西门子840D数控系统调试.doc

上电之前的准备一：将NCK主板卸下，检查NCK主板上的电池是否正确安装。正确安装之后将NCK主板安装到NCU盒上。二：外围线路的连接 (1) 每根轴的动力线,编码器反馈线是否正确安装（X411轴1编码器，X422轴2编码器，动力线插口X轴对应A1口，Z轴对应A2口，2AXIS） (2) 设备总线，直流母线等是否正确可靠连接。 (3) 3相电源进线连接是否可靠，U,V,W是否对应。 (4) SIMATIC线的连接（IM361接OUT口，NCK接X111口） (5) MPI线的连接（两头ON中间OFF) (6) MCP面板的节地址开关设置（810D面板的节地址为14，机床控制面板后面的S3开关(1-8) 依次设为OFF OFF ON ON ON ON OFF OFF;840D面板的节地址为6，机床控制面板后面的S3开关从左到右依次设为ON OFF ON OFF ON ON OFF OFF) (7) 如果是PCU50，要将显示器后面的硬盘开关拨到ON的位置。上电之后先安装HMI 软件。软件拷贝到E盘三：上电 (1) 上电之前请将数控系统的热控断开，MCP和OPI面板上的24V电源拔掉，以免由于接线错误造成器件烧坏。 (2) 上电之后检查供给数控系统的电压是否为380V，MCP和OPI面板的电源是否为直流24V，且正负极性正确。 (3) 如果2正确，断电，合上热控，MCP和OPI面板的直流电源插上，上电调试。四：PLC，NC总清1、NC总清步骤： (1)将NC启动开关S3“1”： (2）启动NC，如NC已启动，按复位按钮S1： (3)待NC启动成功，七段显示器显示“6”或者“b”，将S3“0”；这时H1（左列）显示灯“+5V”显示绿灯，NC总清执行完成。即：将S3置于1位置后，按下复位按钮S1,待七段码管显示“6”或者“b”后，将S3置于0位置。NC总清后，SRAM内存中的内容被全部清掉，所有机器数据被预置为缺省值。2、 PLC总清步骤： (1)将PLC启动开关S4“2”;=PS灯会亮。 (2)S4“3”并保持等到PS灯再次亮=PS灯灭了又再亮。 (3)在3秒之内，快速地执行下述操作S4： “2”“3”“2”：=PS灯先闪，后又亮，PS灯亮。（有时PS灯不亮） (4)等PS和PF灯亮了，S4“0”:=PS和PF灯灭，而PR灯亮。即：将S4按钮“232320”；或者打开任意一个PLC程序，通过PLCClear/Rest 来实现。PLC总清后，PLC程序可通过STEP7软件下传至系统。如PLC总清后屏幕上有报警可作一次NCK复位（热启动）。五：配轴1、设置密码Startup Password Set Password SUNRISE OK2、R参数扩展 MD28050:通道R专用参数。通常扩展为900 MD 18120 Number of global user variable GUD data 1020 MD 22200 Output time of M functions0 = Output before motion1 = Output during motion YES MD 222300 Output time of H functions0 = Output before motion1 = Output during motion YES MD 10350 Number of active digital NCK input bytes 015 MD 10360 Number of active digital NCK output bytes 015 MD 18120 Number of global user variable GUD data 1020 MD 19100 5 MD 19200 2 MD 19270 2 264KB MD 32084 Effect of VDI signals on handwheel travel FFH3FH MD 10720 Setting of mode after power ON76 6 = JOG modeMD 10300Number of analog NCK-InputsMD 10320Standardization (adaption to measured quantity).e.g.: Analogmodule +/- 10V = 32767Stroke of measuring test key 15mm = 10VMD10320 = 30 (i.e. max stroke = 30mm)MD 10362Hardware referencee.g.:01 0F 03 011st Byte = 01 = with 840 in any case2nd Byte = 0F = Modul number (Drive number)3rd Byte = 03 = Plug in location on Module4th Byte = 01 = Low-Byte No. of I/O-Bytes on DMP-Module3、垂度斜度补偿（双向螺补） MD1930004H HASH table size for subdirectories MD183420=10第一轴正向补偿点数 MD183421=10第一轴负向补偿点数 MD183422=10第二轴正向补偿点数 MD183423=10第二轴负向补偿点数 与补偿有关的参数双向补偿 MD2015020=2 Initial setting of G groups MD 31030 丝杆螺距 MD 36920 Lead screw pitch MD 1320 Spindle pitch MD32450 反向间隙 MD 31060 Numerator load gearbox MD36922 Numerator of gearbox encoder/load MD1322 Numerator of gear unit encoder / load MD32710 1 Enable of sag compensation SD41300 1 Compensation table enable单向补偿 MD38000 Number of intermediate points for interpol. compensation (SRAM) 插补补偿点数 MD32700 Encoder/spindle error compensation. 插补补偿生效补偿文件的生成：服务输出数据垂度/斜度4、配轴 MD10000:机床坐标轴名 MD20000:通道名称 MD20050:指定几何轴到通道轴 MD20060:通道中几何轴名 MD20070:通道中有效的机床轴号 MD20080:通道中的通道轴名称以七轴双通道设置为例说明（第三主轴为公共轴） MD19100 ON_NUM_AXES_ IN_SYSTEM = 3;系统中最大轴数（实际轴数1） MD19110 ON_NUM_ IPO_AXES = 3 ;联动轴数实际轴数 MD19200 ON_NUM_CHANNELS = 2;系统中通道数 MD19220 ON_NUM_MODE_GROUPS = 1;系统中方式组数 MD10000 Machine axis name 0 = X1 ;系统中的轴名称 MD10000 Machine axis name 1 = Z2 MD10000 Machine axis name 2 = X2 MD10000 Machine axis name 3 = Z2 MD10000 Machine axis name 4 = A1 MD10000 Machine axis name 5 = A2 MD10000 Machine axis name 6 = A3 MD10010 Channel valid in mode group 0 = 1 ;通道指定到方式组 MD10010 Channel valid in mode group 1 = 1CHANDATA (1) ;通道1数据 MD20050 Assignment of geometry axis to channel axis 0 = 1 ;通道中几何轴的轴号 MD20050 Assignment of geometry axis to channel axis 1 = 0 MD20050 Assignment of geometry axis to channel axis 2 = 2 MD20060 Geometry axis name in channel 0 = X ;通道中几何轴的名称 MD20060 Geometry axis name in channel 1 = Y MD20060 Geometry axis name in channel 2 = Z MD20070 Machine axis number valid in channel 0 = 1 ;系统分配通道1的轴号 MD20070 Machine axis number valid in channel 1 = 2 MD20070 Machine axis number valid in channel 2 = 5 MD20070 Machine axis number valid in channel 3 = 7 MD20080 Channel axis name in channel 0 = X ;通道中轴的名称 MD20080 Channel axis name in channel 1 = Z MD20080 Channel axis name in channel 2 = A MD20080 Channel axis name in channel 3 = SPCHANDATA (2) ;通道2数据 MD20050 Assignment of geometry axis to channel axis 0 = 1 ;通道中几何轴的轴号 MD20050 Assignment of geometry axis to channel axis 1 = 0 MD20050 Assignment of geometry axis to channel axis 2 = 3 MD20060 Geometry axis name in channel 0 = X ;通道中几何轴的名称 MD20060 Geometry axis name in channel 1 = Y MD20060 Geometry axis name in channel 2 = Z MD20070 Machine axis number valid in channel 0 = 3 ;系统分配通道2的轴号 MD20070 Machine axis number valid in channel 1 = 4 MD20070 Machine axis number valid in channel 2 = 6 MD20070 Machine axis number valid in channel 3 = 7 MD20080 Channel axis name in channel 0 = X ;通道中轴的名称 MD20080 Channel axis name in channel 1 = Z MD20080 Channel axis name in channel 2 = A MD20080 Channel axis name in channel 3 = SP硬件配置：A1、A2、X1、Z1、X2、Z2、A3驱动配置：位置 1 2 3 4 5 6 7 驱动 5 6 1 2 3 4 7 PLC 的处理CALL FC 19BAGNo :=B#16#1 操作面板控制方式组一ChanNo :=B#16#1 操作面板控制通道一SpindleIFNo:=B#16#3 主轴信号传送到轴三，即第三轴为主轴FeedHold :=M1.0 当面板上按FeedStop键后此位输出1 SpindleHold:=M1.1 当面板上按SpindleStop键后此位输出1 5、斜轴功能 MD19410=8 (位3=1) 选件位: MD 24100: Definition of transformation 1 in channel=1024 MD 24110: AXIS ASSIGNMENT FOR THE 1ST TRANSFORMATION IN THE0=1 斜轴轴号 MD 24110: AXIS ASSIGNMENT FOR THE 1ST TRANSFORMATION IN THE1=2 MD 24120: ASSIGNMENT OF GEOMETRY AXES TO CHANNEL AXES FOR0=1 MD 24120: ASSIGNMENT OF GEOMETRY AXES TO CHANNEL AXES FOR1=0 MD 24120: ASSIGNMENT OF GEOMETRY AXES TO CHANNEL AXES FOR2=2 MD 24700: ANGLE BETWEEN CARTESIAN AXIS AND REAL (INCLINED)=30 斜轴角度 激活/取消斜轴功能:编程: 激活: TRAANG(30) 取消: TRAFOOF参数： MD20140: Transformation data block selected during run up 16、直径编程 MD 20100 Geometry axis with transverse axis function =X MD 20150 Initial setting of G groups28=2 7、偏置设置 MD 20110 Definition of basic control settings after reset =4081/4001 MD 20112 Definition of basic control settings at NC Start=400 MD9422 Select PRESET/Basic offset in JOG=400 SD42440 Traversing from zero offset with incr. programming=08、软限位 1、第一软限位PLC 处理SET= DB3*.DBX2.0参数设置 MD19310=06H MD36100 1st software limit switch minus MCS MD36110 1st software limit switch plus MCS2、第二软限位 PLC 处理DB3*.DBX12.2 第二软限位负DB3*.DBX12.3 第二软限位正参数设置 MD36120 2st software limit switch minus MCS MD36130 2st software limit switch plus MCS 9、位置开关 MD10450 Assignment of software cams to machine axes MD41500 Trigger points at falling cam 1-8 软限位挡块负值（对应DB10.DBX110.*） MD41501 Trigger points at falling cam 1-8 软限位挡块正值（对应DB10.DBX114.*）10、编码器回零 1、回零相关参数 MD11300 INC and REF in jog mode 0、点动 1、保持 MD20700 NC start disable without reference point 0、不需要回零就可执行NC程序 1、需要回零 MD30240 Encoder type of actual value sensing 1、增量 4、绝对 MD34000 Axis with reference point cam 0、无撞块 1、有撞块 MD34010 Approach reference point in minus direction 0、按“”回零 1、按“”回零 MD34210 Adjustment status of absolute encoder 设为1 回零后自动变为22、 绝对编码器回零 MD30240 编码器类型 0 4绝对编码器 MD34210 0 =1 MD34200 Referencing mode 0=03、 增量编码器回零 MD30240 编码器类型 0 1增量编码器 MD34210 0 =1 MD34000 0=1有撞块 MD34020= Reference point approach velocity 回参考点速率（找撞块的速度） 20 MD34030= Maximum distance to reference cam找撞块的安全距离 视机床行程而定 MD34040= Creep velocity 爬行速率 2 MD34050= Direction reversal to reference cam反向到参考点（找零脉的时机，0下降沿，1上升沿） MD34060= maximum distance to reference mark找零脉的安全距离最好1020mm MD34070= Reference point positioning velocity返回参考点定位速度 60 MD34080= Reference point distance参考点位移 0.02 MD34090= Reference point offset/absolute offset参考点偏移绝对位移编码器偏移11、主轴功能 MD20090主主轴的选择 MD30300旋转轴/主轴 1 MD30310旋转轴/主轴的模数转换 1 MD30320旋转轴和主轴的系数360度显示 1 MD30550公共轴被默认分配到哪个通道 1 MD31050负载变速箱分母 MD31060负载变速箱分子 MD32000最大轴速度 MD32010点动模式下的快速移动 MD32020点动轴速率 MD32300轴加速度 MD35000指定主轴到机床轴 MD35040主轴复位 1遇到M02/M17/不停止 MD35100最大轴速度 MD35110齿轮换档的最大速度 MD35130齿轮级的最大速度 MD35140齿轮档的最大速度 MD35200速度模式下的加速度 MD35210位置模式下的加速度 MD36200速率监控门槛 MD36210最大速度设定值 SD43220最大速度设定值 SD43200手动状态的速度/2为1 MD30350 Bit5=1主轴旋转 M1=3(4) S1=N M2=3(4) S2=N12、主轴同步 1、参数 MD19310=06H MD19320=400 MD19330=20 MD19340=F MD19500=1 2、NC程序 头尾架主轴同步SPOS1=ACP0SPOS2=ACP0COUPDEF(S2,S1,1,1,”N0”,”DV”)SPCON1SPCON2SPCON(S2,S1,0) ;0相位角SOPS=ACP(0)M17 头尾架主轴准停COUPDEF(S2,S1,1,1,”N0”,”DV”)SPCON1SPCON2COUPON(S2,S1,0)SPOS=ACP(0)M1713、中心架MD 3700=1 通道程序激活MD37010=*