Program sending drill through part

[steelcogs]

I have a really simple spot/drill/counterbore program I'm trying to run and something is way off with one of the drill cycles. I'll include the gcode but it's just canned drill cycles. First is spot drill, works fine. The second drill is where the issue occurs. I change the tool (I have all 4 tools for this program with their heights preset, and I have verified that they are indeed correct so that's not the issue), restart my spindle, hit cycle start and it starts to rapid over to the next hole but the Z height goes way past the Zero point/retract height and just keeps going down, slamming into my part before even getting to the correct X/Y position. It's broken 2 of my drills. Dry running it appears to want to go all the way to the bottom Z point of the hole, THEN move up and start drilling normally once it's at the correct X/Y. I can only test so much in dry run since it's a long drill and soft limits come into play, let alone physical space I have before it crashes into something more important than a drill. I can't imagine this is a post processing error. I'm making 2 (almost) identical parts, they're symmetrical. So the holes and c'bores are offset from center on one part, then the opposite way on the second part. Because of this I modeled and did the CAM separately in F360 with 2 different setups, one for each drilling/c'bore cycle.

If I post process JUST this one drill, it works perfectly fine. But that's inconvenient and defeats the purpose of presetting tool heights. There's also no way of predicting this happening to any given tool in the future either and could break something more expensive than a HSS drill bit. Even with the feedrate at minimum there's really no way to stop it in time from crashing without a ridiculous retract height set in the program.

I was also sent another software update 3.37.10pre that I hadn't yet loaded. 3.37.7pre seemed to be working fine for the most part until now and I was unsure what 3.37.10 entailed so I didn't want to just blindly update to it. I'll have to try that once I have some more time then update the post.

As always, using Clearpath servos on all 3 axes, and my gcode and masso settings are attached.

Thanks,

Brandon

 

[masso-support]

so as per your gcode does this happen on (DRILL7) N125 ?



also why are there two tool change gocdes next to each other:

N30 T2 M6
N35 T3

So in the above, whats your target tool that you are trying to load, is it tool 2 or tool 3?

 

[steelcogs]

Correct, Drill 7 N125.

I also noticed that there were two tool codes, but I would assume it only does anything on the one with an M6 after it. The tool I'm trying to use with this issue is T3. So under the DRILL7 it shows

N140 T3 M6

N145 T4

Just making sure you knew the gcode lines you pulled pointing out the weird double tool callout was from the first drilling cycle with the spot drill, which worked as expected.

 

[peter35]

I have been caught out with this also.

Am using fusion 360 and when you renumber tools it does not renumber tool offset.

I have been opening nc file and changing line under tool change to be the same as tool, this works fine now.

Line 30 is tool change.

Line 35 is tool offset, this needs to be same as tool.

 

[steelcogs]

Woah, really? That's a big issue if so. What I don't get though is why it did that for all the tools (each different operation has a different tool number in the line after the tool change line) except the one drill.

 

[masso-support]

@steelcogs we ran your file today and it worked fine.

On drill 7, tool no. 3 it worked fine and drilled to a depth of Z-1.0607.

So Z-1.0607 is the the right depth you want from this drilling cycle?

And yes the second tool command in the next line after M6 in your gcode will be ignored and wont have any effect.



In you case when you load the second tool, does it first move to the right R position? and the end depth is wrong or to start with the R location is not right?

Will you be able to do a dry run and put a ruler or something, take some photos of your observations because at times we can have different results as the machine setups are different.

 

[steelcogs]

Yeah Z-1.0607 should be the correct height. The hole is 1" into the part but I had the option to put drill tip through so that would explain the extra.

So on your run, after the first op finishes and it asks for the tool change. After pressing cycle start, your machine goes to the retract height (Z.200"), then goes on to drill the hole?

I assume by "R position" you mean retract position I have set in Fusion 360? In that case, no. It completely ignores that and continues downward as if I had the retract position mistakenly at the bottom of a part or if I had a tool offset incorrect. I know neither of these are the case as I double checked the retract height and if I post process just the drill operation and run that alone it works as expected, so it's not the tool offset either.

Let me see if I can get a very evident/easy to see occurrence of this happening with a video or photos. I may just end up having to sacrifice having my vise set up for now.

 

[masso-support]

how much is the height difference between your first and second tool?

As we run auto tool zero on our machine the results might have been different, once we know the tool length difference then we will setup our machine to manual tool change and do the test again.

 

[steelcogs]

The first tool (tool 2 in the program) is offset by 2.494, and the second tool (the drill in question) is offset by 4.6362, making the difference 2.1422".

I currently zero my tools by zeroing my spindle nose on a manual tool setter with tool 0 "loaded" in Masso (not that that really does anything but anyway), zeroing the Z axis, then using the DRO to do the same with each of my tools and just input the number the DRO gives in the tool offset menu for each appropriate tool. I'd eventually like to have an auto tool zero setup sort of like a renishaw tool height setter where I can just tell it to zero the tool then have it zero and automatically apply the offset to the tool. Not sure if you have that feature available though.

 

[steelcogs]

Quick update: I went out and recorded some videos so hopefully they show exactly what's happening.

Here's the first video, I show what happens on the DRO as I swap tools and attempt to start the next part of the program. - https://drive.google.com/file/d/1I09FHn2VOwNVPDbI221AY4AkqrU6DOSu/view?usp=sharing

In the second video I try to show (what's left of) the drill physically going too far down. It's difficult to tell because it's broken off but it goes down to something like Z-1.9 before coming up and doing the program normally. - https://drive.google.com/open?id=1Wh5m_4cdmcW8E0IZEWJh84UFdpfCN8qm

 

[masso-support]

thanks for the video and yes it does move Z in a odd manner, looks like manual and linear tool change logic working together. As we could not replicate the issue it might be that earlier the controller had some different tool changer set and the settings are still in the memory.

Will email you a version of the software today that will automatically clear the memory, simply install that software version and give it a go.

 

[steelcogs]

Ok so good news, the software update didn't ram my drill past Z0!

There is a slight side effect however (nothing malicious that I can tell), being that after I do a tool change and hit cycle start, the XY move slightly, stop, then require me to press cycle start again to continue the program. It may be something you're aware of and it might not be any issue at all, but I thought it's worth mentioning.

 

[peter35]

Has this been sorted yet? l have had the same issue. Have had a look at the fanuc post processor on the fusion site and it is written the same as steelcogs.

T1M6

and next line is T3, l thought by matching both "T" numbers this would fix issue.

Am concerned as l have run six tools.

Facing head,ok

end mill rough and finish, both ok

centre drill,ok

and then next drill cycle crashes machine.

Thought first time was my mistake and ran program through Gwizard editor and fusion simulator did not call out any errors.

Went through and reprogrammed part and had the same issue, appears to be drilling cycle only so far.

Very frustrating, thankfully only a couple of drill bits and a non critical job.

I have also found that l need to reset new programs before running them, if l hit start without resetting machine is erratic.

l dont believe l have had a program that will go right through to M30 and go back to start, program goes to M5 and M9 and then stops, will not go to next line @ M30.

 

[steelcogs]

Yeah the software update they sent me seemed to fix it. I haven't noticed any other issues but since updating I've only run the one program I was having an issue with.

 

[peter35]

Have just set up a job, 2 drilling operations.

T1 is centre drill, ok

Line N30 T1m6

Line 35 T2

T2 is an 8mm drillbit, drill was offset by +25mm.

Thankfully did not destroy job or tooling this time

Line N125 T2m6

Line N135 T1

VMC 5A-2192

Fusion 360

Have attached nc file

 

[masso-support]

@peter35 so you having a similar issue with the tool offset? we can email you the software to reset the memory, whats your controller serial number?

 

[peter35]

Serial number 5A-2192

Thanks

 

[masso-support]

Quote from steelcogs on September 28, 2018, 3:04 am

Ok so good news, the software update didn't ram my drill past Z0!

There is a slight side effect however (nothing malicious that I can tell), being that after I do a tool change and hit cycle start, the XY move slightly, stop, then require me to press cycle start again to continue the program. It may be something you're aware of and it might not be any issue at all, but I thought it's worth mentioning.

that's great that its resolved the issue. Could the small movement be the machine going to your predefined location for tool change?

 

[masso-support]

Quote from Peter35 on October 1, 2018, 5:59 am

Serial number 5A-2192

Thanks

thanks, email sent.

 

[steelcogs]

Quote from MASSO - Support on October 1, 2018, 6:01 am

Quote from steelcogs on September 28, 2018, 3:04 am

Ok so good news, the software update didn't ram my drill past Z0!

There is a slight side effect however (nothing malicious that I can tell), being that after I do a tool change and hit cycle start, the XY move slightly, stop, then require me to press cycle start again to continue the program. It may be something you're aware of and it might not be any issue at all, but I thought it's worth mentioning.

that's great that its resolved the issue. Could the small movement be the machine going to your predefined location for tool change?

That may be it. I think this actually stopped happening though after I restarted the machine again. When it did this I was just doing an air run to make sure everything was in ship shape. When I re set up my vise and finished my part the next day I don't believe I had this issue.