GL SINU840Dsl

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
A
Acceleration with jerk limitation

To achieve an optimum acceleration pattern with reduced wear on the machine's mechanical parts, you can select SOFT
in the part program to ensure a continuous, jerk-free acceleration profile. When you select acceleration with jerk
limitation, the speed characteristic over the path is generated as a bell-shaped curve.
Access protection
Protection level Type PLC User Access to (examples)
DB10
DBB 56
bit ...
0 Password – Siemens All functions, programs, data
1 Password – Machine manufacturers: Defined functions, programs and data (options)

Development
2 Password – Machine manufacturers: Defined functions, programs and data (machine

System startup engineers data)
3 Password – End user: Assigned functions, programs and data

Service
4 Red key 7 End user: < Protection level 0-3

Switch position 3 Programmer, machine setter Machine manufacturers/end users
5 Green key 6 End user: < Protection level 0-3 End users
Switch position 2 Qualified operator who does not program
6 Black key 5 End user: Program selection only,

Switch position 1 Trained operator who does not program tool wear entries and work offset entries
7 Switch position 0 4 End user: No input and program selection possible, only the
Semi-skilled operator machine control panel can be operated
Access to programs, data and functions is protected in a user-oriented hierarchical system of eight access levels.
These are subdivided into:
• 4 password levels (protection levels 0 to 3) for Siemens, machine manufacturers and end users, and
• 4 keyswitch positions (protection levels 4 to 7) for end users (keyswitch positions can also be evaluated via PLC).
SINUMERIK controls thus provide a multi-level concept for controlling access rights.
Protection level 0 has the highest, protection level 7 the lowest access rights. A higher protection level automatically
includes all protection levels below it. Access rights for protection levels 0 to 3 are preprogrammed by Siemens as
standard.
An entered password takes precedence over a keyswitch position, and machine manufacturers or end users can change
access rights for protection levels 4 through 7.
Subprograms can be protected in their entirety against unauthorized reading and displaying.
Action log
The action log (tachograph) records all operator actions and pending alarms for diagnostics purposes.
Glossary for NC 61 • 2010 1/79

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Actual-value system for workpiece

The term "actual-value system for workpiece" is used to designate functions, which allow the SINUMERIK user to:
• begin machining in a workpiece coordinate system defined via machine data in JOG and AUTOMATIC mode without
any additional manipulations after powering up the control
• retain the valid settings relating to active level, settable frames (G54-G57), kinematic transformations, and active tool
compensation at the end of the part program for use in the next part program
• toggle between the workpiece coordinate system and the machine coordinate system
• change the workpiece coordinate system (e.g., by changing the settable frames or tool offset)
Advanced Position Control (APC) (option M13)

The natural frequency of the machine can have a detrimental effect on the maximum speed of the machine and the
surface characteristics. The Advanced Position Control (APC) function raises the KV factor, improves the surface and
therefore increases productivity.
Advanced Surface (option S07)

The Advanced Surface function is used to optimize the motion control. Accurate contours and perfect surfaces can be
achieved even at high machining speeds. With optimized speed management, Advanced Surface delivers better
workpiece surfaces at high workpiece output rates.
2/79 Glossary for NC 61 • 2010

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Alarms and messages
Programming and displaying message texts

• Alarms and messages:
All messages and alarms are output separately on the operator panel in plain text with the date and time and a
symbol indicating the cancel criterion. All alarms are saved in an alarm log that can be configured according to size.
• Alarms and messages in the part program:
Messages can be programmed to give the operator information on the current machining situation during the program
run. Message texts may be up to 124 characters long, and are displayed in two lines (of 62 characters each). The
contents of variables can also be displayed in message texts.
Example 1:
N10 G1 F2000 B=33,333
N15 MSG ("Rotary table position: "«$AA_IW[B]« "Degrees")
Display in message line following traversal of block N10:
Rotary table position: 33,333 degrees
Example 2:
N20 MSG ("X-position" »$AA_IW[X]« "Check!")
Display: X-position ... Check!
In addition to programming messages, you can also set alarms in a CNC program. An alarm always goes hand in hand
with a response from the control according to the alarm category.
You will find a list of responses to the various alarms in the Startup Guide. The alarm text must be configured. Alarm
numbers 65000 to 67999 are reserved for the user.
Example 3:
N100 SETAL (65001) Effect:
Display CNC start interlock
Delete: with Reset
• Alarms and messages from the PLC:
Machine-specific alarms and messages from the PLC program can be displayed as plain text. Messages comprise
status messages and error messages. Whereas the display of a status message is immediately deleted when the
condition is no longer active, error messages must always be acknowledged. Application-specific alarm numbers in
the range 40000 to 89999 can be assigned to general, channel-specific, axis-specific and spindle-specific application
alarms and messages. The response of the control to alarms or messages can be configured. The configured alarm
and message texts are saved in application-specific text files.
• Specific evaluation of alarms:
A channel-specific signal can be used to decide whether other channels may continue to be used when an alarm is
issued.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Analog value control

System variable $A_OUTA(n) enables values from up to eight analog outputs to be preset directly in the part program.
They are output via a SIMATIC DP ET 200 analog module. The value defined by the NCK can be changed by the PLC
before it is output to the hardware. The hardware outputs are written in the interpolation cycle.
Asynchronous subprograms
→ Interrupt routines with fast retraction from the contour
An asynchronous subprogram (ASUB) is a CNC program, which can be started based on an external event (e.g., a
digital input) or from the PLC. Inputs are allocated to subprograms and activated by programming SETINT. If the relevant
event occurs, the CNC block currently being processed is immediately interrupted. The CNC program can be continued
later at the point of interruption. Multiple asynchronous subprograms must be assigned different priorities (PRIO) so that
they can be processed in a certain order. Asynchronous subprograms can be disabled and re-enabled in the CNC
program (DISABLE/ENABLE).
Auxiliary function output

Auxiliary function output informs the PLC when the part program wants the PLC to handle certain machine switching
operations. This is accomplished by transferring the appropriate auxiliary functions and their parameters to the PLC
interface. The transferred values and signals must be processed by the PLC user program. The following functions can
be transferred to the PLC:
• Tool selection T
• Tool offset D/DL
• Feed F/FA
• Spindle speed S
• H functions
• M functions
Auxiliary function output may be carried out either with velocity reduction and PLC acknowledgement up to the next
block, or before and during travel without velocity reduction and without block change delay. Following blocks are then
retracted without a time-out.
Axes, trailing
When a defined master axis moves, the coupled-motion axes (following axes) assigned to it travel the traverse paths
derived from the master axis, taking into account a coupling factor (setpoint coupling). Together, the master axis and the
following axes form a coupled-axis grouping. Definition and activation of a coupled-axis grouping take place
simultaneously with the modal-like instruction TRAILON. A coupled-axis grouping can consist of any desired
combinations of linear and rotary axes. A coupled-motion axis can be assigned up to two master axes (in different
coupled-axis groupings) simultaneously. A simulated axis can also be defined as the master axis, in which case the real
axis actually does the traveling, taking into account the coupling factor. Another application for coupled-motion axes is
the use of two coupled-axis groupings to machine the two sides of a workpiece.
Axes/spindles (option A01-A26)

→ Spindle functions
Axes
Interpolating path axes
An additional interpolating axis/spindle can extend the number of axes/spindles in the basic configuration.
Spindles
Spindle drives can be speed-controlled or position-controlled.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Axial coupling in the machine coordinate system MCS

(option M23)
Axial coupling in the machine coordinate system is required in order to be able to use coupled axes implemented in the
basic coordinate system for transformations as well. A coupling is carried out 1:1 in the machine coordinate system.
The participating axes can be reconfigured following Reset.
On machine tools with separately movable heads on which a transformation must be activated, the orientation axes
cannot be coupled using the standard coupling methods (COUPON, TRAILON).
The axes participating in the coupling are determined via axial machine data that is updated with RESET. This makes it
possible to redefine pairs of axes during operation and enable and disable them via CNC language commands.
There are master and slave axes. A master axis can have more than one slave axis, but a slave axis cannot be a master
axis at the same time (no cascading). To protect the heads from collisions, collision protection can be set and activated
either via machine data or the VDI interface.
Axis data output via PROFIBUS ADAS (option N07)

The loadable compile cycle supports output of axis and spindle data to a special PROFIBUS slave module.
This function can be used, for example, for process or machine monitoring functions in real time outside the CNC. The
required axis and signal type are selected by transferring a selection command (length: 8 bytes) to the CNC.
The compile cycle in the NC kernel then sends up to 30 axis data items (of 4 bytes each) to the slave in each PROFIBUS
cycle. With the slaves in isochronous mode, the transfer cycle can be equal to the position control cycle, or a multiple of
it.
Axis limitation from the PLC

→ Protection areas
The preactivation of protection zones with specification of a position offset is programmed in the part program. You can
put the preactivated protection zones into effect in the PLC user program via the PLC interface. As a result, the relevant
protection zone is activated, for example, before a tool probe is swiveled into position in the working area, to see whether
the tool or a workpiece is in the path of the swiveling part.
The PLC can put another axis limitation into effect by activating the 2nd software limit switch via a PLC interface signal.
This reduction of the working area may become necessary, for example, when a tailstock is swiveled into position. The
change is immediately effective, and the 1st software limit switch plus/minus is no longer valid.
Axis/spindle replacement
An axis/a spindle is permanently assigned to a specific channel via machine data. The axis/spindle replacement function
can be used to release an axis/a spindle (RELEASE) and to assign it to another channel (GET), i.e., to replace the
axis/spindle. The relevant axes/spindles are determined via machine data.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Backlash compensation
Positive backlash (normal case)

The actual encoder value is ahead of the true actual value (table): The table does not travel far enough.
During power transmission between a moving machine part and its drive (e.g., ball screw), there is normally a small
amount of backlash because setting mechanical parts so that they are completely free of backlash would result in too
much wear and tear on the machine. In the case of axes/spindles with indirect measuring systems, mechanical backlash
results in corruption of the traverse path. For example, when the direction of movement is reversed, an axis will travel too
much or too little by the amount of the backlash.
To compensate for backlash, the axis-specific actual value is corrected by the amount of the backlash every time the
axis/spindle reverses its direction of movement.
If a 2nd measuring system is available, the relevant backlash on reversal must be entered for each of the two measuring
systems. Backlash compensation is always active in all modes following reference point approach.
Block search
The block search function allows any point in the part program to be selected, at which machining must start or be
continued. The function is provided for the purpose of testing part programs or continuing machining after a program
abort. Cascaded block search is also possible.
You have a choice of 4 different search options:
• Block search with calculation at the contour:
During the block search, the same calculations are executed as during normal program operation. The target block is
then traversed true-to-contour until the end position is reached. Using this function it is possible to approach the
contour again from any situation.
• Block search with calculation at the block end point:
This function allows you to approach a target position (such as tool change position). All calculations are also
executed here as during normal program operation. The end point of the target block or the next programmed
position is approached using the method of interpolation valid in the target block.
• Block search without calculation:
This method is used for high-speed searches in the main program. No calculations are carried out during the search.
The internal control values remain the same as before the block search.
• External block search without calculation:
In the menus "Search position" and "Search pointer", you can use the softkey "External without calc." to start an
accelerated block search for programs which are executed by an external device (local hard disk or network drive).
You can specify the search destination by:
• Directly positioning the cursor on the target block
• Specifying a block number, a jump label, any character string, a program name, or a line number

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Cartesian PTP travel

For handling and robot-related tasks, two types of movement are required, either in the Cartesian coordinate system
(continuous path, CP), or as a point-to-point (PTP) movement. With PTP, the shortest way to reach the end point is with
activated (!) TRAORI transformation. PTP generates a linear interpolation in the axis space of the machine axes. By
smoothing from PTP to CP movement, it is possible to switch from fast infeed to a mounting or positioning movement
with optimum timing.
PTP travel does not result in an axis overload when traveling through a singularity, such as the changing of an arm
position during handling.
PTP travel is also possible in JOG mode and does not require Cartesian positions (e.g., from CAD systems) to be
converted into machine axis values. Cartesian PTP travel is also used for cylindrical grinding machines with an inclined
axis: With active transformation, the infeed axis can be moved either according to Cartesian coordinates or at the angle
of the inclined axis.
Circle via center point and end point

Circular interpolation causes the tool to move along a circular path in a clockwise or counter-clockwise direction. The
required circle is described by:
• Starting point of circular path (actual position in the block before the circle)
• Direction of rotation of circle
• Circle end position (target defined in circular block)
• Circle center
The circle center can be programmed as an absolute value with reference to the current zero point or as an incremental
value with reference to the starting point of the circular path.
If the opening angle is apparent from the drawing, then it can be directly programmed.
In many cases, the dimensioning of a drawing is chosen so that it is more convenient to program the radius in order to
define the circular path. In the case of a circular arc of more than 180 degrees, the radius specification is given a
negative sign.
Circle via intermediate point and end point

If a circle is to be programmed, which does not lie in a paraxial plane but obliquely in space, an intermediate point can be
used to program it instead of the circle center. Three points are required to program the circle: the starting point,
intermediate point and end point.
Clamping monitoring
→ Position monitoring, standstill monitoring
Clamping monitoring is one of SINUMERIK's many extensive monitoring mechanisms for axes.
When an axis is to be clamped on completion of the positioning action, you can activate clamping monitoring using the
PLC interface signal "clamping in progress". This may become necessary because it is possible for the axis to be pushed
beyond the standstill tolerance from the position setpoint during the clamping procedure. The amount of deviation from
the position setpoint is set via the machine data. During the clamping procedure, clamping monitoring replaces standstill
monitoring, and is effective for linear axes, rotary axes, and position-controlled spindles. Clamping monitoring is not
active in follow-up mode. When the monitor responds, its reactions are the same as those of the standstill monitor.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Clearance control 1D in the IPO cycle

Clearance control 1D in the IPO cycle can be used, for example, to evaluate sensor signals via a high-speed analog
input. It can also be used to compute a position offset $AA_OFF for an axis via a synchronous action.
Clearance control 1D/3D in the position-control cycle

(option M40)
Clearance control 1D/3D in the position-control cycle (which includes the IPO cycle) controls three machine axes as well
as a gantry axis and makes it possible to automatically maintain the constant clearance that is technologically required
for the machining process.
The most important applications for this are water jet cutting and laser cutting, for example, the radial cutting of rods with
non-circular cross sections.
Limited functionality of export control versions:
Clearance control 1D in the position-control cycle only, number of interpolating axes restricted to 4.
CNC program messages

→ Alarms and messages
All messages programmed in the part program and all alarms recognized by the system are displayed on the operator
panel in plain text. Alarms and messages are displayed separately. You can program messages in order to provide the
operator with the latest information on the current machining situation during the program run.
CNC user memory

All programs and data, such as part programs, subprograms, comments, tool offsets, and work offsets/frames, as well as
channel and program user data, can be stored in the shared CNC user memory. The CNC user memory is battery-
backed.
Compensation of a forced mechanical coupling, AXCO (option)

The loadable compile cycle allows a movement of an axis that occurs due to mechanical coupling of an axis to a
following axis, to be compensated such that the axis remains mechanically stationary despite the coupling. The motor of
the coupled axis, in this case, is rotated in the set coupling ratio.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Concatenated transformations
Grinding a TRANSMIT contour with inclined axis

With the TRACON command, two transformations can be concatenated: TRAANG (inclined axis), as the base
transformation, can be linked with TRAORI (5-axis transformation), TRANSMIT (front end machining of turned parts) or
TRACYL (cylinder surface transformation).
Applications:
• Rotary milling with mechanically non-orthogonal Y axis to X, Z (inclined-bed rotary milling machine)
• Grinding of contours programmed with TRACYL (cylinder processing)
• Finishing of a distorted contour created with TRANSMIT
Continue machining at the contour (Retrace Support)

(option M24)
When using 2D flat bed cutting procedures, e.g., laser, oxygen or water jet cutting, the machine operator can return to
the program continuation point (selected solely for the view of the workpiece) following an interruption in machining
without exact knowledge of the part program in order to continue machining the workpiece from there.
The Continue machining at the countour function (Retrace Support) contains a ring buffer for the geometric information of
the blocks already executed.
A new part program is generated from this for the reverse travel. Retracing is used, for example, when the machine
operator only notices the failure or interruption a few blocks after the actual interruption. The head has usually already
progressed further in the machining, and must, therefore, be appropriately returned for continuation of machining.
Continuous dressing (parallel dressing)
Parallel dressing
With this function, the form of the grinding wheel can be dressed in parallel with the machining process. The grinding
wheel compensation resulting from dressing the wheel takes immediate effect as tool length compensation.
When the tool radius compensation is programmed to machine the contour and the tool radius changes because of the
dressing of the grinding wheel, the CNC computes the dressing amount online as a true tool radius compensation.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Continuous-path mode with programmable rounding clearance
Continuous-path mode with programmable rounding clearance

The aim of the continuous-path mode is to avoid excessive deceleration at the block boundaries and to achieve as
constant a tool path velocity as possible during tangential transitions from one block to the next. Because the tool does
not stop at block boundaries, no undercuts are made on the workpiece. If continuous-path mode (G64) is selected,
reduction in velocity takes place and contour corners are rounded on non-tangential transitions. A soft contour transition
without a jump in acceleration can be programmed with G641 ADIS=...
Contour definition programming

Contour definition programming allows you to input simple contours quickly. With the aid of help displays in the editor,
you can program 1-point, 2-point or 3-point definitions with transition elements chamfer or corner easily and clearly by
entering Cartesian coordinates and/or angles.
Contour handwheel (option M08)

→ Feedrate interpolation
When the contour handwheel function is activated, the handwheel has a velocity-generating effect in AUTOMATIC and
MDI modes on all programmed traversing movements of the path and synchronized axes.
A feedrate specified via the CNC program becomes ineffective and a programmed velocity profile is no longer valid. The
feedrate, in mm/min, results from the handwheel pulses as based on pulse weighting (machine data) and the active
increment. The handwheel's direction of rotation determines the direction of travel:
• Clockwise:
In the programmed direction of travel (even beyond block boundaries)
• Counter-clockwise:
Against the programmed direction of travel (continuation beyond the start of the block is prevented)
Contour monitoring
→ Travel to fixed stop
The following error is monitored within a definable tolerance band as a measure of contour accuracy. An impermissibly
high following error might be caused by a drive overload, for example. If an error occurs, the axes/spindles are stopped.
"Contour monitoring" is always enabled when a channel is active and in position-controlled mode.
If the channel is interrupted or in the reset state, contour monitoring is not active. Contour monitoring is also deactivated
during execution of the "travel to fixed stop" function.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Contour monitoring with tunnel function (option M52)

With the "contour monitoring with tunnel function" function, the absolute movement of the tool tip in space can be
monitored in 5-axis machining or when complex workpieces are being machined. This function provides optimum
protection for high-quality workpieces. A cylindrical tunnel (tolerance field) with a definable diameter is placed around the
programmed path.
If during machining the deviation from the path caused by axis errors is greater than the defined tunnel diameter, the
axes are brought to a standstill immediately. The deviation from the path can be written simultaneously to an analog
output.
Control unit management

The Thin Client Unit (TCU) for distributed installation allows the spatial separation of SINUMERIK OP (TP) operator
panel fronts and SINUMERIK PCUs, as well as the connection of up to 4 operator panel fronts to a PCU with one TCU
each. To this end, the user interface of a PCU 50.3 is copied to several OPs with one TCU each. Advantages:
• Low-vibration installation of the PCU in the control cabinet
• Efficient operation of larger machines using up to 5 uniform operator panels
• Signal transmission between PCU and operator panel front via Industrial Ethernet
• Operation on the active operator panel with the option to enable the passive operator panel on request
• Mixed operation of operator panel fronts on a TCU or with an integrated TCU and an operator panel front directly
connected to the PCU possible
• Distance between PCU and operator panel fronts of up to 100 m (max. distance between two network nodes)
Crank interpolation "CRIP" (option)

It supports simple programming and machining of pin bearing seats on a crankshaft. The function can be utilized in more
than one channel, which means that a single workpiece can be machined simultaneously with several grinding units. The
function calculates the compensating movement of the grinding wheel in relation to the rotating workpiece surface. As
with normal cylindrical grinding, the pin bearing journal is programmed as a radial distance X between the workpiece and
grinding wheel.
Cross-mode actions (option M43)

→ Interrupt routines with fast retraction from the contour
Asynchronous subprograms (ASUB) make it possible to respond immediately to high-priority events not only during
program execution, but in all modes and program states.
In the case of such an interrupt, it is also possible to start an asynchronous subprogram in manual modes. The
asynchronous subprogram can be used, for example, to bring the grinding wheel to a safe position to avoid collision. This
option also enables statically effective IDS synchronous actions, which are active in all modes.
Cycle protection (OEM) (option P54)

With cycle protection, cycles can be encrypted and then stored protected in the control. Execution in the NC is possible
without restrictions, but it is not possible to view the cycle. This protects the internal company know-how. The cycle can,
however, be copied in encrypted form. It can, therefore, be used on other machines.
If this should also be prevented, the cycle can be permanently bound to a particular CNC hardware unit by means of an
addition to the program.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Cycle support
→ SINUMERIK Operate runtime license OA Easy Screen
The technology cycles for drilling, milling and turning and the measuring cycles are supported by cycle screens. Similar
input displays are also available for geometric contour programming. You can, however, also define a number of
softkeys, input fields and displays yourself using the "Expand user interface" or "Easy Screen" function.
Data exchange between machining channels

→ High-level CNC language
In the "program coordination" function, variables shared by the channels (NCK-specific global variables) can be used for
data exchange between the programs. The program message itself is separate for each channel.
Diagnostics functions
For service purposes, a self-diagnostics program and testing aids have been integrated in the controls. The status of the
following can be displayed on the operator panel:
• Interface signals between the CNC and the PLC and between the PLC and the machine
• Data blocks
• PLC bit memories, timers and counters
• PLC inputs and outputs
For testing purposes, signal combinations can be set for the output signals, input signals, and bit memories. All alarms
and messages are displayed in plain text on the operator panel along with the corresponding acknowledgement criterion.
Alarms and messages are displayed separately.
In the "service display" menu, it is possible to call up important information about the axis and spindle drives, such as:
• Absolute actual position
• Position setpoint
• Following error
• Speed setpoint
• Actual speed value
• Trace of CNC and drive variables
Dimensions metric/inches
Depending on the measuring system used in the production drawing, you can program workpiece-related geometrical
data in either metric measure (G71) or inches (G70). The control can be set to a basic system regardless of the
programmed dimensional notation. You can enter the following geometrical data directly and let the control convert them
into the other measuring system (examples):
• Position data X, Y, Z, etc.
• Interpolation parameters I, J, K and circle radius CR
• Pitch
• Programmable work offset (TRANS)
• Polar radius RP
With the G700/G710 programming expansion, all feedrates are also interpreted in the programmed measuring system
(inch/min or mm/min). In the "Machine" operating area, you can switch back and forth between inch and metric
dimensional notation using a softkey.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Display functions
All current information can be displayed on the operator panel's screen, such as:
• Block currently being executed
• Previous and following block
• Actual position, distance-to-go
• Current feedrate
• Spindle speed
• G functions
• Auxiliary functions
• Workpiece designation
• Main program name
• Subprogram name
• All data entered, such as part programs, user data and machine data
• Help texts
Important operating states are displayed in plain text, for example:
• Alarms and messages
• Position not yet reached
• Feed stop
• Program in progress
• Data input/output in progress
DOUBLETRANSMIT transformation, 2TRA (option M25)

The function supports machining on the end face or peripheral surface with a driven tool that is always held vertically with
respect to the contour by means of an appropriate swivel movement and balancing movement in X.
Transformation, doubletransmit
DRF offset (differential resolver function)

→ Handwheel override
The differential resolver function generates an additional incremental work offset in AUTOMATIC mode via the electronic
handwheel. This function can be used, for example, to correct tool wear within a programmed block.

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Glossary
Functions and Terms
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SINUMERIK 840D sl
Dynamic preprocessing memory (FIFO)

The traversing blocks are readied prior to execution and stored in a preprocessing memory (FIFO = first in/first out) of
specifiable size. In contour sections that are machined at high velocity with short path lengths, blocks can be executed
from this preprocessing memory at very high speed. The preprocessing memory is constantly reloaded during execution.
Block execution can be interrupted with the STARTFIFO command until the preprocessing memory been filled, or
STOPFIFO (start high-speed machining section) or STOPRE (stop preprocessor) can be programmed.
Easy Screen (option P64)

Electronic gear (option M22)

The electronic gear function allows highly accurate kinematic coupling of axes with programmable gear ratio. Linking can
be specified and selected for any CNC axes via program or operator panel.
The electronic gear function makes it possible to control the movement of a following axis, depending on up to 5 master
axes.
The relations between the master axis and the following axis are defined for each master axis by a fixed gear ratio
(numerator/denominator) or as a linear or non-linear coupling using a curve table. The following axis can be a master
axis for another gear system (cascading). Real as well as simulated linear and rotary axes can be used as the master
and following axes. Master input values can be setpoints generated by the interpolator (setpoint linkage) or actual values
delivered by the measuring system (actual-value linkage). Using the electronic gear with non-linear coupling, it is
possible to create convex tooth faces during gear cutting and also to compensate the non-linear properties of the
process, for example.
Limited functionality of export control versions: The number of simultaneously traversing axes is restricted to 4.
Electronic handwheels
Using electronic handwheels, it is possible to move selected axes simultaneously in manual mode. The handwheel clicks
are analyzed by the increment analyzer. If coordinate offset or coordinate rotation is selected, it is also possible to move
the axes manually in the transformed workpiece coordinate system. The maximum input frequency of the handwheel
inputs is 100 kHz.
A third handwheel can also be operated as a contour handwheel.
The "contour handwheel" function permits use of a handwheel on conventional turning machines (for ShopTurn
applications, for example) and also during grinding for traversing on a contour.
Once the "contour handwheel" function has been activated, the handwheel has a velocity-generating effect in
AUTOMATIC and MDA modes, i.e., a feedrate specified via the CNC program is no longer effective and a programmed
velocity profile is no longer valid. The feedrate, in mm/min, results from the handwheel pulses as based on pulse
evaluation (via machine data) and the active increment (INC1, INC10, etc.).
The handwheel's direction of rotation determines the direction of travel: clockwise in the programmed direction, even
over block boundaries, and counter-clockwise up to the block start.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Electronic transfer (option M35)

→ Position switching signals/cam controller
→ Polynomial interpolation
→ Master value coupling and curve table interpolation
→ Cross-mode actions
→ I/O interfacing via PROFIBUS DP
→ Synchronized actions stage 2
→ Pairs of synchronized axes (gantry axes)
In presses with transfer step tools as well as in large-part transfer presses, a modern transfer system handles part
transport. Positioning drives are controlled in step with the press's main motions. The "electronic transfer" option makes it
possible to control sequences of motion in transfer systems (such as gripper or suction lines, etc.), depending on a
master value, which corresponds to the current ram position of the press. The "electronic transfer" option contains
secondary options for "position switching signals/cam controller", "polynomial interpolation", "master value coupling and
curve table interpolation", "cross-mode actions", "I/O interfacing via PROFIBUS DP", "synchronized actions stage 2", as
well as two "pairs of synchronized axes (gantry axes)". Combinations of these individual options satisfy all requirements
for highly dynamic and accurate transfer controls. When using the "electronic transfer" option, the "spindle" and "tool
offset" functions cannot be activated.
Limited functionality of export control versions: The number of simultaneously traversing axes is restricted to four.
Electronic transfer CP (option M76)

→ Position switching signals/cam controller, → Polynomial interpolation, → Generic couplings,
→ Cross-mode actions, → I/O interfacing via PROFIBUS DP, → Synchronized actions stage 2,
→ Pair of synchronized axes (gantry axes)
In presses with transfer step tools as well as in large-part transfer presses, a modern transfer system handles part
transport. Positioning drives are controlled in step with the press's main motions. The "Electronic transfer CP" option
makes it possible to control sequences of motion in transfer systems (such as gripper or suction lines, etc.), depending
on a master value, which corresponds to the current ram position of the press. The "Electronic transfer CP" option
includes the options:
• Position switching signals/cam controller
• Polynomial interpolation
• Generic coupling CP Comfort
• Cross-mode actions
• I/O interfacing via PROFIBUS DP
• Synchronized actions stage 2
• Pairs of synchronized axes (gantry axes)
Combinations of these individual options satisfy all requirements for highly dynamic and accurate transfer controls. When
using the "Electronic transfer CP" option, the "Spindle" and "Tool offset" functions cannot be activated.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Electronic weight counterbalance
Electronic weight counterbalance

With weight-loaded axes without mechanical or hydraulic weight counterbalance, the vertical axis drops when the brake
is released and the servo enable is switched on. The undesired lowering (dZ) of the axis can be compensated by
activating electronic weight counterbalance. After releasing the brake, the constant weight counterbalance torque
maintains the position of the vertical axis.
Sequence:
1. Brake holds Z axis.
2. Brake is released; servo enable on; pulse enable on
3. Z axis does not drop, holding its position.
Evaluation of internal drive variables (option M41)

The evaluation of internal drive variables can be used to control (adaptive control) a second process variable (such as a
path-specific or axis-specific feedrate) depending on a measured process variable (such as spindle current).
This permits, for example, the cutting volume to be kept constant when grinding, or faster covering of the grinding gap
when scratching (first touch). Evaluation of these drive variables also permits machines and tools to be protected from
overloading, as well as shorter machining times and an improved surface quality for the workpieces to be achieved.
Evaluation of internal drive variables is a prerequisite for implementing adaptive control (AC). Adaptive control can be
parameterized within the part program as follows:
• Additive influence: The programmed value (F word) is corrected by adding.
• Multiplicative influence: The F word is multiplied by a factor (override).
The following real-time variables can be evaluated as internal drive variables:
$AA_LOAD drive capacity utilization in %
$AA_POWER drive active power in W
$AA_TORQUE drive torque setpoint in Nm
$AA_CURR actual axis/spindle current in A

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Extended stop and retract (incl. generator operation)

(option M60)
A safe position is assumed from the machining level without any collision between tool and workpiece.
As well as the drive-autonomous stop and retract function, the "CNC-controlled stop and retract" functionality is also
provided. To permit gentle interpolated retraction on the path or contour, the path interpolation can be processed further
for a definable period following the triggering event. The retraction axes are subsequently traversed in synchronism to an
absolute or incremental position as programmed.
These functions are primarily used for gearing and grinding technologies.
Fast-IPO-Link (option M12)

Non-circular machining can be carried out for general workpiece contours using polynomial interpolation or, with
sinusoidal default settings, using master value coupling and curve table interpolation.
In the case of very fast non-circular machining, Fast-IPO-Link permits transfer of the non-circular task (e.g. movement of
X axis) to a separate NCU with fast cycle. Speeds greater than 3,000 rpm can then be achieved for sinusoidal
movements.
Feedforward control
The following errors can be reduced to almost zero with feedforward control. This feedforward control is therefore also
called following error compensation. Particularly during acceleration in contour curvatures, e.g. circles and corners, this
following error leads to undesirable, velocity-dependent contour violations.
• Velocity-dependent speed feedforward control (basic version):
In velocity-dependent feedforward control, the following error can be reduced almost to zero at constant velocity.
• Acceleration-dependent torque feedforward control (option):
In order to achieve precise contours even when the demand for dynamics is at its highest, you can use torque
feedforward control. If the settings are right, you can compensate the following error almost completely, even during
acceleration. The result is excellent machining precision even at high tool path feedrates.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Feedrate interpolation (feed characteristic)

→ Polynomial interpolation
Programming example for feedrate interpolation

N1 Constant feedrate profile F1000: FNORM
N2 Abrupt set velocity change F2000: FNORM
N3 Feedrate profile via polynomial : F = FPO (4000, 6000, -4000)
N4 Polynomial feedrate 4000 as modal value
N5 Linear feedrate profile F3000: FLIN
N6 Linear feedrate 2000 as modal value
N7 Linear feedrate, as modal value
N8 Constant feedrate profile with abrupt acceleration change F1000: FNORM
N9 All subsequent F values are linked by splines F1400: FCUB
N13 Switch off spline profile
N14 FNORM
In accordance with DIN 66025, a constant feedrate over the part program block can be defined via address F. For a
more flexible definition of the feedrate profile, programming to DIN 66025 is extended by linear and cubic profiles over
the path. The cubic profiles can be programmed directly or as an interpolating spline.
This makes it possible, depending on the curvature of the workpiece to be machined, to program continually smooth
velocity profiles, which in turn allow jerk-free acceleration changes and thus the production of uniform workpiece
surfaces. You can program the following feedrate profiles:
• FNORM
Behavior as per DIN 66025 (default setting). An F value programmed in the CNC block is applied over the entire path
of the block, and is subsequently regarded as a fixed modal value.
• FLIN
An F value programmed in the block can be traversed linearly (rising or falling) over the path from the current value at
the beginning of the block to the end of the block, and is subsequently regarded as modal value.
• FCUB
The non-modally programmed F values, referred to the end of the block, are connected through a spline. The spline
starts and ends tangentially to the previous or following feedrate setting.
• FPO
You can also program the feedrate profile directly via a polynomial. The polynomial coefficients are specified
analogous to polynomial interpolation.
Feedrate override
The programmed velocity is overridden by the current velocity setting via the machine control panel or by the PLC (0 %
to 200 %). In order for the cutting velocity on the contour to be kept constant, the feedrate calculation is referred to the
operating point or tool end point. The feedrate can also be corrected by a programmable percentage factor (1 % to 200
%) in the machining program. This factor is overlaid (multiplication) on the setting made on the machine control panel.
The velocity setting from the PLC is axis-specific.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Follow-up mode
In follow-up mode, an axis/a spindle can be moved independently, while the actual value continues to be detected. The
traverse paths are updated in the display. Standstill, clamping and positioning monitoring functions are not effective in
follow-up mode. Once follow-up mode is cancelled, reference-point approach of the axis does not have to be repeated.
Frame concept
Frame is the common term for a geometric expression describing an arithmetic operation, for example, translation or
rotation.
On SINUMERIK controls, the frame in the CNC program transfers from one Cartesian coordinate system to another, and
represents the spatial description of the workpiece coordinate system.
The following are possible:
• Basic frames: Coordinate transformation from basic coordinate system (BCS) into basic zero system (BZS)
• Settable frames: Work offsets using G54 to G57/G505 to G599
• Programmable frames: Definition of workpiece coordinate system (WCS)
The frame concept makes it possible to transform Cartesian coordinate systems very simply by offsetting, rotating,
scaling and mirroring.
The following instructions are used to program these options:
• TRANS programmable work offset
• ROT rotation in space or in a plane
• ROTS rotation referred to the solid angle projected into the planes
• SCALE scaling (scale factor)
• MIRROR mirroring
• TOFRAME frame according to tool orientation
• TOROT rotary component of programmed frame
• PAROT frame for workpiece rotation (table rotation)
• MEAFRAME frame calculation from three measuring points in space (for measuring cycles)
The instructions can also be used several times within one program. Existing offsets can either be overwritten or new
ones can be added.
Additive frame instructions:
ATRANS additive programmable work offset
AROT additive rotation in space or in a plane
ASCALE scale factor (multiplication)
AMIRROR repeated mirroring
AROTS additive rotation referred to the solid angle projected into the planes
If swivel-mounted tools or workpieces are available, machining can be implemented very flexibly, for example:
• By machining several sides of a workpiece by rotation and swiveling of the machining plane
• By machining of inclined surfaces using tool length and tool radius compensation
Generator operation
With the generator operation function, brief power outages can be bridged or power provided for retraction. To make this
possible, the energy stored during spindle rotation or axis movement is fed back into the DC link, following the same
principle as that used by generators.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Generic coupling Basic: "CP Basic" (option M72)

This option offers:
• Up to 4 x coupled motion and
• 1 x "Synchronous spindles/multi-edge turning" or "Master value coupling/curve table interpolation" or "Axial coupling
in the machine coordinate system"
Generic coupling Comfort: "CP Comfort" (option M73)

This option offers:
→ Up to 4 x coupled motion and
→ Up to 4 x "Synchronous spindles/multi-edge turning" and/or "Master value coupling/curve table interpolation" and/or
"Axial coupling in the machine coordinate system"
Also
→ 1 x "Electronic gear unit" function for up to 3 master axes is possible (without curve table interpolation and without
cascading).
Generic coupling Expert: "CP Expert" (option M74)

This option offers:
• Up to 8 x coupled motion and
• Up to 8 x "Synchronous spindles/multi-edge turning" and/or "Master value coupling/curve table interpolation" and/or
"Axial coupling in the machine coordinate system"
Also:
• Up to 8 x "Electronic gear unit" function for up to 3 master axes as well as
• Up to 5 x "Electronic gear unit" function for up to 5 master axes (each with curve table interpolation and with
cascading).
The CP Expert option is only possible in combination with NCU 720/730.
Generic coupling Standard: "CP Standard"

The basic version already offers:
• Up to 4 x simple coupled motion (with one master axis, not used with synchronized actions)
Generic coupling Static: "CP Static" (option M75)

This option offers:
• One simple synchronous spindle (with coupling ratio 1:1, no multi-edge machining)
Generic couplings (basic version/options)

For generic (general) coupling (CP) of axes/spindles, we offer 5 different performance levels. The functionality is scalable
via the number of master axes to one slave axis, via coupling characteristics ranging from simple functionality through to
technological innovations and via the simultaneously activatable coupling types. The options CP Static, CP Basic,
CP Comfort and CP Expert are available. These options can be combined as required.
Functionality limitations on the SINUMERIK 840DE sl/840DiE sl: see the functional limitations for each of the above-
mentioned functions and options.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Geometry axes, switchable online in the CNC program
Geometry axes, switchable online

In the CNC, geometry axes form axis groupings per channel for the interpolation of path motions in space.
Channel axes are assigned to geometry axes via machine data.
With the switchable geometry axes function, it is possible, from the part program, to assemble the geometry axis
grouping from other channel axes. This makes problem-free operation of machine kinematics with parallel axes possible.
Grinding wheel surface speed, constant

Automatic conversion of the grinding wheel surface speed to a speed of rotation as a function of the current grinding
wheel diameter. This function can be active for several grinding wheels simultaneously in one CNC channel. The
grinding wheel surface speed is monitored.
A constant grinding wheel surface speed is not only useful during processing of a part program in AUTOMATIC and MDA
modes, but can also be effective immediately after power-up of the control, on reset, and at the end of the part program,
and remain in force beyond all mode changes (depending on the machine data).
Handling package (option S31)

For handling systems, the handling package offers a cost-effective solution:
• 3 additional axes
• 3 additional channels
• Transformation package Handling (option M31; requires a loadable compile cycle)
• Synchronized actions stage 2 (option M36)
• No tool offsets and no spindles

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Handwheel override
Handwheel override in AUTOMATIC mode

With the handwheel override function, an axis can be traversed or the velocity of an axis can be overridden. The function
is effective blockwise.
At the same time, additional axes can be traversed simultaneously or using interpolation. The actual-value display is
continuously updated.
Application: Grinding machines
Helical interpolation 2D+6
Helical interpolation: Thread milling with form cutter

The helical interpolation function is ideal for machining internal and external threads using form milling cutters and for
milling lubrication grooves. The helix comprises two movements:
• Circular movement in one plane
• Linear movement perpendicular to this plane
The programmed feedrate F either refers only to the circular movement or to the total path velocity of the three CNC
axes involved.
In addition to the two CNC axes performing circular interpolation, other linear movements can be performed
synchronously. The programmed feedrate F refers to the axes specially selected in the program.
Limited functionality of export control versions: Not possible.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
High-level CNC language

To meet the various technological demands of modern machine tools, a CNC high-level language has been implemented
in SINUMERIK that provides a high degree of programming freedom.
System variables
The system variables ($.) can be processed in the CNC program (read, partially write). System variables allow access to,
for example, machine data, setting data, tool management data, programmed values, and current values.
User variables
If a program is to be used flexibly, variables and parameters are used instead of constant values.
SINUMERIK gives you the option of executing all CNC functions and addresses as variables. The names of the variables
can be freely defined by the user. Read and write access protection can also be assigned using attributes. This means
that part programs can be written in a clear and neutral fashion and then adapted to the machine as required, for
example, free selection of axis and spindle address designations.
User variables are either global (GUD) or local (LUD). LUD can also be redefined via machine data to make them into
global program user variables (PUD). They are displayed in the Parameters operating area under the user data softkey,
where they can also be changed.
Global user variables (GUD) are CNC variables that are set up by the machine manufacturer. They apply in all programs.
Local user data (LUD) are provided for parameterizing CNC programs. These data can be redefined in every CNC
program. These variables make programming more user-friendly and allow the users to integrate their own programming
philosophy.
Indirect programming
Another option for the universal use of a program is indirect programming. Here, the addresses of axes, spindles, R
parameters, etc., are not programmed directly, but are addressed via a variable in which their required address is then
entered.
Program jumps
The inclusion of program jumps allows extremely flexible control of the machining process. Conditional and unconditional
jumps are available as well as program branches that depend on a current value. Labels that are written at the beginning
of the block are used as jump destinations. The jump destination can be before or after the exit jump block.
Program coordination (in several channels)
Program coordination makes it possible to control the time-related execution in parallel operation of several CNC
channels using plain text instructions in the part program. Programs can be loaded, started and stopped in several
channels. Channels can be synchronized.
Arithmetic and trigonometric functions
Extensive arithmetic functions can be implemented with user variables and arithmetic variables. In addition to the 4 basic
arithmetic operations, there are also:
• Sine, cosine, tangent
• Arc sine, arc cosine, arc tangent
• Square root
• Absolute value
• Power of 2 (squaring)
• Integer component
• Round to integer
• Natural logarithm
• Exponential function
• Offset
• Rotation
• Scale modification
• Mirroring

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
High-level CNC language (continued)

Comparison operations and logic combinations
Comparison operations with variables can be used to formulate jump conditions. The comparison functions that can be
used are:
• Equal to, not equal to
• Greater than, less than
• Greater than or equal to
• Less than or equal to
• Concatenation of strings
The following logic combinations are also available: AND, OR, NOT, EXOR
These logic operations can also be performed bit by bit.
Macro techniques
Using macros, single instructions from a programming language can be grouped together to form a complex instruction.
This shortened instruction sequence is given a freely definable name and can be called in the CNC program. The macro
command is executed in the same way as the single instructions.
Control structures
The control normally processes the CNC blocks in the order in which they are programmed.
Like program jumps, control structures allow the programmer to define additional alternatives and program loops. The
commands make structured programming possible, and make the programs much easier to read:
• Choice of 2 alternatives (IF-ELSE-ENDIF)
• Continuous loop control (LOOP)
• Counting loop (FOR)
• Program loop with start condition (WHILE)
• Program loop with end condition (REPEAT)

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
High-speed CNC inputs/outputs

→ Position switching signals/cam controller
The "high-speed CNC inputs/outputs" function supports the input or output of signals in the position-control/interpolation
cycle.
The high-speed CNC inputs/outputs can be used for machines, such as those used for grinding and laser machining, as
well as in SINUMERIK Safety Integrated.
Input signals are possible for the following:
• Multiple feedrate values per block (calipers function)
The function allows modification of the feedrate through external signals. Six digital inputs can be combined with six
different feedrate values in a CNC block. There is no feed interruption in this case. An additional input can be used
for infeed termination (starting a dwell time), and another input can be used to start an immediate retraction
movement. Depending on the input, the retraction of the infeed axis (or axes) is initiated by a previously specified
absolute value in the IPO cycle. The remaining residual distance is deleted.
• Multiple auxiliary functions in the block
Several auxiliary functions can be programmed in one CNC block. These functions are transferred to the PLC
depending on a comparison operation or on an external signal.
• Axis-specific deletion of the residual distance
The high-speed inputs affect a conditional stop and delete the residual distance for the path or positioning axes.
• Program branches
The high-speed inputs make program branches within a user program possible.
• Fast CNC start
Machining can be enabled conditionally in the CNC program depending on an external input.
• Analog calipers
Various feedrates, a dwell time and a retraction path can be activated depending on an external analog input
(threshold values are specified via machine data).
• Safety-related signals such as EMERGENCY STOP
Output signals are possible for the following:
• Position switching signals
The position switching signals can be output with the function “Position switching signals/cam controller”.
• Programmable outputs
• Analog-value output
• Safety-related signals such as safety door interlock
HMI programming package sl/HMI runtime license OA

programming (option P60)
→ SINUMERIK Operate programming package / SINUMERIK Operate runtime license OA programming
"IMD base" (option)

This option supports the "Tool missing" monitoring function as well as programming the maximum permissible overload
for a tool.
The parameters are taught on program setup as for the "Missing tool" monitoring function, and saved in the function-
specific global user data (GUD). For all subsequent program runs, the taught signals will be compared with the current
ones and tool overload is avoided.
Language command in the part program: CC_START_TASK("Fixed_Overload", …, ...)
The compile cycle "IMD base" is also the prerequisite (interface) for customized add-ons in the field of process
monitoring and diagnostics. The openness in the real-time part of the SINUMERIK 840D sl is utilized, for example, by the
SINUMERIK Solution Partners.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
"IMD light" (option)

This option supports a "Tool missing" monitoring function within the IMD package. For this purpose, cuts (transition from
rapid traverse to creep feed) must be selected and parameterized (CC_START_TASK( "MissingTool", …, ...) in the part
program. For example, select "Torque of spindle" or "Torque of a specific axis". The torque can be learned in an initial
program run (teach-in). In productive operation, the tool is assumed to be present when the actual signal is equal to the
taught signal. If not, an individually parameterized alarm response is triggered (RESET, CANCEL, Stop Spindle, Stop
Axes, etc.).
I/O interfacing via PROFIBUS DP

PROFIBUS DP represents the protocol profile for distributed I/Os. It enables high-speed cyclic communication.
Advantages of PROFIBUS DP: very short bus cycle times, high degree of availability, data integrity, and standard
message frame structure.
Inclined axis (option M28)
Oblique plunge-cut grinding: machine with non-Cartesian X axis (U)

The "Inclined axis" function is used for fixed-angle interpolation using an oblique infeed axis (used primarily in
conjunction with cylindrical grinding machines). The axes are programmed and displayed in the Cartesian coordinate
system.
Tool offsets and work offsets are also entered in the Cartesian system and transformed to the real machine axes.
For oblique plunge-cutting with G05, it is necessary to program the start position with G07. In JOG mode, the grinding
wheel can be traversed either in the Cartesian coordinate system or in the direction of inclined axis U (selection via the
channel DB).

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Inclined-surface machining with frames

→ Frame concept
Inclined-surface machining with frames

Drilling and milling operations on workpiece surfaces that do not lie in the coordinate planes of the machine can be
performed easily with the aid of inclined-surface machining. The position of the inclined surface in space can be defined
by coordinate system rotation.
Integrated tool monitoring and diagnostics "IMD"

The compile cycle "Integrated Monitoring & Diagnostics" is a software package with easy access to drive data (drive
torque, encoder values, setpoint speed, etc.) and program data (programmed distance, programmed speed,
programmed interpolation type, etc.) directly in the real-time part of the control. The function offers interfaces to the part
program (language commands), to the PLC (fast I/O) and to the HMI (files, GUD).
Intermediate blocks for tool radius compensation

→ Tool radius compensation
Traversing movements with selected tool offset can be interrupted by a limited number of intermediate blocks (block
without axis movements in the compensating plane). The permissible number of intermediate blocks can be set in
system parameters.
Interrupt routines with fast retraction from the contour

(option M42)
Interrupt routines are special subprograms which can be started on the basis of events (external signal) in the machining
process. Any part program block currently in progress is interrupted. The positions of the axes at the time of interruption
are saved automatically. It is also possible to save such things as the current states of G functions and the current offsets
(SAVE mechanism) in buffer storage, making it possible to resume the program at the point of interruption later without
difficulty. Four additional program levels are available for interrupt routines, that is, an interrupt routine can be started in
the 8th program level and lead as high as the 12th program level.
An interrupt (for example, the switching of a high-speed CNC input) can trigger a movement via the special subprogram,
which allows fast retraction of the tool from the workpiece contour currently being machined. The retraction angle and the
distance retracted can also be parameterized. An interrupt routine can also be executed following the fast retraction.
Inverse-time feedrate
On the SINUMERIK, it is possible to program the time required to traverse the path of a block (rpm) instead of
programming the feedrate for the axis movement with G93.
If the path lengths differ greatly from block to block, a new F value should be determined in every block when using G93.
When machining with rotary axes, the feedrate can also be specified in degrees/revolution.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Involute interpolation (option M21)

Using involute interpolation, it is possible to program a spiral contour with the shape of a so-called circular involute in one
CNC block instead of many approximated individual blocks.
The exact mathematical description of the contour enables a higher path velocity to be achieved, together with a
reduction in machining time. Undesirable facets, which could result from coarse polygon functions, are thus avoided.
Furthermore, it is unnecessary to define the end point for the involute interpolation exactly on the involute defined by the
start point; it is possible to enter a maximum permissible deviation using machine data.
Job list
This can be used to create a job list (loading list) for each workpiece.
This job list contains instructions on making the following preparations for executing part programs, even when multiple
channels are involved:
• Parallel setup (LOAD/COPY):
Load or copy main programs and subprograms and associated data such as initialization programs (INI), R
parameters (RPA), user data (GUD), work offsets (UFR), tool/magazine data (TOA/TMA), setting data (SEA),
protective zones (PRO), and sag/angularity (CEC) from the PCU's (MMC's) hard disk into the CNC's RAM.
• Preparations for CNC start (SELECT):
Select programs in different channels and make initial preparations for processing them.
• Parallel clean-up (reverse LOAD/COPY):
Swap main programs and subprograms and associated data from CNC work memory back out to the hard disk.
You can also save your own templates for job lists. Following loading and job list selection, CNC start initiates the
processing of all programs and data required for workpiece production.
Laser switching signal, high-speed (option M38)

For high-speed laser machining, e.g. of aperture plates, the laser is switched on and off automatically and with a very
high positional accuracy relating to the path. Under the prerequisite that all movements for which the laser must be
switched off are made in rapid traverse mode G0, it is possible to logically combine the switching signal for the laser with
the rising or falling edge of G0.
The laser switching signal can also be coupled to an adjustable G1 feedrate threshold value, if required. To achieve the
fastest possible responses, the switching on and off of the digital laser signal is controlled by the position controller,
depending on the actual axis position.
No programming measures are required for switching the laser itself on and off, as these procedures are directly linked
to the programmed G functions. The overall procedure, however, requires programming of a release (at the beginning of
the program) with CC_FASTON (DIFF1, DIFF2). Together with this release, the two offset values, which can offset the
switching on and off of the laser by a specific path differential in relation to the position setpoint are entered. A negative
value means an offset before the setpoint (derivative action), a positive value means an offset after the setpoint. If the
programmed derivative action value is too high, that is, if the setpoint had already been exceeded when the edge was
detected, the signal is switched immediately.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Leadscrew error compensation / measuring system error

compensation
On SINUMERIK controls, interpolating compensation is divided into two categories:
• Leadscrew error compensation (LEC) or measuring system error compensation (MSEC) as axial compensation
(basic axis and compensating axis are always identical) and
• Sag error and angularity error compensation as cross-axis compensation (basic axis affects other compensation axis)
The principle of "indirect measuring" on CNC-controlled machines is based on the assumption that the leadscrew pitch is
constant at every point within the traversing range, so that the actual position of the axis can be derived from the position
of the drive spindle (ideal situation). Tolerances in ball screw production, however, result in large dimensional deviations
to a lesser or greater extent (referred to as leadscrew error). Added to this are the dimensional deviations caused by the
measuring system as well as its installation tolerances on the machine (so-called measuring system errors), plus any
machine-dependent error sources.
Because these dimensional deviations directly affect the accuracy of workpiece machining, they must be compensated
for by the relevant position-dependent compensation values.
The compensation values are derived from measured error curves and entered in the control in the form of compensation
tables during commissioning. The relevant axis is compensated using linear interpolation between the intermediate
points.
Limit switch monitoring
Overview of travel limits

Preceding the EMERGENCY-STOP switch, hardware limit switches, which take the form of digital inputs controlled via
the PLC interface, limit the traversing range of the machine axes. Deceleration is effected either as rapid deceleration
with setpoint zero or in accordance with a braking characteristic. The axes must be retracted in the opposite direction in
JOG mode.
Software limit switches precede the hardware limit switches, are not overtraveled, and are not active until reference point
approach has been completed.
Following preset, software limit switches are no longer effective. A second pair of plus/minus software limit switches can
be activated via the PLC.
Linear interpolation
"Linear interpolation" is understood to be the CNC-internal calculation of points on a straight path between the
programmed starting and end points.
Limited functionality of export control versions: The number of simultaneously interpolating axes is restricted to 4.

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Functions and Terms
CNC
SINUMERIK 840D sl
Look Ahead
→ Continuous-path mode with programmable rounding clearance
Comparison of velocity response with exact stop G60 and continuous-path mode G64 with look ahead for short displacements.
During the machining of complex contours, most of the resulting program blocks have very short paths with sharp
changes in direction. If a contour of this type is processed with a fixed programmed path velocity, an optimum result
cannot be obtained. In short traversing blocks with tangential block transitions, the drives cannot attain the required final
velocity because of the short path distances. Contours are rounded when traveling around corners.
The Look Ahead function is a means of optimizing the machining speed by looking ahead over a parameterizable
number of traversing blocks. With tangential block transitions, the axis is accelerated and decelerated beyond block
boundaries, so that no drops in velocity occur. On sharp changes of direction, rounding of the contour is reduced to a
programmable path dimension.
Look-ahead detection of contour violations
Behavior when tool radius > circle radius

With CDON (Collision Detection ON) and active tool radius compensation, the control monitors tool paths through look-
ahead contour calculation. This makes it possible for the control to actively detect and avert possible collisions.
The control detects the following critical machining situations, for example when the tool radius is too large, and
compensates through tool path modification.
• Bottleneck detection:
Because the tool radius is too large to produce a narrow inside contour, the bottleneck is bypassed and an alarm
output.
• Contour path shorter than tool radius:
The tool bypasses the workpiece corner on a transition circle, then continues on the programmed path.
• Tool radius too large for internal machining:
In such cases, the contours are machined only as much as is possible without causing a contour violation.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Machining channels (option C11-C19)

→ Mode group
Idle times can be shortened via a channel structure using parallel sequences of motion, such as moving a loading gantry
during machining. A machining channel must be regarded as a separate CNC with decoding, block preparation and
interpolation. The channel structure makes it possible to process the individual channels' part programs simultaneously
and asynchronously. The relevant channel with the associated images is selected with the channel switchover button on
the operator panel. Part programs can then be chosen and started for that specific channel. Each possible channel can
run in a separate mode group. Additional machining channels are optional. One machining channel is available in the
basic version. With the option C11-C19, the number can be increased to up to 10 machining channels.
Machining package 5 axes (option M30)
Universal milling head

Five-axis machining tasks, such as the milling of free-form surfaces, can be solved easily and in a user-friendly manner.
To this end, the "Machining package 5 axes" provides the following functions:
• 5-axis transformation with tool orientation
In 5-axis machining, geometric axes X, Y and Z are supplemented by additional axes (such as rotary axes for tilting
the tool). The machining task can be completely defined in Cartesian spatial coordinates with Cartesian position and
orientation. The path vector is converted in the control into the machine axes, including position and orientation, via
5-axis transformation.
• 5-axis tool length compensation for 5-axis machining
When machining with the 4th/5th axis, the lengths of the selected tool are automatically included and compensated in
the axis movement.
• Oriented tool retraction
If machining is interrupted (because of tool breakage, for example), a program command can be used to carry out
defined, oriented tool retraction.
• Tool-oriented RTCP
With the RTCP (remote tool center point) function, the tool swivel axes can be positioned in manual mode, as long as
there is compliance with the tool center point marked by the tool tip. The RTCP function simplifies the inclusion of
program interpolation points in manual mode with orientation of the tool.
• Universal milling head/nutating head
Precondition: Machining package 5 axes with 5-axis transformation. Using a universal milling head in conjunction with
the "nutating head" function, it is possible to machine outside contours of spatially formed parts at a high feedrate. To
do this, the control executes a 5-axis transformation. Three translatory main axes (X, Y, Z) determine the tool
operating point; two rotary axes, one of which is an inclined axis (angle can be set in the machine data), permit
virtually any orientation in the working area. Version 1 and version 2 of the universal milling heads are supported. In
the case of version 2, the position of the operating point does not change when the tool is swiveled; the
compensating movements required for orientation changes are minimal.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Machining package 5 axes, additional function 7th axis

(option S01)
In combination with "Machining package 5 axes", this option supports 7-axis interpolation. This means that redundant
rotation of a workpiece is possible in the work space, with 5th/6th axis tool kinematics active at the same time.
Application example: Fiber placement machines in aircraft assembly.
Machining package milling (option M26)

• 5-axis machining package
• Multi-axis interpolation
• Spline interpolation for 5-axis machining
• 3D tool offset
The milling machining package contains the following options: "5-axis machining package", "Multi-axis interpolation",
"Spline interpolation for 5-axis machining", and "3D tool offset".
Machining step programming (option P04)

Machining steps are programmed graphically with a graphic, interactive machining step editor. In this case, each
program line represents a machining step (e.g. face milling, centering, drilling, tapping) or geometric data required for the
machining steps (pattern positions or contours). All required technical and geometric parameters are entered in screen
forms. Simple, intuitive programming with machining steps can always be expanded very flexibly through input of
DIN/ISO blocks.
Highlights:
• Intuitive program input, no DIN/ISO knowledge or operating manual required
• Compact, clearly arranged machining programs
• Reduction of programming time through graphical input screens, copying/inserting and linking machining steps
Main program call from main program and subprogram

If machining operations recur frequently, it is advisable to store them in a subprogram. The subprogram is called from a
main program (number of passes ≤ 9999). Eleven subprogram levels (including three levels for interrupt routines) are
possible in one main program. A main program can also be called from within another main program or subprogram.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Manual machine (option P11)

We offer the manual machine function for beginners switching over from conventional machines, but also for experienced
CNC machine operators who often only use individual machining steps. The basic screen MANUAL is displayed
immediately after booting the machine offering the direct machining options without having to create a part program.
Master value coupling and curve table interpolation

(option M20)
→ Measuring, stage 2; synchronous spindle
Example for cyclic machines: Flying saw

For special technologies (presses, transfer lines, printing machines, etc.), the replacement of mechanical, cyclic transport
tasks with electronic functionality in AUTOMATIC mode requires constant coupling and decoupling functions between
leading and following axes. To this end, the synchronous spindle function has been expanded to include the master
value coupling function, which makes it possible for linear master and following axes to be coupled via curve tables in the
CNC program.
Any function relations between axis positions can be approximated.
Soft coupling avoids the sudden change in velocity that occurs when the master axis is activated. Offsets (e.g., 12°),
scalings (e.g., 1.00023) and mirroring using frame instructions are possible.
Electronic curve table interpolation replaces the cam discs that were once required for the control of cyclic machines.
Complex sequences of motion can be easily defined using familiar CNC language elements. The external reference
variable (e.g., "line shaft") is formed by the control's master value. The functional relation between leading and following
axis can be subdivided into segments of the master axis (curve segments). In these curve segments, the link between
master value and following value is described using mathematical functions (normally through 3rd degree polynomials).
Cyclic machines are distinguished by constantly repeated cyclic operations with high throughput and high productivity in
machining, transport, packaging and parts handling (for example, packaging machines, presses, woodworking machines,
printing machines).
With SINUMERIK, technological functions such as synchronism, electronic transfer and positioning for cyclic machines
can be implemented. Mechanics (line shaft, gearing, cam discs, couplings and cams) are replaced by an electronic
solution (master value coupling, curve tables, synchronous actions, and electronic cams).
In addition, the electronic functionality permits fast, axis-specific optimization, high-speed phase and path compensation,
fast responses to faulty or missing parts, and fast synchronization and resynchronization, as well as decoupling from the
master axis and executing autonomous movements.
Axis cycles and synchronization calculations are carried out in the IPO cycle.
Measuring from synchronous actions, for example, is used for detecting edges on continuous workpieces and for
measuring pressure marks (on continuous films, for example).

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Master/slave for drives (option M03)
Example: Axis 1 is simultaneously the master axis for axis 2 and axis 3
The "master/slave for drives" function is required when two electrical drives are mechanically linked to an axis. With this
link, a torque controller ensures that both drives produce the exact same amount of torque, so that the motors do not
work in opposition. In order to attain tensioning between the master and slave drives, a tension torque specifiable via
machine data can be applied on the torque controller.
Application examples:
• Performance enhancement and (occasional) mechanical coupling of drives
• Drive with 2 motors that operate on a gear rack
• Remachining of wheel sets for rail-bound vehicles
• Zero backlash reversing of mutually tensioned drives
An axis can also be a master axis for multiple couplings.
Measure kinematics (option P18)

The "Measure kinematics" function supports the calibration of kinematic structures of 5-axis machines. The SINUMERIK
840D sl is now able to determine the parameters of kinematic transformations of the digitally or manually alignable rotary
axes quickly and automatically. The function is ideal for initial startup, because a dimensioned drawing of the machine is
not required. The function can also be used for regular checking of the production process, when high precision is
required.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Measuring cycles (option P28)
Example: Measuring a shaft Example: Two angle measurement for determining the
position of a plane in space
In the case of tool measuring, the loaded tool (typically in the revolver on turning machines) is moved towards the probe
which is either in a fixed position or swiveled into the working range by a mechanical device. The automatically derived
tool geometry is entered in the relevant tool offset data record.
In the case of workpiece measuring, a probe is moved towards the clamped workpiece like a tool. The flexible selection
of measuring cycles means that you can handle practically every measuring task associated with turning or milling.
The principle of "on-the-fly measurement" is used in SINUMERIK controls. The advantage of this principle is that the
probe signal is processed directly in the CNC. The measuring parameters and the results of the measurements are
output extremely clearly in separate displays which are either automatically deselected at the end of the cycle, or can be
acknowledged when starting the CNC.
The result of the workpiece measurement can either include automatic offset of the zero point or a correction of the tool
wear by the difference between the actual value and the setpoint. The measured results can be logged in a file. The
Siemens measuring cycles offer a standard log which you can also adapt.
In order to measure tool and workpiece dimensions, a touch-trigger probe is required that supplies a constant signal
(rather than a pulse) when deflected. The probe should switch bounce-free, and mechanical adjustment may be
necessary.
Multidirectional probes can be used for all tool and workpiece measurements on turning and milling machines.
Bidirectional probes are treated like a mono probe for workpiece measurements on milling and machining centers, but
are not suitable for tool measurements.
Monodirectional probes can be used on milling machines and machining centers with slight restrictions in workpiece
measurements, but are not suitable for tool measurements or for workpiece measurements on turning machines.
Measuring Cycles for Turning Machines
• Tool measurements (calibration/measurement) for turning tools
• Tool measurements for milling tools and drills on turning machines
• Calibrating workpiece probes
• 1-point workpiece measurement
• 2-point workpiece measurement
Measuring cycles for milling machines and machining centers
• Tool measurements (calibration/measurement) for milling tools
• Calibrating workpiece probes
• Paraxial workpiece measurement on hole/shaft/slot/web/rectangle
• 1-point workpiece measurement on area
• Workpiece measurement at any angle on hole/shaft/slot/web
• Workpiece measurement at angular position (1-/2-angle measurement)
• Automatic set-up corner internal and external
• Measurement of workpiece sphere and automatic correction of work offset

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Measuring functions/measuring cycles

Measuring functions can execute either channel-specifically including all axes programmed in the measuring set as well
as axially from the parts program or from synchronous actions beyond NC block limits.
Measuring cycles are subprograms for implementing specific measuring tasks on tools or workpieces. They are easy to
use and simply require the input of values in predefined parameters.
• Measuring in JOG
• 2 probes can be connected simultaneously
• Measurement in space with frame
• Adaptable measuring modes with/without deletion of distance to go
• Display and logging of measuring parameters and results (with measuring cycles)
• Results can be read in the machine or workpiece coordinate system
• Cyclic measurement with synchronized actions parallel to workpiece machining
With the advantages of the measuring functions and measuring cycles, the machining accuracy is assured, unproductive
time is reduced, sources of error are dispensed with and the manufacturing process is automated further.
Measuring stage 1
You can connect up to two switching touch probes to the control at the same time. In the case of channel-specific
measuring, the measuring process for a CNC channel is always activated from the part program running in the relevant
channel. All of the axes programmed in the measuring block take part in the measuring process.
You can program a trigger event (rising or falling edge) and a measuring mode (with or without deletion of the residual
path) for each measuring process.
The results of measurements can be read in the part program or with synchronous actions in both the machine and the
workpiece coordination system. You can test the deflection of the touch probe by scanning a variable and outputting it to
the PLC interface and deriving responses in the part program. The option Measuring stage 2 (option M32) provides you
with expanded functionality (for example for axial measuring, evaluating up to 4 trigger events, and cyclic measuring).
Measuring stage 2 (option M32)

While the measuring function in motion blocks in the part program is limited to one block, you can activate measuring
functions from synchronous actions at any time, independent of the part program. The measuring events can be
assigned to the axes in the CNC block. In the case of simultaneous measuring, up to 4 trigger events can be evaluated
per position control cycle. Measured values are read as a function of the three parameters: touch probe, axis and
measuring edge.
In the case of continuous (cyclic) measuring, the measurement results are written to a FIFO variable. Endless measuring
can be achieved by reading out the FIFO values cyclically.
Measurement results can be logged in the form of a file. The measuring cycles (option P28) contain a standard log,
which can be configured as the user wishes.
Measuring system 1 and 2, selectable

For special applications, two encoders can be assigned to one axis, e.g., a direct measuring system for the machining
process with high demands on accuracy, and an indirect measuring system for high-speed positioning tasks. The
switchover between measuring systems 1 and 2 is performed via the PLC.
Measuring system error compensation

→ Leadscrew error compensation / measuring system error compensation

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Mode group (option C01-C09)

A mode group combines CNC channels with axes and spindles to form a machining unit.
A mode group contains channels that must always be in the same mode at the same time during the machining
sequence. Within a mode group, every axis can be programmed in every channel. A mode group can be regarded as an
independent, multi-channel CNC.
One mode group is available in the basic version. With the option C01-C09, the number can be increased to up to 10
mode groups.
Monitoring functions
The controls contain watchdog monitors, which are always active. These monitors detect faults in the CNC, PLC or
machine in time to prevent damage to workpiece, tool or machine. When a fault occurs, the machine operation is
interrupted and the drives brought to a standstill.
The cause of the fault is saved and displayed as an alarm. At the same time, the PLC is notified that a CNC alarm has
been triggered.
Monitoring functions exist for the following areas:
• Read in
• Format
• Encoder and drive
• Contour
• Position
• Standstill
• Clamping
• Speed setpoint
• Actual velocity
• Enabling signals
• Voltage
• Temperatures
• Microprocessors
• Serial interfaces
• Transfer between CNC and PLC
• Backup battery voltage
• System memory and user memory
Motion-synchronous actions
→ Synchronized actions
Multi-axis interpolation (> 4 interpolating axes) (option M15)

The number of interpolating axes can be expanded and is limited by option and machine data as well as by the number
of axes available in the channel.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Multi-channel display
In the machine operating area, the M key can be used to select either single-channel or multi-channel display. In the
multi-channel display, only channel information is displayed; the channel can be operated or influenced in the single-
channel display. Focus switching, scroll bars and window selection can be operated in the multi-channel display, but it is
not possible to change the NC channel data. The same windows are always displayed together in all channels. The
softkeys for switching the windows, therefore, always affect all the channels that are on display. In the multi-channel
display, the axis actual values are displayed in the top window and the selection menus (T/F/S values, program blocks)
in the bottom window, depending on which of the softkeys is activated.
Multiple clamping of various workpieces (option P14)

Several identical workpieces can be clamped onto the machine table. With the multiple clamping function, an entire
program is generated from the graphic program of the relevant single machining operation. The machining steps are
sorted in this program so that the number of tool changes (and thus idle times) is reduced to a minimum.
This function allows similar and different workpieces to be finished on multiple vises or gripping yokes, while saving time.
Multiple feedrates in one block

Depending on external digital and/or analog inputs, this function can be used for motion-synchronous activation of up to
6 different feedrates, a dwell time, and a retraction in a single CNC block. The input signals are combined in an input
byte with a permanently assigned function. The retraction is initiated by an amount defined in advance within an IPO
cycle. Retraction movement or dwell time (e.g., sparking-out time during grinding) lead to deletion of the distance-to-go.
Typical applications involve analog or digital calipers or a change from infeed feedrate to machining feedrate via
proximity switches. During internal grinding of a ball bearing ring, for instance, in which calipers are used to measure the
actual diameter, the feedrate value required for roughing, finishing or smooth-finishing can be activated depending on
threshold values.
Number of subprogram repetitions

In order to execute a subprogram several times in succession, the desired number of program repetitions can be
programmed in the block with the subprogram call at address P (range of values: 1 to 9999).
Parameters are transferred only when the program is called or in the first pass. The parameters remain the same for all
repetitions. If you want to change the parameters between passes, you should make the relevant declarations in the
subprogram.
Online ISO dialect interpreter

In general, part programs for SINUMERIK controls are programmed according to DIN 66025 and relevant expansions.
Part programs created according to the ISO standard (e.g., G codes from other manufacturers) can be read in, edited
and executed on SINUMERIK controls using the online ISO dialect interpreter.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Operating modes
In the "Machine" operating area, you have a choice of three modes:
• JOG
JOG mode (jogging) is intended for the manual movement of axes and spindles, as well as for setting up the
machine. The set-up functions are reference point approach, repositioning, traveling with the handwheel or in the
predefined incremental mode, and redefinition of control zero (preset/set actual value).
• MDA
In MDA (Manual Data Automatic/Manual Input) mode, you can enter individual program blocks or sequences of
blocks, then execute them immediately via NC Start. The tested blocks can then be saved in part programs. The
Teach In submode allows you to transfer sequences of motion to the MDA program by returning and storing
positions.
• AUTO
In AUTO mode, the part programs are executed fully automatically once they have been selected from the workpiece,
part program or subprogram directory (normal operation). During AUTO mode it is possible to generate and correct
another part program.
In the operating modes MDI and AUTO, you can modify the sequence of a program using the following program control
functions:
SKP Skip block (up to eight skip levels)
DRY Dry run feedrate
ROV Rapid traverse override
SBL1 Single block with stop after sets of machine functions
SBL2 Single block with stop after every block
SBL3 Stop in cycle
M01 Programmed stop
DRF Differential resolver function
PRT Program test
Operating software languages (option N00)

The operating software supports the following languages as standard for user interface display texts: English, French,
German, Italian, Simplified Chinese, and Spanish. The operator can switch back and forth online between foreground
and background languages. Further languages can also be ordered with option N00.
Operator control without SINUMERIK OP (P00)

Operation of SINUMERIK via the VNC viewer requires a confirmation on the SINUMERIK operator panel that operation
is now permitted via the VNC viewer. When a SINUMERIK operator panel is not used, this option can be used to
suppress scanning of the confirmation.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Oscillation functions (option M34)
Oscillation functions
With this function, an axis oscillates at the programmed feedrate between two reversal points. A possible application is a
grinding machine.
Asynchronous oscillation across block boundaries
Several reciprocating axes may be active. During reciprocating movement, other axes can interpolate at will. The
reciprocating axis can be the input axis for the dynamic transformation or the master axis for gantry or coupled-motion
axes.
Block-related oscillation
• Oscillation with infeed in both or only in the left or right reversal point. Infeed is possible along a programmable path
prior to the reversal point.
• Sparking-out strokes after oscillation are possible.
Behavior of the reciprocating axis in the reversal point:
• A change of direction is initiated
- Without reaching the exact stop limit (soft reversal)
- After reaching the programmed position or
- After reaching the programmed position and expiration of the dwell time.
• The following manipulations are possible:
- Reciprocating movement and infeed can be terminated by deleting the residual distance
- Modification of the reversal points via CNC program, PLC, handwheel or direction keys
- Manipulation of the reciprocating axis feedrate via CNC program, PLC or override
- Control of the reciprocating movement via the PLC
The spindles can also perform reciprocating movement.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Pair of synchronized axes (gantry axes) (option M02)
Gantry axes (pair of synchronized axes X/X1)

The "gantry axes" function can be used to traverse the axes of up to three pairs of mechanically-coupled axes
simultaneously without mechanical offset. The actual values are continuously compared and even the smallest
deviations corrected.
During both operation and programming, the axes defined in a gantry grouping are treated like machine axes. A gantry
grouping consists of a master axis and up to 2 synchronized axes. 2 master axes can be coupled using curve table
interpolation.
Path length evaluation (option M53)

→ Synchronous actions
With path length evaluation, data in the control can be battery-backed, so that conclusions can be drawn in respect of the
maintenance state of the machine.
In the first stage, the following data are acquired:
• Total travel path for each axis
• Total travel time for each axis
• Number of traversing actions per axis (stop - traverse - stop)
• Total sum of jerks per axis
These data are stored in the SRAM and are not affected by power on/off. Using an external utility, consistent data can,
therefore, be achieved for the complete life cycle of a machine. These data can also be read through system variables in
the part program and in synchronous actions.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Path switch signals/cam controller (option M07)

→ High-speed CNC inputs/outputs
Position-dependent interface signals for the PLC can be set using position switching signals. The position values at
which the signal output and a derivative action/hold up time are to be set can be programmed in the part program and
entered via the setting data. The function can be controlled via the PLC.
The function is used for applications such as activating protection zones or position-dependent triggering of movements
(e.g., hydraulic reciprocating axes during grinding).
Although position switching signals are output in the IPO cycle, they can also be output as switching outputs in the
position-control cycle using the high-speed CNC inputs/outputs function.
Path-velocity-dependent analog output (option M37)

Using the path-velocity-dependent analog output, the current path velocity can be output in the interpolation cycle via a
SIMATIC DP ET 200 analog module. The function is programmed via synchronous actions.
One application is laser power control.
Plain text display of user variables

→ High-level CNC language
In addition to the predefined variables, programmers can define their own variables and assign values to them.
The variables are displayed in plain text format, e.g. definition: DEF INT NUMBER/Display: NUMBER or definition: DEF
REAL DEPTH/Display: DEPTH.

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Functions and Terms
CNC
SINUMERIK 840D sl
PLC
SIMATIC STEP 7
The PLC on the SINUMERIK is programmed using the user-friendly SIMATIC STEP 7 software.
The STEP 7 programming software is based on the Windows operating system, and combines the proven STEP 5
programming functions with innovative further developments. The STL (statement list), FBD (function block diagram),
and LAD (ladder diagram) programming languages are available.
The user can switch from one to the other using STEP 7 pull-down menus.
The following blocks are available for structured programming:
• Organization blocks (OBs)
• Function blocks (FBs) and function calls (FCs)
• Data blocks (DBs)
In addition, system function blocks (SFBs) and system functions (SFCs) integrated in the operating system can also be
called.
The STEP 7 software package (for SIMATIC S7-300) is a standard component of SIMATIC programming devices (e.g.,
Field PG). A software package for standard industrial PCs is also available.
The PLC can also be programmed in other SIMATIC S7 high-level languages, such as S7 HiGraph and S7 Graph.
PLC/NCK interface
A number of functions can be executed via the NCK and PLC interface, ensuring excellent machining flexibility. Some of
these are:
• Controlling positioning axes
• Executing synchronous actions (auxiliary functions)
• Reading and writing of NCK system variables by the PLC
• Reading and writing of NCK user variables by the PLC
The PLC basic program, which is part of the toolbox, organizes the exchange of signals and data between the PLC user
program and the NCK, PCU and machine control panel areas. In the case of signals and data, a distinction is made
between the following groups:
• Cyclic signal transfer:
Commands from the PLC to the NCK (such as start, stop) and NCK status information (e.g., program running). The
basic program carries out cyclic signal transfer at the beginning of the PLC cycle (OB 1). This ensures, for example,
that the signals from the NCK remain constant throughout a PLC cycle.
• Event-driven signal transfer NCK → PLC
PLC functions executed depending on the workpiece program are initiated via auxiliary functions in the workpiece
program. If a block with auxiliary functions is executed, the type of auxiliary function determines whether the NCK has
to wait for this function to execute (e.g., tool change) or whether the function will be executed together with the
workpiece machining process (e.g., tool loading on milling machines with chain magazine). In order for CNC
machining to be affected as little as possible, data transfer must be as fast as possible, yet reliable. It is therefore
alarm and acknowledgment-controlled. The basic program evaluates the signals and data, sends an
acknowledgment to the NCK, and transfers some of the data to OB40 and the rest to the user interface at the
beginning of the cycle. If the data do not require an acknowledgment from the user, CNC machining is not affected.
• Event-driven signal exchange PLC → NCK
Whenever the PLC sends a request to the NCK (such as a request to traverse an auxiliary axis), a PLC → NCK
event-driven signal exchange takes place. Here again, the data transfer is acknowledgment-controlled. Such a signal
transfer is initiated by the user program via an FB or FC. The associated FBs (function blocks) and FCs (function
calls) are provided together with the basic program.
• Messages
The acquisition and editing of user messages is handled by the basic program. The message signals are transferred
to the basic program via a specified bit array. Here, the signals are evaluated, then transferred to the PLC diagnostic
buffer when one of the message events occurs. If an OP is available, the messages are transferred to the OP and
displayed on it.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
PLC programming with HiGraph

The HiGraph method is used for describing technical systems and converting these descriptions into PLC programs.
With HiGraph, a machine or plant is seen as a combination of separate functional units. These functional units can be
made up of basic mechanical and electrical elements. The HiGraph method is used in the automation of machines and
plants where mechanical movements and time sequences take priority, e.g., on machine tools, transfer lines, conveyor,
and transportation systems.
The HiGraph method can be used:
• During the machine and plant planning phase
• During the function planning phase
• During the design phase, e.g., of the mechanics
• For developing programs
• During the test stage and startup
• To operate the automated machine
• For maintenance and diagnostic tasks
Advantages of the HiGraph method:
• Quicker from design to result
• Shorter testing phases
• Structuring using symbolic names
• Application-oriented
• Object-oriented thinking
• Graphic programming
• Easy to use
• Reliable software
• Faster and simpler diagnostics
• Service at the machine level
PLC status
In its "diagnostics" operating area, the operator panel allows you to check and modify PLC status signals.
This allows you to do the following on site without a programming device:
• Check the input and output signals from the PLC's I/Os
• Carry out limited troubleshooting
• Check the NCK/PLC and PCU/PLC interface signals for diagnostic purposes
The status of the following data items can be displayed separately on the operator panel:
• Interface signals from/to the machine control panel
• NCK/PLC and PCU/PLC interface signals
• Data blocks, bit memories, timers, counters, inputs and outputs
The status of the above signals can be changed for tests. Signal combinations are also possible, and up to 10 addresses
can be modified simultaneously.
PLC user memory

In the PLC user memory of the PLC CPU, the PLC user program and the user data are stored together with the PLC
basic program.
The memory of the PLC CPU is divided up into load memory, work memory and system memory. Load memory is
retentive, and takes the form of either integrated RAM or a RAM module (plug-in memory card). It contains data and
program and decompiling information.
The load memory and the high-speed work memory for execution-relevant program tests provide sufficient space for
user programs.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Polar coordinates
Programming in polar coordinates, it is possible to define positions with reference to a defined center point by specifying
the radius and angle. The center point can be defined by an absolute dimension or incremental dimension.
Polynomial interpolation (option M18)
Polynomial interpolation
Curves can be interpolated using polynomial interpolation, whereby the CNC axes follow the function:
f(p) = a0 + a1p + a2p2 + a3p3 + a4p4 + a5p5 (polynomial, max. 5th degree)
The coefficient a0 is the end point of the previous block, a1 is calculated as the end point of the current block, a2, a3, a4,
and a5 must be calculated externally and then programmed.
With polynomial interpolation, it is possible to generate many different curve characteristics, such as straight line,
parabolic and exponential functions.
Polynomial interpolation primarily serves as an interface for programming externally generated spline curves. 5th degree
polynomials can be used optimally if the coefficients are obtained directly from a CAD/CAM system (closer to the
surface). A prerequisite for efficient utilization of this polynomial interpolation is, therefore, a corresponding CAD/CAM
system.
Tool radius compensation can be used as in linear and circular interpolation.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Position monitoring
SINUMERIK controls provide extensive monitoring mechanisms for axis monitoring:
• Motion monitoring:
Contour monitoring, position monitoring, standstill monitoring, clamping monitoring, speed setpoint monitoring, actual
speed monitoring, encoder monitoring
• Static limits monitoring:
Limit switch monitoring, working area limitation
Position monitoring is always activated after termination of motion blocks according to the setpoint. To ensure that an
axis is in position within a specified period of time, the timer configured in the machine data is started when a traversing
block terminates; when the timer expires, a check is made to ascertain whether the following error fell below the limit
value (machine data). When the specified fine exact stop limit has been reached or following output of a new position
setpoint other than zero (e.g. after positioning to coarse exact stop and subsequent block change), position monitoring is
deactivated and replaced by standstill monitoring.
Position monitoring is effective for linear and rotary axes as well as for position-controlled spindles. In follow-up mode,
position monitoring is not active.
Positioning axes/auxiliary spindles (option B01-B26)

Positioning axes can execute movements simultaneously with machining, thus reducing non-productive times
considerably. They can be used to advantage when controlling workpiece and tool feeders or tool magazines. They can
be programmed with an axis-specific feedrate in the part program. Axis movement beyond block boundaries is also
possible. Positioning axes can also be controlled by the PLC. This means that axis movements can be started
independently of the part program without using up an additional machining channel.
Auxiliary spindles are speed-controlled spindle drives without an actual-position sensor, e.g., for tool drives.
Positioning axes/spindles via synchronous actions

You can position axes/spindles depending on conditions (the actual values of other axes, high-speed inputs, etc.) with a
special feedrate or speed to a specific setpoint via synchronous actions. Synchronous actions are executed in the
interpolation cycle, are carried out in parallel with the actual workpiece machining procedure, and are not limited to CNC
block boundaries.
These so-called command axes and command spindles can be started in the IPO cycle direct from the main program.
The path to be traversed is either predefined or is calculated from real-time variables (with expanded arithmetic
functions) in the IPO cycle. Spindles can be started, stopped or positioned asynchronously depending on input signals
without PLC intervention.
Preset
With the Preset function, you can redefine the machine zero point in the machine coordinate system. The preset values
affect machine axes. Axes do not move when Preset is active. but a new position value is entered for the current axis
positions. Once the actual values have been reset, a new reference point approach is required before protection zones
and software limit switches can be reactivated.
PROFIBUS tool and process monitoring (option M62)

Spotting errors before they happen. This is the motto for our SINUMERIK controls, which allow you to implement tool and
process monitoring. Active power monitoring keeps an eye on such things as breakage, wear and missing tools. Precise
operating status recognition and process optimization are also possible.
Using the PROFIBUS tool and process monitoring function, the digital drive data for torque, active power and actual
current are directly transferred to a special PROFIBUS slave module. This hardware and the software for evaluation is
offered, for example, by SINUMERIK Solution Partners. Up to 2 PROFIBUS slaves can be connected.

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Glossary
Functions and Terms
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SINUMERIK 840D sl
PROFINET
PROFINET is the open Industrial Ethernet standard of PROFIBUS International for automation systems. PROFINET is
based on Industrial Ethernet and uses TCP/IP and IT standards.
Two versions are available:
• PROFINET CBA (Component Based Automation) for networking distributed plants, (component engineering)
• PROFINET IO (Input Output) for controlling sensors and actuators using one or several central controllers in
production engineering.
PROFINET is supported by PROFIBUS International and the INTERBUS Club and has been included in standards
IEC 61158 and IEC 61784 since 2003.
PROFINET includes:
• A multi-level real-time concept
• Simple field devices which operate IOs directly on Ethernet
• Design of modular, highly re-usable systems
• Simple integration of existing PROFIBUS or Interbus systems
PROFINET CBA
PROFINET CBA is an automation system for plants with distributed, decentralized intelligence. The key characteristics of
this model inspired by standard IEC 61499 are therefore:
• Structuring of logical plant sections into clearly organized subunits and their re-usability
• Clearly defined engineering of the plant
• Seamless integration of existing field bus systems
• Ethernet-based communication
A PROFINET CBA system therefore always comprises a variety of intelligent programmable controllers (components). A
component includes all mechanical, electrical and IT variables (PLC program). Each individual component is created with
its own manufacturer-specific, standard programming tools. A graphical, vendor-independent component connection
editor (iMAP) is available for linking individual components to the higher-level system, i.e. for engineering the system as
a whole. In this context, "engineering" means:
• Configuring the system
• Defining the exchange of data
• Loading configuring data to the components
A standardized PROFINET Component Description (PCD) file is created in XML to describe a component. The
component connection editor loads these descriptions and uses them to set up logical connections between individual
components.
A PROFINET component always consists of:
• Exactly one Physical Device (PDev), with MAC and IP address
• One or several logical devices (LDev)
• One ACCO per LDEV
• One or several runtime automation objects per LDEV (RT-Auto)
The ACCO (Active Control Connection Object) functions as a consumer and provider and is the heart of the
communication system. The RT-Auto provides the technological functionality, i.e. the executable program.

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Glossary
Functions and Terms
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PROFINET IO
A PROFINET IO system comprises the following devices:
• An IO controller is an automation control system, typically a PLC, CNC, robot control or motion controller. (An IO
controller is a master as compared to PROFIBUS.)
• An IO device is a distributed field device which is linked up via PROFINET IO. It is controlled by an IO controller. An
IO device can consist of several modules and submodules. All data to be exchanged are assigned slots and subslots
for the purpose of addressing. These are defined in the General Station Description (GSD) file.
ET200 distributed I/Os or a SINAMICS drive are examples of PROFINET IO devices. (An IO device is a slave as
compared to PROFIBUS.)
• An IO Supervisor is typically a programming device, a PC or an HMI unit for commissioning or diagnostics. It features
an engineering tool which can be used to parameterize and diagnose individual IO devices. (As compared to
PROFINET, this would be a class 2 master in terms of function.)
PROFINET IO provides protocol definitions for the following functions:
• Cyclical transmission of IO data
• Acyclical transmission of alarms which require acknowledgement
• Acyclical transmission of data (parameters, detailed diagnostic information, commissioning data, I&M data)
An application relation (AR) is formed between an IO controller and an IO device. The communication relations,
diagnostic options and potential useful data exchange are determined by the communication view. Communication
relations (CR) with varying properties are specified for the transfer of parameters, cyclical data communication and alarm
handling based on this AR.
Communication channels are set up to handle the data exchange between each IO controller and the IO device. It is
possible to form more than one application relation between different devices.
Isochronous drive controls can be implemented with PROFINET IO and the PROFIdrive profile for motion control
applications.
In the GSD file, the device manufacturer must exactly describe how the device functions are specifically mapped on the
PROFINET IO model, i.e. the properties of the IO device. GSDML (GSD Markup Language), an XML-based language, is
used for this purpose. The GSD file is read in by the engineering tool and forms the basis for planning the configuration
of a PROFINET IO system.
Program preprocessing (option M00)

The execution time of a CNC program is reduced considerably by preprocessing cycles. The programs in the directories
for standard and user cycles are preprocessed at "power on" with set machine data. In particular in the case of programs
containing sections written in a high-level language and in the case of calculation-intensive programs, e.g., programs
containing check structures, motion-synchronous actions or cutting cycles, execution times can be reduced by up to 1/3.
ProgramGUIDE
→ SINUMERIK Operate Easy Screen
The "ProgramGUIDE" with the "Animated Elements" and the "Cursor Text" provides perfect support for integrating the
cycles into part programs. You can, however, also define a number of softkeys, input fields and displays yourself using
the "Easy Screen" function.
Programmable acceleration
With the "programmable acceleration" function, it is possible to modify the axis acceleration in the program in order to
limit mechanical vibrations in critical program sections.
The path or positioning axis is then accelerated at the programmed value. The acceleration value set in the machine data
can be exceeded by up to 100 %. This limitation is active in AUTOMATIC mode and in all interpolation modes. As part of
intelligent motion control, this function provides a more precise workpiece surface.

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Functions and Terms
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Programming language
The CNC programming language is based on DIN 66025. The new functions of the CNC high-level language also
contain macro definitions (combined sequences of instructions).
PROT collision protection for axes (option N06)

The loadable compile cycle supports collision protection of up to 5 axis pairs that, for example, move along a common
guide rail and that can collide with each other. The axes concerned can also be active in different channels. The
traversing directions of the axes of an axis pair can differ. A maximum spacing can also be monitored.
Protection zones 2D/3D
Protection zones
Protection zones allow you to protect various elements on the machine and its equipment, as well as the workpiece to be
created, from incorrect movements.
Some of the elements that can be protected are, for example:
• Fixed machine components and built-on accessories (tool magazines, swiveling touch probes)
• Moving parts belonging to the tool (tool carriers)
• Moving parts belonging to the workpiece (mounting tables, clamps, spindle chucks, tailstocks)
For the elements to be protected, 2D or 3D protection zones are defined in the part program or via system variables.
These protection zones can be activated and deactivated in the part program. Protection zones must always be divided
into workpiece-related and tool-related zones. During machining in JOG, MDA or AUTOMATIC mode, a check is always
made to see whether the tool (or its protection zones) violate the protection zones of the workpiece.
Monitoring of the protection zones is channel-based, that is, all active protection zones for a channel are mutually
monitored for collisions (protection zones not channel-specific with NCU system software for 2/6 axes).
A maximum of ten protection zones and ten contour elements, which describe a protection zone, are available.

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Punching/nibbling (option M33)

The punching/nibbling functions are implemented essentially via the language commands, stroke control and automatic
path division.
• Language commands
The punching/nibbling functions are activated and deactivated using simple, clear high-level language elements such
as PON, SON, PONS, PDELAYON, and so on.
• Stroke control
CNC and punch are synchronized to each other by the high-speed signals that are input and output via the drive bus
in the control's position-control cycle, making it possible to attain high velocities and maximum precision.
• Automatic path division
You can choose whether you want the control to break the machining path down automatically by stroke length (SPP)
or stroke rate (SPN). With SPP, the travel path is broken down into programmable segments of identical size (modal
effect). SPN breaks the travel path down into a programmable number of path sections (non-modal effect).

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Glossary
Functions and Terms
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SINUMERIK 840D sl
Quadrant error compensation
Quadrant transitions without compensation Quadrant transitions with quadrant error compensation
Quadrant error compensation (also referred to as friction compensation) ensures a much higher degree of contour
precision, particularly when machining circular contours. At the quadrant transitions, one axis traverses at the maximum
path velocity while the second axis is stationary. The different friction conditions can cause contour errors. Quadrant
error compensation virtually eliminates this problem and produces excellent results, without contour errors, in the very
first machining operation.
In operator-controlled quadrant error compensation, you set the intensity of the correction pulse as per an acceleration-
based characteristic. This characteristic is determined and parameterized on startup with the aid of the circularity test.
During the circularity test, deviations of the actual position from the programmed radius (particularly at the quadrant
transitions) are recorded by measurement and graphically represented while the circular contour is being retracted.
Reference point approach

When using a machine axis in program-controlled mode, it is important to ensure that the actual values supplied by the
measuring system agree with the machine coordinate values. Reference point approach (limit switch) is performed
separately for each axis at a defined velocity either using the direction keys, in a sequence that can be defined in the
machine data, or automatically via program command G74. If length measuring systems with distance-coded reference
marks are used, reference point approach is shorter, as it is necessary to approach only the nearest reference mark.
Reference point approach of an axis with absolute-value encoders is carried out automatically when the control is
switched on (without movement of axis), if the corresponding axis is recognized as being calibrated.

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Repos
Following a program interruption in AUTOMATIC mode (e.g., to take a measurement on the workpiece and correct the
tool wear values or because of tool breakage), the tool can be retracted from the contour manually after changing to JOG
mode.
In this case, the control stores the interruption point coordinates and displays the differential travel of the axes in JOG
mode in the actual-value window as a Repos (repositioning) offset.
The contour can be reapproached:
• In JOG mode using the axis and direction keys. It is not possible to overshoot the interruption point; the feedrate
override switch is effective.
• By the program (with reference to the interruption block), either at the point of interruption, the start of the block, at a
point between the start of the block and the interruption point, or at the end of the block. Modified tool offsets are
taken into account. You can program approach movements as straight lines, in quadrants or in semicircles.
Representation (2D) of 3D protection zones/work areas

→ Working area limitation; protection zones
You can use protection zones to protect various elements on the machine, their components and the workpiece against
incorrect movements. The three-dimensionally programmed protection zones are displayed in 2D. This also applies to
the programmed working area limitations.
Residual material detection (option P13)

Contour ranges which cannot be machined with large tools are automatically recognized by the cycle for contour pockets
or the stock removal cycle. The operator can rework these regions using a smaller tool.
Contour turning offers:
• Contour/axis-parallel cutting with residual material detection
• Contour cutting with residual material detection
• Plunge-turning with residual material detection
Contour milling offers:
• Contour spigot with residual material detection
• Contour pocket with residual material detection
• Machining, e.g. in the steps: centering, predrilling, rough machining and rough machining residual material,
smoothing, edge/base, gripping
Rotary axis, turning endlessly

Depending on the application, the working area of a rotary axis can be limited via a software switch (e.g., working area
between 0° and 60°) or to a corresponding number of rotations (e.g., 1000°), or it can be unlimited (endlessly turning in
both directions).
This function can also be used with absolute-value encoders.

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SINUMERIK 840D sl
Safety Integrated
SINUMERIK Safety Integrated are integrated safety functions that support the implementation of highly effective
personnel and machine protection. The safety functions meet the requirements of DIN EN 61508 for use up to and
including SIL 2 and Category 3, and PL d according to DIN EN ISO 13849. This allows the main requirements for
functional safety to be implemented easily and cost-effectively. Available functions include, among others:
• Functions for safety monitoring of velocity and standstill
• Functions for establishing safe boundaries in work spaces and protected spaces, and for range recognition
• Direct connection of all safety-related signals and their internal logical linkage
Safety Integrated (option M63)

SI Basic function package (incl. 1 axis/spindle, up to 64 SPL I/Os) for one NCU.
Safety Integrated (option M64)

SI Comfort function package (incl. 1 axis/spindle, up to 64 SPL I/Os) for one NCU
Sag compensation, multi-dimensional (option M55)
Example: Sag compensation

Multidimensional compensation is also possible for the effects of physical influences and manufacturing tolerances such
as sag or leadscrew pitch errors. The compensation tables can be switched from the PLC.
When the reference axis and the compensating axis are identical, leadscrew pitch errors can be compensated. By
transferring weighting factors (PLC interface), stored compensating characteristics can be adapted to different conditions
(e.g., tools).
The most important features of interpolation and compensation using tables are as follows:
• Independent error characteristics can be defined, in number twice the maximum number of axes
• Freely selectable compensating positions, the number of which is configurable (dependent on the configuration of
CNC user memory)
• Interpolating inclusion of the compensation values
• Weighting factor for compensation of tool weights
• Reference axis and compensating axis are selectable
The tolerance band that can be corrected is limited to 1 mm (0.039 in) (in standard control versions: 10 mm (0.39 in)).

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SCIS transformation for pantograph kinematics (option)

"Pantograph" kinematic transformation is a type of 2-/4-axis transformation with parallel kinematics. It can work with
fixed-length rods, or rods whose lengths can be modified.
When using kinematic transformations, workpieces can be programmed in Cartesian coordinates as usual. The
SINUMERIK control calculates the required movements of the machine axes online. Therefore, the programmer can
create part programs in the same way as on a conventional machine, and does not have to take the special kinematics of
the machine into account.
Scratching, determining work offset

A work offset can also be determined through scratching, taking into consideration an (active) tool and, where applicable,
the base offset, by moving the axis to the workpiece, entering the desired setpoint position (e.g. "0"), and the controller
calculates the work offset.
Screen blanking
When screen blanking is activated, both the screen and backlighting of the operator panel go blank under PLC control or
after a programmable period of time has elapsed. This increases the service life of the screens.
Separate path feed for corners and chamfers

To optimize solutions for machining tasks, a separate path feed can be programmed with FRCM (modal) or FRC (non-
modal) for the corner and chamfer contour elements. Feed reduction thus makes it possible to achieve the desired
geometrically precise definition of corners and chamfers.
Series machine startup

Files called series machine startup files can be generated to enable transfer of a particular configuration, in its entirety, to
other controls that use the exact same software version, for example, controls that are to be used for the same
machines. Series machine startup thus means bringing a series of controls to the same initial state as regards their data.
You can archive/read selected CNC, PLC and PCU data for series machine startup. Compensation data can be
optionally saved. The drive data are stored as binary data, and cannot be modified.
Series machine startups can even be performed readily and easily without a programming device. Simply create a
startup file in the PCU, save it on a PC card in the control, insert this card in the next control, and begin the series
machine startup procedure. Series machine startups can also be performed via a network drive or a USB stick.
Set actual value

The "Set actual value" function is provided as an alternative to the "Preset" function: To use this function, the control
must be in the workpiece coordination system (WCS). With "Set actual value", the workpiece coordinate system is set to
a defined actual coordinate and the resulting offset between the previous and a newly entered actual value computed in
the WCS as 1st basic offset. The reference points remain unchanged.
Setpoint exchange (option M05)

Setpoint exchange is used on milling machines with special milling heads on which, for example, the spindle motor is
used both for driving the tool and for orientation of the milling head. In this case, the spindle and the milling head axes
are defined as independent axes in the control, but are traversed only in succession by one motor.
It is possible to connect up to 4 axes to one motor. The axes, which the setpoint switches between, can be assigned to
different channels or mode groups.

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ShopMill/ShopTurn (option P17)

The "ShopMill/ShopTurn" option includes the functions:
• Machining step programming
Machining step programming

Processes such as drilling, centering, plunging or pocket milling are represented as machining steps in a simple and
clear manner. In this way part programs – even for complex machining operations – are very compact and easily read.
Associated sequences are automatically interlinked and can be assigned any position patterns. This unique
programming convenience allows you to achieve the shortest programming times even for highly demanding machining
tasks.
SI axis/spindle, additional axis/spindle (option C71-C78)

One additional SI axis/spindle
SI axis/spindle package, additional 15 axes/spindles

(option C61/C62)
Additional 15 SI axes/spindles)
Simulation
Simulation is supported by an autonomous program interpreter and a separate simulation data environment at HMI level.
The simulation interpreter extensively considers the complete syntax of the SINUMERIK range of controls, including the
possibility of incorporating special user options on the machine by comparing data with the NCK environment. The
simulation data can be matched statically as required with the NCK environment (initialization data, macros, user data,
tool data, machining cycles) or also dynamically when tool data or machining cycles are changed.
Machining simulations, with emphasis on drilling/milling and turning technologies, can be executed on the control's HMI
in the workpiece coordinate system for certain machine kinematics depending on the active operating software (see also
function overview) and its software version as follows:

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Simulation (SINUMERIK Operate)

• 3D simulation 1 (option P25)
While a workpiece is being machined, machining of a different workpiece can be simulated. The finished part is
simulated using the real data and the NC kernel. The NC data is automatically updated on every switchover to
3D simulation. 3D simulation on the NCU can be used from NCU 720.2 upwards.
Simulation (HMI Advanced)
Simulation drilling/turning with HMI Advanced Simulation of turning with HMI Advanced
• Drilling/milling:
Simulation of multiface drilling and milling operations with display of material removal and/or displayable tool path line
graphs. Simulation of removal is primarily designed for paraxial machining in a rectangular 3D workpiece space.
Other kinematics which cannot be exactly represented with the 3D removal simulation, or machining operations
based on incomplete tool data, can nonetheless provide informative approximations using the integral tool path
simulation.
• Turning complete machining:
Turning operations can be displayed here in side views as linear tool path graphics with dynamic updating of the
blank envelope in the dynamically balanced 2½D workpiece space. Drilling and milling on the front face or on the
peripheral surface of turned parts can be simulated with representation of the removed material and/or the tool path
graphics with the same features as described under "Drilling/milling". Furthermore, display versions are available for
variable machine arrangements (e.g. for turning in front of or behind the turning center, on the main spindle or
counterspindle, for horizontal or vertical turning machine orientations).
In this manner, the simulation results in several part programs in succession can be superimposed in a complete
representation on the same unmachined part (e.g. starting from preformed blanks, for multiface machining when milling,
multi-slide and multi-spindle machining when turning etc.).The machined part finally originates from the sequential
interaction of all individually simulated part programs. For turning, input of a length offset for rear-side machining with
mirrored tools is possible, as well as input of CNC keywords for dynamic spindle changeover, e.g. for main spindle and
counterspindle operation. Visualization of the simulation can be customized using parameterization screens in many
areas. Graphics can be observed in various views and sections, in zoom representations, or in several windows
simultaneously.
Simultaneous recording (option P23/P24)

During machining, the tool paths can be simultaneously recorded on the display of the controller in three-side view or in
3D view. Workpiece graphics and views correspond to the graphic simulation.

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SINUMERIK MDynamics
Technology packages for 3-axis and 5-axis milling.
SINUMERIK MDynamics ensures perfect surfaces through innovative motion control and an optimized NC data
compressor, rapid adaptation to the workpiece, tool and program handling, optimum machining thanks to the flexible
programming of programGuide and ShopMill and, as a result, the shortest programming times.
• MDynamics 3 axes (option S32)
Contains the options:
ShopTurn/ShopMill, residual material detection and machining for contour pockets and cutting.
3D simulation 1 (finished part), simultaneous recording, advanced surface, spline interpolation, transmit and
peripheral surfaces transformation and measuring cycles.
• MDynamics 5 axes (option S33)
Contains the options:
ShopTurn/ShopMill, residual material detection and machining for contour pockets and cutting.
3D simulation 1 (finished part), simultaneous recording, advanced surface, spline interpolation, transmit and
peripheral surfaces transformation and measuring cycles.
Machining package 5 axes, 3D tool radius compensation and measure kinematics.
SINUMERIK Operate programming package/

SINUMERIK Operate runtime license OA programming
(option P60)
The SINUMERIK Operate programming package allows SINUMERIK users to design their own user interfaces to
visualize either machine-manufacturer or end-user functional expansions or simply their own screen form layouts.
User interfaces programmed by Siemens or other machine manufacturers can be modified or replaced. This function is
realized in a high-level language development environment based on C++/QT that can generate a platform-independent
execution code for Windows XP (SINUMERIK PCU 50.3) and Linux (NCU).
The screen forms are created platform-independently in the development environment.
The compiled program parts are transferred to the corresponding user directories of the PCU 50.3 or NCU.
Configuring examples for new screen forms, which can also be used as the basis for the user's own new screen forms,
can be found on the product DVD of the SINUMERIK Operate programming package.
You can implement the following functions with the "SINUMERIK Operate programming package":
• Display screen forms and softkeys, variables, tables, texts, help texts, graphics, and help screens
• Start actions when screen forms are displayed and exited, press softkeys, and enter values (variables)
• Dynamically restructure screen forms, including changing softkeys, designing arrays and displaying, replacing and
deleting display texts and graphics
• Read and write variables, combine with mathematical, comparative or logical operators
• Execute subprograms, file functions, program instance services (PI services) or external functions (SINUMERIK
Operate)
• Enable data exchange between screen forms
The SINUMERIK Operate runtime license OA programming (option P60) is required for executing the programmed user
screens.

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SINUMERIK Operate runtime license OA Easy Screen

(option P64)
The "Easy Screen" functionality allows SINUMERIK users to design their own user interfaces to visualize either machine-
manufacturer or end-user functional expansions or simply their own screen form layouts.
User interfaces configured by Siemens or other machine manufacturers can be modified or replaced. This function is
implemented via an integrated interpreter and via configuring files containing the description of the user interface.
The screen forms can be designed directly on the control itself. A graphic tool is required to create graphics and pictures.
Part programs can be processed with newly created user interfaces.
Configuring examples for new screen forms, which can also be used as the basis for the user's own new screen forms,
can be found in the supplied toolbox.
You can implement the following functions using "Easy Screen":
• Display screen forms and softkeys, variables, tables, texts, help texts, graphics, and help screens
• Start actions when screen forms are displayed and exited, press softkeys, and enter values (variables)
• Dynamically restructure screen forms, including changing softkeys, designing arrays and displaying, replacing and
deleting display texts and graphics
• Read and write variables, combine with mathematical, comparative or logical operators
• Execute subprograms, file functions, program instance services (PI services) or external functions (HMI Advanced)
• Enable data exchange between screen forms
• Easy Screen is configured using ASCII files that can be stored on the PCU. Files that contain ASCII descriptions for
the layout of interactive screen forms, softkey functions and display texts and graphics are interpreted. These
configuring files are created with the ASCII editor, taking into account certain special rules of syntax.
With the integrated editor, even the basic version of the user interface can be expanded at predefined softkeys by up to 5
screens (more than 5 screens with Operate runtime license OA Easy Screen (option P64)).
Skip blocks
CNC blocks that are not to be executed in every program run, e.g., execute a trial program run, can be skipped. Skip
blocks are identified by placing a "/" character in front of the block number. The instructions in the skip blocks are not
executed and the program resumes with the next block that is not skipped.
As many as eight skip levels (/0 to /7) may be programmed. The individual skip levels are activated via a data block in
the PLC interface.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Space compensation, VCS plus (option N17)

VCS plus is designed for use on large machines (3-axis and 5-axis gantry milling machines). The requirements for
positioning accuracy of these machines in the complete work space (= volumetric accuracy) increases constantly and is
specified in individual cases as < 50 µm.
The compile cycle "VCS plus" implements volumetric compensation of all 21 aspects of freedom from errors that the
3 basic axes of a cartesian machine tool can demonstrate (per axis: linearity, 2 degrees of error, rolling, pitching,
swerving as well as deviations from the perpendicular between axes). These geometrical machine errors cause offsetting
of the tool center point and an orientation error in the tool.
On a 5-axis machine, the tool center point and the orientation error of the tool are compensated with VCS plus with
TRAORI active.
In comparison to LEC (leadscrew error compensation) and CEC (circle error compensation), VCS plus supports the total
compensation of the geometric error of a cartesian machine tool. VCS plus can be superimposed on the previously set
LEC and CEC values.
The geometric error of a machine tool is measured with external laser-based instruments that determine these errors as
effectively as possible. The measured results are supplied to the SINUMERIK as a file in the specified readable VCS
format.
Measurement of the machine error is the responsibility of the OEM or machine operator. Several SINUMERIK Solution
Partners offer support and measurement as a service and they can generate the machine-specific VCS files necessary
for VCS plus.
Space error compensation for kinematic transformations

(option M57)
Space error compensation (SEC) is a method for compensating static position errors at the tool center point (TCP). In
this way, these position errors can be compensated in the three directions in space (x, y and z) simultaneously.
Measuring instruments are required for determining the error that allow the three coordinates of a measuring point to be
recorded simultaneously at multiple points distributed throughout the working area (e.g. a 3D laser tracker). The
SINUMERIK control can then use the resulting 3D error table to compensate each positioning window in real time.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Spindle functions
Spindle modes are:
• Open-loop control mode (constant spindle speed S or constant cutting rate G96)
• Oscillation mode
• Positioning mode
• Synchronous mode (synchronous spindle)
• Thread cutting/tapping
Functions of the spindle modes:
• Spindle speed with spindle override
• 5 gear stages, specified in the
- Part program (commands M41 to M45)
- Automatically via programmed spindle speed (M40) or
- PLC function block FC18
•
1)
Oriented spindle stop (positioning mode) with SPOS
•
1)
Spindle monitoring with the functions:
- Axis/spindle stationary (n < nmin)
- Spindle in set range
- Max. spindle speed
- Programmable lower (G25) and upper (G26) spindle speed limitation
- Min./max. speed of the gear stage
- Max. encoder limit frequency
- End point monitoring for SPOS
• Constant cutting speed with G96 (in m/min or inch/min) at the tool tip for uniform turning finish and thus better surface
quality. Spindle control via PLC for oscillation (for easier engaging of a new gear stage) and positioning
• Switch to axis operation:
For machining with a position-controlled spindle (face machining of turned parts, for example), the main spindle drive
can be switched to axis mode with a program command. A common encoder can be used for both axis and spindle
modes. The zero mark of the spindle is also the reference mark of the C axis, so there is no longer any need to home
the C axis (synchronize C axis on the fly).
• Thread cutting with constant pitch:1)
With G33 you can produce the following thread types: cylindrical, taper and face thread, single-start or multiple-start,
as left-hand or right-hand thread. In addition, multiple-block threads can be produced by concatenating threading
blocks.
• Thread cutting with variable pitch:1)
Threads can also be programmed with linearly progressive (G34) or linearly degressive (G35) pitch.
• Programmable run-in and run-out of thread:
When thread cutting, you can use DITS/DITE (displacement thread start/end) to program the path ramp for the
acceleration or deceleration process as a displacement. This makes it possible, for example, to adjust the
acceleration on the thread shoulder when the tool run-in or run-out is too short and initiate smoothing at the next CNC
start.
• Tapping with compensating chuck/rigid tapping:
When tapping with compensating chuck (G63), the compensating chuck equalizes differences between spindle
movement and drilling axis. A prerequisite for rigid tapping (G331/G332) is a position-controlled spindle with position
measuring system. The traversing range of the drilling axis is therefore not restricted. By using the method whereby
the spindle, as a rotary axis, and the drilling axis interpolate, threads can be cut to a precise final drilling depth (e.g.,
for blind hole threads).
1)
Prerequisite: actual-position sensor (measuring system) with corresponding resolution (mounted directly on the spindle).
Spindle speed limitation


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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Spline interpolation
• Spline interpolation for 3-axis machining (option M16)
• Spline interpolation for 5-axis machining (option M17)
• Spline interpolation (option S16)
By using spline interpolation it is possible to obtain a very smooth curve from just a few defined interpolation points along
a set contour. The intermediate points are connected by polynomials. The compressor converts linear motions (e.g., from
CAD) at block transitions to splines of constant speed (COMPON) or splines of constant acceleration (COMPCURV).
This yields soft transitions that reduce wear on the mechanical parts of the machine tool. However, if the intermediate
points are placed close together, quite sharp edges can also be programmed. Spline interpolation also considerably
reduces the number of program blocks required.
Extremely smooth workpiece surfaces are often very important in mold and tool making, both optically and
technologically, e.g., for rubber gaskets.
Tool radius compensation is also possible in spline interpolation, as it is in linear or circular interpolation.
Every polynomial can represent a spline. Only the algorithm determines the type of spline.
• A spline is only true to the tangents.
• B spline is true to the tangents and the curvature, but does not run through the nodes (intermediate points).
• C spline is true to the tangents and the curvature and runs through the nodes.
With the COMPCAD compressor, such "smooth" curves can be approximated within the boundaries of compressor
tolerance (parallel tool paths) and surfaces of a high optical quality can also be obtained in the case of large tolerances.
Spline interpolation for 3-axis machining is suitable for simple applications and for the JobShop area.
Standstill monitoring
→ Position monitoring
Standstill monitoring represents one of the most comprehensive mechanisms for monitoring axes. The monitor checks to
see whether the following error has reached the standstill tolerance limit following the elapse of a programmable time
period. Upon termination of a positioning action, standstill monitoring takes over from position monitoring, and checks to
see whether the axis moves further from its position than stipulated in the machine data's standstill tolerance field. The
standstill monitoring function is always active following expiration of the zero speed delay time or upon reaching the fine
exact stop limit as long as no new traversing command is pending.
When the monitor responds, an alarm is generated and the relevant axis/spindle brought to standstill with rapid stop via a
speed setpoint ramp. Standstill monitoring is effective for linear and rotary axes as well as for position-controlled
spindles. Standstill monitoring is inactive in follow-up mode.
Subprogram levels and interrupt routines

Subprograms can be called not only in the main program, but also in other subprograms. Subroutines can be nested to a
depth of 12 levels, including the main program level. This means that a main program may contain as many as 11 nested
subroutine calls. When working with Siemens cycles, three levels are required. If such a cycle is to be called from a
subprogram, the call can be nested at a depth of no more than 9 levels.
Programs can also be called on the basis of events following resetting of the part program start or end, or following
booting of the control. Users can then make the basic function settings or carry out initializations using a part program
command.
A system variable can be used to scan the event, which activated the associated program.
Synchronized actions stage 2 (option M36)

More than 24 synchronous actions can be active in the CNC block. As many as 255 parallel actions can be programmed
in each channel. Technology cycles can be combined into programs using synchronized actions stage 2, making it
possible, for example, to start axis programs in the same IPO cycle by scanning digital inputs.
The number of simultaneously traversed axes is limited to 4 (path and positioning axes).

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Synchronous actions
→ Cross-mode actions
Even in its basic configuration, SINUMERIK allows you to initiate up to 24 actions synchronous to the axis and spindle
movements. These actions run in parallel with workpiece machining, and their inception can be determined on the basis
of conditions. The starting of such motion-synchronous actions (or synchronous actions for short) is, therefore, not
restricted to CNC block boundaries.
Synchronous actions are always executed in the interpolation cycle. Several actions can even be carried out in the same
IPO cycle.
Synchronous actions without validity identifier are non-modal only in AUTOMATIC mode. Synchronous actions with
validity identifier ID are modal in the subsequently programmed blocks in AUTOMATIC mode. Statically effective
synchronous actions with the identifier IDS remain active in all modes ("Cross-mode actions").
Synchronous actions provide you with an excellent programming tool to respond very quickly to events in the
interpolation cycle. Here are some typical applications:
• Comparison operation-dependent or external signal-dependent transfer of auxiliary functions M and H to the PLC
user software and derived machine responses
• Fast, axis-specific, input signal-based deletion of the residual distance
• External signal-controlled read-in disable for the CNC block
• Monitoring of system variables such as velocity, power and torque
• Controlling process variables (velocity, speed, distance, etc.)
Only 1 active synchronous function (SYNFCT) is possible at a time. The number of simultaneously traversed axes is
limited to 4 (path and positioning axes).

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Synchronous spindle/multi-edge turning (option M14)
Examples for synchronous spindles/multi-edge turning

True-to-angle synchronization of one leading and one or more following spindles enables on-the-fly workpiece transfer,
particularly for turning machines, from spindle 1 to spindle 2, for example for the purpose of finishing, without
experiencing the non-productive times normally associated with rechucking.
In addition to the speed synchronism, the relative angular position of the spindles to one another, e.g., on-the-fly,
position-oriented transfer of edged workpieces, is also specifiable.
On-the-fly transfer:
• n1 = n2
• Angle 1 = angle 2 or
• Angle 2 = angle 1 + angle Δ
Finally, specification of an integer speed ratio between the main spindle and a tool spindle provides the prerequisites for
multi-edge machining (polygon turning).
Multi-edge turning:
n2 = T · n1
Configuring and selection take place either via the CNC program or the operator panel. Several pairs of synchronous
spindles can be implemented.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Tangential control (option M06)
Representation of a rotatable tool axis and die during punching/nibbling

Tangential control makes it possible to correct a rotary axis in the direction of the tangents of two path axes. The two
leading axes and the corrected axis lie in the same channel.
Applications:
• Tangential setting of a rotatable tool during punching/nibbling
• Correction of the workpiece alignment for a belt saw
• Setting of a dressing tool on a grinding wheel
• Tangential feed of a wire for 5-axis welding
• Setting of a cutting wheel for machining glass or paper
Tangential control is effective in all interpolation modes.
On punching and nibbling machines with a rotatable punching tool and associated lower tool, the following functions may
be used to ensure universality of the tool:
• Tangential control
TANGON/TANGOF for vertical rotary axis alignment of the punching tool to the direction vector of the programmed
path
• Coupled motion
TRAILON/TRAILOF for synchronous rotation of upper and lower tool (stamp and die)
Tapping with compensating chuck/rigid tapping


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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Technology cycles
Example: Swiveling to any surface Example: Milling the circular pocket

For frequently repeated machining tasks, technology cycles are available for the drilling/milling and turning technologies.
Technology cycles are generally applicable technology subprograms, with which specific machining processes can be
implemented, such as tapping a thread or milling a pocket. The cycles are adapted to a concrete machining task by
means of parameters. The parameterization can also be implemented using graphically supported input screens.
• Drilling:
Drilling/centering, drilling/counterboring, deep-hole drilling, tapping with and without compensating chuck, boring 1 ...
5, row of holes/circle of holes, grid of holes, machining on inclined surfaces
• Milling:
Thread milling, elongated holes in a circle, groove in a circle, circumferential groove, rectangular/circular pocket, face
milling, path milling, rectangular/circular spigot, machining on inclined surfaces, high-speed settings for optimized
HSC machining, engraving cycle
• Turning:
Groove, undercut, cutting with relief cut, thread undercut, thread cutting, chaining of threads, thread recutting
Temperature compensation
Heat causes machine parts to expand. This expansion depends, among other things, on the temperature and on the
thermal conductivity of the machine parts. The actual positions of the individual axes, which change on the basis of
variations in temperature, have a negative effect on the precision with which workpieces are machined. These actual
value modifications can be corrected using temperature compensation.
At a specific temperature, measure the actual-value offset over the positioning range of the axis to obtain the error curve
for this temperature value. Error curves for different temperatures can be defined for each axis.
In order to ensure proper compensation of thermal expansion in changing temperatures, the temperature compensation
value, reference position, and linear angle of lead parameters must be transferred from the PLC to the CNC via function
blocks each time the temperature changes. Abrupt changes in these parameters are automatically smoothed by the
control in order to prevent machine overload and avoid triggering watchdog monitors unnecessarily.
Thread cutting

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Tool carrier with orientation capability
Kinematics type T
Kinematics type M
Kinematics type P

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Functions and Terms
CNC
SINUMERIK 840D sl
Tool carrier with orientation capability (continued)

For machine tools, which have tool carriers with settable tool orientation, the user of a SINUMERIK control can freely
configure these kinematics without using 5-axis transformation. The "tool carrier with orientation capability" function
enables 2½D/3D machining with fixed spatial orientation of the tool/workpiece table.
Vectors l1 to l4 represent the geometrical dimensions of the machine. The rotary axes need not move in parallel to the
Cartesian axes, but instead can be inclined at any angle (e.g., cardan milling head with 45° inclination).
The angles α1 and α2 can be either specified or computed from the active frame and assigned to the tool carrier with
orientation capability or to the workpiece table.
The following kinematics can be configured flexibly:
• Rotatable tool: type T (tool)
• Rotatable tool/rotatable workpiece table: type M (mixed)
• Rotatable workpiece table: type P (part)
Tool change via T number

In chain, rotary-plate and box magazines, a tool change normally takes place in two stages: A T command locates the
tool in the magazine, and an M command inserts it in the spindle. In circular magazines on turning machines, the T
command carries out the entire tool change, that is, locates and inserts the tool. The tool change mode can be set using
machine data.
Tool identification systems

The Siemens Tool Management tool load and unload dialog boxes offer a link to an automatic tool identification system.
This allows you to replace manual input of the tool data with automatic reading and writing of the tool code carrier.
During unloading, the data block for the tool is saved; during loading, it is read via the code carrier and entered in the tool
management. In the interim, the tool data can be re-edited as during tool selection from the tool catalog (offset data,
etc.).
Using an editable description file containing precisely defined tool and cutting data, the code carrier data are converted
during loading into dialog data, which can be read by the tool management. During unloading, the dialog data are
converted back into code carrier data with the aid, once again, of the description file.
Tool management (option M50)

Tool management ensures that the correct tool is in the correct location on the machine at any given time and that the
data assigned to the tool are up to date. Tool management is used on machine tools with circular magazines, chain
magazines or box magazines. It also allows fast tool changes and avoids both scrap by monitoring the tool service life
and machine downtimes by using spare tools.
The most important functions of tool management are:
• Tool selection throughout all magazines and turrets for active tools and spare tools
• Ascertaining of a suitable empty location depending on tool size and location type
• Tool-dependent location coding (fixed and variable)
• Initiation of tool changes with T or M command
• Axis movements during a tool change with automatic synchronization when next D number is encountered
• Quantity and tool life monitoring with prewarning limit monitoring function
Missing tools can be loaded based on a decision made by the operator. Tools with similar wear characteristics can be
combined into wear groups.
Tool management also takes tool length compensations for adapters that are permanently mounted at certain magazine
locations and fitted with different tools into account.

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Glossary
Functions and Terms
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SINUMERIK 840D sl
Tool management with more than 3 magazines (option M88)

In the basic version of the SINUMERIK 840D sl, 3 magazines (magazine, spindle, tool buffer) are included. With option
M88, the number of magazines can be increased.
Tool offsets
Tool offsets
By programming a T function (5-figure integer number) in the block, you can select the tool. Every T number can be
assigned up to 12 cutting edges (D addresses). The number of tools to be managed in the control is set at the
configuration stage. A tool offset block comprises 25 parameters, e.g.:
• Tool type
• Up to three tool length offsets
• Radius compensation
• Wear dimension for length and radius
• Tool base dimension
The wear and the tool base dimension are added to the corresponding offset.
When writing the program, you need not take tool dimensions such as cutter diameter, cutter position or tool length into
account.
You program the workpiece dimensions directly, following the production drawing, for example. When a workpiece is
produced, the tool paths, depending on the relevant tool geometry, are controlled so that the programmed contour can
be produced with every tool used.
You enter the tool data separately in the control's tool table, and in the program you call only the required tool with its
offset data. During program execution, the control fetches the required offset data from the tool files and corrects the tool
path for various tools automatically.
Tool offset D can be programmed with reference to tool number T (when the Siemens tool management is active, e.g.,
with monitoring functions and management of sister tools) or without internal references to existing tools.
You can define as many as 32,000 D values per control. D numbers can be freely assigned, checked, renamed,
ascertained with the associated T number, invalidated, and activated on a site-dependent basis during programming.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Tool offsets, grinding-specific

→ Grinding wheel surface speed
Grinding-specific tool offsets are available (minimum wheel radius, maximum speed, maximum surface speed, etc.) for
grinding technology. When a cutting edge is created for grinding tools (tool type 400 to 499), these are stored
automatically for the tool in question.
Tool types are:
400: Surface grinding wheel
401: Surface grinding wheel with monitoring
403: Surface grinding wheel with monitoring and without tool base dimensions for grinding wheel surface speed
410: Facing wheel
411: Facing wheel with monitoring
413: Facing wheel with monitoring and without tool base dimensions for grinding wheel surface speed
490 to 499: Dresser
With the TMON command, you can activate geometry and speed monitoring for grinding tools (type 400 to 499) in the
CNC part program. Monitoring remains active until deactivated in the part program with TMOF. The current wheel radius
and the current wheel width are monitored. The speed setpoint monitoring is monitored cyclically in relation to the speed
limit value, taking into consideration the spindle override.
The speed limit value is the smaller of the values resulting from comparison of the maximum speed with the speed
computed from the maximum grinding wheel surface speed and the current wheel radius.
Tool orientation interpolation

→ Transformation, generic
Interpolations of tool orientations supplement generic transformation: The tool orientation can be programmed in a plane
as large circle interpolation (ORIPLAN program command), on the outside surface of a taper in the clockwise or
counterclockwise direction (ORICONCW/ORICONCCW), or even with free definition of the tool curve orientation
(ORICURVE).

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SINUMERIK 840D sl
Tool radius compensation
KONT for behind the contour
Bypassing the outside corners with transition circle/transition ellipse

When tool radius compensation is enabled, the control automatically computes the equidistant tool paths for different
tools. To do so, it requires the tool number T, the tool offset number D (with cutting edge number), the machining
direction G41/G42, and the relevant working plane G17 to G19.
The path is corrected in the programmed level depending on the selected tool radius. You can match the approach and
retract paths to the required contour profile or rough-part forms, for example:
• NORM
The tool travels directly in a straight line to the contour, and is vertically aligned to the path tangent at the starting
point.
• KONT
If the starting point is behind the contour, the corner point P1 of the contour is bypassed. If the starting point is in front
of the contour, in NORM the normal position at the starting point P1 is approached.
In the part program it is also possible to select the strategy with which the outside corners of the contour are to be
bypassed:
• With transition radii (circle or ellipse)
• Intersection of equidistant paths
For soft approach to/retraction from the contour, i.e., tangential approach and retraction irrespective of the position of the
starting point, various strategies are available: Approach and retract from left or right, on a straight line, on a quadrant or
semicircle, in space or in the plane.
The control can also automatically insert a circle or a straight line in the block with the tool radius compensation when no
intersection with the previous block is possible.
The offset process of tool radius compensation may be interrupted only by a certain number of successive blocks or
M commands containing no motion commands or positional data in the compensating plane.
This number of successive blocks (or M commands) can be set using machine data (standard 3, max. 5).

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
3D tool radius compensation (option M48)

Inclined surfaces can be machined with 3D tool radius compensation or tool offset in space. This function supports
circumferential milling and face milling with a defined path. The inclined tool clamping position on the machine can be
entered and compensated. The control computes the resulting positions and movement automatically. The radius of a
cylindrical milling cutter at the tool insertion point is included in the calculation.
The insertion depth of a cylindrical milling cutter can be programmed. The milling cutter can be turned not only in the X, Y
and Z planes, but also by the lead or hitch angle and the side angle.
Tool types
Geometry of turning tool
Geometry of slotting saw

The tool type determines the geometry specifications required for the tool offset memory, and how they are to be used.
Entries are made for the relevant tool type in tool parameter DP. The control combines these individual components to
produce a result variable (e.g., total length, total radius). The relevant overall dimension goes into effect when the offset
memory is activated. The use of these values in the axes is determined by the tool type and current machining plane
G17, G18 or G19.
The following tool types can be parameterized:
Group 1xy: milling cutters (from spherical head cutter to bevel cutter)
Group 2xy: drills (from twist drill to reamer)
Group 4xy: grinding tools (from surface grinding wheel to dresser)
Group 5xy: turning tools (from roughing tool to threading tool)
Group 700: slotting saw
The saving of all tool offsets is supported by input screens.
For wood technology, the slotting saw tool is available as a tool type.

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Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Transformation, generic
Generic transformation is used to define any tool orientation in space with the initial state of the axes, and not just
according to the Z direction. It can then be used much more flexibly and universally.
It is then possible to also control machine kinematics by the CNC where the orientation of the rotary axes is not exactly
parallel to the linear axes. Generic 5-axis transformation has been extended to 3-axis and/or 4-axis transformation, i.e., it
can also be used for machines with only one rotary axis (rotatable tool or workpiece).
Transformation package for handling, RCTRA (option M31)
Transformation package Handling

The transformation package for handling contains the so-called standard transformation block, with whose help typical 2-
axis to 5-axis handling devices such as gantries or SCARAs can be operated. This coordinate transformation package
converts the axis-specific actual values for the axes (e.g., A1 to A4) into Cartesian values (e.g., X, Y, Z, A) and the
programmed Cartesian setpoints back into axis-specific values for the handling devices.
Thanks to this coordinate transformation, the movements of the handling device become simpler and more user-friendly.
The handling device can be set up, that is, manually traversed not only in the axis-specific coordinate system, but also in
the Cartesian coordinate system of the handling device, using, for example, the jog keys on the handheld programming
unit. Adaptation of the respective kinematics is carried out via machine data.
A 6-axis transformation for defined applications is also available on request.
Transformation HEXAPOD (option)
HEXAPOD animation

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SINUMERIK 840D sl
Transformation PARACOP (option)
PARACOP animation
Transformation TRICEPT (option)
TRICEPT animation
HEXAPOD, PARACOP, TRICEPT kinematic transformations and pantograph kinematics are used on parallel-kinematics
machines (PKM). Parallel kinematics means that the drive forces engage on the spindle head (Stuart platform)
simultaneously (virtually in parallel).
With HEXAPOD, the Stuart platform is moved by six actuators, whose lengths can be modified. The Stuart platform can
be moved to any position, including within the working area, by these six actuators, and its inclination in space
(orientation) can also be set specifically. This allows workpieces to be machined on 5 axes on these machines. The
orientation angle is only limited by the mechanical properties of the cardan or ball joints.
PARACOP and TRICEPT machines are TRIPODEN types, whereby the Stuart platform is moved by three actuators.
Design measures are used to ensure that the Stuart platform cannot move in an undefined manner on these TRIPODEN
types. On PARACOP machines, two parallel rods run on a slide for each actuator. These machines are suitable for 3-
axis machining. On TRICEPT, an additional passive telescope (center tube) is used. On TRICEPT, two additional rotary
axes are required to define the tool orientation in space. These axes can be arranged as with a fork head on a 5-axis
machine, for example, thus the design allows the machine to carry out 5-axis machining.

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SINUMERIK 840D sl
Transformation TRIPOD HYBRID Kinematic (option)

This kinematic transformation (THYK) is a 5-axis transformation for 3 parallel linear axes and two rotary axes (see
parallel kinematic type Exechon). The tool movements are programmed complete with their orientation in the same
manner as the cartesian 5-axis machine. The real-time transformation calculates the necessary paths and speeds for the
real machine axes.
Parallel kinematic type Exechon

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SINUMERIK 840D sl
TRANSMIT/peripheral surface transformation (option M27)
Face machining with TRANSMIT Tool-center-point path through the pole

TRANSMIT is used for milling outside contours on turned parts, e.g., square parts (linear axis with rotary axis).
As a result, programs become much more simple and complete machining increases machine efficiency. Turning and
milling can be performed on one machine without rechucking.
3D interpolation with two linear axes and one rotary axis is possible. The two linear axes are mutually perpendicular and
the rotary axis lies at right angles to one of the linear axes.
TRANSMIT can be called up in different channels simultaneously. The function can be selected and deselected with a
preparatory function (straight line, helix, polynomial and activating tool radius compensation) in the part program or MDA.
With TRANSMIT, the area of the transformation pole is reached when the tool center can be positioned at least to the
turning center of the rotary axis entering the transformation.
TRANSMIT through the pole is implemented in different ways:
• When traveling through the pole, the rotary axis is turned automatically by 180° when the turning center is reached
and the remaining block is then executed.
• When traveling close by the pole, the control automatically reduces the feedrate and the path acceleration.
• If the path contains a corner in the pole, the position jump in the rotary axis is compensated by the control through
automatic block insertion.
Peripheral surface transformation is used on turning machines and milling machines, and enables peripheral surface
transformation, e.g., for turned parts.
The TRACYL peripheral surface transformation or cylinder surface transformation can be used to manufacture grooves
of any shape on the surface of cylindrical bodies with or without groove side offset. The shape of the grooves is
programmed in reference to the plane cylinder surface processed.

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SINUMERIK 840D sl
Travel to fixed stop

With this function, tailstocks or sleeves, for example, can be traversed to a fixed stop in order to clamp workpieces. The
pressure applied can be defined in the part program. Several axes can be traversed to a fixed stop simultaneously and
while other axes are traversing.
Travel to fixed stop with Force Control (option M01)

The "extended travel to fixed stop" function can be used to adapt torque or force on a modal or non-modal basis; travel
with limited torque/limited force (force control, FOC) can be initiated, or synchronous actions can be used at any time to
program traversing functions.
Traversing range
The range of values for the traversing ranges depends on the selected computational resolution. When the default value
is specified in the machine data field "Computational resolution for linear or angular position" (1,000 increments per mm
or degree), the ranges of values specified in the table can be programmed with this resolution:
G70 [inches, degrees] G71 [mm, degrees]
Linear axes X, Y, Z, etc. ± 399999,999 ± 999999,999
Rotary axes A, B, C, etc. ± 999999,999 ± 999999,999
Interpolation parameters I, J, K ± 399999,999 ± 999999,999
If the computational resolution is increased/decreased by a factor of 10, then the value ranges change accordingly. The
traversing range can be restricted by software limit switches and operating ranges.
Universal interpolator NURBS

Internal motion control and path interpolation are performed using NURBS (non-uniform rational B splines). This provides
a uniform method for all internal interpolations that can also be used for future complex interpolation tasks.
The following input formats are available irrespective of the internal structure:
Linear, circular, helical, involute interpolation, splines (A, B, C) and polynomials.
User interface
The user interface has a clear layout with 8 horizontal and 8 vertical softkeys. The targeted use of Windows-type
technology permits simple and user-friendly operation of the machine.
The interface is subdivided into 6 operating areas:
• Machine
• Parameters
• Program
• Services
• Diagnostics
• Startup
In this way, it is possible, for example, to create another part program while parts production is in progress and to
transfer data from an external storage unit at the same time. On changing the operating area, the last active menu is
always stored. There are two hotkeys for switching between operating areas.
User interface expansion


© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
User machine data

The NCK makes machine data available for configuring the PLC user program. These user machine data are stored in
the NCK-PLC interface during control power-up, prior to PLC power-up. The PLC basic program reads these data from
the NCK-PLC interface during its initialization phase. This means that specific machine configurations, machine
expansions and user options can be activated.
Variables and arithmetic parameters

Using variables in place of constant values permits the development of flexible programs. Variables make it possible to
respond to signals, e.g. measured values. If variables are used as a setpoint value, the same program can be used for
different geometries.
Variable types
The control uses 3 classes of variable:
User-defined variable Name and type of variable defined by the user, e.g. arithmetic parameter
Arithmetic parameters Special, predefined arithmetic variable whose address is R plus a number. The predefined arithmetic
variables are of the REAL type.
System variables Variables provided by the control that can be processed in the program (write, read). System variables
enable access to work offsets, tool offsets, actual values, measured axis values, control conditions, etc.
Variable types
Type Meaning Value range
INT Integers with sign ±(231 - 1)
REAL Real numbers (fractions with decimal point, LONG REAL ±(10-300 ... 10+300)
in acc. with IEEE)
BOOL Boolean values: TRUE (1) and FALSE (0) 1.0
CHAR ASCII character specified by the code 0 ... 255
STRING Character string, number of characters in [...], maximum Sequence of values with 0 ... 255
of 200 characters
AXIS Axis names (axis addresses) only Any axis identifiers in the channel
FRAME Geometrical parameters for moving, rotation, scaling, and

mirroring
Velocity
The maximum path and axis velocity and spindle speed are affected by the machine and drive dynamic response and
the limit frequency of actual-value acquisition (encoder limit frequency and limit frequency of the input circuit). The
resulting velocity from the programmed path length in the CNC block and interpolation cycle (IPO cycle) is always limited
to the maximum velocity or, in the case of short path lengths, reduced to the velocity that can be travelled during one IPO
cycle.
The minimum velocity must not go below 10-3 units/IPO cycle. The minimum and maximum axis velocities are dependent
on the selected computational resolution. The maximum velocity of the axis is generally limited by the mechanics or by
the limit frequency of the encoder or actual-value acquisition. The velocity value range is not limited by the CNC (max.
300 m/s).
Vibration extinction "VIBX" (option N11)

The function is implemented as a loadable compile cycle and supports the axis-specific damping of machine vibrations.
Up to 8 axes can be parameterized in the CNC, each with 2 machine data for the filter frequency and the required
damping factor. The function can significantly reduce disturbing oscillations that follow positioning actions.

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Work offsets
→ Frame concept
Coordinate system
According to DIN 66217, clockwise, rectangular (Cartesian) coordinate systems are used in machine tools.
The following coordinate systems are defined:
• Machine coordinate system MCS
The machine coordinate system is formed by all the available physical machine axes.
• Basic coordinate system BCS
The basic coordinate system consists of three Cartesian axes (geometry axes), as well as other non-geometric axes
(special axes).
• BCS and MCS are always in
conformance when the BCS can be mapped to the MCS without kinematic transformation (e.g.,
TRANSMIT/interfacial transformation, 5-axis transformation and max. three machine axes).
• Basic zero system BZS
DRF offsets, external work offsets and basic frames map the BCS on the BZS.
• Settable zero system SZS
An activated settable work offset G54 to G599 transfers the BZS to the SZS.
• Workpiece coordinate system WCS
The programmable frame determines the WCS representing the basis for programming.
Thus, you use work offsets to transform your machine zero point into the workpiece zero point in order to simplify
programming. You can choose from among various work offsets:
• Settable work offsets:
You can enter offset coordinates, angles and scaling factors in up to 100 possible work offsets (G54 to G57, G505 to
G599), in order to call zero points from any program for various fixtures or clamping operations, for example. The
work offsets can be suppressed block-by-block.
• Programmable work offsets:
Work offsets can be programmed with TRANS (substitution function, basis G54 to G599) or ATRANS (additive
function). This allows you, for example, to work with different work offsets for repetitive machining operations at
different positions on the workpiece. G58/G59 make previously programmed work offsets axially replaceable.
• External work offsets:
You can also activate axis-related linear work offsets via the PLC user software (function blocks) with assignment of
system variable $AA_ETRANS [axis].

© Siemens AG 2010
Glossary
Functions and Terms
CNC
SINUMERIK 840D sl
Working area limitation

→ Work offsets
Working area limitations describe the area in which machining is permitted.
These limitations refer to the basic coordinate system BCS. Checks are made to see whether the tool tip has penetrated
the protected working area (also taking into account the tool radius). One value pair (plus/minus) per axis may be used to
describe the protected working area.
The upper and lower working area limits, which can be set and activated via setting data, may be modified using the
G25/G26 commands. Working area limitations restrict the traversing range of the axes in addition to the limit switches.
Protective zones in which tool movements are suspended and which protect equipment such as tool turrets, measuring
stations, etc., against damage, are thus set up in the machine's working area.
Working plane
→ Tool radius compensation
When specifying the working plane in which the desired contour is to be machined, the following functions are defined at
the same time:
• Plane for the tool radius compensation
• Infeed direction for the tool length compensation depending on the type of tool
• Plane for the circle interpolation
When calling the tool path correction G41/G42, the working plane must be defined so that the control can correct the tool
length and radius.
In the basic setting, the working plane G17 (X/Y) is preset for drilling/milling, and G18 (Z/X) for turning.
Zero offsets
→ Work offsets

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© Siemens AG 2010

Acceleration with jerk limitation

0 Password – Siemens All functions, programs, data

1 Password – Machine manufacturers: Defined functions, programs and data (options)

2 Password – Machine manufacturers: Defined functions, programs and data (machine

3 Password – End user: Assigned functions, programs and data

4 Red key 7 End user: < Protection level 0-3

6 Black key 5 End user: Program selection only,

Glossary for NC 61 • 2010 1/79

Actual-value system for workpiece

Advanced Position Control (APC) (option M13)

Advanced Surface (option S07)

2/79 Glossary for NC 61 • 2010

Alarms and messages

Programming and displaying message texts

Glossary for NC 61 • 2010 3/79

Analog value control

Auxiliary function output

Axes/spindles (option A01-A26)

4/79 Glossary for NC 61 • 2010

Axial coupling in the machine coordinate system MCS

Axis data output via PROFIBUS ADAS (option N07)

Axis limitation from the PLC

Glossary for NC 61 • 2010 5/79

Positive backlash (normal case)

6/79 Glossary for NC 61 • 2010

Cartesian PTP travel

Circle via center point and end point

Circle via intermediate point and end point

Glossary for NC 61 • 2010 7/79

Clearance control 1D in the IPO cycle

Clearance control 1D/3D in the position-control cycle

CNC program messages

CNC user memory

Compensation of a forced mechanical coupling, AXCO (option)

8/79 Glossary for NC 61 • 2010

Grinding a TRANSMIT contour with inclined axis

Continue machining at the contour (Retrace Support)

Continuous dressing (parallel dressing)

Glossary for NC 61 • 2010 9/79

Continuous-path mode with programmable rounding clearance

Continuous-path mode with programmable rounding clearance

Contour definition programming

Contour handwheel (option M08)

10/79 Glossary for NC 61 • 2010

Contour monitoring with tunnel function (option M52)

Control unit management

Crank interpolation "CRIP" (option)

Cross-mode actions (option M43)

Cycle protection (OEM) (option P54)

Glossary for NC 61 • 2010 11/79

Data exchange between machining channels

12/79 Glossary for NC 61 • 2010

DOUBLETRANSMIT transformation, 2TRA (option M25)

DRF offset (differential resolver function)

Glossary for NC 61 • 2010 13/79

Dynamic preprocessing memory (FIFO)

Easy Screen (option P64)

Electronic gear (option M22)