Auto Run Experts....

[[Mi...]]

OK I have the 5 pcs set up on my machine as pictured. Been running great for 3 years but now all of a sudden when it gets to #5 on the right, it goes bonkers. It will drive out of the part at 45 deg, then back in to resume to prg. ONLY does this on #5. WTH. Should run the prg as usual, but it will not. Again this just started with me.
I plane out on the bottom of the part, then make a cyl in the top ID. From there it drives down and checks 4 more IDs. But again on #5 after it takes my top cyl, it goes wacko and drives out of the part.

Any Ideas........................................

[[To...]]

Typically, if you use a (cnc) alignment for your part alignment, it will move off the last part the X distance but then stops because it can't find the part. It usually doesn't find the next part. Can't explain why it worked for 3 years though. Is there a position point in the last feature that got added accidentally?

[[Ri...]]

The first thing to check is the fixture. Layout the station to station distances to make sure they are all the same and the AutoRun Pallet X value is exactly what the fixture distances are. If that doesn't yield any results then create a new pallet in AutoRun and see if that behaves differently. I have a few questions you've probably asked and answered yourself but just in case:
1.) Are you using a "grand" pallet alignment routine to define the location and orientation of your fixture?
2.) If you only run station five, does the program still "go crazy"?
3.) If you watch each BA run on all five stations, is the BA running exactly in the same location on each part? Watch very closely at a reduced speed.
4.) In regular old Calypso, does the program run normally at the station 5 location?
5.) What version Calypso and service pack are you running?
6.) Have you updated either recently?
AutoRun is normally pretty well behaved once you get everything buttoned down.

[[Mi...]]

Thanks guys, I will try some of the suggestions. Some I have tried to no avail but Ill re do them.

Tom... No points added. I have torn the prg apart and nothing is in there out of the ordinary.

Only acts up on THIS program. Ill dig deeper today as I have some time

[[Mi...]]

2.) If you only run station five, does the program still "go crazy"?
**Yes
3.) If you watch each BA run on all five stations, is the BA running exactly in the same location on each part? Watch very closely at a reduced speed.
**Yes

Fixed my issue. The mounting bar was off end to end by 0.4 for some crazee reason. Somebody has been messing round somewhere. SO I did a total re align on the bar that holds the 3 jaw chuck and it measured #5 ok this time. Will run it through the others but Im sure they are ok.

Thanks All

[[Ri...]]

Good to hear. As I said, AutoRun is generally pretty well behaved. You might want to take the opportunity of laying out and determining exactly what the distance is from stations 1 to 2 and 2 to 3, and so on. Also, the distance from the centerline of the mounting bar to the center of the 3 jaw chuck of each station might be interesting to know. Who knows, maybe there's room for improvement there. Plus, it beats working for a living.