ATRUMP E216 Mill Conversion

[martyscncgarage]

Agreed on Unclamp fault. I did manually test switches for clamp and unclamp by physically pushing roller switches. Inputs were coming on and off. Manual push of physical tool unlock button also works.

Have to do some more digging in on this.

The right way to do it is either use the M codes in the ATC manual or force the outputs on and off (and then back to normal state and not the off state) in the Diagnostic screen while watching the sensor inputs. Do you have the correct air pressures to the machine?

[cncsnw]

I cannot guess why it worked before, and is not working now.

There are some things about the PLC programming and macros that I find a little odd.

Lines 29-69 of your M6 macro, mfunc6.mac, includes the following (with some irrelevant lines deleted):

Code: Select all

M5                                                  ;Command 0 speed
M9                                                  ;Turn off coolant
M107                                                ;Send tool number 
G4 P1
M94 /8                                              ;Request tool change
M107                                                ;Send tool number  
M101 /50012                                         ;Wait for 0 speed
M19                                             ;Orient spindle
M3 S200                                             ;Command slow speed 
G4P1    
M101 /50017                                         ;Wait for tool to orient

G30 G91 Z0                                          ;Move Z to tool change position
G90
M101 /50017                                         ;Confirm spindle is oriented
M101 /70007                                         ;Wait for carousel at putback location
G4 P.25                                             ;Wait for 250 milli   
M101 /50017                                         ;Confirm spindle is oriented
M80                                                 ;Request carousel in                                            
M101 /50032                                         ;Wait for carousel is in

M15                                                 ;Unclamp tool
M101 /50022                                         ;Wait for tool unclamped
    
G53 Z0                                              ;Raise head to clearance

The "M3 S200" that follows the M19 orient command is a bit of a mystery. Many spindle drives, yours probably included, do need a run command to accompany the orient command, but that was already ensured by the "M3 S0" that was specified in the M19 macro.

The M19 macro also included an "M101/50017" (wait for INP17 "OrientComplete_I" closed), so the two subsequent "M101/50017" lines in the M6 macro are not really necessary. They were probably put in there to be extra sure the spindle was still oriented. But there is code in the PLC program (lines 3097 - 3110) which, once the spindle has completed orient, will trigger a fault if orient is lost for more than 200ms.

The orient section of your PLC program, lines 3097 - 3110, reads:

Code: Select all

;Orient spindle
IF True_M THEN OrientTimer_T = 5000, OrientLostTimer_T = 200
IF M19_SV THEN (OrientRequest_O)
IF OrientRequest_O THEN SET OrientTimer_T
IF OrientRequest_O && OrientComplete_I THEN SET MonitorOrient_M, RST OrientTimer_T 
IF OrientRequest_O && !OrientComplete_I && MonitorOrient_M 
  THEN SET OrientLostTimer_T
IF OrientComplete_I THEN RST OrientLostTimer_T  
  
IF ToolUnclampOut_O || !SV_PROGRAM_RUNNING 
  THEN RST M19_SV, RST OrientRequest_O, RST MonitorOrient_M, RST OrientLostTimer_T,
  RST OrientTimer_T

IF OrientLostTimer_T THEN FaultMsg_W = ORIENT_LOST_FAULT_C, SET OtherFault_M  
IF OrientTimer_T THEN FaultMsg_W = ORIENT_TIMEOUT_C, SET OtherFault_M 

Note that the orient command to the spindle drive, OUT17 "OrientRequest_O", is only turned on when the M19 request is present; and that as soon as the tool unclamp solenoid, OUT22 "ToolUnclampOut_O" is turned on, the PLC program cancels M19 and OrientRequest_O. That will leave the spindle drive with a run-forward command; a 200 RPM (6.67Hz) analog speed request; and no orient request.

With most spindle drives, the orient request will override the analog speed command and cause the drive to orient and hold. But if you remove the orient command, the drive would be expected to resume normal operation.

I would have expected code to ensure that the forward-run request is removed at the same time that the orient request is removed, but I am not seeing it anywhere.

Perhaps Keith McCulloch or Chris Bowser can comment on how this logic is supposed to work.

[cncsnw]

I should add that canceling spindle orientation as soon as the tool is unclamped is routine, since the force of the release cylinder on the drawbar is generally sufficient to hold the spindle in place.

The issue here seems to be that the orient request is canceled, but the run request is not.

Also, it would be better to wait until the tool-unclamped confirmation switch is made before canceling orient, rather than doing it as soon as the solenoid is powered.

[Jqmce]

Thanks a bunch guys.
Ok so i have read through this a few times and am trying to wrap my head around it.
Software or PLC programs do not normally change on their own so i have to do some sanity checks here.
I'm not really good at reading code.

I think the next double checks are the following?
-Double check air pressure and ensure tool clamp / unclamp functions are happening in a timely manner. (Nothing appeared wrong with functionality
last week but no harm in another look)
-Check orient signal is strong and consistent and check timing for it dropping. (Is this a 24V signal?)
-Double check encoder wiring?

This is the software as provided by Centroid. Should I be reloading any software in case its some sort of corrupt bit?
Please let me know if there is further info required.

What else should i be physically verifying? Are there any I/O i should be specifically checking besides the obvious?

Thanks
Jules

[martyscncgarage]

Make sure all your sensors are operating correctly by exercising them from the control. (not just pushing on them)
CNC12 PLC relies on the inputs and expects to see them during the tool change cycle. If one is amiss, that could be a problem.
Chris from Centroid is going to look at your report in the mean time.

Marty

[Jqmce]

Hey Guys,
Quick update.
So i verified all sensors again via MDI commands and checking I/O screen.
I have said this before but the only way i know of testing the sensors on the Carousel in Carousel out is via a tool change or physically as the AUX12 and AUX 14 functions on my VCP don't work or are non existent.
I sped up the tool clamp / unclamp a little via flow controls in case the unclamp sensor was not falling within the allotted time. This made no difference.
Encoder cable appears to be intact and termination of VFD verified tight.

I'm at a bit of a loss as to what to try next.

Thanks
Jules

[martyscncgarage]

Hey Guys,
Quick update.
So i verified all sensors again via MDI commands and checking I/O screen.
I have said this before but the only way i know of testing the sensors on the Carousel in Carousel out is via a tool change or physically as the AUX12 and AUX 14 functions on my VCP don't work or are non existent.
I sped up the tool clamp / unclamp a little via flow controls in case the unclamp sensor was not falling within the allotted time. This made no difference.
Encoder cable appears to be intact and termination of VFD verified tight.

I'm at a bit of a loss as to what to try next.

Thanks
Jules

Do you have this manual?
https://www.centroidcnc.com/downloads/U ... ctions.pdf
Page 8 M80 and M81
What console do you have? OR do you have a physical jog panel? Or are you trying to make do with the VCP?

Marty

[Jqmce]

Hey Marty,
Yes i do have the manual.
M80 and M81 can only be used (to the best of my knowledge) in conjunction with AUX 12 OR according to marc with the PLC software i have AUX14.
See post in this thread from March 14th 2021 @ 4:48 PM.
I'm assuming this is for safety reasons to ensure operators don't accidently push carousel into spindle.
I do not have a physical control panel. I do have a VCP.
A lot of the Centroid documentation in general only applies to either the physical jog panel or the Acorn architecture which is different.

Thanks
Jules

[martyscncgarage]

Hey Marty,
Yes i do have the manual.
M80 and M81 can only be used (to the best of my knowledge) in conjunction with AUX 12 OR according to marc with the PLC software i have AUX14.
See post in this thread from March 14th 2021 @ 4:48 PM.
I'm assuming this is for safety reasons to ensure operators don't accidently push carousel into spindle.
I do not have a physical control panel. I do have a VCP.
A lot of the Centroid documentation in general only applies to either the physical jog panel or the Acorn architecture which is different.

Thanks
Jules

Let's see if we can have VCP modified.....
You could use the button on the pneumatic solenoid to move the carousel in and out. Have you checked for a button on your valve?

[Jqmce]

Hey Marty,
Yes the valve has two manual override buttons. One for extend and one for retract.
When using override both sensors at either end of stroke are met and the corresponding input is confirmed via I/O on HMI.