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1. END Program table editing Hechining status Pallet IO1 1 PAL T Where is TOM currently Where can you see e 1 ll 1 Uorkpiece 255 g being used how TOM works ee 11 This machining technology has already Tool oriented machining in full sequence atua f F proven its worth with well known operation can be tested with program P EES t watch makers in Switzerland As soon examples from the latest version of our Solena TTIE E as a functioning pallet program has programming station During installation been created It only has to be copied standard with examples must be se l E to be used for a wide variety of pro lected Status BLANK z grams ENE B F aM Can 5 axis programs also be Erfe 1 1 ery re entered Entry form as overview of all workpieces of a pallet view of pallet level With the latest software versions of the iTNC 530 such complex calcula tions are of course also possible Program table editing Hachining status File TNHCt TOLPALLETSTOLUORKPIECE P PGH 5 Pallet ID Hethod TOOL OGRIENTED fal Status ELANK E WFE a WFE a EN PALLET rey IEW Dat 1 1 Soft key for alternating between workpiece level view and pallet Entry form seen in detail for inout of required machining view of workpiece level SEQUENCE
2. 3 1 i tit a 8 A me P e 3 Klartext Issue 49 09 2008 Understanding challenges to accu racy and being able to judge meas urement concepts help in gaining an insight into measuring technology and machine tools That can be im portant for example when selecting a suitable machine tool for your own Closed Loop If an angle encoder mounted direct ly on the rotary axis is used for position measurement most sources of error can be avoided This method is known as the closed loop method Use of an angle en coder with integral bearing is recommen ded in this respect so that the previously described elasticity deviations do not lead to additional angle deviation When using an angle encoder with integral bearing It Is presumed that the minimal angle error of an axis lies within the system accura cy of the angle encoder the accuracy of an angle encoder of applications Especially if produc tion quality has a high priority After placing emphasis on the accuracy of linear axes in the last Klartext edition this time we are concentrat ing on rotary axes The best solution is angle encoders with integral bearing integrated coupling and absolute position measurement directly mounted to the rotary axis 2 corresponds to a deviation of 5 um for a table diameter of 1 m Of course Spatial deviations also accumulate due to elasticity of th
3. Oi 1 LAL HTE H FOS jo Useful special function Automatic program start at a specific time Control Program table editing 5 re 6 0 ce 0 IT NC 530 Application for Innovative Medical lechnology Every day Helmut B gets on his bike at 6 45 am It s a lovely October morning and it s still a bit dusky He s cycled on his bike to work for years just like to day After one kilometer the field track goes through a forest The track and the surrounding forest are both covered in leaves making orientation more difficult Suddenly a tree looms up in front of Helmut 8 he hits the brakes the front wheel jams the back wheel shoots upwards and Helmut B crashes against the tree with his back The diag nosis at the hospital is shattering the fourth cervical vertebra is broken and compressed the adjacent interverte bral disks have been compacted In Salzburg Austria the company SYN THES has a manufacturing plant the Aus trian sales office and a subsidiary called the SYNTHES Innovation Workshop as part of the Paracelsus Private Medical University The objective of this laboratory is to evaluate new solutions for the opera tive treatment of Injuries and skeletal de generation Miniaturization is the trend in medical technology as well both in terms of implants as well as sections required for insertion of the impl
4. field tested and also in particular have to be optimized Working with ana tomical specimens is something that has to be got used to and It s not something for everyone but it definitely cannot be avoided if optimal products are to be de veloped and if an essential contribution to improving the health and quality of life of patients is to be made SYNTHES products for sta bilization of the cervical and lumbar spinal regions The PICOMAX 55 and PICOMAX 60 for prototype preparation at SYNTHES Alfred Niederberger left and Johann Fierlbeck right talking to Udo Nowak HEIDENHAIN center with the 1TNC 530 From the operating table to prototypes At the beginning of a project a wet labo ratory may well have difficulties because medical opinions often differ greatly when several doctors discuss a mechanical prob lem In examples like that it is absolutely essential for a timely decision to discuss different views at the operating table in order to clear up uncertainties or differ ences of opinion That works really well because otherwise when the idea is put into practice unproductive time intervals would occur and we cannot really afford that explains Alfred Niederberger After a prototype has run through several optimization phases and passed a realistic test in the wet laboratory and if it is con sidered fit for series production then the idea is passed on to the corresponding SYNTHES development
5. rotary and swivel axes is also a topic at Visit us Hall 4 Booth 4 612 LL Communications EH Controls o ou Programming with smarT NC DCM Dynamic Collision Monitoring KinematicsOpt the AMB Here HEIDENHAIN shows the KinematicsOpt feature which makes it possible to easily measure the tilting ac curacy of rotary axes In addition at several 1TNC programming stations our application experts will be available to demonstrate the newest fea tures of the control The new touch probes are also in focus With its TS 740 HEIDENHAIN will present a high accuracy infrared touch probe for very demanding 3 D measuring tasks on machine tools or measuring machines The device operates with a piezo sensor and features a repeatability of better than 0 3 um The TS 444 is a version with small er dimensions that like its larger cousin is also a 3 D touch probe with infrared transmission of the trigger signal The TS 444 needs no batteries The power supply consists of integrated capacitors charged from a small wind turbine driven by the compressed air of the machine Linear and Angular Digital Readouts for Manually Operated Machine Tools Accuracy of Machine Tools Touch probes Klartext Issue 49 09 2008 3 t our interactive KLARTEXT ne as well with even more ation animations ge Take a look at de klartext Check ou e magazi background inform and expert know
6. data collected can be used for cor rection of the NC program or tool data but are only applicable for a specific workpiece With complex workpieces with free form surfaces however these measurements can be very difficult In some cases dimensional accuracy of workpieces can only be checked after they are finished Deviations can however often lead to changed kinematics of the tool machine for example via temperature changes and mechanical loads That is why the new KinematicsOpt iTNC feature follows the general principle of modifying the kinematics model instead of the NC pro gram With the aid of a highly accurate HEIDENHAIN touch probe and a highly precise and very stiff HEIDENHAIN cali bration ball changes in the kinematics are quickly recognized and compensated for As a result the machine is able to guide the tool with greater precision along the programmed contour A look at rotary and swivel axes With 5 axis tool machines tilting accuracy Is especially critical Depending on the machine type and use specified devia tions can typically be trusted for about 3 to 15 hours Complete calibration may take a whole day and is therefore unsuitable for solving the drift of the machine kinemat ics This deficit can be compensated for by later recalibration which can be per formed during production and only takes little time Fast and simple recalibration This method for error compensation does not come as a Surpri
7. departments All further steps are taken there to turn the idea into a marketable product that can successfully exist in the market Helmut B today rides his bike again Thanks to SYNTHES products his verte brae are now stable again The Real World ining Tra All Round Support for CNC Apprentice and Advanced Iraining CNC technology cannot be ignored that is especially true for apprentice and advanced training in the metal working industry Because ever more know how and greater capabilities are demanded of skilled workers As such CNC qualifications are becoming more important both as a part of vocational education and for technical advanced training In accordance with this trend HEIDENHAIN supports apprentice and advanced training at vocational schools and other institutes of vocational educa tion with the goal of machine operators becoming as familiar as possible with the functions of HEIDENHAIN controls In this respect HEIDENHAIN is committed in a variety of ways An overview F PS support program for schools The support program aims to train appren tices and skilled workers as far as possible with those controls that are used in the corresponding companies HEIDENHAIN supports this with the following activities With the HEIDENHAIN programming station this is possible with the original keyboard or with a virtual keyboard The programming station software limited to 100 blocks can a
8. of HEIDENHAIN touch probes and HEIDENHAIN controls best results can be expected trom the symbiosis between accuracy and efficiency For example In terms of functionality and technol ogy control and touch probes are per fectly matched The range of touch probes offered is oriented according to the typical de mands of diverse applications Wear free and dependable tool measurement via disk shaped TT 140 probing element Reduction of ancillary times and in creased production quality creates competitive advantages Ask for information directly from HEIDENHAIN Contact hd3 heidenhain de 0 ko O ons A 0 5 z 0 2 Q o lt q In contrast to conventional 3 axis ma chines 5 axis machining has com pletely new demands in terms of axis accuracy It is not only a question of the precision of individual axes here but of their accuracy in the working space As a result however the number of error sources is significantly increased by the higher number of mechanical com ponents in the machine design Depen ding on the specific machine design angle measurement is of particular im portance here What sources of error exist The many mechanical components of a machine are all possible sources of errors These are all stressed by the enormous dynamics of the working processes Typi cal causes for inaccuracies are Wear caused by high mechanical loads for example o
9. on page 11 of F marah TST f parr iit Klartext Issue 49 09 2008 HEIDENHAIN s tradition of providing highly accurate encoders for machine tools also applies to touch probes The sensors function wearfree and gener ate trigger signals of the highest qual ity which are optimally evaluated by HEIDENHAIN controls signal propaga tion times for example influence the probe repeatability of the 3 D touch probe 1 fEditieren a Einspeichern in der Tasijsystenachse E ba N 5 aE porn p Renee Wi Ere 4 li TR GF i 3 ee k hn Tom Se e giti oe Fee rr Fo Japi EAE Ti z ETE 1 RITE 1 i 7 a Pisa i 31 lj Li What is Probe accuracy The probe accuracy specifies the error resulting trom probing a test component from various directions at 20 C ambient temperature The probe accuracy also includes the effective ball radius The ef fective ball radius is calculated from the actual ball radius and the stylus deflection 1 abe If especially tricky measuring and test ing tasks have to be carried out in con nection with a HEIDENHAIN control the HEIDENHAIN hotline is there to help with its extensive wealth of knowl edge and HEIDENHAIN controls required to produce the trigger signal This also includes stylus bending Probe repeatability Probe repeatability is the
10. HEIDENHAIN Kiar oc News from the World of HEIDENHAIN Controls Issue 49 9 2008 A Sense of Feeling a for Accuracy and Efficiency Editorial Dear Klartext Reader Encoders from HEIDENHAIN make machines more accurate as lin ear encoders and angle encoders directly on the machine or in the form of touch probes for tools and workpieces An even greater benefit can be gained with the TNC controls from HEIDENHAIN A Sense of Feel ing for Accuracy and Efficiency and KinematicsOpt No Chance for Drift amp Co will certainly convince you A new section focuses on reality With the title Are you familiar with this function we outline practical TNC functions to simplify or signifi cantly accelerate your tasks The editorial staff of Klartext wishes you informative reading Image Page 4 Stock xchng Kliverap Page 17 Synthes All other images DR JOHANNES HEIDENHAIN GmbH AMB 2008 Sep 9 13 8 HEIDENHAIN show places machine tool accuracy on center stage The motto of the HEIDENHAIN exhibi tion at this year s AMB trade show is HEIDENHAIN shows the way to precision Demo units and presenta tions will help illustrate the differences between machining on machine tools equipped with linear encoders bringing dramatically higher position ing precision and higher production efficiency and machines that operate without them The accuracy of 5 axis machines with
11. N website presents infor mation about the wide range of TNC pro gramming training at www heidenhain de schulung The course offerings can also be used by specialist teachers and CNC trainers ere Pred refira eon Larni hyperbel Prec Desorption PO counter card for TSH compatibie Fes with PCI Bus i GGRESGMIEDLSe anotar LOPURE Jista idal zit 5155833 11 mpg Sinuscidal voltage gignals i Ver ERDA anteriac Saf shteriace i Tererpelarion r CEL iMi uL You can use the HEIDENHAIN Service Product Information online to call up 40 years of expert know how and application knowledge concerning HEIDENHAIN products in a quick and user friendly way Even about products that have have been avail able for a long time In order that absolutely everything about your product is available the system also hosts information about accessory articles such as cables and testing equipment The documentation area makes available a wide range of information such as user s manuals replacement instructions and mounting instructions The system also offers the possibility of saving selected articles as a link and sending these 2 A All product information at a glance Which documents are available Replacement instructions User s manuals Pilot Mounting instructions Service manuals What information can I find in the system Fundamental info
12. ants Health pro fessionals refer to these as minimally in vasive operation techniques Innovation from interdisciplanary experience In addition difficult operations that can only be carried out by a handful of spe clalists should be simplified with techni cal aids so that less specialized surgeons are capable of carrying out the same pro cedures The team working on the new ideas consists of two people Alfred Nie derberger from Grenchen Switzerland a SYNTHES employee for 15 years and Johann Fierlbeck from Deggendorf Bavar la part of the team since October 2006 As well as the mandatory mechanical Skills both also have corresponding medi cal knowledge and also talents that would be more suited to a surgeon These capabilities are absolutely neces sary because doctors from all over the world visit this superlatively equipped lab oratory and can discuss their ideas with both of the engineers One of the possibil ities offered by the lab is to make a three dimensional model of the bone to be re paired The required data is captured by a 3D capable C arm in a computer tomogra phy scan of the bone and transferred to a Sports injuries work accidents or traffic accidents In today s world there are many ways to break a few bones But on the other hand there were never as many pos sibilities to repair fractures or to support healing processes The Swiss American company With simple contours crea
13. dispersion of the results derived from repeated probing of a test component from the same direc TNC cycle Setting the datum for the aligned workpiece Z TNC cycle Workpiece measurement tion Influence of the styli Stylus length and stylus material significantly influence the trigger characteristics of a 3 D touch probe Styli from HEIDENHAIN ensure a probing accuracy grade of better than ES UM N 02 2 si A 9 5 0 me 86 A 5 Application oriented Suitable technologies for varied demands As well as the ideal combination of a HEIDENHAIN control with HEIDENHAIN touch probes selection of the right tech nology is also the key to success Fine matching is primarily possible when the optimal touch probe is available for spe cific applications Workpiece Touch Probes For series production machines with au tomatic tool changers are practically stan dard Time consuming manual fitting of the spindle or disruptions to machining are unthinkable A workpiece touch probe must therefore be just as easily exchange able from the magazine as a tool is All requirements clearly defined Because touch probes must guaran tee unobstructed workpiece machining for series production their function ality must be absolutely reliable The TS 440 TS 444 and TS 640 touch probes are thus equipped with an op tical sensor The advantage the sensor works wit
14. e axes Angle encoders with integral bearing and a hollow shaft have an additional advantage an integrated coup ling that compensates for shifts of the axis midpoints without additional an gle errors On the other hand an gle encoders without integral bearing would lead to ec centric deviations and would therefore provoke additi onal angle errors S z 0 2 Q o lt Angle encoders The term angle encoder is typically used to describe encoders that have an accuracy better than 5 In contrast rotary encoders are encod ers that typically have an accuracy worse than 12 Angle encoders are found in applications requiring precision angular measurement to accuracy within several arc seconds These include rotary tables and swivel heads on machine tools C axes of lathes measuring ma chines for gears printing units of printing machines spectrometers telescopes etc The following mechanical design principles can be defined Angle encoders with integral bear ing hollow shaft and integrated stator coupling Angle encoders with integral bear ing for separate shaft coupling Angle encoders without integral bearing S 0 2 Q Q q Are direct drives a positive trend With respect to accuracy direct drives have several advantages and hardly any disadvantages In the mid term an ex tensive transition from mechanical trans fer elements with servo motors to direct drives torq
15. e is performed taking just a few minutes That s it The KinematicsOpt Software The KinematicsOpt software is a cycle of the 1TNC 530 and has a familiar user interface for the machine operator For calibration a HEIDENHAIN calibra tion ball mounted to the machine table is also needed The highly precise 3 D touch probe measures the midpoint of the precision ball at various positions of the rotary axes Using the measured deviations the kinematics model of the machine is determined by the control and automatically modified To make sure that measurement and recalibra tion are executed in an application orl ented way and in as brief a time as possible the aim of this method is not the determination of a complete error model but the rapid identification of the relevant part of the kinematics model This prevents the machining error from exceeding a specific magnitude despite conditional changes KinematicsOpt provides a dialog guided measurement cycle with support graph ics that the machine operator can quickly become acquainted with since it is simi lar to all other measurement cycles of the iTNC The measurement cycle is the same for all machine kinematics With selection of suitable input parameters the mea surement process can be comfortably and flexibly modified according to demands It is also possible to choose between vari ous positioning strategies This allows ro tary axes with Hirth coupling to be tested Th
16. eates the triggering signal Probing requires only low levels of force an important prereo uisite for particularly high probe accuracy and repeatability Control and measuring technology are best from a single supplier That leads to optimal results and holder are detected and corrected directly The measuring result is oriented to operating conditions and is therefore especially accurate If normal or larger tools are used the TT 140 a 3 D touch trigger probe is suitable For specification of the exact tool dimensions a disk shaped probing element is deflected by probing An opti cal sensor then creates a triggering signal rellably and without wear Whichever tool touch probe is used a measuring pro cess normally consists of several steps These of course do not need to be manu ally performed or programmed Instead Battery free power supply with integrated air turbine generator via central compressed air supply hs T TS 444 workpiece touch probe r 5 Highly precise pressure sensor E TS 740 workpiece touch probe measuring cycles measure tool lengths and diameters inspect the form of the in dividual teeth and check for tool wear or breakage The control automatically saves the results of measurement in the tool ta ble This is very fast and uncomplicated Under program control the NC control po sitions the tool and starts the measuring cycle In order to secure constant produc
17. ematicsOpt inspects all machine rotary axes one after another gt First the point of origin of the work piece coordinate system is set to the midpoint of the calibration ball for this the corresponding rotary axis is automatically measured at the O position gt Then the workpiece coordinate system Is rotated at various points around the point of origin and the midpoint of the ball is calculated Because the machine and the kine matics model do not exactly match deviations of the calculated ball mid point can occur Only when the kine matics model is exactly matched to the machine does the position of the ball remain constant in the workpiece coordinate system The determined deviations allow the position of the ro tary axis in the kinematics model to be modified The deviations are recorded for each axis separately in files The statisti cal evaluations inform the user as to whether the required accuracy can be maintained by recalibration or wheth er a more time consuming complete calibration is necessary Realistic input of parameters The end angle in the A axis is defined here Why recalibration is so important When a machine is commis sioned the machine tool builder carries out a complete calibration of the machine in order to exactly match the machine s kinemat ics model to the actual machine During operation however the machine s kinematics changes because of thermal and mechani cal i
18. ening for thousands of years in Nature was only hesitantly learned by machine tools Despite initial scepticism many ma chine tools cannot now be imagined without touch probes The sensitive helpers create technological and eco nomic advantages over the competition provided that the symbiosis between control and touch probe functions Elementary Save time increase quality Machine tool experts have known it for a long time both workpiece touch probes as well as tool touch probes help to reduce setup times increase utilization times of machines and improve the dimensional accuracy of finished workpieces Decisive for their success are the high accuracy levels of the touch probes and their effi cient use which must claim as little time as possible Exact coordination between the touch probe and the control includ ing the whole range of components and functions is therefore of particular signifi cance Decisive Fine synchronization between control and touch probe Operators of HEIDENHAIN controls ap preciate the combination of convenient operation powerful functions and highly developed technology that together en able a high level of contour fidelity and dimensional accuracy Optimal results can be expected from machines whose entire control loops are implemented with coor dinated components from HEIDENHAIN This includes the control a complete elec tronics package the drives and also the linear and an
19. ese are used especially in the swivel heads of large machines Inout of measurement cycle pa rameters such as ball radius set up clearance reference angle etc Programming and editing Node 5 gt 1 5 5 1 li calibrate Hanual 6Peration BEGIN PEH NEU AR 1 BLE FORM 8 12 Yeo 2 48 2 BLE FORH 2 Fil Veiga 228 3 TOOL CALL 1 Z 55800 TCH PROSE 451 MEASURE KINEMATICS FEES EE O407 412 5 SPHERE RADIUS O3970 0 FSET UP CLEARANCE RETR HEIGHT 8 5 PRE POSITIONING 02532 REFERENCE ANGLE 053282 START ANGLE A AXIS 411 98 END ANGLE A AXIS 1122 ANGLE A AXIS 232243102 4133 HEAS POINTS A AXIS 2414242 START ANGLE BE AXIS 98 0415 1 3 7 END ANGLE AXIS A1 7 2 INCITO ANGLE AXIS FS MEAS POINTS 5 AXIS 2 1 13 1 52 58 START ANGLE 2 AXIS g END ANGLE AXIS 2 2 INCID ANGLE AXIS 1 42 e 2222 7MEAS POINTS 2 AXIS N OF MEAS POINTS 4 18232 FSET PRESET 2 2 1831 L Z i Re FMAX L X 70 V 30 R FHAX H3 END PEM NEU MM moo fs O486 1 E r BE m 4348838 TEET Klartext Issue 49 09 2008 If the calibration ball remains on the machine table and the machine fea tures an automatic tool changer such a recalibration can be performed auto matically The touch probe cycle works as follows Kin
20. gle encoders For the sake of consistency no compromises should be made in connection with the touch probes either There are very good reasons for this HEIDENHAIN controls make available countless practical functions based on workshop reality and optimally coor dinated to the various HEIDENHAIN touch probes This is shown by the di versity of cycles available on the con trols ranging from calibration of touch probes via simple cycles for setup and datum setting to programmed measu ring and testing during machining All of this is simply documented in the Touch Optimal coordination between HEIDENHAIN touch probes Only the combination of HEIDENHAIN touch probes with HEIDENHAIN controls guarantees particularly high accuracy Probe Cycles User s Manual within the TNCguide for downloading from www heidenhain de gt Services and Documentation gt TNCguide Especially demanding measuring tasks can also be implemented with the aid of additional software free form sur faces can be measured directly on the machine Machining errors are detected immediately and can still be corrected during setup Even More Accuracy via Kinematics Optimization The KinematicsOpt TNC func tion helps to further increase machining accuracy of 5 axis machines In this case it concerns the perfect coordination of the control to the machine kinemat ics For more information about this topic see the KLARTEXT article
21. hout wear and therefore has long term dependability When using a tool changer connection via cable is of course not possible The triggering signal is therefore transmitted via infrared to the NC Tool touch probes HEIDENHAIN also listened to the various demands made by operators and offers two technologies regarding tool touch probes When tools are particularly small or if ma terials sensitive to breakage are used the TL Laser System is especially suitable The contact free measuring method by la ser beam enables you to check even the smallest tools rapidly reliably and without collision Because the tool is measured at rated speed errors on the tool spindle An interesting technology shows that the development of new touch probes is ori ented to practical and economic criteria The TS 444 is without batteries and kills two birds with one stone an air turbine generator creates electrical energy that is stored in high performance capacitors Compressed air that is supplied through the spindle drives the turbine The com pressed air can also be used for cleaning the workpiece The capacitors are charged very quickly and workpiece cleaning oc curs with the same operation so ancillary time is reduced even further Some applications have demands in terms of accuracy that are even greater than usu al In this case use of the TS 740 is rec ommended Instead of an optical sensor a highly precise pressure sensor cr
22. led www heidenhain i 1 Ty HEIDENHAIN controls together Touch Probes with HEIDENHAIN touch probes ae A Sense of Feeling for Accuracy and Efficiency 4 an unbeatable combination Page 4 Applications 5 Axis Machining Getting a Grip 8 on the Accuracy of Rotary Axes Software KinematicsOpt 11 No Chance for Drift amp Co Controls Special Functions of the iTNC 530 14 Tool Oriented Machining TOM The Real World ITNC 530 Application for Innovative 16 Medical Technology 1 E HEIDENHAIN controls used at Training SYNTHES in the medical All Round Support 18 technology sector for CNC Apprentice and Advanced Training Page 16 Service HEIDENHAIN Service Product Information 19 40 Years of Service Know How Available Online Production Publisher DR JOHANNES HEIDENHAIN GmbH Post box 1260 83292 Traunreut Germany Tel 49 8669 31 0 HEIDENHAIN on the Internet www heidenhain de Editor Frank Muthmann Fax 49 8669 31 1888 E mail info heidenhain de KLARTEXT on the Internet www heidenhain de klartext Layout and Typesetting Expert Communication GmbH Richard ReitznerAllee 1 85540 Haar Germany Tel 49 89 666375 0 E mail info expert communication de www expert communication de Touch Probes Insects feel their way through life Their antennae register the environment assess hazards search for and evaluate objects and thus secure survival What has been hap p
23. lso be downloaded tree from the Internet As well as the regular training program for operators of HEIDENHAIN con trols HEIDENHAIN also offers teacher specific TNC programming training with contents oriented to the needs of the CNC training education For this HEIDENHAIN makes available a teacher and trainee documentation drawn up to getherwithspecialistteachers seeright TNC Training e learning In addition HEIDENHAIN supports au todidactic learning with a freely avail able interactive TNC Training e learn ing software on the Internet covering the fundamentals of CNC programming tilted working plane machining and touch probe applications Individual units from this modularly designed software can also be used for CNC training for better under standing of both fundamentals and more complex contexts HEIDENHAIN supports teachers at vocational schools with the cre ation of their CNC training docu ments It was decided together with specialist teachers from several schools which topics should be taught for specific vocations The topics were then collected structured and drawn up The documentation is available in PDF format for presentation purposes and as files for printing and con tains themes ranging from the fundamentals of CNC technology and first programming steps to the use of various cycles for lathe and milling operations If you are interested in our teacher and pupil documentatio
24. n please contact mtt heidenhain de Klartext Issue 49 09 2008 Make yourself fit for daily work with HEIDENHAIN training seminars HEIDENHAIN Service Product Information 40 Years of Service Know How Available Online CNC Learning With CNC Learning HEIDENHAIN sup ports a sponsorship scheme for CNC training in Switzerland together with the SWISSMEM association and Fehlmann AG COMENIUS As a partner of industry HEIDENHAIN is a part of the EU program COMENIUS The Lifelong Learning Programme HEIDENHAIN supports participating schools in the Train for Europe and CNC Network projects Within the framework of these projects the ex change of experience and teaching ma terials between schools is promoted with the aim of improving the methods and content of CNC technical training Authorized training partners for HEIDENHAIN TNC programming courses Via a network of authorized training part ners HEIDENHAIN promotes the vocational retraining and advanced training of adults and industry wide apprentice training via institutes of vocational education Emphasis is placed on quality and practi cal relevance of the CNC qualifications That is why all authorized training partners have original HEIDENHAIN programming stations and a machine with HEIDENHAIN control CNC trainers are always up to date thanks to yearly upgrade training HEIDENHAIN training program The HEIDENHAI
25. ncod ers can also significantly increase the accuracy of feed axes And here as well as is often the case with HEIDENHAIN many influences are rendered unimportant by the design If a linear encoder is used for measure ment of the slide position the position control loop covers the complete feed component Play and inaccuracies in the transfer elements of the machine have no influence in this case on the accuracy of the position measurement Measurement accuracy really only depends upon the precision and instal lation location of the linear encoder Read the complete article in issue 47 of KLARTEXT can be downloaded from www heidenhain de w 5 k d Klartext Issue 49 09 2008 The KinematicsOpt S No Chance for r Drift amp Co s Machine tool builders place much empha sis on constantly increasing the accuracy and efficiency of their machines So suc cessfully in fact that nearly every machine today significantly surpass its predeces sors in terms of performance With the implementation of the new KinematicsOpt feature a high level of precision for work piece machining can be permanently at tained Changing ambient conditions and high demands placed on the accuracy of workpieces require several actions by the operator each day in order to guar antee the workpiece accuracy needed Until now it was normal to use a 3 D touch probe for workpiece inspection The
26. nfluences Critical is for example the ther mal expansion of the ball screws Ball screws have short time con stants and measurement of the temperatures is difficult Use of linear encoders has proven to be best In some cases the slower ther mal expansion of machine com ponents is taken into account by measuring the temperature at specific locations of the ma chine with sensors and then cor respondingly modifying the kine matics model during operation Maintaining accuracy with KinematicsOpt means Permanent safeguarding of machining quality of the workpieces Ensuring your profit The advantages of b axis machining are obvious With an optimal alignment of the cutting tool to the workpiece a higher cut ting performance and a better surface defi nition are achieved Often less alignments are required These are important pre con ditions for efficient machining that lead to lower unit costs To prevent this profit from being sacrificed due to a diminishing machining quality consistent recalibration with KinematicsOpt is recommended This is especially effective as the correc tion directly influences machine accuracy and therefore every workpiece Service Mg Fe a a iITNC 530 Special functions understandably explained What is meant by tool oriented machining With tool oriented machining you can machine several identical or similar parts tool optimized
27. r collisions during machin ing Elasticities in transfer elements e g the worm shaft or instabilities of the bearings Geometric errors e g radial eccentric ity of mechanical transfer elements or incorrectly installed components How can sources of error be avoided or reduced During the design of a machine sources of error in connection with the rotary axes should be ruled out as far as possible As a part of the kinematic influences different mechanical and control oriented designs of rotary axes should be compared Rotary axes feature complex mechanics with various components subjected to possible sources of error Optimal com pensation would have as a prerequisite the recognition of all possible error sourc es for every situation And exactly that IS not possible A possibility for getting a grip on position deviations of rotary axes is the use of a suitable HEIDENHAIN angle encoder For bet ter understanding of the effect here are two basic strategies for the design of ro tary axes In control loops 5 a 5 Semi Closed Loop If the position of the rotary axis is meas ured solely via the rotary encoder on the motor then we refer to a semi closed loop Not only is the lack of accuracy of the motor encoder significant with this arrangement but many other errors also play a part such as wear elasticity devia tions and geometric errors of the mechan ical transfer elements 2
28. r workpieces using the tool oriented method The machine tool builder must prepare the TNC for tool oriented machining Once this has been done you simply need a conventional machining program and a pallet file Klartext Issue 49 09 2008 The reality of the workshop demands great flexibility when working with NC machines Often jobs must be interrupted to carry out more urgent orders Tool ori full Program run aN x 50 PAg o 0 paa ented machining handles this very easily 120 000 ac 8 While executing the pallet file the iTNC MTh T R3 BRILL TMG TOOL _ DE stores a code valid for two weeks used gt pgm BLANK CTO L a moda R 5 Boo to reenter the program at the point of in pas Ha ero uoprpr DL TAB DR TAE i DL PGH DR FG terruption 0 4 Pan BL Ae A field tested function is the assignment of blank spaces in the pallet file This way art progras ati you can take into account tool breakage Date 00 HH YYYY 09 05 2008 or the machining of the remaining work ll feel i y S IST Pos TIT 810 859 5 pieces of a job easily and without much cag ie adie POM al effort 50 000 Y 120 0900 100 6 An example of the other functions is the A 6 6 5 6 0 83 automatic program start at a pre defined time tp 5 1 359 186 8 16 T 63 Z 3 i280 F HS p f AUTCSTART ana 2
29. rmation Article texts New devices Accessories How can I search in the system Two possibilities are available for searching Either you search via the product name or via the product ID number Both are printed on the HEIDENHAIN ID label 0065 UI A IE AAMC 1 gt IC A ne
30. se because at HEIDENHAIN we always strive precisely measure relevant machine components and so avoid errors before they can occur An example of this is the high level of ac curacy with which HEIDENHAIN linear en coders measure the axis position directly at the machine slides What is Machine kinematics Kinematics is the theory of the move ment of bodies within space described by the dimensions of path angle veloc ity and acceleration For exact calcula tion of the positions of machine axes the control requires a kinematics model of the machine The kinemat ics model defines among other things how the individual machine axes are designated where their point of origin is and with rotary axes where the cen ter of rotation Is 11 Software Software N KinematicsOpt is similar deviations of the kinematics are determined via a precision ball mounted directly to the machine table and a HEIDENHAIN touch probe integrat ed like a tool in the spindle i e directly at the center of action under very similar conditions It is surprising how simple it is to perform such a fast recalibration KinematicsOpt functions like a conventional touch probe cycle and can be configured just as easily The user merely has to enter parameters via the usual dialogs iITNC support graphics help here as do the easily understandable instructions in the touch probe user s manual Following that the calibration cycl
31. te the program directly with the ITNC and that happens so quickly and easily that am not absolutely dependent upon CAM and postprocessor Johann Fierlbeck SYNTHES CAD system Following that the prototype to be prepared can be simply modified ac cording to the 3D model An NC program is then created via Mastercam and post processor Using the strengths of the IT NC 530 The prototypes are then prepared on two ITNC 530 equipped Fehlmann machines and a 3 axis PICOMAX 55 for simpler piec es or a b axis PICOMAX 60 with HSC set up for more complex pieces The iT NC 530 can take full advantage of its strengths On the one hand it can optimally execute the data created via the postprocessor and read in via the standard Ethernet inter face and on the other hand a 2 D contour can quickly be created in plain language di rectly at the machine and In particular can be quickly modified Until now everything sounds rather familiar just routine work in Klartext Issue 49 09 2008 SYNTHES specializes in the develop ment manufacture and marketing of instruments implants and bioma terials for the surgical treatment of bone fractures SYNTHES is a glob ally active company with approx 9 000 employees and a turnover in 2007 of approx 2 8 billion USD a normal workshop But the laboratory has in addition to the normal mechanical equipment an optimally equipped wet laboratory After all the prototypes have to be
32. tion quality cyclical measurements are re commended either before machining or Klartext Issue 49 09 2008 between machining steps Uncritical Rapid amortization with high levels of production quality It sounds good ancillary times down ma chine operation times up and at the same time quality optimization If this evalua tion does not suffice then facts are need ed that withstand economic inspection And that works best with an amortization calculation An example a task gt Align the workpiece blank parallel to the axes gt Set the reference point in the machining plane at a corner gt In the tool axis set the reference point on the surface of the workpiece blank The time saved If this setup process is performed with a TS 3D touch probe system from HEIDENHAIN the time saved is approx 4 minutes or approx 72 Meaning that if this setup process is carried out once a day you save over 1 000 in one year with 220 workdays at an hourly machine rate of 70 Tip Repeat the calculation with figures from your production experiences If the advantages gained from accuracy and the reduction in rework and scrap are considered then an investment in a HEIDENHAIN touch probe really proves its worth especially for series production Optical contact free tool measurement TL tool touch probe Conclusion Stretch out your antennae and make contact with us With the combined use
33. ue motors can be expected The decisive advantage is the very stiff coupling of the drive to the feed compo nent without any other mechanical trans fer elements This is of true significance for a high level of contour constancy and optimal surface quality With the use of direct drives an additi onal rotary encoder for speed definition is required Position and shaft speed are defined by the angle encoder mounted di rectly to the rotary axis a closed loop Since there is no mechanical transmis sion between the speed encoder and the feed unit the angle encoder must have a correspondingly high resolution and signal quality in order to allow exact speed con trol particularly at slow speeds Conclusion System errors can be avoided with the selection of suitable measuring tech nology That applies in particular to ro tary axes Because of their complexity accuracy is a major challenge Especially with interpolated 5 axis ma chining and direct drive technology en coders that do not convert unavoidable spatial deviations into large scale angle errors are recommended This challenge can be mastered with angle encoders with integral bearing integrated coupling and absolute posi tion measurement directly mounted on the rotary axis such as the RCN model Rotary table of the tool machine Rotary axis HEIDENHAIN angle encoder For comparison Accuracy of linear axes As with angle encoders linear e
34. with just one machining program What is the advantage of this method The programmer can do without complex programming of several fixtures with sub programming and program calls First a machining step with a certain tool is ex ecuted on all specified workpieces and only then does the next workstep follow This means that all workpieces are ma chined with the appropriate tool before a tool change for subsequent machining occurs This decreases the number of tool changes to a necessary minimum greatly reducing the machining time Why was TOM developed Tool oriented machining was originally in tended for pallet management in order to machine multiple workpieces on one pal letin as brief a time as possible However it is obvious that this machining method can also be used for other applications For example this means that you can save a great deal of time when machining identical workpieces on multiple fixtures or vices on the machine table The advantages of tool oriented machining are not only to be found in time savings and the resulting production costs An other significant advantage is the support from clear and simple entry forms Here you enter in a pallet file at which location each machining step is to take place Use the soft keys at any time to toggle be tween a simplified overview with all the workpieces listed and the detail view for each workpiece This way you can easily and efficiently program you

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