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DR. COUNT, Excellon TMS Cassette Designers

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Maximizes cassette efficiency, and "hands-off" time
The FASTechnologies Dr. Count program offers a simple, reliable tool for creating optimized Excellon TMS cassette maps. Drawing heavily from FASTechnologies' extensive drilling CAM technology, Dr. Count extracts the needed hit counts directly from your CNC drill programs, eliminating hit-count induced errors in the cassette maps. It produces cassette maps and loading diagrams which maximize cassette "hands-off" time, while minimizing costly cassette over-loading.

Reads drill data files
Mode 1 does long-run jobs with no over-loading
Dr. Count is actually two products in one. Dr. Count/Mode 1 supports the Mode 1 cassetting style for long runs of an individual part number. The Mode 1 version optimizes not only the cassette maps, but also the actual number of required tools as well: When an odd number of table loads would not fully exhaust the last set of cassettes, the Dr. Count load diagrams reflect this, preventing wasted tools.
Mode 2 does short-run jobs with no over-use
Dr. Count/Mode 2 creates optimized cassettes for use with a selected group of different part numbers, letting your operators load their drill cassettes only once for the entire group of jobs. This maximizes short-run drilling productivity while reducing wasted tools to a minimum. Even jobs with varying maximum hit counts are handled intelligently, to avoid accidentally over-using dull tools.

General
There are two versions of Dr. Count included in the software package; Dr. Count/Mode 1 and Dr. Count/Mode 2. The Mode 1 version creates Excellon TMS cassette maps for the tool-number addressing mode, useful for drilling large quantities of a single part number. The Mode 2 version creates Excellon TMS cassette maps for the tool-diameter addressing mode, useful for drilling smaller quantities of several different part numbers from one cassette map.
Dr. Count extracts the needed part program hit counts and maximum hit values directly from the CNC drill programs and diameter pages actually used to drill the production jobs. The program allocates cassette space for the needed tool sizes in the pattern which will result in the maximum utilization of the available cassette space.

Cassette styles
Dr. Count supports drilling machines using Excellon 120-tool TMS drill cassettes. The cassette map files generated by Dr. Count conform to the format specified in the Excellon CNC-7 User Reference Manual, and they are generally compatible with all Excellon software revisions. Support for other cassette types may be available in the future, or upon request: Contact FASTechnologies for details.

Data formats
Drill hit counts are extracted from actual production drill programs. These programs must be coded in Excellon Format-2, although there is some format flexibility available via a user-defined editing script in the FASTechnologies "Swapper" language. Where diameter pages are used, these must conform to Excellon Format-2. Note that the hit counts accorded to high-level drilling commands such as the "G84" nibbled circle, "G85" nibbled slot, and "M97" "M98" drilled text commands are consistent with the actual hit counts produced on the current revision of the Excellon CNC-6 operating software.

Conflict resolution
A special case occurs in the Mode 2 product when jobs having different maximum hit counts for tools of one diameter are encountered. In this case, Dr. Count forces the job(s) with the higher maximum hit counts to be listed prior to those with the lower maximum hit counts. The purpose of this is to prevent a tool dulled but not exhausted in a small number of hits (in a tough material) from being overused in a subsequent job. Dr. Count will refuse to accept different jobs whose conflicting maximum hit counts cannot be consistently resolved in this fashion.

Printed output
Dr. Count offers printed output of the cassette maps. These printed outputs delineate the needed tool diameters and quantities, as well as depicting a matrix showing the appropriate locations for the tools in the cassette. The matrix may be printed in either a "points up" or a "points down" orientation, based on a user menu selection. In the case of the multi-job Mode 2 version, a listing of the appropriate sequence in which to drill the jobs is also provided.

System requirements
A PC compatible computer running Microsoft Windows '95 (or 3.1), with one megabyte of available hard disk space. A network connection to the drill file storage directory (or directories) is highly recommended.

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Total

 

Total Utilization for Machines 30-48

Total Utilization Graph
Data source:
 
Start date End date Shift Information
Day of Week
Sat, Nov 24, 2001 Mon, Dec 03, 2001 SUN-SAT
Day
Running
Stopped
Error
Load Change
Off
Sunday
66.0
2.6
13.8
13.8
3.6
Monday
74.2
2.0
9.6
11.5
2.5
Tuesday
75.4
1.0
8.8
9.3
5.2
Wednesday
75.7
0.5
7.5
10.8
5.2
Thursday
74.3
2.2
9.6
11.6
2.0
Friday
70.2
2.4
11.2
15.9
0.0
Saturday
63.0
3.0
14.3
15.4
4.1


Machine Utilization

Machine Utilization for Machines 30-48

Data source:
 
Start date End date Shift Information
Day of Week
Sat, Nov 24, 2001 Mon, Dec 03, 2001 SUN-SAT
Machine#
Running
Stopped
Error
Load Change
Off
30
74.1
2.6
10.4
12.6
0.0
31
73.5
1.6
10.0
14.6
0.0
32
77.0
1.2
12.8
8.7
0.0
33
71.3
2.6
10.1
15.7
0.0
34
67.8
1.7
13.5
16.6
0.0
35
76.9
0.9
8.0
13.9
0.0
36
75.8
2.1
9.8
12.1
0.0
37
70.7
4.4
13.6
11.1
0.0
38
73.2
2.0
9.2
15.3
0.0
39
33.7
1.5
5.8
6.0
52.7
40
74.3
1.4
12.3
11.7
0.0
41
77.8
2.2
10.4
9.3
0.0
42
61.1
1.8
16.8
11.6
8.5
43
73.6
1.5
12.8
11.8
0.0
44
77.2
2.5
7.8
12.2
0.0
45
75.7
2.6
9.1
12.3
0.0
46
67.2
4.4
10.9
17.1
0.0
47
65.1
2.7
14.3
17.6
0.0
48
67.6
1.2
16.0
14.8
0.1

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Daily Utilization for Machines 30-48

Data source:
 
Start date End date Shift Information
Day of Week
Sat, Nov 24, 2001 Mon, Dec 03, 2001 SUN-SAT
Date
Running
Stopped
Error
Load Change
Off
11/24/01
57.2
2.7
17.1
14.5
8.2
11/25/01
60.6
2.9
15.3
13.8
7.2
11/26/01
72.9
3.2
9.6
9.1
5.0
11/27/01
75.4
1.0
8.8
9.3
5.2
11/28/01
75.7
0.5
7.5
10.8
5.2
11/29/01
74.3
2.2
9.6
11.6
2.0
11/30/01
70.2
2.4
11.2
15.9
0.0
12/01/01
68.7
3.3
11.5
16.3
0.0
12/02/01
71.3
2.4
12.3
13.8
0.0
12/03/01
75.5
0.8
9.6
13.9
0.0

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By hour

Hourly Utilization for Machines 30-48

Hourly Utilization Graph
Data source:
 
Start date End date Shift Information
Day of Week
Sat, Nov 24, 2001 Mon, Dec 03, 2001 SUN-SAT
Hour of Day
Running
Stopped
Error
Load Change
Off
1
62.5
4.1
12.4
15.7
5.1
2
68.7
2.0
11.3
14.5
3.2
3
75.2
1.3
9.1
10.5
3.6
4
76.1
1.1
8.6
10.4
3.6
5
72.7
0.4
11.9
11.1
3.6
6
74.7
0.7
9.7
11.0
3.7
7
74.3
0.9
8.7
12.3
3.6
8
78.1
1.8
8.8
7.3
3.7
9
74.6
1.1
10.3
10.3
3.5
10
78.4
1.3
8.2
9.1
2.7
11
73.9
1.0
12.4
9.8
2.6
12
75.0
1.3
9.1
11.8
2.6
13
72.5
3.2
11.8
9.4
2.8
14
66.3
1.9
15.3
13.1
3.1
15
74.7
2.8
12.6
6.9
2.8
16
71.2
2.8
12.6
10.4
2.8
17
54.1
9.1
14.0
19.5
3.1
18
58.7
1.0
15.5
21.4
3.1
19
69.5
0.9
11.0
15.4
3.1
20
64.8
1.6
12.0
18.2
3.1
21
75.3
1.4
9.2
10.7
3.1
22
64.6
1.6
12.8
17.6
3.1
23
71.7
2.6
9.1
13.2
3.1
24
56.8
6.0
13.6
20.1
3.1

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Total Errors

 

Total Errors for Machines 30-48

Data source:
 
Start date End date Shift Information
Day of Week
Sat, Nov 24, 2001 Mon, Dec 03, 2001 SUN-SAT
Errors sorted by most time:
    Time   Err# Message                        
 161:02:00 263  TOOL HEIGHT TOO HIGH           
 151:09:51 311  SAFETY SENSOR-1 ACTIVATED      
  55:53:11 262  TOOL DEPOSIT ERROR             
  51:32:54 250  LIMIT OF DRILL LIFE            
  32:27:49 307  DRILL BIT(S) BROKEN            
  25:11:56 260  TOOL HEIGHT TOO LOW            
  15:13:53 290  TOOL CHUCK DOWN POS. ERROR     
   6:24:17 329  WAITING CYCLE START            
   6:00:19 261  USED TOOL TOO LOW              
   4:42:34 264  USED TOOL TOO HIGH             
   1:58:11 061  PROGRAM STOP                   
   1:45:54 067  WAITING CYCLE START            
Errors sorted by most occurrences:
  #  Err# Message                        
3001  311  SAFETY SENSOR-1 ACTIVATED      
2067  263  TOOL HEIGHT TOO HIGH           
1720  262  TOOL DEPOSIT ERROR             
500  250  LIMIT OF DRILL LIFE            
473  290  TOOL CHUCK DOWN POS. ERROR     
403  260  TOOL HEIGHT TOO LOW            
281  307  DRILL BIT(S) BROKEN            
257  207  TOP OF "MACHINE REVERSE"       
223  061  PROGRAM STOP                   
190  208  END OF "MACHINE REVERSE"       
186  329  WAITING CYCLE START            
104  264  USED TOOL TOO HIGH             

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Last modified: 2018-12-09