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iTNC 530

New Functions with the NC Software 340 49x-04

September 2007

New Functions with the NC Software 340 49x-04 The iTNC 530 Makes Setup Even Easier
The iTNC 530 from HEIDENHAIN has proven itself for years as a versatile contouring control for milling, drilling and boring machines as well as machining centers. Along with HEIDENHAINs plainlanguage conversational programming for the shop-oor, the iTNC 530 is characterized by many useful functions and innovative features. To name just a few, they include: Exact tool guidance with ve-axis machining Simple tilting of the working plane Practice-oriented setup functions Very high contour accuracy for HSC milling Extensive xed cycles Useful programming support through unambiguous function keys, free contour programming and help graphics Upwardly compatible part programs External programming and fast data transfer The success story of the iTNC 530 also includes smarT.NCthe new operating mode from HEIDENHAIN. It represents another successful step toward a userfriendly interface for shop-oor programming. Well-structured input forms, straightforward graphic support, and comprehensive help texts combine with the easy-to-use pattern generator to form a compelling programming environment.
New functions for the iTNC 530 Of course there is always potential for new development, improvement and simplication. The NC software 340 49x-04 for the iTNC 530 includes a series of new functions for machine manufacturers and users. These functions make it even easier to work with the control, and they also make operation of the machine more safe. The most important are: Touch probe cycles for kinematic measurement New function in dynamic collision monitoring (DCM) Handwheel-superimposed traverse in the active tool-axis direction (virtual axis)
Error xes, expansion of functions and options As of NC software 340 49x-02, error xes were separated from software improvements. An update of NC software will predominantly contain only error xes. New functions certainly offer added value in user-friendliness and operational reliability. Of course you also have the opportunity to purchase these new functions after a software update: These improvements in function will be offered as feature upgrades, and are enabled via the Feature Content Level option. If, for example, a control is updated from 340 49x-02 to 340 49x-04, the functions identied with FCL 04 in the following tables are only available if the Feature Content Level is set from 02 to 04. Of course, the current feature content level also includes the upgrade functions of the previous NC software levels. All of the options included in the respective NC software can be purchased, no matter which feature content level you have.
Inspecting and Optimizing Machine Accuracy Calibrating Rotary Axes with KinematicsOpt (Option)
Accuracy requirements are becoming increasingly stringent, particularly in the area of 5-axis machining. Complex parts are required to manufactured with precision and reproducible accuracy even over long periods The new TNC function KinematicsOpt is an important component to help you meet these high requirements: With a HEIDENHAIN touch probe inserted, a 3-D-touch probe cycle measures your machine's rotary axes fully automatically. The measurement process is the same regardless of whether the axis is a rotary table, a tilting table or a swivel head. To measure the rotary axes, a calibration ball is xed at any position on the machine table and probed with the HEIDENHAIN touch probe. But rst you dene the resolution of the measurement and dene for each rotary axis the area that you want to measure. From the measured values, the TNC calculates the statistical tilting accuracy. The software minimizes the spatial error arising from the tilting movements and, at the end of the measurement process, automatically saves the machine geometry in the respective machine constants of the kinematic table. Of course, a comprehensive log le is also saved with the actual measured values and the measured and optimized dispersion (measure for the statistical tilting accuracy) as well as the actual compensation values.

Machining Safely Option for Integrated Dynamic Collision Monitoring (DCM)
Since its inception in the fall of 2005, Dynamic Collision Monitoring (DCM) has proven itself countless times. About 1100 machines, or approx. 12 % of all iTNCs shipped since this time have been equipped with this option. To improve the user's ability to observe the programmed movements within the machine's working space, the screen layout can now be arranged to show the machine kinematics as entered by the machine manufacturer with all dened obstacles at the right next to the program. If desired, the machine kinematics can be shown full screen.
Now the machine manufacturers, too, can develop kinematic tables more quickly. With KinematicsDesign, the user now has a PC tool that gives him graphic support when dening kinematic tables. KinematicsDesign makes it possible to simulate critical axis positions during the conception phase and avoid them by setting limit switches at the right positions on the machine.
Machining Flexibly Option for Global Program Settings (GS)
The Global Program Settings function (GS) was already introduced in the NC software 340 49x-03. In the program run modes, this feature enables you to dene a wide variety of coordinate transformations and settings that have global effect and are superimposed on the selected part program. Besides datum shifts, rotations and mirror images, now you can also switch axes, lock them, or set handwheel superimpositionsall functions that you can always use especially effectively when you have to modify huge, externally written part programs. Now you can also use the global program settings (GS) to activate the virtual axis (VT) function that is so important for largescale mold making. With Tool Center Point Management active (TCPM), you can use it to move the tool manually in the currently active tool axis direction, for example in order to run the entire part program with a constant oversize. When using the HR 420 handwheel, you can select the virtual axis (VT) directly over the handwheel soft keys. At the same time, in the handwheel's display you can see the value of the distance moved in the virtual axis direction. For handwheels without integrated position display, the virtual axis can be assigned to a machine key dened by the machine manufacturer. The TNC shows the distance moved in a separate position display and also in the global program settings form. The value remains stored until you change the tool or switch the function off.

New Programming Functions General
3-D basic rotation, machine-specic (upgrade function) With this function, the TNC can correct any workpiece misalignment in three dimensions (3-D set-up compensation). To use this function, your machine must be equipped with at least two rotary axes and your machine manufacturer must adapt the function to your machine. In one of the upcoming software releases, this function will be integrated in the preset table to make it machine-independent. Option for Adaptive Feed Control (AFC) The adaptive feed control feature (AFC) also offers new and improved functions. In the additional status display, a dynamic line chart shows the relationship of the spindle power consumption and the feed rate controlled by the TNC. During the learning phase, the TNC shows the currently saved reference power in a pop-up window. If required, you can use a soft key to reset the reference power measured up to that point and restart the learning process. In addition, your machine manufacturer can dene any desired control parameter as input value for adaptive control instead of the current spindle power consumption. This makes it easier to realize special applications that require changing the feed rate when some value dened by your machine manufacturer changes.
File management The le management was completely revised and adapted to the le management in smarT.NC. The following functions are available: The le management can now be operated completely by mouse and soft keys Sorting by name, type, size, date of change and status Favorites management for very simple directory selection Fast le selection through immediate, automatic highlight positioning during le-name entry Congurable display of le information Congurable date format
DXF converter (option) Several improvements were made in the operation of the DXF converter. Now the TNC saves the zoom setting and the reference point of the most recently selected DXF le. The next time you select this le you can use these settings to start work immediately. The use of circle centers as machining positions was also simplied: the TNC now saves the center directly with a simple mouse click. The use of positions on quadrant transitions remains available as an option. The new info box is particularly informative. It shows all the les of each selected element. You can see the X/Y coordinates for machining positions, the start and end points of contour elements, and also the center and direction of arc rotation. Creating service les For better support when problems or questions arise, a new feature collects all important les on the problem at hand and provides them in le. le includes the active part program, the tool table TOOL.T, and if required, the active datum table and important system les. You can then send le by e-mail over the data interface to your machine manufacturer or your HEIDENHAIN service agency. Additional conversational languages (option) Turkish and Romanian are now available as options.

New Programming Functions smarT.NC
Datum shift Axis-specic datum shifts can now be dened directly in a form. Until now, datum shifts were possible only through datum tables. In addition, the datum can easily be reset by soft key without having to program the shift value 0 in each axis. Machining rectangular and circular studs The new Units 256 and 257 make it possible to easily machine rectangular and circular slots. In their denition and function, these new units are similar to the already available milling units 251 to 254. The constant cut distribution is particularly helpful when the difference between the dimensions of the blank and the nished part is greater than the tool radius. Of course, the distribution of cuts can be modied by an overlap factor. Program end unit With the program end unit you can make the following settings at the end of a smarT.NC program: Dening M functions, e.g. M5, M30 Optional approach to a safety position in the tool axis, as selected in the tool or machine coordinate system Optional approach to a safety position in the working plane, as selected in the tool or machine coordinate system Inline pattern denitions Now machining patterns can also be dened directly in the overview form of a machining unit. Up to now it was necessary to call the pattern generator and dene the respective pattern there. The following machining patterns are available: Points (up to 9 individual positions) Row Frame Surface Circular arc Full circle
Loading values from previous units If you want to dene a unit that you have already dened in the same smarT.NC program, you can use the values dened in the earlier unit as default values for the new one. Particularly in the milling units, this makes it very easy to realize roughing and nishing denitions with different tools and/or oversizes. Setting the number of probing points In touch probe units 412, 413, 421 and 422 you can now choose whether you want to measure circles with 4 (default) or 3 probe points. Machining strategy for clearing In Unit 22 you can now choose how the TNC will move the tool during clearing: Machining the complete contour: The TNC moves at constant height to the areas to be cleared without removing the tool from the nished part contour. This strategy works well when the distance between the areas to be cleared is small and the ne roughing tool is large enough to machine the remaining material in one step. Machining individual areas separately: After ne roughing each area to be cleared, the TNC moves the tool at rapid traverse to the safety clearance. This strategy is helpful when there is a large distance between the areas. Fast retraction during tapping In the tapping unit 209, you can now you can enter a factor by which the TNC increases the traversing speed when retracting the tool. This reduces your machining time.

New Programming Functions Conversational Programming
File functions With the FUNCTION FILE feature you can copy, move and delete les from within the part program. This enables you, for example, to copy and start part programs that you have saved on an external drive. Pattern denitions With the point pattern generator feature familiar to users of smarT.NC, you can use the PATTERN DEF function to dene machining patterns. The following machining patterns are available: Points (up to 9 individual positions) Row Frame Surface Circular arc Full circle The machining positions dened in this way can be called with the CYCL CALL PATTERN function.
Globally effective cycle parameters With the new GLOBAL DEF cycles you can dene a wide variety of cycle parameters at the beginning of the program with global affect. The GLOBAL DEF cycles are classied in the following groups: General cycle parameters such as safety clearance or retraction feed rate Drilling-specic cycle parameters, such as dwell times Milling-specic cycle parameters, such as the plunging behavior Touch-probe-specic cycle parameters, such as clearance height If you have entered GLOBAL DEF cycles in the program header, when dening a cycle you can use soft keys to apply the values dened there. The TNC then enters the word PREDEF (for predened) in the cycle denition. Any change in the GLOBAL DEF cycle then affects all cycles that refer to the PREDEF entry in the respective GLOBAL DEF cycle.
Machining rectangular and circular studs The new Cycles 256 and 257 make it possible to easily machine rectangular and circular slots. In their denition and function, these new cycles are similar to the already available milling cycles 251 to 254. The constant cut distribution is particularly helpful when the difference between the dimensions of the blank and the nished part is greater than the tool radius. Of course, the distribution of cuts can be modied by an overlap factor.
Overview All Options in the NC Software 340 49x-04

Option number

As of NC software 340 49x01


Additional axis
354 540-904-905-867-868-291-292-293-591-01
Additional control loops 1 to 8
Software option 1 (for MC 420)
Machining with a rotary table Programming of cylindrical contours as if in two axes Feed rate in distance per minute Coordinate transformation Tilting the working plane, PLANE function Interpolation Circle in 3 axes with tilted working plane 3-D machining Motion control with minimum jerk 3-D tool compensation through surface normal vectors Tool Center Point Management (TCPM): Using the electronic handwheel to change the angle of the swivel head during program run without affecting the position of the tool point Keeping the tool normal to the contour Tool radius compensation normal to the tool direction Manual traverse in the active tool-axis system Interpolation Line in 5 axes (subject to export permit) Spline: execution of splines (3rd degree polynomials) Block processing time 0.5 ms Communication with external PC applications over COM components Dynamic Collision Monitoring DCM (only with MC 422 B, MC 422 C) Additional conversational language: Slovene Slovak Latvian Norwegian Korean1) Estonian Turkish Romanian Load and convert DXF contours Global program settings Adaptive feed control Python application on the iTNC
Software option 2 (for MC 420)

367 590-01


526 451-01

DCM Collision Additional language

526 452-01

530 184-184-184-184-184-184-184-184-450-057-648-650-916-969-01
DXF Converter Global PGM Settings
AFC Adaptive Feed Control 03 Python OEM Process KinematicsOpt Feature content level 02
Touch probe cycles for automatic measurement of rotary axes Level of features
Only with at least 256 MB RAM Only with at least 512 MB RAM
Overview New Functions with NC Software 340 49x

As of NC software

Operating mode


General information 02 02
40 DCM: Dynamic Collision Monitoring (only with MC 422 B) USB support for peripheral memory devices (memory sticks, hard disks, CD-ROMs) DHCP (Dynamic Host Conguration Protocol) and DNS (Domain Name System) for network settings Freely denable tables visible also in form view All soft keys revised 41 Slovene language 340 49x-02 Czech user interface now with native characters Congurable update procedure for future software updates (e.g. automatic update over USB storage devices) Additional HR 420 functions: Selection of the active override possible on the HR 420 Freely denable soft-key menu for machine functions Smaller pop-up window when HR 420 is active, to improve legibility of axis positions on screen Look-ahead can be congured via machine parameters Calculation of dynamic load for tilting axes Inclined tool machining with noncontrolled axes 44 Global program settings (GS) make it possible to superimpose various coordinate transformations and settings in the Program Run operating modes 340 49x-AFC: Adaptive feed control adjusts the contouring feed rate to the spindle power 03 TNCguide: The integrated help system. User information available directly on the iTNC 530 (only with at least 256 MB RAM) 41 Conversational languages in Slovak, Norwegian, Estonian, Latvian, Korean (Asian languages require at least 256 MB RAM)


General information
Option Expanded and completely revised le management Automatic and manual generation of service les for faster error diagnostics Tool-change macro for Test Run Graphic display of machine kinematics in the Program Run modes of operation 3-D basic rotation light: aligning workpieces in three dimensions 40 Improvements in Dynamic Collision Monitoring (DCM): Handwheel superimposition possible with active DCM in stopped condition Automatic cancelation of collision protection for touch probe measurement 41 Turkish and Romanian languages 44 Improvements in Global Program Setting (GS): Procedure with handwheel superimposition in the active tool-axis system (virtual axis) with active TCPM 45 Improvements to Adaptive Feed Control (AFC): Expanded status display Resetting the reference power in the learning mode Use of any value as control parameter over PLC 46 Python OEM process: Simpler integration of OEM applications in the iTNC 48 KinematicsOpt: Touch probe cycles for automatic measurement of rotary axes

340 49x-04

smarT.NC 340 49x-02
42 Direct loading of contours from DXF data and saving as smarT.NC contouring programs Cycles for coordinate transformation introduced PLANE function introduced Contour pocket: Separate depth can be assigned for each subcontour Mid-program startup with graphical support 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) Tool data can be edited in a pop-up window during tool selection Axis keys now also position the cursor in the forms. The I key (incremental/absolute switchover) and P key (polar/rectangular switchover) now also function for contour programming. CUT/COPY/PASTE of one or more units Automatic entry of workpiece blank into contour program Incremental entry of machining positions in forms for machining units Tooltips displayed when using the mouse Navigation by axis key through the forms


42 DXF data processing: Separation of laterally joined contour elements Generate point les (.HP les) directly from the DXF converter 03 49x-03 340 49x-04 smarT.NC editor in the Programming and Editing operating mode Expanded and completely revised le management Tool table shown as a llable form Machining a contour pocket on a point pattern Individually denable positioning heights in point patterns Touch probe units 408 and 409 for setting datums in the centerline of a slot or ridge Setting of probing parameters in a separate unit Automatic feed rate reduction in contour pockets during full tool engagement Climb milling/up-cut milling for helical nish milling Retraction speed for tapping with chip breaking Measured workpiece misalignment can now also be compensated by rotating a C axis Zoom function in the pattern generator Entry of stopping angle or angular step in a pitch circle denition Unit 141, datum shift Unit 256, machining rectangular studs Unit 257 machining circular studs , Unit 799, program end unit Unit 22, ne roughing: Selectable machining strategy Unit 209, tapping: Denable rotational speed of retraction Touch probe units 412, 413, 421 and 422: Circles can be measured at either 3 or 4 points Inline pattern denition with PATTERN DEF Taking data from a similar, previously dene unit 42 DXF data processing: Handling improvements Info box displays data on the selected element 48 Units 450 and 451, KinematicsOpt: touch probe cycles for automatic measurement of rotary axes

Conversational programming 340 49x-02
42 Reading of contours from DXF data and saving them as conversational programs Cycle for global setting of touch-probe parameters Point lter for smoothing externally created NC programs 3-D line graphics for verication of programs created ofine Manual traverse in the active tool-axis system Entry of cutting speed as alternative to the spindle shaft speed Simplication when working with the preset table, incremental correction of preset values possible, correction of the active preset possible Contour pockets can now contain signicantly more contour elements Consideration of an active basic rotation in manual probe cycles Measuring log for probing cycles can now also be displayed on the screen during program interruption FK transformation selectable as structured plain-language or linearized plain-language 42 DXF data processing: Separation of laterally joined contour elements Generate point les (.HP les) directly from the DXF converter 49x-Touch probe cycles 408 and 409 for setting datums in the centerline of a slot or ridge Probing cycle for three-dimensional measurements. Results of measurement shown as desired in the coordinate system of the tool or the machine Automatic feed rate reduction in contour pockets during full tool engagement Climb milling/up-cut milling for helical nish milling Retraction speed for tapping with chip breaking Workpiece misalignment can now also be compensated by rotating a C axis
Conversational programming
Option Cycle 256, machining rectangular studs Cycle 257 machining circular studs , Cycle 22, ne roughing: selectable machining strategy Cycle 209, tapping: denable rotational speed of retraction Touch probe cycles 412, 413, 421 and 422: circles can be measured at either 3 or 4 points Special functions of smarT.NC available for conversational programming: Dening machining patterns with PATTERN DEF Dening cycle parameters globally with GLOBAL DEF File management (copying, moving, deleting) from within the NC program 42 DXF data processing: Handling improvements Info box displays data on the selected element 48 KinematicsOpt: touch probe cycles for automatic measurement of rotary axes PLANE function also in possible in ISO Virtual keyboard can be displayed with new version of the programming station PLC program provided for optional installation (can be used to move axes) Access to the PLC with the keyword PLC All options and FCL functions are available Support for Windows Vista iTNC programming station available with network license
340 49x-04 ISO 340 494-494-04 Programming station
CS CZ DR. JOHANNES HEIDENHAIN GmbH Dr.-Johannes-Heidenhain-Strae Traunreut, Germany { +49 (8669) 31-0 | +49 (8669) 5061 E-Mail: ES DE HEIDENHAIN Technisches Bro Nord 12681 Berlin, Deutschland { (030) 54705-240 E-Mail: HEIDENHAIN Technisches Bro Mitte 08468 Heinsdorfergrund, Deutschland { (03765) 69544 E-Mail: HEIDENHAIN Technisches Bro West 44379 Dortmund, Deutschland { (0231) 618083-0 E-Mail: HEIDENHAINTechnisches Bro Sdwest 70771 Leinfelden-Echterdingen, Deutschland { (0711) 993395-0 E-Mail: HEIDENHAIN Technisches Bro Sdost 83301 Traunreut, Deutschland { (08669) 31-1345 E-Mail: AR NAKASE SRL. B1653AOX Villa Ballester, Argentina { +54 (11) 47684242 E-Mail: HEIDENHAIN Techn. Bro sterreich 83301 Traunreut, Germany { +49 (8669) 31-1337 E-Mail: FCR Motion Technology Pty. Ltd Laverton North 3026, Australia { +61 (3) 93626800 E-Mail: HEIDENHAIN NV/SA 1760 Roosdaal, Belgium { +32 (54) 343158 E-Mail: ESD Bulgaria Ltd. Soa 1172, Bulgaria { +359 (2) 9632949 E-Mail: DIADUR Indstria e Comrcio Ltda. 04763-070 So Paulo SP Brazil , { +55 (11) 5696-6777 E-Mail: Belarus RU HEIDENHAIN CORPORATION Mississauga, Ontario L5T 2N2, Canada { +1 (905) 670-8900 E-Mail: HEIDENHAIN (SCHWEIZ) AG 8603 Schwerzenbach, Switzerland { +41 (44) 8062727 E-Mail: DR. JOHANNES HEIDENHAIN (CHINA) Co., Ltd. Beijing 101312, China { +86 10-80420000 E-Mail: ID

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Vollstndige Adressen siehe For complete addresses see
636 226-5/2008 H Printed in Germany Subject to change without notice
Zum Abheften hier falzen! / Fold here for ling!


Klartext The TNC-Newsletter Edition 41 10/2003


New iTNC 530 Functions
New TS 640 3-D Touch Probe

New HR 420 Handwheel

Seite 2


Dear Klartext Reader! HEIDENHAIN is strongly emphasizing the iTNC 530 contouring control at this years EMO in Milan. A large number of new user functions will be presented. Of special note is the PLANE function, which makes it very easy to define a tilted working plane. New and powerful machining cycles, as well as a new datum management system using preset tables, improve the application possibilities and the user friendliness of the wellestablished TNC contouring controls. We would also like to welcome a new accessory: There is a new version of the HEIDENHAIN handwheel, the HR 420. The incremental motion of this handwheel ensures that manual, delicate positioning can now be carried out even more precisely. In addition, the handwheel features a display on which the handwheel status and several soft keys for certain control functions are shown. This makes direct alignment of the workpiece much more reliable and easy, and reduces your setup times. Things have also changed with the 3-D touch probes. HEIDENHAIN will present the TS 640 with infrared transmission at the EMO. It features an integrated blasting unit, with which coolant or clean air is blasted onto the probing point. This clears any coarse contaminants from the workpiece before the actual probing operation, removing a source of significant error in the measurement result. We hope you enjoy this issue!

page 3

New iTNC 530 User Functions Preset table PLANE function New milling cycles Programming support Other functions Tool-Oriented Machining 11
New Infrared TS 640 3-D Touch Probe
New Diagnostic Functions of the iTNC 530
HR 420: New Handwheel with Display
Programming any Shape of Pocket


Publisher DR. JOHANNES HEIDENHAIN GmbH Postfach 1260 D-83292 Traunreut Tel: (69) 31- 0 HEIDENHAIN im Internet: Editor Frank Muthmann Fax: (69) 31-e-mail: Klartext on the Internet Layout Expert Communication GmbH Inselkammerstrae Unterhaching/Mnchen Tel: (0 89) e-mail:

Seite 4

New iTNC 530 User Functions: Overview
During the course of 2003, numerous new, practice-oriented user functions were integrated in the iTNC 530 software. We also released functions that better support the machine operator during programming and test runs. Below is a summary of the most important improvements. More detailed information about each function is found in the individual articles.
New functions Preset table (page 5) New powerful table for managing any number of datums, especially in combination with the PLANE function. PLANE function (page 6) A function for easily defining tilted working planes. Animations simplify the process for selecting the correct plane definition. The function expands on Cycle 19 MACHINING PLANE, which was already included on the TNC 415. New milling cycles (page 8) Cycle 232 Plan Milling New powerful and flexible cycle for plan milling with allowances and infeeds. Cycles 251 to 254 New cycles for milling rectangular and circular pockets, as well as slots and rounded slots.
Programming support (page 9) Test graphics You can now set the speed of the test run. Error messages All current error messages can be displayed with the ERR key. Displaying messages on the screen Use the Q-parameter function FN16: FPRINT to display messages in any format on the iTNC display, in order to give the operator specific instructions, for example. Convert FK to H The conversion of FK programs to conversational dialog programs was reintroduced. Other functions (page10) Reentering a program The program reentry function (midprogram startup) has been available since
the TNC 415. With this function you can start at any block in a program. Generate reverse contour Function for machining a programmed contour in the reverse direction. Feed-rate programming Rather than entering a feed rate in a traversing block, you can also enter a time over which the programmed block is to be traversed. New probing functions (page13) Probing a center axis New probing function in the Manual operating mode for capturing the center axis of two probe points.


The introduction of the PLANE function in the spring of 2003 greatly expanded the possibilities for defining a tilted working plane, and at the same time simplified them. Using Cycle 19, only axis and space angles were permitted as plane definitions. The PLANE function gives you seven different methods for defining tilted working planes, depending on the information given in the workpiece drawings. In order to keep the procedures of these complex functions as simple as possible, the iTNCs support graphics have learned how to walk. A separate animation is available for each possible plane definition. You can even view them before selecting the function. During the definition, comprehensive support graphics long familiar from the cycle definitions show you the entries that the iTNC expects. A special advantage of the PLANE function is that you can define the positioning behavior, so that there are no unpleasant surprises when the program is run. The settings available for defining the positioning behavior are identical for all PLANE functions, making everything that much easier.




page 7
PLANE RESET The PLANE RESET function resets an active plane-tilting function, regardless of how you defined the tilted plane. The double resetting required by Cycle 19 is not necessary here. You can also define the positioning behavior for the resetting motions. Specifying the positioning behavior MOVE/TURN/STAY positioning (input mandatory) The MOVE function specifies that the iTNC is to automatically position the rotary axes while executing a PLANE function. The position of the tool relative to the workpiece is maintained, meaning that the iTNC carries out a compensating motion during positioning. You freely define the positioning feed rate and the distance from the center of rotation to the tool tip directly in the PLANE function. The TURN function, developed especially for machines with rotary and/or tilting tables, also positions the rotary axes automatically, but does not change the position of the tool. This means that the iTNC does not carry out a compensating motion during positioning. If you do not want any automatic positioning to occur, use the STAY function. In this case the iTNC only activates the tilted working plane mathematically, so you must use a separate positioning block to position the rotary axes to the angles calculated by the iTNC. The iTNC stores the calculated angle settings in parameters Q120 to Q122 when performing a PLANE function, just as with Cycle 19. Selecting a solution SEQ (input optional) All plane definitions can be realized with two different settings of the machine axes. The SEQ function lets you specify yourself which of the two possibilities you would like to use.

Selecting a solution SEQ PLANE POINTS
Rotate table or coordinate system: TABLE ROT/COORD ROT (input optional) If a new machining plane, achievable by rotating just one rotary axis, becomes necessary, you can specify whether the iTNC should actually rotate the axis, or if it should only rotate the coordinate system internally. This function is useful when a very large workpiece is on the rotary table for machining, and the danger of collision makes it impossible to rotate the table.




Seite 8

New Machining Cycles

Cycles 251 to 254 Together with the PLANE function, the four milling cycles Rectangular Pocket (Cycle 251), Circular Pocket (Cycle 252), Slot (Cycle 253) and Circular Slot (Cycle 254) were introduced in the spring of 2003. An important goal was for the programming of these cycles to be as similar to each other as possible. After having used the cycles in machine shops for several months, machine tool operators gave us ideas for the rough-out strategies, which we have now incorporated into the cycles. Of special importance is that the cycles have been programmed to reduce non-productive motions as much as possible. Many unnecessary retraction and repositioning motions between the roughing and finishing operations were removed, which of course has a positive effect on the machining time. Due to the rough-out strategy for slot cycles 253 and 254, until now the slot width was not allowed to be greater than three times the tool diameter. Now you can use tools with diameters as small as you like to create slots as large as you like. The cycles continually expand the slot from the inside out.
Cycle 232 Face Milling Cycle 232 is used to face mill a level surface in multiple infeeds while taking the finishing allowance into account. Three machining strategies are available: Strategy Q389 = 0 Meander machining, stepover outside the surface being machined Strategy Q389 = 1 Meander machining, stepover within the surface being machined Strategy Q389 = 2 Line-by-line machining, retraction and stepover at the positioning feed rate In order to machine the surface as evenly as possible, the TNC calculates both the plunging depth and the stepover so that each machining pass cuts in a uniform manner. The TNC even takes face-milling cutters whose tooth radius is entered in the tool table into account when calculating the stepover. In order to optimize the machining time, returning to the entered starting point is omitted. At the end of the last milling pass, the TNC immediately plunges to the next depth and machines in reverse to the entered starting point.

Use the algebraic sign of the two side lengths to specify beginning from the entered starting point in the working plane in which direction the first milling pass takes place. This increases your flexibility, since the starting point is not at the bottom left of every workpiece.

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New Functions for Programming Support
Displaying all current error messages You can use the ERR key (only on the TE 530 keyboard unit) to open a pop-up window in which the iTNC lists all current error messages. The displayed errors can come from the NC or from the machine tool builder. The HELP key is especially useful, since parallel to the list of error messages you can display the error description for each message.
Conversion of FK (Free Contour programming) to conversational dialog
Setting the speed of the test-run graphics The increased processing power of the iTNC 530 naturally led to the graphic simulation running at a higher speed. However, for TNC beginners this supposedly pleasing situation actually led to uncertainties, since due to the high speed of the simulation the tool path was no longer clearly visible. Now you can use soft keys to set the speed of the graphic simulation to any rate that you want. In effect, the soft keys work like the feed-rate potentiometer when machining a program.
Displaying messages on the screen

Error message

Displaying messages on the screen Until now you have been able to use the Q-parameter function FN16: FPRINT to create formatted text files from within the NC program, such as for logging measurement results. Now, if you define the keyword SCREEN: instead of the file name, the TNC outputs the Q-parameter contents or the texts stored in a format file directly on the iTNCs screen, for giving the operator specific instructions, for example. The message remains on the screen until the operator acknowledges it. However, the program will continue to be machined by the iTNC, unless a STOP block is programmed directly after the FN16 block.
When the iTNC 530 was introduced, the Convert FK program to conversational dialog function familiar from older controls was removed from the software. As it turns out, however, this function is intensely used by many TNC 426/TNC 430 operators, who requested that this function be reinstated. Since we always pay attention to what our users want, this function was reintroduced with the release of software 340 422-06, and was modified a little to improve the clarity: The conversational dialog program generated by the iTNC contains as a comment the block number that the FK block had in the FK program, making it easier to align the sequences of the source and target files.

Seite 10

Other NC Functions
Reentering the program The program reentry function (midprogram startup) has been available since the TNC 415. With this function you can start at any block in a program. A new feature is that with the iTNC, the point of interruption is remembered if an emergency stop or sudden power interruption occurs. When you restart the machine, a message stating that the NC program was interrupted is displayed immediately. If you activate the reentry function in the Program Run, Full Sequence mode, the iTNC displays the point of interruption, which you can select via soft key as the reentry point. Generate reverse contour This new iTNC function is used to reverse the machining direction of an existing contour, which preferably was created with a CAD/CAM system. This function, well-known from electrical discharge machines, lets you machine a contour forwards and backwards in multiple infeeds, in order to avoid any unnecessary non-productive times caused by retracting motions. The contour itself may contain all common iTNC path-function elements, including FK blocks. The iTNC shifts RND and CHF blocks so that they are at the correct position in the reverse program. Feed-rate programming Rather than entering a feed rate in a traversing block, you can also enter a time in seconds over which the programmed block is to be traversed. The function is activated with the FT soft key in the feed rate dialog box, and is effective blockwise.

Reentering the program

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Tool-Oriented Machining

With tool-oriented machining you can machine multiple identical parts with just one machining program, using the tooloriented method. The advantage comes from machining each workpiece entered in the program before proceeding with the next machining step. This means that all workpieces are machined with the required tool, before the next tool change. This decreases the number of tool changes to a necessary minimum, greatly reducing the machining time. Tool-oriented machining was originally intended for pallet management in order to machine multiple workpieces on one pallet in as brief a time as possible. However, it is obvious that this machining method can also be used for other applications. For example, this means that you can save a great deal of time when machining identical workpieces on multiple fixtures or vices on the machine table, without needing a special structure in the NC program. The advantages of tool-oriented machining are not limited to just the savings in time and therefore production costs. Another significant advantage is the support from clear and simple entry forms. Here you enter in a pallet file at which location each machining step is to take place. Use the soft keys at any time within the pallet file to toggle between a simplified over-

view (with all the workpieces listed) and the detail view for each workpiece. This way you can easily and efficiently program your workpieces using the tool-oriented method. The machine tool builder must prepare the iTNC for tool-oriented machining. Once this has been done, you simply need a conventional machining program and a pallet file.
Entry form: simplified view for a workpiece
The reality of the workshop demands great flexibility when working with NC machines. Often jobs must be interrupted to carry out more urgent orders. Tooloriented machining handles this very easily. While executing the pallet file, the iTNC stores a code (valid for two weeks) used to reenter the program at the point of interruption. A field-tested function is the assignment of blank spaces in the pallet file. This way you can take into account tool breakage or the machining of the remaining workpieces of a job, easily and without much effort. Of course other special features, such as automatic program start at a specified time, are available in connection with the pallet table.
Entry form: detailed view for a workpiece

Automatic program start

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New Infrared TS 640 3-D Touch Probe For Aligning and Measuring Workpieces
The 3-D touch trigger probes from HEIDENHAIN are used to carry out repeated setup procedures easily, exactly and quickly. We are proud to present a new addition to this product group the TS 640. In combination with the introduction of the new version of the iTNC 530, the TS 632 is being discontinued. The old EA 632 receiver unit will be replaced by the new SE 640 transceiver unit. The most interesting new feature on the TS 640 is the integrated blasting unit consisting of three nozzles at the bottom of the touch probe. The nozzles use a blast of air or coolant to remove coarse contaminants from the area being probed. This saves time and enables unattended, automated measuring cycles. We were also able to improve the transmission of the infrared signal. Now the infrared LEDs
and receiver modules for signal transmission are evenly arranged around the circumference of the TS 640. This ensures transmission in all directions of the working plane as well as a reliable signal reception without requiring an oriented spindle stop. In addition, the signal can also be transmitted by reflection, which lets you take advantage of the transceivers generous mounting tolerances, and most importantly, permits the use of swivel heads.
The TS 640s area of transmission was also greatly enlarged. It was increased from 3 m to 7 m, making the touch probe suitable for use on larger machines without requiring additional receiver units within the machine envelope. The TS 640 is switched on and off by the new SE 640, meaning that no mechanical switch is necessary. The IP 67 protection class (dust-proof and temporary submersion in liquids) also increases the system reliability.

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New Touch Probe Functions
The SE 640 transceiver unit has an impact-resistant synthetic window (immune to high-pressure emulsion), which also significantly increases the system reliability. The status display immediately shows the user whether the transmission path is in order and whether the system is ready. The improved data transmission makes the system less susceptible to light contamination (such as machinefloor lighting) or magnetic influences (improved EMC protection). Probing a center axis With this new touch probe function in the Manual operating mode, you can have the iTNC determine the center point between any two probing points (of a slot or ridge, for example) in the active working plane, and then directly set it as a datum, save it in a datum table, or save it in the preset table. In addition, the iTNC displays the measured distance.

Seite 14

For several years now, HEIDENHAIN has produced controls with complete drive packages. These consist of inverters and the appropriate motors. The inverters provide the electrical energy, which (regulated by the controls nominal values) is passed on to the motors. Each inverter consists of a power supply unit and a power module. The motors (usually synchronous motors for axis drives and asynchronous motors for spindle drives) transform the electrical energy into mechanical energy, i.e. for moving the axes and spindle. It goes without saying that the motors are equipped with rotary encoders from HEIDENHAIN for capturing the rotational speeds. In combination with the newest HEIDENHAIN software, the complete packages from HEIDENHAIN make it possible to run multifaceted diagnostic functions when the time comes in order to localize the problem as quickly as possible. After the error has been found, all the service technician needs to do is correct the error. A significant advantage is gained by using the TNCdiag PC software from HEIDENHAIN, which displays the possible error causes as well as giving suggestions for further procedures. The diagnostic functions permit a simple, fast and convenient search for the errors: Support while commissioning a control Automatic identification of motors and power modules Automatic function test of motors and inverters Diagnosis of hardware errors (in the wiring, for example); display of possible errors, their causes and further procedures for correcting the problems

Display and evaluation of internal control statuses (including the controllers) Analysis of the position and speed controller signals Display of the momentary values of the dc-link voltage During startup, the iTNC automatically detects the connected and dc-link current, supply voltages, and UM 121D power module of the Y axis via the electronic ID label the temperatures of inverters, motors, and controller PCBs Use of the diagnostic functions via remote diagnosis as well Electronic ID labels A significant step towards improving the ease of diagnosing HEIDENHAIN components was equipping the inverter components and synchronous motors with absolute rotary encoders with an electronic ID label. This electronic ID label is a memory module in the devices, containing the model name, the ID number and the serial number of the device. The first advantage comes into play when commissioning a HEIDENHAIN system: The power modules and motors are automatically detected by the control; this simplifies the parameterization and avoids input errors. Other advantages become apparent when a device fails. Axis motors, for example, are often mounted in shafts, making it anywhere between difficult and impossible to read the ID label. The TNCdiag software automatically reads the required information. You can also use the TeleService software for customers who are hundreds of miles away. This ensures that the service technician will bring the correct motor with him. After the new motor (or power module) has been mounted, the control compares the new device with the previous device, and displays a message if the two do not match. Then the service technician can decide if this is OK or not. In effect, the control regulates the exchange of the components. Of course controls from HEIDENHAIN are extremely reliable, which is important for avoiding machine downtimes. But sometimes a machine tool can develop a problem that cannot be solved without support. Automatic function test of the drive components The highlight of the new diagnostic functions is the automatic function test of the complete drive, meaning that the motor and inverter are tested. First the correct communication between the control and inverter is checked, to ensure that the components are attached to each other correctly. Then a test algorithm which automatically checks the drive components is begun. No action by a technician is necessary. Now even errors can be

page 15

found that previously only a technician with additional inspection devices could find. The following errors are detected automatically: Faulty connection between controller and inverter (e.g. connecting cable attached incorrectly or not at all) Significant wiring error (e.g. defective main contactor) Error in the power supply unit (e.g. due to incorrect dc-link voltage) Ground fault or short circuit of a power transistor (e.g. defective power module) Ground fault of individual motor phases (e.g. defective socket connection results in a ground fault of a motor phase) Interruptions of individual motor phases (e.g. break in the power supply cable) Short circuit of two motor phases (e.g. defective motor coils)
Automatic function test of the encoders The new HEIDENHAIN diagnostic functions are not limited to just the drive components, but naturally also support the encodTNCdiag automatically detects faulty parameterization of the direction of rotation for the motor in the Z axis ers for capturing both the position and the rotational speed. An automated test procedure checks tions are very helpful. Since the hardthe peak-to-peak values of the encoder ware and software of the controller work signals, and displays the result via status together, all control-loop relevant inforLEDs. The signal is simultaneously dismation of the hardware and the software played on an X/Y graph for the service is displayed together in the window. technician. Of course the status LEDs are used to clearly display this information. All analog Integrated in the test procedure for signals of the drive system, which are speed encoders is a test of the direction also available to the controller software, of rotation. The motors direction of rotaare shown in another window from tion stored in the control is compared the momentary dc-link voltage, dc-link with the actual direction of rotation, and current, and all motor temperatures to the result is shown by the status LEDs. It the power supply and auxiliary voltages is a quick and simple test, detecting misof the controller hardware. As a suppleleading subsequent errors that can occur ment to these windows, TNCdiag offers during parameterizing while commission- suggestions to the possible causes of ing the control. error as well as how to fix them. Here you can also generate an overview of Diagnostic functions for the complete drive system including the supporting the service technician parameterization and the data from the electronic ID label. There is no need to With a subject matter as complex as search through various system files for control and drive technology of machine the desired information it is all here at tools, especially with the many ambient a glance. conditions to be considered, it is often not possible to find an error automatiRemote diagnosis cally. When this is the case, the service searching for errors online technicians experience and ability to put two and two together are required The diagnostic functions described up in order to diagnose the correct cause of until now are carried out either directly error from the measurements. But even on the control via soft keys, or from an here the HEIDENHAIN diagnostic funcexternal PC connected to the control

TNCopt detects, for example, interrupted motor phases in the X axis

Seite 16

via the Ethernet interface, for example. However, a requirement for this is always an appropriately-trained service technician at the machine. The technicians travel time to the machine is already an expense, even though the cause of error might not be completely clear. This is where the advantages of remote diagnosis become obvious. The technician, still sitting in his office, establishes a connection with the machine via the telephone lines. This results in the cost of a simple phone call. Using the TeleService software from HEIDENHAIN, the technician can then access all relevant information
about the control. Once the cause of the error has been detected, it can be solved by the end user (in simple cases, such as a loose connector), or in more complicated cases the service technician can at least narrow down the possible error causes. TNCdiag is an integral part of the newest version of TeleService, meaning that all the possibilities described above are also available online. These diverse tests can now be carried out remotely, and electronic ID labels can also be read. These are advantages that use todays information technology to help shorten repair times and therefore reduce costs.
Remote diagnosis of the iTNC 530 with the TeleService PC software
Conclusion HEIDENHAIN uses proprietary test algorithms together with state-of-the-art software components and drive technology adapted to this combination for these new diagnostic functions. The experiences gained, as well as the application thereof with the greatest possible flexibility regarding these functions directly at the control, externally on a PC, or even via remote diagnosis raise HEIDENHAIN above other control manufacturers when it comes down to ease of diagnosis. So if, when the time comes, a HEIDENHAIN component should ever fail, comprehensive and automated tools are available for ensuring a quick and reliable search for errors. This helps to reduce machine downtimes, from which machine manufacturers and end users all profit.
Viewing control-loop relevant information with the status LEDs on the iTNC 530 and with TNCdiag
Viewing the analog signals of the drive system on the iTNC 530 and with TNCdiag

page 17

Since 1981, electronic handwheels have been as much a part of TNC controls as conversational programming has. They are an indispensable aid for expert machinists, especially when setting up workpieces. They are used to move the axis slides via the feed motors according to the rotation of the handwheel just as delicately as on a manually-operated machine tool.
HEIDENHAIN will present the new HR 420 incremental handwheel with status display at the EMO in Milan. The display provides the machine operator with much useful information. It directly shows the actual position of each axis. The display also presents the traverse path of the axes for each handwheel increment, the programmed feed rate, the programmed spindle speed, the selected operating mode and any error messages. Use the keys to select the axis to be moved, as well as the traverse path per

Use the new Contour Formula function to specify how the iTNC should combine the subcontours with each other:
Form the intersection of the subcontours Form the area of inclusion of the subcontours Form the area of inclusion but without the intersection of the subcontours Mill subcontour 1 without the intersection of subcontour 2
You define the machining parameters in the Cycles 20 CONTOUR DATA and 22 ROUGH-OUT. The machining cycle carries out the approach and departure movements itself, and naturally finishing allowances for side and depth can be taken into account. Cycle 22 ROUGH-OUT can also be used to define the fine roughing of subsections with a smaller tool: simply define Cycle 22 again, and define the number of the coarse-roughing tool in the appropriate cycle parameter. When the cycle is called, the TNC then only machines the areas that the larger tool could not machine. The following programming example is intended to show how easily the contour formula can be used, and how simple it is to define the fine roughing.
Without radius compensation, Without needing to take the machining direction of the tool into account, Without needing to take the starting point into account, and Without entry of technology data (feed rates, M functions).
Mill subcontour 1 (e.g. a pocket) without subcontour 2 (e.g. an island)
This means that once a subcontour has been defined, it can be used in any program, whether as part of a pocket or an island. Of course you can also create the subcontour with the very powerful Free Contour Programming FK function of the iTNC.
The programming graphics of the iTNC display the programmed contours in differing colors (which can be selected via machine parameters):
Each subcontour in blue The total contour in green The traverse paths of the tool in black
Traverse paths of the tool

page 19

Subcontour 1: Ridge, used as an island 0 BEGIN PGM ISLAND MM 1 L X+55 Y+L X+CR X+25 Y+60 R+10 DR4 L X+CR X+55 Y+40 R+10 DR6 END PGM ISLAND MM Subcontour 2: Rectangular contour with corner radii, used as a pocket 0 BEGIN PGM RECPOC1 MM 1 L X+25 Y+L X+L Y+L X+RND RL Y+RND RL X+END PGM RECPOC1MM Subcontour 3: Circular contour, used as a pocket 0 BEGIN PGM CIRCPOC1 MM 1 CC X+60 Y+LP PR+35 PA+0 RCP PA+360 DR4 END PGM CIRCPOC1 MM Contour-calculation program 0 BEGIN PGM CONTCALC MM 1 DECLARE CONTOUR QC1 = RECPOCDECLARE CONTOUR QC2 = CIRCPOCDECLARE CONTOUR QC3 = ISLAND 4 QC10 = ( QC1 | QC2 ) \ QCEND PGM CONTCALC MM Block/Meaning Blocks 1 to 3: Definition of the subcontour Block 4: Contour formula: Resulting contour 10 (QC10) should be calculated as intersection of contours QC1 and QC3 without contour QC3

Machining program 0 BEGIN PGM MILL MM 1 BLK FORM 0.1 Z X+0 Y+0 Z-BLK FORM 0.2 X+10 Y+100 Z+TOOL CALL 5 Z SL Z+100 R0 FMAX MSEL CONTOUR CONTCALC 6 CYCL DEF 20 CONTOUR DATA Q1=-20 ;MILLING DEPTH Q2=+1 ;TOOL PATH OVERLAP Q3=+0 ;ALLOWANCE FOR SIDE Q4=+0 ;ALLOWANCE FOR FLOOR Q5=+0 ;WORKPIECE SURFACE COORD. Q6=+2 ;SET CLEARANCE -UP Q7=+50 ;CLEARANCE HEIGHT Q8=+0 ;ROUNDING RADIUS Q9=+1 ;DIRECTION OF ROTATION 7 CYCL DEF 22 ROUGH-OUT Q10=-5 ;PLUNGING DEPTH Q11=+150 ;FEED RATE FOR PLUNGING Q12=+500 ;FEED RATE FOR MILLING Q18=+0 ;COARSE ROUGHING TOOL Q19=+100 ;RECIPROCATION FEED RATE 8 CYCL CALL 9 L Z+100 R0 FMAX MTOOL CALL 2 Z SCYCL DEF 22 ROUGH-OUT Q10=-5 ;PLUNGING DEPTH Q11=+150 ;FEED RATE FOR PLUNGING Q12=+750 ;FEED RATE FOR MILLING Q18=+5 ;COARSE ROUGHING TOOL Q19=+100 ;RECIPROCATION FEED RATE 12 CYCL CALL 13 L Z+100 R0 FMAX MEND PGM MILL MM Block/Meaning Block 3: Block 4: Block 5: Blocks 6 and 7: Block 8: Block 9: Block 10: Block 11: Block 12: Block 13: Tool call, cutter diameter 10 Retract tool Select contour to be machined Define coarse roughing machining data Call machining: Contour-parallel coarse roughing (see figure 1) Retract tool Tool call, cutter diameter 4 Define fine roughing machining data Call machining: Contour-parallel fine roughing (see figure 2) Retract in the tool axis, end program
Figure 1: Traverse paths during roughing
Figure 2: Traverse paths during fine roughing
angle encoders linear encoders contouring controls digital readouts length gauges rotary encoders
How well-conditioned does a control have to be?
Perfect performance depends on proper conditioning and professional techniques. Thats why the TNC is the right control for your daily milling operations: Its forward-looking precontrol techniques, integrated digital motor control and jerk-limited path control result in workpieces with very high surface definition. The dimensional accuracy of the finished workpieces can be attributed largely to HEIDENHAIN linear and angular encoders, which capture the axis motions directly at the machine table. Thats how you can achieve quick gains and stay in excellent shape. HEIDENHAIN (G.B.) Limited, 200 London Road, Burgess Hill, West Sussex RH 15 9RD, Great Britain, phone (01444) 247711, fax (01444) 870024, e-mail:



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