Heidenhain TNC 640
Heidenhain TNC 640
Heidenhain TNC 640
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New functions of the TNC controls Efficient and convenient from page 10 New training center A spacious environment for imparting knowledge page 22
Editorial
Editorial
Dear Klartext Reader, How well does the new HEIDENHAIN control for multi-operation machining perform in practice? This is exactly what the Klartext staff wanted to find out. We wasted no time before visiting the GrozBeckert company in the German Swabian town of Albstadt. Here approx. 500 employees develop and manufacture machines and fixtures exclusively for their own use. We were all very excited. After all, this was to be the first users report on our brand new TNC 640! You can read all about the successful application of the milling/turning control in the field report on page 6. And while were on the topic, on page 4 you can read about the valuable new functions that the TNC 640 offers you for calibrating, turning, milling, smoothing and engraving. The iTNC 530, the TNC 620 and the TNC 320 also feature important innovations. Youll find an overview of them starting on page 10. In our Do you know this function? section youll learn about the advantages that the DXF converter can provide you as the user and how you can make your machining work even more convenient and efficient. The excitement continues with a users story on the production of ultramodern medical operation lamps. At the SIMEON company in Tuttlingen, Germany, attractive and highly heatdissipating lamp housings are milled.
With its new training center, HEIDENHAIN has procured equipment at the cutting edge of modern technology.
The housings serve to hold numerous LEDs, which in turn provide perfect illumination of surgery rooms. Read how a HEIDENHAIN iTNC 530 masters this difficult milling task in only one setup. The demand-oriented and optimal application of the TNCs enjoys first priority at HEIDENHAIN. The new HEIDENHAIN training center is a highlight in the transfer of technical knowledge. More space in a building dedicated to the purpose as well as the most modern of media technology provide an optimal environment for effective education. Learn more in our Klartext report on page 22. Read and enjoy, with best wishes from the Klartext staff!
Production
Publisher DR. JOHANNES HEIDENHAIN GmbH Postfach 1260 83292 Traunreut, Germany Tel: +49 8669 31-0 HEIDENHAIN on the Internet: www.heidenhain.de
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Now you can enjoy many new functions both convenient and practical for the TNC controls.
New functions ... for the TNC 640 on page 4 ... for the iTNC 530 and the compact TNC controls TNC 620 and TNC 320 on page 10 ... for the CNC PILOT 620 on page 16
Editing and layout Expert Communication GmbH Richard-Reitzner-Allee 1 85540 Haar, Germany Tel: +49 89 666375-0 E-mail: [email protected] www.expert-communication.de
Photo credits iStockphoto: page 17 middle , All other images DR. JOHANNES HEIDENHAIN GmbH
Contents
Contents
Software version 2
The TNC 640: thanks to new functions, even more user-friendly and powerful than before
Controls
g Turning functions
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g Options
g Tables
g Milling functions
g Touch-probe cycles
Controls
Report from the field Users evaluate a combination of milling and turning
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The TNC 640 makes it very easy to switch between turning and milling
Looking back, Dennis Hagg, the Project Group Manager for CAM Programming sums up: For Groz-Beckerts tool and fixture construction, dimensional accuracy, contour fidelity, but also surface definition are very important. In all disciplines, the new TNC 640 did a really good job, just as we have come to expect from the other HEIDENHAIN controls here at Groz-Beckert.
a valuable functional description. The machine operators praise the well organized layout. Values and parameters specific to milling or turning are easily recognized as such. The workers are very happy with it. The control feels good to operate, sum marizes Lffler.
Gradually the machinists got acquainted both with the new machine and the new control. Functions were tested, machining strategies were tried out. Many different parts with greatly varying materials had to be machined. Errors and suggestions for improvements were documented in monthly collective records. Sometimes they received quick help by e-mail in the form of change files that they transferred to the control.
hundred thousand blocks. The control supports the user in complicated turning operations with a tilted table, for example with the PLANE function. Thanks to the selective definition of the tilted working plane he keeps a good overview of the coordinate system. Also, the TNC 640 compensates and appropriately converts the datum from the preset table. There are also new challenges for the machining strategies, which are different from the familiar procedures with several machine tools. On the one hand, its important to reduce the number of setups as far as possible, and on the other hand you can change as desired now between turning and milling operations. To ease the change in thinking, the TNC 640 supports this new flexibility in machining with an especially convenient new feature: the user can give standardized plain-language commands in the part program to switch
as desired between turning and milling. There are almost no restrictions, since the switchover is independent of the momentary axis configuration. The people at Groz-Beckert are quick to assure us: Switching between turning and milling goes completely without problems. The new TNC 640 has everything that makes working with the control easier.
Focus on productivity
The primary aspect of the project with the TNC 640 was increasing productivity through multi-operation machining of turned and milled parts. At Groz-Beckert theyre very satisfied with the current results: After an intensive startup phase where small problems were quickly solved, they found the combination of the new control and new machine tool to be remarkably well-suited for the job.
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The easy switching between milling and turning has impressed us.
Dennis Hagg, project manager at Groz-Beckert
Long operations lasting 8 to 10 hours are run unattendedwhich further improves productivity and at the same time is a sign of confidence in the new combination. In the interview, Dennis Hagg and Alexander Lffler both agreed: The new turning-milling combination has become an important part of our tool and fixture construction, and today its simply indispensable. When the KLARTEXT staff asked them for their general opinion of the control, the answer was concise: Very good in practical application. And with that, were satisfied.
Groz-Beckert
Groz-Beckert is best known for its needles, which are used in industrial weft and warp knitting machines. For over 155 years, the company from the German Swabian town of Albstadt has produced tools for textile manufacturing. The processes in question are weft knitting, warp knitting, weaving, needling, tufting or sewing. Today, Groz-Beckert develops entire systems in collaboration with manufacturers of textile machines.
g www.groz-beckert.com
Alexander Lffler praises the application-oriented and convenient operation of the TNC 640
"The time savings and the working results fulfill our expectations of multi-operation machining," says the project manager Mr. Hagg. We were especially nervous about turningbut here, too, were completely satisfied.
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g You will find detailed information on special functions on the Web at tnc.heidenhain.de
The iTNC 530 with new functions for efficient machining Controls
S o ft w a r e 6 0 6 4 2 x- 0 v e r s i o n 3
Graphically supported file selection Find the right program more quickly: when you select programs from within different functions (e.g. during PGM CALL) the TNC shows a graphic in a pop-up windowin addition to the directory tree. In the graphic, the TNC shows the content of the selected file in the form of a line graphic (graphic representation of the contour).
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Additional status display A new tab in the status displays keeps you constantly informed. It shows which handwheel superimposition values are allowed and which can actually be realized. Optimization in the DXF converter (option) You can use the DXF converter to open CAD data directly on the TNC in order to extract contours. The most important innovations in this function are described in our Klartext article Do You Know This Function?
New status display for handwheel superimposition values
New features of the TNC 620 and TNC 320 offer the user numerous capabilities in machining
Controls
Storing and discarding With the SAVE and DISCARD functions, the user can specifically decide at which time any changes made should be saved or discarded. Saving to a new file is possible with the new SAVE AS function.
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With the DXF converter you can very easily import milling and turning contours and machining positions from existing DXF files.
CAD/CAM system
DXF converter: select the contour and create the part program
Which locations can I define as a datum? The datum of the DXF file is not always located where you can use it directly as the workpiece preset, especially when the drawing contains multiple views or cuts. However, you can also simply move the datum by clicking an element at an appropriate location. You define the position at the beginning, middle or end of a distance as the datum. What other settings can I make with the DXF converter? A powerful zoom function and useful setting options complement the functionality of the DXF converter. For example, you
can define the resolution of the contour program to be transferred for when you want to use it on older TNC controls. Or you can set a transition tolerance if occasionally the elements do not quite adjoin. Does the new version of the DXF converter support polylines, too? Polylines are used in CAD drawings when the desired contour cannot be created with circles or lines alone. In addition to the LINE, CIRCLE and ARC elements, the new version now also supports the POLYLINE element.
The DXF converter is for the following TNC controls TNC 640 HSCI TNC 620 HSCI TNC 320 iTNC 530 HSCI iTNC 530 As of NC SW 34059x-02 As of NC SW 34056x-04/73498x-02 As of NC SW 34055x-06 As of NC SW 60642x-01 As of NC SW 34049x-02
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New features of the DXF converter: more efficiency and convenience in operation Control
Now you can copy contours and points automatically to the buffer memory and copy it directly into the NC program by using the function after exiting the DXF converter. In the option box, select whether the positions should be saved as a point file or PNT file. You can also save the positions as plain-language blocks (L X.. Y.. FMAX M99) in order to use them in programs on older TNC controls that do not support point tables. You can select directly in the options box whether to save the contour as an .H program or as a contour program with the file extension .HC. The DXF converter now runs as a parallel application on the TNCs 3rd desktop. This enables you to transfer data quickly to various positions in an NC program. Operation of this application is now possible with only the mouse. Soft keys have been removed in order to provide more space for the graphics. You simply use the mouse and icons to select the desired functions. The TNC automatically shows all available functions for the current mode without your having to switch through soft-key rows.
In the option box you have your own choice: you can save positions as point files, as PNT files or a plain-language dialog blocks.
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Report from the field Manufacturing operating-room lamps with the iTNC 530
The exact alignment of the holders for the LED blocks is an important contribution to a homogenous light field
that have extremely thin walls on the inside. Small inaccuracies at this connecting point can quickly turn the relatively large component into scrap. For this reason, the combination of machine tool and NC control has to ensure high machining accuracy.
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deviations of the centers of rotation are checked regularly and the compensation values are transferred to the kinematic model. Recalibration takes only a very short time and can be performed by the machine user without help. This ensures high and lasting accuracy in tilting operations.
machine operator to visualize their movements. For this reason the actual danger of collision is hardly predictable during programming and setup. DCM is not only effective for workpiece machining operations generated by CAD/ CAM. The function can also prevent collision damage during setup, manual intervention, or the execution of programs that were written directly at the machine.
Conclusion
SIMEON makes use of new LED technology for the manufacture of innovative medical operation lamps that combine a modern, compact mechanical design with optimal illumination. The new design, however, is possible only with precise and powerful manufacturing technology that can fulfill the high quality requirements of todays medical technology. The milling machines at SIMEON are therefore uniformly equipped with HEIDENHAIN TNC controls.
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The CNC PILOT 620 lathe control is used in many workshops. It distinguishes itself particularly by convenience in program creation. Now it boasts another feature: TURN PLUS, a powerful function with which you can write part programs very quickly.
The powerful TURN PLUS function of the CNC PILOT 620 guarantees fast and easy operation: Once you have entered the workpiece geometry you only need to select the material and chucking devices. TURN PLUS handles everything else automatically, such as: Creating a working plan Selecting the machining strategy Selecting tools and cutting data Generating NC blocks
The automatically generated part program can later be altered or optimized in TURN PLUS. You simply watch all the machining steps and stop at the program point you would like to optimize (using interactive graphics). You choose the sector for machining and the appropriate fixed
Result: A thoroughly commented DIN PLUS program TURN PLUS makes it easy to automatically create a part program for falling contours. Often, the angle the contour falls off at is steeper than the tool tip angle. In that case, the CNC PILOT 620 automatically chooses another tool and machines the contour in the opposite direction or as a recess. As a result, your part program is ready to run sooner.
TURN PLUS automatically selects all cycles, tools and cutting data for the entire machining operation.
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cycle, and TURN PLUS proposes the tool and cutting data. Following that, the control automatically generates the new machining step. You can also use TURN PLUS for milling, drilling and boring operations with the C or Y axis on face and cylindrical surfaces. The same goes for machines with opposing spindles for rear surfaces.
With the new TURN PLUS function (software option) you can create NC programs in a very short time.
HER S
HEROS 5 (the new HEIDENHAIN Real-time Operating System) readies our family of controls for future developments. It integrates new and powerful functions into the control software. For example, a new connection to the Internet is possible: the controls integrated browser grants you direct access to the Web. The new PDF viewer enables you to open PDF files directly on the control. New editors also make it possible to open work instructions, drawings and other information in additional file formats.
The following additional formats are supported: Text files ending with .txt or .ini Graphic files ending with .gif, .bmp, .jpg, or .png Table files ending with .xls or .csv HTML files The HEROS 5 operating system makes it easier to interconnect HEIDENHAIN controls in your network. The settings dialogs have been standardized, and now look the same on all controls. The new HEROS 5 operating system currently runs on the TNC 640, TNC 620, iTNC 530 and CNC PILOT 620 controls.
Opening PDF files directly on the control: the PDF viewer makes it possible.
Software
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A retrofit builds on the tried and tested. The reconditioning is intended not only to restore the original condition of a machine, but also to prepare it for the demands of today and tomorrow. A new control frequently opens up entirely new machining opportunities. This has been proven by a MANUALplus 620 in Varel way up in northern Germany at the Haar Mechanical Machining GmbH & Co. KG. Here the new HEIDENHAIN lathe control combines the new with the past in a special way. The workpieces at Haar are impressive in their size and weight. The company in the North Sea town of Varel is part of the Sande Stahlguss GmbH casting group, from which some of their steel and stainless steel cast workpiece blanks come. These are components for power plant construction such as complicated turbine and valve housings. The machine workpieces have an individual total weight up to 100 metric tons and sport a maximum turning diameter of 7,100 mm. The company performs both the mechanical machining andin a special machine hallthe preparation of the workpieces for assembly. For decades, the Drries vertical boring and turning mill in Haar has been doing very heavy work in the area of mechanical preparatory machining. The sturdy machine from the 60s has unusually solid substance. So they decided to have it reconditioned by equipping the timeproven conventional machine with new technology and substantially expanded capabilities.
The company performed the mechanical renovation itself. The changes in the control, encoders and electrical parts were commissioned to a qualified company that has specialized in machine modernization with HEIDENHAIN controls. After the project planninga detailed plan of all measuresthe two companies tackled the retrofit in close coordination. The measures proceeded without a hitch and were completed after a few weeks.
Every workpiece differs from another machining in series is almost nonexistent at Haar. For this reason, the part programs are created or modified individually for each workpiece. The details of what has to be done often do not become apparent until after delivery of the massive components. Then its an important advantage to be able to create reliable part programs quickly and flexibly. Once again, a significant plus for the HEIDENHAIN control.
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Counts since the 1960s as indispensablethe Drries vertical boring and turning mill
Now the machine provides dramatically increased performance with the MANUALplus 620
Programming stations and controls are networked throughout the entire company. In this way the part programs are easily transferred from the office to the machine.
Here the machine operator needs to keep a very close eye on the entire machining process. When problems such as tool breakage occur, he has to be able to react quickly and effectively. This places a huge responsibility on each and every machine operator! The new MANUALplus 620 makes manual intervention as easy and safe as possible. Even interventions directly in the machining process are not unusual: with feed-rate superimpositioning, for example, you can optimize protracted operations. And in many cases it can be helpful that the control can take a contour oversize into account. Manual operations are typical in the mechanical preparation department. The machining steps are very different from workpiece to workpiece. Because the workpiece blank contours are frequently not defined exactly and no more than one axis is needed, it often is not worth writing a complete part program. Instead, this company places its trust in the year-long experience of its employees and the particularly simple and safe operation of the controls.
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HEIDENHAIN recommends having a machine tool reconditioned with a new control by qualified service providers. We would be glad to advise you. Please send your inquiries by e-mail to:
Johannes Jrgens and Jens Haar are very satisfied with the new capabilities of the large machine
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HEIDENHAIN Helpline
An important piece of advice: Use the Helpline. Regardless of whether you require rapid on-site assistance, or need to exchange a defective device, or your machine needs to be inspected and calibrated, a personal contact partner will take care of your request and coordinate the appropriate support. Do you have any technical questions? Our specialists from the HEIDENHAIN Helpline can advise you competently about solutions for encoders, controls, NC and PLC programming, and other topics.
Helpline hours:
Monday to Thursday: 7:00 a.m. to 4:30 p.m. Friday: 7:00 a.m. to 3:00 p.m.
Service
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All rooms are optimally equipped: powerful beamers, large projection screens, and PC boards with touchscreen functionality are provided for the course participants. In addition, the entire range of control hardware is available for the technical courses.
The demand-oriented and optimal application of the TNCs enjoy first priority at HEIDENHAIN, since we want our users to be able to take full advantage of our products, and use our controls entire potential for efficient and productive machining. Keeping this in mind, we have been holding TNC programming courses regularly since 1982. HEIDENHAIN also considers highquality imparting of knowledge to be a service to the customer. Hannes Wechselberger, Manager of Technical Training, puts it in a nutshell: Customers and users shouldnt decide in favor of HEIDENHAIN just because of the capabilities of our high-quality products, but also because we are an excellent service provider, thereby providing added value. This definitely includes our professional training courses. The numbers prove that this training program is well received: in 2011, more than
1,300 students participated in about 200 NC programming courses in Traunreut, and the numbers are rising. The generally good economic situation, as well as the good reputation of the HEIDENHAIN courses, resulted in a serious capacity problem in the previous classrooms. HEIDENHAIN saw the need for more space in sufficient time to do what was necessary.
The reception area of the new training center is captivating, with its simple elegance and modern furnishings. The new course rooms are very aesthetic, and make learning even more fun.
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Our professional training program is a true added value for the users.
Hannes Wechselberger, Manager of Technical Training
also provide access to the compatible encoders in addition to all the control hardware. The use of such modern educational media permits the interactive and practical transfer of knowledge about the entire world of TNCs. This makes it easy for course participants to run a simulation on the programming station, and then put the program into practice on a real CNC machine in the new workshop. If it had only been like this back in school, one young participant raves about the new training center in Traunreut. The well-thought out approach has already proven itself: Its really fun to learn with this modern media equipment, another participant in an NC course adds.
The sleek and modern building offers much space and many capabilities for technical courses.
The new training center enables HEIDENHAIN to significantly improve the practical relevance of the courses, since an increasing number of customers want courses on specific topics: They want to learn exactly what they need to know for the individual tasks in their respective companies. Gaining this same knowledge through regular courses would require much more time and we all know how little there is of that. And thats why we simply needed more rooms, Wechselberg er explains.
After an initial trial run, courses have been held officially in the new training center since July 1, 2012. The machine operators are the most important target group, but close behind are the knowledge multipliers, including the trainers in HEIDENHAINs network of training partners. Furthermore, HEIDENHAIN trains its machine manufacturers in PLC programming, kinematics, commissioning, and machine optimization. Numerous service courses covering all HEIDENHAIN products are available to expert maintenance and service technicians from machine manufacturers and dealers, retrofitters, and service providers. More details can be found on the HEIDENHAIN training portal. In total, about 60 percent of the courses deal with NC programming, and the other 40 percent emphasize OEM and service topics. HEIDENHAIN is an internationally active company, so courses are regularly held in Traunreut both in German as well as English. Courses in other languages, such as Polish, can also be held in Traunreut by native speakers. Upon request, courses in further languages such as Chinese are possible through an interpreter.
Compared with the earlier situation, the new machine hall offers ten times as much space, and five powerful machines for practical exercises.
Schulung
The new TNC 640: for the first time, milling and turning are combined in one TNC. Now users can switch as desired between milling and turningwithin one and the same NC program. Switchover is independent of the machine kinematics. It automatically takes the respective operating mode into account and requires no additional action. This new simplicity is complemented by dialog-guided plain language programming, the optimized user interface, powerful programming aids as well as comprehensive cycle packets taken from widely field-proven HEIDENHAIN controls into the new TNC 640. This is technological edge built-in. DR. JOHANNES HEIDENHAIN GmbH, www.heidenhain.de
Angle Encoders
Linear Encoders
Contouring Controls
Position Displays
Length Gauges
Rotary Encoders