Fundamentals

Application

If you want to approach a position in the machine's working space while the guard door is open or if you execute a small infeed movement, you can use the electronic handwheel. The electronic handwheel allows you to traverse the axes and perform various functions provided by the control.

Requirement

  • Electronic handwheel (e.g., HR 550FS)
  • The control supports the following electronic handwheels:

    • HR 410: Cable-bound handwheel without display
    • HR 420: Cable-bound handwheel with display
    • HR 510: Cable-bound handwheel without display
    • HR 520: Cable-bound handwheel with display
    • HR 550FS: Wireless handwheel with display, data transmission via radio

Description of function

You can use electronic handwheels in Manual or Program Run operating mode.

The HR 520 and HR 550FS portable handwheels feature a display that allows the control to show different types of information. You can use the handwheel soft keys for setup functions, such as the setting of presets or the activation of miscellaneous functions.

Once you have activated the handwheel with the handwheel activation key or the Handwheel toggle switch, you can operate the control only by using the handwheel. If you press the axis keys in this state, the control will display the message Handwheel active: Handwheel-1, MB0.

If you select Manual operating mode, the control deactivates the handwheel.

If more than one handwheel is connected to a control, you can activate or deactivate a handwheel only by pressing the handwheel activation key on the respective handwheel. You need to deactivate the active handwheel in order to be able to select another handwheel.

Functions in Program Run operating mode

You can perform the following functions in Program Run operating mode:

  • The NC Start key (NC Start handwheel key)
  • The NC Stop key (NC Stop handwheel key)
  • After you have pressed the NC Stop key: Internal stop (handwheel soft keys MOP and then Stop)
  • After you have pressed the NC Stop key: Manual traverse of axes (handwheel soft keys MOP and then MAN)
  • Return to the contour after axes were manually traversed during an interruption of the program run (handwheel soft keys MOP and then REPO). The handwheel soft keys are used for operating.
  • Returning to the contour

  • Switch on/off the "Tilt working plane" function (handwheel soft keys MOP and then 3D)

Operating elements of an electronic handwheel

An electronic handwheel provides the following operating elements:

1

EMERGENCY STOP key

2

Handwheel display for status and for selecting functions

3

Handwheel soft keys

4

Axis keys; can be exchanged by the machine manufacturer depending on the axis configuration

5

Permissive button

The permissive button is on the rear side of the handwheel.

6

Arrow keys for defining the handwheel resolution

7

Handwheel activation key

You can activate or deactivate the handwheel.

8

Axis-direction key

Key for the direction of the traverse motion

9

Rapid traverse override for the traverse motion

10

Spindle switch-on (machine-dependent function, key can be exchanged by the machine manufacturer)

11

Generate NC block key (machine-dependent function, key can be exchanged by the machine manufacturer)

12

Spindle switch-off (machine-dependent function, key can be exchanged by the machine manufacturer)

13

CTRL key for special functions (machine-dependent function, key can be exchanged by the machine manufacturer)

14

NC Start key (machine-dependent function, key can be exchanged by the machine manufacturer)

15

NC Stop key

Machine-dependent function; key can be exchanged by the machine manufacturer

16

Handwheel

17

Spindle speed potentiometer

18

Feed rate potentiometer

19

Cable connection; not required for the HR 550FS wireless handwheel

Contents of an electronic handwheel display

The display of an electronic handwheel consists of the following areas:

    1

    Handwheel is in the docking station or radio mode is active

    Only with HR 550FS wireless handwheel

    2

    Field strength

    Six bars = maximum field strength

    Only with HR 550FS wireless handwheel

    3

    Charging condition of battery

    Six bars = maximum charging condition. A bar moves from the left to the right during recharging.

    Only with HR 550FS wireless handwheel

    4

    X+50.000: Position of the selected axis

    5

    *: Control in operation; program run has been started or axis is in motion

    6

    Handwheel superimpositioning from M118 (#21 / #4-02-1)

    Activating handwheel superimpositioning with M118 (#21 / #4-02-1)

    7

    S1000: Current spindle speed

    8

    Feed rate at which the selected axis is moving

    The control displays the current contouring feed rate while the program is running.

    9

    E: Error message

    If an error message appears on the control, the handwheel display shows the ERROR message for three seconds. Then the letter E is shown in the display as long as the error is pending on the control.

    10

    Active setting in the 3-D rotation window:

    • VT: function Tool axis
    • WP: function Basic rotation
    • WPL: 3D ROT function

    The 3-D rotation window (#8 / #1-01-1)

    11

    Handwheel resolution

    Distance that the selected axis moves per handwheel revolution

    Handwheel resolution

    12

    Incremental jog active or inactive

    If the function is active, the control will display the active traverse step.

    13

    Soft-key row

    The soft key row provides the following functions:

    • AX: Select the machine axis
    • Creating a positioning block

    • STEP: Incremental jog positioning
    • Incremental jog positioning

    • MSF: Execute various functions of the Manual operating mode (e.g., entering the feed rate F)
    • Entering miscellaneous functions M

    • OPM: Select the operating mode
      • MAN: Manual operating mode
      • MDI: MDI application in Manual operating mode
      • RUN: Program Run operating mode
      • SGL: Single Block mode of the Program Run operating mode
    • MA: Switching the magazine pockets

    Handwheel resolution

    The handwheel sensitivity specifies the distance an axis moves per handwheel revolution. The handwheel sensitivity results from the defined handwheel speed of the axis and the speed level used internally by the control. The speed level describes a percentage of the handwheel speed. The control calculates a specific handwheel sensitivity value for each speed level. The resulting handwheel sensitivity values are directly selectable with the handwheel arrow keys (only if incremental jog is not active).

    The handwheel speed indicates the increment (e.g., 0.01 mm) traversed per handwheel detent position. You can change the handwheel speed with the handwheel's arrow keys.

    If you have defined a handwheel speed of 1, the following handwheel resolutions are available:

    Resulting handwheel sensitivity levels in mm/revolution and degrees/revolution: 0.0001/0.0002/0.0005/0.001/0.002/0.005/0.01/0.02/0.05/0.1/0.2/0.5/1

    Resulting handwheel sensitivity levels in inches/revolution: 0.000127/0.000254/0.000508/0.00127/0.00254/0.00508/0.0127/0.0254/0.0508/0.127/0.254/0.508

    Examples for resulting handwheel sensitivity values:

    Defined handwheel speed

    Speed level

    Resulting handwheel sensitivity

    10

    0.01%

    0.001 mm/revolution

    10

    0.01%

    0.001 degrees/revolution

    10

    0.0127%

    0.00005 inches/revolution

    Effect of the feed-rate potentiometer when handwheel is active

     
    Notice
    Caution: Possible damage to the workpiece!
    When toggling between the machine operating panel and the handwheel, the feed rate may be reduced. This can cause visible marks on the workpiece.
    1. Make sure to retract the tool before toggling between the handwheel and the machine operating panel.

    The settings of the feed-rate potentiometer on the handwheel may differ from those on the machine operating panel. When you activate the handwheel, the control automatically activates the feed-rate potentiometer of the handwheel. When you deactivate the handwheel, the control automatically activates the feed-rate potentiometer of the machine operating panel.

    In order to make sure that the feed rate does not increase while you switch between the potentiometers, the feed rate is either frozen or reduced.

    If the feed rate before switching is higher than the feed rate after switching, the control automatically reduces the feed rate to the smaller value.

    If the feed rate before switching is less than the feed rate after switching, the control automatically freezes the feed rate. In this case, you must turn the feed-rate potentiometer back to the previous value because the activated feed-rate potentiometer will only then be effective.

    Entering spindle speed S

    To enter the spindle speed S by using an electronic handwheel:

    1. Press the handwheel soft key F3 (MSF)
    2. Press the handwheel soft key F2 (S)
    3. Select the desired spindle speed by pressing the F1 or F2 key
    4. Press the NC Start key
    5. The control activates the entered spindle speed.
     
    Tip

    If you press and hold the F1 or F2 key, the control will increase the counting increment by a factor of 10 each time it reaches a decimal value of 0.

    By additionally pressing the CTRL key, you can increase the counting increment by a factor of 100 when pressing F1 or F2.

    Entering the feed rate F

    To enter the feed rate F by using an electronic handwheel:

    1. Press the handwheel soft key F3 (MSF)
    2. Press the handwheel soft key F3 (F)
    3. Select the desired feed rate by pressing the F1 or F2 key
    4. Load the new feed rate F with the handwheel soft key F3 (OK)
     
    Tip

    If you press and hold the F1 or F2 key, the control will increase the counting increment by a factor of 10 each time it reaches a decimal value of 0.

    By additionally pressing the CTRL key, you can increase the counting increment by a factor of 100 when pressing F1 or F2.

    Entering miscellaneous functions M

    To enter a miscellaneous function by using an electronic handwheel:

    1. Press the handwheel soft key F3 (MSF)
    2. Press the handwheel soft key F1 (M)
    3. Select the desired M function number by pressing the F1 or F2 key
    4. Press the NC Start key
    5. The control activates the miscellaneous function

    Overview of miscellaneous functions

    Creating a positioning block

     
    Machine

    Refer to your machine manual.

    Your machine manufacturer can assign any function to the Generate NC block handwheel key.

    To create a positioning block by using an electronic handwheel:

      1. Select the Manual operating mode

      1. Select the MDI application
      2. If necessary, select the NC block after which the positioning block should be inserted
      3. Activate the handwheel

      1. Press the Generate NC block key on the handwheel
      2. The control inserts a straight line L, including all of the axis positions.

      Incremental jog positioning

      Incremental jog positioning allows you to move the selected axis by a preset value.

      To incrementally position an axis by using an electronic handwheel:

      1. Press the handwheel soft key F2 (STEP)
      2. Press the handwheel soft key 3 (ON)
      3. The control activates incremental jog positioning.
      4. Set the desired jog increment by using the F1 or F2 keys
      5.  
        Tip

        The smallest possible increment is 0.0001 mm (0.00001 inches). The largest possible increment is 10 mm (0.3937 inches).

      6. Confirm the selected jog increment by pressing the handwheel soft key F4 (OK)
      7. Use the + or - handwheel key to move the active handwheel axis in the corresponding direction
      8. The control moves the active axis by the entered increment every time the handwheel key is pressed.
       
      Tip

      If you press and hold the F1 or F2 key, the control will increase the counting increment by a factor of 10 each time it reaches a decimal value of 0.

      By additionally pressing the CTRL key, you can increase the counting increment by a factor of 100 when pressing F1 or F2.

      Notes

       
      Danger
      Caution: hazard to the user!
      Unsecured connections, defective cables, and improper use are always sources of electrical dangers. The hazard starts when the machine is powered up!
      1. Devices should be connected or removed only by authorized service technicians
      2. Only switch on the machine via a connected handwheel or a secured connection
       
      Notice
      Caution: Danger to the tool and workpiece!
      The wireless handwheel triggers an emergency stop reaction if the radio transmission is interrupted, the battery is fully empty, or if there is a defect. Emergency stop reactions during machining can cause damage to the tool or workpiece.
      1. Place the handwheel in the handwheel holder when it is not in use
      2. Keep the distance between the handwheel and the handwheel holder small (pay attention to the vibration alarm)
      3. Test the handwheel before machining
      • The machine manufacturer can provide additional functions for the HR5xx handwheels.
      • Refer to your machine manual.

      • You can use the axis keys to activate the X, Y, and Z axes, as well as three other axes that can be defined by the machine manufacturer. Your machine manufacturer can also place the virtual axis VT on one of the free axis keys.
      • If the handwheel is active, the control shows a symbol next to the selected axis in the Positions workspace. The symbol indicates whether you can move the axis with the handwheel.
      • The Positions workspace

      •  
        Machine

        Refer to your machine manual.

        The machine manufacturer defines which axes you can move with the handwheel.