September 2011

iTNC 530

New Functions with
NC Software 340 49x-07

2

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 plain-

language 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 user-

friendliness 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.

New Functions with NC Software 340 49x-07
—The iTNC 530 Makes Working with the Machine Even Easier

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.

3

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.

4

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.

The Future is Now
—Graphic Selection of Contours and Contour Sections (Option)

5

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.

6

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 defi ned 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 fi nishing.

Roughing operations with multiple steps

are not possible. The machining strategy

can be chosen fl exibly: 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.

7

—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).

8

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.

9

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 (comma-

separated 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.

10

Overview
—All Options in NC Software 340 49x-07

Option
number

Option

As of NC
software
340 49x-

ID

Comment

0
1
2
3
4
5
6
7

Additional axis

01

354 540-01

353 904-01

353 905-01

367 867-01

367 868-01

370 291-01

370 292-01

370 293-01

Additional control loops 1 to 8

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

Slovenian

Slovak

Latvian

Norwegian

Korean

Estonian

Turkish

Romanian

Lithuanian

11

Option
number

Option

As of NC
software
340 49x-

ID

Comment

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

07

751 653-01 Cycle for interpolation turning

12

Overview
—New Functions with NC Software 340 49x

Operating mode

As of NC sof

tw

ar

e

Standar

d

FCL

Option

Function

Independent of
operating mode

340

49x

-02

40 DCM: Dynamic collision monitoring (only with MC 422 B, MC 422 C)

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

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)

13

Operating mode

As of NC sof

tw

ar

e

Standar

d

FCL

Option

Function

Independent of
operating mode

340

49x

-04

•

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

•

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

340

49x

-05

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

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

14

Operating mode

As of NC sof

tw

ar

e

Standar

d

FCL

Option

Function

Independent of
operating mode

340

49x

-06

92 3D-ToolComp: 3-D radius compensation depending on the tool’s contact angle

•

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

340

49x

-07

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)

15

Operating mode

As of NC sof

tw

ar

e

Standar

d

FCL

Option

Function

smarT.NC

340

49x

-02

42 Direct loading of contours from DXF data and saving as smarT.NC contouring programs

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

340

49x

-03

42 DXF data processing:

Separation of laterally joined contour elements

•

Generate point files (.HP files) directly from the DXF converter

•

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

16

Operating mode

As of NC sof

tw

ar

e

Standar

d

FCL

Option

Function

smarT.NC

340

49x

-03

•

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

340

49x

-04

•

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

340

49x

-05

42 DXF data processing:

POLYLINE support

•

Selection of machining positions with the mouse, including path optimization

•

•

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

17

Operating mode

As of NC sof

tw

ar

e

Standar

d

FCL

Option

Function

smarT.NC

340

49x

-06

•

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

•

340

49x

-07

•

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)

18

Operating mode

As of NC sof

tw

ar

e

Standar

d

FCL

Option

Function

Conversational
programming

340

49x

-02

42 Direct loading of contours from DXF data and saving as conversational programs

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

•

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

19

Operating mode

As of NC sof

tw

ar

e

Standar

d

FCL

Option

Function

Conversational
programming

340

49x

-04

•

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

•

48 KinematicsOpt: Touch probe cycles for automatic measurement of rotary axes

340

49x

-05

•

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

48 Improvements to KinematicsOpt:

Improved logging in Cycle 450

•

Time savings through shortening of the probing paths

•

Automatic presetting

•

Hiding individual rotary axes

•

340

49x

-06

•

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

•

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Operating mode

As of NC sof

tw

ar

e

Standar

d

FCL

Option

Function

Conversational
programming

340

49x

-07

•

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)

DIN/ISO

340

494-02

•

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

340

494-04

•

Support for Windows Vista

•

iTNC programming station available with network license

340

494-06

•

Support for Windows 7

*I_842 239-21*

842 239-21 · 10 · 9/2011 · F&W · Printed in Germany