Operation Manual DOOSAN Tool load Monitor for Turning Centers (DTML) Release Version 3.X Under-load detect version

Operation Manual DOOSAN Tool load Monitor for Turning Centers (DTML) Release Version 3.X Under-load detect version

Quick setup Guide For detailed information and operation of the Tool Load Monitor, please refer to pages from 4 to 21 of this document. Once you have familiarized yourself with the TLM-operation and controls, you may use this setup guide as shown here for getting started, initially. Please keep in mind that the use of the tool load monitoring function may not be effective for certain types of operations such as for light duty machining, drilling or tapping of small diameter holes. The load on a given tool that performs multiple cutting passes may vary from one cut to another. For this reason, the Tool Load Monitoring should be applied selectively for individual tools and machining operations by use of the M200 / M201 commands that turn the TLM-function OFF or ON. For setting up the Tool Load Monitoring on selective machining operation, please proceed as follows: 1. At the beginning of your NC-program, ahead of any move command or spindle command, please put the command "M200" into the program. This command overrides the TLM-function (turning it OFF). Once the TLM-function has been activated by depressing the ON -soft-key at TLM-parameter page, monitoring is always active, except at the time when the M200-command is active. When RESET is pushed after the M200-command the TLM-function will default to active status. 2. In the NC-program sequence where tool load monitoring is to be applied, please put the command "M201". This command activates the TLM-function. At the end of that sequence (just before or just after retracting the tool), please put the command "M200", turning the monitoring function OFF again. Please repeat the above steps on any other machining operation that is to be monitored. Please be sure that the "M30"-command (not M99) is used at the end of the program (See explanation on step 4, below). 3. When tool commands other than T0101 through T1212 are used in the NC-program, you must register any other tool command in the tool list at the TLM-parameter pages. (See page 11, item 7) For example: the tool command T0121 should be registered under the tool list item number T0021. This is accomplished by altering the number T0021 to T0121. 4. Next, please display the tool load parameter page. On the bottom of the page you will see the softkeys "AUTO", "ON" and "OFF". When the OFF-key is pressed the TLM is turned OFF completely. When the "AUTO"-key is pressed the TLM "Measuring-Mode" is active. When AUTO is active, you should run the machining program through from beginning to end, actually machining a part under normal cutting conditions. During measuring mode, tools with relatively new cutting edges should be used and the feed rate override as well as the spindle speed override-selector switches must be set at 100%. While executing the program with the TLM in "Measuring Mode the tool load data will be recorded. At the end of the program the TLM will be reset by the M30-command and the load data for a given tool will be posted to the tool load parameter display pages. When there is no M30- command at the end of the program the load data will not be posted. The M30 command can be replaced (with M99 if required) once the Measuring Mode has been completed. 5. Once the tool load data for the selected tools has been posted, you can now push the "ON" soft key that is located on the tool load parameter page. This will activate the load monitoring. During program execution the system will monitor axis and spindle load. When the load exceeds the limits as recorded on the tool load parameter pages (overload or under load) the machine will stop and a detailed alarm message will be posted on the tool load monitoring alarm page. Tool load data, warning and breakage limit settings can be edited if necessary. 6. Please note that during program execution any variation in stock removal, feed rate or spindle speed override conditions may produce a false TLM-alarm. 2

1. Introduction..P3 2. DTML Basic Operation......P4 2-1. Cutting OP Ready... P4 2-2. Select DTML MAIN window by [CUSTOM] key... P4 2-3. Select DTML PARAMETER window by {TPARA} key... P4 2-4. Register T-CODE at DTML PARAMETER. P5 2-5. Set the range value of WARN/BREAK LIMIT P5 2-6. Measuring Work load by {AUTO} key... P5 2-7. Execute Work Program. P5 2-8. Starting abnormal load detection by {ON} key. P6 2-9. Releasing abnormal load alarm. P6 3. DTML Detail Operation..P8 3-1. Introduction of DTML PARAMETER list... P8 3-2. DTML PARAMETER edit.. P12 3-3. Explanation of DTML LOAD DISPLAY window.. P13 3-4. Explanation OF DTML ALARM HISTORY window. P14 3-5. DTML PMC parameter related issue. P15 4. DTML Load Measurement & Detection standard..p17 4-1. Normal Load Measurement Method..... P17 4-2. Example of Normal Load Measurement.. P18 3

1. Introduction This document is the Operation Manual for DTML (DOOSAN TOOL LOAD MONITOR FOR Turning Center) Version 3.x, under-load detect version. It effects on all Doosan FANUC ITB Turing Center with this option. DTML (DOOSAN TOOL LOAD MONITOR FOR Turning Center) protects Tool and Tool Holder from the further damage. If DTML detect the abnormal load during the cutting process, machine will stop immediately or escape from cutting condition and stop by the level of abnormal load. In the normal operation, it sets workload range from Min to Max for each Servo Drive (MAIN SPINDLE, X, Z, Y, C, M, C2, and SUB SPINDLE) of each tools. If DTML detects a certain value of off-range, it will generate PMC ALARM. If tool draws only small load such as small drill and taps, even though tool has been broke, it may be still within normal load range which case DTML cannot detect this situation. In the normal operation, when an abnormal load occurs at the out of range of Min and Max load, if load is detected out of range, which was preset as minimum and maximum, during the operation, DTML will escape the tool from cutting condition by the tool skip function, if the load detected in WARN LIMIT, and Machine will be stopped (Feed Hold Condition), if Load detected is over Break Limit. *TOOL SKIP is FANUC TOOL LIFE MANAGEMENT OPTION, Followings are additional or modified figures of DTML VERSION 3.0 (1) At abnormal Tool condition, it operates at not only OVERLOAD condition but also UNDERLOAD condition. (2) It detects in Feed mode only. (3) Even in the normal cutting condition, Air-Cutting period could be occurred as tool approach or escape from part, to prohibit this errors, APPROACH TIME, ESCAPE TIME function has been added. (4) Even, in the normal condition like POCKET cutting with live tooling, it is possible that no-load, or over-load can happen, to prevent this kind of problem, an additional M- CODE has been added to bypass DTML load detection in certain block. 4

2. DTML Basic Operation Useful Definition which you need to know: [key-name] ; It stands for FANUC MDI KEY (POS, PROG, RESET, DELETE, ALTER and etc ). {key-name} ; It stands for F1~F10 menu button located at the below LCD. [UP][DOWN][LEFT][RIGHT] ; Moving Keys among the other FANUC MDI KEYs. [PG DN][PG UP] ; Page down, page up moving keys among the other FANUC MDI KEYs. 2-1. Cutting OP Ready. Even though, Tools are set for the same Tool Holder, DTML programs work independently by offset numbers which describe Rough or Finish and I.D or O.D and Left or Right tools. 2-2. Select DTML MAIN window by [CUSTOM] key. 2-3. Select DTML PARAMETER window by {TPARA}key. Select {OFF} button on the bottom part of MENU to Turn OFF DTML operation, and select [ALTER] button to select TOOL DATA. 5

And select a certain Tool DATA with [UP][DOWN] button. Originally, Number T0001 ~ T0012 been registered, every values are empty or null. 2-4. Register T-CODE at DTML PARAMETER Load data will be registered in DTML on T0001 ~ T0012 in corresponding Tool Number. If you want to input the tool data in specific Tool numbers such as T0101, T0199, T0103 as used in program, add these tool numbers into load monitor screen using [up] [down] [left] [right] as shown. 2-5. Set the range value of WARN/BREAK LIMIT. Select LIMIT DATA with [ALTER] button If you push [DELETE] with LIMIT WARN and BREAK line selected, it will automatically set the original values from Parameter. 2-6. Measuring Work load by {AUTO} key. Select {AUTO} to change from DTML MODE to measuring mode, READ ONLY will appear as shown. You cannot edit DTML PARAMETER at the measuring mode. 6

2-7. Execute Work Program Set each override switch at 100%, and don t change. After the program finishes (M30), select DTML with [CUSTOM], the measured load DATA will appear at DTML PARAMETER for each axes. During the process, DTML will measure the normal load level of the tool of each feed axis, and then enter those values into the system so you can see them on the screen. If MAIN/SUB SPINDLE is using CSSC(Constant Surface Speed Control), MAIN/SUB SPINDLE are subjected to an abnormal load detection Measurement, because, even in a normal cutting condition, there is a possibility for a sudden turning axis s acceleration and deceleration. 2-8. starting abnormal load detection by {ON} key. The system is now ready to use DTML to detect abnormal load, you may put the next workpiece in and run the same program with the feedrate override at 100%. 7

2-9. releasing abnormal load alarm. When an abnormal load occurs, a PMC ALARM will be generated and messages will appear in DTML ALARM HISTORY. WARN/BREAK LIMIT OVER SIGN (W or B) and Alarm will appear at the DTML PARAMETER of the problem Tool. Select {TALRM} after pushing the [CUSTOM] button, the DTML ALARM HISTORY window will appear, at this window you can see information of time /tool /axis / and the value of abnormal load. Select the tool for exchange, which depends on information from DTML ALARM HISTORY window. DTML ALARM HISTORY window When an Alarm occurs, select either [POS] or [PROG] to change this window to the standard NC window, then press the [RESET] button to release the PMC alarm. Inspect the tool condition and exchange the Tool. Also, select the [CUSTOM] button for the DTML PARAMETER window and select either [RESET] or {CLEAR} to release DTML ALARM. DTML PARAMETER window when alarm occurs 8

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3. DTML Detail Operation Useful Definition, you need to know. [key-name] ; It stands for FANUC MDI KEY (POS, PROG, RESET, DELETE, ALTER and etc ). {key-name} ; It stands for F1~F10 menu button located at below the LCD. [UP][DOWN][LEFT][RIGHT] ; Moving Keys among the other FANUC MDI KEYs. [PG DN][PG UP] ; Page down, page up moving keys among the other FANUC MDI KEYs. 3-1. Introduction of DTML PARAMETER list 6 7 3 8 4 10 1 5 2 9 11 1) DTML VERSION It verifies Doosan Tool Load Monitor for Lathes program version. (This manual is for DTML version 3.0) 2) Execution of the program and the sequence number Just like the standard Fanuc CNC window, this stands for program number and sequence number. 3) DTML Parameter Line number. It shows the selected line to edit from the Tool Data List. You can register 16 Tools. 10

4) DTML Parameter edit mode Shows the mode that the data is Read only can be edited. When DTML is operating, (with {AUTO},{ON}), you cannot edit the Parameter because it is in a READ ONLY condition. However, When DTML is not operating, and, ({OFF} is selected), you can use the [LEFT][RIGHT] keys to move to a certain line in the Parameter. Automatically the condition will be changed to EDIT, so you can edit DATA. You will however, need to end the EDIT condition by pressing either [PAGE UP] or [PAGE DOWN] one time. 5) DTML Parameter Table select Shows the selected Data Table to edit. There are 2 tables in the DTML Parameter window, one is the Tool Data Table and Limit Data Table which set the range of permissible Load. To edit DATA, you need to select one of two tables by [ALTER] key. 6) Tool Condition Warn, Break sign When an abnormal load occurs, W and B signs show at the side of each problem Tool. If you choose the DTML Parameter window, when an abnormal load detection PMC- ALARM occurs, you will see W(arn) or B(reak) have been marked. You need to clear W(arn) or B(reak) by selecting either the {CLEAR} or [RESET] keys after changing the problem tool. 7) Tool list to. Measures and detects loads of the Tool Numbers with the original values of T0001~T0012, for 12 Tools. If you need to, you may separate the load detection levels by the processes even with the same tool by using a different offset number. If you program as T0000, DTML will not be sensing or generating any alarm related to abnormal load detection. 8) Input Line For (Approach Time), and(escape Time) 11

Air Cutting could occur before a tool contacts the material (Approach), or after the tool escape from material (Escape) during feed-axis move to cut. So, you need to set an Approach Time in the lines of AP and Escape Time in the lines of ES by using 100[m sec] unit (the recommendation is set for every line as 5 which means 500m sec). These values are critical to detect a problem during Air Cutting. It is good practice when programing to keep the Escape Time as small as possible. If there is a pocket area which could make an Air-cutting situation during a feed-axis move, you will need to use the following M-codes. M201 (TOOL MONITOR OFF) M200 (TOOL MONITOR ON) When Auto-Mode is finished, it goes to M201 (TOOL MONITOR ON) automatically. If you want to turn off DTML, select {OFF} at DTML PARAMETER MENU. 9) Output lines of a normal load for each Axis during the sample cut. At DTML [AUTO] mode, the normal cut load values show for each registered servo (MAIN SPINDLE, X, Z,Y, C, M, C2, and SUB SPINDLE) after auto-mode process finishes (M30). When in SPINDLE rotation with CSSC (Constant Surface Speed Control) mode, the load value shows only when X-axis is not moving. Other Servo- Axes (Not-SPINDLE) shows value only when feed-axis is moving. Each axis output shows min. and max. Cutting load values. However, if you want to turn-off detecting UNDERLOAD (AIR CUTTING), set MIN to 0(Zero). 12

10) Input line for permissive overload. You must set the permissive overload range for generating a WARNNING ALARM and BREAK ALARM. Use the [ALTER] key to select LIMIT DATA and use the [LEFT][RIGHT][PAGE UP][PAGE DOWN] to edit. (See 5) After selecting a line and pressing the [Delete] key, all the default parameters will be set automatically. Followings are sample values DTML PARAMETER X AXIS MIN - MAX T0001 20-30 : : : : WARN 05-08 BREAK 10-16 From following example, Normal loads of X-axis % value is 20 ~ 30% for Real Cut. If you include WARN LIMIT value, 15 ~ 38% is normal. So, if values is under 15% or above 38%, DTML will send WARN ALRM(Tool Skip). Further more, values is under 10% or above 46%, DTML will generate Break Alarm (FeedHold) Break Overload Alarm (Load value > MAX (30) + MAXBREAK (16) =46) Warn Overload Alarm (Load value > MAX (30) + MAXWARN (8) =38) NORMAL LOAD (MAX (30) < Load value < MAX (30) + MAXWARN (8) =38) NORMAL LOAD (MIN (20) <= Load value <= MAX (30)) NORMAL LOAD (MIN (20) > Load value > MIN (20) MINWARN (5) =15) Warn Underload Alarm (Load value < MIN (20) MINWARN (5) =15) Break Underload Alarm (Load value < MIN (20) MINBREAK (10) =10) 13

11) DTML Parameter Menu [ DTML PARAMETER edit & OP Mode ] Set DTML OP Mode as AUTO (Measure Mode) Set DTML OP Mode as ON (Detect Mode) Set DTML OP Mode as OFF DTML Alarm CLEAR (same as [RESET]key) Clear DTML PARAMETER [ Window Change Menu ] Move to DTML MAIN Move to DTML LOAD DISPLAY Move to DTML ALARM HISTORY Move to DTML M ; Move to DTML MAIN Window. If you use the Doosan Easy GUIDE option, DTML MAIN window has menu to change from standard NC PROGAM window to Doosan Easy GUIDE. > : Move to the other DTML window. From the DTML PARAMETER window, it move to DTML LOAD DISPLAY window. 3-2. DTML PARAMETER additional edit function. After select 1 line and push [DELETE] key, TOOL DATA of this tool goes 0(Zero) and LIMIT DATA goes the given value, PMC PARAMETER, automatically. At DTML EDIT Mode, if you select the one certain DATA and push [DELETE] key, only the one certain DATA goes 0(Zero). When you edit DATA, if you input the value and press the [INPUT] key, the value will be a new DATA. However, if you push the [INSERT] key after inputing the value, it will add the value to the old value. 14

3-3. Explanation of DTML LOAD DISPLAY window Each servo s real time load display at DTML LOAD DISPLAY window. Also, it shows the current operating DTML TOOL NO. and PARAMETER. Example from MAIN SPINDLE. Current using tool line # at DTML PARAMETER. Current using tool DTML PARAMETER registered tool number. Real value of load and line graph for each axe s MIN, MAX value for current using Tool Shown axis for load (S1-MAIN SPINDLE, X, Z, Y, C, M, C2, S-SUB SPINDLE) 15

3-4. Explanation OF DTML ALARM HISTORY window DTML ALARM HISTORY shows record of abnormal load alarms and it keeps the history of record. It includes Time, Tool, Contents, Servo-axis, and condition of Alarm. Followings are examples The Date of Alarm Occur (Year/Mo./Day) Time of Alarm Occur (Hr./Min./Sec.) Kind of Alarm (WARN or BREAK) Tool Number from DTML PARAMETER Name of Servo-axis Kind of Alarm (OVERLOAD/UNDERLOAD) Real value of load and limit value of PARAMETER (Real Value/Limit) Kind of PMC ALARM It is possible that load can be smaller for Cutting load than Air Cutting load depends on condition and direction of Tool attachment. OVERLOAD ALARM may occur during Air Cutting. Especially, X-axis real cutting load in the Finishing Face Process could be lower than Aircutting load. It is good idea that use different offset number to register at DTML PARAMETER, so, depending on process (Rough, Finishing, Face and ETC). 16

3-5. DTML PMC parameter related issue If you adjust PMC PARAMETER depends on various cutting conditions, you may detect abnormal load better. If you change following PMC PARAMETER, you must turn off POWER before you begin processing. 1 Default Warn/Break %Overload Value D-data Value Comment D0850 5 % Default Warn %Overload Value D0852 10 % Default Break %Overload Value At DTML PARAMETER window, if you select LIMIT DATA TABLE and push [DELETE] key, all LIMIT DATA TABLE will be set up with value as D0850, and D0852 of PMC data. 2 Warning Alarm Delay Time D-data Value Comment D0854 1000 m sec Warn Alarm Delay Time It takes about for 300msec to generate Break Alarm after load is over BREAK LIMIT. Warn Alarm will be delayed as set by PMC data in D0854. 3 Load Bypass Time D-data Value Comment D0856 1000 msec Load Bypass time for Main/Sub Spindle D0858 0 msec Load Bypass time for X,Z,Y,M D0860 2500 msec Load Bypass time for C,C2 Spindle could give over load even after SAR is ON during the regular cutting condition or the beginning of cutting that depends on cutting material. For every axis, if you may modify values (Bypass time) for D0856~D0860, DTML does not detect load problem whenever Z-axis change from Rapid-Axis to Feed-Axis before this bypass time as set on [D858], and by pass the load sending the certain time as set D856 and D858 after SAR signal is on. 4 TOOL MONITOR ON/OFF M-CODE M200 TOOL MONITOR OFF (Temporary DTML Stop) M201 TOOL MONITOR ON (Temporary DTML Stop Release) You can stop detecting abnormal load for the certain axis, tool, BLOCK. If you want to omit detection for certain axis, you need to set the certain axis LIMIT DATA as 0(Zero). If you may ignore overload for the certain tool, don t register the certain tool at DTML PARAMETER. If you want to ignore the overload detection for the certain BLOCK, add M201, M200 before the BLOCK and after the BLOCK. M200 M-CODE is for TOOL MONITOR OFF by M-CODE, TOOL MONITOR will ON at the end of the program. If you want to stop detection continuously, select {OFF} key which located at bottom of DTML PARAMETER window. 17

5 PMC ALARM MESSAGE PMC Alarm occurs as Warn Alarm (Tool Skip Alarm): number 2086, Break Alarm (FeedHold Alarm): number 2087 2086 TOOL MONITOR ALARM. DETECT ABNORMAL LOAD AND TOOL WARN ALARM 2087 TOOL MONITOR ALARM. DETECT ABNORMAL LOAD AND TOOL BREAK ALARM When number 2087(break alarm) occur, you must exchange tool and go to DTML PARAMETER window press either {CLEAR} key or [RESET] key at the bottom menu. 18

4. DTML Load Measurement & Detection standard 4-1. Normal Load Measurement Method DTML Ver 3.x measure normal load and detect abnormal load with following standards. 1 Only measure normal load and detect abnormal load for servo-axes which are factory pre-set from MTB such as MAIN SPINDLE, X, Z, Y, C, M, C2, and SUB SPINDLE. 2 Only measure normal load and detect abnormal load for Tool number registered at DTML PARAMETER. 3 Only measure normal load and detect abnormal load for LIMIT DATA is not 0(Zero) at DTML PARAMETER. 4 It does not measure normal load and detect abnormal load after M200 (TOOL MONITOR OFF) command and before M201 (TOOL MONITOR ON) command. It goes M201 automatically at the end of the program. 5 Only measure normal load and detect abnormal load for axis, which is rotating or moving feed-axis at feed-axis mode (G01/02/03). Further more, if the operation is not Auto-Mode or is not in feed, DTML does not measure normal load and detect abnormal load. 6 It does not measure normal load and detect abnormal during change from rapid-axis move to feed-axis move during PMC PARAMETER Load Bypass Time. (See 3.5-3) 7 It does not measure normal load and detect abnormal during between servo-axis move to stop or stop to move for 1 scan time (=250msec), because DTML consider this time as range of acceleration/ deceleration. 8 It does not measure normal load and detect abnormal during changing to feed-axis mode (G01/02/03) for the amount of DTML PARAMETER AP (approach time). Because this time is Approach Time, to detect under-load, DTML does not measure normal load and detect abnormal during change. 9 It does not measure normal load and detect abnormal during changing to feed-axis mode (G01/02/03) for the amount of DTML PARAMETER ES (Escape time). Because this time is Escape time, to detect under-load, DTML does not measure normal load and detect abnormal during change. 10 DTML measure normal load and detect abnormal for every 1 scan-time (=250msec). So, if abnormal load is less than 1 scan-time (=250msec), it is possible that DTML cannot measure normal load and detect abnormal. Further more, if there is rapid-axis block which shorter than 1 scan time between feedaxis blocks, explanation at 4-1 9 can not be true. 19

4-2. Example of Normal Load Measurement Following is example of DTML Z-axis load measurement FEED axis move signal Z-axis move signal Real Time Z-axis servo %load Z-axis servo %load after filtering(2 nd ) of AP No measuring block for AP period. DTML use 3 filters by software to measure and detect load for servo-axes. Percent (%) load from every servo amplifier go through 1 st filter which removes measuring of acceleration/ deceleration block and by-pass block. AP block load will be remove by 2 nd filter, ES block load will be removed by 3 rd filter You can see No measuring block for AP period has 0(Zero) load. Following graph shows %load by the 2 nd and the 3 rd filter. Because AP was set as 0(Zero) for this graph, the load after the 2 nd filtering is same as after the 1 st filtering. 20

FEED axis move signal Z-axis move signal Real Time Z-axis servo %load Z-axis servo %load after filtering(3 rd ) of ES No measuring block for ES period. Load value after filtering acceleration/ deceleration block, by-pass block and ES (2 nd filter, AP=0) Even though normal cutting condition, no-load can occur during ES block, so don t measure and detect load for that period, but we cannot find block of changing feed-axis move to rapid axis move, so we delay real-time %load after 2 nd filter as much as Escape time. According to graph, we can find ES delaying after filtering acceleration/ deceleration block, and by-pass block. Also, from No measuring block for ES period we can find the value after 2 nd filtering and 3 rd filtering are different and it has been removed as much as the delayed time. DTML use delay filter to measure and detect under-load during ES block, real alarm occurs after abnormal load detected and Escape Time passed. So, it is a good idea that you program work process with the smallest Escape Time possible, which makes alarm fires quickly. 21

5. An appendix (Ver 3.4) 5-1. WARN / BREAK LIMIT LEVEL to Append WARN / BREAK LIMIT table one more add (LV 0 / LV 1) {TPARA2}select => LIMIT LEVEL 0 1 input => LV 0 LV 1. T00003 WARN / BREAK LIMIT table (LV 0, LV 1 ). 5-2. B1,B2 AXIS to Append ( {TPARA2}, {TLOAD} ) 5-3. To change TOOL a number of five ciphers (4 cipher->5 cipher)_ Only MX -Series EX) T13100 ; TOOL number 13 / OFFSET number 100 22

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