SinuTrain 6.3 Counter-Spindle Setup for Lathe Machines

SinuTrain 6.3 Edition 3 is the Siemens PC-based training and programming environment for the SINUMERIK 840D sl / ONE platform. It mirrors the HMI, NC kernel behavior, and PLC interface of the production controller so that part programs written and validated on the office PC run identically on the shop-floor CNC. Configuring a counter-spindle (also called a sub-spindle or opposing spindle) on a turning center requires more than a normal 2-axis lathe template: the machine database (MMC / CF card image) must expose a second spindle axis, a second channel for synchronous operations, and the matching technology cycles. This article consolidates the version-specific installation steps, G-code programming patterns, multichannel coordination rules, and Y-axis integration paths required to bring a counter-spindle lathe online inside SinuTrain 6.3 Edition 3.

1. SinuTrain 6.3 Edition 3 Architecture Overview

SinuTrain 6.3 is the third major release branch of the SinuTrain product line aligned with the SINUMERIK 840D sl SW 4.x / 6.x generation controllers. Edition 3 (Ed 3) corresponds to the Operate HMI generation that introduces the modernized HMI sl-style sidebar, the run-MyScreens extensibility API, and the SINUMERIK Integrate cross-platform commissioning tools.

Refer to the official Programming counter-spindles in G-code - SINUMERIK PDF for the canonical description of how the second spindle is positioned, synchronized, and used to receive the part from the main spindle.

2. Counter-Spindle Kinematics in SINUMERIK

The counter-spindle is a fully functional second spindle mounted on a linear axis (typically Z2 or a dedicated slide) that travels along the Z axis. It is more than a tailstock: it has its own spindle motor, chuck, and speed/position control loops. From a programming standpoint it behaves like a second main spindle with synchronized Z-axis travel.

Key machine-data slots that must be enabled for counter-spindle operation:

3. Prerequisites

Before adding a counter-spindle machine to SinuTrain 6.3 Edition 3, confirm the following:

1. License. The counter-spindle machine setup file is a separately orderable item. It is normally supplied as an archive (*.arc) or as a prebuilt CF-card image. The base SinuTrain 6.3 DVD does not include counter-spindle data.
2. Windows workstation. Windows 10 / 11 x64 (1809 or newer) or Windows Server 2016 / 2019. The SinuTrain installer requires .NET Framework 4.7.2 and Visual C++ 2015-2022 redistributable. Administrator rights are required to install the HMI sl services.
3. Disk space. Minimum 25 GB free for the base product, technology cycles, and machine data images. A counter-spindle machine with full ShopTurn macro library can reach 8-12 GB per machine slot.
4. Display. 1920x1080 minimum. Operate HMI scales poorly below 1366x768; counter-spindle channel overview panels need at least 1680x1050.
5. Language packs. SinuTrain 6.3 Ed 3 supports German, English, French, Italian, Spanish, Chinese (simplified), Japanese, and Korean. If any additional language has been installed, it must be re-installed after loading the counter-spindle machine archive to refresh the new text resources for the second channel.
6. PLC program. The PLC part of the counter-spindle archive (STEP 7 project) is loaded into the PLCSIM instance that SinuTrain 6.3 starts together with the NCK simulator. The PLC handles the chuck and part-catcher I/O.

4. Installing the Counter-Spindle Machine Archive

Two installation paths are common in the field. Use whichever matches the file you received from the OEM.

4.1 Path A: Setup Arc loaded from the HMI

1. Start SinuTrain 6.3 Edition 3 and select the Commissioning area.
2. Navigate to System data > Setup archives > Read in.
3. Select the counter-spindle setup file (typically counter_spindle_<OEM>_v<xx>.arc).
4. Confirm the import; the NCK is restarted automatically.
5. Verify that the channel overview now shows a second channel with a spindle symbol.

4.2 Path B: Prebuilt CF-card image

1. Locate the cf_card folder of the counter-spindle machine directory.
2. Copy the contents into %ProgramData%\Siemens\Automation\SinuTrain\SinuTrain_6_3_Ed3\HMI\cf_card.
3. Restart the HMI service. SinuTrain reads the new directory tree on the next launch and updates the machine picker.
4. If multiple languages were previously installed, re-run the language pack setup to refresh the resources for the newly added channel.

5. Configuring the Second Channel

SinuTrain 6.3 Ed 3 supports a maximum of two channels in the standard counter-spindle license, with up to 12 axes total. Verify the channel configuration by opening Commissioning > Channels > Channel assignment:

When the machine archive is loaded, the channel overview in Operate HMI shows both channels side-by-side, and Show channel assignment lists the axis-to-channel mapping. The counter-spindle channel can be programmed either with G-code or with ShopTurn programGUIDE.

5.1 Spindle Numbering and Setpoint Routing

The default address mapping uses S1 for the main spindle and S2 for the counter-spindle. Program commands are therefore:

S1=1500 M3   ; main spindle, CW, 1500 rpm
S2=2000 M3=2 ; counter-spindle, CW, 2000 rpm (M3=2 selects spindle 2)

If the machine builder uses a non-standard mapping, override the spindle number in MD 30134 or in the SETMS / SETMS(2) instruction inside the part program.

6. G-Code Programming for Counter-Spindle Operations

The canonical Siemens reference for counter-spindle G-code is the Programming counter-spindles in G-code - SINUMERIK PDF. The four core operations are: position, clamp, transfer, and retract.

6.1 Approach the Counter-Spindle to a Safe Pickup Position

G0 Z2=10.   ; counter-spindle slide to Z2=10 (stand-off)
G0 Z2=2.     ; approach to pickup

6.2 Open the Main Spindle Chuck and Close the Counter-Spindle Chuck

M0 ; or shopTurn macro call
M11 ; main spindle chuck open (manufacturer-specific M-code)
M72 ; counter-spindle chuck close (manufacturer-specific M-code)

6.3 Pull the Part Out and Synchronize

COUPON(S2, S1, 1)    ; couple counter-spindle to main spindle, ratio 1:1, both CW
SPOS=0                ; orient both spindles to 0 deg
G0 Z2=-50.            ; pull part out of main spindle

6.4 Reverse Coupling and Machining on the Reverse Side

COUPOF(S2, S1)     ; decouple
M73 ; counter-spindle chuck open
M10 ; main spindle chuck close
S2=3000 M3=2         ; counter-spindle becomes the active spindle

6.5 Retract the Counter-Spindle

The full cycle - approach, transfer, retract - is normally wrapped in a manufacturer cycle (CYCLE975 or a ShopTurn "Counter-spindle" macro). Engineers writing free-form G-code can call the cycle directly:

Argument list (see cycle reference):

1. Operation tag: "TRANSFER" / "STROKE" / "EJECT"
2. Source spindle: 1 = main, 2 = counter
3. Stroke length (mm)
4. Pull-out feed (mm/rev)
5. Target spindle: 1 or 2
6. Lead-in approach distance
7. Lead-out retract distance
8. Chuck-clamp mode
9. Safe Z name (string parameter from the setup file)

7. Multichannel Programming

For machines that run the main and counter-spindle operations simultaneously - for example, machining the back side of one part while the next blank is being turned on the main spindle - the program runs across both channels. Siemens supports this with the SETINT, WAITM, WAITE, and START commands.

Reference material: Turn-milling with counterspindle, multichannel from Siemens CNC4you.

7.1 Parallel Channels Example

INIT(2, "_N_PROG2_MPF")     ; initialize channel 2 with program PROG2
START(2)                     ; start channel 2
; Channel 1 continues:
G0 X50. Z50.
WAITM(10, 1, 2)              ; both channels wait for marker 10
M30

Markers coordinate handoffs. SETM(10) on one side and WAITM(10,1,2) on the other side creates a strict rendezvous. Loose synchronization is done with WAITE(2) (wait for channel 2 to terminate) or WAITM with a marker tag.

8. Y-Axis Integration

Many modern turning centers add a Y-axis to the turret to allow off-center drilling, milling, and slotting, sometimes combined with a Y-axis on the counter-spindle slide to support fully back-side machining. SinuTrain 6.3 Edition 3 supports both, but the Y-axis must be enabled in the machine archive and the kinematics configured before the operator can use it.

Y-axis enabling steps:

1. Load the counter-spindle + Y-axis machine archive (a separate option from the basic counter-spindle archive).
2. Confirm MD 20050 contains the Y geometry axis assignment; for a turret Y, it is usually on channel 1; for a counter-spindle Y, on channel 2.
3. Configure the swivel-data block MD 62500 to MD 62574 for the Y-axis orientation frame (TCARR / TCOFR).
4. Calibrate the Y-axis with the standard axis-commissioning procedure (axis plus / minus references, software-limit switches, and the spindle-centers offset).
5. Verify the kinematics by jogging through G18 / G19 plane changes and confirming that X, Y, Z offsets match the machine tool reference point.

9. Tool Management with Two Spindles

Each spindle has its own work offsets and the tool list is global. The tool-management screen in Operate HMI allows the user to assign each tool to a spindle ("Main", "Counter", or "Both"). Turret tools that are used by the counter-spindle must be loaded with the correct Spindle assignment flag set in the tool list; otherwise the runtime will not move the turret across the counter-spindle Z2 range and the program will fail with alarm 61282 ("Tool not assigned to active spindle").

9.1 Recommended Tool-List Schema

10. Simulation and Verification

Before running the program on the shop-floor controller, validate it inside SinuTrain 6.3 using the built-in 3D simulation view. The counter-spindle HMI extension adds:

• Live spindle-2 speed and torque trace
• Counter-spindle Z2 position overlay on the main view
• Chuck-state LEDs (open / closed / unclamped)
• Channel cross-reference (which blocks of which program are active in each channel)

10.1 Verification Checklist

1. Run a dry run with DRYRUN enabled and rapid override at 5%.
2. Confirm both spindles reach the programmed RPM (verify with the HMI readouts; S1 and S2 should be in tolerance within +/- 2%).
3. Step the part-transfer cycle block-by-block; verify COUPON and COUPOF execute without alarm 16770 "Coupling not allowed".
4. Check the chuck-state bits on the PLC diagnostics screen.
5. Run a full part-cycle in 3D simulation; visually confirm no collisions between the main-spindle tooling, the turret, and the counter-spindle slide.
6. Save a settings backup via Commissioning > Create setup archive once the verification is complete.

11. PLC Interface for the Counter-Spindle

The PLC part of the counter-spindle archive is a STEP 7 project that ships with the machine data. The key I/O addresses for the chuck and the parts catcher are exposed on the PLCSIM instance that runs alongside SinuTrain. Use the STEP 7 watch table to confirm the bit states during commissioning:

Exact DB and byte offsets vary by machine builder. Confirm with the OEM-supplied symbol table before any field debugging.

12. Troubleshooting

13. Commissioning Procedure Summary

Bringing a counter-spindle lathe online inside SinuTrain 6.3 Edition 3 follows a five-step loop:

1. Install the counter-spindle machine archive (or the counter-spindle + Y-axis archive).
2. Re-install all language packs to refresh the HMI text resources for the second channel.
3. Power-cycle the NCK and PLCSIM, then re-check the channel overview.
4. Load the part program, dry-run at 5% rapid override, and step the transfer cycle.
5. Save a settings backup; document the MD differences relative to the base 2-axis configuration for future machine rollouts.