Help with 8025M Tool Change Subroutine

[TAProwler]

Hey Everyone,
I could use some help with getting my tool change subroutine to work on my 8025M router. The tool changer is a Non-Random 6 tool changer (basically just X/Y tool positions {ISO30 tool clips} mounted along the long side of a 4'x8' table). Here is a rough diagram:

....._T1_T2_T3_T4_T5_T6_
__/____________________\__
|......................................| ^
|......................................| |
|......................................| Y
|......................................| |
|o_______________________| v
<----------- X ------------>

After a machine reference (Home):
The absolute coordinates of the table origin are at (X6.365,Y0.135,Z-5.75).
The absolute coordinates of T1 are @ (X39.643,Y59.990,Z-4.702).
The TC subr references the position of T2-T6 to the positon of T1.
The table soft limits (absolute referenced from machine ref zero) are:
XPos=111.0, XNeg= -1.0
YPos=61.5, YNeg=-0.5
ZPos=1.0, ZNeg=-5.75

There are two programs that I am trying to use (attached at the bottom of this post). The first program (%43210) is a short program that simply calls for a tool change. The second is the tool change subroutine (%99998). The TC subr has a lot of comments included here, but I have stripped them out on the version that I have loaded on the machine.

PROBLEM #1
When I try to use step through %43210 using single block mode I get the following:

Error 066 : X Limit
N0220 M6

However, this error comes as the next block to execute is:
N0060 G59 X0 Y0 Z0

The Error Code Book says: Error 066 is X Axis Travel Limit Overrun. It is genereated either becasue the machine is beyond limit or because a block has been programmed which would force the machine to go beyond limits.

I have gone thru the code and done the math by hand, and I can't see where a position is being genereated that will fall outside of the soft limits. I assume that is the limit that is being checked. If not a soft limit, then what limit is being exceeded?

PROBLEM #2
If I try to just run the %99998 in single block mode, I get the following:

Error 016 : N _ _ Doesn't Exist
N0310 G26N3000.3030

However, I get this error when the next block to execute is:
N0030 G22N99 (DEFINE %99998 AS A STND SUBR #99)

The Error Code Book says: Error 016 - The called subroutine or block does not exist or the block searched by means of a special function F17 does not exist.

As I scroll thru the lines of code on the machine, the blocks N3000 thru N3030 are definitely in there, but?!?!?!

Any help or insight would be greatly appreciated.
R/Todd

Here are the two programs:

%43210
%43210
N0040 G90
N0050 G70 (Inch)
N0060 G59 X0 Y0 Z0
N0140 M05
N0200 T6.6
N0220 M6
N0280 G0 X0.0 Y0.0 Z0.0
N0290 M05
N0540 M30

%99998
%99998
N0010 (TOOL CHANGE PROGRAM WITH NEW X&Y AXES)
N0020 ()
N0030 G22N99 (DEFINES THIS AS A STANDARD SUBROUTINE NUMBER 99)
N0040 G90 (SET ALL MOVES TO ABSOLUTE PROGRAMMING)
N0050 G53 (ZERO ALL OFFSETS)
N0060 M5 (TURN SPINDLE OFF)
N0070 P40=K39.643 (X BASE POS - X POS OF TOOL #1)
N0080 P41=K59.990 (Y BASE POS - Y POS OF TOOL #1)
N0090 P42=K-4.702 (Z BASE POS - Z POS OF TOOL #1)
N0100 ()
N0110 (P45=LAST OR OLD TOOL NUMBER)
N0120 (P49=SELECTED OR NEW TOOL NUMBER)
N0130 (P50=CALC X POS FOR OLD OR NEW TOOL)
N0140 (P51=CALC Y POS FOR OLD OR NEW TOOL)
N0150 (P52=CALC Z POS FOR OLD OR NEW TOOL)
N0160 P53=K57.000 (SET P53 TO A TEMP Y POSITION 1)
N0170 P54=K50.000 (SET P54 TO A TEMP Y POSITION 2)
N0180 ()
N0190 (-------------------------------------------------------------)
N0200 (DETERMINE THE OLD TOOL NUMBER FOR X,Y&Z CALCS)
N0210 ()
N0220 P23=P45 (SETS PARAMETER P23 = LAST/OLD TOOL NUMBER)
N0230 (IS THIS OLD TOOL #1 ?)
N0240 P49=P23F2K1 (IF O.T.#1-1=0, THEN DO NEXT LINE, ELSE SKIP)
N0250 G26N1000.1030 (IF O.T. WAS #1 THEN GOTO LINES 1000 TO 1030)
N0260 (IS THIS OLD TOOL #2 ?)
N0270 P49=P23F2K2 (IF O.T.#2-2=0, THEN DO NEXT LINE, ELSE SKIP)
N0280 G26N2000.2030 (IF O.T. WAS #2 THEN GOTO LINES 2000 TO 2030)
N0290 (IS THIS OLD TOOL #3 ?)
N0300 P49=P23F2K3 (IF O.T.#3-3=0, THEN DO NEXT LINE, ELSE SKIP)
N0310 G26N3000.3030 (IF O.T. WAS #3 THEN GOTO LINES 3000 TO 3030)
N0320 (IS THIS OLD TOOL #4 ?)
N0330 P49=P23F2K4 (IF O.T.#4-4=0, THEN DO NEXT LINE, ELSE SKIP)
N0340 G26N4000.4030 (IF O.T. WAS #4 THEN GOTO LINES 4000 TO 4030)
N0350 (IS THIS OLD TOOL #5 ?)
N0360 P49=P23F2K5 (IF O.T.#5-5=0, THEN DO NEXT LINE, ELSE SKIP)
N0370 G26N5000.5030 (IF O.T. WAS #5 THEN GOTO LINES 5000 TO 5030)
N0380 (IS THIS OLD TOOL #6 ?)
N0390 P49=P23F2K6 (IF O.T.#6-6=0, THEN DO NEXT LINE, ELSE SKIP)
N0400 G26N6000.6030 (IF O.T. WAS #6 THEN GOTO LINES 6000 TO 6030)
N0410 ()
N0420 (------------------------------------------------------------------)
N0430 ( REMOVE THE OLD TOOL FROM SPINDLE )
N0440 ()
N0450 G0YP54 (MOVE Y TO TEMP Y POSTION Y2)
N0460 XP50 (MOVE X TO CALC X POS FOR IN/OUT OF CUR TOOL)
N0470 YP53 (MOVE Y TO TEMP Y POSITION Y1)
N0480 ZP52 (MOVE Z TO CALC Z POS FOR IN/OUT OF CUR TOOL)
N0490 M89 (DECODED M FUNCT FOR TSDEVICE RELEASE)
N0500 G1G7YP51F200 (MOVE RACK TO SPINDLE IN SQUARE MOTION)
N0510 (G7 = Y MOVE MUST BE DONE BEFORE Z1 MOVE)
N0520 M91 (DECODED M FUNCTION FOR RELEASE DRAWBAR)
N0530 G4K1 (DWELL FOR 1 SEC)
N0540 Z1 (MOVE Z TO ABSOLUTE Z=1.0 - APPROX 5.5" UP)
N0550 G0YP54 (RAPID Y TO TEMP Y POSITION 2)
N0560 ()
N0570 (---------------------------------------------------------------)
N0580 (DETERMINE NEW TOOL AND CALC NEW POSITIONS)
N0590 ()
N0600 P29=F29 (SET PARAM P29=VALUE OF NEW TOOL#)
N0610 (FOR NEW TOOL = 1)
N0620 P49=P29F2K1 (IF N.T.#1-1=0, THEN DO NEXT LINE, ELSE SKIP)
N0630 G26N1000.1030 (IF N.T. IS #1 THEN GOTO LINES 1000 TO 1030)
N0640 (FOR NEW TOOL = 2)
N0650 P49=P29F2K2 (IF N.T.#2-2=0, THEN DO NEXT LINE, ELSE SKIP)
N0660 G26N2000.2030 (IF N.T. IS #2 THEN GOTO LINES 2000 TO 2030)
N0670 (FOR NEW TOOL = 3)
N0680 P49=P29F2K3 (IF N.T.#3-3=0, THEN DO NEXT LINE, ELSE SKIP)
N0690 G26N3000.3030 (IF N.T. IS #3 THEN GOTO LINES 3000 TO 3030)
N0700 (FOR NEW TOOL = 4)
N0710 P49=P29F2K4 (IF N.T.#4-4=0, THEN DO NEXT LINE, ELSE SKIP)
N0720 G26N4000.4030 (IF N.T. IS #4 THEN GOTO LINES 4000 TO 4030)
N0730 (FOR NEW TOOL = 5)
N0740 P49=P29F2K5 (IF N.T.#5-5=0, THEN DO NEXT LINE, ELSE SKIP)
N0750 G26N5000.5030 (IF N.T. IS #5 THEN GOTO LINES 5000 TO 5030)
N0760 (FOR NEW TOOL = 6)
N0770 P49=P29F2K6 (IF N.T.#6-6=0, THEN DO NEXT LINE, ELSE SKIP)
N0780 G26N6000.6030 (IF N.T. IS #6 THEN GOTO LINES 6000 TO 6030)
N0790 ()
N0800 (-------------------------------------------------------------)
N0810 (NEW TOOL INTO SPINDLE)
N0820 ()
N0830 XP50 (MOVE X TO CALC X POSITION)
N0840 YP51 (MOVE Y TO CALC Y POSITION)
N0850 G1ZP52 (LINEAR MOVE Z TO CALC Z POSITION FROM Z1.0)
N0860 M92 (DECODED M FUNCTION FOR DRAW BAR HOLD)
N0870 G4K1 (DWELL FOR 1 SEC)
N0880 G0YP53 (RAPID Y TO TEMP Y POSITION 1 - TOOL OUT OF HOLDER)
N0890 Z1 (MOVE Z BACK UP TO ABS Z=1.0)
N0900 YP54 (MOVE Y TO TEMP Y POSITION 2)
N0910 M90 (DECODED M FUNTION FOR TSDEVICE HOLD)
N0920 P45=F29 (SET P45 = NEW TOOL# DETERMINED ABOVE SECT)
N0930 G24 (END OF SUBROUTINE)
N0940 ()
N0950 (------------------------------------------------------------)
N0960 ()
N1000 P50=P40 (CALC X FOR TOOL #1 = X BASE POS VALUE)
N1010 P51=P41 (CALC Y FOR TOOL #1 = Y BASE POS VALUE)
N1020 P52=P42 (CALC Z FOR TOOL #1 = Z BASE POS VALUE)
N1030 ()
N1040 ()
N2000 P50=P40F1K6.004 (CALC X FOR T#2 = X BASE + T2 X OFFSET)
N2010 P51=P41F1K-0.042 (CALC Y FOR T#2 = Y BASE VALUE)
N2020 P52=P42F1K0.044 (CALC Z FOR T#2 = Z BASE + T2 Z OFFSET)
N2030 ()
N2040 ()
N3000 P50=P40F1K12.020 (CALC X FOR T#3 = X BASE + T3 X OFFSET)
N3010 P51=P41F1K-0.137 (CALC Y FOR T#3 = Y BASE)
N3020 P52=P42F1K0.105 (CALC Z FOR T#3 = Z BASE + T3 Z OFFSET)
N3030 ()
N3040 ()
N4000 P50=P40F1K18.005 (CALC X FOR T#4 = X BASE + T4 X OFFSET)
N4010 P51=P41F1K-0.077 (CALC Y FOR T#4 = Y BASE)
N4020 P52=P42F1K0.142 (CALC Z FOR T#4 = Z BASE + T4 Z OFFSET)
N4030 ()
N4040 ()
N5000 P50=P40F1K24.051 (CALC X FOR T#5 = X BASE + T5 X OFFSET)
N5010 P51=P41F1K-0.150 (CALC Y FOR T#5 = Y BASE)
N5020 P52=P42F1K0.209 (CALC Z FOR T#5 = Z BASE + T5 Z OFFSET)
N5030 ()
N5040 ()
N6000 P50=P40F1K30.0 (CALC X FOR T#6 = X BASE + T6 X OFFSET)
N6010 P51=P41F1K-0.188 (CALC Y FOR T#6 = Y BASE)
N6020 P52=P42K0.57 (CALC Z FOR T#6 = Z BASE + T6 Z OFFSET)
N6030 ()
N6040 ()

[TAProwler]

In working to try to figure out why these errors are happening, I've considered the following:

1. If I am using BLOCK STEP to go through a subroutine program, does the machine have problems because there was no original "calling" program?

2. Why does the machine seem to jump several blocks ahead and give an error code for a block that hasn't even been STEPPED to yet?

3. I did find a potential logic problem when the TC subr is being run for the first time. If P45 hasn't been previously defined then it is probably being assumed to be 0 (Zero). If that is the case, then in the block of code that decides what the current tool is to be replaced into the rack, none of the condtions will have been met because the code only checks for 1,2,3,4,5 & 6. I will try a short program that defines P45 in the part program BEFORE the block with the tool change. This should define P45 to be the old tool number and prevent the case of P45=0.

4. Does the machine share Parametric Variables between part programs and standard subroutines that are called? I assume so, but can't determine from the manuals if this is actually the case.

Thanks for any help or insight.
R/Todd

[TAProwler]

I might have figured this out. The following "fix" essentially addresses Items #2 & #4 from the previous post.

Turns out, when I researched the M06 command in the Programming Manual, there are several parameters that are "used" to execute the M06, in particular: P702-P705, P709 & P900-P903. Also, if the spindle tool holders reaquire alignment an M19 is run, but this is not used in my setup.

I reformatted my table and swapped the X & Y axes in setting up my system. I was aware of, and I did swap all of the parameters directly related to X axis and Y axis. However, I was unaware of, and did not swap the old X and Y settings for:
P703=2(Y Axis is 2nd move on an M06) => P901=-10.0 (Now is 59.90)
P704=3(X Axis is 3rd move on an M06) => P902=-56.0 (Now is 39.65)

As you can see from my 1st post my soft limits for X axis were -1.0 to 111.0 Obviously, the P902=-56.0 is way out of limits. So, I have corrected this.

I'm on the road right now and cannot try to single step thru this code, but I wll try it when I get back to the shop.

Item #1 from the previous post is still unclear to me. IF this fixes the program that calls the TC subroutine and IF the subroutine call does work, will I still get the:
Error 016 : N _ _ Doesn't Exist
N0310 G26N3000.3030
error??


With reference to Item #3 on previous post, the parameter P45 was OK and correctly had the value of 3 (the tool that is actually in the spindle). Once it is set correctly (and since the memory is non-volatile) it should always work.

I'll report back on what I find out when I get back to the shop.

[TAProwler]

So, setting the correct parameters for P702-P705 and P900-P903 fixed problem #1 from the first post.

However, the subroutine is still failing on:

Error 016 : N _ _ Doesn't Exist
N0310 G26N3000.3030

Blocks N3000 to N3030 do exist and they are displayed in the subroutine.
The machine just doesn't "see" them for some reason!?!?

Anyone have any ideas why this block of code is failing/erroring?

Thanks for any insight.
R/Todd

[TAProwler]

So, in an effort to try to troubleshoot this, I forced the machine to think that there was a different tool in the spindle.

Prior to this, the machine last thought (correctly) that T3 was in the spindle, and when I ran the TC program it errored as described above.

Now, I forced the machine to think that T4 was in the spindle (changed T03 P00 & T04 P04 to new T03 P03 & T04 P00). In addition, checked to make sure that the tool table showed T00 P04.

When I ran the TC program this time, the machine got stuck "In Execution" somewhere in the M06 routine. I let it sit for 5-6 minutes waiting to see if it would do something (which it did not). It seems that the machine is waiting for something, or the program is stuck in an infinite loop of some kind.

I also have noticed that after interrupting the program, the tool parameters show T06 P99. This seems important since the tool change program is trying to change to T6.

The book says that P99 indicates one of two things:
The tool is in the tool changer, or;
M06 has not been executed yet.

Since I don't actually have a tool changer (only spindle and pockets) - it would seem that the machine is waiting for something to actually finish executing the M06.

Any ideas?

Back to troubleshooting.
R/Todd

[TAProwler]

OK, so when you have the Feedrate Override knob set to 0 (Zero) - you get "In Execution" forever when you are trying to step through your program (or pretty much anything, really)

Duuhhhooo!!!!

That also means that the Error 16 is back. Yay!

It has to be something about the G26 format/syntax.
Back to the drawing board.

R/Todd

[TAProwler]

I shortened my subroutine calling program and the called subroutine program to try to test the system.

Here's the calling program:
%43210
%43210
N0040 G90
N0050 G70 (Inch)
N0060 G59 X0 Y0 Z0
N0140 M05
N0200 T6.6
N0220 M6
N0280 G0 X0.0 Y0.0 Z0.0
N0290 M05
N0540 M30

And here's the called subroutine:

%99998
%99998
N10 (JUMP TEST PROGRAM)
N12 G22 N99
N15 G90
N16 G53
N20 P50=K4.0
N21 P51=P50F2K4.0
N22 G26 N70.80.1
N23 G25 N90
N30 G01 Y10
N40 G25 N80
N50 ()
N60 ()
N70 G01 X50
N80 ()
N90 G24

All that the called subroutine was supposed to do was see if the X axis moved to the X50.0 position - And it did.

This tests the G26 conditional jump statement in a manner similar to what the TC Subr does - and it works. So, now I have to figure out what's so different between the two and maybe I can get this thing working.

R/Todd

[TAProwler]

Although, I don't know exactly why. I just took the orginal code that I recovered from the machine when I got my RS232/DNC connection working and re-swapped the X/Y variables (using the absolute minumum of changes necessary).

Then I tried it and it ran!

It's the same thing I did to create the first set of code that I was trying to get to work, but there must have been some hidden character or something, somewhere that was fouling the code.

Anyway, I ran 10 different tool swaps while tweaking the code to get the best results and all is well now.

Here's the code that finally got it to work:

%54321 (Tool Swap Calling Program):
%54321
N0040 G90
N0050 G70 (Inch)
N0060 G59 X0 Y0 Z0
N0140 M05
N0200 T5.5
N0220 M6
N0280 G0 X0.0 Y0.0 Z0.0
N0290 M05
N0540 M30

I actually made 6 of the above programs, one for each tool T1-T6.

%99998 (TC Subroutine Called by M06):
%99998
N0010 (TOOL CHANGE)
N0020 G22N99
N0025 G90
N0030 G53
N0035 M5
N0040 P40=K39.643(XBASE POS)
N0045 P41=K59.990(Y BASE POS)
N0050 P42=K-4.702( ZBASE POS)
N0055 (P45=LAST POS)
N0060 (P50=X POSITION)
N0065 (P51=Y POSITION)
N0070 (P52=Z POSITION)
N0075 P53=K57(Y1 TEMP POSITION)
N0080 P54=K50(Y2)
N0085 ()
N0090 P23=P45
N0110 (OLD TOOL 1 ?)
N0111 P49=P23F2K1
N0112 G26N1000.1030
N0120 (OLD TOOL 2 ?)
N0121 P49=P23F2K2
N0122 G26N2000.2030
N0130 (OLD TOOL 3 ?)
N0131 P49=P23F2K3
N0132 G26N3000.3030
N0140 (OLD TOOL 4 ?)
N0141 P49=P23F2K4
N0142 G26N4000.4030
N0150 (OLD TOOL 5 ?)
N0151 P49=P23F2K5
N0152 G26N5000.5030
N0160 (OLD TOOL 6 ?)
N0161 P49=P23F2K6
N0162 G26N6000.6030
N0170 ()
N0180 G0YP54
N0190 XP50
N0200 ZP52
N0210 YP53
N0220 M89(CLAMP RELEASE)
N0230 G1G7YP51F200(MOVE IN RACK)
N0240 M91(RELEASE DRAWBAR)
N0250 G4K1
N0260 Z1
N0270 G0YP53
N0280 ()
N0290 P29=F29
N0310 (NEW TOOL 1)
N0311 P49=P29F2K1
N0312 G26N1000.1030
N0320 (NEW TOOL 2)
N0321 P49=P29F2K2
N0322 G26N2000.2030
N0330 (NEW TOOL 3)
N0331 P49=P29F2K3
N0332 G26N3000.3030
N0340 (NEW TOOL 4)
N0341 P49=P29F2K4
N0342 G26N4000.4030
N0350 (NEW TOOL 5)
N0351 P49=P29F2K5
N0352 G26N5000.5030
N0360 (NEW TOOL 6)
N0361 P49=P29F2K6
N0362 G26N6000.6030
N0365 ()
N0370 XP50
N0380 YP51
N0390 G1ZP52
N0400 M92(DRAW BAR HOLD)
N0410 G4K1
N0420 G0YP53
N0430 Z1
N0440 YP54
N0450 M90(CLAMP HOLD)
N0460 P45=F29
N0470 G24
N0480 ()
N1000 P50=P40(TOOL #1)
N1010 P51=P41
N1020 P52=P42
N1030 ()
N1040 ()
N2000 P50=P40F1K6.004(TOOL #2)
N2010 P51=P41F1K-0.042
N2020 P52=P42F1K0.044
N2030 ()
N2040 ()
N3000 P50=P40F1K12.020(TOOL #3)
N3010 P51=P41F1K-0.137
N3020 P52=P42F1K0.105
N3030 ()
N3040 ()
N4000 P50=P40F1K18.005(TOOL #4)
N4010 P51=P41F1K-0.077
N4020 P52=P42F1K0.142
N4030 ()
N4040 ()
N5000 P50=P40F1K24.051(TOOL #5)
N5010 P51=P41F1K-0.150
N5020 P52=P42F1K0.209
N5030 ()
N5040 ()
N6000 P50=P40F1K30.000(TOOL #6)
N6010 P51=P41F1K-0.188
N6020 P52=P42F1K0.570
N6030 ()
N6040 ()

If anyone can see what the functional difference is between the above code and the code that I first posted that was giving problems, please enlighten me. I sure can't see it.

But, hey - it works now, and I'm happy. Time to move on to the next part of this project - finding the most cost effective, efficient way to get 380V, 3phase power to the spindle (via the VFD) with only single phase 220V in the shop.
R/Todd