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The sensors are the "eyes and ears" of the ToolScope. The device observes processes by observing the sensor data curve.

It uses start and stop signals, which are provided to it as sensor data, to detect the start or end of a process to be monitored. The ToolScope receives these signals by evaluating which G commands (e.g. G1) are active or when the user sets M commands in the NC program.

Last but not least, a minimum of one sensor signal must be available, which is expected to change its course in the event of an error. The main spindle's torque generally serves this purpose.

Quick guide

The ToolScope input data must contain information that indicates which process is currently running, so that the ToolScope can distinguish between different processes. These signals are received from the control system. The default ToolScope configuration in control systems allows for certain data to be transferred to the monitoring automatically. This data is:

  • The name of the current program (as "Program name" signal),

  • The name of the current tool (as "Tool name" signal).

The "Trigger" signal switches from "0" to "1" when a certain M command (default M800) occurs. It is reset by a different M command (default: M801). M800 starts the monitoring. M801 stops the monitoring.

Detailed guide

M commands to generate triggers and counters

In the device's user interface, there are three sensor signals at your disposal, whose content you can control using M commands from the NC program. You can use these to identify processes, or to signal the start or stop of a monitoring process to the ToolScope.

The signals in question are:

  • Trigger
  • Trigger (2)
  • Counting

The below figure shows how these signals can be selected in the configuration view of a monitoring algorithm.

 

Selection of start / stop conditions

 

The following M commands act on the following signals:

 

M command

Acts on signal

M800, M801

Trigger ON / OFF

M802, M803

Counting ON / OFF

M806, M807

Trigger (2) ON / OFF

M808, M809

Automatic trigger ON / OFF

M814

Transfers the program name to ToolScope (only for Siemens)

M815

Transfers the GUD variable "BRINKHAUS" to ToolScope as the tool name (Siemens only)

 

All signals can, completely independently of each other, be sent from the control system to the ToolScope and read out here. However, the following interactions exist:

If the "Counting" signal is switched on, the ToolScope counts the positive flank change of the "Trigger" signal. The result is provided as the "Counter" signal.

 

Interaction of "Counting", "Trigger" and "Counter" signals

 

The "Trigger", "Counting" and "Counter" signals are deleted following an NC reset (  //   ) or program end (M30).

Marking of processes in the NC program

Based on the content of data channels, the ToolScope recognizes which process is currently running in the machine. If the values of these channels match a learned process, this process is recognized by monitoring.

Four of these channels can be programmed as character strings. In the ToolScope, these channels are called "Program", "Tool", "ID" and "Processing", as standard.

Depending on the machine manufacturer, some of these strings are set automatically by the control system in the standard implementation of a ToolScope.

 

On Siemens control systems, the content of these channels can be set manually by the NC command (NC cycle)

TS_SETSTRING(INT STRING_NO, STRING[32] CONTENT)

 

On Heidenhain control systems, an FN19 call-up is required:

FN19: XXX, STRING_NO

Only numbers can be transferred via FN19 (Heidenhain).

 

The field STRING_NO determines which string is set:

Content of STRING_NO

Overwritten character string

1

Tool

2

Program

3

ID

4

Processing

 

Other channels can be overwritten on Siemens control systems via H commands (Siemens) or macro variables (Fanuc). The following assignment applies:

 

H command
(Siemens)

Macro variable (Fanuc)

Transfer automatically (Heidenhain)

Small Profibus image

Name in large Profibus image (from PLC 4.0, 2 / 4 channels)

H93=XXX

(1…16777216)

automatic

(free)

(unused)

Row no. (1…4294967295)
 

H94=XXX
(1…65535)

#104
(1…99999999)

(free)

(unused)

Tool type (1…65535)

H95=XXX
(1…127)

#105
(1…99999999)

(free)

(unused)

Axis no.
(1…127)

H96=XXX
(1…16777216)

#106
(1…99999999)

(free)

Program no. (1…65535)

Program no.
(1…4294967295)

H97=XXX
(1…16777216)

#107
(1…99999999)

Line no.
(1…65535)

Processing no. (1…65535)

Processing no. (1…4294967295)

H98=XXX
(1…16777216)

#108
(1…99999999)

Tool no.
(1…65535)

Tool number (1…65535)

Tool no. (1…4294967295)

H99=XXX
(1…16777216)

#109
(1…99999999)

(free)

Process ID (1…65535)

Cutting edge no. (1…4294967295)

 

The value ranges of numbers >65535 are dependent on your control system and the machine manufacturer. In the Siemens default configuration in particular, it is not possible to transfer values greater than 2^24-1 = 16777216 using H commands; changeable with Siemens MD22110; MD22110=1 results in 1…2147483648. Using Fanuc macro variables, you can transfer maximum 8-digit numbers to the device.

The content of all data channels is deleted by an NC reset (  //  ) or by a program end (M30).

Process identification

The ToolScope monitoring functions recognize a process again if the following data is the same:

  • Program number, program (*)
  • Tool number, tool (*)
  • Axis
  • Tool type
  • Value of counter
  • Processing number, processing
  • ID

Processes that are to be checked for similarity, must have the same combination of the above-mentioned data channels.

It does not matter which of these channels you use to identify your process. It is only important that the ToolScope recognizes different processes based on different values of the same combinations of data.

The rows marked with (*) are data channels that are transferred to the ToolScope fully automatically on many machine tools.

NC code compatibility with other monitoring systems

KOMET®  BRINKHAUS provides an NC command with which the above-mentioned data channels can be automatically set to the correct value at the start of processing. This command also guarantees increased NC code compatibility with some competitors.

In general, the NC command is:

BRINKHAUS_ON(

INT Programmnumber, INT Toolnumber,

INT Processnumber, INT Process-ID)

 

The command sets the data channels specified in brackets..

If the command precedes a processing sequence, the ToolScope will apply the data specified in brackets.

To reset the counters, insert the command

BRINKHAUS_OFF()

at the end of your processing sequence.

 

Hint: As many competitors do not evaluate the program name, tool name, etc., they provide the user with a system of program numbers, tool numbers, etc. To monitor these, they provide NC commands which program these numbers.

By renaming and slightly modifying the "BRINKHAUS_ON" and "BRINKHAUS_OFF" commands to the syntax of the respective competitor, you can use NC codes that were written for these competitors with the ToolScope too.

Use of NC data (e.g. torque)

The ToolScope reads some sensor data directly from the control system. The data that is read out depends on the type of control system and the design of the machine tool.

This sensor data is configured when the monitoring is commissioned and can only be influenced by service personnel.

The most important information obtained in this way is the torque of the main spindle.

Use of analog and digital inputs

You can use analog and digital inputs freely.

For information e.g. about the input range of the modules, see their knowledge base entries.

Manual input of process identifiers with "Set Process ID"

ToolScopes and SoftScopes can be configured in such a way that data, with which processes are identified, can be entered manually. If this is configured accordingly, the "Set process ID" softkey is available during monitoring.

The "Set process ID" softkey can only be selected if the checkmark next to "Activate 'Set process ID' softkey" is set under "Service / Settings / Base / Display".

 

Example for "Set process ID"

 

Once you have pressed the "Set process ID" softkey, a window will be displayed in which you can overwrite individual signals.

 

Window for overwriting different signals

 

Press the "Previous element" / "Next element" softkeys to select the element in which entries can be made.

The content of fields next to which a checkbox has been selected overwrites the signals set by the machine control system or other signal sources. The ToolScope can also be configured in such a way that the checkboxes and corresponding values are not displayed.

In the above figure, a program number 4711 was selected as an example. Your selection is applied when you press the OK button.