OSP-P200M/P200MA/P20M, OSP-P200M-R/P200MA-R/P20M-R
INSTRUCTION MANUAL
(7th Edition)
SAFETY PRECAUTIONS
The machine is equipped with safety devices which serve to protect personnel and the machine itself from hazards arising from unforeseen accidents. However, operators must not rely exclusively on these safety devices: they must also become fully familiar with the safety guidelines presented below to ensure accident-free operation.
This instruction manual and the warning signs attached to the machine cover only those hazards which Okuma can predict. Be aware that they do not cover all possible hazards.
1.
Precautions Relating to Installation
(1) Please be noted about a primary power supply as follows.•
Do not draw the primary power supply from a distribution panel that also supplies a major noise source (for example, an electric welder or electric discharge machine) since this could cause malfunction of the CNC unit.•
If possible, connect the machine to a ground not used by any other equipment. If there is no choice but to use a common ground, the other equipment must not generate a large amount of noise (such as an electric welder or electric discharge machine).(2) Installation Environment
Observe the following points when installing the control enclosure.
•
Make sure that the CNC unit will not be subject to direct sunlight.•
Make sure that the control enclosure will not be splashed with chips, water, or oil.•
Make sure that the control enclosure and operation panel are not subject to excessive vibrations or shock.•
The permissible ambient temperature range for the control enclosure is 5 to 40°C.•
The permissible ambient humidity range for the control enclosure is related humidity 50% or less at 40°C (no condensation).•
The maximum altitude at which the control enclosure can be used is 1000 m (3281ft.).2.
Points to Check before Turning on the Power
(1) Close all the doors of the control enclosure and operation panel to prevent the entry of water, chips, and dust.
(2) Make absolutely sure that there is nobody near the moving parts of the machine, and that there are no obstacles around the machine, before starting machine operation.
(3) When turning on the power, turn on the main power disconnect switch first, then the CONTROL ON switch on the operation panel.
3.
Precautions Relating to Operation
(1) After turning on the power, carry out inspection and adjustment in accordance with the daily inspection procedure described in this instruction manual.
(2) Use tools whose dimensions and type are appropriate for the work undertaken and the machine specifications. Do not use badly worn tools since they can cause accidents.
(3) Do not, for any reason, touch the spindle or tool while spindle indexing is in progress since the spindle could rotate: this is dangerous.
(4) Check that the workpiece and tool are properly secured.
(5) Never touch a workpiece or tool while it is rotating: this is extremely dangerous.
(6) Do not remove chips by hand while machining is in progress since this is dangerous. Always stop the machine first, then remove the chips with a brush or broom.
(7) Do not operate the machine with any of the safety devices removed. Do not operate the machine with any of the covers removed unless it is necessary to do so.
(8) Always stop the machine before mounting or removing a tool.
(9) Do not approach or touch any moving part of the machine while it is operating. (10) Do not touch any switch or button with wet hands. This is extremely dangerous.
(11) Before using any switch or button on the operation panel, check that it is the one intended.
4.
Precautions Relating to the ATC
(1) The tool clamps of the magazine, spindle, etc., are designed for reliability, but it is possible that a tool could be released and fall in the event of an unforeseen accident, exposing you to dan-ger: do not touch or approach the ATC mechanism during ATC operation.
(2) Always inspect and change tools in the magazine in the manual magazine interrupt mode. (3) Remove chips adhering to the magazine at appropriate intervals since they can cause
misoper-ation. Do not use compressed air to remove these chips since it will only push the chips further in.
(4) If the ATC stops during operation for some reason and it has to be inspected without turning the power off, do not touch the ATC since it may start moving suddenly.
5.
On Finishing Work
(1) On finishing work, clean the vicinity of the machine.
(2) Return the ATC, APC and other equipment to the predetermined retraction position. (3) Always turn off the power to the machine before leaving it.
(4) To turn off the power, turn off the CONTROL ON switch on the operation panel first, then the main power disconnect switch.
6.
Precautions during Maintenance Inspection and When
Trouble Occurs
In order to prevent unforeseen accidents, damage to the machine, etc., it is essential to observe the following points when performing maintenance inspections or during checking when trouble has occurred.
(1) When trouble occurs, press the emergency stop button on the operation panel to stop the machine.
(2) Consult the person responsible for maintenance to determine what corrective measures need to be taken.
(3) If two or more persons must work together, establish signals so that they can communicate to confirm safety before proceeding to each new step.
(4) Use only the specified replacement parts and fuses.
(5) Always turn the power off before starting inspection or changing parts.
(6) When parts are removed during inspection or repair work, always replace them as they were and secure them properly with their screws, etc.
(7) When carrying out inspections in which measuring instruments are used - for example voltage checks - make sure the instrument is properly calibrated.
(8) Do not keep combustible materials or metals inside the control enclosure or terminal box. (9) Check that cables and wires are free of damage: damaged cables and wires will cause current
leakage and electric shocks.
(10) Maintenance inside the Control Enclosure
a. Switch the main power disconnect switch OFF before opening the control enclosure door. b. Even when the main power disconnect switch is OFF, there may some residual charge in
the MCS drive unit (servo/spindle), and for this reason only service personnel are permitted to perform any work on this unit. Even then, they must observe the following precautions.
•
MCS drive unit (servo/spindle)c. The control enclosure contains the NC unit, and the NC unit has a printed circuit board whose memory stores the machining programs, parameters, etc. In order to ensure that the contents of this memory will be retained even when the power is switched off, the memory is supplied with power by a battery. Depending on how the printed circuit boards are han-dled, the contents of the memory may be destroyed and for this reason only service per-sonnel should handle these boards.
(11) Periodic Inspection of the Control Enclosure a. Cleaning the cooling unit
The cooling unit in the door of the control enclosure serves to prevent excessive tempera-ture rise inside the control enclosure and increase the reliability of the NC unit. Inspect the following points every three months.
•
Is the fan motor inside the cooling unit working?The motor is normal if there is a strong draft from the unit.
•
Is the external air inlet blocked?If it is blocked, clean it with compressed air.
7.
General Precautions
(1) Keep the vicinity of the machine clean and tidy.
(2) Wear appropriate clothing while working, and follow the instructions of someone with sufficient training.
(3) Make sure that your clothes and hair cannot become entangled in the machine. Machine opera-tors must wear safety equipment such as safety shoes and goggles.
(4) Machine operators must read the instruction manual carefully and make sure of the correct pro-cedure before operating the machine.
(5) Memorize the position of the emergency stop button so that you can press it immediately at any time and from any position.
(6) Do not access the inside of the control panel, transformer, motor, etc., since they contain high-voltage terminals and other components which are extremely dangerous.
(7) If two or more persons must work together, establish signals so that they can communicate to confirm safety before proceeding to each new step.
8.
Symbols Used in This Manual
The following warning indications are used in this manual to draw attention to information of particu-lar importance. Read the instructions marked with these symbols carefully and follow them.
indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
indicates a potentially hazardous situation which, if not avoided, may result in minor or moder-ate injury.
indicates a potentially hazardous situation which, if not avoided, may result in damage to your property.
indicates general instructions for safe operation.
DANGER
WARNING
CAUTION
CAUTION
TABLE OF CONTENTS
SECTION 1 AUTOMATIC TOOL LENGTH OFFSET/AUTOMATIC TOOL
BREAKAGE DETECTION FUNCTION ...1
1. Overview... 1
1-1. Displaying the Result of Gauging ... 2
1-2. Function Menu... 3
2. Automatic Tool Length Offset/Automatic Tool Breakage Detection Operation... 9
2-1. Setting the Touch Sensor Zero Point ... 10
2-2. Setting the Tool Pot No./Tool No. Table... 16
2-3. Operation Mode Designation... 17
2-4. Automatic Tool Length Offset Function ... 19
2-5. Setting the Tool Change Position (Other Than MC-H) ... 23
2-6. Automatic Tool Breakage Detection ... 24
2-7. Cycle Time Reduction for Automatic Tool Length Offset/Automatic Tool Break-age Detection Cycle ... 29
2-8. New Cycle Time Reduction Function for Automatic Tool Length Offset/Auto-matic Tool Breakage Detection Cycle ... 31
3. Automatic Tool Length Offset/Automatic Tool Breakage Detection Function for Special Tools and Attachments ... 35
3-1. Automatic Tool Length Offset/Automatic Tool Breakage Detection Function for Horizontal Tools of MCM ... 35
3-2. Operation for Automatic Tool Length Offset/Automatic Tool Breakage Detec-tion on B/C-axis Attachments, 90° Angular Attachments and Extension Attach-ments (Option)... 42
3-3. Operation of Automatic Tool Length Offset/Automatic Tool Breakage Detec-tion with 30° Angular Attachments (OpDetec-tion)... 51
3-4. Operation of Automatic Tool Length Offset/Automatic Tool Breakage Detec-tion with 45° Angular Attachments (OpDetec-tion)... 63
4. Y-axis Escape Position (MCM-B/MCR-B II/MCR-A/VH-40)... 75
4-1. Setting the Y-axis Escape Position... 75
4-2. Tool Movements during Automatic Tool Length Offset (Cutter Radius Com-pensation)/Automatic Tool Breakage Detection Cycle ... 76
5. Interference Prevention Measures for MCV-A/MCV-A II During Execution of the Automatic Tool Length Offset/Automatic Tool Breakage Detection Cycle... 78
5-1. Touch Sensor Operation Interlock... 78
5-2. Measures against Interference during Execution of the Automatic Tool Length Offset/Tool Breakage Detection Cycle ... 78
6. Variables Used in Subprograms ... 80
6-1. Table of Subprograms and Variables ... 80
6-2. Table of Subprograms and Variables (MCM Horizontal Tools) ... 83
6-3. How to Use Variables ... 86
7. Cautions on Operation... 94
8. Program Examples ... 97
8-2. Automatic Tool Breakage Detection ... 99
9. Alarm List... 102
SECTION 2 AUTOMATIC GAUGING FUNCTION...109
1. Overview... 109
1-1. Dimension Check Function... 109
1-2. Automatic Zero Offset Function... 109
2. Operation of the Automatic Gauging Function... 110
2-1. Setting the Datum Hole Zero Point... 111
2-2. Touch Probe Radius Compensation... 113
2-3. Touch Probe Length Offset ... 119
2-4. Inner Diameter (ID) Gauging Function ... 121
2-5. Outer Diameter (OD) Gauging Function ... 123
2-6. End Face Gauging Cycle... 126
2-7. Saving of Gauging Cycle Results ... 132
2-8. Calculating the Center and Distance between Two Points... 133
2-9. Calculating the Center and Distance between Two End Faces ... 135
2-10.Automatic Zero Offset Function... 138
2-11.Copying the Touch Probe Offset Data... 139
3. Automatic Gauging Function for B-/C-axis, 90° Angular and Extension Attach-ments (Option) ... 140
3-1. Automatic Gauging for 90° Angular Attachment and B-/C-axis Attachment (PAB=90°)... 142
3-2. Automatic Gauging for Extension Attachment and B-/C-axis Attachment (PAB=0°)... 143
3-3. Automatic Gauging for Millac 800 VH and Millac 1000 VH ... 144
4. Power ON/OFF Cycle of the Touch Probe ... 147
4-1. Power ON/OFF Cycle Operation ... 148
5. Details... 151
5-1. Touch Probe Movements ... 151
5-2. Approach Speed to the Workpiece... 154
5-3. Dwell Time in Work Gauging ... 156
5-4. Reducing Time before Movement of Touch Probe... 156
5-5. Variables Used in Subprograms... 157
6. Touch Probe Safety Measures ... 171
6-1. Checking Proximity Switch Operation ... 171
6-2. Replacing the Touch Probe Battery... 172
7. Supplementary Information... 173
8. Program Examples ... 175
8-1. ID Gauging ... 175
8-2. OD Gauging... 176
8-3. End Face Gauging on Z-axis... 177
8-4. Distance between End Faces (X-axis direction)... 178
8-6. Example Program for MCM Horizontal Spindle ... 180
9. Examples of Gauging Result Display ... 183
10.Alarm List... 186
10-1.Alarm List... 186
10-2.Gauging Impossible Cause Code Chart (Alarm B 2305)... 188
SECTION 3 GAUGING DATA OUTPUT TO FILE...194
1. Outline ... 194
2. Parameters ... 194
2-1. NC Optional Parameter Bit ... 194
3. Designation of Displaying Device ... 195
4. Print Command... 195
4-1. System Variables for Printing ... 196
SECTION 4 MANUAL GAUGING ...197
1. Overview... 197
1-1. Specifications ... 197
1-2. Overview of Manual Gauging Functions... 198
1-3. List of Display Screens ... 202
2. Basic Operation ... 203
3. Preparation for Gauging ... 204
3-1. Preparation for Work Gauging/Tool Length Gauging Cycles ... 204
3-2. Preparation for Cutter Radius Compensation Cycle... 211
4. Work Gauging... 213
4-1. End Face Gauging (X, Y, Z) ... 213
4-2. I.D. Center Gauging... 218
4-3. O.D. Center Gauging... 223
4-4. Internal Faces Center Gauging ... 230
4-5. External Faces Center Gauging ... 244
4-6. Inclination and Corner Gauging... 258
5. Tool Length Gauging ... 267
6. Cutter Radius Gauging ... 270
7. Comparison and Calculation of Gauging Results ... 273
7-1. Transferring Gauging Results... 273
7-2. Comparison with Gauging Data... 275
7-3. Example of Calculation Results Display ... 276
8. Error List ... 279
SECTION 5 INTERACTIVE GAUGING FUNCTION...281
1. Specifications... 281
2. List of Display Screen ... 282
3-1. Interactive Gauging Operation Panel ... 283
4. Terminology ... 284
5. Basic Operation ... 285
6. Outline of Interactive Gauging Function ... 286
7. Work Gauging Function ... 292
7-1. PARAMETER (WORK) Screen ... 292
7-2. PREPARATION (WORK) Screen... 293
7-3. X, Y, Z END FACE ... 299
7-4. I.D. CENTER ... 303
7-5. O.D. CENTER ... 307
7-6. INT END CENTER ... 310
7-7. EXT END CENTER ... 313
7-8. INCLINE, CORNER... 316
8. Tool Length Gauging ... 319
8-1. Parameter (Tool Length) ... 319
8-2. Preparation (Tool Length)... 321
8-3. Tool Length Gauging ... 324
9. Other Supplementary Explanations ... 327
10.Operation Flow ... 329
11.Error List ... 330
SECTION 6 NON-CONTACT SENSOR CALCULATION FUNCTION ...332
1. What is Non-contact Sensor? ... 332
2. Outline ... 333
3. Maker’s Subprogram in the Movable Sensor Mode... 334
4. Maker’s Subprogram in the Fixed Sensor Mode ... 353
5. Maker’s Subprogram for Gauging a Vertical Spindle Tool in the Fixed Sensor Mode... 354
6. Maker’s Subprogram for Gauging a Horizontal Spindle Tool in the Fixed Sensor Mode... 370
7. List of Alarms ... 385
SECTION 7 NON-CONTACT SENSOR GAUGING FUNCTION FOR
HORI-ZONTAL MC...386
1. What is Non-contact Sensor? ... 386
2. Outline ... 387
3. Gauging with the Fixed Sensor... 387
4. Each Manufacturer’s Subprogram for the Fixed Sensor... 388
5. List of Alarms ... 406
SECTION 8 SPECIAL BARRIER FUNCTION FOR HORIZONTAL MC ...407
1. Outline ... 407
2-1. Parameter Setting... 407
2-2. Setting Items... 408
2-3. Barrier Range Setting Example ... 409
2-4. Barrier Alarm and Resetting Method ... 409
3. Alarms... 410
3-1. Alarm A... 410
SECTION 9 NON-CONTACT SENSOR GAUGING FUNCTION FOR
MCR-AF ...411
1. What is Non-contact Sensor? ... 411
2. Outline ... 412
3. Manufacturer’s Subprogram for the Fixed Sensor... 412
4. Manufacturer’s Subprogram for Gauging Vertical Spindle Tools with the Fixed Sen-sor... 413
5. List of Alarms ... 432
SECTION 10NON-CONTACT SENSOR GAUGING FUNCTION FOR 30°/
45° AT (103 VERSIONS) ...433
1. What is Non-contact Sensor? ... 433
2. Outline ... 434
3. Manufacturer’s Subprogram for the Fixed Sensor... 435
4. Manufacturer’s Subprogram for 30°/45° AT Tool Gauging by the Fixed Sensor ... 436
SECTION 1 AUTOMATIC TOOL LENGTH OFFSET/
AUTOMATIC TOOL BREAKAGE
DETEC-TION FUNCDETEC-TION
1.
Overview
The automatic tool length offset/automatic tool breakage detection function automatically calculates the tool offset data and detects breakage (chipping) of tools such as drills, taps, reamers and boring bars.
The specifications of this function are classified into the following two types.
•
Specifications for automatic tool length offset only, and•
Specifications for automatic tool length offset and automatic tool breakage detectionA touch sensor is mounted in the machine: a tool mounted in the spindle is brought into contact with this touch sensor to determine the tool offset data and to detect if the tool has been broken.
For tools which are mounted and removed without using the ATC, refer to the section Tool Manage-ment Function in the special specifications of the Operation Manual.
(1) Automatic Tool Length Offset
With the tool length offset function, the tool mounted in the spindle is brought into contact with the touch sensor to calculate the tool length. A subprogram prepared for this purpose is used for this operation.
(2) Automatic Tool Breakage Detection
With the automatic tool breakage detection function, the same contact detection cycle as used for the tool length offset function is executed to obtain the tool length.
The function compares the obtained tool length with the tool length offset data stored in the CNC memory to judge if the tool has been broken.
1-1.
Displaying the Result of Gauging
Display the screen that displays the gauging result (GAUGING RESULTS screen) by following the steps indicated below.
Procedure :
1
Select an operation mode (automatic, MDI, manual).2
Press function key [F8] (DISPLAY CHANGE). The DISPLAY CHANGE window opens.3
In the DISPLAY CHANGE window, select “GAUGING RESULTS”.4
Press function key [F8] (CLOSE).The GAUGING RESULTS screen, shown below, is displayed.
1-2.
Function Menu
The function menu switches as shown below to display the functions relating to the gauging result when the extend key, to the right of function key [F8] (DISPLAY CHANGE), is pressed.
ME61012R0700300030001
When the extend key is pressed.
ME61012R0700300030002
The function menu relating to gauging result processing is described below.
For details on the function keys, refer to [1-2-1. TOOL/ZERO Function Key] to [1-2-5. VARIOUS ON/ OFF Function Key].
Function Menu Description
TOOL/ZERO Displays the presently set zero offset/tool offset number.
MSB ZERO ON/OFF Displays the offset data presently set for the individual zero offset num-bers.
MSB TOOL ON/OFF Displays the offset data presently set for the tool length offset number and the cutter diameter offset number.
SENSstat ON/OFF Displays the value set for system variable VNCOM and the sensor con-tact status.
1-2-1. TOOL/ZERO Function Key
The TOOL/ZERO pop-up window displays the presently set zero offset number and tool offset num-bers. To display the TOOL/ZERO pop-up window, follow the procedure indicated below.
Procedure :
1
Display the GAUGING RESULTS screen.For the procedure used to display the GAUGING RESULTS screen, refer to [1-1. Displaying the Result of Gauging].
2
Press the extend key to switch the function menu.3
Press function key [F2] (TOOL/ZERO). The TOOL/ZERO pop-up window opens.ME61012R0700300040001
The TOOL/ZERO pop-up window closes when function key [F2] (TOOL/ZERO) is pressed again.
1-2-2. MSB ZERO ON/OFF Function Key
The MSB (VSZO*[N]) pop-up window displays the offset data set for the individual zero offset num-bers. To display the MSB (VSZO*[N]) pop-up window, follow the procedure indicated below.
Procedure :
1
Display the GAUGING RESULTS screen.For the procedure used to display the GAUGING RESULTS screen, refer to [1-1. Displaying the Result of Gauging].
2
Press the extend key to switch the function menu.3
Press function key [F4] (MSB ZERO ON/OFF). The MSB (VSZO*[N]) pop-up window opens.ME61012R0700300050001
The MSB (VSZO*[N]) pop-up window closes when function key [F4] (MSB ZERO ON/OFF) is pressed again.
1-2-3. MSB TOOL ON/OFF Function Key
The TOOL OFFSET/COMPENSATION pop-up window displays the offset data set for the individual tool length offset and cutter radius compensation numbers. To display the TOOL OFFSET/COM-PENSATION pop-up window, follow the procedure indicated below.
Procedure :
1
Display the GAUGING RESULTS screen.For the procedure used to display the GAUGING RESULTS screen, refer to [1-1. Displaying the Result of Gauging].
2
Press the extend key to switch the function menu.3
Press function key [F5] (MSB TOOL ON/OFF).The MSB TOOL LENGTH OFFSET (VSTOH[N])/MSB CUTR RADIUS COMP (VSTOD[N]) pop-up window opens.
ME61012R0700300060001
The MSB TOOL LENGTH OFFSET (VSTOH[N])/MSB CUTR RADIUS COMP (VSTOD[N]) pop-up window closes when function key [F5] (MSB TOOL ON/OFF) is pressed again.
1-2-4. SENSstat ON/OFF Function Key
The NC COMMUNICATION (VNCOM[N]) pop-up window displays the values set for system vari-ables VNCOM and the contact status of the sensor. To display the NC COMMUNICATION (VNCOM[N]) pop-up window, follow the procedure indicated below.
Procedure :
1
Display the GAUGING RESULTS screen.For the procedure used to display the GAUGING RESULTS screen, refer to [1-1. Displaying the Result of Gauging].
2
Press the extend key to switch the function menu.3
Press function key [F6] (SENSstat ON/OFF).The NC COMMUNICATION (VNCOM[N]) pop-up window opens.
ME61012R0700300070001
The NC COMMUNICATION (VNCOM[N]) pop-up window closes when function key [F6] (SENSstat ON/OFF) is pressed again.
1-2-5. VARIOUS ON/OFF Function Key
The VARIOUS DATA pop-up window displays the values set for the individual system variables. To display the VARIOUS DATA pop-up window, follow the procedure indicated below.
Procedure :
1
Display the GAUGING RESULTS screen.For the procedure used to display the GAUGING RESULTS screen, refer to [1-1. Displaying the Result of Gauging].
2
Press the extend key to switch the function menu.3
Press function key [F7] (VARIOUS ON/OFF). The VARIOUS DATA pop-up window opens.ME61012R0700300080001
The VARIOUS DATA pop-up window closes when function key [F7] (VARIOUS ON/OFF) is pressed again.
2.
Automatic Tool Length Offset/Automatic Tool Breakage
Detection Operation
A general breakdown of the operational procedure for carrying out automatic tool length and tool breakage detection functions is given below.
ME61012R0700300090001
[Supplement]
With a double-column machining center that has a touch sensor at a location other than the crossrail (on the table, for example), the Z-axis zero point must be set after positioning the cross-rail.
Setting the zero point for the touch sensor
Setting the correspondence between pot numbers/tool
numbers
Executing the automatic tool length offset cycle with the tool
used for setting the touch sensor zero point
Executing automatic tool length offset for other tools
Setting the tool change position data
Executing automatic tool breakage detection cycle
Checking for breakage
Pallet change, etc. Tool not
broken Tool broken
Zero point setting is necessary only when the machine is installed.
(If higher gauging accuracy is required, however, you are recommended to set the zero point occasionally.) When tools in the magazine are replaced, it is neces-sary to set the new correspondence between the tool pot numbers and the tool numbers.
Make sure that the tool length offset value is "0±0.005 mm" or "PLI setting±0.005mm".
Call the tool whose tool length offset data is to be set from the magazine and mount it in the spindle, then execute the automatic tool length offset cycle. Repeat this operation for all tools that require tool length offset data setting.
This step is not necessary for MC-H.
Usually, the tool breakage detection cycle is exe-cuted after each cutting operation with the relevant tool is completed.
Tool length offset data must be set for tools that are checked for breakage.
The function determines whether the machining is continued as programmed or error processing is exe-cuted according to the result of the automatic tool breakage detection cycle.
This step is not necessary if the setting that specifies the machine should stop in the alarm stop state when tool breakage is detected is made.
When the setting that specifies automatic selection of a spare tool if tool breakage is detected is made, the error processing on occurrence of tool breakage should be as follows: the CNC judges that the work-piece machined using the broken tool is defective, changes the pallet to a new one and starts machining for a new workpiece.
2-1.
Setting the Touch Sensor Zero Point
2-1-1. Setting the Touch Sensor Zero Point (Z-axis)
Set the Z-axis direction offset value of the touch sensor zero point using a reference tool so that the automatic tool length offset/automatic tool breakage detection function operates correctly.
[Supplement]
Procedure :
1
After selecting the MDI mode, input “VFST=**”, press the CYCLE START button.Set an appropriate value for “**” by referring to [2-3. Operation Mode Designation]. In this set-ting, either the automatic tool length offset mode or the automatic tool breakage detection cycle may be selected.
The set value can be confirmed by opening the VARIOUS DATA pop-up window on the GAUG-ING RESULTS screen.
ME61012R0700300100001
For the procedure for opening the VARIOUS DATA pop-up window, refer to [1-2-5. VARIOUS ON/OFF Function Key].
2
Execute the sensor advance command M144 in the MDI mode. (In the case of a movable type sensor)3
Set the reference tool in the spindle, and manually bring the nose of the reference tool near the Z-axis touch sensor.There will inevitably be some slight displacement between the center of the sensor and the center of the reference tool. This displacement, however, does not pose a problem for the suc-ceeding operation.
If Y-axis has to be retracted to set the touch sensor zero point, set the Y-axis retraction position first by referring to [4. Y-axis Escape Position (MCM-B/MCR-B II/MCR-A/VH-40)].
[Supplement]
4
At this position, execute the following program after selecting the automatic mode. CALL OO30 PAXI=7 PLI=** (VFST=**)M02
[Supplement]
Usually, the tool used for zero setting of the work coordinate system is also used for the sensor zero point setting cycle. Therefore, there is no tool length difference between the tools used for the two different zero point setting cycles, and the setting for PLI should be “zero” (PLI = 0). For the absolute offset type, set the accurate length of the tool currently set in the spindle as illustrated to the left.
If no value is set for PLI, either “PLI = 150 mm.” or “PLI = 200 mm” is assumed. Which of the values is used is determined by the machine model.
ME61012R0700300100002
[Supplement]
The “reference tool” means the tool used for setting the zero point in a work coordinate sys-tem.
The settings for PLI should be as indicated below
Offset Type PLl Setting Relative offset type 0
Absolute offset type Length from the spindle nose face
VFST may be set in this step instead of setting it first in the MDI mode.
As the program above is executed, the reference tool automatically comes into contact with the Z-axis touch sensor, whereupon Z-axis zero offset is executed.
Zero offset of both the X and Y axes is executed so that the present (actual) position of the reference tool becomes X = 0, Y = 0.
How the reference tool moves during the execution of the program is explained in [2-1-2. Reference Tool Movements during Z-axis Touch Sensor Zero Point Setting].
Relative offset type
PLI PLI = 0
Absolute offset type Tool used for zero setting of the work coordinate system
5
Execute the sensor advance command M144 in the MDI mode. (In the case of a movable type sensor)6
Mount a small-diameter drill in the spindle.7
Bring the drill tip manually near to the touch sensor and align the spindle center (drill center) with the center of the touch sensor.8
At this position, execute the following program after selecting the automatic mode. CALL OO30 PAXI=3M02
X- and Y-axis zero offset is executed so that the present (actual) position of the drill becomes X = 0, Y = 0. (The Z-axis does not move.)
After the execution of the X- and Y-axis zero offset, the Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction and the sensor retracts, completing touch sensor zero point setting.
The result is fed back to the offset data of system work coordinate system No. 1.
The set offset data can be checked by opening the MSB ZERO OFFSET (VSZO*[N]) pop-up window on the GAUGING RESULTS screen. The offset data of the X-, Y- and Z-axis is dis-played at the X, Y, and Z columns of the NO. 1 line
ME61012R0700300100003
[Supplement]
This completes the Z-axis touch sensor zero point setting.
Since system work coordinate system No. 1 is used exclusively for the automatic tool length offset and automatic tool breakage detection functions, it cannot normally be set or refer-enced.
For the procedure for opening the MSB ZERO OFFSET (VSZO*[N]) pop-up window, refer to [1-2-2. MSB ZERO ON/OFF Function Key].
2-1-2. Reference Tool Movements during Z-axis Touch Sensor Zero Point Setting
During the execution of the Z-axis touch sensor zero point setting, the reference tool moves as indi-cated below.
Machine operation
(1) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction. (2) The spindle is oriented.
(3) If the movable type sensor is used, the sensor moves back once and then moves forward. (4) The Z-axis moves at an approach feedrate in the negative (-) direction until the reference tool
comes into contact with the touch sensor.
(5) The Z-axis comes to a stop when the reference tool comes into contact with the touch sensor. (6) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction.
(7) If the movable type sensor is used, the sensor moves back.
2-1-3. Setting the Touch Sensor Zero Point (Y-axis)
When the specifications for automatic tool length offset and automatic breakage detection in the Y-axis direction (diameter direction) are selected, set the Y-Y-axis touch sensor zero point retraction position first by referring to [2-4. Automatic Tool Length Offset Function].
Procedure :
1
After selecting the MDI mode, input “VFST=**”, and press the CYCLE START button.Set an appropriate value for “**” by referring to [2-3. Operation Mode Designation]. In this set-ting, either the automatic tool length offset mode or the automatic tool breakage detection cycle may be selected.
If an appropriate value is already set for VFST, it is not necessary to set the value here. The set value can be confirmed by opening the VARIOUS DATA pop-up window on the GAUG-ING RESULTS screen. For the procedure for opening the VARIOUS DATA pop-up window, refer to [1-2-5. VARIOUS ON/OFF Function Key].
2
Execute the sensor advance command M144 in the MDI mode. (In the case of a movable type sensor)3
Set the reference tool in the spindle, and manually bring the nose of the reference tool near the Y-axis touch sensor.Align the center of the reference tool with the center of the Y-axis touch sensor.
4
At this position, execute the following program after selecting the automatic mode.ME61012R0700300120001
In actual programming, the three lines of program above are expressed in one line as indicated below.
CALL OO30 PAXI=#17H PLI=0(or accurate length of reference tool) PY=Accurate radius of reference tool (VFST=**)
[Example]
ME61012R0700300120002
[Supplement]
For the procedure for opening the MSB ZERO OFFSET (VSZO*[N]) pop-up window, refer to [1-2-2. MSB ZERO ON/OFF Function Key].
This completes the Y-axis touch sensor zero point setting.
1) When setting PLI, pay attention to the same point as explained in [2-1-1. Setting the Touch Sensor Zero Point (Z-axis)].
2) Always set PY. If it is not set, “PY = 0” is assumed.
3) VFST may be set in this step instead of setting it first in the MDI mode.
As the program above is executed, the reference tool automatically comes into contact with the Y-axis touch sensor, whereupon Y-axis zero offset is executed. Zero offset of both the Z-and X-axes is executed at the same time.
How the reference tool moves during the execution of the program is explained in [2-1-4. Ref-erence Tool Movements during Y-axis Touch Sensor Zero Point Setting].
The result is fed back to the offset data of system work coordinate system No. 4.
The set offset data can be checked by opening the MSB ZERO OFFSET (VSZO*[N]) pop-up window on the GAUGING RESULTS screen. The offset data of the X-, Y- and Z-axis is dis-played at the X, Y, and Z columns, respectively.
4) Since system work coordinate system No. 4 is used exclusively for the automatic tool length offset and automatic tool breakage detection functions, it cannot normally be set nor refer-enced.
CALL OO30 PAXI=#17H PLI=0 PY=10 (VFST=1)
2-1-4. Reference Tool Movements during Y-axis Touch Sensor Zero Point Setting
During the execution of the Y-axis touch sensor zero point setting, the reference tool moves as indi-cated below.
Machine operation
(1) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction. (2) The spindle is oriented.
(3) If the movable type sensor is used, the sensor moves back once and then moves forward. (4) The Z-axis moves to the Y-axis touch sensor position (the position where the Z-axis was first
moved manually).
(5) The Y-axis moves at an approach feedrate until the reference tool comes into contact with the touch sensor.
(6) The Y-axis comes to a stop when the reference tool comes into contact with the touch sensor. (7) The Y-axis moves at a rapid feedrate to the approach start position.
(8) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction. (9) If the movable type sensor is used, the sensor moves back.
2-2.
Setting the Tool Pot No./Tool No. Table
Set the correspondence between tool numbers and tool pot numbers in the tool pot number - tool number correspondence table.
The table setting shown below uses a machine with 10-tool capacity magazine as an example.
ME61012R0700300140001
The tool offset data obtained by the execution of an automatic tool length offset cycle is set for the same offset number as the tool number of the tool presently being used (active tool).Similarly, the tool offset number referred to and compared when the automatic tool breakage detection cycle is executed is the same offset number as the tool number of the active tool.
[Supplement]
To automatically change a tool for a spare tool, tools must be registered in a tool group.
For the procedure for registering tools in a group, refer to the Tool Management Function section of the special specifications of the Operation Manual.
Toolpot Number Correspondence Table Magazine capacity: 10 tools
1 2 3 4 5 6 7 8 9 10
Tool Number Write the correspondence between the
tool number and the pot number on the screen when tools in the magazine are to be changed for new setup.
The total number of tools user for cutting the various types of workpieces is 300. Assign a tool number
to each tool.
The memory of the OSP can hold the life expectancy data of up to 300 tools. Max. tool number:
Standard 50 Option 300 1 2 3 20 30 31 32 105 270 271
2-3.
Operation Mode Designation
The basic operation mode of automatic tool length offset and automatic tool breakage detection is designated by the system variable VFST.
Since the system variable VFST is backed up in the CNC memory, it only has to be designated once: it does not have to be set each time the MSB of the automatic tool length offset/automatic tool breakage detection cycle is called.
VFST consists of one byte (8 bits) and each bit has the following significance.
ME61012R0700300150001
Bit No Setting Description
Bit 0 0 Automatic tool breakage detection cycle 1 Automatic tool length offset cycle
Bit 1 1 Executes the automatic tool length offset/automatic tool breakage detec-tion cycle in the Y-axis direction.
Bit 2 1
Executes the automatic tool length offset/automatic tool breakage detec-tion cycle in the Y-axis direcdetec-tion after the execudetec-tion of the automatic tool length offset/automatic tool breakage detection cycle in the Z-axis direc-tion.
To execute automatic tool length offset/automatic tool breakage detec-tion cycle only in the Z-axis direcdetec-tion, set “0” for both Bit 1 and Bit 2. Bit 3 1
Does not move the X-axis when positioning a reference tool at the touch sensor position.
Set “1” for Bit 3 with machine models such as MCV in which the touch sensor is installed independently of the X-axis movement.
Bit 4 0 Always set “0”. Bit 5 0 Always set “0”. Bit 6 0 Always set “0”.
Bit 7
0
Designates the relative offset type.
The tool length in reference to the reference tool used for zero point set-ting of a work coordinate system is used as the tool length offset data. 1
Designates the absolute offset type.
The length of the tool from the spindle nose surface is regarded as the tool length offset data.
An example of VFST settings is given in the following table. [Supplement] Model Relative/ Absolute Offset Type X-axis Movement Yes/No Z-axis/Y-axis Offset
Automatic Tool Length Offset/Automatic Tool Breakage Detection VFST Value MC-H MC-V Relative
offset Yes Only Z-axis offset
Automatic tool length offset #01H Automatic tool breakage
detection #00H Absolute
offset Yes Only Z-axis offset
Automatic tool length offset #81H Automatic tool breakage
detection #80H MCV MCR MCM (Vertical spindle) Relative offset No
Only Z-axis offset
Automatic tool length offset #09H Automatic tool breakage
detection #08H Only Y-axis offset
Automatic tool length offset #0BH Automatic tool breakage
detection #0AH Y-axis offset after
Z-axis offset
Automatic tool length offset #0DH Automatic tool breakage
detection #0CH
Absolute
offset No
Only Z-axis offset
Automatic tool length offset #89H Automatic tool breakage
detection #88H Only Y-axis offset
Automatic tool length offset #8BH Automatic tool breakage
detection #8AH Y-axis offset after
Z-axis offset
Automatic tool length offset #8DH Automatic tool breakage
detection #8CH
Refer to [3-1. Automatic Tool Length Offset/Automatic Tool Breakage Detection Function for Hori-zontal Tools of MCM] for details of automatic tool length offset/automatic tool breakage detection for the horizontal tools of MCM horizontal.
2-4.
Automatic Tool Length Offset Function
The automatic tool length offset function automatically corrects the tool length according to the offset data set using the reference tool.
2-4-1. Z-axis Automatic Tool Length Offset
Automatic tool length offset in the Z-axis direction is executed in the manner indicated below.
[Supplement]
Procedure :
1
After selecting the MDI mode, input “VFST=**”, and press the CYCLE START button. Set an appropriate value for “**” by referring to [2-3. Operation Mode Designation].The set value can be confirmed by opening the VARIOUS DATA pop-up window on the GAUG-ING RESULTS screen. Refer to [1-2-5. VARIOUS ON/OFF Function Key].
2
Mount the tool for which automatic tool length offset is to be executed in the spindle.When the tool is mounted in the spindle manually, make sure that the active tool number dis-played on the ATC TOOL DISPLAY (MEMORY RANDOM) screen (for the ATC memory ran-dom specification) or the POT NO./TOOL NO. TABLE (FIXED ADDRESS) screen (for the ATC fixed address specification) agrees with the tool number of the tool mounted in the spindle. This operation is not necessary when the tool is mounted in the spindle by executing the M06 command, either in automatic or MDI operation.
3
Execute the following program after selecting the automatic mode. CALL OO30 (VFST=**) (PLI = Anticipated tool length)M02
When the program is executed, the tool is automatically brought into contact with the Z-axis touch sensor and the tool length offset data is calculated and stored in the CNC memory. The set tool length offset data can be checked by displaying the TOOL LENGTH OFFSET/ CUTTER RADIUS COMPENSATION screen of the TOOL DATA screen.
Make sure that the zero point of the Z-axis touch sensor has been set before executing Z-axis automatic tool length offset. Never execute Z-axis automatic tool length offset when the Z-axis touch sensor zero point has not been set.
The obtained results are also displayed on the GAUGING RESULTS screen
ME61012R0700300170001
This ends the Z-axis automatic tool length offset processing.
[Supplement]
Machine operation
During the execution of the Z-axis automatic tool length offset, the tool moves as indicated below. (1) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction.
(2) The spindle is oriented.
(3) The X- and Y-axis move at a rapid feedrate to align the tool nose with the center of the touch sensor.
For tools whose nose is not at the center of the spindle, refer to items (6) PX and (7) PY in [6-3. How to Use Variables].
(4) The Z-axis moves at a fast approach feedrate until the tool comes into contact with the touch sensor.
(5) The Z-axis comes to a stop when the reference tool comes into contact with the touch sensor. (6) The Z-axis moves back several millimeters at a rapid feedrate.
(7) The Z-axis moves at an approach feedrate until the tool comes into contact with the touch sen-sor again.
1) VFST may be set in this step instead of setting it first in the MDI mode. 2) Set the anticipated tool length for PLI.
If no value is set for PLI, the value set for CNC optional parameter (long word) No. 43 (dis-tance from the spindle gauge line) is automatically set as the anticipated tool length.
(8) The Z-axis comes to a stop when the reference tool comes into contact with the touch sensor. The result of gauging is stored under the same tool length offset number as the tool number of the active tool.
(9) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction.
2-4-2. Y-axis Automatic Tool Length Offset
Automatic tool length offset in the Y-axis direction is executed in the manner indicated below.
[Supplement]
Procedure :
1
After selecting the MDI mode, input “VFST=**”, and press the CYCLE START button. Set an appropriate value for “**” by referring to [2-3. Operation Mode Designation].The set value can be confirmed by opening the VARIOUS DATA pop-up window on the GAUG-ING RESULTS screen. Refer to [1-2-5. VARIOUS ON/OFF Function Key].
2
Mount the tool for which Y-axis automatic tool length offset is to be executed in the spindle. When the tool is mounted in the spindle manually, make sure that the active tool number dis-played on the ATC TOOL DISPLAY (MEMORY RANDOM) screen (for the ATC memory ran-dom specification) or the POT NO./TOOL NO. TABLE (FIXED ADDRESS) screen (for the ATC fixed address specification) agrees with the tool number of spindle mounted tool.This operation is not necessary when the tool is mounted in the spindle by executing the M06 command either in automatic or MDI operation.
3
Execute the following program after selecting the automatic mode. CALL OO30 PY= Anticipated cutter radius(VFST=**)M02
When the program is executed, the tool is automatically brought into contact with the Y-axis touch sensor and the cutter radius compensation data is calculated and stored in the CNC memory.
The set cutter radius compensation data can be checked by displaying the TOOL LENGTH OFFSET/CUTTER RADIUS COMPENSATION screen of the TOOL DATA screen. The obtained results are also displayed at the GAUGING RESULTS screen.
This ends the Y-axis automatic tool length offset processing.
[Supplement]
1) Make sure that the zero point of the Z-axis and Y-axis touch sensors has been set before exe-cuting Y-axis automatic tool length offset. Never execute Y-axis automatic tool length offset when the touch sensor zero point has not been set.
2) Before executing automatic tool length offset in the Y-axis direction, set the Z-axis tool length offset data of the tools.
The Z-axis tool length offset data can be set either by executing the Z-axis automatic tool length offset or by inputting an appropriate value at the TOOL DATA screen.
Machine operation
During the execution of the Y-axis automatic tool length offset, the tool moves as indicated below. (1) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction.
(2) The spindle is oriented.
(3) The X- and Y-axis move at a rapid feedrate to align the tool nose with the center of the Z-axis touch sensor.
(4) The Z-axis moves at a fast approach feedrate to align the tool nose with the center of the Y-axis touch sensor.
(5) The Y-axis moves at an approach feedrate until the tool comes into contact with the Y-axis touch sensor.
(6) The Y-axis comes to a stop when the tool comes into contact with the touch sensor.
The result of gauging is stored under the same cutter radius compensation number as the tool number of the active tool.
(7) The Y-axis returns at a rapid feedrate.
(8) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction.
2-4-3. Continuous Z-axis and Y-axis Automatic Tool Length Offset
To execute automatic tool length offset on the Z-axis and the Y-axis continuously, follow the proce-dure indicated below.
For points of caution and details of the tool length offset, refer to [2-4-1. Z-axis Automatic Tool Length Offset] and [2-4-2. Y-axis Automatic Tool Length Offset].
Procedure :
1
After selecting the MDI mode, input “VFST=**”, and press the CYCLE START button.2
Execute the following program after selecting the automatic mode.CALL OO30 PY= Anticipated cutter radius (PLI = Anticipated tool length) (VFST=**) M02
The tool is first brought into contact with the Z-axis touch sensor then the Y-axis touch sensor. This ends the continuous Z-axis and Y-axis automatic tool length offset processing.
2-5.
Setting the Tool Change Position (Other Than MC-H)
When a tool is found to be broken in the automatic tool breakage detection cycle, the broken tool can be automatically returned to the magazine by using a subprogram.
In order to execute this automatic tool return cycle, the tool change position must be set for MC-V and double-column machining centers since these types of machining centers do not have a preset ATC home position like MC-H.
If the tool change position is not set for these types of machining centers, the tool change will be car-ried out just above the touch sensor. Since this may cause problems with some kinds of workpieces, it is necessary to set the tool change position for MC-V and double-column machining centers.
Procedure :
1
Move the spindle to the desired tool change position.Note that X- and Y-axis must be positioned at the desired tool change position. Positioning of the Z-axis is not necessary.
2
At this position, execute the following program after selecting the automatic mode. CALL OO31M02
The axes will not move at all even when a program is executed.
The set tool change position data can be checked by opening the MSB ZERO OFFSET (VSZO*[N]) pop-up window on the GAUGING RESULTS screen. The tool change position data of the X-, Y- and Z-axis is displayed at the X, Y, and Z columns of the NO. 2 line.
This completes the tool change position setting.
[Supplement]
Since system work coordinate system No. 2 is used exclusively for the automatic tool length off-set and automatic tool breakage detection functions, it cannot normally be off-set or referenced.
2-6.
Automatic Tool Breakage Detection
2-6-1. Z-axis Automatic Tool Breakage Detection
Automatic tool breakage detection in the Z-axis direction is executed in the manner indicated below.
[Supplement]
Procedure :
1
After selecting the MDI mode, input “VFST=**”, and press the CYCLE START button. Set an appropriate value for “**” by referring to [2-3. Operation Mode Designation].2
Mount the tool for which automatic tool breakage detection is to be executed in the spindle. When the tool is mounted in the spindle manually, make sure that the active tool number dis-played on the ATC TOOL DISPLAY (MEMORY RANDOM) screen (for the ATC memory ran-dom specification) or the POT NO./TOOL NO. TABLE (FIXED ADDRESS) screen (for the ATC fixed address specification) agrees with the tool number of the tool mounted in the spindle. This operation is not necessary when the tool is mounted in the spindle by executing the M06 command either in automatic or MDI operation.3
Execute the following program after selecting the automatic mode. CALL OO30 PLE1 = Tool breakage judgment value (VFST=**) (PGO=**) M02When the program is executed, the tool is automatically brought into contact with the touch sensor and the tool length is obtained.
The obtained tool length is compared to the tool length offset data stored in the CNC memory and a tool breakage alarm occurs if the difference is greater than the value set for PLE1. The tool breakage alarm also occurs if the tool nose fails to contact the touch sensor during the execution of the program.
This ends the Z-axis automatic tool breakage detection processing.
[Supplement]
Before executing Z-axis automatic tool breakage detection, make sure that the zero point of the touch sensor and the tool change position have been set.
1) VFST may be set in this step instead of setting it first in the MDI mode. 2) To replace a broken tool with a spare tool, PGO must be designated.
Machine operation
During the execution of the Z-axis automatic tool breakage detection, the tool moves as indicated below.
(1) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction. (2) The spindle is oriented.
(3) The X- and Y-axis move at a rapid feedrate to align the tool nose with the center of the Z-axis touch sensor.
For tools whose nose is not at the center of the spindle, refer to items (6) PX and (7) PY in [6-3. How to Use Variables].
(4) The tool edge moves at the rapid traverse to a position in front of the touch sensor with a clear-ance of the safety distclear-ance (PUDT). (*1)
If PUDT is not specified, the axis moves at the rapid traverse to a position in front of the touch sensor with a clearance of 5 mm.
(5) The Z-axis moves at an approach feedrate to the position 10 mm past the point where the tool nose would be in contact with the touch sensor.
•
If the tool has not been broken or the amount of chipping is smaller than 10 mm:The tool nose comes into contact with the touch sensor and the Z-axis stops. The tool length is calculated from the coordinate value of the contact position and is stored in the CNC memory temporarily.
•
If the tool has been broken (amount of chipping is greater than 10 mm): The tool nose will not contact the touch sensor.(6) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction.
(*1) If the NC optional parameter bit No.74 bit 4 is check marked, the setting is changed from “moves at the rapid traverse” to “moves at the rapid approach rate”.
2-6-2. Y-axis Automatic Tool Breakage Detection
Automatic tool breakage detection in the Y-axis direction is executed in the manner indicated below.
[Supplement]
Procedure :
1
After selecting the MDI mode, input “VFST=**”, and press the CYCLE START button. Set an appropriate value for “**” by referring to [2-3. Operation Mode Designation].2
Mount the tool for which automatic tool breakage detection is to be executed in the spindle. When the tool is mounted to the spindle manually, make sure that the active tool number dis-played on the ATC TOOL DISPLAY (MEMORY RANDOM) screen (for the ATC memory ran-dom specification) or the POT NO./TOOL NO. TABLE (FIXED ADDRESS) screen (for the ATC fixed address specification) agrees with the tool number of the tool mounted in the spindle. This operation is not necessary when the tool is mounted in the spindle by executing the M06 command either in automatic or MDI operation.3
Execute the following program after selecting the automatic mode.CALL OO30 PLEY=Tool breakage judgment value PY=Anticipated cutter radius (VFST=**) M02
When the program is executed, the tool is automatically brought into contact with the touch sensor and the cutter radius is obtained.
The obtained cutter radius is compared to the cutter radius compensation data stored in the CNC memory and a tool breakage alarm occurs if the difference is greater than the value set for PLEY.
The tool breakage alarm also occurs if the tool fails to contact the touch sensor during the exe-cution of the program.
This ends the Y-axis automatic tool breakage detection processing.
[Supplement]
Before executing Y-axis automatic tool breakage detection, make sure that the zero point of the touch sensor has been set.
Machine operation
During the execution of the Y-axis automatic tool breakage detection, the tool moves as indicated below.
(1) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction. (2) The spindle is oriented.
(3) The X- and Y-axis move at a rapid feedrate to align the tool nose with the center of the touch sensor.
(4) The Z-axis moves at a rapid feedrate to align the tool nose with the center of the Y-axis touch sensor.
(5) The Y-axis moves at an approach feedrate to the position 10 mm past the point where the tool nose would be in contact with the touch sensor.
•
If the tool has not been broken or amount of chipping is smaller than 10 mm:The tool nose comes into contact with the touch sensor and the Y-axis stops. The cutter radius is calculated from the coordinate value of the contact position and is stored in the CNC memory temporarily.
•
If the tool has been broken (amount of chipping is greater than 10 mm): The tool nose will not contact the touch sensor.(6) The Y-axis returns at a rapid feedrate.
(7) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction.
2-6-3. Continuous Z-axis and Y-axis Automatic Tool Breakage Detection
To execute automatic tool breakage detection on the Z-axis and the Y-axis continuously, follow the procedure indicated below.
For items carefully attended to and details of the tool length offset, refer to [2-6-1. Z-axis Automatic Tool Breakage Detection] and [2-6-2. Y-axis Automatic Tool Breakage Detection].
Procedure :
1
After selecting the MDI mode, input “VFST=**” and press the CYCLE START button.2
Execute the following program after selecting the automatic mode.ME61012R0700300230001
3
The tool is first brought into contact with the Z-axis touch sensor to check tool breakage in the Z-axis direction. When tool breakage is not detected in the Z-axis direction, tool breakage in the Y-axis direction is checked.CALL OO30 (VFST=**) PY=Anticipated cutter radius
PLE1=Tool breakage judgment value (Z-axis) PLEY=Tool breakage judgment value (Y-axis) M02
2-6-4. Judgment of Tool Breakage
When a spare tool is selected in response to the detection of tool breakage, operation does not stop even when the breakage is detected. Therefore, it is necessary to judge the occurrence of tool breakage at the end of the automatic tool breakage detection cycle and branch the program execu-tion in accordance with the result of the judgement.
•
It can be judged whether or not the tool is broken by reading system variable VOK1. VOK1 = 0 Tool is not broken.VOK1 ≠ 0 Tool is broken.
VOK1 indicates the result of the previously executed automatic tool breakage detection cycle.
•
Another system variable VOK2 is also available for judgement.VOK2 indicates the result of automatic tool breakage detection cycles executed after clearance to 0 (VOK2 = 0). If tool breakage is detected even once, the value set for VOK2 is “VOK2 ≠ 0”.
•
VOK1 and VOK2 are not cleared to 0 when the CNC is reset.[Supplement]
When tool breakage is detected by the automatic tool breakage detection function, the tool num-ber is registered by the tool management function as that of a broken tool.
In order to use the same tool number after taking the necessary measures, such as replacement with a new tool, the registration of the broken tool number must be cleared.
Refer to Tool Management Function in special specifications of the Operation Manual for the pro-cedure for resetting broken tool registration.
2-7.
Cycle Time Reduction for Automatic Tool Length Offset/Automatic
Tool Breakage Detection Cycle
By feeding a tool close to the sensor at a rapid feedrate, it is possible to reduce the cycle time of the automatic tool length offset/automatic tool breakage detection cycle.
Fig.1-1 Cycle Time Reduction Function
ME61012R0700300250001
To use this function, it is necessary to set the following parameters.
•
Optional parameter (bit) No. 36, bit 3:Default of maximum tool length for automatic tool length offset/tool breakage detection With check mark: Valid
Without check mark: Invalid (Initial value)
•
Optional parameter (long ward) No. 44: Max. tool lengthFor this parameter, set the maximum tool length among the tools that will be used. Setting range: 0 to 999
Unit: mm Initial setting: 0
[Supplement]
Set an appropriate value for the maximum tool length setting parameter since “0” is set as the ini-tial value.
Spindle nose face
Tool Anticipatedtool length PL1 Max. tool length VLTL Safety distancePUDT Sensor G31F2000 G31F=PF1 (5) (6) G0 (4)
2-7-1. Automatic tool length offset cycle
Machine operation
(1) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction. (2) The spindle is oriented.
(3) The X- and Y-axis move at a rapid feedrate to align the tool nose with the center of the touch sensor.
(4) The Z-axis moves at a rapid feedrate to the point distanced from the touch sensor by “safety distance (PUDT) + max. tool length (VLTL)”.
This operation is or is not executed according to the setting for the parameter.
(5) The Z-axis moves at a skip feedrate, specified by PF1, to the point distanced from the touch sensor by “anticipated tool length (PLI) + safety distance (PUDT)”.
If the PLI command is not specified, the Z-axis moves at a skip feedrate specified by PF1 to the point distanced from the touch sensor by “safety distance (PUDT)”. If the PF1 command is not specified, the Z-axis moves at F2000.
(6) The Z-axis moves at F2000 to the point 10 mm beyond the anticipated contact point. It stops when the tool comes into contact with the touch sensor.
(7) The Z-axis returns 5 mm from the contact point.
(8) The Z-axis moves at a skip feedrate, specified by PF2, to the point 10 mm beyond the contact point.
It stops when the tool comes into contact with the touch sensor.
(9) The tool length offset data is written to the active tool number or the offset number specified by the PH command.
(10) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction.
2-7-2. Automatic tool breakage detection cycle
Machine operation
(1) The same operation as steps 1) to 4) of the automatic tool length offset cycle explained above is executed.
(2) The Z-axis moves at rapid feedrate to the point 5 mm away the anticipated contact point. (*1) (3) The Z-axis moves at skip feedrate F1000 to the point 10 mm beyond the anticipated contact
point.
It stops when the tool comes into contact with the touch sensor.
(4) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction.
(*1) If the NC optional parameter bit No.74 bit 4 is check marked, the setting is changed from “moves at the rapid traverse” to “moves at the rapid approach rate”.
2-8.
New Cycle Time Reduction Function for Automatic Tool Length
Offset/Automatic Tool Breakage Detection Cycle
By reducing the execution time of the cycle steps that can be reduced in the previous automatic tool length offset/automatic tool breakage detection cycle, the cycle time reduction function is made more powerful.
This new cycle time reduction function is usable only in the vertical tool direction.
2-8-1. Command Format and Variables of the New Cycle Time Reduction Function
The command format and the variables used by the new cycle time reduction function are described below.
•
Command formatThe following is an example command to use the cycle time reduction function. CALL OO30 PZRC=1 PSFT=10 POVT=20 PF1=5000 PF2=2000 M02
•
VariablesPZRC Used to select the new or conventional cycle time reduction function.
“1” selects the new cycle time reduction function and “0” selects the conventional cycle time reduction function. The default is “0”.
PUDT: Undertravel distance (safety distance)
This defines the point where, during the approach of a cutting tool to the touch sensor, the approach speed is changed from high-speed to low-speed. The dis-tance from the touch sensor to the tool nose is designated.
For the automatic tool breakage detection cycle, the default is 5 mm. POVT: Overtravel distance (sensor breakage prevention distance)
Default is 10 mm.
PFA: Approach speed to undertravel point
For the automatic tool breakage detection cycle, the default is F4000. PF2: Approach speed to overtravel point
For the automatic tool breakage detection cycle, the default is F1000. VMSBU: Setting for CNC optional parameter (bit) No. 36
If the setting for bit 3 of this parameter is “1”, with “0” set for PZRC, the conven-tional cycle time reduction function is selected.
VLTL: Maximum tool length
The value set for CNC optional parameter (long word) No. 44 PSFT: Feedrate shift distance
This defines the point where, during approach of a cutting tool to the touch sen-sor, the approach speed is changed from a rapid feedrate to high-speed (low-speed if PSFT is not specified). The distance from the touch sensor to the tool nose is designated.
2-8-2. Tool Movements of New Cycle Time Reduction Function
During the execution of the new cycle time reduction function, the tool moves as indicated below. Note that tool movements differ according to the setting of the variables.
Variable setting: PZRC = 0, Bit 3 of VMSBU = 0
Machine operation
(1) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction (2) The spindle is oriented.
(3) The Y-axis and the X-axis, in this order, move at a rapid feedrate to align the tool nose with the center of the touch sensor.
(4) The Z-axis moves at a skip feedrate, specified by PFA, to the position PUDT above the touch sensor zero point.
The Z-axis stops when the tool comes into contact with the sensor.
(5) The Z-axis moves at a skip feedrate, specified by PF2, to the position POVT below the touch sensor zero point.
The Z-axis stops when the tool comes into contact with the sensor.
(6) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction.
ME61012R0700300300001 2) Rapid feed 3) Rapid feed 1) PFA 4 ) Rapid feed 6) Touch sensor zero point PF2 5) PUDT POVT
Variable setting: PZRC = 0, Bit 3 of VMSBU = 1
Machine operation
(1) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction. (2) The spindle is oriented.
(3) The Y-axis and the X-axis, in this order, move at a rapid feedrate to align the tool nose with the center of the touch sensor.
(4) The Z-axis moves down at a rapid feedrate until the spindle nose face reaches the point VLTL above the touch sensor zero point.
(5) The Z-axis moves at a skip feedrate, specified by PFA, to the position PUDT above the touch sensor zero point.
The Z-axis stops when the tool comes into contact with the sensor.
(6) The Z-axis moves at a skip feedrate, specified by PF2, to the position POVT below the touch sensor zero point.
The Z-axis stops when the tool comes into contact with the sensor.
(7) The Z-axis moves at a rapid feedrate to the travel end in the positive (+) direction.
ME61012R0700300300002 2) Rapid feed 3) Rapid feed 1) P FA 5 ) Rapid feed 7) Rapid feed 4) PF2 6) PUDT POVT VLTL
Variable setting: PZRC = 1, Bit 3 of VMSBU = 0 or 1
If “PUDT > PSFT”, an alarm (Alarm B 2305 UNTENDED: gauging impossible 64) occurs.
Machine operation
(1) If the tool nose is below the point “touch sensor zero point + PSFT”, the Z-axis moves up at a rapid feedrate to the point “touch sensor zero point + PSFT”
(2) The spindle is oriented.
(3) The Y-axis and the X-axis, in this order, move at a rapid feedrate to align the tool nose with the center of the touch sensor.
(4) The Z-axis moves down at a rapid feedrate to the point “touch sensor zero point + PSFT”. (5) The Z-axis moves down at a skip feedrate PFA to the point “touch sensor zero point + PUDT”. (6) The Z-axis moves down at a skip feedrate PF2 to the point “touch sensor zero point - POVT”. (7) The Z-axis moves up at rapid feedrate to the point “touch sensor zero point + PSFT”.
ME61012R0700300300003 2) 2) Rapid feed 3) Rapid feed 1) Rapid feed 4) PFA 5) PF2 6) PSFT PUDT POVT Rapid feed 7)
