When it comes to achieving efficient and precise machining processes, proper probing is essential. Tormach CEO Daniel Rogge and machinist Jason Pulvermacher discussed the unique probing setup used to integrate the ZA6 industrial robot with the 1500MX CNC mill for the IMTS demo. This detailed approach not only showcased Tormach’s capabilities but also highlighted how strategic probing and specific G-code applications make automated CNC processes smoother and more reliable.
Understanding the Probing Setup for the 1500MX and ZA6 integration
One of the first elements of this probing process is ensuring the probe remains clean throughout the operation. In the IMTS setup, the probe is stored in the tool changer, which can expose it to chips during machining. A quick wash cycle with a short burst of coolant is used to clean the probe, preventing chips from affecting measurement accuracy. This seemingly simple step is essential for consistent, error-free probing.
The probe then comes down to check the surface of each workpiece. This step verifies the presence of the parts, ensuring they’re correctly positioned and seated in the vise. If a part is misaligned — perhaps due to not being fully clamped between the soft jaws — the program stops, and the robot pauses, signaling for manual assistance. This routine has programmable tolerances, allowing flexibility depending on the stock’s thickness and tolerance requirements, which reduces the need for constant adjustments.
The ruby stylus allows the probe to get below the top hat so it can probe the machined surfaces.
Probing G54 and G55 Offsets
Once the parts are confirmed to be accurately positioned, the probing routine moves to the G54 and G55 offsets. In this setup, the G54 offset is applied to the blank workpiece (Op1), while the G55 offset is for the halfway finished workpiece (Op2). For this process, the team chose to center the raw stock on the XY plane, ensuring consistency across both operations. This setup minimizes issues with thickness and alignment, especially given that the vise’s jaw is already set as a reference point, so it doesn’t need to be re-probed for each part.
It’s also essential to probe the X and Y axes every time the part is flipped. This extra step keeps tolerances tight, contributing to greater process reliability. For example, using a centered alignment helps account for saw tolerance, keeping the cutter load balanced and reducing potential for error due to variations in the stock.
Using Fusion for CAD/CAM Setup
After detailing the probing setup, Jason demonstrated the Fusion CAD/CAM setup for Op1 and Op2. The process begins with creating a manual NC (Numerical Control) program. This allows users to input code directly, making it possible to customize commands that facilitate proper communication between the 1500MX and the ZA6.
Fusion provides built-in probing routines that can be customized for the specific parts being machined. For example, users can set up the probe to touch off on the top surface of the part, defining parameters such as feed rates, geometry, and target locations. These adjustments ensure that the probe interacts with the part’s surfaces correctly, avoiding areas like pockets and holes that could skew results.
Each probing routine within Fusion also includes an approach distance, which is set to reduce the risk of accidental contact with the part’s surface. For instance, adding extra clearance of 200 thousandths of an inch may slightly extend the cycle time, but it significantly reduces the chance of the probe colliding with the part.
microARC 6 motor mount in CAD/CAM software.
G-Code for Probing Position Verification
The G-code setup is a crucial element that supports this automated process by checking the workpiece’s position within the vise. To start, variables such as the first position and maximum allowable position for probing are defined in G54. This way, if a workpiece isn’t detected within a certain range — like within 25 thousandths of the Z position — an error is triggered, stopping the program and preventing further issues.
An M8 command then activates the probe, followed by a wash-off sequence. This ensures that each probing cycle begins with a clean probe, free from any residue that could impact accuracy. Afterward, the program sets feed rates and positions the probe on the XY plane for a precise touch-off to verify the position of each part. This cycle continues until the probing and machining sequence for both operations are completed.
Benefits of a Robust Probing Setup for Automated CNC
By implementing these probing routines and specific G-code programs, Tormach has created a more reliable and adaptable automated CNC process. Having a programmable, adaptable probing system helps minimize human error and downtime, allowing the ZA6 and 1500MX setup to operate efficiently.
The flexibility provided by Fusion’s manual NC input and robust, tailored probing commands allows users to adapt the setup to different part geometries. Additionally, Tormach’s unique system helps ensure that these machines can perform at a high level while reducing the need for constant manual oversight.
Continuing the Series: What’s Next
This video with Rogge and Jason offers just a glimpse of the setup process for the ZA6 and 1500MX integration at IMTS. In the next videos in this series, we'll delve deeper into essential aspects such as gripper finger design and using LiDAR for automated part recognition and alignment.
