Tool Area Systematics

Introduction

Function scope of the tool management system

The tool management system supports you in all areas of tool handling, e.g. the physical loading and unloading of the tool magazine by data and tool transportation.

The key functions at a glance:

Operator interface of the NC for operating, programming and simulation.

For operator panels, see:
"Machine overview"
"Overview of operating devices"

Write/read device in the magazine (option) for automatic data transfer when loading or unloading tools.

The SINUMERIK 840D sl control provides for the tool management system various lists that display the tool data by function:

A distinction is drawn between the following areas within the lists:

  • Tools that are loaded into the magazine have a magazine place number.
  • Tools that are not loaded into the magazine have no magazine place number and appear at the end of the list after the last magazine place number.
  • Blocked tools are marked with a red cross.

Tool List

The tool list includes all tool data required for loading and unloading of tools. Necessary monitoring data also are managed here.

  • Length
  • Radius
  • State
  • Max. speed
  • Change speed
  • Tool envelope contour

Tool wear

The "Tool wear" list includes all tool data that are important during machining. If the tool wear exceeds a certain value, an alarm is output. The following values are displayed:

  • Wear length
  • Wear radius
  • Number of duty cycles
  • Tool life

Magazine

The tool and magazine are positioned using the "Magazine" list.

  • The magazine place information can be found here.

If a tool that is no longer required is unloaded from the magazine, the stored tool data can remain in the tool list for use at a later date. These tool data are shown at the end of the tool list.

OEM tool

The "OEM tool" list includes data that are relevant for diagnostics and troubleshooting.

For further information on the tool lists, see:

The operating data of the tools is updated by the control in the tool lists.

If the machine is fitted with an optional codechip device, the operating data are saved to the codechip as the tools are being unloaded from the magazine.

If a tool is located at a stop-off place outside the magazine on a machine, this is referred to as the buffer location. Buffer locations are:

  • Spindle
  • Gripper 1
  • Gripper 2
  • Provisioning place
  • Setting station

More detailed information on the tool management system can be found in the SIEMENS documentation.

Safe Tool Handling

Check for correct balance of the tools. Unbalanced tools destroy the spindle bearing. The required balance quality of the tools is:

  • For speeds up to 8000min-1 balance quality G6,3 (DIN ISO 1940).
  • For speeds > 8000min-1 balance quality G2,5 (DIN ISO 1940).

Make sure the tool geometry is within the permissible limits.

Leave enough clearance between tools.

  • The tools are inserted from the long side of the magazine. The clearance on the rotary track becomes narrower, allowing collisions to occur if tools are not rotation-symmetrical. In this regard, always follow the information on the plate at the tool setting station.
  • Generally, one magazine place must remain free and must not contain a tool cartridge.

The control can guarantee collision monitoring only for tools with known data.

On machines with internal cooling lubricant feed, the cooling lubricant pipe must always be inserted into the tool holding fixture.

Ensure that the cap nut for securing the cooling lubricant pipe is secured against working loose. If the nut works loose this may result in the tool not being released from the spindle.

The cooling lubricant pipe should also be used on tools without internal cooling lubricant feed. This protects the spindle from internal cooling lubricant being inadvertently switched-on.

The tools standard was revised in 2003. The dimension d9 was increased from 85 mm to 88 mm.


The tool holder was modified accordingly. Old and new tool holding fixtures can be combined in the same magazine. Older machines can be upgraded by replacing all tool holders if required.

General handling data

All user-related tool data for the magazine tools are managed in the tool list.

Handling data such as envelope contour or speed of changing are needed by the tool manager to enable size-related position assignment and to carry out tool transport without collisions.

Caution:

Risk of collision resulting from incorrect handling data.

Damage to tools and machine to be expected.

Enter handling parameters carefully and in full. In case of doubt, check and re-measure.

Speed Limiting

The rotational speed at which the tools can be used is limited by default. Where the tool data record of a particular tool contains no speed value, a machine-specific maximum spindle speed defined by HELLER automatically applies.

Up to this limiting speed, which is set as standard, we guarantee that any tool fragments resulting from a tool break will not penetrate the guard panels of the machine.

Where a higher speed is required for machining, this must be explicitly defined in the tool data record. This maximum rotational speed must be specified by the tool manufacturer. It must not, however, exceed the maximum admissible spindle speed. The definition of this tool-dependent maximum speed is not checked and does not fall within HELLER's sphere of responsibility.

If a tool's limit speed is exceeded by a programmed speed (manual input, NC program), the machining speed is limited to the limiting speed. A message is displayed on the screen.

If a gearbox attachment is used to increase the tool speed compared to the spindle speed, this must be taken into account by the user.

HELLER guarantees the puncture strength of the guard panels providing the tool speed does not exceed the specified default limiting speed. This applies to standard versions of the machine as well as the standard permissible tool dimensions. If this is not the case, the permissible limiting speed will be lower. If these conditions are not adhered to, the user of the machine will be responsible for the puncture strength of the guard panels.

Tool weight and tool change speed

Caution:

The tools must not exceed the specified weights and moments of weight. The tool changer may run with heavy tools only at reduced speed.

Adhere to the following limits!

Take special care when entering the tool change speed in the tool data section of the tool list. If no data are entered, all tools will be changed quickly (standard).

Loading Tool in the Correct Position

When loading tools make sure that they are inserted in correct position into the tool cartridges at the tool setting station.

-Hollow taper shanks tool holding fixture

To insert a tool in correct position into the tool cartridge, the spindle taper must be positioned as follows:

  • The locating hole for the code chip (1) must be pointing towards the tool setting station.
  • The notch (2) is in the bottom right position when the tool is viewed from the front.

Tool Loading Station

For manual loading of the magazine, a tool loading station is provided on the side of the tool magazine facing away from the machine.
An exterior, electrically-locking "Tool setting station" safety door offers access to the tool loading position, a position on the tool magazine at which the tools can be individually removed and inserted. This safety door can be unlocked or locked by the operator for tools to be loaded and unloaded.
An interior safety door separates the loading place from the peripheral chain magazine; this door is opened and closed by the controller.



Following the loading operation during which a new tool is inserted, the tool identity of the controller notified and the exterior safety door re-closed again, the tool is automatically transported to the magazine. A traverse attachment picks up the tool from the loading place and slides in into the holder at the empty location provided in the magazine.
The precondition for tool loading is that the data for the tool concerned are known to the controller.
The additional safety door between loading place and magazine enables the machine to be set with tools during machining. This also applies for the removal of old tools, which are moved by the controller to the loading place for removal by the operator.

When the machining program requests a new spindle tool, the machine starts up and transports the tool concerned to the side of the tool magazine that faces the machine. A traverse attachment (magazine - provisioning place) is also located here. The tool changer starts up as soon as the tool has been pushed to the provisioning place.

A complete monitor cooperating unit (terminal operating unit) is available at the tool setting station. The setting dialogue and the input of the tool data is performed here using the terminal operating unit at the tool setting station.

The SINUMERIK 840D sl control provides for the tool management system various lists that display the tool data by function:

Settings Loading Tools

Further function-oriented settings for tool loading are available to persons with the corresponding access rights.

Depending on the selected settings, the tool loading procedure may vary.

Calling up the "Settings" window

Step 1:

The corresponding access right is issued.
Call up the machine's basic menu using the Data menu key.

Press the etc. key.
The "Settings" softkey is displayed.

Press the "Settings" softkey.
The "Settings" window will be displayed.

Step 2:

Highlight the "Tool loading" line using the Cursor keys.

Press the "open" softkey.
The "Settings - Tool loading" window opens.

Step 3:

Select the settings you wish to change using the Cursor keys.

Press the "Editor Help" softkey.
The "Editor help" window is opened.

Step 4:

Select the desired parameter using the Cursor keys.

Press "Ok" softkey to accept the entry.

Loading Tools With Codechip

Step 1:

Precondition:

  • Tool setting station safety door locked.
  • Tool with described codechip is at setting station ready to load.

Press the 'Parameter' softkey.

  • The 'Tool' area is opened.

Press the 'Magazine' softkey.

  • The 'Magazine' list is opened.

Step 2:

Select a suitable empty magazine place using the 'Cursor Keys'. Observe the plate at the tool setting station for half-place assignments of tools. Large tools occupy more than one magazine place.

Press the "Position Magazine' softkey.

  • The selected magazine place is positioned at the tool setting station. The safety station door tool setting station is unlocked.

Step 3:

Open tool loading station safety door.

Step 4:

Caution:

Danger of injury from sharp edges and centres.

Wear protective gloves.

Hold tool in horizontal position and load firmly into cartridge. observe tool position.

For further information see "Handling at the Tool Setting Station"

Step 5:

Observe 'Acknowledge Tool' key.

The codechip read process is executed.

  • Key lamp flickers during read operation. (Wait until the reading process has finished. Otherwise,read process not correct).
  • Key lamp goes out once read operation ends.
  • Tool data are written to the buffer storage place 'R" in the tools list.
  • Read operation completed successfully.

Step 6:

Observe ACKNOWLEDGE TOOL key. The codechip read process is executed.

  • Key lamp flashes.
  • Read operation finished with errors.
  • Errors are displayed on the control panel.

Remove tool from cartridge again.
Tool is deleted from the tool list.

If necessary, press and hold ACKNOWLEDGE TOOL key for more than 1.5 seconds.
Errors with regard to tool loading are deleted.

Step 7:

Close tool loading station safety door.
Press the SAFETY DOOR REQUEST TOOL MAGAZINE key to lock the safety door.

The setting operation is complete.

  • "Tool setting station safety door" key lamp extinguishes.
  • As soon as the machining operation permits movement of the magazine chain, the selected magazine place moves to the loading position of the chain-type magazine.
  • The inner tool setting station safety door is opened.
  • The tool holder of the chain is aligned for tool transfer.
  • The tool traverse attachment moves the cartridge with the tool into the transport chain of the magazine.
  • The inner tool setting station safety door is closed.
  • In the tool list, the tool in the buffer storage place "R" is written to the selected magazine place.

Unloading Tools With Codechip

Step 1:

Preconditions:

  • Tool setting station safety door locked.

Press the "Parameter" softkey.

  • The "Tool" area is opened.

Press the "Tool list" softkey.

  • The tool list is displayed.

Step 2:

Use the Cursor keys to select the tool you wish to unload.

  • Tools not located in the magazine appear at the start of the list with a magazine place number.

Press the "Unload" softkey. The unloading operation is executed.

  • As soon as the machining operation permits movement of the magazine chain, the selected magazine place moves to the unloading position of the chain-type magazine.
  • The inner tool setting station safety door is opened.
  • The tool holder of the chain is aligned for tool transfer.
  • The traverse attachment moves the cartridge with the tool from the transport chain of the magazine to the tool setting station.
  • The inner tool setting station safety door is closed.
  • In the tool list, the tool is written from the magazine place to the buffer storage place "R".
  • The safety door tool setting station is unlocked.

Step 3:

Open tool loading station safety door.

Step 4:

Caution:

Danger of injury from sharp edges and centres.

Wear protective gloves.

Observe ACKNOWLEDGE TOOL key. The data is written to the codechip.

  • Key lamp flickers during the write/read operation.
  • Key lamp flashes when the write/read operation finishes but the tool is still to be loaded.

Step 5:

Take hold of the tool and at the same time push the pedal in front of the tool setting station with your foot.

  • The tool is released from the cartridge.
  • "Acknowledge tool" key lamp extinguishes.
  • The tool is deleted from the buffer storage place "R" in the tool list.

When the pedal is pushed, and the tool is not released from the cartridge.

  • Slide the tool setting station safety door to the left as far as it will go. Push the pedal again.

Step 6:

Close tool loading station safety door.

Press the SAFETY DOOR REQUEST TOOL MAGAZINE key to lock the safety door.

  • "Tool setting station safety door" key lamp extinguishes.

Loading tools without codehip

Step 1:

Preconditions:

  • Tool is created in the tool list.
  • Tool setting station safety door locked.
  • Tool is at setting station ready to load.

Press the "Parameter" softkey. The "Tool" area is opened.

Press the "Tool list" softkey. The tool list is displayed.

Step 2:

Use the Cursor keys to select the tool you wish to load. Tools not located in the magazine appear at the end of the list without a magazine place number.

Observe the plate at the tool setting station for half-place assignment of tools. Large tools occupy more than one magazine place.


Press the "Load" softkey.

  • "Load to..." window opens.

Step 3:

The next possible, empty magazine place is suggested. If necessary, enter a different magazine place using the Alphanumeric keys.

Press the "Ok" softkey.

  • The selected magazine place is positioned at the tool setting station. The safety door tool setting station is unlocked.

Step 4:

Open tool loading station safety door.

Step 5:

Caution:

Danger of injury from sharp edges and centres.

Wear protective gloves.

Hold tool in a horizontal position and load firmly into the cartridge. Observe tool position.

For further information see "Handling at the Tool Setting Station"

The tool is written to the buffer storage place "R" in the tool list and disappears at the end of the list.

Step 6:

Close tool loading station safety door. Press the SAFETY DOOR REQUEST TOOL MAGAZINE key to lock the safety door.

  • "Tool setting station safety door" key lamp extinguishes.
  • As soon as the machining operation permits movement of the magazine chain, the selected magazine place moves to the loading position of the chain-type magazine.
  • The inner tool setting station safety door is opened.
  • The tool holder of the chain is aligned for tool transfer.
  • The tool traverse attachment moves the cartridge with the tool into the transport chain of the magazine.
  • The inner tool setting station safety door is closed.
  • In the tool list, the tool in the buffer storage place "R" is written to the selected magazine place.

Unloading tools without codechip

Step 1:

Preconditions:

  • Tool setting station safety door locked.

Press the "Parameter" softkey.

  • The "Tool" area is opened.

Press the "Tool list" softkey.

  • The tool list is displayed.

Step 2:

Use the Cursor keys to select the tool you wish to unload.

  • Tools not located in the magazine appear at the start of the list with a magazine place number.

Press the "Unload" softkey. The unloading operation is executed.

  • As soon as the machining operation permits movement of the magazine chain, the selected magazine place moves to the unloading position of the chain-type magazine.
  • The inner tool setting station safety door is opened.
  • The tool holder of the chain is aligned for tool transfer.
  • The traverse attachment moves the cartridge with the tool from the transport chain of the magazine to the tool setting station.
  • The inner tool setting station safety door is closed.
  • In the tool list, the tool is written from the magazine place to the buffer storage place "R".
  • The safety door tool setting station is unlocked.

Step 3:

Open tool loading station safety door.

Step 4:

Take hold of the tool and at the same time push the pedal in front of the tool setting station with your foot.

  • The tool is released from the cartridge.
  • "Acknowledge tool" key lamp extinguishes.
  • The tool is deleted from the buffer storage place "R" in the tool list.

When the pedal is pushed, and the tool is not released from the cartridge.

  • Slide the tool setting station safety door to the left as far as it will go. Push the pedal again.

Step 5:

Close tool loading station safety door.

Press the SAFETY DOOR REQUEST TOOL MAGAZINE key to lock the safety door.

  • "Tool setting station safety door" key lamp extinguishes.The tool is unloaded from the magazine by data and now appears at the end of the tool list without a magazine place number.

Unloading tool and loading a different tool

Once you have unloaded a tool, you can immediately load another tool type to the cartridge at the tool setting station.

Step 1:

Preconditions:

  • Tool setting station safety door is open and unlocked.
  • After you have unloaded a tool, the empty cartridge is at the tool setting station. (The cartridge is pulled from the transport chain).
  • Use the Cursor keys to select the tool in the magazine you wish to load.

Use the Cursor keys to select the tool in the magazine you wish to load.Tools not located in the magazine appear at the start of the list with a magazine place number.

Press the "Load" softkey. The magazine place already located at the setting station is displayed.

Step 2:

Caution:

Danger of injury from sharp edges and centres.

Wear protective gloves.

Insert tool into the correct position.

Complete tool loading as described in chapter "Tool loading without code carrier".

Performing visual inspection of tool without codechip

To determine the status of a tool, you can make a visual check at the tool setting station by removing and examining the tool. Depending on the outcome of the examination, you can reload the same tool or replace it by an identical, new tool.

Step 1:

Preconditions:

  • Tool setting station safety door locked.

Press the "Parameter" softkey.

  • The "Tool" area is opened.

Press the "Tool list" softkey.

  • The tool list is displayed.

Step 2:

Use the Cursor keys to select the tool in the magazine you wish to examine. Tools not located in the magazine appear at the start of the list with a magazine place number.

Press the "Unload" softkey. The unloading operation is executed.

  • As soon as the machining operation permits movement of the magazine chain, the selected magazine place moves to the unloading position of the chain-type magazine.
  • The traverse attachment moves the cartridge with the tool from the transport chain of the magazine to the tool setting station.
  • The inner tool setting station safety door is closed.
  • In the tool list, the tool is written from the magazine place to the buffer storage place "R".
  • The safety door tool setting station is unlocked.

Step 3:

Open tool loading station safety door.

Step 4:

Caution:

Danger of injury from sharp edges and centres.

Wear protective gloves.

Remove the tool.
Check the tool.

Step 5:

Continue to use used tool. No tool change required...

Hold the same tool in a horizontal position and load firmly into the cartridge. The data for the tool are not changed in the tool list.

"Acknowledge tool" key lamp flashes.

Step 6:

Close tool loading station safety door. Press the SAFETY DOOR REQUEST TOOL MAGAZINE key to lock the safety door. The visual inspection is completed.

  • "Acknowledge tool" key lamp extinguishes.
  • "Tool setting station safety door" key lamp extinguishes.
  • As soon as the machining step allows the magazine to move, the tool is carried via the traverse attachment to the original magazine place.
  • In the tool list, the tool is written from buffer location "R" to the magazine place.

Step 7

Insert new tool. Tool change required...

Hold the same, new tool in a horizontal position and load firmly into the cartridge. The data for the tool are not changed in the tool list. "Acknowledge tool" key lamp flashes.

Step 8

Close tool loading station safety door.
Press the ACKNOWLEDGE TOOL key.

In the "Tool wear" list the following parameter values are changed:

  • the values for tool life and/or number of items are set to the setpoint values.
  • the wear values are set to "0".
  • "Acknowledge tool" key lamp extinguishes.

Step 9

Press the SAFETY DOOR REQUEST TOOL MAGAZINE key to lock the safety door. The visual inspection is completed.

  • "Acknowledge tool" key lamp extinguishes.
  • "Tool setting station safety door" key lamp extinguishes.
  • As soon as the machining step allows the magazine to move, the tool is carried via the traverse attachment to the original magazine place.
  • In the tool list, the tool is written from buffer location "R" to the magazine place.

Loading tool with code chip without write/read operation

In special cases, if the codechip is absent or faulty for example, tools can to be loaded without the write/read process.

Deactivating the reading/updating code carrier function

If the code carrier is not to be read or updated during tool loading, you have to activate corresponding functions. To do so, there are general functions available in the "Settings" menu. In addition, it is possible to deactivate the reading process for individual tools in the tool list.

Step 1

The setting made in the "Tool coding" menu generally apply to all tools within the machine. These settings remain in force even after a machine restart and must be reset.

Press Data menu key.

Press the etc. key. The "Settings" softkey is displayed.

Press the "Settings" softkey. The "Settings" window will be displayed.

Step 2:

Select the "tool coding" line using the Cursor keys.

Press the "open" softkey. The "Settings - tool coding" window is opened.

Step 3:

Select the required function using the Cursor keys. Press the "Editor Help" softkey. The "Editor help" window is opened.

Step 4:

Use the Cursor keys to select parameter "1" in order to activate the function or select parameter "0" to deactivate the function. Press "Ok" softkey to accept the entry.

Step 5:

If a certain tool is to be excluded from the read process during loading, parameter "CT" must be activated in the OEM data tool list. The reading process is executed for all other tools.

Press the "Parameter" softkey.The "Tool" area is opened.

Press the "OEM tools" softkey. The "OEM tools" list is opened.

Use the Cursor keys to select the "CT" parameter of the tool which is to be excluded from reading the code carrier during loading.

Loading ghost tools

Depending on the expansion stage of the machine, it may be useful to simplify the loading operation by loading "ghost tools". This especially accelerates the loading process significantly.

"Loading of ghost tools" simplifies the loading operation when the following preconditions have been fulfilled:

  • The machine is equipped with the standard operating unit at the tool setting station.
  • The tools are not equipped with code carriers.
  • Several tools are to be loaded one after the other.

To use the "Loading of ghost tools" function, you need to activate it. See also: "Settings - loading tools"

Caution:

Risk of collision from incorrect handling during tool loading.

Loading of ghost tools may only be performed by trained personnel. Damage to tools and machine to be expected.

Preconditions:

  • The tools are at the setting station ready to load.
  • The "magazine" list is open.

Further information on "magazine" list, see Chapter "Magazine list"

Step 1

Preconditions:

  • Tools are created in the tool list.
  • The tool list is opened.

Use the Cursor keys to select the tool you wish to load by data.
Tools not located in the magazine have no magazine place number in the tool list.


Press the "Load" softkey.

"Load to..." window opens.

Step 2:

A magazine place is suggested.
The control considers the envelope contour of the tool and proposes a suitable magazine place based on the data entered. The proposed magazine place can be overwritten, but the envelope contour must, however, be taken into account.

Make a note of the magazine place to which the tool was loaded by data.

Press the "Ok" softkey. The tool is loaded by data.

  • The tool is written to the relevant magazine place in the tool list and disappears at the end of the list.
  • "0" remains in the "magazine" list in column "W" of the magazine place. Thus, it becomes apparent that no tool is located on this magazine place.
Repeat the procedure until all ghost tools have been loaded by data.

Step 3:

Preconditions:

  • Tool setting station safety door is closed and locked.
  • The tools are at the setting station ready to load.
  • The "magazine" list is open.

Press the TOOL MAGAZINE DOWN key on the standard operating unit of the tool setting station until a magazine place that is only loaded by data is at the setting station.

-To do this, refer to your notes.

Step 4:

Caution:

Risk of collision resulting from incorrect magazine place assignment.
Only load tools to free magazine places. A magazine place may also be occupied when there is no tool on the magazine place.
- The place is a return location for the spindle tool.
- The place is occupied by the envelope contour of the adjacent tool.

Check the the "magazine" list for this.

Observe section.
Press the SAFETY DOOR REQUEST TOOL MAGAZINE key.

Step 5:

Open safety door.

Step 6:

Insert the tool corresponding to the data.

The following error text is displayed: "Ghost tool inserted or removed,check required"
"1" is entered in the "magazine" list in column "W" of the magazine place. That makes it obvious that only one tool is located on this magazine place.



If you wish to insert a tool on a place that is already occupied, the error message "Magazine place already occupied" is displayed.

For further information on tool loading refer to Chapter "Loading tool without code chip".

Step 7:

Close and lock the safety door.

Repeat the procedure until all ghost tools have been inserted.

Step 8:

After inserting ghost tools, it must be ensured that the corresponding data is available for each tool in the magazine or a tool has been inserted for all the tool data. The "Check ghost tools" function is provided for this purpose. At the next tool provisioning all magazine data are compared to the "Tool present" bit. In case of a deviation, a corresponding error message is output.

Press the Setup key. The machine is removed from the system linkage. Setup mode is activated.


With Data menu key call up the basic menu on the main operator panel.Press lower horizontal softkey "Manual Mode". The menu of the "Hand functions" area is opened.

The available HMI screens for the individual functions are displayed in the upper horizontal softkey bar.

Step 9:

Press upper horizontal softkey "HMI". Then press "Manual Mode" and "TC".

Step 10:

Scroll to page 3 in the "Tool change" menu and trigger the "Check ghost tools - request" function.

At the next tool provisioning the tool data of the magazine are compared to the "Tool present" bit. If inconsistencies are detected in the magazine, the following error message is output:

  • "Tool data absent or tool not inserted (place: xx). Magazine movement disabled."

Step 11:

Rectify errors in the magazine if needed and again execute the "Check ghost tools" function. For further information on executing individual functions, refer to "Initiating individual functions"

Fundamental Principles

The lists in the tool area show all tools and, if configured, also all magazine places, which have been created and/or configured in the NC.

All lists show the same tools in the same order. On toggling between the lists, the cursor remains on the same tool in the same image section.

The lists differ in the displayed parameters and the softkey assignment. Toggling between the lists is a systematic movement from one area to the next.

Tool List

All parameters and functions for creating and setting tools are displayed.

Tool Wear

Located here are all parameters and functions that are required during operation, e.g. wearing and monitoring functions.

OEM Tool Data

This list is available to the OEM for free design.

Magazine

Located here are the magazine-related and/or magazine placerelated parameters and functions for the tools/magazine places.

Context sensitive help

Irrespective of which tool you select in the list, the corresponding data for this line will be displayed. This means, for example, that a column for the point angle is available for a drill or a second radius can be entered for a milling cutter. The meaning of the individual columns will be displayed when you select the field concerned.

Geometric data

If a further tool is to be included in or deleted from the lists, you must do this in the tool list. A tool created in the tool list will automatically appear in all further lists. The tool list contains all geometry data. Tool wear data can be found in the "Tool wear" list. For a description of the individual lists, see next Chapter. Further geometric data can be displayed in the lists using the scrollbar at the bottom of the screen. Unit of geometric data is mm, resolution 0.001 mm (= 1 µm)

Edit geometric data

Most data can be edited in the lists themselves. To do this, use the "Cursor" keys to select the required value and enter the new value with the "Alphanumeric" keys . The new value will be accepted as soon as you exit the selected fields with the "Cursor" keys.

Tool List

All relevant geometry and handling data of tools are managed in the tool list. Handling data such as envelope contour or speed of changing are needed by the system module to enable size-related position assignment and to carry out tool transport without collisions.

Step 1

Press Data menu key to call-up the machine's basic menu.

Press the "Parameter" softkey.
The "Tool" area is opened.

Press the "Tool list" softkey.
The "Tool list" window is opened.

Step 2:

Actual display may differ.

Step 3:

List of parameters

Step 4:

The softkey "Magazine selection" is used to navigate between the NC memory, tool buffer and the chain.

Creating New tool in the tool list

Step 1:

The "tool list" window is open.

For further information on handling the tool list, see

Press the right softkey "Select magazine" until "NC memory" is displayed in the tool list header.
This prevents automatic tool transport to the tool setting station being triggered.

Press the right softkey "New tool".
The right menu bar changes its assignment.

Step 2:

Press the right softkey "Favorites".
The "New tool - favorites" window opens.

Step 3:

Select the required tool type from the right menu bar.
- "Cutters 100-199"
- "Drill 200-299"
- "Spec. tool 700-900".

Press the "Ok" softkey.
The selected tool type will be transferred to the tool list. The tool will be displayed as a symbol in the "Type" column in all lists.

The the tool name if necessary.

Enter the required geometric data. (See parameters described below.)

geometric data

Defining Place Coding

Column P in the tool list can be used to specify either variable or fixed place coding for each tool.

It is generally required to mark the column "P" for "Tool at fixed location".

Exception: the machine is fitted with the "variable place coding" option. In this case, combinations can be selected in column "P".

Place coding can be set to active or inactive in the tool list and also, in the loaded state, in the magazine list.

Specify Changing Speed

The tools must not exceed the specified weights and moments of weight. The tool changer may run with heavy tools only at reduced change speed.

See also General layout and Technical data. The documents always appear in the chapter headed "Drawings, Plans" in the Machine Operator Manual (BD).

Maximum Speed

See Chapter

Specify envelope contour

Tools may occupy more than one magazine place. In order to define the place assignment for a tool within the magazine, you have to determine the half-place assignment for the tool by means of the tool's envelope contour. Envelope contour and parameters for the half-place assignment must be entered into the tool list.

Caution:

Risk of collision resulting from incorrect handling data.

Damage to tools and machine to be expected.

Enter handling parameters carefully and in full. In case of doubt, check and re-measure.
Observe the plate at the tool setting station.

4 Possible situations for the half-place assignment



With the "Code carrier" option, half-place assignment is automatically calculated by means of the envelope contour.

Handling data must be changed while the tools are in the magazine. The envelope contour is entered in mm, resolution 0.001mm (= 1μm).

For further information, refer to section:

Tool wear List

Cutting tip-related monitoring data are managed in the "Tool wear list".

Tools and cutting edges that are used for long periods wear and become unusable. This wear is measured in trial runs and entered into the tool wear list. The control then uses these data to calculate tool lengths and/or radius correction. This achieves consistent precision during workpiece machining.

Step 1:

Preconditions:

  • The "Parameter" main menu is opened.

Press the "Tool wear" softkey.
The "Tool wear list" is opened.

Step 2:

Actual display may differ.

Step 3:

The tool wear data can also be called-up directly in the "HMI" main menu ("Tools - Wear" menu).

Step 4:

You can use the "Reactivate" softkey to reset individual edge wear values to the setpoint. Select the required tip using the Cursor keys and press the "Reactivate" softkey. If the tool is disabled due to the wear values for this tip, it will now be released. In the case of machines with a tool magazine, the softkey is of less importance, since the corresponding wear values are reset automatically (to the reference value for tool life/number of duty cycles), when new tools are loaded.

OEM Data Tool List

The user-related tool data for the tools are managed in the "OEM tools" list.

The special codes for tool handling via the control are entered into this list.

Step 1:

Preconditions:

  • - The "Parameter" main menu is opened.

Press the "OEM tools" softkey.

The "OEM tools" list is opened.

Step 2:

Actual display may differ

Step 3:

List of Parameters.

Calling up the Magazine List

Step 1:

Preconditions:

  • The "Parameter" main menu is opened.

Press the "Magazine" softkey.

The "Magazine" list is opened.

Step 2:

Actual display may differ.

To avoid errors, the last magazine place must always be disabled. This means that parameters "G" (disabled) and "F" (magazine place not occupied) must be selected.

Step 3:

Large tools occupy more than one magazine place. The "Magazine" list reflects for example parameters for the envelope contour and the half-place assignment entered in the tool list.

The assignment of magazine places in the "Magazine" list is shown below and described based on examples:

See section

Also observe the plate at the machine setting station.

Step 4:

Tool is located in the magazine

As an example, the display is explained by means of the tools on place 5 and place 11:

Milling cutter on place 5
The milling cutter takes up 3 places.
- Place 5 is an occupied place where the tool is actually located.
- Second and third occupied place:
- The tool projects over places 4 and 5. These places are displayed as follows:
- Columns "O" and "U" are ticked, because the milling cutter protrudes over two half-places.
- The column "F" is ticked because no tool is located on these places in terms of data.



Drill on place 11 The drill takes up 2 places.
- Place 11 is an occupied place where the tool is actually located.
- The tool projects one half-place each over places 10 and 12:
- The drill projects over the lower half of place 10, therefore column "U" is ticked.
- The drill projects over the upper half of place 12, therefore column "O" is ticked.
- The column "F" is ticked in places 10 and 12 because no tool is located on these places in terms of data.

Step 5:

The tool is located inside the spindle or at the provisioning place

When the tool is placed inside the spindle or moved to the provisioning place, the place in the magazine must be kept free. Halfplaces must be taken into consideration:

The tool on place 5 has been placed into the spindle. The place is kept empty for intermediate storage.
- Column "Z" is ticked.
- The column "F" is ticked because no tool is located on the place.

To indicate that the relevant half-places need to be kept free, columns "o" and "u" are ticked.

Observe the context-sensitive help in columns "O", "U", "o" and "u" in order to avoid mistakes.

Step 1:

Integrated Process Monitoring (IPM) is a dynamic addition to the existing standard procedure in connection with tool management.

IPM allows you to detect tool overloads early, thereby avoiding tool fracture and all the consequential damage to machine and tool.

To achieve this aim, the IPM area, with which freely parameterisable monitoring methods can be generated, has been developed.

By pressing the "IPM" softkey from the extended basic menu, tool monitoring is called up.

Fast Drill Break Monitoring

General

If a tool is to be measured using "Fast tool break monitoring", the parameter for the "fast tool break monitoring" must be entered into the tool list after the tool has been loaded into the magazine. This activates "Fast tool break monitoring" for this tool.

Before the first tool is loaded, a reference measurement is taken at the provisioning place. The determined value is entered into the "OEM tools" list against the "SBBK" parameter.

Each time the tool is loaded, a measurement is taken and then compared to the reference value.

The "Fast tool break monitoring" option allows tools to be checked for breakage during a tool change. Only complete broken tools are detected, not breaks in individual cutting tips. Length changes of 2 mm and more (tolerance), which may result in a tool break, are detected.

Measuring is carried out "mechanically" by scanning the tool with a measuring needle. During the measuring process, the tool is located in the provisioning place.

The measuring needle moves at maximum speed out from the idle position towards the measuring angle (see diagram). The measuring angle to be approached is derived from the determined reference value of the tool, to which a tolerance value is applied. Before the tool is scanned, the speed is reduced.

To prevent a waiting period occurring during measuring, the traverse movement can be triggered at the next machining position as early as the tool change.

Boring tools with the following geometric data can be tested:

- Tool length: 70 mm to 600 mm
- diameter: 1 mm to 5 mm
- Point angle: up to 118 degrees

With these geometric data, a length change of 2 mm or more is reliably detected and any break event is ascertained.

Application

The "Fast tool break monitoring" option supplements the online monitoring facility "Integrated Process Monitoring (IPM)" This enables the checking of tools, which due to their low performance/ torque and/or feed power can no longer be reliably recorded by the "IPM".

Fast tool break monitoring is intended particularly for time-critical NC machining, which involves predominantly those tools listed below.

The following tool types can be monitoring particularly effectively with the "Fast tool break monitoring" option.
- Drilling tools diameter up to 5 mm, e.g.
- HSS drills
- Coated drills
- Solid carbide drills
- Step drills
- Tap up to M6

Tool fracture monitoring on tools with a diameter greater than 5 mm may only be included in the monitoring option following consultation with HELLER.

Fast tool break monitoring can of course be combined with the alternative strategy (option), which reacts appropriately to a tool break without parts machining coming to a halt.