Star SR20-R freezing problem...

MaDmaNmArKuS · Mar 31, 2017

Im running a STAR SR-20R and Im having an issue with the machine completing the first cycle (One Cycle activated) makes a good part then as soon as I de-activate the one cycle button and press start for production it freezes on the first tool call out...

Any help with this would be awesome! I have tried wait codes, Dwells , checked the format.. Im stumped!

Code is posted below:

HEAD 1
%
O5110
#531=.640
#529=1200
G80G40M09
G99G97
M03S500
M11
G00Z0T0
G121
M10
M200
M20
G00Z-.05
M25
T0100
M27

N1(#3 C-DRILL)
T1100
G00Z-.05M03S3275T11
M01
G01Z-.025F.005
G01Z.210F.0015
G04U10000
G00Z-.05
T0
M01

N2(1/8-DRILL-.125 DIA.)
T1200
G00Z-.05M03S4584T12
M01
G01Z-.025F.005
G83Z.675Q02500F.0015
G80
G00Z-.05
T0
M01

N3(FACE/TURN .015R)
T300
G00X.724Z-.05T2M03S3728
M01
M84
G00X.298
G01Z0F.005
G01Z.388W.045F.001
G01Z.786F.002
G01X.545
G01W.027X.640F.001
X.680W.02
G00X1.
T0
T0
M01

N4(CUT-OFF .080-RIGHT HAND)
T100
G99G00X.660Z.545T1M03S1582
M01
G01X.400F.02
X.318F.001
G00X.400
Z.610
G01X.318
G00X.400
Z.674
G01X.318
G00X.400
Z.5243
G01X.388F.005
W.0205G01X.316F.001
Z.6495U.001F.0005
G00X.4
Z.710
G01X.388F.005
G01W-.0207X.316F.0005
Z.5848U.001F.001
G00X.725
G00X1.
T0
M01

N5(10mm X 1.0 UNJF THREAD)
T200
G00G99X.660Z.0984T2M03S1000
M01
G01X.457F.005
G92X.388Z.505F.03937
X.384
X.380
X.376
X.372
X.368
X.364
X.360
X.356
X.352
X.348
X.344
X.342
X.342
G00X.660
X1.
T0
M01

N6(1/4 X 90 DEG. SPOT DRILL)
T3300
M08(C-AXIS ON)
G00C0Z-.574
M36S3820
M06(MAIN SPINDLE CLAMP ON)
G0G98X.0Y.66Z-.574T33
M01
Y.326
G01V-.150F4.
G00Y.660
M07(MAIN SPINDLE CLAMP OFF)
G00C180.
M06(MAIN SPINDLE CLAMP ON)
Y.326
G01V-.150F4.
G00Y.660
M07(MAIN SPINDLE CLAMP OFF)
Y1.5
T0
M38(LIVE TOOLING OFF)
M09(C-AXIS OFF)
M01

N7(1/8 DRILL)
T3400
M08(C-AXIS ON)
G00C0Z-.574
M36S3820
M06(MAIN SPINDLE CLAMP ON)
G0G98X.0Y.66Z-.574T34
M01
Y.326
G01Y.316F2.
G87V-.660Q02500F4.
G00Y.660
M07(MAIN SPINDLE CLAMP OFF)
Y1.5
T0
M38(LIVE TOOLING OFF)
M09(C-AXIS OFF)
M01

N8(CUT-OFF .080-RIGHT HAND)
(PART CUT-OFF)
T0100
G99G00Z1.040X.660T1M03S#529
G96S200
M01
X.545F.001
G00X.66
W-.026
G01X.640F.003
G01X.550W.026F.0005
X-.025F.001
M41
M83
G97M3S500
M80
/M98P7000
M81
M99
%

HEAD 2
%
O5112
G28W0
G50Z0
G99M05
G0Z0T0
T2000
M200
M20
M84

M75

/N2(3/4 BALL E.M.-MOD.SHANK)
/T2100
/G00Z-.05M03S1112T21
/M01
/G83Z.100Q01500F.002
/G80
/G00Z0
/T00
/M01

/N100(PART EJECT)
/T2900
/M3S500
/G00Z.750
/M14
/M11
/G04U5.
/M15
/M84
/M27
M76

N200
T2000(PARTS PICK UP)
M84
M82
M11
G00Z5.615
M14
M68
G98G01Z6.405F50.
M69
M10
G04U.2
M15
G99
M84
M40
M41
M68
M84
M84
G00W-.50
M69
M83
G28W0T0
G130
M05
M84
M99
%

Thanks for your time!

dpolseno41 · Mar 31, 2017

Exactly what line does it freeze at? It's not the optional stop right?

MaDmaNmArKuS · Mar 31, 2017

No , not at the op-stop.

HEAD 1
%
O5110
#531=.640
#529=1200
G80G40M09
G99G97
M03S500
M11
G00Z0T0
G121
M10
M200
M20
G00Z-.05
M25
T0100(FREEZES RIGHT HERE)
M27

N1(#3 C-DRILL)
T1100--------------------(AND SOMETIMES HERE)
G00Z-.05M03S3275T11
M01
G01Z-.025F.005
G01Z.210F.0015
G04U10000
G00Z-.05
T0
M01

ALWAYS IN ONE OR THE OTHER SPOTS

james siffel · Mar 31, 2017

At a glance it seems your not cancelling your tool callout. Fyi, if you use the search function on here, theres tons and tons of Star program examples. Plus I know in their manuals they have proper program structure.

TeachMePlease · Mar 31, 2017

Ok, at the risk of sounding stupid, we see where it freezes on Head 1... What is Head 2 doing, or supposed to be doing at this same point? Are there any weird sync or wait codes happening? Long shot, just thinking of things I've run into in the past. Never run an SR20, but I have experience with SB16s and ECAS20s, but I'm mainly a Citizen guy. Trying to generalize the weird stuff I've seen in the past haha. The weirdest part is that it works in one cycle.

jhearons · Apr 1, 2017

I've seen something like this before. Try putting a small dwell between "M10" and "M200" on Head 1. Also, your pick off is a bit of a mess and may play a role in this. M82, M83, M40, and M41 all act as wait codes and look for a corresponding / matching code from the other head when in SIMUL. mode.

MaDmaNmArKuS · Apr 3, 2017

james siffel said:
At a glance it seems your not cancelling your tool callout. Fyi, if you use the search function on here, theres tons and tons of Star program examples. Plus I know in their manuals they have proper program structure.

I have tried canceling tool call but it just freezes on the cancel T0 call out.
as fare as STAR programs, this one was modified from a proven program, it does run one full cycle and produces a good part but wont run consecutive cycles without freezing in spots pointed out.
I have compared this program format to the manuals format as well as other proven programs and found no errors.\
I have even sent it to STAR and they say it should run fine.
Beginning to think its a Machine issue but don't want to rule anything out until im sure.

thanks for the responce

MaDmaNmArKuS · Apr 3, 2017

jhearons said:
I've seen something like this before. Try putting a small dwell between "M10" and "M200" on Head 1. Also, your pick off is a bit of a mess and may play a role in this. M82, M83, M40, and M41 all act as wait codes and look for a corresponding / matching code from the other head when in SIMUL. mode.

I tried the dwell as you described from .5 sec. to 3 sec. no change.

Aside from eliminating the extra M84's on the pick-off segment how could I make it less messy?

Thanks for responding

Vancbiker · Apr 3, 2017

MaDmaNmArKuS said:
......I have even sent it to STAR and they say it should run fine.
Beginning to think its a Machine issue but don't want to rule anything out until im sure.

Have you tried running a different program, one that you know runs in continuous mode, to see if it is a machine issue?

How is your barfeeder interfaced? I've seen some where the end of bar signal stops the machine from running in continuous mode (not a Star though).

MaDmaNmArKuS · Apr 3, 2017

TeachMePlease said:
Ok, at the risk of sounding stupid, we see where it freezes on Head 1... What is Head 2 doing, or supposed to be doing at this same point? Are there any weird sync or wait codes happening? Long shot, just thinking of things I've run into in the past. Never run an SR20, but I have experience with SB16s and ECAS20s, but I'm mainly a Citizen guy. Trying to generalize the weird stuff I've seen in the past haha. The weirdest part is that it works in one cycle.

Head 2 is machining while head 1 freezes.... then its waiting at M82 for head 1 to catch up. then it just sits there shooting oil lol

MaDmaNmArKuS · Apr 3, 2017

Vancbiker said:
Have you tried running a different program, one that you know runs in continuous mode, to see if it is a machine issue?

How is your barfeeder interfaced? I've seen some where the end of bar signal stops the machine from running in continuous mode (not a Star though).

I had the same problem with another similar Part Program couldn't figure it out and needed another part so we switched it out and program ran fine...no issues. I compared the two programs against each other and format was identical. only Tooling , tool path, and speed and feeds were different. not sure what to think about that??? the program that ran was longer in cycle time and used sync machining head1/2 but it didn't have issue...

MaDmaNmArKuS · Apr 3, 2017

MaDmaNmArKuS said:
I had the same problem with another similar Part Program couldn't figure it out and needed another part so we switched it out and program ran fine...no issues. I compared the two programs against each other and format was identical. only Tooling , tool path, and speed and feeds were different. not sure what to think about that??? the program that ran was longer in cycle time and used sync machining head1/2 but it didn't have issue...

Bar-feeder is a LNS HYDROBAR EXPRESS 226. Its interface is through the bar-feed pendant and is attached to the STAR via a big serial plug.
My gut tells me the barfeed isn't the problem but my gut has been wrong before. Bar-feeder seems to be working fine though...no weirdness.

MaDmaNmArKuS · Apr 3, 2017

would seem more like a program error to me if it didn't run a full cycle ...but it does.
I feel like its a timing issue between Head 1 and Head 2, or possibly control read error?? Seems like if it were the latter there would be an alarm , which there isn't.

MaDmaNmArKuS · Apr 6, 2017

Nobody else has any ideas?

Nerdlinger · Apr 6, 2017

Just for goofs can you add another pair of wait codes at the end and beginning of both programs and then at the end put a "GOTO" to bring you back to the beginning? That way even in "one cycle" mode it should keep going until you stop it. Just to see if it keeps going... I don't know, now that I wrote that it sounds stupid...

AHC · Apr 10, 2017

MaDmaNmArKuS said:
Im running a STAR SR-20R and Im having an issue with the machine completing the first cycle (One Cycle activated) makes a good part then as soon as I de-activate the one cycle button and press start for production it freezes on the first tool call out...

Any help with this would be awesome! I have tried wait codes, Dwells , checked the format.. Im stumped!

Code is posted below:

HEAD 1
%
O5110
#531=.640
#529=1200
G80G40M09
G99G97
M03S500
M11
G00Z0T0
G121
M10
M200
M20
G00Z-.05
M25
T0100
M27

Just for giggles, try putting your G00Z-.05 after the T0100 tool call. Like this:

T100
G00Z-.05

Johnny Larue · Apr 10, 2017

MaDmaNmArKuS said:
Nobody else has any ideas?

ya...put M06 in every line after the tool and it will probably work

T2100 M06 etc...

Vancbiker · Apr 10, 2017

Johnny Larue said:
ya...put M06 in every line after the tool and it will probably work

T2100 M06 etc...

Incredible!

How's he gonna turn something with the spindle clamp on?

Star SR20-R freezing problem...

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