Topics

1

HiCON Motion Controller / Error: Disarmed Drives Unexpectedly

« on: November 06, 2017, 11:14:32 AM »

Using an Integra  with an encoder board. Everything is connected and we get communication with Mach 4 - Tested e-stop button, limits, probe and some outputs while the system is in disable state - all working.

The issue is when we arm the system we get:

Error: Disarmed Drivers Unexpectedly. Please do not run any other software on this computer while Mach is controlling the machine.

Nothing else is running (except the standard windows services)


Any ideas?

Thanks in advance!

2

General Mach Discussion / Z plunging deeper after each retraction. Not mechanical

« on: July 21, 2016, 11:57:38 PM »

Hello all and thank to those who helped me with tool offsets. Machine is running great with my ATC with the exception of a new issue I discovered during a large run with many successive Z moves.

The machine specs as follows:

60x120 wood/aluminum/plastic flatbed router that, at least according to the equipment we have, is accurate to +/- 0.0006 per 2000mm,  uses C1/C2 grade linear motion components, dual 110mm frame 1.8Kw servos for X, single 110mm 1.3Kw servo for the Y, single 1Kw Z , harmonic gear reduction and very precise proximity sensors. Using an ESS, C62 R3, AC filters, dual shielded cable and RF chokes on every wire in and out of the machine. The control box is hidden under the skirt and is 1/8" steel. It contains the drivers, spindle speed control, ESS, BOB and mains contactor. The entire machine grounds to a single point and is routed to the outside of the building (it is near a back wall) to an 8' ground rod.

Now on to the issue. With each successive plunge the Z moves a bit further down. Please note - THIS IS NOT mechanical. I run two timing pulleys, one on the motor and one on the X ball screw. I have marked them both with the shaft and have checked the Z nut. All is tight and use keyways. I marked the motor shaft and put a spot of nail polish on the expected point and relation to the shaft of the motor. Did the same with the Z screw pulley and timing gear. This is the only place I am not using harmonic gear reduction as a belt to a screw done right has little to no measurable backlash.

All of those tests indicate the Z nut, pulleys, and motor are staying in sync - it is like the motor is receiving too many pulses. I have the driver set to if there is any deviance from the number of pulses relating to the amount moved the machine will throw an alarm and take you to a custom screen explaining the axis is out of alignment and to re-home the machine. This does not happen even though I know the checking system works as I "made it" miss 1 pulse intentionally and it threw an alarm.

I am pretty sure it is not noise being that I have way overdone the noise protection and the other axes move perfectly and the drivers are all in a bank.

I have tried setting the velocity and acceleration to ridiculously slow and no difference - the Z continues to get lower with each retract and plunge. It is roughly .001 per plunge but that adds up quickly on a run with 700 plunges.

Oddly I reversed the motor and ran the job in the air and the problem didn't appear on retract moves which led me back to mechanical. After a complete Z teardown I am confident this is not mechanical.

The Z is on a 20MM C2 screw with a 1" thick base plate attached to a Y that is also 1" thick aluminum . I am running 20MM sliders and again marked the screw, shaft motor and pulleys. They are all in sync just dropping too far as the program proceeds.holding a 20HP Colombo RS series ATC spindle. The VFD is not mounted in the control box and has a separate enclosure with cooling under the skirt of the machine. Even the braking resistor is enclosed so I don't thing noise is the issue.

I made a test program with simple Z retracts and plunges and the problem exists there so it is not the program I am running. My Z code would plunge into a dial indicator - pause for 3 seconds, retract and repeat. I recorded each measurement on the pauses which is how I cam to discover the issue.

I also tried another pin set for step/direction thinking the ESS or BOB may have something wrong - no joy.

I even increased the hero torque to just to the point of "humming" and backed it off just below the "hum" point (my drivers are programed via RS232 and I have leads out of the control box that make tuning quick and painless).

It simply acts like it is getting a few more pulses than it should. I have a spare ESS and c62 Rev 4 - this is the only thing I have not tried since a rewire is going to be a PITA.

Please. If anyone has experienced this let me know. I am at a complete loss here as I don't know what else to check.

Thanks in advance!

Kind regards,


Gio

3

General Mach Discussion / Where are tool length offsets referenced from?

« on: July 03, 2016, 03:49:53 AM »

I get the basic idea of tool length offsets but I am wondering where they are referenced from. Obviously the actual tool length has little to do with where Mach3 would define the tools zero position in relation to my workpiece.

I have done a lot of research but I have yet to find clear info about the actual reference point...

Am I assuming correctly that if my Z zero position is at the top of the travel, I'm my case 12" above the bed, that Mach3 determines the length offset from that point for each tool?

If someone would be so kind as to offer what I may enter in the tool table for, lets use the example of a tool that is 1.5" and the travel to the touch plate is -10.5" I would greatly appreciate it. This would let me see how the offsets are calculated and what data I actually enter into the tool length offset table.

Additionally, I believe I would prefer positive offsets. Is this possible since my Z operates from 0 to negative 12"?

Lastly, zero to the top of my workpiece - I am willing to alter this to the top of the table but since I have a wood router the table height will constantly change since I surface the spoil board.

Any example would be greatly appreciated.


Thanks in advance,



Gio