Can't get Abs Pos to count positive with CW rotation

[martyscncgarage]

No really, post a fresh report. It helps.

[kevincnc]

Okay I'll be sure to attach the reports, I'm sure there are many more to come..

I hooked up an old Huanyang drive and it's perfectly stable, so I re-tried tapping. It still faulted at 400 RPM so I increased parameter 240 from .1 to .2, and then it worked at 400 but not 500. I tried increasing #240 .3, and it still faulted at 500 RPM. That's where this report was taken.

My Z Accel/Decel is .3, do I just need to keep increasing #240? .3 Accel on the Z seems reasonable to me if you watch the video, maybe it's too slow?
Thanks,
Kevin

[martyscncgarage]

What is the make and model of your spindle encoder?
Please post pictures or it and how it is mounted

[kevincnc]

It's an Omron E6B2-CWZIX 2000 PULSE/REV, belted 1:1.

[martyscncgarage]

Is this a genuine Omron encoder or the Chinese knock off from ebay?

[kevincnc]

It was cheap, surely a knockoff. Is there a way to test it to see if that's the problem?

Is there a way to tell if it's a knockoff of not? Maybe the ones with a yellow band are real? All the ones on ebay seem to be from China.

[martyscncgarage]

It was cheap, surely a knockoff. Is there a way to test it to see if that's the problem?

Is there a way to tell if it's a knockoff of not? Maybe the ones with a yellow band are real? All the ones on ebay seem to be from China.

Some guys say they are having success with them. I am skeptical.
I would purchase a medium duty encoder from automationdirect.com
https://www.automationdirect.com/adc/sh ... ential)%22

Or find a true name brand line driver differential encoder from somewhere. 1000 line is fine for the spindle.
I don't trust the chinese Omron knock off personally.

Marty

[kevincnc]

Okay before I work on a different encoder (not excited about that,) is there something you're seeing in the report that makes you think it's the encoder?

If it can single point thread at higher RPM, would that prove that encoder is okay? I don't know if I've tried it.

It looks good on the RPM display..would a flaky index pulse be the problem? Maybe I could put my scope on the index line and see a problem.

Thanks,
Kevin

[martyscncgarage]

The index pulse is very important. You are getting slave position errors:
Either noise on the cable or the encoder in my opinion. Since the machine actually runs otherwise (constant surface speed is working ok?
Definition of 438 Spindle Slave Position Error: "The slaved axis moved too far in the wrong direction during a spindle-slaved move (such as in rigid tapping, threading, and feedper-revolution moves). Job is cancelled."

You also have a couple of Drive Faults. What axis are they on and what is causing them?


(1) 02-22-2020 18:25:53 CNC12 Lathe v4.20 (revision 4.20.1) Jan 17 2020, 09:50:27
(4) 02-22-2020 18:25:54 9033 Reset Initiated, Press Reset to Clear
(4) 02-22-2020 18:26:06 4032 Reset Cleared
(1) 02-22-2020 18:26:12 407 Z+ limit (#50002) tripped
(1) 02-22-2020 18:26:14 407 X- limit (#50001) tripped
(4) 02-22-2020 19:01:31 9033 Reset Initiated, Press Reset to Clear
(1) 02-22-2020 19:01:41 204 Exiting CNC...Normal Exit (66)
(1) 02-23-2020 9:41:30 199 CNC Started
(1) 02-23-2020 9:41:36 CNC12 Lathe v4.20 (revision 4.20.1) Jan 17 2020, 09:50:27
(4) 02-23-2020 9:41:37 9033 Reset Initiated, Press Reset to Clear
(4) 02-23-2020 9:50:17 4032 Reset Cleared
(1) 02-23-2020 10:10:05 407 Z+ limit (#50002) tripped
(1) 02-23-2020 10:10:07 407 X- limit (#50001) tripped
(4) 02-23-2020 11:30:08 9031 DRIVE FAULT!
(4) 02-23-2020 11:31:42 9033 Reset Initiated, Press Reset to Clear
(4) 02-23-2020 11:31:44 4032 Reset Cleared
(1) 02-23-2020 11:33:36 406 Emergency stop detected
(1) 02-23-2020 11:36:28 406 Emergency stop detected
(4) 02-23-2020 12:03:04 9031 DRIVE FAULT!
(1) 02-23-2020 12:03:06 406 Emergency stop detected
(1) 02-23-2020 12:03:11 406 Emergency stop detected
(4) 02-23-2020 12:04:07 9031 DRIVE FAULT!
(1) 02-23-2020 12:04:13 406 Emergency stop detected
(1) 02-23-2020 12:06:46 406 Emergency stop detected
(1) 02-23-2020 12:08:25 406 Emergency stop detected
(4) 02-23-2020 12:09:41 9031 DRIVE FAULT!
(1) 02-23-2020 12:09:51 406 Emergency stop detected
(1) 02-23-2020 12:10:55 406 Emergency stop detected
(1) 02-23-2020 12:11:53 406 Emergency stop detected
(1) 02-23-2020 12:14:24 407 Z+ limit (#50002) tripped
(1) 02-23-2020 12:14:26 407 X- limit (#50001) tripped
(4) 02-23-2020 12:14:31 4053 Select Auto Spindle, press CYCLE START
(4) 02-23-2020 12:15:28 9031 DRIVE FAULT!
(1) 02-23-2020 12:33:16 Creating report...
(1) 02-23-2020 12:33:21 Saved report to D:\\report_780473842B28-0131191600_2020-02-23_12-33-16.zip
(4) 02-23-2020 12:40:29 9033 Reset Initiated, Press Reset to Clear
(1) 02-23-2020 12:40:32 406 Emergency stop detected
(1) 02-23-2020 12:47:50 204 Exiting CNC...Normal Exit (66)
(1) 02-23-2020 12:48:03 199 CNC Started
(4) 02-23-2020 12:48:07 9039 Software Exited, Cycle E-Stop/Reset to Continue
(1) 02-23-2020 12:48:09 CNC12 Lathe v4.20 (revision 4.20.1) Jan 17 2020, 09:50:27
(4) 02-23-2020 12:48:09 9039 Software Exited, Cycle E-Stop/Reset to Continue
(4) 02-23-2020 12:49:33 9033 Reset Initiated, Press Reset to Clear
(4) 02-23-2020 12:49:34 4032 Reset Cleared
(1) 02-23-2020 12:50:00 407 Z+ limit (#50002) tripped
(1) 02-23-2020 12:50:20 407 X- limit (#50001) tripped
(4) 02-23-2020 12:50:53 999 Parm #240 modified: 0.10000 -> 0.20000
(1) 02-23-2020 12:52:01 438 Spindle slave position error
(4) 02-23-2020 12:52:18 9033 Reset Initiated, Press Reset to Clear
(4) 02-23-2020 12:52:19 4032 Reset Cleared
(4) 02-23-2020 12:52:21 9031 DRIVE FAULT!
(4) 02-23-2020 12:52:23 9033 Reset Initiated, Press Reset to Clear
(4) 02-23-2020 12:52:25 4032 Reset Cleared
(1) 02-23-2020 12:52:46 407 Z+ limit (#50002) tripped
(1) 02-23-2020 12:53:00 407 X- limit (#50001) tripped
(4) 02-23-2020 12:54:25 999 Parm #240 modified: 0.20000 -> 0.30000
(1) 02-23-2020 12:54:38 438 Spindle slave position error

[tblough]

If you assume your encoder is good, it would then appear that your drives are under-powered. When you increase the value of parameter 240, you are slowing down the acceleration for the Z axis, which gives the Z axis more time to synchronize movement with the spindle, and that lets you tap at a faster RPM. At faster spindle speeds, your slave axis (Z) needs to be able to keep up which it is unable to do at faster acceleration rates.

So, either your encoder is no good causing your Z axis to jump around trying to keep up the synchronized movement, or your axis just doesn't have the power to accelerate and decelerate fast enough to keep up the synchronization.