New Build King Rich KRV-3000 Knee Mill with GSK AC Servos DA98B driver

[suntravel]

What If you try going through one small part at a time and make a short notice about what is of need for your tasks?

Often it is better to learn with writing things down.

Uwe

[dmbgo]

Thanks Uwe,
I do write things down, but memory is my major failing.

[dmbgo]

Here is the latest.
I decided to Use Tinkercad to design and 3D-print a mounting plate to go onto the Mill control box, this accepts the connections from the mill's axis etc.
Originally I was going to use a DB9 connector for the limit switches, but in the end, because I already had holes and cable glands for them, I used the existing control box holes. I now have an empty spot for a DB9 next to the "L" on the panel, but I think I will just install a blanking plate over that - you never know, I might come up with a use for that spot in the future.

The oiler, coolant and work light are now working under the control of the touchscreen which is yet to be installed on the Mill.
The inside of the control box looks like a bit of a mess now, but I have documented everything, and it is still a work in progress.

[dmbgo]

The touchscreen is now finished, there was a bit of work getting all the cables etc to be routed neatly, but I'm happy enough with the final configuration. I got to use my 3D printer to make some custom brackets and PSU holders to fit to the rear of the touchscreen.

I have fitted the touchscreen to the mill, using the existing arm. Everything installed so far works, but I have an intermittent problem with the Z axis.

All of the Axis home etc, but when I leave the mill turned on for say an hour, the Z axis stops moving. The Acorn controller thinks the Z axis is moving and increments the DRO accordingly, but the Z axis is actually stationary. The other axis (X and Y ATM) move normally.
I don't think this is a cabling issue, since it consistently works when the mill is turned on from cold, but there could be an issue with the AC Servo controller on the Z, perhaps it's overheating?

[dmbgo]

A bit more about the Z axis problem, when the Z axis stops moving, the DRO on the Acorn increments and decrements, so as far as the Acorn controller is concerned, everything is normal. The servo controller for the Z axis, however, shows nothing other than its normal display.
When the Z axis is working normally, the controller shows movement of the axis.
The controller display is user selectable - it can show the percentage of controller utilization, the number of pulses received by the controller, etc. I have it setup by default to show pulses received.

[cncsnw]

So Acorn says it is sending pulses; but the drive says it is not receiving any pulses?

An oscilloscope, or even a multimeter, should show who is telling the truth.

[dmbgo]

Thanks for that. I knew that I'd have to find the root cause of the issue - I was just putting it off.
You provided the impetus I need

[dmbgo]

The root cause of the issue with the Z axis motor not moving after a while, was a faulty AC servo controller on the Z axis. The support person at Tomatech (where I bought the motor and drive several years ago) told me that the FN14 function on the servo drive, displayed the pulses received by the drive.
It was definitely receiving pulses from the Acorn controller, so in the end I replaced the driver.
This immediately fixed the issue (after I made a new cable to suit the new servo drive).

[dmbgo]

Here is the current state of the mill:

[dmbgo]

Here is the current To Do status:

1/ Get knee working -Done.
2/ Make x,y,z,a cables -Done.
3/ Make new plate to mount knee motor -Done.
4/ Get new belt for servo motor on knee -Done.
4/(a) Adjust thickness of knee motor mounting spacers to make belt run in middle of toothed pulley. it is running up the pulley atm - Done.
5/ Cut key-way in upper knee pulley. - Done
6/ Get coolant under Acorn control. -Done
7/ Mount controller on mill. -Done
8/ Setup new MPG (when it arrives). -Done.
9/ Register Acorn mill software. -Done
10/ Make bracket and fit touch screen and NUC to mill arm -Done.
11/ Mount E-Stop Switch -Done.
12/ Make cable for Rotary Axis. -Done
13/ Setup Rotary Axis with Acorn -Done.
14/ Calibrate X axis steps per mm -Done.
15/ Calibrate Y axis steps per mm -Done.
16/ Calibrate Z axis steps per mm -Done.
17/ Calibrate A axis steps per degree -Done.
18/ Sort out home switches -Done.
19/ Make mill move to desired working position after homing is finished -Done.
20/ Make "knee down" movement positive + instead of negative -Done.
21/ Fit rotary encoder to spindle -Done
22/ Install shims to adjust spindle rotary encoder belt position (belt is running up on front rotary encoder pulley atm) -Done.
23/ Decide where to mount, and mount WMPG-6 bracket on mill -Done.
24/ Fit Handwheels to ballscrews -Done.
25/ Make metal tray below touchscreen for keyboard and mouse to sit on when not in use.
26/ Work out where to connect and connect home switch for rotary axis.

The outstanding jobs ATM are:
25/ Make metal tray below touchscreen for keyboard and mouse to sit on when not in use.
26/ Work out where to connect and connect home switch for rotary axis.