HG400III / MiconIII with tool changer issue

[SirCrashAlot]

We had a power spike which completely killed the machine. We re-powered up the machine which gave us an alarm "LD Sum Check Error". We reset the ladder and resolved that. Now we can not get the Tool Changer working. We have reset the values to correctly identify tools in spindle ,wait pos and mag pos. The magazine will rotate when a M6 is called but the magazine will always rotate to pot 1 regardless of what tool is called.

The machine will not carry out any of the tool change other than rotating to pot 1 and open the ATC door.

I pushed the Magazine Origin button which will rotate the magazine until the #1 pot lines up with the tool changer then stops, but the button stays flashing which should be on continuously.

[Stevo]

If you set all of your PMC data to the correct positions of the magazine and tool in the spindle the only other issue I can see having is if a macro is controlling some variables that may also need to be set. Does your machine run a macro program when doing a tool change? If so can you post it so we can have a look?

Stevo

[SirCrashAlot]

I should also note that the machine uses a electric motor to drive the magazine as it was originally equiped with a 120 pot ATC. Thats why there's a magazine origin button. Hydraulic equiped machines don't have this. The machine ran fine before the spike.

O9006
G00G80G98M15
M16
G91G30Z0
G30G40X0Y0
M17
M19
T#4320M6
G49H0D0
S2500
M99

Thanks for the help!

[SirCrashAlot]

It gets to the point of doing a tool change (postions the xyz axis, does the air blast, orients the spindle, then freezes at the T#4320 M6 command, the tool changer door does not open). The magazine always rotates fully around (it starts and finishes at the tool #1 pot being lined up for a tool change. It won't go to any other pot.

I've checked the value that is stored in the #4320 variable but it has a good number in it.

I've never had to bring in an outside tech in 4 years, but it looks like I have to now.

[Stevo]

What is the value in #4320? Is it being set to the modal T() value when you program the M6T()?

Don't call in a Tech just yet!!

Stevo

[SirCrashAlot]

yes

I called up the value by:

#521=#4320

the value would read the last T value called.

It was 3 the last time checked.

[Stevo]

When you say called it by #521 do you mean that your program or MDI you did an M6T#521 and the value of #521 was 3 and then you checked the status of #4320 and it was also set to 3? When the code reaches the M6 line of program 9006 does it register that line in the buffer and show it on the screen as T3M6?

I would like to try a few things. First off I am not yet convinced it is the #4320 line that is the problem. Does the arrow move from the M19 line to the T#4320 line? IOW does the M19 actual receive the FIN signal and move to the next line? You can test this by say doing and M19 in MDI mode and then say a M8 in the next block. If your coolant does not come on then the M19 did not finish. You could also put a bunch of ; EOB (about 15) after the M19 and see if the program ever reaches the next line.

The other thing to try is to change your macro line to T3M6 instead of T#4320M6 and see if it picks up T3.

Above is just to troubleshoot what is actually going on to find the rootcause.

Stevo

[SirCrashAlot]

I put the line #521=#4320 to tranfer the value from the system variable to a common variable which is viewable. This leads me to believe that the value inputed in is being read.

I will try what you siad about bypassing the system variable.

What do you think about the magazine always only going to pot #1?

We are not getting any real alarms. (only time out)

In manual mode the magazine will not rotate using the manual buttons. It will rotate to the home position using the magazine home postion button.

[Stevo]

I think the pot rotating to 1 every time may have something to do with the PMC parameters but I think we need to get the machine to actually change a tool before we can determine that problem.

I was suspecting that you were getting a timeout alarm and that is why I am slightly convinced that it is not finishing the M19 code. I did a quick search on the 4320 variable and came across a timer with the M19 but this was in a Fanuc manual which IIRC the Micon used a lot of similar structure to Fanuc. I could be on the wrong path but it’s all I can see right now.

I am more curious to see if the M19 is getting the FIN signal. Let me know what you come up with.

Do you have documentation on this machine or control? Is this a Hitachi? IIRC I may have some Micron manuals buried in my basement somewhere but not 100%.

Stevo

[SirCrashAlot]

I replace the variable (#4320) with T3, I also put an M8 after the M19 and the coolant came on. I believe the spindle is orienting fine but I'll try anything.

We have books for the machine. We own 6 of the same machines. This machine has a fanuc 15m. The only difference this machine has is the servo motor to drive the magazine.

The manual functions to move the single arm is the only part of the ATC manual functions that will work. Its like the ATC is locked out by something that is hung up.

[SirCrashAlot]

I got it to do a tool change by making it think tool 1 was in stand by.

The twin arm swapped tools(there are none in the machine in reality).

The single arm did not do anything as the magazine only goes to pot 1.

We beleive the problem is in the magazine.

[Stevo]

Have you tried precalling a tool with T() in MDI? How did you tell it had T1 in standby in the PMC data?

I don't have any data with me here but I have a few things to look at tomorrow at work. It's a PITA to type on this iPad

Stevo

[SirCrashAlot]

Yes, I tried calling up a tool in MDI, As I said it always will go to pot#1, regardless of the tool # called. We tried referencing the tool changer with the button that is only on machines with 90 or 120 tool magazines, which it rotates to pot 1 but the light in the button continues to flash leading me to believe that it is not finished referencing.

After checking alot of things out I am pretty convinced it is a problem with the magazine referencing. We have a book and have followed the procedures, they just don't work. We are getting an alarm "2B32 ATC Magazine Zero Return Alarm". The book says to just fix the problem...

[Stevo]

I think you are probably spot on and have found the problem. If the magazine reference light is still flashing then it has not referenced the magazine. Your book does not tell you how to repair it? How does the magazine reference? Prox switch?

Stevo

[SirCrashAlot]

It has a deceleration proximity switch, but it does not seem to have one for the home position. It has a servo motor with an encoder to drive the magazine.