CNC machine tool system data protection and backup recovery example analysis - Database & Sql Blog Articles

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After the commissioning of a machine tool, the following data needs to be backed up: machine data, pitch error compensation, test data, plc logic control program, user alarm text, etc. The test data includes: backlash compensation for each axis, soft limit of coordinates, screw pitch error compensation, drive data, and so on. The machine data is set when the CNC machine is shipped from the factory. The data backup process is the protection process of the system data. How to protect the backup machine data becomes an important issue. In practical applications, the following problems often occur: due to insufficient understanding of the machine data and its effects, the machine data is arbitrarily modified, so that the original backup data changes, the CNC machine tool can not play the original performance; there is a data backup disk (or CF backup card) Improperly stored, the data medium is invalid or lost. If there is a problem with the machine tool, the data backup cannot be used normally. During the acceptance period, the complete system data backup file is not provided. When the machine data is lost, it cannot play its due role. The technical data such as drawings and manuals are incomplete, the system password setting random data is not involved, and the system data setting status cannot be entered. Therefore, understanding the role of machine data, protection methods and recovery through backup after loss is very important, and is also a prerequisite for ensuring the normal operation of CNC machine tools.

Application example 1

CKW61125/5M CNC lathe adopts SIEMENS802D system, spindle AC servo control stepless speed regulation, machine feed axis AC servo SIEMENS611 drive, equipped with grating ruler to realize position adjustment full closed loop control, electronic handwheel feed, four station automatic Rotary tool holder, SIEMENS PLC S7-300 logic controller, Profibus interface and other functions. The machine is equipped with centralized lubrication and cooling.

When the machine is running, 510018 alarm occurs, ROV feedrate override, FST axis feed prohibition alarm, human-machine communication MMC and OP (OP031) board do not work. The auxiliary functions such as start-stop and cooling of the MCP spindle of the machine control panel are manually normal. Press and hold the reset button to perform the homing and X and Z axis feed operations.

Cause analysis and recovery: From the phenomenon generated by the machine tool, the data communication between the NC system and the MMC and OP board enters an infinite loop. The axis feed prohibition means that the drive shaft is not enabled. The alarm number 510018 is diagnosed as a channel report. The hardware is initially considered. Problem, data communication failure between MMC and OP board. And take measures to replace the MMC, OP (OP031) communication board, and replace the NC system board at the same time. However, after the replacement, the fault is not eliminated and the original fault state remains unchanged.

According to the above processing situation, the following measures are taken: 1 Test feed enable: After pressing “Feed Start”, the S510118 alarm is eliminated, but the 700132 alarm occurs, and the feed is disabled. 2 Test “Cycle Start”, there is 10203 channel 1 alarm, no reference axis. 3 Test JOG: Display 5100088 alarm. 4 Test Spind Start: Display 600308 alarm. 5 Calling the machine data Data-(x, z, c), All.Data and Plc programs cannot enter the setting state.

The test result is: the alarm can not be eliminated, and the alarm numbers 5100088 and 600308 are beyond the diagnostic range.

The reason for the analysis is that the machine system data file is missing.

Measures taken and recovery methods: Using the machine system data backup file, re-execute the machine data-(x, z, c), All.Data data and Plc program files.

transmission. The method is: using 802D WinPCIN system communication software, through the machine data file between RS232 and NC system, Transfer Toolbox→WinPCIN.

(1) Data data transmission: 1 Data1→RS232 interface setting: set communication interface (comm part), select COM2; set baud rate (Baudrate) to 9600; select Data bits to “8”; select stop The bits are 1; select hardware (RTS/CTS). 2 Complete the transfer of MD2→Data1, using the “Drive 1 Drive X Drive Z”.3 format selection: Among them, 802D selects the binary data format; WinPCIN selects the binary data format→starts data reading.

(2) Transfer and status setting of the PLC program. Select "Simatic Manager" → "aptians" → "pc Adapter (MPI) (display)" → "properties" → "status". Among them, "PG/PC is the only maeter on the bes" is not selected; “0”; “Time-out” select “30S”; “Transmission Rate” select “187.5kbps”; “Highest Station Address” select “63”; Terminal 7 is set to “+24V”, and Terminal 15 is set to “ 0V".

According to the above data setting, and the machine data backup file is transferred and then restarted, all the machine alarms are eliminated, and the following test run and processing are performed at the same time.

(1) Return to the reference point operation and reset the adjustment as follows.

Start → Machine Data → Axis Parameters

34100→X→0; 34100→Z→1;

The first reference point sets X + 502 Z + 40 ; the second reference point sets X + 502 Z + 3480 ;

(2) Machine limit adjustment.

X axis: 10720 alarm; set bits 36100, 36110; Z axis: 16621 alarm; set bits 36100, 36110, 36120, 36130;

(3) When the workpiece is processed, the G54 offset setting problem occurs. Set as follows: G54 menu → zero offset → zero offset reference → modify the parameter setting.

After the above processing, the CNC system is restarted and the machined parts are tested, and the machine tool is completely restored.

Application example 2

CKW61100/3M CNC lathe SIEMENS802D system, machine tool feed AC servo drive, full closed loop control. The spindle is geared to achieve stepless speed regulation. The machine tool adopts SIEMENS PLC S7-300 logic controller to meet the control functions of the machine tool system. The machine adopts four-station electric rotary tool holder, and has CRT 10.4 "monochrome display, graphic display, tool compensation, fault diagnosis, simultaneous programming, Profibus interface and other functions.

During the operation of the machine tool: All the indicators of the 1MCP panel are strobed and output. The 2MMC and OP boards display normally, but the Plc ON Start alarm appears. The 3PLC/OUT output is not displayed, but the PLC/INPUT has an input display. 4 Infeed, spindle, etc. No action, there is indicator light alarm indication. The 5OP board plug connector has black signs, and the connection and communication are normal.

Cause analysis and recovery: Although there is no system alarm prompt, the fault phenomenon is relatively intuitive, and the indicator panel of the machine operation panel is strobed, indicating that there is a problem with the NC communication, and the PLC, F feed, and spindle S functions are abnormal. The analysis believes that the fault is related to the PLC program and the machine data. Because the system status cannot make adjustments to the machine data parameters, the method of re-transmitting the machine data backup file is adopted. The related settings and transmissions are the same as the application examples.

After the above measures are taken, the machine fault phenomenon is eliminated, but the following problems remain: 1 The spindle cannot be operated. 2 Tool T function is not normal. 3 There is a problem with the limit. The 4G54 offset bit is the same as the application example 1. Modify the following data settings: reset the tool T, spindle (Smin / Smax), (X, Z) axis limit bit function parameters, after modification, T function, spindle S function, (X, Z) axis limit function returns to normal The G54 offset setting is the same as the application example. After the above work is completed, the vehicle is re-commissioned, all the machine logs are eliminated, and the workpieces of the test pieces are completely restored.

It can be seen from the application example 1 and the application example 2 that although the phenomenon reflected by the machine tool is different, the cause of the problem is due to the loss of data of the machine tool system. The two machine tools are separated into two places, and in the southern region where the temperature is high and the humidity is high, it also appears in the hot high temperature season. In the process of two application examples, the same common problem is also exposed: the system data backup file is not complete enough, and the retransmitted file is different from the actual running state and needs to be re-adjusted. One of the machine data backups was invalid due to improper storage, and the data medium failed. As far as the numerical control system is concerned, it is necessary for the application unit to take necessary measures and prevent it from reacting to the adaptability of the high temperature and high humidity environment that it can withstand, and the impact on the use of the system and the machine tool.

The protection and backup of CNC machine tool system data is an indispensable task for CNC machine tool application enterprises. With the increasing popularity of CNC machine tools, it is very important for the system to understand the function, protection and recovery methods of system data. The normal operation of the machine tool and accurate grasp, quickly solve the problems in the machine tool application, ensure the safe and reliable operation of the machine tool, and improve the equipment utilization rate. At the same time, it also reflects that only a reasonable and correct application of CNC machine tools can make the system safer and the machine operation more reliable.