Tooleye Sensor Calibration.

I actually had to replace the tooleye sensor, then calibrate the

new one. First off, are you needing to calibrate because of a crash? If so, do all four buttons
of the tooleye work properly (other than being out of calibration) with good repeatability? If
not, then you'll need to replace it first, otherwise there are a few steps you'll need to take.
Starting with X axis: Teach a turning tool in X (inside sensor button). Then turn a piece of
barstock to a nice even number (1.000, 1.250, etc.). Measure the diameter to determine
how far off it is. Then look up parameter BA97 (X axis sensor position) and write it down.
You'll need to adjust this number +/- to bring it in. Keep in mind that the X axis value is
diametrical and Z is not. It is not nescesary to power down for this parameter change to be
active so once you change it then re-teach your tool and cut it again and remeasure. Repat
the process until you have it right. I usually have it in 3-4 tries. Once you are able to teach
a tool and have it accurate within a couple tenths, the you'll need to teach a boring bar in X
(outer sensor button). Predrill your barstock for your boring bar, the bore it to a nice round
number and measure it. Look up parameter BA95 (X axis sensor width) and write it down.
Note that this value is not diametrical, it is the actual with between the sensor buttons.
Adjust as needed until your bar is accurate. Z axis works pretty much the same except Z is
not diametrical.
The parameters are as follows:
BA95 is X Axis Width (Linear)
BA96 is Z Axis Width (Linear)
BA97 is X Axis Position (Diametrical)
BA99 is Z Axis Position (Linear)

I hope this helps.

The parameters for the Fusion control (and T32 control) are:

B61 is X Axis Width (Linear)

B62 is Z Axis Width (Linear)
B63 is X Axis Position (Diametrical)
B64 is Z Axis Position (Linear)

Make sure before you calibrate the tool eye that is in the arm square. The mazak tooleyes
have a square bottom and 2 flats put an indicator on the flats and make sure that they are
straight.
for fusion B63 is X diameter B61 is for I.D. tools. B61 is adjusted by 1/2 error for B63 teach a tool off
a cut dia. Do not move X, write the value down now adjust B63 until the tool eye gives you the same
number you just wrote down.
Machine B Parameter: B61 for OD and B63 for ID.

I am not sure you have to minus or plus from B61. For example B61=15344 + 320(320 is equal .032 since
no decimal allow). Note: you have to change B63 half of .032(which is .015), if not ID will cut oversize
by .032.
it is parameter number B63 in the machine parameters. The bigger the number
you put in it the smaller the difference in diameter. Meaning if you are cutting to
big you increase the number in the parameter.

In regards to the tool eye, I suspect that someone bumped the turret and moved
it out of alignment. That could be why your parts are undersize. Take a facing
cut on some material. If there is a protrusion in the center, then the tool is not on
the center line of the spindle. After the turret checks out O.K., then indicate the
tool eye parallel to the X-axis. It should have two small flats on it that can be
used to indicate from. Mount the indicator on the turret and move the X-axis with
the handwheel.
There is an adjustment for the tool eye in the up and down direction. The middle
of the sensor should be where the tool touches off. On the top cover, opposite of
the motor, there is an eccentric pin. It has two holes for a pin spanner wrench
and another hole for a split pin. It is threaded in the middle and there is also a
small set screw on the side of the cover to hold it in place. This eccentric pin is
the positive stop for the tool eye in the down position. By rotating this pin with a
pin spanner, you can adjust the height of the tool sensor. If this eccentric pin has
a roll pin holding it in place, then you will have to use a slide hammer and screw
it into the tapped hole in the center. Pull out the entire eccentric pin, remove the
roll pin from the casting and then reinsert the eccentric pin. After it is adjusted,
use the set screw on the side of the cover to hold it and then re-pin it with a roll
pin.
Before setting any tool eye parameters, open the tool data page and make sure
the tool eye compensation (TL EYE CM) is set to zero for each tool. Also, set any
offsets to zero.
Tool eye parameters are in micron values. 25 microns = .001" for all practical
purposes. The O.D. parameter must be set first. This is B63 located under the
machine parameter menu. B63 is a diameter value that is the actual distance
from the centerline of the spindle to the edge of the tool eye in the X-axis. If your
part is bigger than programmed, then add the difference to B63.
After setting the O.D. correctly, then set the I.D. It is parameter B61 which is
essentially the width of the sensor in the X-axis direction. If the I.D. is cut
smaller than programmed, then add half the difference to parameter B61.
For setting tools in the Z-axis, you must do the face first, then the back face. B64
is a distance from Z-axis home to the edge of the sensor. This is set for facing.
B62 is the width of the sensor in the Z-axis direction and it is for back facing.
Before doing his procedure, you should check to see if the axes have any backlash and
correct that first. Send both axes to home position. Check your tool data page and make
sure that the Tool Eye Compensation (TL Eye CM) is set to zero for each tool.

The tool eye parameters are in MICRONS (.001mm). Parameter B63 is set first. This is
a DIAMETER value. When set correctly, your position screen would exactly match what you
programmed the outside diameter of the test cut to be. Parameter B61 is for the I.D. It is not
a diameter value. It is the width of the sensor in the X direction. If you subtract B61 from
B63, that should be the exact distance from the sensor to the centerline of the spindle (X0).
If the I.D. is smaller than programmed, then add half the amount to parameter B61. If the
I.D. is larger than programmed, then subtract half the amount from parameter B61.

Parameter B64 is for facing a part. It is the distance from Z-axis home to the sensor. It will
be a negative value. B62 is the width of the sensor in the Z-axis direction for back facing.
B62 is a positive value.

Chuck sensors
Those are NPN sensors. The light comes on when they are NOT MADE. One is for
unclamp confirmation, one is for OVERTRAVEL confirmation. When clamped, both lights
must be on. When unclamped only 1 should be on. Been a while, but I believe this to be
correct. Make sure you have the correct one in the correct spot. Seems like I remember X35
and X36.......but I've slept since then....so that could be very wrong..

Turret stuff:

Alrighty, what a weekend with this machine.

I corrected the sensor locations according to Tony and voila, the machine now knows when
it is clamped and unclamped.
I then moved on to the spindle like everyone suggested, chucked up on a 2.5" x 9" hunk of
aluminum, cleaned it up, and was very surprised...
No more than .0002" over 8"!

Moving on to the turret.

I indicated an O.D. tool holder in X and recorded the run out at ~.0002" over 4", not too bad.
I then checked the Z axis on the tool mount portion of the turret and recorded that at
~.0003" over 6", nothing I am worried about.

I finally went back to a boring bar holder and that was out .002" again...
Playing around with the holder itself, I noticed if I tightened the mounting bolt too much, the
run out was much worse.
Does anyone know what the torque value should be for them??

Also, after speaking with a Mazak tech again, it looks like there are two sets of bolts I could
have played with.
A set of 8 right behind the mill knuckle and a set of 10 plus 2 pins under the tool holders.

He told me to play with the ones behind the mill knuckle.

Does that look right to you?
After that fun process, I indicated all my tools again and found that all my tools were not
even close to the center of the tool eye.

Can I assume that the tool eye actuator is over traveling?

After indicating my tools, I cut my jaws again... worse than before?!

About to give up, I checked the program again and watched the machine position in
simulation mode.
My rough depth of cut for the steel jaws is .160" with a finishing allowance of .030".
I figured that was too much to I changed the rough doc to .100".
Now correct me if I am wrong, but the DOC is how much my cutter protrudes into the
material?
Watching the position in simulation mode, with my new .1" doc, the machine moved .2"!!

So it looks like my original issue was too deep of a cut.

Why does the program do that?