Introduction

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.

Topics covered in this article

This article contains the following topics:

• Power Supply
• Connect Signals
  • Utilization
  • Stack Light
  • Spindle Drive
• Part Count
  • Part Count Relay
  • Auxiliary M codes
• Adapter Script

Power Supply

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 generally labeled +24V, and 0V. 

If you are integrating on a wireless network using the LabJack U3, you will need to provide power for a wifi enabled edge device:

• Wireless Edge Device Installation

If you are integrating on a hardwired network using the LabJack T4, you will need to provide power for the USB Power Supply:

• USB power supply installation

Connect Signals

Locating and connecting to the signals that will indicate certain machine states will require someone with some experience with wiring and reading electrical schematics. Please review the following article topics before attempting this IO integration.

Utilization

Depending on the make, model and year of the machine, there may be a number of ways to capture active/idle states.

Stack Lights

The output for the Green stack light is a good signal to indicate machine activity.

Citizen machines 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, and when the red light is on the machine is in an alarm state. By monitoring these two stack light signals, we have a good indication of whether the machine is active, idle, or in alarm. Keep in mind it is generally not necessary to collect the Yellow light signal, as the absence of the Green light indicates that the machine is idle.

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.

CONNECTION DIAGRAM: Connect the Green stack light output to AIN0. If connecting for alarm state, connect the Red stack light output to AIN1.

*Below is the signal from the Green stack light, expressed in volts. A voltage threshold in the configuration determines whether the machine is active (green) or idle (blue).

Spindle Drive

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. 

For detailed instructions on how to install a current transducer, follow the link below:

How to install a Current Transducer

CONNECTION DIAGRAM: Connect the positive terminal of the CT to AIN0, and the negative to GND.

*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).

Part Count

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 ideal method of capturing part count. The labeling for this relay can vary. BFWK = bar feeder work count, BF4, or CTR are common standards.

CONNECTION: There is usually a diode associated with this relay which can be clipped onto (+/anode side) to retrieve the 24VDC signal. Connect the diode clip to AIN2 of the LabJack. Refer to your machine's electrical schematics to locate the relay. Confirm what M code triggers the part count relay in the Operators Manual. 

*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. On many Citizen machines, 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 sends a 24VDC signal to an associated output terminal. The program will hang on that code until a finish signal is satisfied. We achieve this by installing a 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 (AIN2) and to the MFIN (external completion) terminal on the machine. As soon as MFIN receives 24VDC, the program moves past M61-65. Our part counter sees this pulse and increments the part counter. The signal from this relay looks identical to the M56 counting method.

CONNECTION DIAGRAM:

Adapter Script

The adapter script below assumes the signal for in-cycle is on AIN0, and the signal for part-count is on AIN2.

version: 2
variables:
  execution-raw:
    - source: AIN0
    - resample: 0.1
    - min-delta: 1
  part-count-raw:
    - source: AIN2
    - resample: 0.1
    - min-delta: 1
  part-in:
    - source: AIN2
    - threshold: 3
    - falling-edge
    - count
  execution:
    - source: AIN0
    - threshold: 3
    - on-delay: 2
    - state:
      - ACTIVE: this
      - READY: true
data-items:
  - execution-raw
  - execution
  - part-count-raw
  - part-in

Have questions? Reach out to your Customer Success Manager or email Support@machinemetrics.com.