Topics

1

General Mach Discussion / EXTERNAL ESTOP REQUESTED

« on: November 21, 2016, 01:34:08 PM »

I have been using Mach3 on a Shopmaster MillTurn for a few years now.  I have not been having any issues with it....  Today, it throws a message "EXTERNAL ESTOP REQUESTED".

It happens when the machine is sitting with no GCODE running and nothing moving.  I checked the ESTOP switches but when they are depressed, the message is "ESTOP SWITCH PRESSED".  It will happen within 30 seconds of resetting it.  It happens in both mill mode and lathe mode.  I have rebooted everything.  Yesterday when I shut the machine down, the PC "hung" while turning off and I finally had to turn off the power switch.  I looked through the configs, but its been a while since I looked at them and I haven't changed anything.

What can cause this message (since pressing a ESTOP has a different message)?  Any ideas as to what it might be?

Thanks,

Terry

2

General Mach Discussion / M3 speed control issue on startup

« on: January 26, 2016, 11:07:56 PM »

When I run a gcode file, when the first M3 S*********x is issued, the spindle goes to full speed.  On following M3 commands, I goes to approximately the correct speed.

Any ideas as to what is happening?

Thanks

3

General Mach Discussion / Issue with Y axis backlash compensation

« on: January 26, 2016, 10:26:54 PM »

I was recently making a part and had a problem that when traversing between two specific G81 cycle hole locations, the X axis would completely loose sync with the step pulses.  It would only occur on these two specific locations.  I simplified my code to G0 moves with the same coordinates during trouble shooting.  The following code will demonstrate the issue:

G00 G49 G40 G17 G80 G50 G90
G20
G0 x1.1983 y1.4473
G0 x1.9043 y1.4479
M5 M9
M30

Although I have my max speeds fairly conservative, I cut them in half and still had the problem.  I created a test loop of G81 cycles all over the table and ran a loop 50 times with no issue.  Through much troubleshooting, I have determined that the problem occurs when there is a very small Y movement required and backlash compensation is turned on.  If I increase the Y movement to .002, it does not happen.  I swapped cables, changed which pin drives which axis, and many other scenarios to isolate the issue.  I thought maybe it was mechanical at that location, so moved to a different location and zeroed the axis.  It still occurs.  If I turn off backlash, it does not occur.

So after much troubleshooting, the basic problem is that during a traverse, if the amount of Y movement is greater than 0 and less than .002 or so, and backlash compensation is turned on, most of the time, the X axis will loose sync with the step pulses.  If I do the same scenario to the X axis, it does not cause the Y to loose sync.

Can anybody shed any light on what might be going on?
If you run the above code, do you get the same result?

4

Modbus / MODBUS vs PWM control of spindle performance

« on: November 18, 2015, 01:43:11 PM »

I am currently using Mach3 in PWM mode to a newforever E100 VFD for spindle control.  I was not able to get closed loop control tuned for sufficient response and accuracy so I am running it open loop.  In this mode, it is responsive and repeatable.  However, I can't set the speed real close as the PWM set point resolution is a function of the clock frequency.  In addition, the accuracy is not spot on and there is a bit of noise or jitter in the PWM output as you might expect.  An example after doing the spindle calibration CFG and then I enter a setpoint for 2000 RPM I get ~2080 RPM with +/- 5 noise.  I recognize the noise is insignificant.  But I would like the set point to be closer.

Other than running the auto spindle calibration, I don't see where I can set the scaling for the PWM output.  Can anybody help with this?

I am considering setting it up for MODBUS control.  From some of the posts I came across, that looks like a bit of a challenge.  If you make it through that challenge and get the MODBUS functioning, is it more accurate and stable than PWM?

5

General Mach Discussion / Adding additional I/O

« on: December 30, 2014, 11:27:30 PM »

I recently purchased a used Patriot VFD with Mach 3 control.  The original owner had only used the machine in manual, so I have been working through getting everything configured.  I have been using a CNC router for many years, but am new to Mach 3.  It has been a bit slow going with Mach 3 having such a full range of options and flexibility. 

I have run out of I/O.  I want to add some limit switches and coolant control and my Geckodrive G540 I/O is full.  I am not really up on the best option for expanding the I/O.  From my web searches, I turn up breakout boards, but they all have axis drives,...  Is there a good choice when all I want are digital inputs and digital outputs?  It would be cleanest if the outputs could drive solenoids, but I can add solid state relays if necessary.  My control PC has a second parallel port.

Thanks for any help.

6

General Mach Discussion / Path to convert to Mach

« on: February 22, 2013, 11:49:48 PM »

I have a Precix 5100 router table.  It is 12 years old but in great shape since it's in a mostly hobby/low volume shop and not a lot of hours.  The operating system is Qunix and the human interface is remarkably "featureless".  I get very jealous when I read about all the functionality in Mach 3.  

My router has servos with encoder feedback, a 3hp Perske spindle with VFD, servo amps, and beefy power supply.  The PC has a motion control board in one of the slots.  All is packaged in a PC enclosure.  The PC is a 12 year old technology mini-AT form factor with a 10G drive.  I guess this used to be high performance ;?). I have new spares of all boards.  

How far would I have to gut it to convert it to Mach?  I assume it couldn't be as easy as installing XP and using the existing motion control board???  If not, would I just by a good modern PC and one of the motion control modules on this website and then reuse from the servo amps on?

Any recommendations on best way to move forward would be appreciated.