User Defined Program for Homing and Auto tool changer

marq_torque wrote:

1) Tool pocket & tool number identification in Linuxcnc i can add different sensor for each tool pocket, please suggest if any sample configuration or anyone have already did it My searching skills are not at par i guess.

Skunkworks has a machine where the tools have a mechanical barcode. But it doesn't work entirely as you would like.
In his case the "Tn" command simply starts the tool chain moving, and then the toolchanger logic stops the chain when the detected tool matches the requested tool. This isn't really applicable to a rack changer.
RFID seems like it ought to be the way to go. I guess you could set up a routine to pick up each tool in turn and see what it was, rather than have a reader for each tool parking position.
What type of holder does your machine use? Is there anywhere obvious to put an RFID chip?

2) Tool release confirmation when tool is dropped in pocket, so spindle tool pocket and collet doesn't get damaged if tool is failed to drop in pocket and will e stop/halt with warning message before it moves to pick new tool.

I think this can be done fairly easily with tool slots that spring up when unloaded. Alternatively perhaps a force sensor in each slot and a stage in the sequence that makes a small upwards move and errors if the tool weight is seen to decrease.
Force sensing resistors are quite cheap: learn.adafruit.com/force-sensitive-resistor-fsr though strain gauges are not terribly expensive: uk.rs-online.com/web/p/strain-gauges/0632180/ and require less design modification to the parking slots, they can just be bonded on to the surface of metal. You don't need precision amplifiers in this application, a single op-amp would do.
As strain gauges are typically wired in 4-element bridge you might want to consider some form of multiplexer to keep the element count down. Or it might be possible to wire 4 slots in a bridge and simply look for changes in the overall reading during the tool change.

3) Tool pickup confirmation from tool pocket sensor with corresponding tool numbers in Linuxcnc, that commanded tool picked successfully and didn't broke during change, it will help if someone put broken tool in pocket by mistake and if collet didn't clamp tool because of some mechanical malfunctioning

Tool breakage detection feels harder. I could imagine that it would be possible to do something clever with machine vision.

marq_torque wrote:

SO i m thinking of clearing these issues with addition of proximity/ laser beam sensors and conditional sub programs. I'm black where to start from ? I have already Remaped M6 in existing setup.

The checks would be additional steps in the remapped tool change routine.

Is that G-code or Python?

OK, so you just need to add some other steps to that sequence.

The feedback would be via HAL pins and the M65 (etc) commands.