Determining tool life is difficult, but if operators can do this themselves, or if they can be told this information, they can be better maintained. To address this, we have provided a custom macro that monitors the time or number of parts a tool has before it becomes dull. When a tool is determined to be dull, the value of a universal variable will show the life of that tool. For long-running operations, it may be easier for the operator to monitor the number of parts, but for short-running operations, monitoring the machining time may be more important.
A command similar to this one would be placed at the end of the program for each cutting tool you want to monitor.
N455 G65 P1001 V501.0 T0.5
The letter address V specifies the universal variable number where the total time or number of parts is stored. In our example command, the value of the letter address V is the permanent universal variable #501. The letter address T specifies the number of minutes the tool is in each part. In our example command (T0.5), the T word specifies 30 seconds. Note that if T is set to one (T1.0), the value in the permanent universal variable will be the number of parts.
Here is the custom macro:
O1001
#[#22] = #[#22] + #20 (accumulate)
M99
We recommend making the variable number correspond to the tool number, for example, #501 displays the data for tool number one, #502 displays the data for tool number two, and so on.
Prior to using this custom macro, the operator must manually set the value of the permanent common variable to zero (0). This is done by placing the mode switch to MDI, calling the permanent common variable display page, positioning the cursor to the desired variable, typing 0 and pressing the enter key.
Once this is done, the operator can run the workpiece with the new tool until the tool dims. He can see the accumulated time in minutes or number of parts by looking at the permanent common variable. When the tool dims, this permanent common variable will display the total life of the tool.
Again, this custom macro determines the life of the tool so that the operator can make a better decision about when to replace a damaged tool. This data can also be used in a tool life monitoring system.
A simple tool life management system can be created using custom macros. A number 1 tool in a process can use about 200 parts, a number 6 tool can use 250 parts, and a number 9 tool can use 150 parts. These commands can be placed at the end of your program.
N450 G65 P1002 V501.0 S1.0 C200.0
N455 G65 P1002 V506.0 S6.0 C250.0
N455 G65 P1002 V509.0 S9.0 C150.0
M30
The letter address "V" specifies the counted permanent common variable number. The "S" letter specifies the tool number. Our custom macro can use up to 10 tools, but it can be modified to more tools. Before using this custom macro for the first time, the relevant permanent common variables must be set to zero. Here is the custom macro.
O1002 (Tool life macro program) #[#22] = #[#22] + 1 (count) IF [#[#22] LT #3] GOTO 99 #[#22] =0 (clear) IF [#19 EQ 1.0] GOTO 1 IF [#19 EQ 2.0] GOTO 2 IF [#19 EQ 3.0] GOTO 3 IF [#19 EQ 4.0] GOTO 4 IF [#19 EQ 5.0] GOTO 5 IF [#19 EQ 6.0] GOTO 6 IF [#19 EQ 7.0] GOTO 7 IF [#19 EQ 8.0] GOTO 8 IF [#19 EQ 9.0] GOTO 9 IF [#19 EQ 10.0] GOTO 10
#3000 = 100 (Tool damage reminder)
N1 #3000 = 101 (Replace tool 1)
GOTO 99
N2 #3000 = 102 (Replace tool 2)
GOTO 99
N3 #3000 = 103 (Replace tool 3)
GOTO 99
N4 #3000 = 104 (Replace tool 4)
GOTO 99
N5 #3000 = 105 (Replace tool 5)
GOTO 99
N6 #3000 = 106 (Replace tool 6)
GOTO 99
N7 #3000 = 107 (Replace tool 7)
GOTO 99
N8 #3000 = 108 (Replace tool 8)
GOTO 99
N9 #3000 = 109 (Replace tool 9)
GOTO 99
N10 #3000 = 110 (Change tool 10)
GOTO 99
N99 M99 |
