FANUC Rigid Tapping: Function, Parameter and Troubleshooting

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Table of Contents

Introduction

FANUC rigid tapping is a CNC machining technique that ensures perfect synchronization between spindle speed and feedrate during tapping, eliminating tension-compression holders for enhanced accuracy and efficiency.

Advantages of Rigid Tapping in CNC Machining

  • High Precision : Perfect spindle-feed synchronization for accurate threads.
  • Increased Efficiency : Faster cycles reduce machining time.
  • Extended Tool Life : Lower axial forces minimize tool breakage.
  • Improved Thread Quality : Reduces deformation for better reliability.

FANUC Control System and Rigid Tapping

FANUC CNC systems offer efficient rigid tapping with real-time spindle control and adaptive synchronization for efficient tool retraction and thread quality improvement, further increasing machining efficiency and thread quality. Features such as rigid tapping retraction ensure smooth tool withdrawal to enhance thread quality and efficiency of thread manufacturing processes.

FANUC Rigid Tapping Retraction

This feature (known in FANUC language as “Rigid Tapping Return”) allows the tapping axis to retract to its R point position after interruption or reset operation has completed, maintaining precision through continued synchronous positions between spindle and feed axes even after stopping operation.

This function, activated through PMC signals or commands, is vital for managing disruptions such as emergency stops or power outages without damaging threads.

System Compatibility & Diagnostics

The FANUC Oi-TD and 31i series offer the rigid tapping retraction function as an optional feature, so to check its availability use the following diagnostic parameters.

  • Oi-TD System: Diagnostic Number 1174#2
  • 31i System: Diagnostic Number 1163#6

By verifying these diagnostic numbers, it’s easy to see whether your FANUC CNC system supports rigid tapping retraction for smoother recovery after an interruption.

Rigid Tapping Implementation

The FANUC rigid tapping retraction function can be activated either via PMC signals or G-code commands depending on your parameter settings, giving you greater control and flexibility in handling tapping interruptions while providing a smooth recovery process.

FANUC Tapping Interruption Handling

When pressing Reset or Emergency Stop during a rigid tapping cycle, an alarm called 2075 TAPPING THE INTERRUPT will sound, signalling that tapping process has been interrupted. In order to resume operation quickly and seamlessly, FANUC provides a tapping retraction feature which returns tool back to R point before restarting operation.

Rigid Tapping Retraction Parameters

The behavior of the tapping retraction depends on Parameter No.5202#1:

  • No.5202#1 = 1 → Retraction via G30 command
  • No.5202#1 = 0 → Retraction via PMC signal (G62.6)

Retraction Using G-Code (No.5202#1 = 1)

If the system loses power during tapping, follow these steps to recover:

1. Restart the machine after power restoration.

2. In MDI mode, enter the command: G30P99M29Sxxx

  • xxx represents the spindle speed before the interruption.

3. The system will automatically execute the tapping retraction process.

Retraction Using PMC Signal (No.5202#1 = 0)

Fanuc rigid tapping

When using a PMC signal to trigger tapping retraction: 

1. Set K5.5 = 1.

2. In MDI mode, press F2 (safety door) or the tapping retraction button.

3. The system will execute the retraction movement and display an alarm:

  • 2076.TAPPING THE FALLBACKT OPEN K5.5=1 F2

4. Once the tool reaches the R point, K5.5 will automatically reset to 0, and the alarm will disappear.

Mitsubishi Tapping Interruption Handling

In Mitsubishi CNC systems, when a rigid tapping cycle is interrupted, the system will typically generate the following alarm:

  • Alarm 0057: TAP Reset Waiting
  • Additionally, the three axes will lock, preventing movement.
Mitsubishi rigid tapping

Treatment

1. Checking PLC Switch for Tapping Retraction

To resolve this issue, follow these steps:

  1. Check the PLC switch settings.
  2. If there is a tapping retraction option (e.g., 31.PLC switch is enabled):
    • Set the mode switch to Zero Return Mode.
    • The tapping axis will automatically retract to the R point.

2. Forcing Retraction via IF Diagnostic

If the PLC switch does not include a tapping retraction option, use the IF diagnostic interface to manually force retraction:

  1. Access the IF diagnostic screen.
  2. Set YC5C = 1 (force ON).
  3. The system will then automatically retract the tapping axis to the R point, allowing normal operation to resume.

This method ensures that interrupted tapping cycles in Mitsubishi CNC systems can be safely recovered, preventing tool damage and maintaining machining accuracy.

FANUC Rigid Tapping Alarm Analysis

1. PS0200: Illegal S Code Command

  • Cause: The spindle speed for rigid tapping exceeds the maximum set speed.
  • Troubleshooting:
    • Verify that the spindle speed set in the program is correct.
    • Adjust the maximum spindle speed parameters: P5241 to P5243.

2. PS0201: No Feedrate Command in Rigid Tapping

  • Cause: The rigid tapping program lacks a feedrate command.
  • Troubleshooting:
    • Confirm that the feedrate for the tapping axis is specified correctly.
    • Check the modal settings G94 (feed per minute) or G95 (feed per revolution).

3. PS0202: Position LSI Overflow

  • Cause: System error, where the spindle allocation value is too large during rigid tapping.
  • Troubleshooting:
    • Simulate the spindle and check the spindle encoder wiring.
    • Adjust the wiring for A, A, B, B signals as necessary.

4. PS0203: Rigid Tapping Command Error

  • Cause: Incorrect command format in the program.
  • Troubleshooting:
    • Ensure the command is written correctly as M29Sxxxx for rigid tapping operations.

5. PS0204: Illegal Axis Command

  • Cause: Illegal axis movement command during rigid tapping.
  • Troubleshooting:
    • Modify the program to avoid axis movements between M29 Sxxx and G84/G74 commands.

6. PS0205: Rigid Tapping DI Signal Off

  • Cause: Error in handling the rigid tapping DI signal in the ladder diagram.
  • Troubleshooting:
    • Modify the ladder diagram to ensure that G61.0 signal is handled correctly during rigid tapping.
    • For multi-spindle setups, verify that the multi-spindle signals are correct.

7. PS0206: Cannot Change Plane

  • Cause: The plane is changed during rigid tapping.
  • Troubleshooting:
    • Modify the program to prevent plane changes (e.g., G17, G18, G19) during the tapping operation.

8. SV0410: Servo Alarm - Axis Overtravel

  • Cause: The error when an axis (tapping axis 1-4) stops and the error exceeds the set limit.
  • Troubleshooting:
    • Adjust the overtravel data for the first spindle using parameters P5312 (for the first spindle) and P5352 (for the second spindle).

9. SV0411: Servo Alarm - Axis Overtravel

  • Cause: Same issue as SV0410, but affects other tapping axes.
  • Troubleshooting:
    • Adjust the overtravel data using parameters P5313 and P5314.

10. SV0740: Rigid Tapping Error - Overtravel

  • Cause: The spindle moves with excessive position error during rigid tapping.
  • Troubleshooting:
    • Increase the values for P5310, P5350, P5312, and P5352.
    • Adjust tapping gain, feedforward, and time constant to reduce errors.

11. SV0741: Rigid Tapping Error - Overtravel (Main Spindle)

  • Cause: The main spindle moves with position error exceeding the set value during rigid tapping.
  • Troubleshooting:
    • Increase the value of P5214 for the main spindle.

Related Resources & Downloads

Fanuc rigid tapping parameter

Looking for more details on FANUC rigid tapping parameters? We have compiled a list of key parameters related to batch drilling and tapping to help optimize your CNC operations.

Download FANUC Rigid Tapping Parameters

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FANUC Rigid Tapping Parameters PDF
What is rigid tapping?

Rigid tapping is a CNC machining process where the spindle and feed axis move in precise synchronization to perform tapping operations without the need for a floating tap holder. This ensures accurate thread depth, improved tool life, and higher efficiency compared to conventional tapping methods.

No.5202#1 Set to 1 to select G30 tapping back
No.5202#1 Set to 0 execution address signal G62.6 tapping back

In Mitsubishi systems, an interrupted tapping cycle may trigger alarm 0057: TAP Reset Waiting, and the axes may lock. You can resolve this by:

  • Checking the PLC switch settings for a tapping fallback mode (e.g., 31.PLC switch).
  • If unavailable, force YC5C = 1 in the IF diagnostic interface to return the spindle to the R point automatically.

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