HUGE Mazak fully automated 5 axis laser cutter for pipes/tubes/profiles/

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08 Jul 2025 01:42 #331497 by tommylight
Been tasked with making this monstrosity work as it was delivered, mounted, installed, but never tested nor shown it actually works. It is a Mazak with Fanuc controls, has probably over 30 axis in total, pneumatic, Oxygen, 4KW of laser power, nearly 40 meters long, works with 15 meter long tubes, etc, etc.
Took me nearly a whole day to figure out everything due to no prior experience with such machines, and having 3 separate PC's controlling it did not help, but a bit of fiddling and by the evening it was fully working, loading files included.
Next day was spent with the CAM portion and teaching a young employee (actually one of the owners sons) about the procedures of transferring files, copying them into the Fanuc memory, opening and running them, homing everything (3 separate homing procedures), measuring the material (done automatically), adjusting feeds and speeds, adjusting laser power and air assist, changing nozzles, recovering from failed cuts, resetting sensors used for area safety, etc, etc.
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08 Jul 2025 01:46 #331498 by tommylight
The following user(s) said Thank You: RotarySMP, Clive S, pommen, besriworld, COFHAL, Daan96, phino

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08 Jul 2025 08:05 #331507 by weedsmoker
that things sick, i wish i worked around something that epic and complicated, what fanuc is that thing running? when was it even made?
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08 Jul 2025 10:22 #331509 by tommylight
160i is what i recall from the naming on the console, it was made in 2012, again i think, as i do not care much about such info when tasked with making such things work.
I will update info whenever i get a chance, as the stress is gone so now i might also do a less shaky video.
I said "i might" ... :)
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09 Jul 2025 19:59 #331594 by tommylight

that things sick, i wish i worked around something that epic and complicated,

And terrifying !!! :)
You see those big things on both ends of the machine with the rotating parts? Those move at 60m/m when at full tilt so the whole concrete floor shakes so much that the left servo drive errors out with over current!!! No errors when moving one or the other, just both. At 50m/m all is fine.
15cm of concrete is not enough rigid for all that monstrosity, but no one ever told them. I would venture a guess at least 30cm or 50cm just to be on the safe side, but i am no expert.

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12 Jul 2025 16:02 #331736 by tommylight
Anyone here know how to delete the files from internal memory on the Fanuc i160 ?
Having a strange issue (not the first time on Fanuc) where everything works, even copying files from the USB to internal memory, loading said program and ... well this is where it gets fuzzy as it will run the first cut/program we copied into memory no matter what O number program we load.
Even stranger, can not delete those files, no matter what or how.
Had a panic attack last night and went to the hospital at 4AM as i was so pissed off, i can figure every damn thing on that huge machine inside of a day, but can not delete something i copied to it!!!
I refuse to believe that it only works with files on another PC as we are being told, there must be a way to use it's internal memory as it is using it to make the first cuts we copied.
Manual is for an older version without GUI, it helped for some stuff, but for this failed miserably as there is no delete button where it should be.
Maybe somewhere in the System menu???

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14 Jul 2025 02:09 - 14 Jul 2025 04:19 #331800 by sivaraj
Any chance you used program numbers O9xxx or O8xxx .This needs parameter setting (3202) to edit from CNC
google for Fanuc manual B–63525EN/02 page 405 & 428
It should be in EDIT mode and EDIT key enabled.
However you may not be able to delete the active foreground program , the program number which usually shows on top right of the screen.
Could you able to select different program to foreground or not? only the foreground program Number will run in Auto.
The last selected or ran program only will be active as foreground program till you select another program to foregraound.
There is Background edit . it is different 

 
Last edit: 14 Jul 2025 04:19 by sivaraj.
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14 Jul 2025 14:56 #331819 by tommylight

Any chance you used program numbers O9xxx or O8xxx .
 

No, from 5000-9000 are subroutines.

It should be in EDIT mode and EDIT key enabled.
 

Yes, of course.

Could you able to select different program to foreground or not? only the foreground program Number will run in Auto.
 

Yes, i can choose any existing program, and no, this one runs everything from the first program in memory, as noted in the manual.
This i understand why, it is a fully automated machine, so can have multiple programs run consecutively, for different materials and cuts.
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My conclusion is there must be some setting that enables deleting those files/programs as a safety feature as not to accidentally delete them, i just have to find it.
Again, having the manual for the old control while the machine has new controls causes much more confusion than help.

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17 Jul 2025 11:08 #331941 by ErrickW
I may be able to help if you can tell me which control(s) are on it. 160i could be L, P, LA, PA, LB, PB. I think those were all the versions of the 160i that would be on such a machine.

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17 Jul 2025 13:35 #331943 by tommylight
Thank you Erick, i am not sure but i think it was the LB version, but if possible wait till i confirm that as i am not near it nor is the person that uses it.
Thank you very much for the offer.

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