Renishaw OTS "probe already triggered" alarm

[Dlrhoss]

I have 6 Robodrills all less than 3 years old all with the same Renishaw OTS and they all run the same parts 24/7. We do about 1000 broken tool checks in each machine daily using the renishaw OTS. Some machines will periodically have an alarm that says " probe already triggered" and the tool will be about .03 above the stylus. I have one machine that has recently started giving the same error more often but also sporadically. Sometimes its every 4 broken tool checks and sometimes it will run several hours. I have contacted renishaw with no resolve. I have changed the trigger filter to "advanced trigger filter" , recalibrated and recalibrated the ots, disassembled and cleaned the ots, angled the eye on the ots more towards the receiver eye, changed feed rates for broken tool check. Has anyone else had this problem?

 

[PROBE]

This OTS phenomena is known to me for over 10 years. Renishaw uses the same macro routine for tool length setting and for breakage detection. Seems that OTS starts to fail occasionally after certain number of operations. When used as tool breakage detector, the extended usage ratio (I believe in your case the ratio between the tool setting task and breakage detection task is at least 1:500 and probably much higher) causes the hardware/inner algorithm/macro combo to fail occasionally and raise the alarm. Changing the OTS is resolving the problem, but is very costly.
I came with the solution of writing the macro dedicated to breakage detection, and it solved the problem. The problem still occasionally occurs during the tool setting, but contrary to tool breakage alarm which causes cease of operation of 24/7 task and can be very costly in "lights off" during the night, in tool setting the operator simply repeats the task.
Let me know how you call the tool breakage detection operation. Is it G65P9023A24... syntax ?

Stefan
Cogito Ergo Sum

 

[Dlrhoss]

This OTS phenomena is known to me for over 10 years. Renishaw uses the same macro routine for tool length setting and for breakage detection. Seems that OTS starts to fail occasionally after certain number of operations. When used as tool breakage detector, the extended usage ratio (I believe in your case the ratio between the tool setting task and breakage detection task is at least 1:500 and probably much higher) causes the hardware/inner algorithm/macro combo to fail occasionally and raise the alarm. Changing the OTS is resolving the problem, but is very costly.
I came with the solution of writing the macro dedicated to breakage detection, and it solved the problem. The problem still occasionally occurs during the tool setting, but contrary to tool breakage alarm which causes cease of operation of 24/7 task and can be very costly in "lights off" during the night, in tool setting the operator simply repeats the task.
Let me know how you call the tool breakage detection operation. Is it G65P9023A24... syntax ?

Stefan
Cogito Ergo Sum

We use g65p9858 T5. H-.005 (for example)

 

[PROBE]

1. Load the O9953 attached program into memory.
2. Edit the variables #14-#18 at the beginning of the program to suit your control.
3. Change the tool to the one you wish to check for breakage.
4. Dial in MDI G65 P9953 H0.005 T5. and execute.
Pay attention:
1. The program is NOT measuring the tool - it is already measured and its length is stored in offset registers.
2. The spindle plunges beside the tool at the distance either set by the argument D in command line or by the default in #7 just after the line 12.
3. It plunges to the depth of tool length minus the tolerance either set in argument H in command line or by the default in #11 just after the line 12.
4. Then it moves toward the center of the tool setter's center. If no contact is made, the tool is broken and alarm is raised.
5. If contact is made, the tool raises double tolerance amount and LONG TOOL check is performed.
6. If it is working correctly, you can changed the program name to O9858 and use it as your breakage detection routine.
7. Your additional benefits: this program is significantly quicker then original one and it will spare you the crater in the center of the tool setter's stylus.

Stefan
Cogito Ergo Sum

%
O9953(SNR BROKEN/LONG TOOL FANUC)
(G65P9953H.005D1.M1F60)
(*********************************)
#14=0.5 (TS DIAMETER)
#15=-2. (TS ORIENT 1-X 2-Y SIGN-STYLUS DIRECTION)
#16=520. (BASE NUMBER)
#17=9855 (SWITCH THE OTS ON PROGRAM NUMBER)
#18=9856 (SWITCH THE OTS OFF PROGRAM NUMBER)
(*********************************)
M5
IF[#4111EQ0]GOTO5
IF[#4111NE#0]GOTO10
N5
#3000=97(NO H OFFSET)
N10
IF[#11NE#0]GOTO12
#11=0.005 (TOLERANCE)
N12
IF[#7NE#0]GOTO14
#7=1. (MAXIMUM TOOL DIAMETER TO CHECK THE BREAKAGE )
N14
IF[#9NE#0]GOTO15
#9=60 (MEASURING FEEDRATE)
N15
G40G80
G0G91G28Z0
G65P#17 (SWITCH OTS ON)
G91
IF[ABS[#15]EQ1.]GOTO16
G0X[#[#16+3]-#5021]Y[#[#16+4]-#5022+[#15/2]*[[#7+#14]/2]]
G53
#21=#5021
#22=#5022
Z[#[#16]-ABS[#11]+#[#4111+2000]+#[#4111+2200]-#5023]
G31Y-[[#15/2]*[[#7+#14]/2]]F#9
G53
IF[#5062NE#5042]GOTO50
GOTO20
N16
G0X[#[#16+3]-#5021+#15*[[#7+#14]/2]]Y[#[#16+4]-#5022]
G53
#21=#5021
#22=#5022
Z[#[#16]-ABS[#11]+#[#4111+2000]+#[#4111+2200]-#5023]
G31X-[#15*[[#7+#14]/2]]F#9
G53
IF[#5061NE#5041]GOTO50
N20
G65P#18 (SWITCH OTS OFF)
N25
#3000=91 (BROKEN TOOL)
N50
G1Z[#11*2]F#9
G0X[#21-#5021]
G0Y[#22-#5022]
G31X[#[#16+3]-#5021]Y[#[#16+4]-#5022]F#9
G53
IF[ABS[#5041-#5061+#5042-#5062]EQ0]GOTO99
G65P#18
N30
#3000=92 (LONG TOOL)
N99
G0G91G28Z0
G65P#18
G90
M99
%

 

[Dlrhoss]

Thanks @PROBE, this looks great I will give this a try. By the way we already have the crater in the center of the stylii on all the machines... LOL