OIC HORIZONTAL MACHINING CENTER OPERATION MANUAL FANUC -16i / 18: / 21i FANUC —160/180is-MB OKK CORPORATION 3-21-9 , TOYOSAKI , KITA-KU OSAKA , JAPAN OPER.-16i/18i/21i,160/180is-H DECEMBER , 2002Contents Preface [1] Operation Panel .. (1) Panel Configuration ... [2] To Turn the Power ON... Power switch layout drawing (1) To Turn the Power Of (2) To Tum the Power O [3] Manual Operation (1) Operation Required for Manual Operation Method A) Moving by Manual Pulse Handle .. B) Machine Zero Return Operatior C)_ Moving in Cutting Feed ... D) Moving in Rapid Traverse Mod E) Operation of the PMC switch F) Zero Method for Relative Coordinate Display G) Operation for Spindle H) Operation for Coolant [4] Automatic Operation (1) Automatic Operation... (2) Program Delete , Input and Edi A)How to Delete the Program in the Memory. B)How to Input and Output a Program into and from the Memory ... Operation! How to input program trom a Floppy disk or the like , using extermal I/O equipmant Operation2 Manual input Method ... C)In-memoryprogram Editing Method Operation’ Program calling Methoc(3) Automatic Operation Method A) MDI Operation Method B) Machine lock / MST lock Operatior [1] Machine lock / MST lock Operation C) Graphic Function and Operation Method [1] Graphicparameter Setting Method... [2] Explanetion of Graphic Parameter Contents .. [8] Tool Path Drawing Method D) Work Before Operation... [1] Tool Registration .. [2] Compensation Amount Measurement and Input Method 1) Tool length compensation 2) Tool diameter compensation amount 3) Work compensation. a) Mesurement of X and Y work compensation b) Mesurement of Z-axis work compensation E) No-load Operation Method ... F) Machining Operation Method ... G) Z-axis cancel Operation Method .. (4) Resetting Method for ATC Stopped in the Course of Operation .. A) Operation Method... B) Carrier Operation Panel (5) APC unit (6) Resetting method for APC stopped in the course of operation ... [5] Centering Procedure... (1) Crtering Procedure for Horizontal Machining Center...< Preface > This operation manual explains machine handling ranging from manual operation to automatic operation which is required for operation of “Horizontal Machining Center with FANUC-16 i" .L12) Uperation ranei (1) Panel Configuration (Display,MDI,Machine Control Panel) Vertical Type T 2.0010.¢ 1869.0 DIET | TOA T@ [ole OSott keys TU select key) Acrosa/Numaric kaye AL RETURN ist ay (Mode sect hays JEDIT hay ALTER) @HCUWP select key OPTION select key @3)EDIT key INSERT) @SOLAWP select key (COOLANT select key @3)EDIT key (DELETE) @®Display unit Que tenors sdec ey @3)INPUT key DAY RUN select key (EPAGE keys 6) Functon select kays Qos sees toys GDSHIFT key @Cura move tye @No power OFF toy @SPINOLE over ene koys @Wachine LAMP key —@)CYCLE START pushbutton @Procran ET key @])SPNOLE mal opan hye @®Nanust hands box — G4)FEED RATE overide eect keys @aues inde angs RPO ter overdo ys @operation READY kay @)Manua! FEED RATE sola kaye @DEMGSTOP pushinvton G7)Manual FEED select keys ©Sswat_e w.00K seed toy (HELP key @®iHandie ood AXIS sot vith GB)ATC CYCLE key ROCK SKP select key (RESET key GS) Han fned ANGE sed er @5)ALARM RESET key OFT STOP select key GO) Atesshumarc keys GO)NC power ON key . @FRED HOLD pushiutonHorizontal Type G 3 hal ) CSCIC OD © sot keys QT cotect key) ArossiNumeric hays GDNC power OFF key —@)SPINDLE override select keys QL RETURN soles key (2)Mods select keys @2)EDIT key (ALTER) @Mecrine LAMP key @2)CYCLE START pushbutton @ = Moving in Rapid Traverse Mode ! é i Adjust the RAPID TRAVERSE RATE of OVER- RIDE % to the objective speed from among . Setting of rapid traverse % CELE) Rapid traverse mode Press of MODE SELECT. @@® @ @e® ‘The machine stops when the finger is removed from the key . Press [MANUAL FEED] of the objective ; axis and direction . é Moves only while the key is being pressed. & IlOs ES POSSz) GEERT FED Gas 12[3] Manual Operation | E) Operation of the PMC switch ‘The PMC switch has the function of selecting the functions that the NC operation has intemally and the selection is made by an input from the screen. The PMG switch call (1) é The PMC switch call (1) 4 Press Dae). Press E™} . ‘The list of function of the PMC switch is displayed on the screen . 110) mo 10) s9¢0) Ko) Making the functions of the PMC switch valid Enter the switch number of the function to be made valid from (4). (4) [ewer VALID INVARID the numeric keys and press ‘The display of the switch number becomes ON and the function 90s into the valid state . Making the functions of the PMC switch invalid Enter the switch number of the function to be made invalid GQ) = (0) our VALID. INVALID from the numeric keys and press The display of the switch number becomes OFF and the function goes into the invalid state . ‘The contents set by the PMC switch will be retained even when the power is switched off . 1314{3] Manual Operation [BB Zero Method for Relative Coordinate Display Zero Method for Relative Coodinate Display Relative coordinate screen Press [=] ( DD ). Relative coordinate screen Press [=] ¢ DD ). fz Press »} ( objective axis) [ SIZE] and press [Pres . Example : When presetting to [X50,000]; Press the [XI[SIO} 10] [aest9. (The relative coordinate display changes to "X50.000",) I516{3] Manual Operation © Operation tor Spindle When the power is turned ON , the spindle speed is “ZERO . IN the "MDI MODE” , an order is given , and itt ‘is not executed , an “Alarm” is produced . Rotate the spindle reversely(CCW) press (8), Stop the spindle in the home position | Press (3) . | [BUTTON] atthe lower part cf the operation panel. Change the tool} (ate) ; d i i Press() . [TURN BUTTON] at magazine {side (Both CW and CCW) . IE) Operation tor Coolant Discharging coolant press (3). Press (2) (The lamp lights up . ) (The lamp lights ct.)14] Automatc Uperauon (1) Automatic operation (Operation by program command) Prior to automatic operation, first select an operation method from para below,and then select the desired item in para. 6 and subsequent para- graphs during operation selected in para according tothe applications. vig Operation method ; MDI operation | Operation executed by the command stored in MDI. i Memory operation | Operation executed by the command stored in the memory. % — Remote operation r X,Y,Z and B axes move as per the command and execute f } X,v.2 and B axes donot move and the operation Machine lock operation | gniy inside the NC unit { Z-axes cancellation E-operation X,Y and B axes move, but Z-axis does not move. Execution of M/S/T commands Normal operation i The M,S and T commands are executed as per the —= a { All, M,S and T commands are not executed. i MST lock operation |" (MO0,MO1,Mo2 and M30 are executed.) } 4 Feed rate Normal operation | The operation is executed at the feed rate as per the ae | program command. an ee The program feed rate is ignored and thie operation Is i Dryrun operation” | executed at a manual feed rate, Nn i. Execution unit Fy continuous operation | The operation is executed continuously until the stop ki 7 = command in the program is given, ciceeeael 5 Regardless of the stop command, the machine stops each j.time when one block is executed. 18 Single operation[4] Automatic Operation (2) Program Delete , Input and Edit [To output a table] ress the "PROG", —— EDIT Screen Press the "LIBRARY", [ Cie) * Max.8 program No. registered . (2) Press the [PAGE] key to go to the (5) next screen ‘© Indicates the number of programs already registered. © Indicates the number of programs which can be additionally registered. ‘e ‘dicates the total number of characters already entered. © Indicates the number of characters which can be additionally entered. © Displays the program number No.registered. 19|B EL) Cae GEER Ayes Fry Ske ETETE (15II") 20[4] Automatic Operation | A) Howto Delete the Program In the Memory Validate program editing ® ou” ‘Set the [EDIT] to "VALID". Edit mode Press the (3) of ne MODE SELECT. ‘When deleting all programs within the memory Press the [0] (Objective program No.) [DELET]. Press the (O][-}[9](9][9}[9][DELET]. Make editing invalid f Press [imey ) : ot Check to see that Program No.is deleted Fin the program table. Set the [EDIT] to *INVALID", ‘When the fixed cycle program and Program Nos.8,000 to 9,999 are deleted, normally, no operation can be performed.When deleting, set the parameter. 2122[4] Automatic Operation [BB © Howto Input and Output a Program Into and from the Memory How to input program from a Floppy disk or the like, using external /O equipment. External I/O equipment is widely varied. However,expianation is given here of the input method using a floppy disk and method of outputting punching out) to the floppy disk with RS232C as an example. Connection with input unit RS232C CH1 1) Connect the machine side ACIO0V3A S232C-CHI receptacle and input unit with a cable To ACI00V3A S, To RS292C CH1 S Validate editing ot Set the [EDIT] to “VALID”. Program screen : Data input operation eee I ane Press [i=sia) ,and press [As . MODE SELECT. 8 23‘aq 24(4] Automatic Operation Data input operation 1) When Program No.is present 2) When no Program No. is present in , in the tape : the tape or the tape program number | Press : is within the memory and the number is i changed for input [© | [Program No.) and pres Make editing invalid ° if o ‘Set the [EDIT] to “INVALID” When several programs are prepared with a single tape, If input by the method b) above, the value of [0] in the tape is ignored,the set value becomes Program No., and Program No. subsequent to the set value is registered with the value incremented by 1 in sequence. 25ele Ieenre Bees Iie Free) [ Oee Ba FI ReEEER 26[4] Automatic Operation Manual (Key board) input Method A simple Program may often be input by this method. Validate the editing Edit mode ® ot § Set the [EDI] to “VALID”. press the (2) otthe MODE SELECT. © Program screen : istration of Program No. Press the [Jortne | | [Program NO| and press EJ. MODE SELECT. i: Make editing invalid sa i Set the [EDIT] to AgINVALIDAh. Ater pressing the (£08) E="Lmanually Input the program (within 32 characters) to the last while repeating For typing errors in the course of input, use the [CAN] button. Payy » P P Bw ee SII | rateae4 a SOE Benes = =a = oy See ats NEED an | [Ul o b ® way oe $550 a 28{41 Automatic Operation [© in-memory Program Editing Method ye Program calling Method F Registration of Program NO. Press (BJottne MODE SELECT, Press(°.dtprogram NO}, and and Press("=]. press [ose . ‘Adjust the cursor to the edit place 1) Method 1 . Call the [ADDRESS] or [WORD] in the corrected place Press the [ADDRESS] or [WORD] , and press Display the program with the block including the calling address or word nearest to the calling position as a head. Press the [Search | ] : ‘the program is searched in the reverse direction. ~ 2) Method 2 i i i | By a push these keys, the program moves vertically in units of one block. By a push on these keys, the program moves to the right and left in units of one word. When altering tf When adding Adjust the cursor fo the place to be ‘Adjust the cursor to the word just anged according to theprocedure ‘ Gatesaeeoasee before the additional place.Press (xe the [Added Contents] fe. [Changed Countents] When deleting | Deleting one word Deleting from the cursor position (EOB) ‘Adjust the cursor to a place (word) | —_Deleting from the cursor position | tobe deleted. Press [") . | 0 (E08); Press the 208) EJ.30[4] Automatic Operation (3) Automatic operation method MDI operation is such that apart from the memory area, there is a screen (MDI screen) in which a program can be entered manually for 6 to 10 blocks Max. and automatic ‘operation (MDI mode) can be performed with this command. | A) MDI operation method | [A program can be entered totally j up 82 characters by the data input of {| § key : input 6 to 10 blocks Max.and the MODE SELECT. § § Foress =". MODE SELECT. £ Adjust the cursor to the head of the block i to be executed . ; g & Execute the command contents with the § [CYCLE START]. Spindle override Use these keys to set the spindle override from 50 to 150% in response to spindle speed set command . The speed increases or decreases 5% each time you press [ +] or [-] key , respec- tively . To set the override rate to 100% , press [ + ] or {-] keys simultaneously . The displayed value is the override rate set on the con- trol panel . The override rate in situations such as high ‘speed spindle warm -up (M108) is not disp! ene rN RET 31Input the following and ex- ecute the program G91G2820; ‘Z-axis zero return G28xove; :X-and Y-axis zero retur (GO0X-300.0¥-200.0; -and Y-axis positioning M02; % Lower Z axis by 0.5mm. | Be an in the handle mode. ate x1x19, % S Move X avis | approx.+50mm in the i manual mode at the feed rate "F500".Hi © Machine tock / MST lock operation Machine lock / MST lock operation is such that the input program Is operated in the Memory mode as. in normal machining operation, but at the machine side, all movements are locked, and only the NC side is executed up to the program end. * By machine lock, X, Y, Z and B axes are locked. * By MST lock, M, S, and T function are locked. The purpose of this operation is to check theoretical errors (character input errors, numeral calculation, work centering, work length compensation input, etc., required. for actual machining are not taken Into account yet, and only the tool diameter com pensation (offset) amount for numerical calculation errors is input. 33; ae au aay ees CES Eg Ch och ® ee oe 2600 34[4] Automatic Operation In a normal case,the above cancel mode is selected, but the opera may often be : : Press ("| [1F2aam)) , and check the display on the (Modal) screen. | restarted in the diameter compensation mode due to alarm in program checking. In i ‘ ‘such a case,execute M02 on the MDI screen and start the cycle cancel condition. i MST lock-ON . NO | S Tool dlameter com- 1 It 100% Is exceed E pensation setting i no eye start is possible a as f during continuous LL press BS (0=mD) ana | operation. re i | | setonly the to! aiameter ' i {_compensatlon(Ofsep, press (5) ot the MODE SELECT. i [Program No] , and press [53=3).. i 4 Press the [CYCLE START]. 35 exusotoenesyeae 36PROGRAM END" lamp # lights up SOD) pnoanan eno E the theory check is completed [4] Automatic Operation F PROGRAM END” lamp light up 2O-SO Proanau stor MOOMO1 stop. ‘ALARM? lamp light up After checking according to the Program -editing procedure,and restart operation. Press the [CYCLE START]. 3738[4] Automatic Operation {© = Graphic function and operation method Inthe standard specifications of F-16/18M, the function of only tool path <¢rawing---machine motion drawing function (tracing function) can be used as ‘a graphic function.(Also optionally available is dynamic graphic display.) [1] Graphicparameter Setting Method Various parameter for drawing (graphic display) should be preset . Graphic parameter z } to the objective position. After keying in the numerical data, press ( [2] Explanation of graphic parameter contents ‘Set the graphic plane.5 types of graphic planes "XY","YZ","XZ","XYZ","ZXY" can be selected. Set the maximum and minimum values of the graphic range for display each axis. Setting range : 0 to 9999999 (Unit: 0.001mm) ‘Set the graphic scale factor. Setting range : 0.01 to 100.00 times Set the coordinate value in the work coordinate sysytem of screen center. Set the maximum and minimim values in the graphic range : these values are set automatically once the graphic display is made. When part of the program is displayed, set the sequence number of the end block. Once the graphic display is made, this value is canceled automatically. : If automatic operation is started in reset conditions, the previous screen is deleted automatically. 0: The screen Is not deleted automatically. 39ow ow oow @e Oe Oe L- 40{41 Automatic Operation [3] Tool path (locus) drawing method 7 Memory operation mode j ff Program call Press Botte move re : )- ‘SELECT. qa If the cycle is started by the aforementioned method, the machine also moves as programmed. ‘Consequentty,when it is desired to make only graphic display,start the cycle in machine lock conditions. (2) Ifthe feed rate is high, no correct graphic display may be made. Reduce the feed rate by dry run, for example. @ When a program using several tools is drawn three-dimensionally, no graphics in the Z direction deviate if graphic display is made with the same tool length compensation. @ In graphic display of a program for muttifaced machining which uses B axis, all surfaces are overlapped. Accordingly, to make it easy to see the graphic display, itis preferable to call "Program Call” halfway for drawing. 41ao 42basis ES so [> Work Before Operatio’ [1] Tool registration In the tool change unit (ATC) of the address fixed system, the same tool is always inserted into the same magazine pot when a tool is changed ; therefore, no tool registration is required for some models. Most models employ the memory type address fixed system which also allows tool registration. in this case, when a tool is mounted to the magazine pot, Its ‘status can be stored in the NC device. This operation is called . ‘There arer two operation methods for tool registration Record the number of a tool mounted of the spindle and magazine pot. [ Sample mounting and recording } ‘Magazine No. ‘SpindleaS BRA PARE oe See al Beceee See] G f =i 44[4] Automatic Operation Registration screen Fi Deleting all registrations 1) Press ( ) ress EY ( De). rt oe At this time, the present registration 2) Press (Tass) ( [ZEes=") ) contents are desplayed. However, spindle No. is not t cleared. ‘The data on the page displayed at present is deleted. ‘The data of all magazines displayed at present is deleted. For a multiple magazine, the data of all magazine is deleted. For a multiple magazine, the data of all magazine is deleted. ‘Only sub number displayed at present is deleted. Both Too! No. and sub number displayed at present are deleted. According to the above § method, register all required tools When registering a tool by the § method of "Tool Registration (1)", do Not register other magazine pots regardless of presence or ab- & sence of the tool and maintain "Too! No.( 0)". objective number with the keys —[3 Input the [TOOL NO] and press The setting range of Tool # No. is 0to 9999. i (1) "Sub* on the screen has no particular meaning in standard specifications. Set this number just as a memo for the tool. The setting range is 0 to 99. (2) Inthe method (b) above, the vacant pot of Too! No. registered with MDI is called to the standby position after tool registration, and the tool sultable for its Tool No. is mounted to the spindle. After repeating this operation, mount all required tools. (3) When itis desired to display the tool in use, press the [LIST]. 45Pomtitt SEnrS Sse = uf =: ats Gi 46[4] Automatic Operation [2] Compensation amount measurement and onput method In the machiningcenter , AgToo! Compensation Memory CAh Is standard used . Accordigly , the same number can be used for length and diameter ‘compensations . 1) Tool length compensation Input the size from the spindle nose (spindle reference surface) position to thetool edge -- "tool length’ as a compensation amount with "plus(no code)". a) Use a tool presetter for measurement Bese: pce: Q@ | b) | Measurement method by machine "PMC" screen Registration of Tool No. Register Tool No. according to the tool registration procedure given in page 51. ‘Tum "Machine Lock / MST lock / Z-axis Cancel” OFF Move Z axis to just ahead of the stroke at the minus side by manual operation . With a dial gauge attached on the table, hold it to the spindle nose and set the dial gauge to zero. Set Z of the relative coordinates for position display to zero. Flom) om os} | is selected .S555 285555) i: CTD Gee : GEE) GEE) ge 48[4] Automatic Operation ? Mount the too! to be measured to the spindle Mount the tool to the spindle , using AgMDI operationAh or AgToo! removing and reinstalling button at the lower part of the operation panelAn , AgToo! changeAh , etc. Move the cutter edge up to the zero position of the dial gauge by Agmanual operationAh , Aghandle ‘operationAh etc . . Compensation amount input At this time , the measured value (Z-axis machine coordinate value) Is display ed also on the too! compensation screen . Adjust the cursor to (2)_(e i AgShape HAh of the objective compensation number , using [3}—[e}>. | E : i Press the Disa) {2}, then [ema) ' e : the measured value is input to the objective compensation number . i é Use this function to add the data to the input value. I E [LX Use this function to input the size directly. ‘According to the above method, measure and input the compensation amount of all tools. 2) Tool diameter compensation amount use a micrometer or calipers for measurement, and normally, use the too! radius as a compensation amount. (The compensation amount is input with plus(no code)".)_ Compensation amount input ees Using ,adjust the cursor to Agshape DAh of the objective compensation number . For example, when a 20mm end mill is used, input the compensation amount as "10.000" and press [_wPuT_): the compensation amount "10.000" is input to the objective compensation number.Le 50[4] Automatic Operation 3) Work compensation ( G54 - G59 ) @ of G54 to G56 on the right figure is the program origin of each work . on Y Mount the centering tool to the spindle. ‘Turn “Machine Lock / MST lock / 5 Move it to the work origin by Z-axis Cancel" OFF Press (™|( (om): the X and Y | | values of the machine ccrdinate t corresponds to the compensation amount. Record this value in the | memo Work compensator Zl Using [Z}(G), adjust the cursor to the axis position of the objective | work compensation number . Enter the address keys [X][Y] of the axis to be | input,type the X and Y values(compensation) of the machine coordinate thus recorded, and press the [Input] : the work compensation amount is input to the objective compensation number. [Z] should be set to "O"(zero). By the above method, input the entire work compensation amount. This key is used when it is desired to add the data to the input value. 51-DeD-0 BBB. 52{41 Automatic Operation b) Measurement of Z-axis work compensation amount mm, Input the distance from the spindle nose in the 1st origin to the work reference surface —. (program origin) as work compensation amount. prrranftmr Wee Mount a test bar to the spindle Mount a tool whose length i {tool length compensation amount) is known or a test bar to the spindole . Tum "Machine Lock / MST lock / Z-axis Cancel" OFF Move the tool edge to the work origin by manual or handle operation . Press} [oeat)): the Z values of the machine cerdinate corresponds to the compensation amount. Record this value in the memo. Work compensation amount input t Using [S}[6} ,aqjust the cursor to the axis position of the objective work compensation number . Type the address key (Z,]of the axis to be Input, key in the recorded machine ccordinate Z value and the length of the tool used ( tool length compensation amount), and press [r=] : the work compensation amount is input to the objective compensation number . When measuring with the height gauge , also add its size . [=i] Use this key to add the size to the input value. 5354[4] Automatic Operation [BB © No-load Operation Method ( Method of moving only Z-axis at a safe height by the same operation as machining operation ) (G40/G80 display check Press (3) . press [=] (Derm) ) , and check the display on the (Modal) screen. In a normal case,the above cancel mode is selected, but the opera may often be restarted | £ Tum "Machine Lock / in the diameter compensation mode due to alarm in program § | MST lock /Z-axis checking. In such a case execute M02 on the MDI screen and start the cycle cancel condition, Single block operation F Set the Single Block to The override can be used upto “| i § § Oto 200% in the single block, ==" Compensation amount check ( [leet ger) ), and check the compensation amount. : Since only Z-axis is operated at no load at a safe height, input a safe height value for ' only Z value of work coordinates. When the work coordinate is not used, start Z-axis in a safe position, j Program call press 1] tprogram No, and press eres | = A Start [Stop Contents Check | * The lamp of [02/30] of [Program End] lights upAcAcThe theory check is completed. * The lamp of [M00 M01] of [Program Stop] lights upAcAcM00 M01 stop. Press the [CYCLE START] ‘once again. The lamp of [ALARM] lights up....... There Is an error in the program and operation. After checking the alarm contents, perform operation ‘once again.Dell Be a 56{4] Automatic Operation {BX Machining Operation Method (Tria! cutting operation is performed with actual machining operation . ) G40/G80 display check (yy i Press Press ( [Prem ) , and check the display on the (Modal) screen. In anormal case,the above cancel mode Is selected, but the opera may often be re- ‘started in the diameter compensation mode due to alarm in program checking. In ‘such @ case,execute M02 on the MDI screen and start the cycle cancel condition. ‘Single block operation Tum "Machine Lock /MST lock /Z-axis |” set the Single Cancel OFF | _Block to "VALID". Override % check ‘Adjust the Cutting Feed Rate of the Override % to the machining condition position. Adjust the Rapid Traverse Rate of the Override % to a ow speed position. Tur "Dry Run” OFF Set the Dry Run ey : i "OFF". - Press = ( [=a , and check the comrensation amount. Return Z value of the work coordinate to a normal value. operation § mode : ae |O E f press (2 «) [Program roe § Press (Sot the 1 | NoJ, and press Press =). | MODE sELecT. | } Doss). iLe Jed el eh Flr 58[4] Automatic Operation [BB © 2-ax's Cancel Operation Method 1) How to use "Z-axis Cancel” Ifthe [Z-axis Cancel] is tumed ON during automatic operation, Z-axis transfer of ‘the program is locked until it is tured OFF. This function Is utilized for program check by moving only the table, and another convenient method is used in the following case. > — For example, in several holes machining, the drill is damaged half- way in some holes, and after resetting, the drill is replaced with a new one, then hole machining is continued once again .At this time, it is desired to machine the hole immediately halfway, but the program may often. not be called halfway. In such a case, by this method, the program is executed from the head, and when the axis moves to the first hole position, turn the [Z-axis Cancel] ON, and when itis transferred to the position of a hole to be machined without machining up to the hole drilling completion place, it is stopped with the [Single Block] and the [Z-axis Cancellis turned OFF to continue the hole machin- ing. Be careful about timing when turning [Z-axis Cancel] ON. "PMC" screen : Z-axis Cancel ON Z-axis Cancel ON/OFF timing (For Z-axis, turn °Z-axis Cancel "ON and OFF at a height in which it transfers to a machining posttion. i £ b Machining with G99. oo 6 6 ‘The above figure shows that the machining is completed for (1) to (4),the Grill is damaged in the position of (5), and no hole is machined after (6) above. When itis desired to start re-machining from hole (5) above, with the [Z-axis Cancel] ON in the position of (a) or (b), perform no-load hole machining between (1) and (4), and with the [Z-axis Cancel] OFF at the Position of (4), continue hole machining after (5). 59 Tt i} |i i} |i i} fi60{41 Automatic Operation (4) Resetting Method for ATC Stopped In the Course of Operation If the arm should stop in the course of swing during ATC operation due to some cause, the operation may be reset by switch operation. Since the tool mounted to the arm cannot be removed at this time, note the operation method. {BB © Operation Method 7 Emergency stop reset ‘Stop the buzzer Pull the button EMER- GENCY STOP on the operation panel clockwise. (Protruded toward Press (3) to stop the buzzer. ‘Check to see that the air pressure Press [Jon the operation panel: | exceeds the set point, using the i the lamp inside the button lights up. {pressure gauge at the rear part of the machine. _ Press @) to complete one cycle of operation. Execute "M101" according to MDI command. Tool registration check ‘The tool registration of “Spindle” "ATC related M signal* and "Standby 1" may deviate B M100 ATC cover open reversely.Check the registration M101 ATC cover closed contents. iGBB ©) carrier operation Panel 1) Switch layout This operation panel is used for resetting the carrier unit when stopped halfway or individual operation of the carrier . this operation panel is effective only in the manual mode . Q~ @—~ @® Operation selector switch Select this switch for carrier operation to sett o the position for the desired operation . @® Manual start OK lamp This lamp lights up when the operation selected with operation selector switch 1 can be performed . If it does not lights up , the operation conditions are not established or some operation is already being executed . © Start push button and lamp when the operation is selected with operation selector switch 1 and manual start OK lamp 2 is lighting , the operation is executed by pressing this button . While the operation is being executed , the lamp lights up . @ Stop push button If this button is depressed during operation execution after the start push button 3 is depressed , the operatin can be stopped . The operatiom can be restarted by pressing the ‘start push button . © _ Emergency stop push button 62{4] Automatic Operation Carrier operation conditions When the following conditions are established , the carrier related operation can be performed . When the tool cannot be changed , make sure the required signal is input on the self-diagnosis screen . < Pot Carrier Side Operation > (1) No pot at carrier side or carrier OUT | (1) No pot at carrier side or carrier IN or (2) No pot at MG'side or carrier IN carrier OUT (3) MG AMP home position (4) MGAMP alarm (5) MGAMP ready (6) MGAMP drive alarm (7) MG AMP control alarm < Carrier OUT> < Cartier IN> (1) Pot carrier side or MG side (1) Pot carrier side or MG side (2) Potunctamp output (2) Pot unclamp output (3) Cartier rotation MG side < Carrier Rotating MG Side > (1) Cartier OUT (1) Carer OUT (2) ATC arm home position (2) ATC arm home position (8) ATC arm stop position (3) ATC arm stop position 3) (4) Cover closed (4) Cover closed Magazine rotating conditions When the following conditions are established , the magazine ( MG ) can be rotated . When it cannot rotate , make sure the required signal is input on the self-ciagnosis screen . (1) PotMG side Pot uncamp (3) MG AMP alarm (4) MG AMP drive alarm (5) MG AMP control alarm 631) (©) APCunit ; Direct Turn System (2 - range APC) APC Operation Panel ‘Switch layout orl a |_ © 2) APC 1 cycle operation @ Setup pallet home position (PALLET H.P) lamp : This lamp lights up when the setup side palletis in the home position . @® Work setting completion (WORK SET) push button : Hf the button is depressed while the lamp 1 above is lighting , the work setting completion state is reached . ‘The work setting complation state can becancelled by pressing this button once again in the work setting complation state . ® @ work set lamp : This lamp lights up when the work is set completely . @ Emergency stop (EMG. STOP) push button If the M60 is executed in the automatic mode when the following conditions are established , the APC unit operates , making it possible to change the pallets on the table and APC main body . When no pallet can be changed , make sure the required signal is input on the self-diagnosis screen . Pallet unclamp ) IC sid o Fork MC side @) (4) Fork MC UP 6) ©) Fork rotation @ (8) Fork DOWN @) (10) Pallet clamp a) Fork APC side Work set X-axis 2nd origin B-axis 1st origin Y/Z-axis 1st origin or 2nd origin Fork APC side Fork DOWN Pallet clamp Table B-axis clamp Fork rotation home position Fork right swing end or left swing end Table touch sensor standby side (optional ) 64[4] Automatic Operation 3) APC operation conditions When each operation is performed during automatic operation , theseconditions are checked . When no palllet can be changed , make sure the requred signal is inputon the self-diagnosis screen . (1) Fork DOWN, (1) Fork DOWN (2) Setup pallet home position (2) Setup pallet home position (8) Fork swing home position * (8) Fork swing home position (4) Fork right swing end or left swing end | (4) Fork right swing end or left swing end (5) X-axis arrival in 2nd origin (6) B-axis arrival in 1st origin (7) Y@Z 1st origin or 2nd origin (1) Fork DOWN No conditions (2) Fork swing home position (8) Fork right swing end or left swing end < Fork UP> (1) Pallet unclamp (1) Setup pallet home position (2) Fork MC side or no right swing end | (2) Fork swing home position or no left swing end or no swing (3) Fork right swing end left swing end home position . (4) Fork MC side or none at MC side (5) Pallet unclamp ‘< Fork Right Swing > (1) Fork MC side (1) Fork MC side (2) Fork UP (2) Fork UP (8) Table clamp (8) Table clamp (4) Pallet unctamp (4) Pallet unciamp (6) APC inverter normal (8) APC inverter normal 65O--0 2 eS BERD ( | Ben ga @ ae GEER : ae SSS CEE moc) EEE) ) CEE) rstsi3| 66{4] Automatic Operation (6) Resetting Method for APC Stoped In the Couse of Operation [Direct tum system (2 - range APC) ] [I © Operation Method {Pull the button [EMG.STOP] on the fj operation panel clockwise. (Protruded toward the operator side) READY ON ‘Check to see that the air pressure ‘exceeds the set point, using the pressure gauge at the rear part of the machine. \n the operation panel: the lamp inside the button lights up. MDI mode ‘Turn "APC Reset "ON MDI operation M110 : Fork MC side/APC side M111 : Pallet unclamp/ciamp M112 : Fork UP DOWN M113 : Fork light swing/eft swing Refer to the following and execute IM Signal] to be operated in the MDI mode. Set the manual feed switch Press (Sf) :the following opera- tion willbe performed. By repeating switch setting ->re-setting, inching operation becomes possible. Press (“J each time .eI) Bees He -0 RRR OEE io fee CSEN ENE 68[4] Automatic Operation Tum "APC Reset "OFF Press (3). The lamp "AEALARM { After completion of resetting, return " goes out. the machine to zero once again ° © \& ALARM 69LSJ] Centering rroceaure a) 1) 2) 3) 4) 5) Centering Procedure for Horizontal Machining Center There is a difference (deviation) between actual stroke and nominal stroke of each axis. Consequently, the following operation is required prior to actual machining. If this is done, when a jig is installed, it facilitates the centering operation which determines the program origin, and the origin can be found by calculation. Method of measuring the distance from X-axis machine origin to the table rotation center. Method of measuring the distance from Z-axis machine origin to the table rotation center. One example of centering method by a jig (only X and Z axes) (Method of measuring the deviation of the work center (reference pin) in X-and Z-axis directions in relation to the index center.) One example of calculation method for the coordinate value at optional angle when the work center deviates in relation to the index center(only X and Z axes) Method of measuring the distance from Y-axis machine origin to the table top surface (Normally, a jig may often be used for direct centering in this case.) 70{5] Centering Procedure 1) Method of measuring the distance from X-axis machine origin to table rotation center Zero retum Mount a test bar to the spindle. (When no test bar is available, a boring bar may be used instead. The boring bar whose tip is polished is preferable.) Retum X-axis to zero. Move X-axis to the minus side manually or with the [HANDLE]. By moving X-axis by half of the nominal stroke, position it nearly in the rotation center. Install a dial gauge (pick tester) on the table, using a magnet stand. Move Y-axis vertically with the [HANDLE] to hold the dial gauge to the test bar. Adjust the most plus side on the gauge reading to zero. ‘ 3) Atthis time, set the X and Y on the position display screen to zero. Escape Y-axis approx.100mm to the plus side. Do this in such a manner that it does not interfere when the index table turns. Itis also necessary to escape Z-axis when it cannot tum due to collision. ah‘Tum the index table 180 with "MDI". G91 GOO B180 ; (MITSUBISHI) B180: (FANUC) Lower Y-axis to the minus side with the [HANDLE]: the position in which itis shifted by half of the dial gauge reading at that time corresponds to the rotation center. Repeat steps B® 10 above several times and find the table tum center.(When the tabie turns 180 degrees, the position in which the dial gauge reading coincides corresponds to the table turn center. However, note the test bar deflection as well ”" *X* ofthe machine on the position display screen at this time corresponds to the distance from the machine origin to the index center. After measurement, execute and check G91G28X0; G00x-. with "MDI".{5] Centering Procedure 2) — Method of measuring the distance from Z-axis machine origin to table tumcenter With the dial gauge used for measurement in para.) above as itis, retum Z-axis to zero. ‘Tum the index table 90 degrees with "MDI" Using the [HANDLE], move Z-axis to the minus side, hold the dial gauge to the tip partof thetest bar in which lengh B is already known, and move § itto the position of dial "0" (zero). ("Z" of the machine value on the position display soreen at this time corresponds to A.) Cis the test bar radius. (Use a micro meter for measurement.) Make caiculations the distance from A+B -C = Z-axis machine origin to the table turn center. 733) One example of centering method by jig (only X and Z-axis) Ret. pin (Work center) (Method measuring the deviation @, of work center (Ref. pin)in X-and ct bia Z-axis directions in relation to the index center) Index center Install the dial gauge (pick tester)to the spindle. Move X, Y and Z axes with the [HANDLE], hold the dial gauge to the highest place of the reference pin with Z-axis, and adjust the dial to zero(0). At this time, set "Z" on the position display screen to zero. 90") Escape Y and Z axes and turn the index table 180 degrees with "MDI" Hold the dial gauge to the highest place of the reference pin once again, and move the axis until the dial reaches "0" (zero). Half the Z value on the position display screen at this time corresponds to "OFF-center in the Z-axis direction *. 74{5] Centering Procedure Next, to measure the off-center in X-axis direction, escape X, ¥ and Z axes and turn the index.table 90 degrees with "MDI" ‘According to the same procedure as. above, move X, Y and Z axes with the [HANDLE], hold the dial gauge to the highest place of the reference pin with Z-axis,and adjust the dial to zero(0). At this time, set "Z" on the position diaplay screen to zero, Escape Y and Z axes and turn the index table 180 degrees with "MDI", Hold the dial gauge to the highest place of the reference pin once again, and move the axis Until the dial reaches "O"(zero). Haif the Z value on the position display screen at this time corresponds to “Oft-center in X-axis direction". 754) One example of calculation method for coordinate value at optional angle when the work center deviates in relation to the index center . (only X and Z axes) Details at part R22A24 82 tan B/Aza R= A242 tan '6/8=a = 782462 tan’!o. 75-0 =¥100 a=36. 870° =10 (mm) 76{5]_ Centering Procedure One example of coordinate value calculating method for X-and Z-axis deviation in index and work centers at optional angle (60-degree surface) Details at part (@) 6=60° +36. 870-90° =6. 870° X=Rsing Z=Rcos@ =10Xsin6. 87 =10Xcos6. 87 =1. 196 (mm) =9. 928 (mm) 77One example of coordinate value calculating method for X-and Z-axis deviation in index and work centers at optional angle . (315-degree surface--45 degrees) Index center New work center Details at part 0=45° +36. 870° =8. 130° X=Rcoos@ Z=Rsing =10Xcos8. 13 =10Xsin8. 13 =9. 899 (mm) =1. 414 (mm) 78