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Automation and Drives

Path action

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Content Page
Optimum Conditions for Machining ................................................................................................... 3
G60 Exact Stop Check (block wise G09) ......................................................................................... 4
G64, G641 ....................................................................................................................................... 5
G642, G643 ..................................................................................................................................... 6
Summary of Continuous-Path Mode ................................................................................................. 7
Rapid traverse .................................................................................................................................. 8
Dynamic Behavior Groups
(Software Version 7.2) ................................................................................................................ 9
Look Ahead Over Multiple Blocks ..................................................................................................... 10
Behavior at Contour Corners ............................................................................................................ 11
Jerk at transitions with constant curvature ....................................................................................... 12
Jerk limitation SOFT ......................................................................................................................... 13
Jerkfree Contour Approach and Retract: KONTT, KONTC (Software 6) ........................................... 14
Contour Errors on Curvatures - CPRECON ...................................................................................... 15
Feedforward Control FFWON / CYCLE832 ...................................................................................... 16
Feedrate Profile FNORM, FLIN, FCUB ........................................................................................... 17
Exercise: Continuous-path mode ...................................................................................................... 18

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Optimum Conditions for Machining

Accuracy
Speed
Surface quality

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Motion Optimization
Optimizing the motion is the most important part of optimizing a manufacturing
process.
On the one hand this refers to optimizing the motion control programmed in the
CAD system or manually via the workpiece.
On the other hand, however, it refers to jerkfree, fast and accurate execution of
this programmed path.

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G60 Exact Stop Check (block wise G09)

Use for boring only normally (Because of jerky movements)

G601

G602 v

G603

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The instructions G601, G602 and G603 are only active if G60/G9 are activated.
They refer to the accuracy window in the machine data:

Note: The exact stop limits should always be set as tight as possible. The tighter the
limits, the longer it takes to position and therefore approach the target position.
With G603 the corner behavior results from the current following error of the axes
and is dependent on the axis speed and machine dynamics.

Standstill Criteria From software version 5 factor the standstill criteria:


MD 36000: $MA_STOP_LIMIT_COARSE,
MD 36010: $MA_ STOP_LIMIT_FINE,
MD 36030: $MA_ STANDSTILL_POS_TOL
can all be reassigned with the factor set in
MD 36012: $MA_ STOP_LIMIT_FACTOR
(e.g. with particularly heavy tools).

Example: N1 $MA_STOP_LIMIT_FACTOR[X]= 1.2


N2 $MA_STOP_LIMIT_FACTOR[Y]= 1.2
N3 $MA_STOP_LIMIT_FACTOR[Z]= 1.2
N4 NEWCONF

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G64, G641

G641

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Predictive Velocity Control, Look Ahead

In continuous-path mode with G64 or G641, the control automatically detects the
velocity control in advance for several NC blocks. This enables acceleration and
deceleration across multiple blocks with almost tangential transitions.
Look Ahead is particularly suitable for the machining of movement sequences
comprising short traverse paths with high path feedrates.

Continuous-path mode with programmable transition rounding, G641

With G641, the control inserts transition elements at non-tangential contour


transitions. With ADIS=... or ADISPOS=..., you can specify the extent to
which the corners are rounded .
Compared to G64 the accuracy decreases in particular with acute-angled motion
transitions. With short distances the value ADIS or ADISPOS is automatically
reduced in the block. At least 36% of the programmed block contour remains.
With extremely short contour blocks the corner rounding can cause the feedrate
to decrease as the rounding requires at least one interpolation cycle.

G642 With software version 4.3 and higher, the rounding can be performed with G642
in dependence on the axial tolerances (from software version 6.2 also on the
contour tolerance – see next page). ADIS and ADISPOS are then not effective.

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G642, G643
Contour precision with G641

ADIS=0.5
ADIS=0.5

Contour precision with G642, G643

MD 33100
$MA_COMPRESS_POS_TOL[X]

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G641 The rounding element is within the ADIS range around the end point. Therefore,
the contour precision is strongly dependent on the transition angle.
G642, G643 The rounding element is within a programmable axial tolerance. Its length
depends on the contour angle. The contour precision is therefore not as strongly
dependent on the contour angle as with G641.

Corner Rounding with Contour Tolerance (from software version 6.2)


With $MC_SMOOTHING_MODE, G642, G643 can be configured such that
Îa maximum axial deviation ($MA_COMPRESS_POS_TOL[.]),
Îthe maximum contour deviation ($SC_SMOOTH_CONTOUR_TOL) or
Îthe rounding clearance (ADIS= ADISPOS= ) can be specified.

MD 20480: SMOOTHING_MODE = x x x x

the following active for G643:


the following applies for G644: the following active for G642:
COMPRESS_POS_TOL active =0 =0 COMPRESS_POS_TOL
ADIS= / ADISPOS= active =1 =1 SMOOTH_CONTOUR_TOL
LOOKAH_FREQUENCY =2 =2 SMOOTH_ORI_TOL
Only limit SOFT / BRISK =3 =3 both new active
=4 ADIS= ADISPOS= are active

no velocity profile for G64x

where: SD 42465 $SC_SMOOTH_CONTOUR_TOL Contour tolerance


SD 42466 $SC_SMOOTH_ORI_TOL Tool orientation tolerance (with
TRAORI)
MD 32440 $MA_LOOKAH_FREQUENCY Limit frequency, above which the
oscillations are suppressed.

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Summary of Continuous-Path Mode

G60 / G9 G64 G641 G642 G643 G644


Jerky movement Look ahead with Look ahead with Look ahead with Look ahead with Smoothing
according decelerating at additional additional additional with max.
G601,G602,G603 corners only smoothing smoothing blockinternal dynamic
at each block (according ADIS= ... according smoothing
change overload factor (ADIS=0 like G64) MD 33100
of axes) ADISPOS= ...

G601 G602 G603


Using Stop limit Using Stop limit Block change at
fine course IPO-Stop
independent from
positioning error
(G9 is non-modal)

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G60 G60 (paired with one of G601, G602 or G603) decelerates at the end of a block
before the next block is executed and is therefore not suitable for milling of
sculptured surfaces.
G64 G64 has limited suitability for sculptured surfaces just like
G641, G642 G641, G642 here the additional block change can lead to a reduced feedrate with
short blocks and very small transition angles.
G643 With G643 (from software version 5.3), no separate rounding block is formed:
the rounding is block-internal (at the end of the previous block).
This means that with short blocks there is no decrease in feedrate for block
change times.
G644 Speed-optimized corner rounding with maximum possible dynamic response
Machine data The reduction in feedrate for curves and corners is dependent on
MD 32300 MAX_AX_ACCEL
MD 32310 MAX_ACCEL_OVL_FACTOR
The OVL_FACTOR does not have a deceleration effect with G643,
from software version 6 you can also remove its effect with G641 and G642 via
MD 20490 IGNORE_OVL_FACTOR_FOR_ADIS.

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Rapid traverse

Both are only active with G60:


Linear interpolation can be activated/deactivated:RTLIOF RTLION
Linear interpolation is constant: MD20730
$MC_G0_LINEAR_MODE=1

G0 with single axes


Settable block change: FINEA[X], COARSEA[X], IPOENDA[X]
in deceleration ramp: IPOBRKA (X, 100)
ADISPOSA (X, 1, 8) additional tolerance

Exact-stop conditions with G0 MD20550 $MC_EXACT_POS_MODE


(one's digit)

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RTLIOF RTLION From software V.6 linear interpolation can be deactivated for G60 G0 with
MD 20730 G0_LINEAR_MODE= true
Jerk then according to BRISKA, SOFTA, DRIVEA setting

G0 with single axes Settable block change time:


FINEA[X], COARSEA[X], IPOENDA[X]
IPOBRKA (X, 100) Motion end within the deceleration ramp
(100% = transition without decelerating)
SW 6.4 ADISPOSA (X, 1, 8) Tolerance window additionally as motion end criterion if
IPOBRKA active
(window 8 mm around programmed endpoint if IPOBRKA % condition is met)
• Tolerance window mode (middle parameter in parentheses)
0: not active 1: with respect to setpoint position 2: with respect to actual
position
• Tolerance window size (right parameter in parentheses)
is entered synchronous to the main run in SD 43610: ADISPOSA_VALUE
Active setting can be queried in $AA_MOTEND[X]: 1= "Fine" 2="Coarse" 3=
"IPO Stop" 4= Deceleration ramp % 5= "Setpoint window" 6= "Actual value
window"

Automatic changeover of exact stop conditions for G0


MD20550 $MC_EXACT_POS_MODE
Software Version 6.1 with G0 (one's digit) or remainder of 1st G code group
(ten's digit)
0= like programmed 1= like G601 2= like G602 3= like G603

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Dynamic Behavior Groups


(Software Version 7.2)

„ Dynamic behavior groups


The introduction of dynamic behavior groups (59th G group)
allows the machine operator or the programmer to select the
dynamic behavior for geometry axes that is suited to the
technological process:

DYNNORM: Standard dynamic behavior


(like up to software version 6.5)
DYNPOS: Positioning mode,
tapping, etc.
DYNROUGH: Roughing
DYNSEMIFIN: Finish cutting
DYNFINISH: Smooth-finishing

By specifying this G code, you can activate a


set of configured dynamic parameters
(without requiring as previously one cycle for writing dynamic
parameters + Newconf)

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Configuring the dynamic response values.


The values for each technology group
are stored in the following machine
data:
Accuracy class 0 ... 4
• Axis MD32300: $MA_ MAX_AX_ACCEL[n,x] DYNNORM (default) 0
MD32310: $MA_ MAX_ACCEL_OVL_FACTOR[n,x] DYNPOS Positioning 1
MD32431: $MA_ MAX_AX_JERK[n,x] DYNROUGH Roughing 2
MD32432: $MA_ PATH_TRANS_JERK_LIM[n,x] DYNSEMIFIN Finish cutting 3
MD32433: $MA_ SOFT_ACCEL_FACTOR[n,x] DYNFINISH Smooth-fin 4
• Path MD20600: $MC_ MAX_PATH_JERK[n]
MD20602: $MC_ CURV_EFFECT_ON_PATH_ACCEL[n]
MD20603: $MC_ CURV_EFFECT_ON_PATH_JERK[n]

Example of programming with index:


$MA_MAX_AX_ACCEL[3, AX1]=1
R1=$MC_ CURV_EFFECT_ON_PATH_ACCEL[4]
Writing the machine data without index sets the same value in all field elements
of the respective machine data.
Reading the machine data without index returns the value of the field [0].

Dynamic behavior groups can be deactivated in MD10712.


NC_USER_CODE_CONF_NAME_TAB[0]="DYNSEMIFIN"
NC_USER_CODE_CONF_NAME_TAB[1]=" "

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Look Ahead Over Multiple Blocks

With 2-block Look Ahead


Reachable speed

With 1-block Look Ahead


Reachable speed

N1 N2 N3 N4 N5 N6 X

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Continuous-Path Mode over multiple blocks

Path axes with travel paths unequal to zero must be programmed in all blocks for
which the continuous-path mode is to apply. Otherwise the last block with path
axes is automatically terminated like with exact step and the continuous-path
mode interrupted. Blocks containing only comments, arithmetic blocks or
subroutine calls do not interrupt the continuous-path control.

Caution: Auxiliary function output before or after the motion interrupt the continuous-path
mode! Alternatively: Output in synchronous actions

SW 5 and higher: MD 22100 AUXFU_QUICK_BLOCK_CHANGE suppresses exact stop with


auxiliary function output before and during the motion.

Maximum number of NC blocks which can be "looked ahead":


MD 29000 $MC_LOOKAH_NUM_CHECKED_BLOCKS
Look Ahead over more than one block was an option up to software version 5.

Maximum number of blocks can be used: MD28060


$MC_MM_IPO_BUFFER_SIZE.
(but max. size in MD18210 $MM_MM_USER_MEM_DYNAMIC )

For HSC machining a value between 70 and 200 is suitable for MD28060
$MC_MM_IPO_BUFFER_SIZE. (Depending on NCU, up to 1000 possible.)
Attention If the value set for MD N28060 $MC_MM_IPO_BUFFER_SIZE exceeds available
memory, with software versions < 3.6 the standard MD is loaded, therefore it is
advisable to create an archive before making the change. With software version
3.7 and higher, an error message is output specifying the number of bytes
exceeding the memory without loading the standard MD. You can determine the
maximum entry by calculating 15 KB for each buffer set.

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Behavior at Contour Corners

Automatic corner
override
G62
(since SW 4.3)

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With non-tangential block transitions, a feedrate reduction is initiated to ensure


the max. permissible axis acceleration is not exceeded while taking MD32300
$MA_MAX_AX_ACCEL[.] and MD32310$MA_ MAX_ACCEL_OVL_FACTOR[.]
into account.
Caution In doing so please observe that the corner jump is only performed
independently of BRISK or SOFT if an axial jerk limitation MD32410
AX_JERK_TIME is activated.
The setting data SD42500 SD_MAX_PATH_ACCEL (with SD42502
IS_SD_MAX_PATH_ACCEL=1) does not influence the corner behavior.
This is particularly important with machines which are set with axis accelerations
>3-4 m/s2 and are only used as additional task for block intensive HSC
machining. The acceleration capability of an axis in combination with the SOFT
path jerk limitation often far exceeds the mechanical and therefore also technical
control stability of an axis in the precision setting range.
ACC [.]=.. A reduction in acceleration programmed via the option "Programmable
acceleration" ACC[.]=.. reduces the corner jump proportionally. Example:
N10 ACC[U1]= 80 (From software V.6)

FENDNORM Automatic corner override OFF (std).


G62 Corner deceleration at inside corners with active tool radius compensation
G621 Corner deceleration at all corners with active tool radius compensation
42520: $SC_CORNER_SLOWDOWN_START Start deceleration before the corner
42522: $SC_CORNER_SLOWDOWN_END End of reduced area
42524: $SC_CORNER_SLOWDOWN_OVR Corner OVR
42526: $SC_CORNER_SLOWDOWN_CRIT Max. reduction angle

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Jerk at transitions with constant curvature

Ruckbetrachtung graphisch

Speed (m/s) Way


(m)

VELOLIM[X]=
VELOLIM[X]=80
80
JERKLIM[X]=
JERKLIM[X]=75
75

Acceleration

Jerk

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The path is the basis for all considerations.


The change in path over time is the velocity
The change of velocity over time is the acceleration
The change of acceleration over time is the jerk

Path Jerk The path jerk limitation activated via MD20600 $MC_MAX_PATH_JERK with
SOFT does not take the max. jerk capability of the axes participating in the path
into account!!!
Axis Jerk The axis jerk limitations specified in MD32410 $MA_AX_JERK_TIME[X] are
always effective, but falsify the control dynamics of the axes and must be set to
the same value in all path axes (including rotary axes) to achieve the greatest
possible path fidelity!!!
Software V.5 $MA_G00_JERK_FACTOR Jerk during positioning (G0)
$MA_G00_ACCEL_FACTOR Acceleration during positioning (G0)
$MA_SOFT_ACCEL_FACTOR Acceleration behavior with SOFT

In critical program sections it may be necessary to limit the velocity or jerk below
the maximum possible values
Î Reduces load on machine / improves machining quality
VELOLIM[X]= 80 Means: The axis slide in X direction must travel at only 80% of the velocity
permissible for the axis.
JERKLIM[X]= 75 Means: The axis slide in X direction must be accelerated/decelerated with only
75% of the jerk permissible for the axis (only effective with SOFT).

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Jerk limitation SOFT

Velocity

Time

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SOFT Path-jerk limitation: controlled, smooth activation/deactivation of the axis


acceleration specified in the machine data
BRISK Its alternative (no limitation) (default)

Advantage of SOFT Reduces the load on the drive elements + increases the contour accuracy
Disadvantage of SOFT Increased duration of machining (if $MA_SOFT_ACCEL_FACTOR[x] =1)

SW 5 and lower Until software V.5, SOFT was primarily used as the basic setting and BRISK was
blocked via a macro. (This procedure is described in the "Macros" section.)

SW 5.3 and higher With software V.5 and higher, the axis accelerations can be increased for SOFT
and G00 motions. This compensates/overcompensates for the loss in machining
speed.

$MA_MAX_AX_JERK[X] Jerk limitation with SOFT


$MA_SOFT_ACCEL_FACTOR[x] Acceleration factor with SOFT
$MA_G00_JERK_FACTOR[x] Jerk factor with G0
$MA_G00_ACCEL_FACTOR Acceleration factor with G0

Axial jerk limitation:


For positioning axes, the jerk limitation can be activated for each axis separately:
SOFTA(U1)
BRISKA (U1)

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Jerkfree Contour Approach and Retract:


KONTT, KONTC (Software 6)

T1 D1 F10000
G1 X0 Y0 Z60 G64
G41 KONTC X70 Y0 Z0
G2 I-70 ;full circle
G40 G1 X0 Y0 Z60

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NORM Tool travels directly to a straight line perpendicular to the contour start point or
away from the end point
KONT The tool travels around the contour point according to the programmed corner
behavior (with G450 in circular form or with G451 angular)
KONTT Tool reaches/exits contour point with constant tangent.
(Generally, continuous tangent is not continuous acceleration)
KONTC Tool reaches/exits contour point with constant curvature. It includes constant
tangent and acceleration is also always constant (jerkfree).

The constant curvature/tangent of KONTC, KONTT


is effective with motions with spatially simultaneous infeed!

Tool center
point path
KONTT

KONTC

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Contour Errors on Curvatures - CPRECON

The following error produces an incorrect contour


Î The contour accuracy is dependent on the feed and servo gain Kv

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Axis Jerk If the transition between two blocks is with constant tangent (velocity constant)
but not with constant curvature (acceleration constant), the machine data
MD32432 $MA_PATH_TRANS_JERK_LIM[x]
(default = 1000 => monitoring disabled) is effective.
Note: The content of the MD is entered in the order of magnitude of MD 20600
$MC_MAX_PATH_JERK.

CPRECON The above mentioned monitoring functions do not provide information about the
path fidelity
CPRECOF during machining. The function "CPRECON" was developed for this purpose:
Should the workpiece contour move during a specified tolerance band, the
function "CPRECON" can minimize the path errors which result from the following
error by reducing the path feed. This function is only effective in curvatures
such as circles, splines and polynomials (also with polynomials generated by the
compressors).
CAD Programs Curvatures which are defined by approximation of straight line blocks and are not
processed with a compressor can also be detected by CPRECON from software
V.4.
Accuracy Criterion for the path behavior is SD $SC_CONTPREC (typical = 0.1), which can
be modified in the program and defines the tolerance range for the function.
$SC_MINFEED To maintain a technology-oriented minimum path feed despite any potentially
required feed reduction by CPRECON (e.g. for laser cutting, wood machining), a
minimum path feed can be maintained with SD $SC_MINFEED (default = 60)
(only valid for CPRECON).
This minimum feed is also only effective with circles, not on corners!

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Feedforward Control FFWON / CYCLE832

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FFWON To reduce the contour errors caused by the following error


FFWOF you can compensate the following error calculated from the servo gain and path
velocity. This allows "virtually following error-free travel" with accordingly
optimized axis data.

Combination If FFWON is used in conjunction with CPRECON, please ensure that MD20470
$MC_CPREC_WITH_FFW =1 is set.
Types of Feedforward Control
Depending on the selection in MD32620 $MA_FFW_MODE the feedforward
control (with identical activation command FFWON) only takes place in position
control loop or additionally in the current control loop (option).
Symmetrization of the feedforward control was improved in software V.5.3 (type 3
and 4).
In general, the parameter settings are made in the machine data
MD32610 $MA_ VELO_FFW_WEIGHT
MD32810 $MA_ EQUIV_SPEEDCTRL_TIME

CYCLE832 (Software V.6.3)The standard cycle "High Speed Settings" CYCLE832 summarizes the
main G code machine data and setting data which are required for roughing,
finish cutting or for HSC machining
(therefore e.g. also CPRECON, FFWON).
This provides a programming friendly presetting option.
Password If a password is set, the modifications to the screen is saved by the operator in
the default settings (in GUDs).

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Feedrate Profile FNORM, FLIN, FCUB

N10 F2000

N20 F3000
N15 F1000
N1 F2000

N5 F3000

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Depending on the curvature conditions of the workpiece to be machined, feedrate


profiles can be used to program constant smooth acceleration profiles. In
particular, oscillations of the machine are reduced by short path lengths.
FNORM Basic setting. The feed value is specified as a function of the travel path of the
block and is then valid as a modal value.
Î Velocity and acceleration jumps !

FLIN Path velocity profile linear:


The feed value is approached linearly via the travel path from the current value at
the block beginning to the block end and is then valid as a modal value.
Î No velocity jumps but acceleration jumps!

FCUB Path velocity profile cubic:


The non-modally programmed F values (relative to the end of the block) are
connected by a spline. The spline starts and ends at a tangent to the previous or
subsequent feed function. If the F address is missing from a block, the last F
value to be programmed is used.
Î No velocity jumps but no acceleration jumps

F=FPO… Polynomial path velocity profile:


The F address defines the feed characteristic via a polynomial from the current
value to the block end. The end value is valid thereafter as a modal value.
Feed Profile Was an option up to software V.5 - activate in MD19320 bit 7

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Exercise: Continuous-path mode

Tool
change
180 position

160

20 20 100 10

10
100

100
40 20
S

100 200 260


40

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Exercise The milled part is to be travelled around clockwise at point S.


Please use the dimensions for the drawing directly, i.e. in the program switch
between reference and incremental so you do not need to convert the dimensions
for the drawing.
Plotter On the plotter you can now clearly see the
Î differences in path and dynamic response with G60, G64 and G641
ADISPOS=20
Î If RTLIOF effective with continuous-path control?
Î Exact stop with output of auxiliary functions dependent on G601 ... G603 ?
Î Test the different feedrates with FNORM, FLIN, FCUB

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