Functions of the
CNC PILOT 640
Comparison with the
CNC PILOT 4290

06/2021

CNC PILOT 640
The control for lathes and turning-milling machines

The CNC PILOT 640 is always the rightchoice, allowing you to produce individual
parts and series as well as simple andcomplex components with high efficiency,
flexibility, and reliability. The CNC PILOT 640
offers a wide range of functions that cover
not only the typical jobs of a conventional
lathe but also automated manufacturing
tasks. Programming directly on the control
is fast and easy, even while other machining
processes are in progress.
The CNC PILOT 640 provides intelligent
support, including:
3D simulation
Gain a reliable assessment of the results
prior to actual machining. The accurate,high-resolution 3D simulation of the
CNC PILOT 640 lets you see whether,where, and why errors are to be expected
and allows you to correct them before asingle chip has fallen.
Touchscreen
Intuitively operate the CNC PILOT 640
with gestures commonly used on mobile
devices. Simply select our 15.6-inch or

19-inch monitor with multi-touch functionality.
A full ASCII keyboard with a number pad isalso available for entering data.
smart.Turn
Create NC programs without needing toknow G-codes. All of the required parameters
are in user-friendly fillable forms illustrated
with context-sensitive help graphics.
TURN PLUS
At the touch of a button, you can generatea work plan, machining strategy, tool
selection, cutting data, and NC blocks foryour machining operation. You just needto specify the geometry, material, andchucking equipment. The CNC PILOT 640
automatically generates the NC program.

Main features of the CNC PILOT 640
Detailed simulation

Send and receive e-mails on the control.
Use the control to work directly with
Windows applications, such as CAD
programs. Forward status information in
paperless format from the control. This is
how you network your manufacturing
process from the design to the shippedcomponent with the shop floor as acommand center in the company network.

The timely recognition of errors isextremely important in NC programming.
With its graphic simulation feature, the
CNC PILOT 640 supports you in checking
the program for errors—with the real andexact dimensions of the contour andcutting edge, because the simulation
works with the geometry values from thetool database.

Compatibility
You can also run existing NC programsfrom old HEIDENHAIN lathe controls on
the CNC PILOT 640. With a convenient
import filter, you can easily transfer older
programs (e.g., from the CNC PILOT 4290)
to the new control for continued use.

Graphic simulation enables you to checkthe following already before machining:• Approach and departure behavior• The machining sequence• The proportioning of cuts
• The finished contour
In the graphic simulation you can also
display the tool cutting edge. You can viewthe cutting-edge radius, width, and position
rendered true to scale. This helps you
recognize machining details or collisionrisks in advance.

Connected Machining
The responsibility for component qualityand delivery date lies where the parts aremachined: on the shop floor. That is why
all information on machining has to cometogether here. And that is why you also needto have access to all relevant data from theshop floor and to apply your experience tothe process chain. This is where the featuresof Connected Machining support you.

3D simulation
The accurate, high-resolution 3D simulation
is particularly well suited for monitoring themachining results from turning, drilling, or
milling processes prior to actual machining,or to monitor the workpiece on the control’s
screen. The 3D simulation visualizes milling
and turning processes using different colors.
This also applies to complex multi-channel
operations. All workpieces are displayed,
as are the tool movements of all slides. The
rendered workpiece blank and finished partcan be rotated on all axes, thus permitting
visual inspection from any angle. With its
intuitive gesture control, you can navigate
and zoom into every programmed detail—of course even with C-axis contours on thecylindrical surface or face, and with Y-axis
contours in the tilted plane. In this way, the3D simulation enables you to detect eventhe smallest error before actual machining.

Your benefits:
Recognize critical tool movements
Identify unintended movement of thetool before machining
Minimize scrap
The detailed graphics let you recognize
unwanted machining effects early on
Find necessary changes quickly
Recognize turning and milling operations
at a glance
Complete simulation
Five-axis milling, turning, drilling, sinking,chamfering, and realistic thread depiction
Avoiding collisions
Realistic representation of the tool holder
in the simulation

Of course, the CNC PILOT 640 is alsoavailable with the tried and tested line
graphics, cutting-path graphics, andmovement simulation (material-removal
graphic) of the CNC PILOT 4290.

Windows 7, Windows 8, and Windows 10
are trademarks of Microsoft Corporation
Options are functions that are integrated
in the control and that allow you to tailor
the feature range of the CNC PILOT 640
to your actual requirements, including at
a later time. Some options need to beadapted by the machine manufacturer.
The features and specifications describedhere apply to the following control andNC software versions:
CNC PILOT 640 with NC software
versions
688946--08(export license required)
688947--08(export license not required)This brochure supersedes all previous
editions, which thereby become invalid.
Subject to change without notice.

23

Main features of the CNC PILOT 640
State-of-the-art multi-touch operation and clear-cut display

The CNC PILOT 640 is equipped with apractical touchscreen designed for harshshop conditions. It is splash-proof, scratchresistant, and features an IP54 protection
rating. The screen can be operated by meansof gestures such as those commonly usedon mobile devices.
The CNC PILOT 640 is available with two
screen formats. The 19-inch TFT color flat
screen is particularly suitable for large or
multi-channel machines that require alarger field of view.
The smaller screen in the 15.6-inch
widescreen format is particularly suitablefor compact machines. The widescreen
format ensures a clear overview of the
programs—particularly in programmingmode.
The CNC PILOT 640 gives you a clear
view of all the information you need forprograming, operating, and checking thecontrol and machine.

During program input, the required
parameters are illustrated in help graphics.
In the simulation, all movements of thetool are displayed in realistic detail. During
program run, the CNC PILOT 640 shows
you complete information on the tool
position, speed, and load of the drives,
as well as the current machine status.
The lathe controls from HEIDENHAIN were
impressing users with their innovative
9-block menu guidance long before theadvent of touchscreen operation. Here thenumeric keypad serves both for theselection of functions and for data input.
This makes fast one-handed operation
possible. However, the user interface design
based on this technique is also ideal for touch
operation. This enhances a simple andeffective operating technique with today's
touchscreen technology. The familiar input
via the ergonomically designed control panel
is fully continued in the CNC PILOT 640. At
the same time, you benefit from the same
intelligent gesture control you've learned
to use on your mobile devices.

Your benefits:
Effective operation
Through swiping (kinetic scrolling) in
NC programs, tables, and lists
Intuitive operation
Through gesture control, e.g., in the3D simulation
Easy to operate
Direct selection of operating elements,
soft-key rows, and navigation in menus
Practical touchscreen
Designed for harsh shopfloor conditions:splash-proof, scratch-resistant, and an
IP54 rating

SymbolGestureTap
Double tap

Programming
Effective, clearly organized and flexible

The smart.Turn principle
The working block—called a unit—plays apivotal role in smart.Turn programs. A unit
completely and unambiguously defines asingle working step. The unit includes thetool call, the technology data, the cycle call,the approach and departure strategies, andglobal data such as the safety clearance.
All of these parameters are displayed
together in a clearly structured dialog box.
The smart.Turn principle gives you thereassurance that the working block isdefined correctly and completely. In the
NC program, smart.Turn lists the unit’s
DIN PLUS commands. This gives you an
overview of all of the working-block details
at any time.
Clearly structured and easy-to-read—these
are the characteristics of smart.Turn
programs. smart.Turn uses section codesthat clearly distinguish between the program
head with setup information, the turretassignment, the workpiece blank andfinished part description, and the actualmachining operation.

Guided by the dialog, you enter thefollowing data in this sequence:• Program head
• Tool assignment in the turret• Description of workpiece blank• Description of finished part
• Individual machining steps
The smart.Turn method not only ensuresthat the program is easy to read; it also
makes it possible to save all of theinformation required for producing theworkpiece in the NC program.
TURN PLUS automatic program
generation
With its powerful TURN PLUS automatic
program generation, the control takes
you on the fast lane from the drawing to
the finished workpiece. After you havegraphically entered the workpiece blankand finished contour, or imported it froma DXF file, simply select the material andfixtures. TURN PLUS does everything else
automatically:• Analysis of the contours• Planning of the work strategy• Selection of tool data and cutting data
• Generation of NC blocks
As a result, you receive a complete andthoroughly commented NC program insmart.Turn format.

Your benefits:
Better readability of NC programs
Well organized and user-friendly depiction.
Program structure can be displayed in atree view
User-friendly programming
Dialog-guided fillable-form input withhelp graphics
Collection of technology data
Automatic collection and input oftechnology data into the respective workblock
Downward compatibility with existing
NC programs
Compatible with predecessor controls
through import filters for NC programs
Effective program creation with TURN
PLUS
Up to 90% time savings in programming
through analysis of the contours,
planning of the working strategy andselection of the tool or cutting data

Long press
Swipe
Technology data

Drag

Material
Speed

Two-finger dragFeed rate
Tools

Spread

Pinch

4

5

SetupTool measurement and workpiece measurement

Workpiece measurement
The CNC PILOT 640 features measuring
cycles for checking the geometry of themachined workpieces.
For the measuring cycles, you simply insert
a 3D touch probe from HEIDENHAIN into
the turret in place of a tool. With a touchprobe you can:• Check whether all machining operations
were conducted correctly• Determine infeeds for finishing• Detect and compensate for tool wear
• Inspect workpiece geometry and sortparts
• Log measured data
• Ascertain the machining trend
The HEIDENHAIN workpiece touch probe
systems help to reduce costs on the shop
floor and in serial production:
The setup, measurement, and inspection
functions can be executed automaticallywith the probing cycles of the
CNC PILOT 640.

6Tool measurement
Exact measurement of the tool dimensions
is a decisive factor for ensuring a consistently
high level of production quality. Tools can bemeasured for this purpose with a TT tool
touch probe from HEIDENHAIN before orafter a machining step.
Due to their rugged design and highprotection rating, these tool touch probes
can be installed directly within the machinetool’s work envelope, thereby enabling tool
measurement directly within the machine.
You can thus determine the tool dimensions
quickly, easily and, above all, very precisely.
The TT tool touch probes from HEIDENHAIN
are the ideal addition for improving theefficiency and quality of your production
system.

Your benefits:
Easy calibration
Fully automatic calibration of the touchprobe
Management of multiple touch probe
data sets
Transparent and central managementof touch probe data
Probe feed manipulation with overrideknob
Adjust the speed of probing without
affecting accuracy
Risk reduction
Avoid collisions in automatic mode andin manual operation

Program run
Manufacturing complex parts productively

The CNC PILOT 640 provides a solution
for any machining task and any machine
configuration: it performs complex machining
tasks with a C or Y axis. It also controls fullsurface cutting on dual-spindle machines.
On machines with a B-axis, machining in thetilted plane and even 5-axis simultaneousmachining are possible.
In multi-channel machining, multiple slides
simultaneously perform different machining
steps. Several workpieces can also be
machined at the same time, e.g., the front
side on one part and the back on the other.
These complex sequences require a perfectcoordination of the individual processing
steps.
A synchronization point analysis can be
conducted beforehand in the simulation,
which shows the time sequence ofworkpiece machining and the dependenceof slides among each other. The CNC
PILOT 640 calculates the productive, nonproductive, and waiting times, as well as all
tool changes and synchronization points.
These are clearly displayed in a separate
window.

Load Monitoring
The load monitor observes the machine’s
spindle and motor load while comparing
them with the utilization values of areference operation. You can set limit
values for the measured load. If thesevalues are exceeded, the CNC PILOT 640
can either stop the machining or continue
with a replacement tool.

tool life and prevention of visible transitions
during the grinding of complex contours.

Advanced Dynamic Prediction (ADP)
ADP expands the previous pre-calculationof the maximum feed rate profile, providing
optimized motion control for faultlesssurfaces and perfect contours, especially inmilling operations. The control dynamicallycalculates the contour in advance and cantherefore use an acceleration-limited motion
control with smoothed jerk to adapt theaxis velocity at contour transitions.

Component Monitoring
Through calculation of the mechanicalloads on the spindle bearing duringmachining, you can avoid additional costs
from unplanned machine downtime. You
can thereby protect machine components
from overloading without the need for
additional sensors.

Simultaneous turning
Easy programming and time-saving
machining of complex contours are possible
directly on the machine and without a
CAM system, with optimized production
processes and fewer tool changes.
Workpiece contours can be monitored
relative to the tool and tool holder, while thetilt angle at the start and end points of thecontour can be specified. The result: longer

Trochoidal milling
The trochoidal milling function gives you
prolonged tool life at higher feed rates andcutting depths, as well as lower machining
times. This function can be used in allmachining planes.

Your benefits:
Shorter machining times
Through asynchronous multi-channelmachining
Higher process reliability
Through spindle and axis supervision via
Load Monitoring
Optimal surface definition
Through particularly smooth and precise
tool movements thanks to ADP

7

Open for communication
Uniformly digital job management with Connected Machining

With Connected Machining, HEIDENHAIN
controls support a thoroughly digital job
management in production. Connected
Machining offers a set of solutions that
permit the exchange of information withall areas of the company that accompany
production.
The HEIDENHAIN DNC software interface
connects a control with resource planningand control console systems and to software
for machine and production data collection
systems. The CNC PILOT 640 provides
comprehensive data as the basis for
decisions in enterprise management via
the DNC interface.
With Remote Desktop Manager, themachine operator can easily and safely
use all data and information available inthe company by directly accessing thecompany's PCs and servers. Of course,
he can also send feedback to all process
participants. Direct networking with theorder processing department is particularly
advantageous. By doing so, the machine
operator can save time by directly processing
job-related information, such as completion
notifications, on MES/ERP portals madeavailable for this purpose.

8

The PC software StateMonitor provides
an easy-to-read overview of machine data
in production. The machine’s efficiency canbe ascertained through the evaluation ofimportant data such as current machine
status, override settings, and the usage
history. Based on the collected data, it
indicates the available optimization potential
and, if necessary, e-mails a notification if a
machine is down or a malfunction occurs.
Extended Workspace enables the machine
operator to work in parallel on the machineand on job management. He simply
connects a second screen with the control
via Ethernet and configures it as an additional
screen. The control can then open PDFs,
3D data, DXF data, DXF files, or Remote
Desktop Manager on a second screen.

Your benefits:
Windows-based applications righton your control
Operate PC systems or manage job
ordersIncreased competitiveness throughoptimized information flow
Gaps in information cost valuable timeand resources. Optimize your data flowon the CNC PILOT 640
Using PC functions without reductionof machine performance
No negative effect on the control fromremote accessHigher production efficiency
Continuous data exchange andcoordinated processes enableeconomical production
Numerous functions provided as
standard features
Even without options, you can use the
CNC PILOT 640 to improve many
processes on the shop floor

Comparison of functions of the CNC PILOT 640
New functions compared with the CNC PILOT 4290

Functions

Brief description

Touch operation

Quick and easy operation by fingertip

Practical touchscreens for:• Intuitive gesture control• Effective operation through swiping (kinetic
scrolling)• Easy navigation in menus

Programming(general)Import of MANUALplus cycle programs

Import and automatic conversion of DIN and cycle
programs

Programmable secondary axes U, V, and W

Simultaneous movement of NC and secondary
axes in the NC program

Eccentric machining and non-circular turning(G725, G726, G727)

Eccentric turning of out-of-round contours without
any additional special mechanical provisions

Face milling (G797)

Milling various figures as islands

Helical slot milling (G798)

Milling of slots with any desired thread pitch

Bore milling (G75)

Milling holes of any desired diameter

Contour thread (G38)

Manufacturing threads without form tools

Simultaneous turning with the B axis (G891, G895)

Roughing and finishing of complex contours ina single stepMultiple plunging (G860)

Expansion of recessing: automatic distribution ofrecesses, taking the recessing width into accountTrochoidal milling (G847, G848)

Efficiently machine pockets with different shapes(circle, rectangle, and polygon) and any slots

Programmable misalignment compensation (G976)

Conical machining or compensation of mechanicaloffsetProgrammable fluctuating spindle speed (G924)

Reduction of resonance during shaft machining

LIFTOFF with NC stop

Safe retraction without workpiece damage, evenduring thread cutting

Names for milling, drilling, and boring contours

Designation of contour parts with freely definablenames to use them in cycles

Definition of milling patterns for free contours

Creating linear or circular patterns with any contours

Cycle extensions

Additional cycle functionality:• Aligning the proportioning of cuts to contour edges• Entering a dwell time in spindle revolutions

Expanded subprogram interface

Transferring string parameters in subprograms andprogramming return values

Expanded variable programming

String operations, e.g., for engraving dates and/or
times

Teach-in mode with blank form update

Machining workpieces step-by-step, thereby
generating a program9

Programming withsmart.Turn

Programming with
TURN PLUS

Simulation

Functions

Brief description

Functions

Brief description

UNIT programming

Structured programming with function blocks

Probing cycles for tool measurement in manual
operation

Calibrating tools with the TT tool touch probe

OEM UNIT and OEM menu

Integrating complete UNITs and menu trees of themachine tool builder into the editing interface

Touch probe cycles in NC programs for workpiecemeasurement

Comprehensive touch probe cycles for:• Datum shift• Tool compensation• Additive correction• Logging

NC program with tree view

Clear depiction of long and complex programs

Generating programs with TURN PLUS

Generating a complete program with functional
blocks (UNITs)

Interactive tool selection

Convenient selection and adjustment of tools
during automatic program creation

Quick-change tool holder

Shortens setup and tool-change times

Tool-holder database

Edit frequently used TURN PLUS parameters in aneasy-to-read dialog box

Acquisition of geometric data on tools, e.g., for the
3D holder graphic

Operating-parameter dialog

Tool filter for tool selection or tool search

3D simulation graphics

Display programmed contours as a 3D graphic
before machining

Comprehensive filter capabilities for fast searches
in the tool table

Tool-magazine management

3D holder graphic

Depicting the tool holder in the 3D machining
simulation

3D simulation

3D simulation for turning, boring, drilling, and milling
operations:• Accurate, high-resolution view
• Section view can be moved• Realistic depiction of threads• Start block can be specified• Genuine C-axis movements• Display mode for engraving• Color scheme based on machining operation(turning / milling)• Simultaneous depiction of multiple contour
groupsSpecial functions for tool magazines:• Magazine pocket management for chain, manual,and circular tool magazines• Support of tool preselection• Tool change in mid-program startup• Loading and unloading during setup

Tool-specific speed limitation

Assign a permissible maximum rotational speed
for each tool

Tool texts

Freely definable additional texts for each tool

Load Monitoring

Detect tool wear and breakage during machining

Component Monitoring

Monitoring of machine components for overloading
and wear

HEIDENHAIN-DNC

Interface for communication between NC andexternal PC applications

Remote Desktop Manager

Display and remote operation of external computer
units, e.g., a Windows PC

HEIDENHAIN StateMonitor

Evaluation tool for all important data such asmachine status, machine messages, etc.

Support of handwheels with display

HR 550 FS and HR 520 (FS)State Reporting Interface (SRI)Interface for convenient reporting of machine
operating statuses for a higher-level MDA or PDA
systemProgram-run graphics

Real-time graphical simulation

Graphical depiction of the current machining
operation

Setup

Touch probe cycles

Touch probe cycles in setup mode:• Touch probe cycles for datum and tool
measurement• Calibrating the TT tool touch probe

LAC weighing cycle

Program run

10

Function G239: load ascertainment for LAC (Load
Adapt. Control) load-dependent adjustment ofcontrol parameters (option 143)

Advanced Dynamic Prediction (ADP)

Optimized motion control for perfect surfaces andcontours, particularly for milling operations

Thread recutting

Repair and rework of threads

Batch mode

Automatic execution of several different main
programs, e.g., bar loader operation, loading by
robotsFive-axis machining

Milling for free-form surfaces

Measuring

Tool management

Monitoring functions

Connectivity

11

Improvements formachine manufacturers

Functions

Brief description

Improved functions compared with the CNC PILOT 4290

Tool identification

Support of tool identification systems

Programming

SQL tables

SQL tables defined by the machine manufacturer
for expert programs or PLC functions

Functional safety (FS)Integrated functions in hardware and software that
support the machine manufacturer in compliancewith EN ISO 13849, “Safety of machinery — Safetyrelated parts of control systems”

Gantry axes

Position and/or torque coupling of NC axes

Simulation

Integrated PLC software development environment Convenient control-integrated development anddiagnostic environment for the PLC user program
PLC window

Display PLC window with Python

Integrated TNCdiag motor diagnostics

Diagnostic possibilities of the entire drive train of
the supply unit, inverter, and motors up to theconnected encoders

Modern computer hardware

Improvements for themachine tool builder

Powerful processors on the NC and CC for
compute-intensive functions

ICP contour programming

Contour programming selectable in DIN orgraphically (equally editable in both display modes)

Recessing cycles with multiple planes

The desired plunging depth can be limited by anadditional parameter

Measuring spindle angular offset (G906)

Replaced by G905

Spindle parting control (G991, G992)

Replaced by G917

2-D simulation

Color marking highlights the areas currently beingmachined by the tool

Tool carrier depiction

Any tool carriers, e.g., turrets or B-axis heads, canbe displayed in the 2-D graphic

PLC and commissioning

Various tools for diagnosis and commissioning areavailable, e.g., TNCopt, ConfigDesign, PLCdesign

Machine display (dashboard)

Display elements for datum shift, display of thecurrent kinematics, FS status, etc.

Editing of the machining sequence

Expanded capabilities for definition of the machining
sequence in TURN PLUS

Definition of multi-edges

Simple definition of tools with multiple edges in thetool editor

Interpreter instead of compiler

Programs can now be started immediately. A
previous compiler run is no longer necessary

Realizing compensations

Tool and additive compensation values are realized
in a movement immediately after a start. The
CNC PILOT 4290 realized compensations gradually
over the entire traverse distance

Clamping fixture description

The clamping devices are described directly in the
program. A clamping table is no longer required

Tool life management

The sequence of exchange is defined in the
NC program. The CNC PILOT 4290 defined thesequence in the turret table

Variable programming with expanded functions

All variables are evaluated during run time. There isno need to distinguish between D and V variables.
In addition, new functions are available forrequesting states internal to the control

Differences in function

12

13

Overview

CNC PILOT 640
NC SW 68894x-08

CNC PILOT 4290
(in the latest software version)Max. 24 drives

Max. 10 drives• Teach-In mode

Option–• smart.Turn

–• DIN PLUS• Interactive Contour Programming (ICP)• DXF Import

OptionOption• TURN PLUS

OptionOptionMachining time analysis

Tool and workpiece measurement

OptionOptionC-, Y-, and B-Axis Machining

Options

Options5-axis machining with X, Y, Z, B, C

Option–ADP for high surface quality

–

Parallel axes (U, V, W)

–Counter Spindle

OptionOptionMulti-channel capability(up to three channels for asynchronous
multi-slide machining)

OptionOptionEccentric and non-circular turning

OptionOption3D simulation

–

Load Monitoring

OptionOptionAdvanced synchronization of axes
and spindles

Option–Magazine management



LimitedTools and Technology

OptionOptionUser administration

–Connected Machining–Component Monitoring

Option–State Reporting

Option–Lathes and turning-milling machines
Program entry

14

15

Mastering nanometer accuracy

DR. JOHANNES HEIDENHAIN GmbH
Dr.-Johannes-Heidenhain-Straße 583301 Traunreut, Germany +49 8669 31-0
 +49 8669 32-5061
info@heidenhain.dewww.heidenhain.com
1224137-21 · 3 · 06/2021 · H · Printed in Germany

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