The broken tool detection (BTD) system captures an image of the tool before and after use. This image is then analyzed to check for any noticeable differences in the tool. When the machine detects a broken tool, the machine will generate an alarm to notify the user and stop the program. The system is intended to be used with drills, taps and endmills. 

Note: The Broken Tool Detection system is not field installable at this time.

The BTD system is made up of:

1. A62 processor - This is brain of the system that controls and powers the LED lights & camera. 
2. BTD A62 PFDM PCB - This BTD A62 PFDM PCB receives power from the PSUP and shares it with the A62 processor.
3. LED lights - These (x2) LED lights illuminate the tool as the camera captures it's image to help detect a broken tool. 
4. Camera - This camera captures an image before and after a tool is used. This image is then used to compare the height difference in the tool before and after use. 
5. Camera mounting hardware - This camera mounting hardware attaches the camera and (x2) LED lights to the machine. This hardware also helps to place the camera and (x2) LED lights in the proper position to be able to detect a broken tool accurately. 

The Broken Tool Detection (BTD) is a feature that detects the length by capturing an image of a tool before and after use. With a noticeable difference in length, an ALARM 9300 Broken Tool will be triggered stopping all machine motion.

Before the system can successfully detect a broken tool, the camera needs to be set up and calibrated. This procedure will show you how to manually adjust the camera mount into the proper position and calibrate the Region of Interest. 

NOTE: For more information on the Broken Tool Detection feature, refer to the Broken Tool Detection - Troubleshooting Guide.

Software Requirements:

• 100.23.000.1110 version or higher

Press DIAGNOSTICS.

Navigate to the Maintenance menu and then to the BTD Calibration tab.

Follow the on-screen instructions of engaging [E-STOP] to enter calibration mode.

NOTE: At any time if [E-STOP] is released, it will exit calibration mode and back to the default screen.

Press [F1] to turn on the camera feed on the machine's screen. 

Press [F2] to turn on the remote display tab. In this tab, an external device can view the camera feed making the calibration process easier.  

Follow the on-screen instructions of turning off WiFi on the remote device.

Scan the QR code on the remote device. 

You will be then be prompted to join the machine's network. 

Scan the QR code on the remote device again. 

The QR code will refresh to the remote display web page showing the camera's live feed. 

With the camera live feed displayed on the remote device, test the camera's feed to ensure it is live.

Do this by turning the work lights [ON/OFF]. The change in brightness will be visible from the video live feed. 

Open the machine window on the tool changer side to access the camera. The camera and lights assembly can be adjusted as a whole to ensure proper calibration. 

Set the positioning by slightly loosening the side [1] and top [2] housing screws. 

The side screws [1] allow for forward and backward movement of the camera assembly.

The top screw [2] allows for side to side movement of the camera assembly. 

The pivot screw [3] sets the camera assembly angle. This fine tunes the system.

Make sure to view the remote display of the camera live feed while adjusting the screws.

The area within the green lines is known as the Region of Interest (ROI). The tool should be positioned horizontally in the middle of the ROI. The ROI determines how much of the image the system is detecting. 

Position the camera so that the tool holder is shown on the left and the tip of the tool is shown on the right.

 NOTE: The tool holder should be far enough on the left side so that it is only partially visible and ensure that other tool holders aren't within the region of interest. 

Try to align the tool with the ROI centerline.

Make sure that the black brushes are in the backdrop behind the tool in question.  

NOTE: The straightness of the tool within the middle of the ROI directly effects the quality of the tool detection. In order to get the most accurate centerline, use a longer tool.

Once the tool is sufficiently aligned, press [F2] to leave the remote display page. 

Press [F1] to display the live camera feed on the machine's screen. 

Adjust the ROI to be able to accommodate different sizes of tools. Make sure that the ROI is wide enough to capture both the tool holder and the tool of the widest tool in the carousel. 

IMPORTANT: If the ROI covers two pockets rather than one, there is potential for the camera to detect the wrong tool. Avoid this. 

Press [PAGE UP] and [PAGE DOWN] buttons to adjust the width of the ROI by one digit at a time OR type a whole number between 1-100 then press [F4] to set that ROI value. 

NOTE: For example, the first image [1] shows the tool with the default ROI of 50%. There is too much extra space surrounding the pocket and tool holder. This caused the ROI to be reduced to 40% in the second image [2]. Now, the ROI is more focused on the tool, while still leaving some extra space to accommodate wider tools. 

The Broken Tool Detection (BTD) is a feature that captures an image & detects the length of a tool before and after use. With a noticeable difference in length, then ALARM 9300 Broken Tool will be triggered forcing the BTD tab to pop up with before and after images.

This procedure will show how to operate a machine equipped with Broken Tool Detection system.

IMPORTANT: With the machine in service mode, make sure that Setting 430 is set to ON.

 NOTE: For more information on the Broken Tool Detection feature, refer to the Broken Tool Detection - Troubleshooting Guide.

The BTD Calibration page can be found under Diagnostic > Maintenance > BTD Calibration. 

This BTD Calibration page is accessible to all. This tab shows a live feed of the BTD camera—either on the machine's screen by pressing [F1] or on the remote display by pressing [F2]. 

When viewing the camera live feed, this page can also be used to set the Value Region of Interest (ROI) Value. This value sets the size of the area for whatever the camera is detecting by pressing [PAGE UP] or [PAGE DOWN]. This detected area is where the tool is expected to be—try aligning the tool with the center ROI line. 

NOTE: It is important to finalize the camera mounting alignment first, before finalizing the ROI Value. To get the default ROI Value, press [ORIGIN] to return back to a ROI Value of 50%. 

The Tool Table page [1] can be found under Current Commands > Tools > Tool Table.

Under the Tool Table, mark the tools that will be checked with the Broken Tool Detection system by pressing [F2]. Now, the Broken Tool Detection will run on those selected tools before and after use such as a G01 with movement.

NOTE: The Broken Tool Detection system only runs during a tool change within a program (M06), not during manual tool changes [ATC FWD].

Note: The BTD Tab [2] under Current Commands > Tools > BTD will only show up when there is a broken tool detected.

This procedure will show how to replace the LED lights on the Broken Tool Detection System. 

This procedure should apply to the follow service kits:

• 93-3813 SVC KIT BTD CAMERA/LED

IMPORTANT: This service kit only includes the LED lights. There is no camera included.

 NOTE: Once the LED lights have been replaced, the camera may need to be re-calibrate to adjust to the new brightness. For more information on the calibration process, refer to the Broken Tool Detection - Calibration procedure.

Disconnect both LED lights from the +12V LED power cable 33-1228 [1] connecting into J3 on the BTD A62 PFDM PCB.  

Follow the LED light cable from the control cabinet around the machine's enclosure panels. Remove the LED light cable. 

Remove the (x4) screws securing both LED lights to the broken tool detection brace. 

Remove & discard both LED lights. 

Install the (x4) screws securing both LED lights to the broken tool detection brace. 

Route the LED lights cable around the machine's enclosure panels into the control cabinet. Route the camera cable into the group of other routed cables behind the tool changer. 

Install the LED lights cable into the LED lights. 

Connect both LED lights from the +12V LED power cable 33-1228 [1] connecting into J3 on the BTD A62 PFDM PCB. 

This procedure will show how to replace the camera of the Broken Tool Detection system that captures the before & after image of the tool.

This procedure should apply to the follow service kits:

• 93-3822 SVC KIT BTD CAMERA ASSY 

Disconnect the camera cable 79-0159 [1] plugged into the USB adapter 74-2003 that connects into the USB port on the A62 processor. 

Follow the camera cable from the control cabinet around the machine's enclosure panels.

Remove the camera cable. 

Remove the top screw [1] on the broken tool detection brace. 

Remove the middle screw [2] on the broken tool detection brace.

Remove the last screw [3] on the broken tool detection brace freeing the brace from the camera [4]. 

Remove the camera [4]. 

Install the camera [1] into the broken tool detection brace with screw [2].

Install the middle screw [3] into the broken tool detection brace. 

Install the top screw [4] connecting the broken tool detection brace together. 

Route the camera cable around the machine's enclosure panels into the control cabinet. Route the camera cable into the group of other routed cables behind the tool changer. 

Install the camera cable into the camera. 

Connect the camera cable 79-0159 [1] plugged into the USB adapter 74-2003 that connects into the USB port on the A62 processor. 

This procedure will show how to replace the A62 processor and BTD A62 PFDM board of the Broken Tool Detection system inside the machine's control cabinet. 

This procedure should apply to the follow service kits:

• 93-3815 SVC KIT BTD A62 
• 93-4199 SVC KIT A62, BTD NO BRKT

NOTE: Use service kit 93-3815 for machines that do not have an enclosure on the main processor and use a bracket [1] to mount the BTD PCB (machines built before 02/25/2024). Use service kit 93-4199 for machines that have an enclosure on the main processor, the BTD PCB will bolt directly onto the enclosure (machines built after 02/25/2024 with main processor P/N 32-4267 or 32-4269).

Disconnect all cables connected to the BTD A62 PFDM PCB [1] and the A62 processor [2].

Remove the BTD A62 PFDM PCB [1] from on top of the A62 processor [2].

Remove the A62 processor [2] from on top of the mounting plate [3]. 

Install the new A62 processor [2] on top of mounting plate [3]. 

 IMPORTANT: There is no mounting plate [3] needed for machines built after 02/25/2024 with the enclosed Main controller. The A62 processor [2] is located directly on Main controller. 

Install the new BTD A62 PFDM PCB [1] on top of the A62 processor [2]. 

Connect the BTD camera cable 79-0159 into the USB adapter 74-2003 [1] that connects into the USB port on the A62 processor. 

Connect both LED lights to the +12V LED power cable 33-1228 [2] that goes into J3 on the BTD A62 PFDM. 

Make sure that the A62 processor power cable 33-1256 [3] is connected from J26 on the A62 processor to J4 on the BTD A62 PFDM. 

Connect the BTD A62 PFDM cable 33-1227 [4] from J2 on the BTD A62 PFDM to J3 on the MAINCON. This cable also has a pigtail that connects to P20 on the PSUP. 

Connect the communication cable 79-0158 [5] from the mico USB B port on the A62 processor to the USB port J8 on the MAINCON. 

IMPORTANT: Make sure to insert the translator cable into the lower USB port J8 on the MAINCOM.

The Broken Tool Detection (BTD) is a feature that detects the length & captures an image of a tool before and after use. With a noticeable difference in length, then ALARM 9300 Broken Tool will be triggered forcing the BTD tab to pop up with before and after images. 

For the most accurate results of the Broken Tool Detection feature, make sure the tool is positioned horizontally in the middle of the grid lines on the screen— the Region of Interest (ROI). The ROI value determines how much of the image the system is detecting. 

This troubleshooting guide will explain each alarm and show ways to troubleshoot the Broken Tool Detection system. 

NOTE: To learn more on how to operate the Broken Tool Detection feature, refer to the Broken Tool Detection - Operation reference document for more information. 

ALARM 9300 Broken Tool will be triggered in the event of a broken tool. 

NOTE: A box will appear around the reference and current tool length. With software version 100.23.000.1110, a green box will appear around the tool. With software version 100.23.000.1200 or higher, a lilac box will appear around the tool with a warning symbol [1].

Due to the alarm, the tool cannot be commanded back into the spindle via M06, but can be commanded back into the spindle via [ATC FWD].

Once the tool is inside the spindle, inspect for breakage and replace as necessary. If the tool is not broken, take an error report [SHIFT] - [F3] of the machine to send to the local HFO. 

The following only applies to Software Version 100.23.000.1110:

ALARM 9301 Broken Tool Detection Fault will be triggered by a hardware issue when the control is unable to communicate with either the A62 board or camera. This alarm will only appear when the program calls for a tool change and the Tool Table is toggled to detect a broken tool, but struggles to find a connection with the BTD system. 

To troubleshoot this alarm, verify that the camera is connected to the A62 board & that the A62 board is connected to the BTD A62 PFDM PCB. Power cycle the machine if the issue continues. 

The following only applies to Software Version 100.23.000.1200 or higher:

ALARM 9301 Broken Tool Detection Fault will be triggered by a software issue. There was an issue with Broken Tool Detection software that resulted in the control not being able to run Broken Tool Detection. 

To troubleshoot this alarm, press [RESET] to continue. Power cycle is necessary. If the issue still persists, then take a [SHIFT] - [F3] and send the results to your local Haas Factory Outlet for further review. 

The following only applies to Software Version 100.23.000.1200 or higher:

ALARM 9302 Broken Tool Detection Board Communication Lost [1] will be triggered by a hardware issue when the control is unable to communicate with the A62 board or when the A62 board is faulty. 

To troubleshoot this alarm, verify that the A62 board is connected to the PFDM PCB properly. Make sure that the A62 board cable functions as excepted. Power cycle the machine if the issue continues. 

The following only applies to Software Version 100.23.000.1200 & later:

ALARM 9303 Broken Tool Detection Camera Communication Lost [1] will be triggered by a hardware issue when the control is unable to communicate with the camera or when the camera is faulty.

To troubleshoot this alarm, verify that the camera is connected to the A62 board & that the A62 board is connected to the PFDM PCB. Make sure that the camera cable functions as excepted. Power cycle the machine if the issue continues. 

Secure the brace [1] to the inside of the corner of the enclosure near the tool changer.

Install the brace with six 1/4"-20 flange nuts [2].

Install the broken tool detection sub-assembly [1] by securing it with four 1/4"-20 X 1/2" flanged button head cap screw (FBHCS) [2] to the brace.

Apply a small amount of loctite on the threads of the screws.

Install the end brace [1] to the inside of the enclosure using two 1/4-20 flange nuts [3] and to the brace with two 1/4"-20 X 1/2" FBHCS [2].

Apply a small amount of loctite on the threads of the FBHCS.

 NOTE: UMC-500s do not use this bracket and skip this step.

Route the BTD cables around the machine's enclosure panels into the control cabinet. route the camera cable into the cable magnets and spiral wrapping closest to the window. 

Install the camera cable into the camera. Use the velcro to hold the cables together.

Install the A62 processor [2] on top of the mounting plate [3].

Install the BTD A62 PFDM PCB [1] on top of the A62 processor [2].

Connect the BTD camera cable 79-0159 into the USB adapter 74-2003 [1] that connects into the USB port on the A62 processor. 

Connect both LED lights to the +12V LED power cable 33-1228 [2] that goes into J3 on the BTD A62 PFDM. 

Make sure that the A62 processor power cable 33-1256 [3] is connected from J26 on the A62 processor to J4 on the BTD A62 PFDM. 

Connect the BTD A62 PFDM cable 33-1227 [4] from J2 on the BTD A62 PFDM to J3 on the MAINCON. This cable also has a pigtail that connects to P20 on the PSUP. 

Connect the communication cable 79-0158 [5] from the mico USB B port on the A62 processor to the USB port J8 on the MAINCON. 

 IMPORTANT: Make sure to insert the translator cable into the lower USB port J8 on the MAINCOM.

Add 64-1252 Ferrite filter to the USB extender 74-2003 where it connects to the A62 board.

Before the system can successfully detect a broken tool. the camera needs to be set up and calibrated. 

Follow the calibration procedure which will show you how to manually adjust the camera mount into the proper position and calibrate the Region of Interest.