Mori Seiki NT Tool-Spindle Overtravel Near Tailstock

[bswihart]

Hi everyone,
We have a 2013 Mori Seiki NT4300DCG 1500SZ and the part I'm trying to prove out is clamped by both the main and sub spindles during machining. When I try to run a toolpath from end to end down the length of the part, the machine alarms out as it approaches the sub spindle, giving me two OT0506 hard overtravel alarms (Z1+ and ZS+) and three OT0507 hard overtravel alarms (X1-, XS-, and A1-). The spindle still has inches to go before any sort of collision:

The chucks are maybe 3.5" thick, jaws 3" thick, part is a little more than 36" from jaw face to jaw face, so we're looking at a stack up of about 49 inches from spindle nose to spindle nose. From cutting position, the tailstock has to move 19 more inches away from the main spindle (A+) to get to its machine zero position. Z1 can travel in Z+ much further than the point it alarmed out at so I know the limit I'm hitting has something to do with some sort of safety zone around the tailstock/sub spindle. Does anyone know a way to adjust or disable this? It doesn't appear that there's any sort of chuck dimensions or jaw dimensions set up in the machine for collision checking, not seeing menus referred to in the manual when I hit the CAPS hard key. If not, anyone know where I can get a long reach Capto C6 weldon endmill holder for a 1" endmill?
Thanks

 

[EMTech]

I wouldn't think that collision checking would cause a hard overtravel alarm.
I could be wrong, but that doesn't seem right.

 

[escapethewrmhole]

Did you check the switches? could have swarf stuck around them. It shouldn't be alarming both the upper and lower when only the upper is moved to the right.

 

[bswihart]

Did you check the switches? could have swarf stuck around them. It shouldn't be alarming both the upper and lower when only the upper is moved to the right.

I think they're buried under way covers. The Z1 axis alarms out at the same place relative to the A position regardless of where A is so I think it might be a parameter. Seems like there's two Z1+ overtravel positions, one when X1 is low that's supposed to prevent the spindle from hitting the chuck and one when X1 is higher up, which prevents the spindle from moving above the sub-spindle.

 

[bswihart]

Turns out it was a matter of adjusting some overtravel zones around the tool-spindle by changing the following data table values:
D1969, D1972, D1976, D1980, D1984, D1988, and D1992.

I wouldn't recommend changing D1968 since it specifies a zone in X in which the tool spindle can utilize its full travel in Z, including traveling above the sub-spindle/tailstock regardless of its position. The default value should be -1000 which pretty much ensures that the tool-spindle can only do so at or near X home.
Adjusting the values isn't exactly intuitive so you just have to jog the tool-spindle to around where it alarms out and change the values until it alarms out, back off, reset, and keep adjusting them like that to get an idea of where the zones are and whether you need to increase or decrease the values.
A Mori Seiki apps engineer sent me the following instructions for accessing the data table and the attached drawing to illustrate the zones:
Make sure you are in HEAD 1
MDI Mode
System hard key
NC System soft key
Arrow right twice >> to find PMC MAINT soft key
Select the PMC MAINT soft key
Arrow right once >
Select the DATA soft key
Select the OPRT soft Key
Cursor to the field that is closest to but not over the D number that you are looking for
Press the ZOOM soft key

Hope this helps someone