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  文件名称: SINUMERIK 828D 简明调试手册 SINUMERIK 828D
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SINUMERIK 828D 简明调试手册

这一部分将介绍 SINUMERIK 828D 最为基础的知识,系统性的介绍调试 SINUMERIK 828D 的基

本流程。旨在帮助用户在较短的时间之内能够进行调试工作。本部分内容将按照如下章节进行介
绍。
如没特别说明,本手册中使用的访问级别为“制造商”口令级别。
  调试准备 – 相关硬件和软件的认识
  系统的连接 – 正确的连接是系统调试顺利进行的基础
  初始设定 – 系统总清,设定口令、语言、日期时间、选项等
  PLC 调试 – 了解 PLC 接口、编辑 PLC 报警文本和报警帮助文本
  驱动调试 – 驱动器固件升级、拓扑识别及轴参数自动分配
  NC 参数设定 – 设置控制参数、机械传动参数、速度参数等
  刀具管理 – 如何实现对刀具的统一管理
  伺服优化 – 速度环、位置环自动优化,圆度测试
  机床日志 – 如何记录机床的工作日志

  批量调试 – 数据备份存档以及数据回装,实现批量机床的调试工作

目录
第 1 章 调试准备 ............................................................................................................. 1-1
1.1 硬件说明 ........................................................................................................................... 1-1
1.1.1 NC 数控系统 ............................................................................................................. 1-1
1.1.2 驱动器部件 .............................................................................................................. 1-4
1.2 调试软件 ........................................................................................................................... 1-7
1.2.1 安装调试软件........................................................................................................... 1-7
1.2.2 连接调试软件........................................................................................................... 1-8
1.2.3 SINUMERIK commissioning 软件.............................................................................. 1-11
1.3 个人计算机 ...................................................................................................................... 1-12
第 2 章 系统的连接 ......................................................................................................... 2-1
2.1 系统各部件的连接总图 ....................................................................................................... 2-1
2.1.1 S120 书本型驱动与 828D 系统连接总图 .................................................................... 2-1
2.1.2 S120 Combi 一体型驱动与 828D 系统连接总图 ......................................................... 2-2
2.2 部件说明 ........................................................................................................................... 2-3
2.2.1 SINUMERIK 828D PPU ............................................................................................... 2-3
2.2.2 输入输出模块 PP72/48D PN ...................................................................................... 2-6
2.2.3 机床控制面板 MCP ................................................................................................... 2-9
2.2.4 编码器接口模块 SMC ............................................................................................. 2-12
2.2.5 DRIVE-CLiQ 集线器模块 DMC20 ............................................................................. 2-12
2.2.6 驱动系统和伺服电机 .............................................................................................. 2-13
2.3 驱动器的连接 .................................................................................................................. 2-17
2.3.1 SINAMICS S120 书本型驱动器的连接 ...................................................................... 2-17
2.3.2 SINAMICS S120 Combi 驱动器的连接 ..................................................................... 2-19
2.4 系统通电 ......................................................................................................................... 2-22
2.4.1 通电前检查 ............................................................................................................ 2-22
2.4.2 第一次通电 ............................................................................................................ 2-22
第 3 章 系统初始设定 ...................................................................................................... 3-1
3.1 系统启动菜单 .................................................................................................................... 3-1
3.2 存取级别 ........................................................................................................................... 3-2
3.3 日期和时间 ........................................................................................................................ 3-3
3.4 系统语言 ........................................................................................................................... 3-3
3.5 报警记录 ........................................................................................................................... 3-4
3.6 外设模块的激活 ................................................................................................................. 3-4
3.6.1 MCP 操作面板激活 ................................................................................................... 3-4
3.6.2 输入输出模块 PP72/48 激活 ..................................................................................... 3-4
3.7 授权管理 ........................................................................................................................... 3-5
3.7.1 查看选项 ................................................................................................................. 3-5
3.7.2 选项注册(授权绑定) ............................................................................................. 3-5
3.7.3 备份授权码 .............................................................................................................. 3-9
3.7.4 遗失、忘记授权码 .................................................................................................. 3-10
3.7.5 试用授权 ............................................................................................................... 3-11
第 4 章 PLC 调试 ............................................................................................................. 4-1
4.1 PLC 程序编写规则 .............................................................................................................. 4-1
4.2 PLC 程序结构 ...................................................................................................................... 4-1
4.3 PLC 接口信号工作原理 ........................................................................................................ 4-2
目录
ii
4.4 PLC 例子程序 ....................................................................................................................... 4-3
4.5 Programming Tool PLC828 软件简介 ................................................................................... 4-3
4.6 在线编辑 PLC 程序 .............................................................................................................. 4-4
4.6.1 打开 PLC 程序 ........................................................................................................... 4-4
4.6.2 在线编辑激活/关闭 ................................................................................................... 4-4
4.6.3 在线编辑操作 ........................................................................................................... 4-5
4.7 DB 块功能介绍 ..................................................................................................................... 4-7
4.8 PLC 用户报警 ....................................................................................................................... 4-8
4.8.1 在 HMI 上创建报警文本 ............................................................................................ 4-9
4.8.2 用 AMM 修改报警文本 .............................................................................................. 4-9
4.8.3 创建 PLC 报警在线帮助 ........................................................................................... 4-10
4.9 轴控制使能链 ................................................................................................................... 4-12
4.10 手轮信号 ........................................................................................................................ 4-12
第 5 章 驱动器调试 ......................................................................................................... 5-1
5.1 固件升级 ............................................................................................................................ 5-1
5.2 配置驱动 ............................................................................................................................ 5-1
5.3 配置电源 ............................................................................................................................ 5-2
5.3.1 电网识别 .................................................................................................................. 5-3
5.4 轴分配 ................................................................................................................................ 5-4
5.5 PPU X122/X132 端子信号分配 ............................................................................................. 5-6
5.5.1 控制端子 X122 的定义(SINAMICS I/O) ....................................................................... 5-6
5.5.2 控制端子 X132 的定义(SINAMICS I/O) ....................................................................... 5-7
第 6 章 NC 调试 .............................................................................................................. 6-1
6.1 传动系统参数设置 .............................................................................................................. 6-1
6.2 速度和加速度设置 .............................................................................................................. 6-1
6.3 参考点相关的参数设置 ....................................................................................................... 6-2
6.4 软限位的设置 ..................................................................................................................... 6-4
6.5 反向间隙补偿 ..................................................................................................................... 6-4
6.6 螺距误差补偿 ..................................................................................................................... 6-4
6.6.1 相关机床参数 ........................................................................................................... 6-4
6.6.2 补偿的原理 ............................................................................................................... 6-4
6.6.3 螺距补偿 .................................................................................................................. 6-5
第 7 章 刀具管理 ............................................................................................................ 7-1
7.1 刀库简介 ............................................................................................................................ 7-1
7.2 刀库初始化 ......................................................................................................................... 7-1
7.3 相关机床参数 ..................................................................................................................... 7-7
7.4 刀库文件 ............................................................................................................................ 7-8
7.5 建立传输/响应步骤表 .......................................................................................................... 7-9
7.6 编写 PLC 程序 ................................................................................................................... 7-10
7.7 应用举例 .......................................................................................................................... 7-13
7.7.1 24 个刀位链式刀库(带有两个卡爪) ...................................................................... 7-13
7.7.2 12 个刀位斗笠式刀库(不带卡爪) .......................................................................... 7-16
7.7.3 4 个刀位的转塔刀架 ................................................................................................ 7-20
第 8 章 伺服优化 ............................................................................................................ 8-1
8.1 伺服自动优化 ..................................................................................................................... 8-1
8.1.1 操作步骤 .................................................................................................................. 8-1
8.2 对测试结果进行调整 ........................................................................................................... 8-7
8.2.1 调整方法示例 ........................................................................................................... 8-8
目录
iii
8.3 圆度测试 ......................................................................................................................... 8-10
8.3.1 圆度测试说明......................................................................................................... 8-10
8.3.2 测试结果对比......................................................................................................... 8-14
第 9 章 机床日志 E-Logbook ........................................................................................... 9-1
9.1 创建日志 ........................................................................................................................... 9-1
9.2 导出日志 ........................................................................................................................... 9-2
9.3 上传日志 ........................................................................................................................... 9-2
第 10 章 批量调试 ......................................................................................................... 10-1
10.1 创建批量调试文件 .......................................................................................................... 10-1
10.2 读入批量调试文件 .......................................................................................................... 10-1
第 11 章 网络功能 ......................................................................................................... 11-1
11.1 SINUMERIK828D 网络端口设置 ....................................................................................... 11-1
11.1.1 端口介绍 ............................................................................................................. 11-1
11.1.2 手动设置 X130 口 IP 地址 ..................................................................................... 11-1
11.1.3 网络连接诊断 ...................................................................................................... 11-2
11.2 OPC-UA 数据访问 ............................................................................................................ 11-3
11.2.1 适用配置 ............................................................................................................. 11-3
11.2.2 什么是 OPC .......................................................................................................... 11-3
11.2.3 OPC UA 功能 ......................................................................................................... 11-3
11.2.4 SINUMERIK OPC UA ............................................................................................... 11-3
11.2.5 网络架构 ............................................................................................................. 11-4
11.2.6 OPC 服务器配置 .................................................................................................... 11-4
11.3 网络驱动器 .................................................................................................................... 11-8
11.3.1 适用配置 ............................................................................................................. 11-8
11.3.2 设置网络端口 ...................................................................................................... 11-8
11.3.3 创建共享文件夹 ................................................................................................... 11-8
11.3.4 建立网络驱动器 ................................................................................................... 11-9
11.4 FTP 功能 ....................................................................................................................... 11-10
11.4.1 适用配置 ........................................................................................................... 11-10
11.4.2 功能简介 ........................................................................................................... 11-10
11.4.3 硬件连接 ........................................................................................................... 11-10
11.4.4 828D 配置 .......................................................................................................... 11-10
11.4.5 连接 FTP 服务器 ................................................................................................. 11-11
11.5 PN/PN Coupler 的应用 ................................................................................................... 11-12
11.5.1 适用配置 ........................................................................................................... 11-12
11.5.2 概述 .................................................................................................................. 11-12
11.5.3 配置及调试 ........................................................................................................ 11-13
11.5.4 诊断 PN/PN Coupler 配置 .................................................................................... 11-16
11.5.5 测试通讯 ........................................................................................................... 11-17
第 12 章 测量功能 ......................................................................................................... 12-1
12.1 快速输入输出 ................................................................................................................ 12-1
12.1.1 硬件接口示意图 ................................................................................................... 12-1
12.1.2 接口定义 ............................................................................................................. 12-1
12.1.3 快速输出的控制方式 ............................................................................................ 12-2
12.2 测头调试 ....................................................................................................................... 12-5
12.2.1 测头信号与系统连接 ............................................................................................ 12-5
12.2.2 设置测量信号相关机床数据 .................................................................................. 12-5
目录
iv
12.2.3 检测信号 .............................................................................................................. 12-6
第 13 章 特殊驱动调试 .................................................................................................. 13-1
13.1 配置第二编码器 .............................................................................................................. 13-1
13.1.1 适用配置 .............................................................................................................. 13-1
13.1.2 功能介绍 .............................................................................................................. 13-1
13.1.3 配置第二编码器 .................................................................................................... 13-1
13.2 模拟主轴 ........................................................................................................................ 13-4
13.2.1 适用配置 .............................................................................................................. 13-4
13.2.2 模拟量主轴类型 .................................................................................................... 13-4
13.2.3 硬件连接 .............................................................................................................. 13-5
13.2.4 参数设定 .............................................................................................................. 13-5
13.3 NX 板配置 ....................................................................................................................... 13-6
13.3.1 适用配置 .............................................................................................................. 13-6
13.3.2 功能介绍 .............................................................................................................. 13-6
13.3.3 调试步骤 .............................................................................................................. 13-6
13.4 利用外部接近开关(BERO)实现主轴定向 ...................................................................... 13-8
13.4.1 适用配置 .............................................................................................................. 13-8
13.4.2 硬件连接 .............................................................................................................. 13-8
13.4.3 相关参数 .............................................................................................................. 13-8
13.4.4 实现步骤 .............................................................................................................. 13-9
13.5 添加删除第四轴 ............................................................................................................ 13-10
13.5.1 适用配置 ............................................................................................................ 13-10
13.5.2 功能介绍 ............................................................................................................ 13-10
13.5.3 添加第四轴调试流程 ........................................................................................... 13-10
13.5.4 删除第四轴 ......................................................................................................... 13-14
13.6 扩展 PLC 辅助轴 ............................................................................................................ 13-14
13.6.1 适用配置 ............................................................................................................ 13-14
13.6.2 功能说明 ............................................................................................................ 13-14
13.6.3 硬件连接 ............................................................................................................ 13-14
13.6.4 调试流程(以配置 CU310-2 PN 为例) ................................................................ 13-15
13.7 断电回退 ...................................................................................................................... 13-19
13.7.1 适用配置 ............................................................................................................ 13-19
13.7.2 硬件及连接 ......................................................................................................... 13-19
13.7.3 功能调试 ............................................................................................................ 13-19
13.7.4 调试实例 ............................................................................................................ 13-21
第 14 章 PLC 功能 ......................................................................................................... 14-1
14.1 PI Service......................................................................................................................... 14-1
14.1.1 异步子程序 ASUP .................................................................................................. 14-2
14.1.2 删除口令 .............................................................................................................. 14-4
14.1.3 数据存储 .............................................................................................................. 14-4
14.2 PLC 与 NC 数据交换 ......................................................................................................... 14-5
14.2.1 PLC 读取轴坐标 ..................................................................................................... 14-5
14.2.2 PLC 读/写 NC 数据和驱动数据 ................................................................................ 14-6
14.2.3 PLC 与 NC 数据交换区 .......................................................................................... 14-16
14.3 PLC 轴 ........................................................................................................................... 14-16
14.3.1 功能说明 ............................................................................................................ 14-16
14.3.2 PLC 接口信号 ....................................................................................................... 14-16
14.3.3 举例说明 ............................................................................................................ 14-17
目录
v
第 15 章 双通道调试 ..................................................................................................... 15-1
15.1 概述 .............................................................................................................................. 15-1
15.2 基本配置 ....................................................................................................................... 15-1
15.2.1 方式组选项 .......................................................................................................... 15-1
15.2.2 双通道相关参数 ................................................................................................... 15-1
15.2.3 PLC 相关地址 ........................................................................................................ 15-3
15.3 双通道相关功能调试 ...................................................................................................... 15-4
15.3.1 通道轴交换 .......................................................................................................... 15-4
15.3.2 双通道刀库调试 ................................................................................................... 15-5
15.3.3 双 MCP 调试 ........................................................................................................ 15-6
15.4 双通道 NC 程序 .............................................................................................................. 15-7
15.4.1 NC 程序加载 ......................................................................................................... 15-7
15.4.2 NC 程序协调 ......................................................................................................... 15-7
15.5 双通道调试相关报警 ...................................................................................................... 15-9
第 16 章 扩展应用功能 .................................................................................................. 16-1
16.1 NC 程序中文注释 ............................................................................................................ 16-1
16.2 外部存储器程序执行(EES) .......................................................................................... 16-2
16.2.1 适用配置 ............................................................................................................. 16-2
16.2.2 功能说明 ............................................................................................................. 16-2
16.3 平衡切削 ....................................................................................................................... 16-5
16.3.1 适用配置 ............................................................................................................. 16-5
16.3.2 功能描述 ............................................................................................................. 16-5
16.3.3 编程说明 ............................................................................................................. 16-5
16.3.4 相关参数 ............................................................................................................. 16-6
16.3.5 编程示例 ............................................................................................................. 16-7
16.3.6 相关报警 ............................................................................................................. 16-8
16.4 设备管理器 Easy Extend ................................................................................................. 16-9
16.4.1 适用配置 ............................................................................................................. 16-9
16.4.2 功能说明 ............................................................................................................. 16-9
16.4.3 举例说明(添加删除第 4 轴为例) ....................................................................... 16-9
16.5 维护计划 ..................................................................................................................... 16-12
16.6 节能控制 Ctrl Energy .................................................................................................... 16-13
16.6.1 适用配置 ........................................................................................................... 16-13
16.6.2 功能介绍 ........................................................................................................... 16-13
16.6.3 安装及调试 ........................................................................................................ 16-13
16.6.4 Ctrl-E 方案 .......................................................................................................... 16-18
16.6.5 Ctrl-E 分析 .......................................................................................................... 16-20
16.7 温度补偿 ..................................................................................................................... 16-21
16.7.1 温度补偿原理 .................................................................................................... 16-21
16.7.2 温度补偿误差值的测量 ....................................................................................... 16-22
16.7.3 相关机床参数 .................................................................................................... 16-22
16.7.4 举例 .................................................................................................................. 16-22
第 17 章 用户自定义界面 EasyScreen ............................................................................ 17-1
17.1 适用配置 ....................................................................................................................... 17-1
17.2 EasyScreen 功能概述 ...................................................................................................... 17-1
17.2.1 概述 .................................................................................................................... 17-1
17.2.2 基本实现功能 ...................................................................................................... 17-1
17.2.3 相关选项 ............................................................................................................. 17-1
目录
vi
17.3 设计基础 ........................................................................................................................ 17-2
17.3.1 相关文件 .............................................................................................................. 17-2
17.3.2 文件的安装 ........................................................................................................... 17-2
17.4 界面的创建及实现 .......................................................................................................... 17-4
17.4.1 源代码基本框架 .................................................................................................... 17-4
17.4.2 登入软键栏定义 .................................................................................................... 17-4
17.4.3 页面框架定义 ....................................................................................................... 17-5
17.4.4 举例 ..................................................................................................................... 17-8
17.5 在 EasyScreen 中的中文显示 ........................................................................................... 17-9
17.5.1 使用报警文本显示中文 ......................................................................................... 17-9
17.5.2 在 com 文件中写中文 .......................................................................................... 17-10
第 18 章 SINUMERIK 828D 各部件的安装尺寸 .............................................................. 18-1
18.1 PPU 尺寸 ......................................................................................................................... 18-1
18.2 水平版 PPU ..................................................................................................................... 18-2
18.3 垂直版 PPU ..................................................................................................................... 18-4
18.4 触摸屏 PPU ..................................................................................................................... 18-6
18.5 MCP 483 ......................................................................................................................... 18-7
18.6 MCP 310 ......................................................................................................................... 18-8
18.7 MCP 416 ......................................................................................................................... 18-9
18.8 PP72/48 ......................................................................................................................... 18-10
18.9 电抗器 .......................................................................................................................... 18-11
18.10 SLM 电源模块 .............................................................................................................. 18-13
18.11 AIM 模块 ..................................................................................................................... 18-15
18.12 电机模块 .................................................................................................................... 18-16
18.13 编码器接口模块 .......................................................................................................... 18-20
18.14 Combi 驱动模块 .......................................................................................................... 18-21
第 19 章 机床参数列表 .................................................................................................. 19-1
19.1 显示数据 ........................................................................................................................ 19-1
19.2 通用数据 ........................................................................................................................ 19-2
19.2.1 通道数据 .............................................................................................................. 19-5
19.2.2 轴数据 ................................................................................................................ 19-10
第 20 章 PLC 接口地址 .................................................................................................. 20-1
20.1 PLC 地址说明 ................................................................................................................... 20-1
20.2 MCP483 PN 机床控制面板信号 ......................................................................................... 20-2
20.3 MCP310 PN 机床控制面板信号 ......................................................................................... 20-3
20.4 MCP USB (483/416/310) I/O 信号 (DB1000~DB1100) ................................................ 20-4
20.5 NC 变量的读写(DB1200) ............................................................................................. 20-5
20.6 可保持数据区(DB1400) .............................................................................................. 20-7
20.7 用户报警(DB1600) ..................................................................................................... 20-7
20.8 HMI 接口信号(DB1700~DB1900) ................................................................................. 20-8
20.9 NC 通道辅助功能(DB2500/DB2501) ........................................................................... 20-11
20.10 NCK 的通用信号(DB2600~DB2700) ......................................................................... 20-13
20.11 快速 I/O 的接口信号(DB2800~DB2900) .................................................................. 20-14
20.12 NCK 的通用方式组信号(DB3000/DB3001~ DB3100/DB3101).................................... 20-15
20.13 NCK 通道信号(DB3200/DB3201~DB3300/DB3301) .................................................. 20-15
20.14 来自 NCK 通道的状态信号(DB3300/DB3301) ............................................................... 20-17
20.15 异步子程序(DB3400/DB3401) ................................................................................. 20-18
20.16 NCK 的 G 功能(DB3500/DB3501) ............................................................................ 20-19
20.17 传递的 M-/S- 功能(DB3700/DB3711) ..................................................................... 20-19
20.18 坐标轴或主轴信号(DB3800~DB3811) ..................................................................... 20-19
目录
vii
20.19 来自坐标轴/主轴的通用信号(DB3900~DB3911) .......................................................... 20-21
20.20 刀具管理(DB4000~DB4300) .................................................................................. 20-22
20.21 PLC 机床数据(DB4500) ........................................................................................... 20-25
20.22 同步动作(DB4600/DB4601~DB4700/DB4701) ........................................................ 20-26
20.23 PLC/NC 变量交换区(DB4900) .................................................................................. 20-27
20.24 刀具管理功能(DB5300) ......................................................................................... 20-27
20.25 读取坐标的实际值和剩余值(DB5700~DB5711) ...................................................... 20-28
20.26 刀具管理用户接口(DB9900~DB9902) .................................................................... 20-28
20.27 维护计划用户接口(DB9903~DB9904) .................................................................... 20-30
20.28 EasyExtend 用户接口(DB9905) ............................................................................... 20-31

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