[Axce]

Hey friends! So I'm running this through the machine with the dry run and machine lock on, checking code and I keep getting the 2463-01 (change timing) A side #4 (constant peripheral speed control) alarm at the G140 line after the P35 sync. It appears that my sync code is not being read for some reason and the program keeps jumping to the G140 on the 'A' turret instead of waiting for the P35 on the 'B' turret to come up. My entire program is below, any pointers you can give on any of it will be worth their weight in craft beer.

NBT01
T0101G90G95
(ROUGH THD PROFILE TO RIBS)
G50S1000
G96G111S300M3
G0X20.Z2.
X1.2Z.05M8
G1X-.12F.01
G0X1.2Z.11
Z.005
G1X-.12F.01
G0X1.2Z.1
G85 NTRN2 U.015 W.001 D.05 F.025
NTRN2 G81
G0X.6293Z.05
G1Z-.0738F.005
X.7003
G3X.7628Z-.1051L.0313
G1Z-1.7033
X.8553Z-1.7804
G3X.8642Z-1.7965L.0313
G1Z-2.496
X.9498Z-2.5674
G3X.957Z-2.5905L.0313
G1Z-4.
X1.2F.01
G80
G0X1.2Z.1M9
X20.Z3.
T100
M1
NBT03
T0303G90G95
(FINISH THD PROFILE TO RIBS)
G96G111S350M3
G0X20.Z2.
G0X.7Z0.M8
G1X-.12F.005
G0X1.2Z.1
G0X.6293Z.05
G1Z-.059F.004
G2X.6591Z-.0738L.0149
G1X.7315
G3X.7628Z-.0895L.0156
G1Z-1.692
X.8597Z-1.7728
G3X.8642Z-1.7808L.0156
G1Z-2.4848
X.9542Z-2.5598
G3X.9579Z-2.5714L.0156
G1Z-4.F.01
X1.2M9
G0X20.Z3.
T1100
M1
NBT07
T0707G90G95
(OD THREAD)
G97G111S750M3
G0X20.Z2.
X1.1Z-1.5M8
G71X.793Z-2.35B45D.005U.002H.06F.1181M22M32M73
G0X1.5Z.2M9
X20.Z3.
T700
M5
M1
P10
G13(UPPER TURRET)
G140(LC)
G50S1000
(STOCK OUT FOR PINCH TURN)
P10
G0Z-9.35W9.55
P15
G97S750
G14(LOWER TURRET)
P15
G97S750
G13(UPPER TURRET)
M84(OPEN LC)
M185(INTERLOCK OFF LC)
M247(INTERLOCK OFF RC)
M151(SYNC)
G94
G1W4.25F250.
M83(CLOSE LC)
M249(OPEN RC)
G1W17.297(SPECIFIC FOR 12.047 DIM)
(ADJUST THIS NUMBER TO QUALIFY)
(POSITION)
M248(CLOSE RC)
M1
P20
G14(LOWER TURRET)
P20
G90
G95
(NOTES: SHOULD BE IN SUSPENDED)
(BETWEEN CHUCKS, SYNC'D, DOING)
(FIN PROFILE)
(RESET B TURRET ZERO)
(VZOFZ=53404.459*ADJUST Z0 HERE)
NBT21
T0101G90G95
(ROUGH FIN PROFILE)
G50S1000
G97G111S750M3
G0X20.Z.05
(***ADD PROGRAM***)
G0X20.Z.05
T100
M1
NBT23
T0303G90G95
(FINISH FIN PROFILE)
G97G111S750M3
G0X20.Z.05
(***ADD PROGRAM***)
G0X20.Z.05
T300
M5
M150(UNSYNC)
M1
P25
G13(UPPER TURRET)
(TRANSFER TO RC)
P25
G0Z-9.35W9.55
M249(OPEN RC)
G94
G1W4.35(ADJUST THIS NUMBER)
(FOR GOOD STOCK OUT FOR SUB)
(SPINDLE TURNING, S/B @5.4)
(OUT FROM RC)
M248(CLOSE RC)
M84(OPEN LC)
G0Z5.W20.
G141
M1
P30
G14(LOWER TURRET)
G141(RC)
P30
G96G111S300
G13(UPPER TURRET)
G96G111S300
G14
G90
G95
(NOTES: SHOULD BE OUT 5.4)
(FINISH OAL AND NOSE PROFILE)
(ADJUST G14 Z ZERO IN G141)
(TO QUALIFY OAL)
NBT09
T0909G90G95
(ROUGH NOSE TO RIBS)
G96S300M3
G0X20.Z2.
X1.2Z.06M8
G1X-.04F.008
G0X1.2Z.1
Z.015
G1X-.04F.008
G0X1.2Z.1
G85 NTRN1 U.01 W.001 D.2 F.01
NTRN1 G81
G0X.2661Z.1
G1X.2966Z-.0265F.005
X.7067Z-1.3565
G3X.7007Z-1.3755L.0313
G2X.7176Z-1.4303L.0475
G3X.7348Z-1.4474L.0313
G1X.859Z-1.8503
G3X.872Z-1.8694L.0313
G1Z-4.6108
G2X.8875Z-4.7028L.5508
G1X.9471Z-4.8786
G3X.9646Z-4.9825L.6218
G1Z-5.05
X1.2F.01
G80
G0X1.3Z.1M9
X20.Z3.
T900
M1
NBT11
T1111G90G95
(FINISH NOSE TO RIBS)
G96G111S350M3
G0X20.Z2.
X1.2Z0.M8
G1X-.04F.005
G0X.2665Z.05
G1X.297Z-.0132F.004
X.7071Z-1.3433
G3X.7041Z-1.3528L.0156
G2X.7265Z-1.4256L.0631
G3X.7351Z-1.4342L.0156
G1X.8608Z-1.8418
G3X.872Z-1.8538L.0156
G1Z-4.5952
G2X.888Z-4.6898L.5665
G1X.9475Z-4.8656
G3X.9646Z-4.9669L.6062
G1Z-5.15
X1.2F.005
G0X20.Z3.
T1100
M5
M1
NBT06
T0606G90G95
(CENTER AND DRILL)
G97G111S825M3
G0X20.Z2.
X0Z.2M8
G73X0Z-.135D.035F.0015K.15
G0Z.2
X1.5748
G73X1.5748Z-.355D.06L.125F.003
G0Z.2M9
X20.Z2.
T600
M5
P35
G140
M1
G13(UPPER TURRET)
(TRANSFER BACK TO LC)
P35
G140 (alarms here)
G0Z-9.35W9.55
G94
M84(OPEN LC)
G1W4.35F250.(SAME AS LAST W)
M83(CLOSE LC)
M249(OPEN RC)
G0Z5.W20.
M1
P45
G14(LOWER TURRET)
P45
G90
G95
(NOTES: FINISH UNDERCUT BEHIND)
(THREAD)
NBT31
T0101G90G95
(ROUGH OD BEHIND THD)
G96G111S300M3
G0X20.Z2.
X1.05Z-2.5674M8
G85 NTRN3 U.015 W.001 D.05 F.025
NTRN3 G81
G0X.97
G1X.9498F.005
G3X.957Z-2.5905L.0313
G1X.8803Z-2.7558
G2X.872Z-2.7919L.1597
G1Z-3.3687
X1.2F.01
G80
G0X1.05Z-2.5674M9
X20.Z3.
T100
M1
NBT33
T0303G90G95
(FINISH OD BEHIND THD)
G96G111S350M3
G0X20.Z2.
X1.05Z-2.5598M8
G1X.9542F.004
G3X.9579Z-2.5714L.0156
G1X.8811Z-2.7367
G2X.872Z-2.7763L.1753
G1Z-3.3687
X1.0M9
G0X20.Z3.
M84(OPEN LC)
T300
M1
T0101
P50
M2
G13
P50
M2

That's all I have. I have run the hand off and spindle work through with material and it works fine. Just added the actual tool profiles..now I have issues.

Thanks for the help, anyone

[OkumaWiz]

Your upper turret is in G96 mode when you call out your G140/G141, just like the alarm says. See your line after the P30 on the A-side?

Pointers> 1. Since the control sorts out G13 and G14 when it runs, it's best for you to do the same and group all of your G13 code together, then switch to G14 and enter all your B-turret code so things "look the same" in edit and is easier to understand.
2. Line numbers are pretty helpful when trying to point out where errors are. The okuma can auto sequence number your code for you if you like.
3. Adding M203 to your code as you rapid away to your limits will cause the turret to unclamp as you rapid.
4. Adding the X and Z positions to your T command line will allow your turret to clamp as it rapids to the part.
5. STM's always come first before rapid moves.
6. M0 and M1 will require P-codes on LT's and should generally be avoided for that reason except for just before a transfer.
7. It will introduce a lot of strain on your drives if G96 is active as you rapid to the part, so it is best to rapid, then G96, then cut, then G97, then rapid.
8. Comments can span multiple lines with only one set of parenthesis on Okuma lathes.
Example:
(NOTES: SHOULD BE IN SUSPENDED
BETWEEN CHUCKS, SYNC'D, DOING
FIN PROFILE
RESET B TURRET ZERO)

10. To switch Spindle modes you must not have these active: M110, G138, G42, G41, G96, G144, Canned cycles, Lap functions. (i'm probably forgetting something)

Enough pointers yet?

Best regards,

[Axce]

Yes, good pointers, thank you!

I figured out the G97/spindle selection error this morning, that's working now.

I'm pinch turning and transferring twice, I'll eliminate all other M1's and reduce my P's.

The parentheticals are for a necessary use, otherwise I'd be leaving them as you stated.

Good call on the positional call-outs/M203...I'll make those changes now.


I'm going to make all these changes and see if I the program still stalls after calling up T0909 for the G141 profile after the pinch turning work, that's what it's doing now. All else before is working well.

I'll get back, thanks again OkumaWiz!!

Btw, were you at one time (or are you currently) an Okuma answer man?

[OkumaWiz]

Yes, Once upon a time I was the Okuma Answerman...How did you guess? I'd do it again if I could do it "remotely". A lot has changed since I was in that position that would make a remote answerman now possible! That must mean I know you...PM me for more details.

Best regards, and glad to hear you're making progress.

[Axce]

Haha! Just pm'd ya. And it wasn't difficult to guess . Not a lot in the field that actually know stuff, know what I mean? Makes me a bit sad, things changing.

I'm having a few problems with this thing but it's the back end of it and I'm sorting them out as they come. If I need more advice, you'll be the first to know. Good to know there's real knowledge still out there. Thanks, buddy!

[fordav11]

6. M0 and M1 will require P-codes on LT's and should generally be avoided for that reason except for just before a transfer.

On my LT I'm using M0 in 2 places in each program and M1 after every tool (aka Fanuc style) without P-codes. It just depends on where the M0/M1 is put and whether the other turret is active or already sitting there waiting on a P code. Plus I have my own disciplined and structured programming style based on real computer programming principles. I don't use the spaghetti code methods used by Okuma ;-)

[Axce]

Thanks fordav11, I like to use similar principles blended with Fanuc style.

So my code works, only thing is when it switches in the program to cut from G140 to G141, it stalls out until I press the manual hard key and then the auto hard key again...then it continues the program just fine. This happens twice as I start in G140, then pinch turn, then transfer to G141 and back to G140 to finish. So the occurrences are just after the tool is called up after switching from G140 to G141, then back again to G140. Here's my program:

OT407
G14(LOWER TURRET)
G140(LEFT COLLET "LC")
G90
G95
M83(CLOSE LC)
M248(CLOSE RIGHT COLLET "RC")
G0X20.Z2.
(PROGRAM: TESTPROG.MIN)
(FORMAT: OKUMA OSP 7000L)
(04/25/2013 AT 7:30 AM)
(OUTPUT IN ABSOLUTE INCHES )
(TESTING MOVEMENT)
(STOCK OUT: *SEE NOTES*)
(T1-DNMG 442/LEFT)
(T3-VBMT 331UM/LEFT)
(T6-#4 CENTER DRILL/4.04MM DRILL)
(T7-SNMG 432 FOR OD THD)
(T9-DNMG 442/RIGHT)
(T11-VBMT 331UM/RIGHT)
(N1)
T0101X20.Z2.
(ROUGH THD PROFILE TO RIBS)
G50S1000
G96G111S300M3
G0X20.Z2.
X1.2Z.05M8
G1X-.12F.01
G0X1.2Z.11
Z.005
G1X-.12F.01
G0X1.2Z.1
G85 NTRN2 U.015 W.001 D.05 F.025
NTRN2 G81
G0X.6293Z.05
G1Z-.0738F.005
X.7003
G3X.7628Z-.1051L.0313
G1Z-1.7033
X.8553Z-1.7804
G3X.8642Z-1.7965L.0313
G1Z-2.496
X.9498Z-2.5674
G3X.957Z-2.5905L.0313
G1Z-4.
X1.2F.01
G80
G0X1.2Z.1M9
X20.Z3.
T100
(N3)
T0303X20.Z2.
(FINISH THD PROFILE TO RIBS)
G96G111S350M3
G0X20.Z2.
G0X.7Z0.M8
G1X-.12F.005
G0X1.2Z.1
G0X.6293Z.05
G1Z-.059F.004
G2X.6591Z-.0738L.0149
G1X.7315
G3X.7628Z-.0895L.0156
G1Z-1.692
X.8597Z-1.7728
G3X.8642Z-1.7808L.0156
G1Z-2.4848
X.9542Z-2.5598
G3X.9579Z-2.5714L.0156
G1Z-4.F.01
X1.2M9
G0X20.Z3.
T300
(N7)
T0707X20.Z2.
(OD THREAD)
G97G111S750M3
G0X20.Z2.
X1.1Z-1.5M8
G71X.793Z-2.35B45D.005U.002H.06F.1181M22M32M73
G0X1.5Z.2M9
X20.Z3.
T700
M5
M1
P10
(G14*LOWER TURRET)
P15
G97S750
P20
G90
G95
(NOTES: SHOULD BE IN SUSPENDED)
(BETWEEN CHUCKS, SYNC'D, DOING)
(FIN PROFILE)
(RESET B TURRET ZERO)
(VZOFZ=53404.459*ADJUST Z0 HERE)
(OR G50 X20. ZXXXXX.)
(N21)
T0101X20.Z2.
(ROUGH FIN PROFILE)
G50S1000
G97G111S750M3
G0X20.Z.05
(***ADD PROGRAM***)
G0X20.Z.05
T100
(N23)
T0303X20.Z2.
(FINISH FIN PROFILE)
G97G111S750M3
G0X20.Z.05
(***ADD PROGRAM***)
G0X20.Z.05
T300
M5
M150(UNSYNC)
M1
G97G111S750
P25
(G14*LOWER TURRET)
P30
G141(RC)
P35
G90
G95
(NOTES: SHOULD BE OUT 5.4)
(FINISH OAL AND NOSE PROFILE)
(ADJUST G14 Z ZERO IN G141)
(TO QUALIFY OAL)
(N9)
T0909X20.Z2. (1ST STALL HERE)
(ROUGH NOSE TO RIBS)
G50S1000
G96G111S300M4
G0X20.Z2.
X1.2Z.06M8
G1X-.04F.008
G0X1.2Z.1
Z.015
G1X-.04F.008
G0X1.2Z.1
G85 NTRN1 U.01 W.001 D.2 F.01
NTRN1 G81
G0X.2661Z.1
G1X.2966Z-.0265F.005
X.7067Z-1.3565
G3X.7007Z-1.3755L.0313
G2X.7176Z-1.4303L.0475
G3X.7348Z-1.4474L.0313
G1X.859Z-1.8503
G3X.872Z-1.8694L.0313
G1Z-4.6108
G2X.8875Z-4.7028L.5508
G1X.9471Z-4.8786
G3X.9646Z-4.9825L.6218
G1Z-5.05
X1.2F.01
G80
G0X1.3Z.1M9
X20.Z3.M203
T900
(N11)
T1111X20.Z2.
(FINISH NOSE TO RIBS)
G96G111S350M4
G0X20.Z2.
X1.2Z0.M8
G1X-.04F.005
G0X.2665Z.05
G1X.297Z-.0132F.004
X.7071Z-1.3433
G3X.7041Z-1.3528L.0156
G2X.7265Z-1.4256L.0631
G3X.7351Z-1.4342L.0156
G1X.8608Z-1.8418
G3X.872Z-1.8538L.0156
G1Z-4.5952
G2X.888Z-4.6898L.5665
G1X.9475Z-4.8656
G3X.9646Z-4.9669L.6062
G1Z-5.15
X1.2F.005
G0X20.Z3.M203
T1100
(N6)
T0606X20.Z2.
(CENTER AND DRILL)
G97G111S825M4
G0X20.Z2.
X0Z.2M8
G74X0Z-.135D.035F.0015K.15
G0Z.2
X1.5748S1875
G74X1.5748Z-.355D.06L.125F.003
G0Z.2M9
X20.Z2.M203
T600
M5
P40
G140
(G14*LOWER TURRET)
P45
G90
G95
(NOTES: FINISH UNDERCUT BEHIND)
(THREAD)
(N31)
T0101X20.Z2. (2ND STALL HERE)
(ROUGH OD BEHIND THD)
G96G111S300M3
G0X20.Z2.
X1.05Z-2.5674M8
G85 NTRN3 U.015 W.001 D.05 F.025
NTRN3 G81
G0X.97
G1X.9498F.005
G3X.957Z-2.5905L.0313
G1X.8803Z-2.7558
G2X.872Z-2.7919L.1597
G1Z-3.3687
X1.2F.01
G80
G0X1.05Z-2.5674M9
X20.Z3.M203
T100
M1
(N33)
T0303X20Z2.
(FINISH OD BEHIND THD)
G96G111S350M3
G0X20.Z2.
X1.05Z-2.5598M8
G1X.9542F.004
G3X.9579Z-2.5714L.0156
G1X.8811Z-2.7367
G2X.872Z-2.7763L.1753
G1Z-3.3687
X1.0M9
G0X20.Z3.M203
T300
M1
T0101
M5
M84(OPEN LC)
P50



G13(UPPER TURRET)
G140(LEFT COLLET "LC")
G90
G95
G50S1000
(STOCK OUT FOR PINCH TURN)
P10
G0Z-9.35W9.55
P15
G97S750
(G13*UPPER TURRET)
M249(OPEN RC)
M185(INTERLOCK OFF LC)
M247(INTERLOCK OFF RC)
M151(SYNC)
G94
G1W5.65F250.
M248(CLOSE RC)
M84(OPEN LC)
G1W16.347(SPECIFIC FOR 12.047 DIM)
(ADJUST THIS NUMBER TO QUALIFY)
(POSITION)
M83(CLOSE LC)
P20
(G13*UPPER TURRET)
(TRANSFER TO RC)
P25
M249(OPEN RC)
G0Z-9.35W9.55
G94
G1W4.35(ADJUST THIS NUMBER)
(FOR GOOD STOCK OUT FOR SUB)
(SPINDLE TURNING, S/B @5.4)
(OUT FROM RC)
M248(CLOSE RC)
M84(OPEN LC)
G0Z5.W20.
(G13*UPPER TURRET)
(TRANSFER BACK TO LC)
M150(UNSYNC)
G97G111S750
P30
G141
P35
P40
G140
G97G111S1875
G0Z-9.35W9.55
G94
M84(OPEN LC)
G1W4.35F250.(SAME AS LAST W)
M83(CLOSE LC)
M249(OPEN RC)
G0Z5.W20.
P45
(G13*UPPER TURRET)
P50
M2


Again, not what I want, but its working, I switch quickly from Auto to Manual and back and the program comes out of its stall each time...any ideas why and how I can solve this?

[fordav11]

It's a little strange that you can switch to manual then back to auto and it keeps going. usually it will just reset the program to the beginning.

when you say 'stall' do you mean the machine just stops and nothing happens but the cycle run light stays on?
If the program hangs it's because the machine is waiting for something or wanting something. In your case it looks like the turret is not fully back and the turret is wanting to index. you can add an M-code to force it to index at any position.

my machine doesn't have the cycle reduction option so I don't have the m-code. According to the info above M203 will unclamp the turret in preparation for an index but you could possibly use M66 to just force the index at any position, further reducing the time. that is IF you have the cycle reduction option. If M203 works then you probably have it.

If you put an index on the same line as the rapid then the machine wants to index first (STM codes are executed first). I personally have the tool index on a separate line by itself because if you are not fully back or have not added the cycle reduction Mcode to the same line where the T code is it won't work and hangs.

I generally just rapid back before any index then again at the end of the operation for that tool and I don't have any stalls even when restarting. I do it in both places because the machine is stupid and sometimes the tool will move minus a few thou on a restart because of it reading some offset from the previous tool (as you know a restart causes the machine to index to the previous tool). Because it reads the whole program it can cause axis movement then the turret won't index. Having the rapid at the start and end solves that problem. although even then sometimes it won't go on a restart and I have to go to manual and move the turret to maximum then re-do the restart. It's typical overly-complicated Okuma B.S.

Anyway, make sure you rapid to maximum stroke before indexing or use the cycle reduction Mcode and your problem may be solved.

[Axce]

Thanks again fordav11. Yes, all operation lights are normal with no alarms when the stalls happen, and both are solved by that quick switch...weird much?

I'm going to try the M66 today. But first I'll make the X travel further to ensure it's seated properly. I do have the rapid movements before and after the sequence of each tool. I also usually program the index and tool home in their own separate lines, but here I have the index's in the same line as a positional call out so (via OkumaWiz) the turret will clamp at each tool index. It's improved the way this program is running so I think I'll leave that code. The M203 is in the same line as each rapid home position after each toolpath..also working very well so as you said, the M66 should work.

I agree with you on the nuances of Okuma...quirky little/big CNC's. One curious thing though is that this stall only occurs after switching from G140 to G141 and back again...ONLY in these two places, it does this. So that is the only variable.

Btw, I AM making parts currently with this program but I cannot take the machine for production in Bulgaria with this 'quirk'. ...it's like..tweaking one of my boy's ears to get him to act right..so funny.

[fordav11]

your programming method is probably causing it. the flow of your program is a little difficult to follow.
If you don't figure it out I can test it on my machine next week and try to narrow it down. I'm sure it's something simple.

[OkumaWiz]

You may have P code/ G140 sync issues. We've got one machine here that "freezes" until you switch to parameter mode and back. Never seen one that didn't reset when going to manual mode. Try putting M331's before your G140/G141 changes to keep it from reading ahead and see if that solves the problem. It worked for us.

Best regards,

[Axce]

Ok, @fordav11: the M66 didn't work, it's still doing the same thing. I have a tech coming this week, he feels the controller is a bit faulty as there are other issues that I have discussed with him that have happened. Things that shouldn't happen likened to switching to manual not resetting the program. Thank you for the advice though, I was able to get further by it.

@OkumaWiz: Thanks, my man! That's something the tech mentioned as well to try. I've established that the set up is good with the exception of that curious problem and have been tasked to move onto another project while this machine gets tech'd out and repaired cosmetically. But before it goes I'll run it with these M codes added. Thank you again! I'm looking forward to reporting the findings after the tech arrives.

[OkumaWiz]

One other thing I thought of: LT machines have 4 coordinate systems. Have you verified that your positive limits in X are the same for Left and Right spindle modes? It could be that switching G140/G141 is taking the turret off the limit if they are not the same.

Best regards,

[Axce]

EXACTLY!! Believe it or not, I had a dream that was the problem..I'm certain you've had the same 'eureka' moments. It's the only thing that makes sense to me right now. When I get back on this machine, that will be the first thing I try. Thanks for the reminder, even if you didn't know that needed to happen.