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