNC 530 with very little effort. This ensure programming procedure has remained the
the greatest possible flexibility in machine same. When you step up to a new control
utilization and provides enormous benefits you need not relearn its operation and
when you have to manufacture old parts programming. Instead you only need to
again. HEIDENHAIN contouring controls become familiar with those functions that
put you in the position to manufacture a are new. So you can apply your
replacement part fast and economically professional knowledge as a machinist
even nowafter more than 30 years immediately even on a new TNC control.
without having to reprogram it.
Inside contour
Modern machines often work with four or 3-D contour machining at its finest The iTNC 530 looks ahead and thinks with
five positioning axes. This makes it possible The iTNC 530s short block processing you. Its look-ahead function anticipates
to machine complex 3-D contours. The time of only 0.5 ms for a 3-D line segment future changes in direction by adjusting the
required programs are usually created on without tool compensation permits high traversing speed to the programmed
external CAM systems and comprise a traversing speeds even on complex surface. If desired, it also enables the iTNC
large number of very short line segments contours. This enables you, for example, to 530 to reduce the feed rate when plunging
that are transferred to the control. Whether mill molds or dies approximated with the tool into the workpiece. This lets you
the workpiece is actually machined 0.2 mm line segments at feed rates as simply program the maximum machining
according the programs instructions high as 24 meters per minute. speed as the feed rate. The iTNC 530
depends essentially on the geometric automatically adapts the actual speed of
behavior of the control. With its optimized The particularly jerk-smoothed path the workpiece contour to save you
motion control, its contour precalculation control when machining 3-D figures and machining time.
and its algorithms for jerk limitation, the the defined rounding of series of straight-
iTNC 530 has the right features for the line segments provide you with smoother For NC programs with normal vectors,
desired perfect surface in the shortest surfaces as well as high dimensional such as those generated by CAM systems,
possible machining time. See for yourself. accuracy. the iTNC 530 automatically calculates a 3-D
In the end, its the quality of the workpiece tool compensation (option) selectably for
that proves the performance of the control. end mills, ball-nose cutters, or toroid
cutters.
10
Compensating form errors of tools with 3D-ToolComp (option)
DR2+0.002
DR20.004
11
Machining with five axes
Guided tool tip
13
Machining with five axes
Swivel head and rotary table controlled by iTNC
Many 5-axis operations that at first glance Tilting the working plane* use of these complex functions as simple
may seem very complex can be reduced to Programs for contours and holes on as possible, a separate animation is
conventional 2-D movements that are inclined surfaces are often very complex available for each possible plane definition,
simply tilted about one or more rotary axes and require time-consuming computing so that you can view them before selecting
or wrapped onto a cylindrical surface. The and programming work. Here the iTNC 530 the function. Clearly arranged support
iTNC supports you with application- helps you to save a great deal of graphics assist you during input.
oriented functions to help you write and programming time.
edit such programs quickly and simply You can also use the PLANE function to
without a CAM system. You program the machining operation as define the positioning behavior for tilting so
usual in the main plane, for example in X/Y. that there are no unpleasant surprises
The machine runs the program in a plane when the program is run. The settings for
that has been tilted by one or more rotary defining the positioning behavior are
axes with respect to the main plane. identical for all PLANE functions, making
everything that much easier.
The PLANE feature makes it easy to define
a tilted working plane: You can specify tilted
working planes in seven different ways, * These functions must be implemented in the
machine and iTNC by the machine tool builder.
depending on the information on the
workpiece drawing. In order to keep the
14
Machining cylindrical surfaces* Manual axis motion in the tool direction Feed rate for rotary axes and tables in
With the iTNC 530 it is quite easy to on 5-axis machines mm/min*
program contours (which consist of straight The safe retraction of a tool is very In the standard version, the feed rate of
lines and arcs) on cylindrical surfaces using important with five-axis machining. The rotary axes is programmed in degrees/
rotary and tilting tables: You simply virtual tool axis function is of assistance minutes. However, the iTNC 530 can
program the contour in a plane as if the here. You can use it to move the tool in the interpret this feed rate in mm/min as well.
cylinder surface were unrolled. The iTNC current direction of the tool axis through an The feed rate at the contour is then
530 then executes the operation on the external direction key or the handwheel. independent of the distance of the tool
surface of the cylinder. This function is especially useful if you center from the center of the rotary axis.
want to
The iTNC 530 features four cycles for retract the tool in the direction of the tool
cylindrical surface machining: axis during interruption of a 5-axis
Slot milling (the slot width is the same as machining program,
the tool diameter) use the handwheel or external direction
Guide-groove milling (the slot width is keys to perform an operation in Manual
greater than the tool diameter) mode with an inclined tool,
Ridge milling move the tool with the handwheel in the
Mill outside of contour active tool axis direction during
machining.
15
Intelligent machining
Dynamic Collision Monitoring option (DCM)
The complex motions and the normally In cases such as these, the machine However, DCM works not only in
high traversing speeds of 5-axis machining operator is supported by the dynamic automatic mode. It is also active in
make axis movements difficult to foresee. collision monitoring (DCM)* feature of manual operation. If, for example, during
This makes collision monitoring a valuable the iTNC 530. The control interrupts setup the machine operator takes a
function that relieves the machine operator machining whenever a collision is collision course to a component or fixture
and protects the machine from damage. imminent, thereby increasing the safety for in the working space, the iTNC 530 detects
the machine and its operator. This helps to it, stops axis movement, and issues an
NC programs from CAM systems may prevent machine damage, which can result error message.
avoid collisions of the tool or tool holder in costly downtimes. Unattended shifts
with the workpiece, but unless you invest become safer and more reliable. Before actually machining a part, you can
in expensive offline machine simulation also check for collisions in the Test Run
software, they ignore the machine With NC functions you can activate or mode, with a real datum and real tools.
components located within the work deactivate previously saved fixture
envelope. And even then it cannot be situations in automatic operation. Specific
guaranteed that machine conditions, such fixtures can also be activated for each NC * These functions must be implemented in the
machine and iTNC by the machine tool builder.
as the fixture position, will be identical to program from pallet tables. This increases
those of the simulation. In the worst case, safety and reliability in automatic
a collision will remain undetected until the production.
damage is done.
16
Of course the iTNC 530 also shows the geometric bodies. The tool is automatically When using the dynamic collision
machine operatorboth with an error considered a cylinder of the tool radius monitoring, please note:
message and graphicallywhich machine (defined in the tool table). For tilting While DCM can help reduce the danger
components are endangered. If a collision devices, the machine tool builder can use of collision, DCM cannot fully eliminate
warning is displayed, the TNC permits the tables for the machine kinematics also it.
retracting the tool only in those directions to define the collision objects. Only the machine manufacturer can
which increase the clearance between the define machine components. The
colliding objects. The last step of the configuration process operator creates fixtures from fixture
defines which machine components can templates, which are provided by
The machine tool builder takes care of the collide. Because the machine design in HEIDENHAIN or by the machine
required definition of machine itself prevents collisions between certain manufacturer.
components. The working space and the machine components, they can be ruled Collisions between machine
collision objects are described using out from the start. For example, a tool components (such as swivel heads) and
geometric bodies such as planes, cubes touch probe like the HEIDENHAIN TT the workpiece cannot be detected.
and cylinders. Complex machine clamped on the machine table can never DCM cannot be used during operation in
components can be modeled with multiple come into contact with the machine cabin. following error mode (i.e. without
feedforward).
In the Test Run operating mode you can
check for collision before actually
machining the workpiece.
17
Global program settings (option)
The global program settings, which come The following functions are available: Limit plane
into play particularly in large-scale mold Swapping axes The powerful limit plane function enables
making, are available in the Program Run Additional, additive datum shift you to easily limit the working space. This
and MDI modes. They allow you to define Superimposed mirroring enable you to:
various coordinate transformations and Axis locking define ranges for machining, e.g. for
settings with global and priority effect for Handwheel superimposition, with axis- repairs
the selected NC program, without having specific memory of paths covered per avoid limit-switch warnings, e.g. when a
to edit it. handwheel, also in virtual axis direction CAM program is run on a machine with a
Superimposed basic rotation smaller traverse range, and
You can change the global program settings Superimposed rotation edit the limit height, for example to
during a program stop even in mid- Globally valid feed-rate factor machine a programmed surface in
program. A clearly structured form is Limiting the machining area (limit plane) multiple steps by limiting the depth
provided for this. After program start the
iTNC then moves, if necessary, to a new
position with a positioning logic influenced
by you.
ABST
18
Interpolation turning (option)
During interpolation turning the tool edge This cycle can only be used for finishing.
describes a circular motion where the Roughing operations with multiple steps
orientation of the cutting edge is always are not possible. The machining strategy
oriented to the circle center. By varying the can be chosen flexibly: from the outside in
circle radius and the axial position, any or vice versa, and also from top to bottom
rotationally symmetric objects can be or vice versa. This results in four different
produced in any working plane. machining strategies, which are distributed
over the four quadrants.
With the interpolation turning cycle, the
iTNC 530 can create a rotationally
symmetric shoulder in the active machining
plane that is defined by its starting and
ending point. The center of rotation is the
tool location in the working plane at the
time the cycle is called. The rotational
surfaces can be inclined or rounded relative
to each other.
19
Intelligent machining
Dynamic Efficiency
With the concept of Dynamic Efficiency, Dynamic Efficiency comprises three Each solution in itself offers decisive
HEIDENHAIN offers innovative TNC software functions: advantages in the machining process. But
functions that help the user to make heavy Active Chatter Control (ACC) The ACC the combination of these TNC features, in
machining and roughing more efficient option reduces chatter tendencies and particular, exploits the potential of the
while also enhancing its process reliability. permits greater infeeds machine and tool and at the same time
The software functions support the Adaptive Feed Control (AFC) The AFC reduces the mechanical load. Changing
machine operator but also make the option controls the feed rate depending machining conditions, such as interrupted
manufacturing process itself faster, more on the machining situation cuts, various material plunging procedures
stable and more predictablein short, Trochoidal millinga function for the or simple clear-out also show that these
more efficient. Dynamic Efficiency permits roughing of slots and pockets that eases features pay for themselves. In practice,
higher removal rates and therefore the load on the tool and the machine removal rates can be increased by 20 to 25
increases productivity without making the percent.
user resort to special tools. At the same
time, it prevents any tool overloading and
the concomitant premature cutter wear. All
of this means that with Dynamic Efficiency
you can manufacture more economically
while increasing process reliability.
20
Active Chatter Control option (ACC)
Strong forces come into play during To reduce the inclination to chattering,
roughing (power milling). Depending on the HEIDENHAIN now offers an effective control
tool spindle speed, the resonances in the function with its Active Chatter Control
machine tool and the chip volume (metal- option (ACC). The use of this control
removal rate during milling), the tool can function is particularly advantageous during
sometimes begin to chatter. This heavy cutting. ACC makes substantially
chattering places heavy strain on the higher metal removal rates possible. This
machine, and causes ugly marks on the makes it possible to increase your metal
workpiece surface. The tool, too, is subject removal rate by up to 25 % and more,
to heavy and irregular wear from depending on the type of machine. You
chattering. In extreme cases it can result in reduce the mechanical load on the machine
tool breakage. and increase the life of your tools at the
same time.
21
Intelligent machining
Adaptive Feed Control option (AFC)
Besides the feed rate for each block or control mode. Of course, various Tool monitoring
cycle, HEIDENHAIN controls have always overload reactions can be provided for, The iTNC's adaptive feed rate control
allowed the programmer to enter a manual which can also be defined by your machine continuously compares the spindle power
compensation through the override tool builder. with the feed rate. As a tool becomes
potentiometer to adjust for the actual blunt, the spindle power increases. As a
machining situation. But this always Adaptive feed rate control offers various result, the iTNC reduces the feed rate. As
depends on the experience and, of course, advantages: soon as the feed rate falls below a defined
the presence of the operator. minimum, the iTNC reacts with an error
Optimizing the machining time message or by switching off. This helps to
Adaptive feed rate control (AFC) Fluctuations in dimensions or material prevent further damage after a tool breaks
automatically regulates the feed rate of the (blowholes) often appear particularly on or is worn out.
TNC, taking into consideration the cast parts. With a corresponding adaptation
respective spindle power and other of the feed rate, the control tries to keep Protection of the machine mechanics
process data. In a teach-in cut, the iTNC the previously learned maximum spindle Reducing the feed rate down to the
records the maximum spindle power. Then, power during the entire machining time. reference value whenever the learned
before actual machining, you define in a The total machining time is shortened by maximum permissible spindle power is
table the respective limit values between an increased feed rate in the machining exceeded also reduces the strain and wear
which the iTNC can influence the feed rate zones with less stock removal. on the machine. It effectively protects the
in the adaptive control mode in the spindle from overload.
22
Machining any contour slots with trochoidal milling
The benefit of trochoidal milling is its ultra- With trochoidal milling, on the other hand, The slot to be machined is described in a
efficient machining of slots of all kinds. The large cutting depths are possible since the contour subprogram as a contour train. You
roughing process is a circular motion prevailing cutting conditions do not define the dimensions of the slot and the
superimposed on a forward linear motion. increase the wear and tear on the tool. On cutting data in a separate cycle. Any
This procedure is referred to as trochoidal the contrary, the entire length of a plain residual material remaining can then easily
milling. It is used particularly for milling cutters cutting edges can be used. This be removed with a subsequent finishing
high-strength or hardened materials, where enables you to achieve a greater chip cut.
the high loads placed on the tool and volume per tooth. Circular plunging into the
machine usually only permit small infeeds. material places less radial force on the tool. The benefits include:
This reduces the mechanical load on the Engagement of the entire cutter length
machine and prevents vibration. Enormous Higher chip volume
time savings can be realized by combining Relief from mechanical load on the
this milling method with the integrated machine
adaptive feed control (AFC) option. Less vibration
Integrated finishing of the side wall
23
Higher speed, more accuracy, truer contours
High speed milling with the iTNC 530
High speed cutting Very high contour accuracy Fast machining at specified accuracy
High speed cutting stands for quick and The iTNC 530 calculates the contour for up You as user specify the accuracy of the
efficient contour milling. The control must to 1024 blocks in advance. This enables it machined contourapart from the NC
be able to transfer large amounts of data to adapt the axis velocities to the contour program. You simply enter in the control
quickly, make long programs efficient to transitions. It controls the axes with special through a cycle the maximum permissible
edit, and produce the desired ideal contour algorithms that ensure path control with deviations from the ideal contour. The
on the workpiece: all qualities that the iTNC the required limits to velocity and iTNC 530 automatically adapts the
530 possesses. acceleration. The integrated filters machining to the tolerance that you define.
specifically suppress machine-specific No contour damage occurs with this
Very short block processing times natural vibration. Of course, the desired method.
Block processing speeds are progressively accuracy of the surface is maintained.
being pushed into the background by Digital drive technology
sophisticated feedforward servo methods. Spline interpolation The position controller, speed controller
Nevertheless, short block processing times If your CAM system describes contours as and, if required, the current controller are
remain a precondition for certain machining splines, you can transfer them directly to integrated in the iTNC 530. The digital
situations. One example is the machining the control. The iTNC 530 features a spline motor control makes it possible to attain
of highly accurate contours with very high interpolator and can process third-degree very high feed rates. Of course, the
resolution. No problem for the iTNC 530. polynomials. iTNC 530 can interpolate simultaneously in
With block processing times below one up to five axes. To reach the required
millisecond, the iTNC 530 provides ideal cutting speed, the iTNC 530 digitally
control. controls spindle speeds up to 60 000 rpm.
24
Dynamic Precision
The hypernym Dynamic Precision stands All the deviations are together responsible The machine tool builder can use the
for a number of HEIDENHAIN solutions for for dimensional errors and faults in the options comprised by Dynamic Precision
milling that can dramatically improve the workpiece surface. They therefore have a either individually or in combination:
dynamic accuracy of a machine tool. It is decisive influence on quality and, when CTC Compensation of position errors
the result of a new perspective on the poor-quality parts are scrapped, also on due machine elasticity between the
competing demand for accuracy, high productivity. encoder and the TCP. This increases
surface quality and short machining times. accuracy during acceleration phases
The dynamic accuracy of machine tools Because the stiffness of machine tools is AVD Active vibration damping
can be seen in position errors at the tool limited for reasons of design and economy, improves surfaces
center point (TCP), which depend on problems such as compliance and vibration PAC Position-dependent adaptation of
motion quantities such as velocity and within the machine design are very difficult controller parameters
acceleration (also jerk) and result from to avoid. Dynamic Precision counteracts LAC Load-dependent adaptation of
vibrations of machine components and these problems with intelligent control control parameters enhances accuracy
other causes. technology to enable designers to further regardless of load and aging
improve the quality and dynamic MAC Motion-dependent adaptation of
performance of machine tools. That saves control parameters
time and money in production.
25
Automated machining
The iTNC 530 manages, measures and communicates
27
Minimize setup times
The iTNC 530 makes setup easy
Before you can begin machining, you must Delicate manual traverse Workpiece alignment
first clamp the tool and set up the machine, For setup, you can use the direction keys With HEIDENHAIN 3-D touch probes (see
find the position and orientation of the to move the machine axes manually or in page 48) and the probing functions of the
workpiece on the machine, and set the incremental jog. A simpler and more iTNC 530, you can forgo any tedious
workpiece reference point. This is a time- reliable way, however, is to use the manual alignment of the workpiece:
consuming but indispensable procedure. electronic handwheels from HEIDENHAIN Clamp the workpiece in any position.
After all, any error directly reduces the (see page 51). Particularly with the portable The touch probe determines the actual
machining accuracy. Particularly in small handwheels you are always close to the workpiece position by probing a surface,
and medium-sized production runs, as well action, enjoy a close-up view of the setup two holes, or two studs.
as for very large workpieces, setup times process, and can control the infeed The iTNC 530 compensates the
become quite a significant factor. responsively and precisely. misalignment with a basic rotation,
which means that in the NC program the
The iTNC 530 features application-oriented, part is rotated by the measured
real-world setup functions. They support misalignment.
the user, help to reduce non-productive
time, and make overnight, unattended
production possible. Together with the 3-D
touch probes, the iTNC 530 offers
numerous probing cycles for automatic
alignment of the workpieces, presetting,
and measurement of the workpiece and
the tool. Compensating workpiece misalignment
Compensate misalignment by rotating the
coordinate system or turning the table
28
Setting datums Datum management On machines with an automatic spindle
You can use a reference point to assign a The datum management makes flexible head changer, the reference point remains
defined value in the iTNC display to any machining, shorter setup times and unchanged after a head exchange, even if
workpiece position. Finding this point increased productivity possible. In other they differ kinematically (i.e. in their
quickly and reliably reduces nonproductive words, it makes it much easier to set up dimensions).
time and increases machining accuracy. the machine.
The iTNC 530 features probing cycles for The iTNC automatically creates separate
automatic presetting. Once found, you can In the datum management you can save preset tables for individual traverse ranges
save reference points any number of datums and assign an (such as for alternating table machining).
in the datum management individual basic rotation to each one. When changing traverse ranges, the iTNC
in a datum table, or activates the correct table with the most
by directly setting the displayed value. When working in a tilted plane and recently active reference point.
presetting a reference point, the iTNC
includes the respective positions of the There are three ways to save datums
rotary axes. In this way, the reference point rapidly in the datum management:
also remains active in any other angular In the Manual mode by soft key
position. By using the probing functions
With the automatic probing cycles
Setting a datum
You can set a datum at a corner, for
example, or in the center of a bolt hole
circle.
29
Programming, editing, testing
The iTNC 530 opens endless possibilities
30
Fast availability of all information
31
Programming, editing, testing
Graphic support in any situation
Programming graphics
The two-dimensional programming
graphics give you additional security: while
you are programming, the iTNC 530 draws
every entered traverse command on the
screen.
Help graphics
During cycle programming in Klartext
dialog, the iTNC shows a separate
illustration for each parameter. This makes
it easier to understand the function and
accelerates programming. In smarT.NC you
will find a separate help graphic for each
required input.
32
Program verification graphics
To play it safe before running a program,
the iTNC 530 can graphically simulate the
machining of the workpiece. It can display
the simulation in various ways:
In a plan view with different shades of
depth
In three planes (as in the workpiece
drawing)
In a solid model, 3-D view
Details can be displayed in magnification.
The high resolution of the 3-D view
visualizes even very fine contours true to
detail and enables you to see even hidden
details clearly and reliably. A simulated light
source provides realistic light-and-shadow
conditions.
Program-run graphics
With the iTNC 530, the programming
graphics or verification graphics are
available even while the workpiece is being
machined. Also, it shows a real-time
graphic of the machining progress during
program run. Coolant spray and protective
enclosures usually obstruct any direct view
of the actual workpiece. You can get around
this with a simple keystroke to see the
simulated progress of workpiece
machining.
33
Programming in the workshop
Straightforward function keys for complex contours
Programming 2-D contours Straight and circular contour elements You simply specify the starting or end point
To program a line segment, for example, of the contour and the approaching or
Two-dimensional contours are the bread simply press the key for linear traverse. The departing radius of the cutter edgethe
and butter of the modern machine shop. iTNC 530 asks for all information control does the rest for you.
Here the iTNC 530 offers a variety of required for a complete programming
possibilities. block, such as target coordinates, feed The iTNC 530 can look ahead over a radius-
rate, cutter radius compensation and compensated contour for up to 99 blocks
Programming with path function keys machine functions. Appropriate path to watch for back cutting and avoid contour
If contours are dimensioned for NC, which function keys for circular movement, damage. Contour damage can occur, for
means that the end points are specified in chamfers, and corner rounding simplify example, when roughing a contour with a
Cartesian or polar coordinates, then you your programming. To avoid surface large tool.
can program them directly with the path blemishes during approach or departure
function keys. from the contour, it must be approached
smoothlythat is, tangentially.
CT
CC C RND Corner
rounding:
Circular path defined circular path with
by its center point, smooth (tangential)
end point, and connection on both
rotational direction sides, defined by
radius and corner point
CHF Chamfer:
defined by the
corner point and the
chamfer length
CR
34
Programming contours unconventionally
35
Programming in the workshop
Field-proven cycles for recurring operations
Comprehensive fixed cycles for Cycles for complex contours Up to twelve subcontours can be
milling, drilling and boring The Subcontour List cycles (SL) are superimposed for machining. The control
particularly helpful for clearing pockets with automatically calculates the resulting
Frequently recurring operations that combined contours This term is used to contour and the tool paths for roughing or
comprise several working steps are stored identify machining cycles for pilot drilling, clearing the surfaces. Subcontours can be
in the iTNC 530 as cycles. You program roughing and finishing when the contour or pockets or islands. Different components
them under conversational guidance and subcontours are specified in subroutines. are combined to form a single pocket in
are supported by graphics that clearly In this way, one contour description can be which the tool avoids the islands.
illustrate the required input parameters. used for more than one operation using
different tools. You can assign a separate depth to each
Standard cycles subcontour. If the subcontour is an island,
Besides the fixed cycles for drilling, tapping the iTNC interprets the depth entered as
(with or without floating tap holder), thread the height of the island.
milling, reaming, and boring, there are
cycles for hole patterns and milling cycles
for clearing plane surfaces, and for
roughing and finishing pockets, slots and
studs.
The iTNC 530 maintains a finishing You can also program open contours
allowance on the wall and floor surfaces with the SL cycles. This enables the iTNC
during roughing. When roughing with 530 to observe allowances for 2-D
different tools, the control identifies contours, to move the tool in alternating
material remaining in inside corners so that directions after each infeed, to avoid
it can be cleared later with smaller tools. A contour damage at undercuts and to
separate cycle is used for milling to the maintain the defined milling direction
finished dimension. (climb or conventional) after coordinate
transformations such as mirroring.
36
OEM cycles
As original equipment manufacturers
(OEMs), machine tool builders can
contribute their special manufacturing
know-how by designing additional fixed
cycles and saving them in the iTNC 530.
However, the end user can write his own
cycles as well. HEIDENHAIN makes this
possible with its PC program CycleDesign.
CycleDesign enables you to organize the
input parameters and soft-key structure of
the iTNC 530 to suit your own needs.
Coordinate transformation
If you should need a contour that has
already been programmed at another
position or in a different size, the iTNC 530
offers you a simple solution: coordinate
transformation.
37
Peripheral milling with the contour train cycle
Special demands are in force during With the Contour Train cycle you can The 3-D contours to be machined can be
peripheral milling of cutting and bending machine such 3-D contours very simply: created very easily if they can be loaded
tools, particularly for large-scale mold you define the contour to be machined in a from existing NC programs that were
making for the automobile industry. The subprogram. You specify the approach generated by a postprocessor. This applies
outlines are generated from CAM systems behavior, machining mode and radius in particular if a smaller tool must be used
and usually include not only the compensation with a separate cycle. You to rework specific areas. An enhancement
coordinates in the working plane, but also can machine the 3-D contour train with or was implemented for this in the DXF
those in the tool axis direction. What is without infeed, depending on whether an converter, making it possible to load
special is that the cutting or bending edge infeed has been defined. contours or parts of contours from
does not run at a constant Z height, but conversational programs.
differs greatly depending on the
component.
38
Well thought out, simple and flexible
smarT.NCthe alternative operating mode
TNC controls from HEIDENHAIN have As always, HEIDENHAIN has also placed
always been user friendly: Thanks to their great value on compatibility. You can switch
simple programming in HEIDENHAIN at any time between smarT.NC and
Klartext conversational language, field- conversational programming. But not only
proven cycles, unambiguous function keys, can you write programs with smarT.NC
and clear and vivid graphic functions, they you can test and run them as well.
now count among the most popular shop-
floor programmable controls. And even the TNC specialist profits from
smarT.NC. The smarT.NC wizard completely
The alternative smarT.NC operating mode unifies the worlds of smarT.NC and
makes programming even easier. conversational programming. The strengths
Particularly as a TNC beginner, with the of both worlds are now available in a single
well thought-out input forms you can user interface. The full flexibility of
create your NC program in a few quick conversational programming, based on NC
steps. Of course youll be aided during blocks, can now be combined at any
programming by help graphics. location with the fast, fillable-form based
work-step programming method of smarT.
NC.
39
smarT.NCthe alternative operating mode (continued)
40
Well-designed for fast operation Superior graphic support
With the split-screen, smarT.NC provides Even as a CNC beginner, you can program
an easily understandable program with smarT.NC quickly and without
structure. On the left screen, you can extensive schooling, because smarT.NC
navigate quickly in a variable tree structure. gives you optimal support.
On the right, clearly arranged input forms
immediately show you the defined Clearly arranged help graphics illustrate all
machining parameters. The soft-key row required input.
shows the input options.
Graphic symbols increase concept
smarT.NC means reduced input: You can
recognition when the same type of input is
enter global program parameters such as
required for different operations.
setup clearances, position feed rates, etc.
once at the beginning of the program to
avoid multiple definitions.
41
Open for communication
The iTNC 530 understands DXF files (option)
Why program complex contours when As a rule, DXF files contain multiple layers, The iTNC also supports you when defining
your drawing is already in DXF format with which the design engineer organizes the workpiece datum. The datum of the
anyway? You can open DXF files directly on the drawing. So that as little unnecessary drawing for the DXF file is not always
the iTNC 530 in order to extract contours information as possible appears on the located in a manner that lets you use it
or machining positions from it. This not only screen during selection of the contours, directly as a reference point for the
saves time otherwise spent on with a keystroke you can hide all excessive workpiece, especially when the drawing
programming and testing, you can also be layers contained in the DXF file. This contains multiple views. Therefore, the
sure that the finished contour is exactly requires a keyboard with touchpad or an iTNC has a function with which you can
according to the design engineers external pointing device. The iTNC can shift the drawing datum to a suitable
specifications. select a contour train even if it has been location simply by clicking an element.
saved in different layers.
The DXF formatparticularly the DXF
format supported by the iTNC 530is very
widespread and is supported by all
common CAD and graphics programs.
42
You can define the following locations as Contour selection is exceptionally user the desired area. In a pop-up window with
reference point: friendly. You select any element by clicking filter function, the TNC displays all hole
The beginning, end or mid-point of a line it with the mouse. As soon as you select a diameters that are within the area you have
The beginning, end or center point of a second element, the iTNC detects your selected. To select the desired hole
circular arc desired direction of machining, and starts diameters and restrict the number of hole
Quadrant transitions or center point of a the automatic contour detection. The positions, simply click the corresponding
circle iTNC automatically selects all clearly filter symbol to change the filter limits.
Intersection of two lines, regardless of identifiable contour elements until the
whether it is located inside or outside contour closes or branches out. There you A zoom function and various possibilities
the programmed segments click the immediately following contour for settings round out the functionality of
Intersection of a line and a circular arc element. In this way you can define even the DXF converter. In addition, you can
Intersection of a line and a circle extensive contours with just a few mouse define the resolution of the contour
clicks. If desired, you can also shorten, program to be output in case you want to
If multiple intersections can result between lengthen or interrupt the contour elements. use it on older TNC controls, or a transition
two elements (e.g., between a straight line tolerance if occasionally the elements do
and a circle), you can select the correct But you can also select machining not quite adjoin.
intersection with a mouse click. positions and save them as point files,
particularly in order to use drilling positions
or starting points for pocket machining.
With drilling positions this can be done
very easily: use the mouse to simply select
Zoom in to details of an imported DXF file Part program on the basis of the imported DXF file
43
Open for communication
Program offline and enjoy the advantages of the iTNC
Frequently, 5-axis programs are written Programs created offline The postprocessor is the link between the
on offline CAM systems and then NC programs for 5-axis operations are CAM system and the CNC control.
transferred to the control over a data line. normally written on CAM systems. The Standard features on all prevalent CAM
The iTNC 530 offers many benefits for workpiece geometry is described in the systems include post-processors for
these applications as well. The fast data CAD system, while the required G-code format as well as for the proven
transfer over the Ethernet interface technology data is added in the CAM and user-friendly HEIDENHAIN
functions safely and reliably, even with system. The technology data specify the conversational format. This enables you to
large 3-D programs. You can make full use methods (such as milling, drilling, or use special TNC functions that are
of the iTNC 530s ease of useeven for boring), the strategy (area pocket available only in conversational format.
offline programming. clearance, plunge milling, etc.), and the Examples are:
parameters (spindle speed, feed rate, etc.) Tool Center Point Management (TCPM)
The iTNC 530 works very well together for machining the workpiece. A Structuring function
with all CAM systems. HEIDENHAIN postprocessor uses the geometry and Special Q-parameter functions
intensively supports the manufacturers of technology data to create an executable
postprocessors for the best possible use of program, which is then usually transferred Program optimization is also easy. As
the iTNC 530s powerful features. over the company network to the usual, the conversational programming is
iTNC 530. graphically supported. And of course you
can use all proven setup functions of the
In principle, postprocessors generate two iTNC 530 to quickly and economically
types of NC programs, both of which can locate the workpiece.
be run by the iTNC 530:
Machine-specific NC programs take the CAM systems dont always generate
respective machine configuration into programs optimized for the machining
account and include all coordinates of process. Therefore, the iTNC 530 offers a
the NC axes on that machine. point filter for smoothing externally created
Machine-neutral NC programs define the NC programs. The filter function creates a
contour and use vectors to define the copy of the original program, and then adds
respective tool position on the contour. any points required by the parameters that
The iTNC 530 then uses the information you set. This smooths the contour to allow
to calculate the axis positions of the the program to run more quickly.
actual machine axes. The key benefit
here is that you can run such NC
programs on various machines with
differing axis configurations.
44
Fast data transfer with the iTNC
MANUALplus 620
Ethernet interface
45
Open for communication
Remote desktop manager (option)
* The iTNC must be prepared by the machine tool builder for this function.
Windows is a brand name of the Microsoft Corporation.
46
The iTNC programming station
Why a programming station? The workstation Or as an alternative, you can even operate
Its well known that it is easy to create part The iTNC programming station software the programming station without an iTNC
programs with an iTNC at the machine, runs on a PC. The programming station is keyboard. You can use your mouse on a
even while another part is being machined. only slightly different from an iTNC built convenient virtual keyboard insteadit is
Nevertheless, short reloading times and onto a machine tool. The familiar TNC displayed together with the iTNC control
other machining tasks can often hinder any keyboard remains unchanged except that it panel and features the most important
prolonged or concentrated programming now includes the soft keys, which are dialog initiation keys of the TNC.
work. With the iTNC programming station otherwise integrated in the visual display
you have the capability to program just as unit. You connect the iTNC keyboard to
you do at the machine, but away from the your PCs USB port. The PC screen displays
noise and distractions of the shop floor. the familiar TNC user interface.
Creating programs
Programming, testing and optimizing your
smarT.NC, HEIDENHAIN conversational or
DIN/ISO programs for the iTNC 530 with
the programming station substantially
reduces machine idle times. You need not
adjust your way of thinkingevery
keystroke fits. On the programming station
you program on the same keyboard as at
the machine.
47
Workpiece measurement
Setup, presetting and measuring with touch trigger probes
Workpiece touch probes* from Touch probes with cable connection for
HEIDENHAIN help you to reduce costs in signal transmission for machines with
the workshop and in series production: manual tool change and for grinding
Together with the iTNC 530, touch probes machines and lathes:
can automatically perform setup,
measuring and inspection functions. TS 260 New generation, axial or radial
cable
The stylus of a TS touch trigger probe is
deflected upon contact with a workpiece Touch probe with radio or infrared signal
surface. At that moment the TS generates transmission for machines with automatic
a trigger signal that, depending on the tool change:
model, is transmitted either by cable or
over an infrared beam to the control. TS 460 New generation standard touch
probe for radio and infrared transmission,
The touch probe* is inserted directly into with compact dimensions
the machine tool spindle. It can be TS 444 Battery-free voltage supply
equipped with various shanks depending through integrated air turbine generator
on the machine. The ruby ball tips are from compressed air, for infrared
available in several diameters, and the styli transmission, with compact dimensions
in different lengths. TS 740 High probing accuracy and
repeatability, low probing force, with
* The touch probes must be interfaced to the iTNC infrared transmission
530 by the machine tool builder.
SE 660
TS 460
TS 260
48
Tool measurement
Measuring length, radius and wear directly in the machine
TL Micro
TT 460
More information about tool touch
probes is available on the Internet at
www.heidenhain.de or in the Touch
Probes brochure.
49
Inspecting and optimizing machine accuracy
Calibrating rotary axes simply with KinematicsOpt (option)
Accuracy requirements are becoming To measure the rotary axes, a calibration Of course, a comprehensive log file is also
increasingly stringent, particularly in the sphere is fixed at any position on the saved with the actual measured values and
area of 5-axis machining. Complex parts machine table and probed with the the measured and optimized dispersion
need to be manufactured with precision HEIDENHAIN touch probe. But first you (measure for the static tilting accuracy), as
and reproducible accuracy even over long define the resolution of the measurement well as the actual compensation values.
periods. and define for each rotary axis the range
that you want to measure. An especially rigid calibration sphere is
The TNC function KinematicsOpt is an necessary for optimum use of
important component to help you meet From the measured values, the TNC KinematicsOpt. This helps to reduce
these high requirements: With a calculates the static tilting accuracy. The deformations that occur as the result of
HEIDENHAIN touch probe inserted, a 3-D software minimizes the spatial error arising probing forces. That is why HEIDENHAIN
touch probe cycle measures your from the tilting movements and, at the end offers calibration spheres with highly rigid
machines rotary axes fully automatically. of the measurement process, automatically holders that are available in various lengths.
The results of measurement are the same saves the machine geometry in the
regardless of whether the axis is a rotary respective machine constants of the
table, a tilting table or a swivel head. kinematics table.
50
Positioning with the electronic handwheel
Delicate axis traverse
You can move machine axes controlled by HR 520 and HR 550 portable The following functions are available:
the iTNC 530 by simply pressing the axis handwheels
keys. A simpler and more sensitive way, The HR 520 and HR 550 are particularly HR 520, HR 550
however, is to use the electronic helpful for when you have to work close to Traverse distance per revolution can be
handwheels from HEIDENHAIN. the machines working space. The axis keys set
and certain functional keys are integrated in Display for operating mode, actual
You can move the axis slide through the the housing. In this way you can switch position value, programmed feed rate
feed motors in direct relation to the axes and set up the machine at any time and spindle speed, error messages
rotation of the handwheel. For delicate regardless of where you happen to be Override potentiometer for feed rate and
operations you can set the transmission standing. As a wireless handwheel, the spindle speed
ratio to certain preset distances per HR 550 is ideal for use on large machine Selection of axes via keys or soft keys
handwheel revolution. tools. If you no longer need the Keys for continuous traverse of the axes
handwheel, just attach it to the machine Emergency stop button
HR 130 and HR 150 panel-mounted somewhere by its built-in magnets. Actual position capture
handwheels NC start/stop
The panel-mounted handwheels from Spindle on/off
HEIDENHAIN can be integrated in the Soft keys for machine functions defined
machine operating panel or mounted at by the machine tool builder
another location on the machine. An
adapter permits connection of up to three
HR 150 electronic handwheels.
HR 550
51
... and if theres a problem?
Diagnostics for HEIDENHAIN controls
The operating reliability of machine tools Remote diagnosis with TeleService Error diagnostics on the control
and controls has improved continually in The TeleService PC software from The TNC provides integrated functions with
recent years. However, interruptions or HEIDENHAIN enables the machine tool which the service technicianin the case
problems can still occur. Often it is simply a builder to provide quick and simple remote of failurecan quickly and simply detect
programming or parameter problem. Here diagnosis and programming support for the faults in the area of the drives or in the
is where the true advantage of remote iTNC 530 controls. hardware.
diagnosis comes into play: The service
technician communicates online with the The TeleService software is also of interest
control over modem, ISDN or DSL, to you, the NC user: Installing it on a
analyzes the control, and repairs it network PC enables remote operation and
immediately. remote monitoring of the iTNC 530
connected to the network.
Remote data
transfer
52
Overview
User functions
User functions
Default
Option
Short description Basic version: 3 axes plus spindle
4th NC axis plus auxiliary axis
or
0-7
77 A total of 14 additional NC axes or 13 additional NC axes plus second spindle
78
Digital current and speed control
Program entry With smarT.NC, in HEIDENHAIN Klartext conversational format and according to DIN/ISO
42 Direct loading of contours or machining positions from DXF files and saving as smarT.NC or
conversational contouring programs, or as point tables
Position entry Nominal positions for lines and arcs in Cartesian coordinates or polar coordinates
Incremental or absolute dimensions
Display and entry in mm or inches
Display of the handwheel path during machining with handwheel superimpositioning
Tool compensation Tool radius in the working plane and tool length
Radius compensated contour look ahead for up to 99 blocks (M120)
9 Three-dimensional tool-radius compensation for changing tool data without having to recalculate
an existing program
Cutting data Cutting data tables for automatic calculation of spindle speeds and feed rates from tool-specific
data (cutting speed, feed per tooth)
Entry of cutting speed as alternative to the spindle shaft speed
Feed rate can also be entered as FZ (feed per tooth) or FU (feed per revolution)
Parallel operation Creating a program with graphical support while another program is being run
Adaptive Feed Control 45 AFC: Adaptive Feed Control adjusts the contouring feed rate to the current spindle power
53
Overview
User functions (continued)
User functions
Default
Contour elements Option Straight line
Chamfer
Circular path
Circle center
Circle radius
Tangentially connecting circular arc
Corner rounding
FK free contour FK free contour programming in HEIDENHAIN conversational format with graphic support for
programming workpiece drawings not dimensioned for NC
Fixed cycles Drilling, conventional and rigid tapping, rectangular and circular pockets
Peck drilling, reaming, boring, counterboring, centering
Milling internal and external threads
Clearing level and oblique surfaces
Multi-operation machining of rectangular and circular pockets, rectangular and circular studs
Multioperation machining of straight and circular slots
Cartesian and polar point patterns
Contour train (incl. 3-D), contour pocketalso with contour-parallel machining
Contour slot with trochoidal milling
96 Interpolation turning
Engraving cycle: Engrave text or numbers in a straight line or on an arc
OEM cycles (special cycles developed by the machine tool builder) can be integrated
Manually definable:
44 Global program settings make it possible to manually define shifts, rotations, and handwheel
superimpositioning
Mathematical functions =, +, , *, /, sin , cos , tan , arc sin, arc cos, arc tan, a , e , In, log, a,
n n
Q parameters
Programming with variables a + b
2 2
Logical operations (=, = /, <, >)
Calculating with parentheses
Absolute value of a number, constant , negation, truncation of digits before or after the decimal
point
Functions for calculation of circles
Functions for text processing
54
User functions
Default
Option
Program verification Graphic simulation before a program run, even while another program is running
graphics Plan view / projection in 3 planes / 3-D view, also in tilted working plane
Display modes Magnification of details
Programming graphics In the Programming and Editing mode, the contours of the NC blocks are drawn on screen while
they are being entered (2-D pencil-trace graphics), even while another program is running
Machining time Calculation of machining time in the Test Run operating mode
Display of the current machining time in the Program Run operating modes
Returning to the contour Mid-program startup in any block in the program, returning the tool to the calculated nominal
position to continue machining. The graphic support in smarT.NC also lets you return to a point
pattern.
Program interruption, contour departure and return
Datum management One table per traverse range for storing datums
Pallet tables Tool-oriented or workpiece-oriented execution of pallet tables with any number of entries for
selection of pallets, NC programs and datums
Conversational languages English, German, Czech, French, Italian, Spanish, Portuguese, Swedish, Danish, Finnish, Dutch,
Polish, Hungarian, Russian (Cyrillic), Chinese (traditional, simplified), Slovenian, Slovak,
Norwegian, Korean, Turkish, Romanian
55
Overview
Accessories
Options
Accessories
Workpiece measurement TS 260: 3-D touch trigger probe with cable connection or
TS 460: 3-D touch trigger probe with radio or infrared transmission or
TS 444: 3-D touch trigger probe with infrared transmission or
TS 740: 3-D touch trigger probe with infrared transmission
Programming station Control software for PCs for programming, archiving, and training
Single-station license with original control keyboard
Single-station license with virtual keyboard
Network license with virtual keyboard
Demo version (operation per PC keyboardfree of charge)
Software for PCs TeleService: Software for remote diagnosis, monitoring, and operation
CycleDesign: Software for creating your own cycle structure
TNCremo: Data transmission softwarefree of charge
TNCremoPlus: Software for data transfer with live-screen function
18 HEIDENHAIN DNC 01 526451-01 Communication with external PC applications over COM component
56
Option Option As of NC ID Remark
number software
60642x-
48 KinematicsOpt 01 630916-01 Touch probe cycles for automatic measurement of rotary axes
133 Remote Desktop 02 894423-01 Display and remote operation of external computer units (e.g. a Windows
Manager PC)
142 Pos. Adapt. Control 02 800544-01 PAC: Position-dependent adaptation of the control parameters
143 Load Adapt. Control 02 800545-01 LAC: Load-dependent adaptation of the control parameters
Control
57
Overview
Specifications
Specifications
Default
Option
Block processing time 0.5 ms (3-D straight line without radius compensation)
Axis feedback control Position loop resolution: Signal period of the position encoder/1024
Cycle time of position controller: 200 s
Cycle time of speed controller: 200 s
Cycle time of current controller: minimum 50 s
Error compensation Linear and nonlinear axis error, backlash, reversal peaks during circular movements, reversal error,
thermal expansion
Static friction, sliding friction
Data interfaces One each RS-232-C/V.24 and RS-422/V.11, max. 115 kbit/s
Extended data interface with LSV2 protocol for remote operation of the iTNC 530 over the data
interface with the HEIDENHAIN software TNCremo or TNCremoPlus
2 x Gigabit Ethernet interface 1000BASE-T
4 x USB (1 x front USB 2.0; 3 x back panel USB 3.0)
18 HEIDENHAIN-DNC for communication between a Windows application and TNC (DCOM
interface)
58
Comparison of controls
Program entry
According to ISO
Input resolution and display step (standard/option) 0.1 m/0.01 m 0.1 m/0.01 m 0.1 m/
New design of the screen and keyboard 15-inch screen 15/19-inch screen 15/19-inch screen
Standard
Not available
59
Vollstndige und weitere Adressen siehe www.heidenhain.de
For complete and further addresses see www.heidenhain.de
*I_895822-25*
895822-25 10 6/2016 H Printed in Germany