If your Citizen machine is not capable of sharing data through the embedded ethernet port, it will have to be integrated using an I/O kit. I/O integrations are generally limited to capturing utilization, part count, and sometimes alarm state.
This integration can be broken down into three stages:
- Find usable power source (24VDC)
- Connect to signal(s) that indicate active/idle states
- Connect to signal that indicates a part has been completed
Whether you are integrating your Citizen machine with a T4 connected to your hardwired network, or a wireless edge device paired with a LabJack U3, you will need to locate 24VDC to power your MachineMetrics hardware. Most Citizen machines are equipped with screw terminals with 24VDC available to power auxiliary equipment. The 24 volt terminals are labeled +24V, and 0V.
Depending on the make, model and year of the machine, there may be a number of ways to capture active/idle states.
Citizen lathes have outputs for the green, yellow, and red stack lights. These are usually labeled PATG, PATY, and PATR. They will be energized with 24VDC depending on what light is on. Sometimes if the stack light is not installed on the machine, these outputs are not active, so check terminals with a multi-meter before relying on this method of active/idle.
In most cases, when the green light is on the machine is active, when the yellow light is on the machine is idle, and when the red light is on the machine is in an alarm state. By monitoring the stack light signals, we have a good indication of whether or not the machine is active, idle, or in alarm.
It is important to note whether the lights stay solid or flash, and the combinations of lights that come on when the machine is in a certain state.
Pictured below are the screw terminal for the Green, Yellow, and Red stack light outputs.
Another way of capturing active and idle states is by monitoring the spindle drive with a current transducer. If you can safely assume that whenever the spindle is rotating the machine is active, this is a good method of capturing utilization. The spindle drive is in the electrical cabinet beside the axis drives. The spindle drive sends three-phase AC power to the spindle motor, so it is important to clamp the current transducer around 1 of the 3 phases (labeled U, V, W) from the drive. It is important to consider that if the machine is capable of both lathe and milling operations, it may be important to monitor the main and sub-spindle. How to install a Current Transducer
*Below is a current transducer readout of activity on the spindle drive expressed in volts. A voltage threshold in the configuration determines whether the machine is active (green) or idle (blue).
Depending on the make, model and year of the machine, there may be a number of ways to capture part count.
Part Count Relay
The majority of citizen machines have a circuit board with a relay slot for a part count relay. This relay comes on for a half second whenever M56; is seen in the parts program. M56; is embedded in most parts programs as a standard part count M code, so this is an idea method of capturing part count as nothing must be added to the parts program to count parts. The labeling for this relay can vary. BFWK = bar feeder work count, BF4, or CTR are common standards. There is usually a diode associated with this relay which can be clipped onto (+/anode side) to retrieve the 24VDC signal. Refer to your machine's owner's manual to confirm what M code triggers the part count relay. On some machines it may be something other than M56;
*Below are examples of the work count relay that pulses when M56; is seen in the parts program:
*Below is a voltage readout of the M56 part count signal. Each black dot represents a part count which corresponds with a .5 seconds spike in voltage whenever M56; is seen in the parts program.
Auxiliary M Codes
If the part count relay is not available, it may be possible to use an auxiliary M code to trigger a part count. M61; through M65; are M codes that send 24VDC to a corresponding output in the machine's electrical cabinet. The outputs are generally on a factory installed terminal block, though it is possible that they are labeled differently and located on a terminal strip with other inputs/outputs. When one of these M codes is seen in the parts program, it will hang on that code until a finish signal is satisfied. We achieve this by installing a double pole relay that sends the 24VDC signal that comes from the respective M61-65 terminal simultaneously to both the part count pin of the I/O Module and to the MFIN (external completion) terminal. As soon as MFIN receives 24VDC the program moves past M61-65. Our part counter sees this pulse and increments the part counter.
Pictured is the terminal block with the M61-M65 outputs. When M65; is seen in the parts program terminal M65 becomes energized and fires the coil of the two pole relay, which sends a 24VDC signal to AIN2 of the I/O module and the MFIN terminal simultaneously.
Have questions? Reach out to your Customer Success Manager or email Support@machinemetrics.com.