iTNC 530
New Functions with
NC Software 340 49x-07
September 2011
New Functions with NC Software 340 49x-07
—The iTNC 530 Makes Working with the Machine Even Easier
The iTNC 530 from HEIDENHAIN has
proven itself for years as a versatile
contouring control for milling, drilling and
boring machines as well as machining
centers. Along with HEIDENHAIN’s plainlanguage conversational programming for
the shop floor, the iTNC 530 is
characterized by many useful functions
and innovative features. To name just a
few:
• Exact tool guidance for five-axis
machining
• Simple tilting of the working plane
• Practice-oriented setup functions
• Very high contour accuracy for HSC
milling
• Extensive fixed cycles
• Helpful programming support through
unambiguous function keys, free contour
programming and help graphics
• Upwardly compatible part programs
• External programming and fast data
transfer
The success story of the iTNC 530 also
includes smarT.NC—the new operating
mode from HEIDENHAIN. It represents
another successful step toward more userfriendliness in a shop-floor programming
interface. Well-structured input forms,
straightforward graphic support, and
comprehensive help texts combine with
the easy-to-use pattern generator to form
a compelling programming environment.
2
New functions for the iTNC 530
Of course there is always potential for
new development, improvement and
simplification. The NC software 340 49x-07
for the iTNC 530 includes a series of new
functions for machine tool builders and
users. These functions make it even easier
to work with the control, and they also
make operation of the machine more safe.
The most important new functions are:
• smarT.NC wizard for inserting smarT.NC
units in conversational programs
• Cycle for interpolation turning (option)
• Cycle for machining 3‑D contour trains
• Engraving cycle
Error fixes, new and improved functions
and options
As of NC software 340 49x-02, error fixes
have been separated from software
improvements. Updates of NC software
usually contain only error fixes.
New functions certainly offer added value
regarding user-friendliness and operational
reliability. Naturally you also have the
opportunity to purchase these new
functions after a software update: These
new and improved functions are offered
as “feature upgrades,” and are enabled via
the Feature Content Level option.
If, for example, a control is to be upgraded
from NC software 340 49x-02 to 340 49x-07,
the functions identified with “FCL xx” in
the following tables are only available if the
feature content level is set from 02 to 04.
Of course the current feature content level
also includes the upgrade functions of the
previous NC software versions.
All of the options included in the
respective NC software can be purchased,
no matter which feature content level you
have.
smarT.NC Goes Conversational
—Inserting smarT.NC Units in Conversational Programs
The new smarT.NC wizard completely
unifies the worlds of smarT.NC and
conversational programming. The
strengths of both worlds are now available
in a single user interface. The full flexibility
of conversational programming, based on
NC blocks, can now be combined at any
location with the fast, form-based
workstep programming method of
smarT.NC. Programming goes much
quicker particularly in combination with the
DXF converter or the graphically supported
definition of any machining patterns. All
other machining units available in smarT.NC
also simplify the creation of conversational
programs.
When inserting a smarT.NC unit, the TNC
displays the conversational program in the
familiar manner on the left side of the
screen. On the right side the TNC shows
the smarT.NC form with the corresponding
input fields specific to the respective unit.
The help graphic belonging to each input
field is shown in the bottom part of the
screen. When the form is saved, the TNC
inserts all conversational blocks necessary
for the defined machining operation.
Changes can later be made either in the
form or directly in the appropriate NC block.
The operator can decide himself which
method he prefers.
3
The Future is Now
—Graphic Selection of Contours and Contour Sections (Option)
For several years now the iTNC 530 has
been able to select contours from DXF
files. Now the DXF converter can also open
conversational programs that were created
externally in CAM systems.
The DXF converter graphically displays the
tool paths generated in the CAM system.
You can select parts of the contour and
save them as separate NC programs. This
is especially helpful, for example, when
you need to rework parts of contours with
a smaller tool, or even if you just want to
rework some parts of a 3-D shape. This
function saves you a trip to the CAM office,
and can be performed at any time directly
on the iTNC.
You can then machine this newly created
NC program directly or in combination with
the TNC’s contour train cycles.
4
Safe Machining
—Option for Integrated Dynamic Collision Monitoring (DCM):
Improvements
Dynamic collision monitoring (DCM)
has now proven itself on approximately
4 500 machines throughout the world.
Since being introduced in 2005, this
function has become an increasingly
important instrument in reducing costly
machine downtimes and relieving the
machine operator, especially when
manually moving the machine axes. During
manual operation, the iTNC automatically
reduces the speed if two collision objects
come too close to each other, and issues
an error message if a collision is imminent.
The iTNC not only monitors the permanent
machine components defined by the
machine tool builder, but also fixtures,
tools and tool carriers.
Automatic activation/deactivation of
fixture situations
With the new NC functions SEL FIXTURE
and FIXTURE SELECTION RESET you can
activate or deactivate previously saved
fixture situations in automatic operation.
Specific fixtures can also be activated for
each NC program from pallet tables. This
increases safety and reliability in
automated production.
Tool carrier management
In order to take tool holders into account
for collision monitoring, you can assign the
corresponding collision body to each tool in
the tool table. There is now graphic support
for selection of the collision body: the TNC
shows a preview of the collision body to be
selected.
Collision monitoring for multiple task
tools
If you use indexed multiple task tools,
the TNC now also monitors these tasks
automatically and correctly, and adapts the
kinematics view correspondingly.
5
Machining Flexibly
—Interpolation Turning (Option)
In interpolation turning the cutting edge of
the tool moves on a circle, with the cutting
edge always oriented to the center of the
circle. By varying the circle radius and the
axial position, any rotationally symmetric
objects can be produced in any working
plane.
With the new Cycle 290 INTERPOLATION
TURNING, the iTNC 530 can create a
rotationally symmetric step in the active
working plane, which is defined by the
starting and end point. The center of
rotation is the tool location in the working
plane at the time the cycle is called. The
rotational surfaces can be inclined or
rounded relative to each other.
This cycle can only be used for finishing.
Roughing operations with multiple steps
are not possible. The machining strategy
can be chosen flexibly: from the outside in
or vice versa, and also from top to bottom
or vice versa. This results in four different
machining strategies, which are distributed
over the four quadrants.
6
—Peripheral Milling with the New Contour Train Cycle
Special demands are in force during
peripheral milling of cutting and bending
tools, particularly for large-scale mold
making for the automobile industry. The
contour edges are generated by CAM
systems, and as a rule do not just contain
coordinates for the machining plane, but
also for the tool-axis direction. Of
importance here is that the cutting or
bending edge does not have a constant
Z height, but can vary greatly on a
workpiece.
The new Cycle 276 CONTOUR TRAIN 3D
can machine such 3-D contours very easily.
Similar to Cycle 25 CONTOUR TRAIN,
which is two-dimensional, the contour to
be machined must be defined in a
subprogram. You specify the approach
behavior, machining mode and radius
compensation with Cycle 270 CONTOUR
TRAIN DATA, and then call Cycle 276. The
3-D contour train can be machined with or
without an infeed, depending on whether
one has been defined.
The 3-D contours to be machined can be
created very easily if they can be loaded
from existing NC programs that were
generated by a postprocessor. This applies
in particular if a smaller tool must be used
to rework specific areas. An enhancement
was implemented for this in the DXF
converter, making it possible to load
contours or parts of contours from
conversational programs (see page 4).
7
New Programming Functions
—Miscellaneous
New engraving cycle 225
The new engraving cycle 225 is a
convenient method for producing texts or
serial numbers. In the cycle you enter the
text via a text parameter, and of course you
can choose whether the text should be in a
straight line or along an arc.
Stud cycles 256/257
Additional input parameters have been
added to the cycles for circular and
rectangular studs so that the radius and
angle for approach and departure can be
specified. This makes it easier to define the
approach and departure behavior when
space is limited.
Thread milling cycles 262, 263, 264 and
267
In these thread milling cycles a separate
feed rate is now available for tangential
entry into the thread. Particularly with small
thread sizes this makes it possible to select
a higher subsequent cutting feed rate,
which reduces production time.
KinematicsOpt cycles 451 and 452
(option)
Fast optimization algorithms reduce the
time for measurement, as does the fact
that position optimization is now performed
simultaneously with angle optimization.
Furthermore, the ascertained offset errors
are now available as result parameters,
permitting subsequent program-controlled
evaluation.
Global Program Settings (GS)
(option)
Via an additional switch in the global
program settings (GS) form you can now
specify whether the values traversed in the
virtual axis direction should be reset upon a
tool change.
8
File management:
Support for ZIP archives
In the iTNC 530’s file manager you can
now create ZIP archives, in order to archive
files of completed jobs, for example. Of
course you can also open existing archives
and extract files from there.
Working with pallets
Selected workpieces can be hidden during
tool-oriented machining in combination
with the pallet table. A new keyword is
available for this.
Optimizations to the DXF converter
(option)
Summary of the most important new
features of the DXF converter:
• Contours and machining positions can be
selected faster and with better accuracy
with a capture function.
• During contour selection the iTNC shows
the size of the smallest contained
contour radius in the status bar. This
smallest radius is also shown in a
different color in the selected contour.
That way you can tell immediately which
tool can machine the contour in any
case.
• Preselected contours can now also be
chosen in the tree view.
Enhanced tool management
(option)
A particularly interesting function has been
added to the enhanced tool management.
There is now an import function for reading
and exporting CSV files. CSV (commaseparated values) is a file format for the
exchange of simply structured data. This
function is especially useful for data
exchange if you measure and calibrate your
tools with external presetters. Excel can
also open and save this file format.
There is now also a simple possibility for
deleting tool data quickly but carefully. The
TNC shows the tool data to be deleted in a
pop-up window, giving you the opportunity
to make sure that no important data is
deleted by accident.
9
Overview
—All Options in NC Software 340 49x-07
Option
number
Option
As of NC
software
340 49x-
ID
0
1
2
3
4
5
6
7
Additional axis
01
354 540-01 Additional control loops 1 to 8
353 904-01
353 905-01
367 867-01
367 868-01
370 291-01
370 292-01
370 293-01
8
Software option 1
01
367 591-01 Machining with a rotary table
• Programming of cylindrical contours as if in two axes
• Feed rate in mm/min
Coordinate transformation
• Tilting the working plane, PLANE function
Interpolation
• Circular in 3 axes with tilted working plane
9
Software option 2
01
367 590-01 3-D machining
• Particularly jerk-free path control
• 3-D tool compensation through surface normal vectors
• TCPM: Tool Center Point Management
• Keeping the tool normal to the contour
• Tool radius compensation normal to the tool direction
• Manual traverse in the active tool-axis system
Interpolation
• Linear in 5 axes (subject to export permit)
• Spline: execution of splines (3rd degree polynomial)
Block processing time: 0.5 ms
18
HEIDENHAIN DNC
01
526 451-01 Communication with external PC applications over COM component
40
DCM Collision
02
526 452-01 Dynamic Collision Monitoring (DCM)
41
Additional language
02
03
03
03
03
03
04
04
05
530 184-01
530 184-02
530 184-03
530 184-04
530 184-06
530 184-07
530 184-08
530 184-09
530 184-10
10
Comment
Slovenian
Slovak
Latvian
Norwegian
Korean
Estonian
Turkish
Romanian
Lithuanian
Option
number
Option
As of NC
software
340 49x-
ID
42
DXF Converter
02
526 450-01 Load and convert DXF contours
44
Global PGM Settings
03
576 057-01 Global program settings
45
Adaptive Feed Control (AFC) 03
579 648-01 Adaptive feed control
46
Python OEM Process
04
579 650-01 Python application on the iTNC
48
KinematicsOpt
04
630 916-01 Touch probe cycles for automatic measurement of rotary axes
52
KinematicsComp
05
661 879-01 Three-dimensional compensation
53
Feature content level
02
529 969-01 –
77
4 Additional Axes
06
634 613-01 4 additional control loops
78
8 Additional Axes
06
634 614-01 8 additional control loops
92
3D-ToolComp
06
679 678-01 3-D radius compensation depending on the tool’s contact angle
93
Extended Tool Management 06
676 938-01 Tool management enhanced
96
Advanced Spindle
Interpolation
751 653-01 Cycle for interpolation turning
07
Comment
11
Option
FCL
Function
Standard
Operating mode
As of NC software
Overview
—New Functions with NC Software 340 49x
40 DCM: Dynamic collision monitoring (only with MC 422 B, MC 422 C)
Independent of
operating mode
02
USB support for peripheral memory devices (memory sticks, hard disks, CD-ROMs)
02
DHCP (Dynamic Host Configuration Protocol) and DNS (Domain Name System) for network
settings
•
Freely definable tables visible also in form view
•
All soft keys revised
340 49x-02
41 Slovenian language
•
Czech user interface now with native characters
•
Configurable update procedure for future software updates (e.g. automatic update over USB
storage devices)
•
Additional HR 420 functions:
• Selection of the active override possible on the HR 420
• Freely definable soft-key menu for machine functions
•
Smaller pop-up window when HR 420 is active, to improve legibility of axis positions on screen
•
Look-ahead can be configured via machine parameters
•
Calculation of dynamic load for tilting axes
•
Inclined tool machining with open-loop axes
340 49x-03
44 Global program settings (GS) make it possible to superimpose various coordinate transformations
and settings in the Program Run operating modes
45 AFC: Adaptive feed control adjusts the contouring feed rate to the spindle power
03
TNCguide: The integrated help system. User information available directly on the iTNC 530 (only
with at least 256 MB RAM)
41 Conversational languages in Slovak, Norwegian, Estonian, Latvian, Korean (Asian languages
require at least 256 MB RAM)
12
Option
FCL
•
Expanded and completely revised file management
•
Automatic and manual generation of service files for faster error diagnostics
•
Tool-change macro for Test Run
04
Graphic display of machine kinematics in the Program Run modes of operation
04
3-D basic rotation light: aligning workpieces in three dimensions
40 Improvements to dynamic collision monitoring (DCM):
• Handwheel superimposition possible with active DCM in stopped condition
• Automatic cancellation of collision protection for touch probe during tool measurement
340 49x-04
Independent of
operating mode
Function
Standard
As of NC software
Operating mode
41 Turkish and Romanian languages
44 Improvements in global program settings (GS): Traverse with handwheel superimposition in the
active tool-axis system (virtual axis) with active TCPM
45 Improvements to adaptive feed control (AFC):
• Expanded status display
• Resetting the reference power in the learning mode
• Use of any value as control parameter over PLC
46 Python OEM process: Simpler integration of OEM applications in the iTNC
48 KinematicsOpt: Touch probe cycles for automatic measurement of rotary axes
40 Improvements to dynamic collision monitoring (DCM):
• Testing the program for possible collisions prior to machining
• Fixture monitoring
• Simplified tool-carrier management
41 Lithuanian language
340 49x-05
44 Improvements to global program settings (GS)
• Optimized display of input form
• Handwheel superimposition can be used together with M91/M92
• Coordinate transformations can be used together with M91/M92
52 KinematicsComp: Three-dimensional compensation of positioning errors that are due to
mechanical causes
•
New, additional DG 3-D position display: Distance-to-go in the tilted coordinate system
•
Separate preset table for pallet presets
•
Support of new HR 5xx handwheels
•
New tool management based on Python
•
TNCguide: Help system with improved context sensitivity
•
Local QL... Q-parameters and nonvolatile QR... Q-parameters
13
Option
FCL
Standard
As of NC software
Function
92 3D-ToolComp: 3-D radius compensation depending on the tool’s contact angle
340 49x-07
Independent of
operating mode
340 49x-06
Operating mode
•
3-D line graphics in full-screen mode
•
Manual operation: Compensate workpiece misalignment through rotation of the table
•
SPEC FCT special functions available in MDI mode
44 Improvements to global program settings (GS):
• Possibility of selecting of whether the value superimposed by the handwheel in the virtual axis
should be reset upon a tool change
• Improved limit-switch handling in conjunction with M91 positioning movements
• Program-controlled setting and resetting of form entries
42 Improvements to DXF data processing:
• Assume contours from conversational programs
• Enhanced information in the status bar
• Integrated capture function
93 Enhanced tool management: Import/export of tool data in CSV format (comma-separated values)
14
Option
FCL
Function
Standard
As of NC software
Operating mode
42 Direct loading of contours from DXF data and saving as smarT.NC contouring programs
340 49x-02
smarT.NC
02
Cycles for coordinate transformation introduced
02
PLANE function introduced
02
Contour pocket: Separate depth can be assigned for each subcontour
02
Block scan with graphic support
•
Entry of cutting speed as alternative to the spindle shaft speed
•
Feed rate can also be entered as Fz (feed per tooth) or Fu (feed per revolution)
•
Tool data can be edited in a pop-up window during tool selection
•
Axis keys now also position the cursor in the forms. The I key (incremental/absolute switchover)
and P key (polar/Cartesian switchover) also function for contour programming.
•
CUT/COPY/PASTE of one or more units
•
Automatic entry of workpiece blank into contour program
•
Incremental entry of machining positions in forms for machining units
•
Tooltips displayed when using the mouse
42 DXF data processing:
• Separation of laterally joined contour elements
• Generate point files (.HP files) directly from the DXF converter
340 49x-03
03
smarT.NC editor in the Programming and Editing operating mode
•
Expanded and completely revised file management
•
Tool table shown as a fillable form
03
Machining a contour pocket on a point pattern
03
Individually definable positioning heights in point patterns
03
Touch probe Units 408 and 409 for setting datums in the centerline of a slot or ridge
03
Setting of probing parameters in a separate Unit 441
03
Automatic feed rate reduction in contour pockets during full tool engagement
15
340 49x-04
340 49x-03
smarT.NC
Option
FCL
Function
Standard
As of NC software
Operating mode
•
Climb milling/up-cut milling for helical finish milling
•
Retraction speed for tapping with chip breaking
•
Ascertained workpiece misalignment can also be compensated by rotating a C axis
•
Zoom function in the pattern generator
•
Entry of stopping angle or angular step in a pitch circle definition
•
Unit 141, datum shift
•
Unit 256, machining rectangular studs
•
Unit 257, machining circular studs
•
Unit 799, program end unit
•
Unit 22, fine roughing: selectable machining strategy
•
Unit 209, tapping: definable rotational speed of retraction
•
Touch probe Units 412, 413, 421 and 422: Circles can be measured at either 3 or 4 points
•
Inline pattern definition with PATTERN DEF
•
Transferring data from identical, previously defined units
42 DXF data processing:
• Improved handling
• Info box displays data on the selected element
48 Units 450 and 451, KinematicsOpt: touch probe cycles for automatic measurement of rotary axes
42 DXF data processing:
• POLYLINE support
• Selection of machining positions with the mouse, including path optimization
340 49x-05
•
16
Unit 241, single-lip deep-hole drilling (new)
48 Improvements to KinematicsOpt:
• Improved logging in Cycle 450
• Time savings through shortening of the probing paths
• Automatic presetting
• Hiding individual rotary axes
•
Touch probe Units 412, 413, 421 and 422: Type of positioning at clearance height can be selected
•
Touch probe Units 408 to 419 also write the datum to line 0 of the preset table
340 49x-07
340 49x-06
smarT.NC
Option
FCL
Function
Standard
As of NC software
Operating mode
•
Unit 275, trochoidal slot (new)
•
Unit 241, single-lip deep-hole drilling: dwell depth (new)
•
Unit 460, calibrate touch probe using calibration sphere (new)
48 Improvements to KinematicsOpt:
• Measurement of backlash possible via additional parameter
• Improved support of Hirth-coupled spindle heads
• Measure and compensate misalignment of a rotary axis
•
Unit 276, contour train 3-D (new)
•
Unit 225, engraving (new)
•
Units 256/257, stud milling: approach radius and angle (new)
•
Units 262/263/264/267, thread milling: entry feed rate (new)
17
Option
FCL
Function
Standard
As of NC software
Operating mode
42 Direct loading of contours from DXF data and saving as conversational programs
340 49x-02
Conversational
programming
02
Cycle for global setting of touch-probe parameters
02
Point filter for smoothing externally created NC programs
02
3-D line graphics for verification of programs created offline
02
Manual traverse in the active tool-axis system
•
Entry of cutting speed as alternative to the spindle shaft speed
•
Simplification when working with the preset table, incremental correction of preset values
possible, correction of the active preset possible
•
Contour pockets can now contain significantly more contour elements
•
Consideration of an active basic rotation in manual probe cycles
•
Measuring log for probing cycles can now also be displayed on the screen during program
interruption
•
FK transformation selectable as structured plain-language or linearized plain-language
340 49x-03
42 DXF data processing:
• Separation of laterally joined contour elements
• Generate point files (.HP files) directly from the DXF converter
18
03
Touch probe Cycles 408 and 409 for setting datums in the centerline of a slot or ridge
03
Touch-probe Cycle 4 for three-dimensional measurements. Toggle between showing the
measurement results in the coordinate system of the workpiece or the machine.
03
Automatic feed rate reduction in contour pockets during full tool engagement
•
Climb milling/up-cut milling for helical finish milling
•
Retraction speed for tapping with chip breaking
•
Ascertained workpiece misalignment can also be compensated by rotating a C axis
340 49x-04
Conversational
programming
Option
FCL
Function
Standard
As of NC software
Operating mode
•
Cycle 256, machining rectangular studs
•
Cycle 257, machining circular studs
•
Cycle 22, fine roughing: selectable machining strategy
•
Cycle 209, tapping: definable rotational speed of retraction
•
Touch probe Cycles 412, 413, 421 and 422: circles can be measured at either 3 or 4 points
•
Special functions of smarT.NC available for conversational programming:
• Defining machining patterns with PATTERN DEF
• Defining cycle parameters globally with GLOBAL DEF
•
File management (copying, moving, deleting) from within the NC program
42 DXF data processing:
• Improved handling
• Info box displays data on the selected element
340 49x-05
48 KinematicsOpt: Touch probe cycles for automatic measurement of rotary axes
•
Cycle 241, single-lip deep-hole drilling (new)
•
Touch probe Cycles 412, 413, 421 and 422: Type of positioning at clearance height can be
selected
42 DXF data processing:
• POLYLINE support
• Selection of machining positions with the mouse, including path optimization
•
Touch probe Cycle 484 for calibrating the TT 449 infrared tool touch probe
•
Touch probe Cycles 408 to 419 also write the datum to line 0 of the preset table
340 49x-06
48 Improvements to KinematicsOpt:
• Improved logging in Cycle 450
• Time savings through shortening of the probing paths
• Automatic presetting
• Hiding individual rotary axes
•
Touch-probe Cycle 460, calibration (new)
•
Cycle 275, trochoidal slot (new)
•
Cycle 241, single-lip deep-hole drilling: dwell depth (new)
•
Program selection window for PGM calls (new)
•
PLANE function: Retraction value for tilting to position with the TURN function (new)
•
Q-parameter programming: Program jumps can be controlled via QS string parameters
48 Improvements to KinematicsOpt:
• Measurement of backlash possible via additional parameter
• Improved support of Hirth-coupled spindle heads
• Measure and compensate misalignment of a rotary axis
19
340 49x-07
Conversational
programming
Option
FCL
Function
Standard
As of NC software
Operating mode
•
Cycle 276, contour train 3-D (new)
•
Cycle 225, engraving (new)
•
Cycles 256/257, stud milling: approach radius and angle (new)
•
Cycles 262/263/264/267, thread milling: entry feed rate (new)
96 Advanced Spindle Interpolation: Cycle 290, interpolation turning (new)
•
PLANE function also in possible in DIN/ISO
Programming
station
•
Virtual keyboard can be displayed with new version of the programming station
•
PLC program provided for optional installation (can be used to move axes)
•
Access to the PLC with the keyword “PLC”
•
All options and FCL functions are enabled
•
Support for Windows Vista
340 494-06
340 494-04
340 494-02
DIN/ISO
•
•
iTNC programming station available with network license
Support for Windows 7
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842 239-21 · 10 · 9/2011 · F&W · Printed in Germany