topic Machine crash - problem of g-code or machine? in HSM Post Processor Forum

Machine crash - problem of g-code or machine?

Anonymous — Tue, 28 Jan 2020 22:55:04 GMT

Hello,

I'm looking for advice to prevent breaking tools in future. We are using 3 axis milling machine with Sinumerik 828d.

Machine generated absurd movement on line N1440.

crash state

Base on my knowledge (and Fusion 360 simulation) machine should stay on height Z=-3. But machine started moving down, look at Z position (Z=-12,301) when we pressed EMG stop.

I have re-run this program and line N1440 moves machine down to about -43.

We are using latest post-processor for Sinumerik 840d with enabled arcturn - is it possible this parameter gives incorrect code?

contour

Re: Machine crash - problem of g-code or machine?

AchimN — Wed, 29 Jan 2020 12:11:47 GMT

Can you please share the fusion file as well as your post processor? We will look into it. Thanks

Re: Machine crash - problem of g-code or machine?

Anonymous — Wed, 29 Jan 2020 16:04:25 GMT

Dear AchimN,

thank you very much for your answer.

In attachment is post-processor. Link to model is: https://a360.co/2RXVLpQ

I have sent you password via private message.

Most problematic edit to post processor is:

else if ((useArcTurn) && (movements != MOVEMENT_LEAD_IN) && (movements !=MOVEMENT_LEAD_OUT)) { // IJK mode

This line should only disable IJK for lead-in and lead-out movements.

Re: Machine crash - problem of g-code or machine?

Tomek.G — Wed, 05 Feb 2020 11:26:13 GMT

Hi @Anonymous,

I'm trying to replicate this issue.
Generated code from your project and post looks different.

IJK isn't disabled on my side.

N1510 G1 X47.679 Y42.335
N1512 G3 X47.547 Y40.643 I0.78 J-0.912
N1514 G2 Y-40.643 I-47.547 J-40.643
N1516 G2 X46.198 Y-42.03 I-11.53 J9.856

Could you provide me your settings of non standard Property values?

Anyway, could you please check if the input of G17 before arc moves could help in this case?

Re: Machine crash - problem of g-code or machine?

Anonymous — Wed, 05 Feb 2020 19:24:52 GMT

Thank you for your answer.

I have exported pp from cloud. But it seems it wasn't synced with "export" computer. I apologize.

In attachment I'm sending problematic pp.

else if ( (useArcTurn) && (movement !== MOVEMENT_LEAD_IN) && (movement !== MOVEMENT_LEAD_OUT) && (movement !== MOVEMENT_PLUNGE) ) { // IJK mode

Compare to pp from my previous post there is change in variable name. From movements to movement.

I was changing this line to disable ArcTurn for lead-in and lead-out.

All pp parameters are default.

Re: Machine crash - problem of g-code or machine?

Tomek.G — Thu, 06 Feb 2020 13:37:06 GMT

Hi @Anonymous,

Your arc doesn't use radius, because it is a MOVEMENT_LINK_DIRECT type.

Below is a list of all movements types:

 MOVEMENT_RAPID = 0; // Rapid movement type.
 MOVEMENT_LEAD_IN = 1; // Lead-in movement type.
 MOVEMENT_CUTTING = 2; // Cutting movement type.
 MOVEMENT_LEAD_OUT = 3; // Lead-out movement type.
 MOVEMENT_LINK_TRANSITION = 4; // Transition linking movement type.
 MOVEMENT_LINK_DIRECT = 5; // Direction linking movement type.
 MOVEMENT_RAMP_HELIX = 6; // Helical ramp movement type.
 MOVEMENT_RAMP_PROFILE = 7; // Profile ramp movement type.
 MOVEMENT_RAMP_ZIG_ZAG = 8; // Zig-zag ramp movement type.
 MOVEMENT_RAMP = 9; // Ramp movement type.
 MOVEMENT_PLUNGE = 10; // Plunge movement type.
 MOVEMENT_PREDRILL = 11; // Predrill movement type.
 MOVEMENT_EXTENDED = 12; // Extended movement type.
 MOVEMENT_REDUCED = 13; // Reduced cutting feed movement type.
 MOVEMENT_FINISH_CUTTING = 14; // Finish cutting movement type.
 MOVEMENT_HIGH_FEED = 15; // High feed movement type.

Please be careful during the tests. Especially with the 2D Contour 3.

I'm not sure if the plane definition doesn't have to be re-called before first IJK circular move on your machine.

To force plane definition you can use gPlaneModal.reset(); command for ex. in line 2306

  } else { // use radius mode
    if (isHelical()) {
      gPlaneModal.reset();
      linearize(tolerance);
      return;
    }

Let us know if it works for you.

The position of the circle plane depends on the active plane (G17-G19). If the tangent of the previous block does not lie in the active plane, its projection in the active plane is used. If the start and end points do not have the same position components perpendicular to the active plane, a helix is produced instead of a circle.

Re: Machine crash - problem of g-code or machine?

Anonymous — Mon, 10 Feb 2020 17:39:51 GMT

Thank you very much for your answer.

We will carefully try with force plane definition.