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IndustryArena Forum > MetalWorking Machines > Daewoo/Doosan > TT1800SY Logic problem causing live drive to violate RPM during G32 thread cutting
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  1. #1
    Join Date
    Jun 2006
    Posts
    424

    TT1800SY Logic problem causing live drive to violate RPM during G32 thread cutting

    Ran into an odd behavior issue. This is e-mailed to Jaimie Ochs at Doosan yesterday.

    Yesterday it wasn't causing a machine crash, today we needed to edit the program on the lower above and it began exhibiting this during a cut and crashed an end mill on the lower by feeding it at zero RPM. We are going to safety this with timing codes for right now, but imagine the implications of this- somebody somewhere may be about to run a face mill on the lower as the upper is cutting a G32 thread cycle. The machine can't walk and chew bubble gum so we have to choose which one we want.

    The lower path reads at the same time as the G32 thread operation on the upper, and it appears the lower is looking for orientation with a sensor as if it is cutting the thread also and that a timer is timing out or something like that (the lower live spindle revs 4K to zero 3-4 times in about 2-4 seconds, and then stabilizes at 4K and cuts with or without the tool depending on how that played out. We tried to figure it out but couldn't. We feel there are scary implications to what could happen if this happens at the wrong time- obviously predicting miscellaneous non-requested communication issues across the paths is near impossible because the timing is variable with the application being different every time a job goes in the machine.

    We tried some re-arrangement but the machine spit consistent "illegal G-code" messages. We put in a dwell after the tool call on the lower G4X5.0 and it temporarily stopped doing this, so apparently something with the way it was reading the thread call on the upper was messing with the lower path behavior. Later when we edited the lower, we realized the dwell was a poor stop gap solution because it changed the timing again and crashed that end mill.


    We have another one of these machines currently on order with Ellison Pewaukee.



    The lower program operation code is as follows

    (*******************************)
    N29
    (OPERATION # 46)
    (MILL SLOTS)
    G28 U0.
    G28 W0.
    (T0808 0.125 FLAT ENDMILL DIA. - 0.125)
    M135
    G56
    T899 ( 0.125 FLAT ENDMILL )
    M07
    M138
    M108
    G4 X2.
    G97 S4000 M03 P22
    M190
    G28 H0.
    G00 C0.
    G00 Z-.3
    X.3331
    G12.1
    G05.1 Q1 R5
    G98 G01 X-.0015 C-.1665 F100.
    Z.0875 F20. (F25.)
    G41 X-.0115 C-.1668 F5.8 (F10.)
    X.0118 C-.4017
    X.0678 C-.4003
    X.0519 C-.2403
    X.0444 C-.1654
    G40 X.0345 C-.1656
    X-.0015 C-.1665
    Z.145 F20. (F25.)
    G41 X-.0115 C-.1668 F5.8 (F10.)
    X.0118 C-.4017
    X.0678 C-.4003
    X.0519 C-.2403
    X.0444 C-.1654
    G40 X.0345 C-.1656
    Z-.15 F100.
    (FINISH 1)
    X-.0135 C-.1668
    Z.15 F20. (F25.)
    G41 X-.0235 C-.1671 F7.8 (F12.)
    X.0004 C-.408
    X.0803 C-.406
    X.0639 C-.24
    X.0564 C-.1651
    G40 X.0464 C-.1653
    Z-.15 F100.
    G05.1 Q0
    (SLOT 2)
    G05.1 Q1 R5
    X.0015 C.1665
    Z.0875 F20. (F25.)
    G41 X.0115 C.1668 F5.8 (F10.)
    X-.0118 C.4017
    X-.0678 C.4003
    X-.0519 C.2403
    X-.0444 C.1654
    G40 X-.0345 C.1656
    X.0015 C.1665
    Z.145 F20. (F25.)
    G41 X.0115 C.1668 F5.8 (F10.)
    X-.0118 C.4017
    X-.0678 C.4003
    X-.0519 C.2403
    X-.0444 C.1654
    G40 X-.0345 C.1656
    Z-.15 F100.
    (FINISH PASS 2)
    X.0135 C.1668
    Z.15 F20. (F25.)
    G41 X.0235 C.1671 F7.8 (F12.)
    X-.0004 C.408
    X-.0803 C.406
    X-.0639 C.24
    X-.0564 C.1651
    G40 X-.0464 C.1653
    Z-.15 F100.
    G13.1
    G05.1 Q0
    M05 P22
    G4 X1.5
    M09
    M139
    M109
    G00 G28 U0.
    G28 W0.
    M134
    M01


    The upper thread program that is running simultaneously is:

    (****************************************)
    N4
    G05.1 Q0
    (OPERATION # 7)
    G28 U0. V0.
    G28 W0.
    (T1010 OD THREAD RIGHT INSERT - NONE)
    M34
    G54
    T1099 ( OD THREAD RIGHT )
    G97 S1200 M03 P11
    M07
    M138
    G18
    G00 Z-1.4796
    X1.2
    Z-1.4924
    X.9835
    G32 Z-1.98 F.05
    G00 X1.2
    Z-1.4895
    X.9731
    G32 Z-1.98
    G00 X1.2
    Z-1.4918
    X.9649
    G32 Z-1.98
    G00 X1.2
    Z-1.4898
    X.9579
    G32 Z-1.98
    G00 X1.2
    Z-1.4916
    X.9516
    G32 Z-1.98
    G00 X1.2
    Z-1.49
    X.9459
    G32 Z-1.98
    G00 X1.2
    Z-1.4924
    M09
    M139
    M315 P11
    G28 U0. V0.
    G28 W0.
    M01
    N1

  2. #2
    Join Date
    Jun 2006
    Posts
    424

    Re: TT1800SY Logic problem causing live drive to violate RPM during G32 thread cuttin

    Jamie requested the programs, tool life and tool offset data for the upper and lower streams and said he planned to have a TT1800SY put on a show floor to run some tests. We sent him that information so he could run those.

  3. #3
    Join Date
    Jun 2006
    Posts
    424

    Re: TT1800SY Logic problem causing live drive to violate RPM during G32 thread cuttin

    It's been a while. I heard that machine was scheduled into the showroom at Doosan corporate, but I haven't heard anything yet. We bought a second TT1800SY. That's fully settup on the floor minus the J2-60 chipblaster that hasn't been settup. The $2000 floor settup on the chipblaster doesn't include safe integration. Chipblaster wants to charge us $1400 in parts and some labor to allow the J2-60 to tell the machine if it stops pumping fluid. We had a failure of our first J2-60 and that was how we learned that it doesn't tell the machine when it fails to pump coolant.

    I wanted to swap it to an MV-60 for $4300 price difference because apparently that better model includes the flow monitoring, but nobody replied to that message. They probably don't want to eat freight, but having the customer fix their botched integrations is sloppy and unethical without literally making the customer sign a notification waiver to buy the equipment informing them of the deficiencies.

  4. #4
    Join Date
    Jun 2006
    Posts
    424

    Re: TT1800SY Logic problem causing live drive to violate RPM during G32 thread cuttin

    This problem was resolved about a month ago. My machine will now run G32 while doing something else on the other side. Doosan also got the machine to use the repeat function in Fanuc so I can use the run timer and parts counter. My tool life isn't reset by tool load monitoring anymore (which is great when a error load limit is hit once in a while), and my tool load monitoring runs properly on the 2013 machine as well as the 2018 machine. We learned about I believe an M350 maintenance code that allows some things to be done with the door open and that was helpful for some things, there is also a maintenance part eject that strokes further than the normal eject and that was necessary for a long part we ran in the machine.

    I had two machines settup here and it seems 2-4 months is the time to get them totally settup and running properly. We use all the technology the machine offers so that's probably not the way it goes for every customer. We did buy a second machine and it was delivered in January and we began running it in April I believe.

    We were finally able to get a part the machine liked into it, and were able to see a run time drop about 50%. That part was a formerly robot unloaded part, that the Doosan with the maintenance eject could now unload inside the machine by itself, and that was pretty cool. With the unload time it took a 2.5 week job to one week. We are using a few through spindle coolant live tools and some 1-2 speeders from MD tooling to allow the machine to work optimally. We don't command RPMS over 4000 on live tools so the MD holders were important in getting the milling speed up.

    Thanks DOOSAN for getting the issues squared away. The TT1800SY is a good machine. I have a lot of respect and admiration for it.

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