Integrex 40-ATC M/C help ATC failure
I got a Integrex 40-ATC M/C with a 60 Tool changer. I have a problem changing tools, it was aligned by a mazak technician but it wont change tools on its own. I feel there is a macro or parameter missing but I don't know where to start. I put the machine in auto, run T2 turning and finish with T3 for example. It roughs the part down then goes to switch tools. I goes to ATC home position and the magazine goes to T3 and the arm grabs it and moves over to grab T2 out of the spindle then stops. The door opens and everything but it just idles. No alarm comes up even after any amount of time. The magazine even goes back to T2 ready to put it back in place. Also to note that on the front of the controller the place where the number is displayed for magazine position is just changing to random numbers. It does it the whole time. This is an old Integrex with Y-Axis capabilities and had a robot arm. I was told it was special designed for Figgie International but that's as much as i know. I have all the manuals. Any help would be appreciated, if more specific info is needed let me know, Thanks.
Make sure the NC is getting the tool unclamp signal. The arm will not extract the tool until it "sees" it.
The arm isn't actually making movement down to the tool that's in the spindle. I was reading down further and saw someone post about a 9000 macro program that should be in the privileged area 1131 but I cant find this. Maybe this could be part of the problem since the y-axis is currently not working. This may not even apply to my machine I'm just looking for any answers. I cant even find a picture of this machine on the internet anywhere.
I have a SQT100msy, if the "Y" is not at 0 for tool change it will give you an error. When I set up my HTC400 with an M+ control it was setup for some kind of a random tool setup so tools can go in differrnt pockets utilizing numbers other than tool numbers. We do not use that but the idea seems cool, the fact that your control is putting up differnt tool numbers might have something to do with that.
Perhaps your magizne drive is shakey? Can you manualy opertate the tool changer from other than the main control?
I am not sure what you are going to do without a Y axis, but I am not familiar with that machine, perhaps someone disabled the Y axis and changed tools manualy?
I probably confused you by saying Y-Axis. I meant A-axis where it comes off center line. Yes in the back there is a control to operate the magazine which works fine. It grabs the right tool in auto mode but when the arm goes over to the turret it just sits there and doesn't swing down to the turret to grab the tool that's in the spindle. It seems like its waiting for something else to happen. A missing macro program is what I am thinking but I don't know how to go about fixing it.
Make sure the door open sense switch is made, check to make sure that X axis is at the number two home or tool change position. It's actually an offset from the number one home position although they can be one in the same. Also, I remember something about Z axis being at a "tool change position". If I remember, your tool magazine is floor mounted and the machine goes to it, or am I thinking of a different model. I recall three ATC macros and you used the 1131 priviledge mode to view them. Once "in" I think you look at the program page and they are there. Maybe hit the param soft key, and third or forth blank key from the right, then 1131? I have this wrote down at work and can't for the life of me remember the procedure to view them. Once back to work I'll get the info I have and share it if it's not too late.
P.S. Is this machine a T32 control?
T32 Priviledge Mode
Press PARAMETER key,
Press 3rd key from the right,
Key in 1131,
This is the procedure but I'm not sure it's going to allow you to look at the macros though.
Yes, this is a T32-3 Control. The Privileged mode appeared to work. I hit the key and typed 1131 input, and the lite up purple. I went to program file and Macros but I couldn't find anything. So it either worked and they aren't there? or that wasn't where I needed to be. Tomorrow I'll look into how to enter in the macros from the books. I think were on the right track though. Thanks a lot. Let me know what ya think.
Something about that .00 or .01 or something area comes to mind but it's been so long........... I'll check my notes at work and let you know.
(Program File?- Maybe, maybe not? My notes don't say this)
Macros should be visable.
Yup same as the book says. All macros are there. I even added that 9000E macro to see if it was supposed to be there but nothing. It's still sitting there doing nothing with no errors. You would think if it was a sensor that there would be an error.
Not all sensors are hooked into alarm timers and circuits. If the arm extracted the next tool from the magazine, the last thing in the sequence should have been was to swing arm to "park" position, then arm retract. For the arm to swing down you must have door open signal on and door close signal off. X and Z must be in the #2home positions. The turret must be at 0 degrees and you must have a turret clamp signal(although if not clamped that will generate an alarm. The tool must have a clamp signal or it will not swing to the turret. Those SL 40 tool clamp/unclamp sensors were prone to break wires. Plus yours might have the original induction type sensor and it possibly may have failed. You are going to have to verify all signals on and off next.
Thanks, with a quick look for the sensor in the parts list book that I have I didn't find it, didn't finish looking though. Would it be in the turret or back of machine where the turret it attached? I'm going to continue searching everything. I don't think it is a door signal because I can go into the maintenance function page (MF1) and use the Arm Change function which works. It comes over, opens door, swings to turret, grabs, rotates and puts in whatever is in the second arm hand, swings back to neutral and goes back to magazine and closes door. We have the key in the controller up front that we use manually to clamp and unclamp tools that we change by hand, the light works properly there. Don't know if that helps.
With the machine is Automatic mode (running a program or using Test Key with M06) the arm will just grab tool and slide over to the Z-Stop position with the door open and idle, even let it sit for a while today and nothing. Is there a way I can trace the ATC to see where it stops? I was browsing memory diagnosis feature but I don't know what the address is to track.
I show the atc macros located on the .01 page not the .00 (first page).
I think the maintenance manual show the sensor locations.
Yes, you want to use the ladder diagram to see where it stops or what it is waiting on. It is not monitor per se, but if you know the sequence routine you can see what conditions are met and what conditions are not. Sounds like you need to find what conditions need to be met for the "arm to swing to turret" or some such line. I don't have the ladders, but in the old electrics they came in the same manual after the electricals. There may be a ladder feature option on your T32-3 enabled that will allow you to call up the ladders on the screen but you still need a hard copy to identify the elements.
Sounds like the door is open and sees the switch or it wouldn't let you manually sequence thru the atc steps, UNLESS...., you had the interlock neglect enabled and I can't remember if your machine has a softkey for that or not. Good luck, sounds like a sequence problem and the machine is just waiting on something.
I appreciate all the help! looked through the books I have again (about 5 of them?) and found a wiring diagram with all the ladder info. I can get into the ladder monitor program on the T32 Controller but exactly how to monitor the sequences I'm lost. Do I need to monitor a sequence then run the ATC in test mode? or I just don't understand how to see exactly where the ladder stops. With that said I did figure this out. The book says this,
Sequence: 7762 Sub Prog-Ram NO. P48 *Arm Change Cycle
There is an "Explamation" as it says. I'm not gonna list everything it does here but I think this is where the problem occurs within the first 3 codes.
*C1 G1196 (ATC Cover Open)
*C2 G1197 (Turret Side Gripper Open Command)
*C3 G1199 (Arm Turret Side)
Once I read this I figured I'd run the ATC again and see if it unclamped. Sure enough it came over to the turret and didn't unclamp, that is where it's idling. Seems odd seeing how the Arm change feature in MF1 page works fine. If you need more ladder info let me know. Thanks again for your input. I feel like were making progress here and seeing this thing sit here next to our slant turn 35 working fine is depressing.
Oh and there is a soft key for neglect interlock which gets turned off once you leave the page, and it was not on.
Last edited by 340sixpack; 01-06-2010 at 06:03 AM.
Reason: Added a reply
Find out the input address for tool unclamp from your electric diagram. it should be X## where ## is a number. Then go to the diagnostic page and see if the input is changing state when you clamp/unclamp the tool manually. If it doesn't change and you can visibly see that it is clamp/unclamping, then you have a sensor or wiring problem.
I got into the ladder today and found out that the ladder at P48 which is ATC is not the same as the book says. Me thinks now that someone had modified it since there is a lot of G codes that don't match the book. Were going to have to get someone in here that knows more about the ladder to help because I'd rather not mess it up.
I'm haveing the same issue on a Integrex 35Y with a T Plus. Did you ever get yours fixed? Does anyone have any suggestions for me?
Looks like search function still works...
On our Integrex 35 T+, the machine would hang during a tool change if you did not fill out the tool data correctly or left areas blank. The machine used a KM63 for the turning and Cat 40 for milling, which are obviously two separate pockets. If you did not tell the machine you had a turning tool or if you incorrectly described a turning tool as a milling tool, the machine would open the door and hang up. The proximity sensors on the tool and tool retention knob verified if machine had a tool and if retention knob was detected, it also meant milling tool.
Originally Posted by machinist360
Fill out tool data page completely even if you are using G-code only programs. No issues after that.
Thanks for the reply Phil, tool is described completely. Even double checked with a T+ 35Y veteran of 15+ years. He poked at it for 3 hours and couldn't find a reason. It also locks up when you turn on the tool setter. I just bought this from a dealer and I wonder if this wasn't the problem when someone traded it to them. They of course want to fix it on my floor instead of let me return it and at this point I'd just rather have it working. Kinda wondering if previous owner didn't have an operator do a little editing on the macros but I know nothing about checking the macros.