Rexroth MTC 200 Tool Management

Transcription

1 Industrial Hydraulics Electric Drives and Controls Linear Motion and Assembly Technologies Pneumatics Service Automation Mobile Hydraulics Rexroth MTC 200 Tool Management R Edition 01 Project Planning Manual

2 About this Documentation Tool Management Title Type of Documentation Rexroth MTC 200 Tool Management Project Planning Manual Document Typecode Internal File Reference Document Number B302-01/EN Purpose of Documentation This documentation is used for project planning of tool management of the MTC 200 CNC control. Record of Revisions Description Release Date Notes B302-01/EN Valid as of version 23 Copyright 2004 Bosch Rexroth AG Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). Validity The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availability of the product. Published by Bosch Rexroth AG Bgm.-Dr.-Nebel-Str. 2 D Lohr a. Main Telephone +49 (0)93 52/40-0 Tx Fax +49 (0)93 52/ Dept. BRC/ESM1 (MaWe) Dept. BRC/ESM6 (DiHa) Note This document has been printed on chlorine-free bleached paper.

3 Tool Management Contents I Contents 1 Basics Basic Idea Activation and Configuration Setup Lists and Tool Lists Setup List Tool List Current Tool List Equipment Check Operation without Setup List Tool Group Management Redefinition of the Term Tool Group Method of Operation Effects of the Setup List on the Tool Groups Parameter Value Assignment Tool Data Elements NC Commands for Tool Groups PLC Data Structures and Function Modules for Tool Groups Diagnosis Elements of the Tool Data Record Overview Basic Tool Data Tool Identification Location Data Units Technology Data User Tool Data Tool Group Data Other User Tool Data Tool Edge Data Tool Edge Identification Tool Life Data Geometry Data Geometry Limit Values Wear Factors User Tool Edge Data Grinding-Specific Tool Data Tool Code WGD DE

4 II Contents Tool Management Representation Type WGD DE NC Functions to Control Tool Management Conditions Default Plane Tool Management Commands Tool Storage Unit Motion Commands of the NC Tool Storage to Reference Position MRF Tool Storage to Home Position MHP Move Tool into Position MTP Move Programmed Pocket into Position MMP MTP/MMP Commands and Tool Correction Freely Position Tool Axis MMA Moving to Free Location MFP Move to Old Position - MOP Tool Storage Ready MRY Enable Tool Storage for Manual Mode MEN Moving Tool Storage Unit with Nonuniform Pocket Distribution Tool Changing Commands of the NC Performing a Complete Tool Change TCH Change the Tool from the Magazine to the Spindle TMS Change Tool from Spindle to Magazine TSM Magazine Pocket Empty? TPE Tool Spindle Empty? TSE PLC Functions to Control Tool Management Tool Magazine Motion Control Tool Magazine Control Signals Magazine Functions Tool Storage Unit Motion Commands of the PLC Magazine Homing Tool Magazine Positioning Tool Change Functions Complete Tool Change Magazine-to-Spindle Tool Change Tool Transfer Functions Tool Transfer Operation Tool Transfer Procedure and Function Modules Further Tool Transfer Functions Combined Spindle/Turret Axis Interrogating and Acknowledging Turret Mode Preselection Interrogating and Acknowledging Spindle Mode Preselection Setting the Parameter Values of the Tool Storage Unit Sequence of the Parameter Value Assignment NC-Controlled Tool Storage Unit

5 Tool Management Contents III Benefits of an NC-Controlled Tool Storage Unit Example: Assigning the Parameter Values of a Disk-Type Magazine PLC-Controlled Tool Storage Unit General Example: Assigning the Parameter Values of a Disk-Type Magazine Typical Applications PLC-Controlled Turret Description of the Turret Parameter Value Assignment NC Programming PLC Programming Combined Spindle/Turret Axis General NC-Controlled Disk-Type Magazine Description of the Magazine Parameter Value Assignment NC Programming PLC Programming PLC-Controlled Chain-Type Magazine Description of the Magazine Parameter Value Assignment NC Programming PLC Module for Magazine Control PLC Module for Changing Tools PLC Module for Gripper Rotation Additional Tool Carriers General Parameter Value Assignment Selecting Additional Tool Carriers Appendix "NC Tool Commands" Overview Overview "SPS Interface Signals" "Tool Storage Unit Control Signals" Overview "Tool Storage Unit Status Signals" Overview "PLC Tool Transfer Commands" Overview "Tool Data Record" Overview Read/Write Tool Data from the NC Program "TLD" Examples Index Service & Support Helpdesk Service-Hotline

6 IV Contents Tool Management 9.3 Internet Vor der Kontaktaufnahme... - Before contacting us Kundenbetreuungsstellen - Sales & Service Facilities

7 Tool Management Basics Basics 1.1 Basic Idea Purpose Tool data record Setup lists Tool preparation Tool storage Configuration and operation Tool management of the MTC 200 provides powerful functions for the configuration and for the handling of various magazine and turret types. Tool management is a permanent component of the NC control it takes care of administrating all the tools and tool lists. Among other things, chain-type and disk-type magazines, as well as tool turrets, can be easily designed and operated. A user-friendly interface, combined with extensive functions in the NC and the PLC, are used to transfer tool data. Besides tool length offset and tool edge / cutter radius compensation, tool management provides an automatic tool life monitoring function, warning limits and machining-related wear factors. During machining, the MTC 200 replaces worn-out tools with tools of the same designation (alternate tools), if such tools are available in the tool storage unit. The extended tool designation (up to 28 characters) permits any operation-related tool designation system to be retained on the control level. Tool management permits "setup lists" to be used; these contain the command data for the tools (not in 22VRS). At the beginning of each new machining process, an automatic comparison is performed between the specified tool data (setup list) that is allocated to the NC program and the current tool data (tool list). This comparison is known as an "equipment check". It permits a check to be performed that almost totally excludes collisions and, consequently, damage to machines, workpieces and tools, as well as standstills during program execution. Tool preparation is used for providing the tool data in parallel to the machining time. It can contain up to 99 tool lists per process. List number 99 contains 999 magazine or turret locations, and can therefore be used as a tool pool. The MTC 200 permits both numerically controlled and PLC-controlled magazines and turrets to be used in the same way. Provided that it has been parameterized and programmed accordingly, each of the processes 0-6 is able to control a magazine, a turret or additional tool carriers and the necessary tool changing procedures between the existing spindles and grippers and the tool storage unit. The movements of a tool storage unit can be executed independently of and asynchronously to the other axis movements of the process. For numerically controlled magazines and turrets, tool management performs the complete machine control. For PLC-controlled magazines and turrets, tool management also performs extensive functions, such as looking for a vacant magazine location. Tool group management supports the utilization of segmented tool storages. It allows tools which are used for machining certain workpieces or phases to be organized in up to 99 tool groups and to be changed in or out of the tool magazine. Extensive functions in the machine parameters, in the PLC, in the NC and in the machine data are available to configure and operate tool management.

8 1-2 Basics Tool Management Configurable data records permit optimum adaptation to the individual technologies (boring, milling, turning, grinding, etc.), and to the individual machine structures and machining processes. Simultaneous employment of different production technologies (such as milling and turning) on the same machine permits precise complete machining processes to be performed without reclamping the workpiece. Abbreviations BTD Basic tool data TSB Tool status bits TG Tool group status bits TED Tool edge data TESB Tool edge status bits 1.2 Activation and Configuration Tool Management Tool data records Tool storage Tool management of the MTC 200 is generally activated for the entire control by system parameter A Tool management. In order to be able to use tool management in the existing processes, process parameter Bxx.014 Tool management must also be set to "yes". As soon as A Tool management has been set to "yes", additional system parameters appear these are used to optimally configure the tool data records to the requirements of the user (see section "Elements of the Tool Data Record"). The structure of the tool data record is identical for all processes within the control. Tool management is adapted to the mechanical tool storage found on the machine for NC-controlled magazines and turrets using the process parameters, axis parameters and the PLC, and for PLC-controlled magazines and turrets using the process parameters, axis parameters, the PLC, and the machine data. 1.3 Setup Lists and Tool Lists Setup List Purpose Using the setup list, the user can define the availability of all tools that are required for machining and, using the equipment check, ensure their usability for the machining processes that are to be performed. The setup list data reflects the required data of the tools that are to be employed (e.g. geometry limit values). Note: From firmware version 23VRS, the MTC 200 will again support full functionality of the setup lists from its MTGUI. Handling The setup lists and the NC packages are loaded into the controller and saved together through the storage function.

9 Tool Management Basics 1-3 Activation Using system parameter A Organization of setup lists, the user defines whether a separate (program-specific) setup list is to be created for each NC program or whether only one (station-specific) setup list is to be created for a process. NC program package <xx> NC program package <xx> process 6 process 6 process 1 process 0 process 2 process 1 process 0 process 2 NC program 1 setup list 1 NC program 1 setup list NC program 2 setup list 2 NC program 2 NC program 3 setup list 3 NC program 3 NC program 99 setup list 99 NC program 99 program-specific organization of the setup lists station-specific organization of the setup lists Pakete.FH7 Fig. 1-1: Organization types of setup lists Tool List Purpose Tool lists are used for preparing and saving tool data of the individual tools. The tool data always contain the basic tool data, which consist of the tool identification, the location data, the units, the technology data and at least one tool edge. Besides the basic tool data, the tool data contain the data that are required for the tool edges (tool tip identification, geometry, tool life data, user-defined data) (see Chapter "Elements of the Tool Data Record"). Preparation With the help of the PC user interface, tool lists can be created, modified, and saved while machining is in progress. This enables the user to load the tool storage device for subsequent machining processes. Loading the tool list This permits the setup time of a new tool storage unit configuration to be reduced to a minimum. The operator loads the tool list prepared in the user interface into the control and loads the tool magazine according to the tool list.

10 1-4 Basics Tool Management Current Tool List The tool list that is currently contained in the control is known as the "current tool list". As soon as a machining process has begun, the tool list in the PC loses its significance; solely the current tool list in the CNC reflects the current state of the tools within the magazine. Note: Any modifications that concern the current workpiece arrangement, such as inserting, removing or moving a tool or modifying the tool data, must be performed directly in the current tool data. The current tool list contains the current information about the location and the state of the individual tools (e.g. current remaining tool life). The current tool list is generated from the tool list while taking the setup list into account. During the machining process, tool management continually updates the current tool data, such as the location data, tool life data, and wear data. Equipment Check The equipment check compares the required tool data (setup list) with the actual tool data (current tool list). The equipment check is performed automatically whenever a program is restarted after data of the setup or tool list have been modified and transferred to the controller or after a different NC memory (A, B) has been selected if interface signal PxxC.MGWTC (Process xx Command MaGazine Without ToolCheck) has been set to log. '0'. Tool management does not perform an automatic equipment check after a restart if PxxC.MGWTC has been set to log. '1'. TID Syntax In addition, NC command TID (Tool IDentification) permits the equipment check to be executed at any position in the NC program, regardless of interface signal PxxC.MGWTC. TID NC command Equipment check TID Forwards start (PxxC.ADV) Interface signal Equipment check (PxxC.MGWTC) & >= 1 Equipment check New and modified setup list New and modified tool list >= 1 Program or storage toggling AUSRUEST.FH7 Fig. 1-2: Conditions for equipment check Each tool that has been entered in the setup list triggers the following sequence during the equipment check:

11 Tool Management Basics 1-5 Basic tool data Tool Edge Data Based on the tool identification (ID), tool management searches the entire current tool list for tools with the same name. Tool management first assigns the setup list-specific data to each located tool. Any setup list-specific data that exist from a previously made comparison will be overwritten. If a tool is not contained in the tool list, it is entered as missing in the tool list of the user interface (sorted by T No.), i.e. tool status bit 1 'Tool does not exist' (Ù "!") is set. Tools in the tool list to which no entry can be assigned in the setup list are marked by tool management by setting tool status bit 2 'Tool not required' (Ù "?"). Depending on the tool, the tool status bits that are responsible for location locking and location assignment are set or reset. Once the setup list-specific data have been assigned, tool management checks the tool edge data and the basic tool data. For the tool edge data, the tool edge orientation, the existing geometry, and the wear state are checked. The result is shown using the related tool edge status bit. If the tool edge orientation and/or the tool geometry of at least one tool edge does not satisfy the requirements, this will be shown in tool status bit 5 ('Faulty tool edges' Ù"f"). Accordingly, the wear state of the Ù tool edges is shown in tool status bits 17 and 18 ('Tool worn out' "d" or 'Tool below warning limit' Ù"w") if at least one tool edge is worn out or below the warning limit. From the basic tool data of the tool list, tool management checks the correction type and the number of tool tips against the specifications made in the setup list. According to the result, it updates tool status bits 3 and 4 'Incorrect correction type' (Ù "t") and 'Incorrect number of tool tips' (Ù "e"). Generate alternate tool chains Tools with the same name that could be assigned to an entry in the setup list (alternate tools) are summarized in alternate tool chains. The tools are arranged in the following sequence in each alternate tool chain: usable tools that have already been used, i.e. at least one tool edge has a remaining tool life of less than 100%. usable tools that are still new, i.e. each tool edge has a remaining tool life of 100%. worn tools that would otherwise be usable broken tools that would otherwise be usable unusable tools. Within these groups, the sequence is according to increasing duplo numbers. The first tool of every alternate tool chain becomes the processing tool (Ù"p") of this chain. All other usable tools are marked as replacement tools (Ù"s"). If interface signal PxxC.MGITW (Process xx Command MaGazine Ignore Tool Worn Out) has been deleted, the NC program terminates with an error message if there is an alternate tool chain that does not have any usable tool. If the interface signal PxxC.MGITW is set, the behavior is basically the same. However, tools that are worn and/or broken, but otherwise usable, are counted as usable tools.

12 1-6 Basics Tool Management NC program package process setup list (command data)? process automatic equipment check tools list (actual data) process tool magazine process autoaus.fh7 Fig. 1-3: Basic method of operation of equipment check (station-specific organization of the setup list) Operation without Setup List The PxxC.MGNSL (Process xx Command No Setup List) interface signal must be set to '1' if the setup lists are not to be used. In this case, the NC generates (internally and invisible to the user) an empty setup list, in which it generates an entry for each T number that occurs at least once in the current tool list. Then the NC uses this setup list to execute the equipment check described above; however, the assignment between the entry in the generated setup list and the associated tools in the tool list is made using the T number. Any previously existing setup list is not taken into account. 1.4 Tool Group Management Redefinition of the Term Tool Group "Tool group" (old) "Tool type group" (new) Up to firmware version 22VRS, the term "tool group" together with the term "tool technology group" has been used in connection with the type of technical utilization of the tools. Tool technology groups are e.g. "drilling tools" or "milling tools". The subdivisions of these technology groups have been described as "tool groups", e.g. "twist drill", "step drill", "end mill", or "angle cutter". From firmware version 23VRS, the term "tool group" is replaced by the term "tool type group". The term "tool group" is redefined from Version 23VRS. Now, it describes a group of different tools also from different tool technologies which are stored in the tool storage for certain machining phases or workpieces and which are changed into or out of the tool magazine together.

13 Tool Management Basics 1-7 Method of Operation The option to combine in one tool group tools which are required for certain machining stages or workpiece types, supports the utilization of segmented tool storages. Each segment of the tool magazine is assigned to one group. After a group is activated, only the tools within this group are used. This reduces traversing distances on tool change, e.g. in flexible production systems, machining centers or in transfer lines, to a minimum. In the case of lathes, the advantage lies in the common replacement of tools in a group (e.g. drilling and thread cutting) when a tool in the group is worn. A tool group can have sister groups. The group 0 which comprises all tools which are not to be assigned to a group, is an exemption. Tool groups are identified by a group number and a group duplo number. Groups of the same group number are linked according to ascending duplo numbers. Tool Segment or group G1.2 G1.1 G0 Group 0 G2.1 G2.2 Alternate tools Alternate groups Toolsegments.FH7 Fig. 1-4: Example for tool groups and sister groups Regulations and conditions Tool groups are subject to the following regulations: 1. Up to 99 tool groups can be administered. 2. A tool group can comprise up to 999 tools. Note: The total number of tools is restricted to 999 per process (resp. tool management). 3. The tools in one tool group can comprise only sister tools in the same group. 4. A tool group can have up to 99 sister groups. 5. Additionally, the tool group has status bits of its own. 6. A tool group is considered worn once the first tool sister sequence of the group is worn. 7. After the wear of a group, the next alternate group is activated automatically and locked tool groups are excluded. If a tool is not available in the active alternate group or it is also not found in other tool groups during correspondingly set tool search mode (NC command TGSM), the CNC displays the error 314 "Tool or tool location not found". Only the respectively active duplo group is used for tool search in

14 1-8 Basics Tool Management each tool group. This provides the possibility that the duplo groups of a tool group should be equipped with the same tools. 8. The interface signal PxxS.MGWRN (Process xx Status MaGazine Tool WaRNing) is set when the first tool alternate chain of the last alternate group has reached the warning limit. 9. The interface signal PxxS.MGTWO (Process xx Status MaGazine Tool WaRNing) is set when the first tool alternate chain of the last alternate group is worn. 10. The last sister tool of a sequence in the last respective spare group can assume negative tool life. 11. A group is blocked and enabled by writing of the corresponding group status bit. 12. There is always a group 0 which comprises all tools which are not to be assigned to any group. There is no sister group for group 0. Tool search mode The following search sequences are available as a tool search mode (NC command: TGSM) Mode Search order Comment 0 Preselected group If the tool is not found in the preselected group, the NC will indicate error 314 Tool or tool location not found. 1 Preselected group, group 0 2 Preselected group, groups First, the tool is searched in the preselected group, then in group 0. If the tool is not in the preselected group, it will be searched for in ascending order in the groups Groups 0 to 99 Irrespective of the enabled group, the tool is searched in ascending order in the groups Fig. 1-5: Tool search mode in tool groups If the requested tool is found in another than the preselected / enabled group, this group will be automatically enabled and preselected once the tool has been enabled. Effects of the Setup List on the Tool Groups The components of the magazines are defined by the setup list. Tools not comprised in the setup list are logically removed from all groups. In the following example (Fig. 1-6), the setup list comprises the tools T1, T3 and T5. The tools T2, T4, T6 and T7 are not comprised in the setup list and are accordingly removed from all tool groups (logically, not physically).

15 Tool Management Basics 1-9 Setup list: T1, T3, T5 Group 1.1 Group 1.2 T1 T2 T1 T2 T3 T4 T3 T4 Group 2.1 Group 2.2 T1 T5 T1 T7 T3 T6 T3 T6 Setuplist.FH7 Fig. 1-6: Effects of the Setup List on Tool Groups The duplo groups are also linked when different tools (different T numbers) are comprised in the duplo groups. In the group status the status bit Group not required (symbol? ) is set when all tools of the groups have been removed by the equipment check. Parameter Value Assignment Machine parameter Bxx.073 "Number of tool groups" By means of machine parameter Bxx.073 "Number of tool groups", tool group management is enabled / disabled: 0: Do no activate group management (pre-assignment). The group information in the tool is not evaluated. All tools are automatically assigned to the enabled group 0 This group is always active and can not be deselected. Addressing through the TLD command does not consider any group data and returns "0" as enabled group : Define available tool groups. Up to 99 tool groups can be defined. However, to attain an optimum memory allocation and access speed, only the number of groups that are actually needed should be entered. Note: Any modification of machine parameter Bxx.073, "Number of tool groups", causes canceling of the control-internal tool list; however, it can be reloaded into the control through GUI.

16 1-10 Basics Tool Management Tool Data Elements Basic tool data For the management of tool groups, the tool data record of the MTC 200 tool management has been extended by three data elements. In the basic tool data, the data elements 30 Group number...and Group duplo number...have been introduced. Note: When the tool data element "Group number" includes the value "0", only this value "0" is permissible for the tool data element "Group duplo number". The permissible entry into the tool data element "Group number" is restricted by the machine parameter Bxx.073, "Number of tool groups" Bxx.073 = 0: Tool group number and tool group duplo number must comprise the value "0". Bxx.073 = n [1..99] The tool group number can be in the range [0..n], and the tool group duplo number in the range [0..99] (exception for tool group 0: only permissible tool group duplo number is 0). Tool data which disregard these restrictions cannot be loaded into the control! Furthermore, for each tool group there is the element 32 Group status The group status can be accessed both through tool addressing and through group addressing. Note: The data elements are illustrated and shown in detail in the Chapter Elements of the Tool Data Record in the Basic Tool Data section. Group status initialization following download of tool data Group status formation during equipment check After download of tool data, the group status of each group is automatically initialized: The "Group not required" ("?") bit is set. The bits "Group disabled" ("L"), "Group worn out" ("d") and "Group warning limit reached" ("w") will be deleted. During each equipment check (TID or implicit equipment check), a new group status is formed. Here, wear status is considered, and sister linking of groups is performed. The following regulations apply: 1. A group is marked as "required" if it comprises at least one tool with the T number required in the setup list. If there is not setup list, all groups are automatically considered "required". 2. Groups belonging to a sister sequence must have at least one tool each of the same T number. 3. The not worn out group with the smallest group duplo number will be the processing group "p". All other groups which are not worn are sorted according to ascending duplo numbers and added as sister groups s.

17 Tool Management Basics 1-11 NC Commands for Tool Groups Tool group management is supported by the following NC commands: ToolGroup - "TG" Use the NC command "TG <Gruppe>" to preselect a tool group. The active group can be read with "@<var>=tg (for a detailed description, see the Chapter Tool Storage Movement Commands of the NC, Tool Group Administration section). Tool Group Search Mode - "TGSM" Use the NC command TGSM=<Mode> to define the tool search mode and accordingly the implicit group enabling on entering the T word. The mode can be read back with "@<var>=tgsm" (for a detailed description, see the Chapter Tool Storage Movement Commands of the NC, Tool Group Administration section). Tool Data - "TLD"The TLD command can be used to read and write the tool data from the NC program; however, some restrictions apply to writing. In addressing, this command has been extended by the optional elements Group number (G) and "Group duplo number" (GD) (see the Chapter Access to Tool Data from the "TDL" NC Program" for a detailed description). PLC Data Structures and Function Modules for Tool Groups The PLC supports tool group management in the following manner: Data structure basic tool data TLBD This data structure comprises the new elements Group number (G_NR) and "Group duplo number" (G_INDEX) Reading / writing tool data - "TLD_RD", "TLD_WR" Reading basic tool data - "TLBD_RD" Reading tool edge data - "TLED_RD" Deleting a tool - "TL_DELETE" Resetting a tool - "TL_RESET" These function modules contain the new elements "Group number" (GNR) and "Group duplo number" (GIND). Moving a tool - "TL_MOVE" This function module contains the elements "Group number" (SGNR) and "Group duplo number" (SGIND). Reading / writing group status TLG_RD", "TLG_WR" New function module Note: The PLC data structures and function modules affecting the tool groups are described in detail in the Chapter Standard Function Modules, section Tool Functions in the PLC in the MTC 200 PLC interface description.

18 1-12 Basics Tool Management Diagnosis NC Diagnosis Messages The following tables shows the specific NC diagnosis messages for the "Tool group management" function: Diagnosis message (no. + text) Cause 314 Tool or tool location not found - There is no more tool group which is not disabled or worn containing the selected tool. - The selected tool was not found in the tool group preselected with TGSM. 322 Invalid function Tool group not available: - The group preselected with TG does not exist. Fig. 1-7: NC diagnosis messages of tool group management PLC Diagnosis Messages Any programming errors in the PLC program may cause incorrect execution of new or extended function blocks. In this case, the PLC will generate a corresponding error message. The two following tables comprise all specific PLC error types and PLC error numbers of tool group management: PLC error type Function module Comment -169 TLD_WR Writing tool data -170 TLD_RD Reading Tool Data -189 TLBD_RD Reading base tool data -190 TLED_RD Reading tool edge data -191 TL_RESET Resetting tool -192 TL_DELETE Deleting tool -193 TL_MOVE Moving tool -213 TLG_RD Reading tool group status -214 TLG_WR Writing tool group status Fig 1-8: PLC error types of tool group management PLC Error no. Comment 1 Invalid input parameter Cause -The value of the "PROC", "GNR" or "GIND" inputs is negative. -The"PROC" input is greater than 6. -The"GNR" input is greater than 99. -The"GIND" input is greater than Internal transfer error - General message error - invalid group number - invalid group index - invalid process number - group status bit cannot be changed Fig. 1-9: PLC error numbers of tool group management

19 Tool Management Elements of the Tool Data Record Elements of the Tool Data Record 2.1 Overview The following overview tables contain the entire tool data record. The tool data record consists of the setup list-specific data and of the tool list-specific data. Tool data record Data type Option User defined tool data The tool data record of a tool consists of Basic tool data (see Chapter 2.2) and 1 to 9 tool edge data records (see section 2.3) The number of tool edges and, therefore, of tool edge data records is set by system parameter A "Maximum tool edge number". The "Data type in the PLC" column specifies the form in which the individual data items are available in the PLC. The data elements for which the number of a system parameter is listed in the column "Optional datum" are only available in the tool data record if the entered system parameter is set. The user can organize application-specific tool data and tool statuses in the tool management function of the MTC 200. Here, information on maximum speed and weight of a tool can be stored in the user data. In the user status bits, binary information can be stored, e.g. Cooling lubricant required or Tools re-ground. The following system parameters allow for definition of the user tool data and user status bits according to the requirements of the respective application: A A Designation of the user tool data 1..9 A A Designation of the user edge data 1..5 A A Designation of the user edge data 6-10 A A Symbol for user tool status bit 1..8 A A Symbol for user tool edge status bit 1-4 "Grinding" technology data If tool management is to be used for a grinding machine, system parameter A Tool technology must be set to "Grinding". The first 5 tool edge user data (data elements 31-35) are assigned with the following grinding-specific data: Min. spindle speed S min Max. spindle speed S max Max. grinding disk circumferential speed SUG max Angle of skew Angle of skew Current grinding wheel diameter Current wheel The first 5 tool user data are not allowed to be used by the user if system parameter A Tool technology is set to "Grinding"!

20 2-2 Elements of the Tool Data Record Tool Management 2.2 Basic Tool Data The data elements of the basic tool data exist once per tool; they can be classified as follows: Tool identification, Location data, Units, Technology data, User data, and Group data (group status exists for each tool group) Basic tool data (per tool) V23_ DESIGNATION RANGE DATA TYPE in the PLC UNIT DE OPT. SL TL Tool identification Index address hexadecimal double word with 32 bits - 01 X X ID (tool NAME) up to 28 characters* STRG28-02 X Memory X Location X Tool number DINT - 05 X X Tool duplo number INT - 06 X Correction type 1-5 USINT - 07 X X Number of tool edges 1-9 USINT - 08 X X Tool Status 0/1 (32 status bits) USINT - 09 X Location data Free half-locations 0-4 USINT - 10 X Old pocket INT - 11 X Stor. of next setup tool 0-2 INT - 12 X Loc. of next setup tool INT - 13 X Stor. of prev. setup tool 0-2 INT - 14 X Loc. of prev. setup tool INT - 15 X Units Time unit 0/1 (0: min, 1: cycl.) USINT - 16 X Unit of length 0/1 (0: mm, 1: inches) USINT - 17 X X Technology data Tool code 0-9 USINT - 18 X X Representation type INT - 19 X X

21 Tool Management Elements of the Tool Data Record 2-3 User data User data 1 REAL 20 A X User data 2 REAL 21 A X User data 3 REAL 22 A X User data 4 REAL 23 A X +/- 1.2 * /- 3.4 * User data 5 REAL 24 A X and 0 (9 significant digits) User data 6 REAL 25 A X User data 7 REAL 26 A X User data 8 REAL 27 A X User data 9 REAL 28 A X Group data 29 Group number 0-99 BYTE - 30 X Group duplo number 0-99 BYTE - 31 X Group status 0/1 (16 status bits) WORD - 32 X any Comment up to 5 x 76 alphanumeric characters - 99 A X Data element 99 Comment is not loaded in the control. * ASCII character string , at least 1 character >32 WGD_all_V23_ xls DE... Data element SL... Setup list-specific datum R.TL... Replacement tool TL... Tool list-specific datum CTRL29... STRING28 OPT... Optional datum In the following, all data elements (= DE column) of the basic tool data are described group-wise in the order of the above illustration.

22 2-4 Elements of the Tool Data Record Tool Management Tool Identification Index address DE 01 Basic tool data Date element 01 Index address Relevant for: Setup list (SL) X Tool list (TL) X Location list (LL) Explanation Index addresses are automatically allocated by the control when entering a tool. The index address can only be accessed in reading; it is used for control-internal management of the tools. Tool name (ID) DE 02 Basic tool data Data element 02 ID (TOOL NAME) Relevant for: Setup list (SL) Tool list (TL) X Location list (LL) Explanation The tool name (also abbreviated as 'ID') can consist of a maximum of 28 characters (ASCII set of characters , min. 1 character > 32), providing a clear differentiation of the tools in use. All utilized tools must be clearly named so that they can be uniquely identified based on their tool name. Only tools that can substitute each other (alternate tools) are grouped under one tool name. Such tools can be further distinguished using an additional duplo number (see data element 06 'Duplo number'). The extended tool designation permits any company-related tool designation system to be retained on the control level. Memory DE 03 Basic tool data Data element 03 MEMORY Relevant for: Setup list (SL) Tool list (TL) X Location list (LL) Explanation The 'Storage' (= tool storage type ) data item is not shown directly within the tool list. Within the data record, it shows the type of location the tool is in:

23 Tool Management Elements of the Tool Data Record := Magazine or turret location 1 := Spindle 2 := Gripper Example NC record for interrogation of the tool storage in the process P in which there is the tool T with the duplo number D Location DE 04 Basic tool data Data element 04 Location Relevant for: Setup list (SL) Tool list (TL) X Location list (LL) Explanation Within the tool storage unit, the 'Location' data item determines the number of the tool pocket. For a spindle, it determines the number of the tool spindle, and for a gripper the gripper location that contains the tool. Using the tool list, all locations of the tool storage unit and all existing spindles and grippers can be prepared with respect to data processing parallel to machining time for reception of the real tools. WARNING Risk of injuries to operators, as well as damage to machine and workpiece by faulty magazine configuration! Ÿ Once a tool list has been loaded into the control, agreement between the actually existing magazine configuration and the tool list must be ensured. Example NC record for interrogation of the tool storage in the process P in which there is the tool T with the duplo number D

24 2-6 Elements of the Tool Data Record Tool Management Tool number DE 05 Basic tool data Data element 05 TOOL NUMBER Relevant for: Setup list (SL) X Tool list (TL) X Location list (LL) Explanation Example Using the T word, which consists of a preceding address letter 'T' and a tool number (up to seven digits) or a tool location number (up to seven digits), a tool or a location can be accessed within the NC program. A programmed tool number causes tool management to determine the current location of the tool on the basis of the tool number and designation from the setup list using the designation and tool location number from the tool list. The assignment of the tool number (as it is used in the NC program) to the tool (company-specific tool name) that is made via the setup list enables the NC program to access a tool. If a setup list is not used, the current location is accessed directly via the allocation tool number <> tool location number within the tool list. 1. NC record for positioning the tool T1234 to reference position b (b=1..4) of the tool storage unit: MTP b T NC record to change the tool T123 into the spindle (e.g. simple milling machine) for the case that the tool change cycle is called up through the jump flag M6 : BSR.M6 T123 Tool Duplo Number DE 06 Basic tool data Data element 06 DUPLO NUMBER Relevant for: Setup list (SL) Tool list (TL) X Location list (LL) Explanation The tool duplo number provides for: an unambiguous identification of alternate tools (tools of the same tool name and the same T number) and defining the utilization sequence of the alternate tools for machining. The alternate tools are used according to their duplo numbers. Provided it is neither worn out nor locked, an alternate tool with a lower duplo number is used for machining before one with a higher duplo number. The NC program employs the same T number for addressing alternate tools. After the previous tool (tool of the same tool number and designation, and the next smaller duplo number) has been worn out or locked, the

25 Tool Management Elements of the Tool Data Record 2-7 control selects a new alternate tool only if the same T number is invoked again. Note: If tools have the same T number and duplo number, tool management employs the tools by their ascending location numbers. Correction type DE 07 Basic tool data Data element 07 Correction type Relevant for: Setup list (SL) X Tool list (TL) X Location list (LL) Explanation The correction type defines the number of corrections of a tool and their locations (see Fig. 2-1). Correction type 1: (Drilling tool) A tool of correction type 1 has only one length compensation value (L3) that is always perpendicular to the current machining plane. Correction type 2: (Milling tool) In addition to the length compensation value (L3) that is always perpendicular to the current machining plane, a tool of correction type 2 has a radius compensation value (R) inside the machining plane. Correction type 3: (Lathing tool) A tool of this type includes 2 length compensation values (L1, L2) and one radius compensation value (R) inside the current machining plane. Correction type 4: (Angle head tool) Tools of this type are able to perform a length compensation (L1, L2, L3) and a radius compensation (R) in the current machining plane in all three main axis directions (X, Y, Z). Length L3 is always perpendicular to the current machining plane, while lengths L1 and L2 always lie within the current machining plane. Correction type 5: (Gripper) Tools of this type are able to perform a length compensation (L1, L2, L3) in all three main axis directions (X, Y, Z). Length L3 is always perpendicular to the current machining plane, while lengths L1 and L2 always lie within the current machining plane. In order to be used for the scheduled machining process, the correction type of the related tool in the magazine must coincide with the type requested in the setup list.

26 2-8 Elements of the Tool Data Record Tool Management Type effective corrections 1 correction: 1 length correc tion perpendicular to machining level 2 corrections: 1 length correc tion perpendicular to machining level Radius correction on machining level 3 corrections: 2 length corrections on the machining level Radius correction on machining level Z Z Z Y L3 Y L3 Y L2 effect of the corrections G 17/G 20 G 18 G 19 Y Y L3 X X L3 X Z Z Y Y R L3 R X R X L3 X Z Z Y Y R R L1 L2 L1 X L1 R X L2 X Z Z Example tool edge orient drilling tool 0 L 3 milling tool 0 R turning tool 0-8 L corrections: 1 length correc tion perpendicular to machining level 2 length corrections on the machining level Radius correction on machining level 3 corrections: 1 length correc tion perpendicular to machining level 2 length corrections on the machining level Z Z Y L2 L3 Y L2 L3 Y Y R R L3 L2 L1 L1 X X L1 R L3 X L2 Z Z Y Y L3 L2 L1 L1 X X L1 L3 X L2 Z Z R L1 angular head tool L1/L2 0-8 L3 R 0 L3 L 3 gripper tool L1/L2 KORR.FH7 Fig. 2-1: Definition of the correction type

27 Tool Management Elements of the Tool Data Record 2-9 Number of tool edges DE 08 Basic tool data DATA ELEMENT 08 NUMBER OF TOOL EDGES Relevant for: Setup list (SL) X Tool list (TL) X Location list (LL) Explanation Each tool can have up to nine tool edge data records assigned, irrespective of the number of real tool edges the tool actually has. To avoid wasting NC storage space, A Maximum tool edge number can be used to reduce the maximum number of tool edges to one tool edge per tool. In order to be able to be used for the scheduled machining process, the related tool must satisfy the number of tool edges that is requested in the setup list. Fig. 2-2: Examples for tools with different tool edge numbers Schneidenanzahl.FH7 Tool Status (Bits) DE 09 Basic tool data Data element 09 Tool Status Setup list (SL) Tool list (TL) Location list (LL) Relevant for: 1See description of the individual bits The tool status bits provide information about the current state of the tools and their locations.

28 2-10 Elements of the Tool Data Record Tool Management Classification They can be subdivided into status bits that are specific to setup list, location, and tool: The setup list-specific status bits describe the state of a tool with respect to the requirements of the setup list. The location-specific status bits reflect the status of a location. The tool-specific status bits describe the state of a tool. The following table lists all tool status bits. The table is followed by a detailed explanation of the individual bits.

29 Tool Management Elements of the Tool Data Record 2-11 Tool status bits 1-16 from basic tool data element 09 Group name Group information Write Access Type Symbol Value Bit Byte Word TM OP ASP SL TL PL Comment Presence Error correction type Tool not available! 1 Tool available 0 Tool is not required? 1 Tool required 0 Correction type wrong t 1 correction type not faulty 0 Error Incorrect number of tool edges e 1 tool edge number Correct number of tool edges 0 Error tool edge Error tool code Tool edge(s) incorrect f 1 Edge(s) not faulty 0 Tool code faulty $ 1 Tool code not faulty 0 1 X X X Tool is missing 2 3 X X X 4 X X X 5 6 LOW-Byte Tool not required for machining Correction type does not comply with requirements Number of tool edges does not comply with requirements Tool edge data does not comply with requirements does not comply with requirements Reserved for extensions Reserved for extensions Location locking Location locked B 1 Location not locked LOW-WORD X X X X X ANP/BED: e.g. location is damaged. TM: Tool will be entered Reserved for extensions Upper half-location locking 10 Reserved for extensions Lower half-location locking 11 Upper half-location reservation Lower half-location reservation Upper Half-Location Reserved ) 1 Upper half-location not reserved 0 Lower Half-Location Reserved ( 1 Lower half-location not reserved 0 High-Byte X X X X Reserved for temp. moved tools 13 X X X X Reserved for temp. moved tools Reserved for extensions Reserved for extensions Location reservation Upper half-location locking 14 Lower half-location locking 15 Location assigned + 1 Location not assigned 0 16 X X X There is a tool in the location WSB_all_V22_ xls TM... Tool Management SL... Setup list-specific status bit OP... Operator TL... Tool list-specific status bit ASP... Application-specific programs in PLC or NC LL... Location-specific status bit

30 2-12 Elements of the Tool Data Record Tool Management Tool status bits from basic tool data element 09 Group name Group information Write Access Symbol Value Bit Byte Word TM OP ASP SL-{ Type TL PL Comment Wear state Name of alternate Tool coding Tool locking Tool breakage Reserved for extensions. User tool status 1 User tool status 2 User tool status 3 User tool status 4 User tool status 5 User tool status 6 User tool status 7 User tool status 8 Tool is worn out d 1 The remaining lifetime of tool is not worn out 0 17 X X the tool has elapsed (replace) Warning limit is reached w 1 Warning limit not reached 0 18 X X The remaining lifetime is about to expire (replace) Machining tool p 1 There is one machining No machining tool 0 19 X X tool for each alternate tool group Replacement tool s 1 A spare tool is a tool that no spare tool 0 20 X X can still be used, no machining tool Tool with fixed location coding C 1 Tool is only valid to be Tool without fixed location coding 0 21 X X X X changed on the predefined tool location Tool locked L 1 Tool is not locked 0 Tool broken D 1 Tool is not broken 0 User tool status bit 1 A User tool status bit 2 A User tool status bit 3 A User tool status bit 4 A User tool status bit 5 A User tool status bit 6 A User tool status bit 7 A User tool status bit 8 A X X X Tool must not be used 23 X X X 24 LOW-Byte Tool is damaged, e.g. a tool edge has broken off 0 25 X X X Any meaning X X X Any meaning 27 X X X Any meaning 28 X X X Any meaning 0 29 X X X Any meaning X X X Any meaning 0 31 X X X Any meaning High-Byte High-Word X X X Any meaning TM... Tool Management SL... Setup list-specific status bit OP... Operator TL... Tool list-specific status bit ASP... Application-specific programs in PLC or NC T Tool LL... Location-specific status bit WSB_all_V22_ xls

31 Tool Management Elements of the Tool Data Record 2-13 Note: The group definitions in the left column of the previous table are only used for display (expedient reduction of the data for the end user). These group definitions are not taken into consideration within the CNC. Status bits with capital letters indicate that the user can change their status via the GUI, the PLC, or the NC user program, if required. Status bits with lower case letters can not be influenced by the user. They are organized by the NC tool management. Setup List-Specific Tool Status Bits If a tool cannot be used for the subsequent machining process, the setup list-specific status bits provide detailed information about the cause. Exclusively the tool management updates the setup list-specific status bits. Neither CNC nor PLC nor the operator can modify the states of these bits. The setup list-specific status bits are not loaded into the PC when the tool list is saved. Tool not available DE 09 Bit 1 Basic tool data Data element 09 Tool Status Tool status bit 1: Tool not available Group information Value Symbol Tool not available 1! Tool available 0 Relevant for: Write access: Setup list (SL) X Tool management (TM) X Tool list (TL) X Operator (OP) Location list (LL) User-specific programs in PLC or NC (USP) Meaning Symbol Updating time Effects A tool marked with such a status bit is missing; it is not contained in the tool storage unit.! (request to the operator) During the equipment check Limitations for the operator: all GUI operating functions are permitted Limitations for the user program: all data manipulations are permitted Restrictions for tool management: starting the program is impossible