Solved Okuma ESV4020 Tool Change Hang Up


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Thread: Okuma ESV4020 Tool Change Hang Up

  1. #1
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    Default Okuma ESV4020 Tool Change Hang Up

    While machining some parts this morning the machine tried to tool change, it placed the tool in the magazine, and refused to move after. It would clamp and unclamp, but that's it. I hit reset, and managed to get the spindle up (leaving the tool in the magazine).

    Upon inspection I found the alignment key was bent upwards. I replaced it with an alignment key from another pot and the tool sits perfectly again.

    My problem now is I can't get the magazine to retract or index. It is currently stuck open, under the spindle. I have tried using Interlock Release and Advancing, Reversing steps and restarting cycles, but nothing works. At the moment the ATC says it's on SEQ 010 and won't move back to SEQ 001.

    If anyone can help, please post. I can give more details if you need, just ask (I'm not sure what else is needed). I'm not really getting alarms (unless I try to move X and Y axis).

    Here's a picture of the machine:


    Here's a picture of the controller:


    And to give you an idea of what the machine looks like right now, pause this video at 0:07-0:08 after the tool is released from the spindle and before the next tool is loaded:
    "http://www.youtube.com/watch?v=MJCtrwiKsDI&feature=related"]Tool Change - YouTube

    Thanks,

    William

    Similar Threads:
    Last edited by Blink; 08-25-2011 at 07:25 AM. Reason: Problem Solved!


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    Member OkumaWiz's Avatar
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    You appear to have gotten yourself "stuck" in the tool change cycle. This can happen easily by losing spindle orientation during a tool change cycle. This prevents it from going forward or backward since it does not see the orientation and does not want to try to change tools without it.

    At this point you will probably need to force the tool change cycle numbers in your system parameters. NOTE: BE CAREFUL! You will need to find the tool changer sequence in your maintenance manual and probably remove the tool under the spindle for safety's sake.

    Then you can SET the sequence number to the correct sequence number to get you to a recovered sequence such as 1 (ready). Use caution as when you SET the number, I/O will change to the appropriate settings for that sequence. If in doubt, call your Rep and have them show you how to do it.

    If you can get back to the seqence 1 with the ready, It should step thru properly from that point.

    Best regards,



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    Here's works on my Okuma.
    Turn the machine off.
    Turn back on.
    Go to manual and push the black button on the upper left side of the control(magazine retract) and at the same time push the interlock release button on the lower right side of the control(atc operations area). You may need to push a few times.
    This should bleed the air from the atc cylinder and it will retract.
    Then do a tool change without a tool in the spindle.

    George



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    George and OkumaWiz,

    Thank you very much for your replies.

    George:
    I had tried using the MG. RETRACT button with the INTERLOCK RELEASE before, and again now, unfortunately it didn't work.

    OkumaWiz,
    I've left our Rep a message and I'm hoping he will get back to me. I never thought about it but I think it definitely had to do with losing the orientation. I tried to re-orient it in this state but MDI isn't overriding the system. I'm going to go through the Maintenance manual as you said and look for information.

    Thanks Again,

    William



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    Default Update

    I found the "MACHINE DIAGNOSIS" and found two pages:

    *ATC SEQUENCE*
    15716
    Spindle orientation is not completed.

    *MAGAZINE*
    15913
    ATC cycle is not Sequence 1.

    I found the steps and sequence numbers in our operation manual, but can't figure out how to force change it in the machine using the parameters. Any ideas?



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    So, you can not do the 1 step forward or backward?

    Here is a VERY INAPPROPRIATE way that I have solved this.

    *FOR ENTERTAINMENT ONLY*

    NOT RESPONSIBLE FOR INJURIES

    If you haven't, turn power off.

    See if you can push the changer back into the retract position. You may need to open the access on the back of the enclosure and manually operate the solenoid to release air out of the line.

    Once you can do this, make sure E-stop is pressed, turn power on while holding the magazine back in the retract position. Make sure you are holding it with your hand away from any pinch points.

    Once power is on and all is up, pop the E-stop and reset/power on. It should hold back after that. If it pushes back out, don't hurt yourself over it.

    I have done this a few times. A couple times some fool forgot to turn on the air compressor and got stuck mid tool change cycle. It won't let me simply forward or back, so I power off, shove the magazine back and power on. It works for me, but this is a cadet mate 4020 with osp-700m



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    Oh yes..... then of course use caution. you may have to 1 step forth or back to get operational. pay attention to what tool is suppose to be in the spindle, if any



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    Annoying,

    Thanks for the tips. I've tried pushing the magazine back but it had no effect. There was a little give but then it just moves back to the original position. I removed the read access panel but can't find any "bleed" valve for the solenoid. I disconnected the air supply but that had no effect. As far as the solenoid goes, there appears to be two air lines, one on each end, but I have no idea how to bleed to air from it.

    Thanks,

    William



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    Default FIXED

    Alright, I managed to fix it! Here's how I did it:

    Parameters
    -SEARCH
    -WRITE
    -8. MACHINE PARAMETERS
    -WRITE

    MC SYSTEM PARAMETERS
    -SET
    -1 (Active)
    -WRITE

    -Page Down until MC SYSTEM PARAMETER No. 2
    -ATC SEQUENCE NUMBER
    -SET
    -__ (Whatever sequence number you need, I used 11 to retract the magazine)
    -WRITE

    MANUAL
    - 1 Step Advance

    All is working good now! Thanks so much to everyone's recommendations and thoughts, it was all extremely appreciated. Hopefully this will help someone someday to avoid the headache I had.

    Regards,

    William



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    Default Re: Okuma ESV4020 Tool Change Hang Up

    Extremely useful information. This saved me yesterday when Gosiger couldn't. Thanks for posting.



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    Default Re: FIXED

    Hi can you please be more specific please.
    which parameters change?


    Parameters
    -SEARCH
    -WRITE
    -8. MACHINE PARAMETERS
    -WRITE

    MC SYSTEM PARAMETERS
    -SET
    -1 (Active)
    -WRITE

    -Page Down until MC SYSTEM PARAMETER No. 2
    -ATC SEQUENCE NUMBER
    -SET
    -__ (Whatever sequence number you need, I used 11 to retract the magazine)
    -WRITE

    MANUAL
    - 1 Step Advance

    All is working good now! Thanks so much to everyone's recommendations and thoughts, it was all extremely appreciated. Hopefully this will help someone someday to avoid the headache I had.

    Regards,

    William[/QUOTE]



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    Default Re: FIXED

    hello, you should know the "sequences list" for a tool change procedure, from the manual i suppose / dealer ?

    after, you should figure it out at what sequence number your cnc stopped, and go forward / backward from it

    procedure for going forward / back is described by mr Blink i will compress all that infos :

    parameters
    ... machine parameters
    ... mc sys parameters : input 1 ( active )
    ... mc sys parameters no 2 : atc sequence number : input * ( *= desired sequence from "sequences list" )

    manual
    ... 1 step advance

    so :
    ... find that tool change sequences list; if there is no way to find it, than maybe there is somebody with a same machine as yours, and so, upload a photo with your current changing status, and maybe there is a chance to have a reply about relative sequence number that you might need
    ... continue from a random sequence, as mr Blink said
    ... input = set + string + write / enter

    i think you can acces the parameters for your machine, or am i wrong ? if so, it should be easy ... kindly !

    Ladyhawke - My Delirium, https://www.youtube.com/watch?v=X_bFO1SNRZg


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Okuma ESV4020 Tool Change Hang Up

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