[Green0]

Tool load monitoring on our new 2100SY II is a new TLM software- it's not like our 2 TT1800SY's or our Lynx 220LYSC, or mills, and if he edits values on one page, the edit populates through all the pages, so it appears that TLM is flawed in this machine, and we're hoping to upgrade to the old version that was functional and like all the other Doosan machines on the floor.

Or maybe there is a keep relay or parameter that allows different tools to be given their own unique TLM data edits? Obviously we can't monitor all the tools in the machine with the same data. This first job should be in, but the machine has a bunch of issues to work through - collision zones not originally settup correctly, TLM wear and break and Tool life tracking not separated currently, Tool life groups not settup currently (only 15 groups), Tool load monitoring not functional currently. The work light also shuts off ever 5 minutes which is just annoying. If the light goes off, it just seems like a maintenance failure to me.

This machine beat a Tsugami MS08Y at $23,000 higher price, because it was understood load monitoring in the control would be functional. I'm excited about the machine, I'm just watching my lead guy lose his week trying to get it to run right now.

[Green0]

The new machine also didn't have the proximity switches set for the MH206 chuck it came with so our guys had to remove the sheet metal twice to set those correctly. The air blows were also not attached so we set those up. Ellison's settup guys missed those steps and the control make ready stuff wasn't really known before they left. We've put in about a week of work on the machine at this point and haven't turned the corner completely.

[DouglasR]

The TLM is Doosan software not Fanuc. Call your distributor. They "should" have an updated instruction book for it. If not, call Doosan and ask for applications.

[Green0]

The TLM is Doosan software not Fanuc. Call your distributor. They "should" have an updated instruction book for it. If not, call Doosan and ask for applications.

We have been calling local and national level support. The TLM on the new machine is not working properly. There must be a parameter or keep relay associated with getting the tool pages for load monitoring to be individually editable as they have to be for the software to be operational. I would happily downgrade to an older known working version of tool load monitoring. We would prefer for the software to be the same as the other Doosan machines on the floor, but we are OK with the new version as long as it can be made to work properly.

[Green0]

Some of the guys tell us to look in the blue books for solutions, and some of them are actually in there. I think it would tremendously help to put those resources on a USB so that a ctrl-F search function could be used to make them easier to locate. After a while we have to focus on other production activity and realize we've expended reasonable resources of time in attempts to resolve something we're not qualified to understand.

[Green0]

The installer came in today to try to get signatures on the install. It's not done. They know the machine load monitoring isn't working but they sent the guy anyway. They claimed yesterday that an application person was scheduled for Wednesday (currently tomorrow). That move didn't make any sense.

I think Doosan USA could majorly benefit from taking a list of known field parameter and ladder edits to a board and deciding what to make part of the standard install package for the install tech. Or perhaps making a published list of known machine attribute modifications and how they get accomplished. This one represents an advertised control feature (tool load monitoring) that doesn't work. It doesn't make sense not to make that part of a standard install data package of modifications to the delivered crated machine as it comes from import. I understand the Ellison hardship here- we're dealing with a problem that doesn't have a known solution so they are burning their time trying to figure one out. Our productivity on this purchase is zero, their productivity is taking a hit, and the problem could be happening 5 or 10 other places right now for lack of standard install modifications lists. Figuring out how to make the interference zone settup page appear on the control was another one that was very helpful once we had it.

So far we've flipped 6802 bit 6 to 1 That one takes a tool load break, and instead of maxing tool life minutes (corrupting the data), it leaves the current life count visible, but it is only part of a solution to that, because it still kills the tool and requires the operator to reset the tool, and manually re-enter the life count which in minutes results in a loss of seconds being tracked. There must be another parameter edit required to get tool load seperated from tool life monitoring completely so that erroneous tool loads don't potentially compromise the integrity of the tool life tracking data. (our other 3 doosan turning machines operate that way).

Our Tool load monitoring tool page individual tool data edit functionality is not there. Our tool life groups are currently 15, so we could use maybe something like 30 groups.

[Green0]

An application tech came today, and we were able to resolve that 6802 bit 6 was not required for the change that we needed. A custom ladder modification to our TT1800SY's allowed them to function the way they do, probably the same in some of our Yama Seiki machines which operate the same way (we worked with Yama Seiki to integrate load monitoring and resolve some problems with it in 2017). I've attached pictures of the solution to the ladder (the images in compare with the red highlights are the TT1800SY showing the concept of how to do this, and the final image is the Lynx 220LYSC with the solution integrated to its ladder. The solution is tested in the Lynx which has a OI-TD control, and the Puma has a OI-TF control and should respond the same, so it is the next machine to get the solution (being mirrored right now by an ellison senior application tech on the floor).

Original TT ladder no mod:

TT ladder with mod:

Lynx ladder with mod: (KEEP RELAY 12 was not available, so 14 was used for this control)


The application tech explained this ladder modification tells tool load to skip the function of communicating a break to tool life- allowing you to safeguard your life tracking data in the control through an erroneous wear or break during settup or regular program run time.

[Green0]

Also it appears Tool load monitoring might be able to be just as functional as the former version- the new screen has wear and break values which are possibly the Delta numbers- formerly standardized on the bottom of the old screen at 5% wear, 10% break, now they are on every page and have to be populated by the end user. They still probably would benefit from being able to be adjusted differently for different tools, but if you leave those at 5 and 10 for all tools, you can edit the other data. We are going to give that a try, and see if that works like the older load monitoring GUI software. The application tech said the documentation for the new GUI load monitoring isn't very explanatory, for example there is a level 1 and level 0 button, that for all we know might totally change the way load monitoring works but the current documentation just says, this button is level 1 and this one is level 0 or something like that.

We're excited to run the job we've been waiting to run. We still need to integrate a robot but we can hand pull parts for now, and see if we can derive function from the new load monitoring GUI software now with the understanding that those delta wear and break values are global and should be set most likely to 5 and 10. We had previously thought they should be 5 and 10 higher than the measured max load for the tool set in the teach mode. IE 34max, set the wear to 39 and the break to 44, but then we would go to the next page and see those numbers on the next tool.

In the old version, the 5's and 10's occupy the bottom of the screen and are basically not touched and thus you don't think about those numbers.

[Green0]

The load monitoring worked when setup like that- it worked properly and we were able to get the first job running. The robot is not integrated, but the machine is otherwise up and running.

[DouglasR]

Very good.
Most likely Michael An or Momo did the ladder change.
I'm glad it's working.
I used to advise against using it, and prefer Tool Life Monitor instead.