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 SIMA TIC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。

(2S4→“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 = 30mmMD 10362 Hardware referencee.g.: 01 0F 03 011st Byte = 01 = with 840 in any case2nd Byte = 0F = Modul number (Drive number3rd 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 for subdirectories 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 groupsMD 31030 丝杆螺距MD 36920 Lead screw pitchMD 1320 Spindle pitchMD32450 反向间隙MD 31060 Numerator load gearboxMD36922 Numerator of gearbox encoder/loadMD1322 Numerator of gear unit encoder / loadMD32710 =1 Enable of sag compensationSD41300 =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 ] = 1CHANDATA (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 ] = 2MD20070 Machine axis number valid in channel[ 2 ] = 5MD20070 Machine axis number valid in channel[ 3 ] = 7MD20080 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 ] = 4MD20070 Machine axis number valid in channel[ 2 ] = 6MD20070 Machine axis number valid in channel[ 3 ] = 7MD20080 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 INTHE[1]=2MD 24120: ASSIGNMENT OF GEOMETRY AXES TO CHANNEL AXESFOR[0]=1MD 24120: ASSIGNMENT OF GEOMETRY AXES TO CHANNEL AXESFOR[1]=0MD 24120: ASSIGNMENT OF GEOMETRY AXES TO CHANNEL AXESFOR[2]=2MD 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 =1 6、直径编程MD 20100 Geometry axis with transverse axis function =XMD 20150 Initial setting of G groups[28]=27、偏置设置MD 20110 Definition of basic control settings after reset=4081/4001MD 20112 Definition of basic control settings at NC Start=400MD9422 Select PRESET/Basic offset in JOG=400SD42440 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=06HMD36100 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 MCS9、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] =1MD34200 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] =1MD34000 [0]=1有撞块MD34020=Reference point approach velocity 回参考点速率(找撞块的速度 20MD34030= 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 2MD34050=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10~20mmMD34070=Reference point positioning velocity返回参考点定位速度 60MD34080=Reference point distance参考点位移 0.02MD34090=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=1MD30310旋转轴/主轴的模数转换=1MD30320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=NM2=3(4 S2=N12、主轴同步1、参数MD19310=06HMD19320=400MD19330=20MD19340=FMD19500=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(0M17头尾架主轴准停COUPDEF(S2,S1,1,1,”N0”,”DV”SPCON[1]SPCON[2]COUPON(S2,S1,0SPOS=ACP(0M1713、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K0SD 43910: 位置相关温度补偿系数tantβSD 43920: 位置相关温度补偿参考位置P0MD 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 43900MD 32750→2 位置相关温度补偿设定SD43910 SD 43920MD 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 43920PLC 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。