Monitoring tasks
A monitoring task consists of the following properties:
- Signal (e.g., spindle current)
- Procedure for evaluating the signal (e.g., waveform comparison)
- One or more parameters (e.g., tolerance), depending on the selected procedure
- Reactions (e.g., stopping the NC program)
The control contains pre-defined monitoring tasks.
Refer to your machine manual.
The following monitoring tasks are included in the standard scope and have been configured by HEIDENHAIN. The machine manufacturer cannot modify these monitoring tasks, but can define further monitoring tasks.
For each monitoring section, you can define up to six monitoring tasks. The control displays the monitoring tasks in the Form column as graphs.
Graphic display of the monitoring tasks
- The Form column with graphs of the monitoring tasks
If the tables of the monitoring tasks are active in the run-time table, the control displays the graphs of the monitoring tasks in the Form column. The control displays the values of the selected recordings in the graphs.
During program run, the control always displays the momentary values for the monitoring tasks.
Each graph represents the machining operation as a resulting value or signal curve. The signal curve additionally shows the reference machining operations used as well as a vertical axis with the relevant unit. The time axis is divided into seconds, or into minutes for longer monitoring sections.
If the control cannot evaluate a monitoring task, it displays the graph with gray hatch marks. If you click or tap this gray hatched area, the control opens a window. In this window the control shows reasons for why the monitoring task was not evaluated.
Icons of monitoring tasks
- Graph as resulting value relative to the error limit
- Graph as non-evaluated signal curve with tunnel
The graphs of the monitoring tasks contain the following icons:
Icon | Meaning |
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The control displays the icon for the monitoring task. The icon is a combination of the signal and the procedure. If you select the icon, the control opens a selection window where you can modify or remove the monitoring task. | |
Open or close the Settings for parameterization | |
Change Signal representation You can change between the following signal representations:
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Reset scaling Show graph of the entire monitoring section Tip If the icon is dimmed, the control displays the entire graph. | |
Rectangular color icons are automatic assessments by process monitoring. The control displays the worst resulting value of the entire monitoring section, regardless of the visible area of the graph. |
Using the graphs
- You can zoom in or out of the graph horizontally by scrolling or dragging.
- You can shift the graph by swiping or while pulling with the left mouse button pressed.
- The control marks the selected NC block number within the graph by a vertical green line.
- If you double-click or double-tap a position within the graph, the control selects the corresponding NC block in the NC program and in the graph.
Overview of monitoring tasks
The table below contains an overview of the monitoring tasks. Detailed information about the following properties can be found in the content below:
The first six monitoring tasks are the standard HEIDENHAIN monitoring tasks. If you or the machine manufacturer have not defined any templates, these monitoring tasks are active by default in a new NC program or monitoring section. You can also modify the monitoring tasks.
The control provides the following monitoring tasks:
Icon | Meaning | ||||||||||
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Spindle current — Tunnel
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Spindle current — Display
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Perpendicular lag — Constant
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Feed-Override — Constant
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Spindle override — Constant
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Spindle current — Waveform Comparison
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Feed per tooth — Display
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Perpendicular servo lag — Tunnel
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Parallel lag — Constant
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Parallel servo lag — Tunnel
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Testing signal — Display Machine This monitoring task is intended for test purposes and should be used only if requested by HEIDENHAIN or by the machine manufacturer!
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Testing signal — Waveform Comparison Machine This monitoring task is intended for test purposes and should be used only if requested by HEIDENHAIN or by the machine manufacturer!
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Testing signal — Tunnel Machine This monitoring task is intended for test purposes and should be used only if requested by HEIDENHAIN or by the machine manufacturer!
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Procedure
Process monitoring offers the following procedures:
- Waveform comparison
- Tunnel
- Display
- Constant
Waveform comparison
In the Waveform comparison procedure, the control compares the current signal wave with the recordings of good parts at short time intervals. If the wave deviates too strongly, the monitoring task identifies a potential fault. A long-term signal drift will not modify the waveform and will therefore not cause any reaction.
In this procedure, the control will not display any error limits in the signal run.
1 | These recordings are assessed as good parts and are used as reference machining operations. | |
2 | Machining with a slight deviation For one machining operation, the signal waveform deviates slightly from the reference machining operations. In the other machining operation, the signal strength deviates from the reference machining operations, but the waveform is identical. These machining operations do not trigger a reaction. | |
3 | Machining with a heavy deviation The waveform of this machining operation deviates heavily from the previous records and will trigger the configured reactions. |
Tunnel
Using the Tunnel procedure, the control monitors whether the parts produced by the current machining operation are within the range of the previously selected good parts, including the tunnel width.
This method reacts to both short-term changes and long-term signal drifts. A short-term change may be due to tool breakage, for example. A long-term drift may originate from a change in temperature, for example.
The tunnel width limits can be defined by the following values:
Value | Graph |
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Absolute, static tolerance (e.g., tunnel width 30 A) The gray lines represent the reference machining operations | |
Percentage deviation from the reference machining operations (e.g., 30 %) | |
Multiple of the standard deviation σ of the reference machining operations (e.g., 3 x σ) |
1 | Error limits The error limits result from the total of all three possible values. | |
2 | Machining with a slight deviation This machining operation deviates slightly from the previous recordings, but is still within the error limits. | |
3 | Machining with a significant deviation This machining operation deviates considerably from the previous recordings. The machining operation exceeds the error limit and triggers the configured reactions after the defined hold time has elapsed. | |
4 | Hold time If the value is below or above the error limits, the control triggers the configured reactions after the defined hold time has elapsed. |
Display
In the Display procedure, the control displays the run of the selected signal of current machining. The control does not carry out any reactions, you can only check the recording visually.
Constant
In the Constant procedure, the control monitors if the current machining is within the defined error limits. The error limits result from the defined tolerances which are independent of the signal. This makes the monitoring task perform monitoring with this procedure starting from the first machining operation, and does not require any assessments of recordings.
Reactions
Refer to your machine manual.
The machine manufacturer can define further reactions.
If a signal exceeds the error limits for longer than the defined hold time, the monitoring task can execute one or more reactions.
You can define the reactions in the following locations of the Process Monitoring workspace:
- Form column if the setup table is active
- Settings for the parameterization of each monitoring task
You can choose from the following reactions, depending on the monitoring task:
Reaction | Meaning |
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Trigger warning | The control displays a warning in the notification menu. |
Trigger NC stop | The control stops the NC program. You can then check the machining status. If you find that there is no serious error, you can resume the NC program. The control reactivates process monitoring in the next monitoring section. |
Abort program run | The control stops the NC program. In this case, the NC program cannot be resumed. Machine The machine manufacturer can define the behavior of the control in connection with pallet machining in case a program is aborted (e.g., continue machining the workpieces on the next pallet). |
Lock the tool | The control blocks the tool in the tool management. |
Settings for parameterizing of monitoring tasks
Use the Settings icon in a monitoring task to change its parameterization.
- Parameterization of a monitoring task
When selecting the settings of a monitoring task, the control displays two areas:
- Parameterization of selected recording
The control dims the parameterization that was active at the time of the selected recording.
- Preview of current parameterization
The control displays the current parameterization for the monitoring task. When changing the settings, the control displays which effects the changes have on the selected machining operation.
The control uses a colored box icon to highlight the worst resulting value in the visible range. To see the worst resulting value of the entire monitoring section, display the entire graph.
The settings of monitoring tasks contain the icons and buttons below:
Icon or button | Meaning |
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Apply | Restore values from the left view |
Cancel | Reject parameterization changes |
OK | Save changes to the parameterization |
Open You can load an existing monitoring template for the selected monitoring task. | |
Save You can save the parameterization of the current monitoring task as a template. You can use the monitoring templates for other monitoring sections or in other NC programs as well. The control saves the template under a user-defined name in the TNC:/system/Processmonitoring folder. The control displays six templates in alphabetical order in the global settings. These six templates will be used for new monitoring sections or NC programs. |
Basics of operation
- You can also use the left and right arrow keys to change the setting of the slider.
- For parameterization, you can select the Signal display icon to toggle between the unevaluated signal run and the resulting value, relative to the error limits.
- It may be necessary to adjust the parameterization to the machining operation (e.g., when decreasing the tunnel width for finishing operations).
- With the Perpendicular servo lag — Tunnel monitoring task and an absolute, static tolerance, you can check a size tolerance compared to reference machining.