西门子840D数控系统调试培训讲学

西门子840D数控系统调试上电之前的准备一：将NCK主板卸下，检查NCK主板上的电池是否正确安装。

正确安装之后将NCK主板安装到NCU盒上。

二：外围线路的连接➢(1) 每根轴的动力线,编码器反馈线是否正确安装（X411－轴1编码器，X422轴2编码器，动力线插口X轴对应A1口，Z轴对应A2口，2－AXIS）➢(2) 设备总线，直流母线等是否正确可靠连接。

➢(3) 3相电源进线连接是否可靠，U,V,W是否对应。

➢(4) SIMATIC线的连接（IM361接OUT口，NCK接X111口）➢(5) MPI线的连接（两头ON中间OFF)➢(6) MCP面板的节地址开关设置（810D面板的节地址为14，机床控制面板后面的S3开关(1-8) 依次设为OFF OFF ON ON ON ON OFF OFF;840D面板的节地址为6，机床控制面板后面的S3开关从左到右依次设为ON OFF ON OFF ON ON OFF OFF)➢(7) 如果是PCU50，要将显示器后面的硬盘开关拨到ON的位置。

上电之后先安装HMI 软件。

软件拷贝到E盘三：上电➢(1) 上电之前请将数控系统的热控断开，MCP和OPI面板上的24V电源拔掉，以免由于接线错误造成器件烧坏。

➢(2) 上电之后检查供给数控系统的电压是否为380V，MCP和OPI面板的电源是否为直流24V，且正负极性正确。

➢(3) 如果2正确，断电，合上热控，MCP和OPI面板的直流电源插上，上电调试。

四：PLC，NC总清1、NC总清步骤：➢(1)将NC启动开关S3→“1”：➢(2）启动NC，如NC已启动，按复位按钮S1：➢(3)待NC启动成功，七段显示器显示“6”或者“b”，将S3→“0”；这时H1（左列）显示灯“+5V”显示绿灯，NC总清执行完成。

即：将S3置于1位置后，按下复位按钮S1,待七段码管显示“6”或者“b”后，将S3置于0位置。

NC总清后，SRAM内存中的内容被全部清掉，所有机器数据被预置为缺省值。

2、PLC总清步骤：➢(1)将PLC启动开关S4→“2”;=>PS灯会亮。

➢(2)S4→“3”并保持等到PS灯再次亮=>PS灯灭了又再亮。

➢(3)在3秒之内，快速地执行下述操作S4：“2”→“3”→“2”：=>PS灯先闪，后又亮，PS灯亮。

（有时PS灯不亮）➢(4)等PS和PF灯亮了，S4→“0”:=>PS和PF灯灭，而PR灯亮。

即：将S4按钮“2→3→2→3→2→0”；或者打开任意一个PLC程序，通过PLC→Clear/Rest 来实现。

PLC总清后，PLC程序可通过STEP7软件下传至系统。

如PLC总清后屏幕上有报警可作一次NCK复位（热启动）。

五：配轴1、设置密码[Startup] →[Password…]→[Set Password] →[SUNRISE] →[OK]2、R参数扩展✧MD28050:通道R专用参数。

通常扩展为900✧MD 18120 Number of global user variable GUD data 10－>20 ✧MD 22200 Output time of M functions0= Output before motion1 = Output during motion YES✧MD 222300 Output time of H functions0 = Output before motion1 = Output during motion YES✧MD 10350 Number of active digital NCK input bytes 01－>5✧MD 10360 Number of active digital NCK output bytes 01－>5 ✧MD 18120 Number of global user variable GUD data 10－>20 ✧MD 19100 ＝5✧MD 19200 ＝2✧MD 19270 ＝2 2－>64KB✧MD 32084 Effect of VDI signals on handwheel travel －>FFH＝>3FH✧MD 10720 Setting of mode after power ON7－>6 6 = JOG modeMD 10300 Number of analog NCK-InputsMD 10320 Standardization (adaption to measured quantity).e.g.: Analogmodule +/- 10V = 32767Stroke of measuring test key 15mm = 10VMD10320 = 30 (i.e. max stroke = 30mm) MD 10362 Hardware referencee.g.: 01 0F 03 011st Byte = 01 = with 840 in any case2nd Byte = 0F = Modul number (Drive number)3rd Byte = 03 = Plug in location on Module4th Byte = 01 = Low-Byte No. of I/O-Bytes on DMP-Module✧3、垂度斜度补偿（双向螺补）➢MD19300＝04H HASH table size forsubdirectories➢MD18342[0]=10第一轴正向补偿点数➢MD18342[1]=10第一轴负向补偿点数➢MD18342[2]=10第二轴正向补偿点数➢MD18342[3]=10第二轴负向补偿点数与补偿有关的参数双向补偿➢MD20150[20]=2 Initial setting of G groups➢MD 31030 丝杆螺距➢MD 36920 Lead screw pitch➢MD 1320 Spindle pitch➢MD32450 反向间隙➢MD 31060 Numerator load gearbox➢MD36922 Numerator of gearbox encoder/load➢MD1322 Numerator of gear unit encoder / load➢MD32710 ＝1 Enable of sag compensation➢SD41300 ＝1 Compensation table enable单向补偿➢MD38000 Number of intermediate points for interpol. compensation (SRAM) 插补补偿点数➢MD32700 Encoder/spindle error compensation. 插补补偿生效补偿文件的生成：服务→输出→数据→垂度/斜度4、配轴✓MD10000:机床坐标轴名✓MD20000:通道名称✓MD20050:指定几何轴到通道轴✓MD20060:通道中几何轴名✓MD20070:通道中有效的机床轴号✓MD20080:通道中的通道轴名称以七轴双通道设置为例说明（第三主轴为公共轴）➢MD19100 ＄ON_NUM_AXES_ IN_SYSTEM = 3;系统中最大轴数（实际轴数＋1）➢MD19110 ＄ON_NUM_ IPO_AXES = 3 ;联动轴数＝实际轴数➢MD19200 ＄ON_NUM_CHANNELS = 2;系统中通道数➢MD19220 ＄ON_NUM_MODE_GROUPS = 1;系统中方式组数➢MD10000 Machine axis name [ 0 ] = " X1" ;系统中的轴名称➢MD10000 Machine axis name [ 1 ] = "Z2"➢MD10000 Machine axis name [ 2 ] = " X2"➢MD10000 Machine axis name [ 3 ] = " Z2"➢MD10000 Machine axis name [ 4 ] = " A1"➢MD10000 Machine axis name [ 5 ] = " A2"➢MD10000 Machine axis name [ 6 ] = " A3"➢MD10010 Channel valid in mode group[ 0 ] = 1 ;通道指定到方式组➢MD10010 Channel valid in mode group[ 1 ] = 1 CHANDATA (1) ;通道1数据➢MD20050 Assignment of geometry axis to channel axis [ 0 ] = 1 ;通道中几何轴的轴号➢MD20050 Assignment of geometry axis to channel axis [ 1 ] = 0 ➢MD20050 Assignment of geometry axis to channel axis [ 2 ] = 2 ➢MD20060 Geometry axis name in channel [ 0 ] = " X" ;通道中几何轴的名称➢MD20060 Geometry axis name in channel [ 1 ] = " Y"➢MD20060 Geometry axis name in channel [ 2 ] = " Z"➢MD20070 Machine axis number valid in channel[ 0 ] = 1 ;系统分配通道1的轴号➢MD20070 Machine axis number valid in channel[ 1 ] = 2➢MD20070 Machine axis number valid in channel[ 2 ] = 5➢MD20070 Machine axis number valid in channel[ 3 ] = 7➢MD20080 Channel axis name in channel [ 0 ] = " X" ;通道中轴的名称➢MD20080 Channel axis name in channel [ 1 ] = " Z"➢MD20080 Channel axis name in channel [ 2 ] = " A"➢MD20080 Channel axis name in channel [ 3 ] = " SP" CHANDATA (2) ;通道2数据➢MD20050 Assignment of geometry axis to channel axis [ 0 ] = 1 ;通道中几何轴的轴号➢MD20050 Assignment of geometry axis to channel axis [ 1 ] = 0 ➢MD20050 Assignment of geometry axis to channel axis [ 2 ] = 3➢MD20060 Geometry axis name in channel [ 0 ] = " X" ;通道中几何轴的名称➢MD20060 Geometry axis name in channel [ 1 ] = " Y"➢MD20060 Geometry axis name in channel [ 2 ] = " Z"➢MD20070 Machine axis number valid in channel[ 0 ] = 3 ;系统分配通道2的轴号➢MD20070 Machine axis number valid in channel[ 1 ] = 4➢MD20070 Machine axis number valid in channel[ 2 ] = 6➢MD20070 Machine axis number valid in channel[ 3 ] = 7➢MD20080 Channel axis name in channel [ 0 ] = " X" ;通道中轴的名称➢MD20080 Channel axis name in channel [ 1 ] = " Z"➢MD20080 Channel axis name in channel [ 2 ] = " A"➢MD20080 Channel axis name in channel [ 3 ] = " SP"硬件配置：A1、A2、X1、Z1、、X2、Z2、A3驱动配置：位置 1 2 3 4 5 6 7驱动 5 6 1 2 3 4 7PLC 的处理CALL FC 19BAGNo :=B#16#1 ←操作面板控制方式组一ChanNo :=B#16#1 ←操作面板控制通道一SpindleIFNo:=B#16#3 ←主轴信号传送到轴三，即第三轴为主轴 FeedHold :=M1.0 ←当面板上按FeedStop键后此位输出1 SpindleHold:=M1.1 ←当面板上按SpindleStop键后此位输出1 5、斜轴功能➢MD19410=8 (位3=1) 选件位:➢MD 24100: Definition of transformation 1 in channel=1024➢MD 24110: AXIS ASSIGNMENT FOR THE 1ST TRANSFORMATION IN THE[0]=1 斜轴轴号➢MD 24110: AXIS ASSIGNMENT FOR THE 1ST TRANSFORMATION IN THE[1]=2➢MD 24120: ASSIGNMENT OF GEOMETRY AXES TO CHANNEL AXES FOR[0]=1➢MD 24120: ASSIGNMENT OF GEOMETRY AXES TO CHANNEL AXES FOR[1]=0➢MD 24120: ASSIGNMENT OF GEOMETRY AXES TO CHANNEL AXES FOR[2]=2➢MD 24700: ANGLE BETWEEN CARTESIAN AXIS AND REAL (INCLINED)=30 斜轴角度激活/取消斜轴功能:编程: 激活: TRAANG(30) 取消: TRAFOOF参数： MD20140: Transformation data block selected during run up＝16、直径编程➢MD 20100 Geometry axis with transverse axis function =X ➢MD 20150 Initial setting of G groups[28]=27、偏置设置➢MD 20110 Definition of basic control settings after reset =4081/4001➢MD 20112 Definition of basic control settings at NCStart=400➢MD9422 Select PRESET/Basic offset in JOG=400➢SD42440 Traversing from zero offset with incr.programming=08、软限位1、第一软限位PLC 处理SET= DB3*.DBX2.0参数设置➢MD19310=06H➢MD36100 1st software limit switch minus MCS➢MD36110 1st software limit switch plus MCS2、第二软限位PLC 处理DB3*.DBX12.2 第二软限位负DB3*.DBX12.3 第二软限位正参数设置➢MD36120 2st software limit switch minus MCS ➢MD36130 2st software limit switch plus MCS 9、位置开关➢MD10450Assignment of software cams to machine axes ➢MD41500 Trigger points at falling cam 1-8 软限位挡块负值（对应DB10.DBX110.*）➢MD41501 Trigger points at falling cam 1-8软限位挡块正值（对应DB10.DBX114.*）10、编码器回零1、回零相关参数➢MD11300INC and REF in jog mode 0、点动 1、保持➢MD20700NC start disable without reference point 0、不需要回零就可执行NC程序 1、需要回零➢MD30240 Encoder type of actual value sensing 1、增量4、绝对➢MD34000 Axis with reference point cam 0、无撞块 1、有撞块➢MD34010 Approach reference point in minus direction 0、按“＋”回零1、按“－”回零➢MD34210Adjustment status of absolute encoder 设为1 回零后自动变为22、绝对编码器回零➢MD30240 编码器类型 [0] ＝4绝对编码器➢MD34210 [0] =1➢MD34200 Referencing mode [0]=03、增量编码器回零➢MD30240 编码器类型 [0] ＝1增量编码器➢MD34210 [0] =1➢MD34000 [0]=1有撞块➢MD34020=Reference point approach velocity 回参考点速率（找撞块的速度） 20➢MD34030= Maximum distance to reference cam找撞块的安全距离视机床行程而定➢MD34040= Creep velocity 爬行速率 2➢MD34050=Direction reversal to reference cam反向到参考点（找零脉的时机，0下降沿，1上升沿）➢MD34060=maximum distance to reference mark找零脉的安全距离最好10～20mm➢MD34070=Reference point positioning velocity返回参考点定位速度 60➢MD34080=Reference point distance参考点位移 0.02➢MD34090=Reference point offset/absolute offset参考点偏移绝对位移编码器偏移11、主轴功能➢MD20090主主轴的选择➢MD30300旋转轴/主轴＝1➢MD30310旋转轴/主轴的模数转换＝1➢MD30320旋转轴和主轴的系数360度显示＝1➢MD30550公共轴被默认分配到哪个通道＝1➢MD31050负载变速箱分母➢MD31060负载变速箱分子➢MD32000最大轴速度➢MD32010点动模式下的快速移动➢MD32020点动轴速率➢MD32300轴加速度➢MD35000指定主轴到机床轴➢MD35040主轴复位＝1遇到M02/M17/不停止➢MD35100最大轴速度➢MD35110齿轮换档的最大速度➢MD35130齿轮级的最大速度➢MD35140齿轮档的最大速度➢MD35200速度模式下的加速度➢MD35210位置模式下的加速度➢MD36200速率监控门槛➢MD36210最大速度设定值➢SD43220最大速度设定值➢SD43200手动状态的速度/2为1 ➢MD30350 Bit5=1主轴旋转➢M1=3(4) S1=N➢M2=3(4) S2=N12、主轴同步1、参数➢MD19310=06H➢MD19320=400➢MD19330=20➢MD19340=F➢MD19500=12、NC程序头尾架主轴同步SPOS[1]=ACP[0]SPOS[2]=ACP[0]COUPDEF(S2,S1,1,1,”N0”,”DV”) SPCON[1]SPCON[2]SPCON(S2,S1,0) ;0相位角SOPS=ACP(0)M17头尾架主轴准停COUPDEF(S2,S1,1,1,”N0”,”DV”) SPCON[1]SPCON[2]COUPON(S2,S1,0)SPOS=ACP(0)M1713、中心架MD 3700=1 通道程序激活MD37010=* % 力矩值MD37020= 监控窗口MD37040 内部编码器FXS[X]=1 X轴名 1，生效FXST[X]=力矩13、温度补偿常用到的参数●参数设置➢SD 43900：位置无关温度补偿值K0➢SD 43910: 位置相关温度补偿系数tantβ➢SD 43920: 位置相关温度补偿参考位置P0➢MD 32750:→0 不需要进行温度补偿➢MD 32750→1 位置无关温度补偿设定SD 43900➢MD 32750→2 位置相关温度补偿设定SD43910 SD 43920➢MD 32750→3 位置无关和位置相关温度补偿同时生效设定SD 43900 SD43910 SD 43920● PLC 需进行以下处理SET= DB31.DBX60.4= DB31.DBX60.5●位置误差与温度对应关系的建立一点在坐标轴上选取P0作为参考位置，当温度变化时测量出该位置的偏差K0，此值称做位置无关温度补偿值。