Messages

1041

General Mach Discussion / Re: Bridgeport Knee Mill Conversion?

« on: October 07, 2016, 06:11:08 AM »

Ok, reply from CS-Labs, my comments quoted in the reply start with >>>....

Dear Dave,
 
>>> As you can see, the system started up normal, then had a software limit switch activated - this was caused buy this line of code - G28 G91 Z0.
 
Soft limit limits are set out and passed to CSMIO/IP-A by  Mach3.
If Soft Limit was set correctly the obviously Mach3 made a mistake during Soft limit calculations or during passing to the controller.
 
>>> Then once i reset Mach it followed with an ePid fault on this line I think - G0 X109.987 Y168.641 or this one - G43 Z25. H2 which followed.
 
The e-PID mens too high difference between  currently set by Mach3 trajectory and currently set axis position read out from encoders.
The fault may be caused by Mach3 and servo drives as well.
 
- E-PID caused by Mach3.
The fault is mostly caused when Mach3 makes a mistake during calculations and it wants to perform very fast uncontrolled axes move.
A corrupted  XML file is usually responsible for that. The e-PID fault may be also caused by incorrectly written VB macros.
 
e-PID caused by servo drives.
That's nothing else but max. following position error exceeding of one of axes.
In this case you should verify your PID loop settings (tuning).
 
I would only like to add that for a milling machines we always use 03.043.022 Mach3 version as it's the most reliable in our opinion.
Version higher than 03.043.045 of Mach3 can sometimes cause problems with synchronization of internal coordinates so it's easier to get the e-PID fault.
 

Now, in my mind this looks like an internal Mach/CSMIO thing because in theory you should NEVER be able to exceed or trip a soft-limit - thats the WHOLE reason they exist, to control the boundaries of motion right?

So, somehow, my code for home is trying to send Mach Z axis beyond Mach Z++ soft-limit home setting - this is clearly wrong no?

Any thoughts?


So, it seems i need to downgrade further, anyone have a link for V022 please?

1042

General Mach Discussion / Re: Bridgeport Knee Mill Conversion?

« on: October 07, 2016, 02:10:03 AM »

It's zero, checked on the 1024 set.

I have no idea what they are leaning towards, I also asked Gerry who did the 2010 set and he has no idea either, the set does not use the 1001dro though.

Baffling

No macro's were in play at the time - it was before the M6 so M6Start was not called and M6End is empty anyway, no probing was being done so the gage block height is irrelevant.

I have passed the log data back to cs-labs

1043

General Mach Discussion / Re: Bridgeport Knee Mill Conversion?

« on: October 06, 2016, 02:12:49 PM »

CS-Labs also stressed that it can be connected with a DRO?

"Even the fact you do not use UserDRO 1001 can be the problem - please verify it."

As far as i can see, the 2010 screen-set does NOT have the DRO1001 on it - "Gage Block Height"

Any ideas?

1044

General Mach Discussion / Re: Bridgeport Knee Mill Conversion?

« on: October 06, 2016, 01:53:04 PM »

Here we go, the log file is a mine of information

It seems the machine started up fine, ran fine until 2016-10-02 | 09:52:21.375 where we get the first "Software limit switch activated!" error - this would be when it sent the Z axis home for a tool-change.

So, as i said, its not a real limit switch thats getting hit, its some sort of software limit.

Its also the Z axis throwing the following ePid fault - 2016-10-02 | 09:56:24.625 -> ePID Fault on Axis(2) : FAULT

Question is - why?

2016-10-02 | 09:17:24.718 -> CSMIO-IP class initialized OK.
2016-10-02 | 09:17:24.734 -> InitUDPSock -> OK.
2016-10-02 | 09:17:24.734 -> piInitControl: Module filename: C:\Mach3\PlugIns\CSMIO_IP_A_plugin.dll
2016-10-02 | 09:17:24.734 -> piInitControl: GetFileVersionInfoSize = 1716
2016-10-02 | 09:17:24.734 -> piInitControl: ProductName: CSMIO-IP-A Mach3 plugin
2016-10-02 | 09:17:24.734 -> piInitControl: ProductVersion: 2.8.5.1
2016-10-02 | 09:17:25.687 -> Our IP address : 10.1.1.1
2016-10-02 | 09:17:25.687 -> Our subnet mask : 255.255.255.0
2016-10-02 | 09:17:25.687 -> Calculated broadcast : 10.1.1.255
2016-10-02 | 09:17:25.687 -> Sending discover message to broadcast.
2016-10-02 | 09:17:26.359 -> All network interfaces checked...
2016-10-02 | 09:17:26.359 -> Discover finished. Found 1 CSMIO-IP device(s).
2016-10-02 | 09:17:26.359 -> Connecting to CSMIO-IP at IP:10.1.1.2
2016-10-02 | 09:17:26.359 -> Connected.
2016-10-02 | 09:17:27.109 -> llComm(c:45): Rx time-out. retry = 0
2016-10-02 | 09:17:27.109 -> llComm(c:45): NAck with nackTRREP received. (no retry).
2016-10-02 | 09:18:05.171 -> Sending reset to idle state request.
2016-10-02 | 09:18:07.218 -> Homing start axis:2
2016-10-02 | 09:18:12.296 -> ClrAxisPos: Axis:2 / DeRef: NO.
2016-10-02 | 09:18:12.296 -> Axis 2 homing ok.
2016-10-02 | 09:18:12.359 -> Homing start axis:1
2016-10-02 | 09:18:15.546 -> ClrAxisPos: Axis:1 / DeRef: NO.
2016-10-02 | 09:18:15.546 -> Axis 1 homing ok.
2016-10-02 | 09:18:15.640 -> Homing start axis:0
2016-10-02 | 09:18:22.515 -> ClrAxisPos: Axis:0 / DeRef: NO.
2016-10-02 | 09:18:22.515 -> Axis 0 homing ok.
2016-10-02 | 09:52:21.375 -> Software limit switch activated!
2016-10-02 | 09:52:58.843 -> Sending reset to idle state request.
2016-10-02 | 09:55:34.437 -> Software limit switch activated!
2016-10-02 | 09:55:42.453 -> Sending reset to idle state request.
2016-10-02 | 09:56:24.625 -> ***********************************
2016-10-02 | 09:56:24.625 -> ePID FAULT! (State = 105)(Alarms=0x00000002)
2016-10-02 | 09:56:24.625 -> (ThreadSt=5) (RTappSt=0)
2016-10-02 | 09:56:24.625 -> ePID MaxError on Axis(0) : 156
2016-10-02 | 09:56:24.625 -> ePID MaxError on Axis(1) : 1
2016-10-02 | 09:56:24.625 -> ePID MaxError on Axis(2) : 681
2016-10-02 | 09:56:24.625 -> ePID MaxError on Axis(3) : 0
2016-10-02 | 09:56:24.625 -> ePID MaxError on Axis(4) : 0
2016-10-02 | 09:56:24.625 -> ePID MaxError on Axis(5) : 0
2016-10-02 | 09:56:24.625 -> ePID Fault on Axis(0) : ok
2016-10-02 | 09:56:24.625 -> ePID Fault on Axis(1) : ok
2016-10-02 | 09:56:24.625 -> ePID Fault on Axis(2) : FAULT
2016-10-02 | 09:56:24.625 -> ePID Fault on Axis(3) : ok
2016-10-02 | 09:56:24.625 -> ePID Fault on Axis(4) : ok
2016-10-02 | 09:56:24.625 -> ePID Fault on Axis(5) : ok
2016-10-02 | 09:56:24.625 -> ***********************************
2016-10-02 | 09:56:34.296 -> Sending reset to idle state request.
2016-10-02 | 09:58:19.750 -> Sending STOP request.
2016-10-02 | 09:58:19.812 -> ***********************************

1045

General Mach Discussion / Re: Why won't they send me my license?

« on: October 06, 2016, 10:02:10 AM »

I think my one took a day or so to arrive

1046

General Mach Discussion / Re: Bridgeport Knee Mill Conversion?

« on: October 06, 2016, 07:32:26 AM »

Going back to my issue with the odd behaviour and imaginary limit switches triggering, I have just got a reply back from CS-LABS and unknown to me, the controller plugin creates a log file - "CSMIO_IP_A.log" somewhere on the PC, they said it should contain details of what switch was triggered and other stuff.

Will have a look tonight, nearly finished the new drive motor so should be back testing by the weekend hopefully.

1047

General Mach Discussion / Re: Bridgeport Knee Mill Conversion?

« on: October 05, 2016, 02:22:47 PM »

Got it running under local control tonight, did an autotune on it, draws a tad over 3A idling.

Question -

When speeding up or slowing down (by twiddling the knob) it overshoots and then stabilises - I *think* this is the sensorless-vector stuff doing its thing.

Now, as it will be running in semi closed-loop when finished, is it best to leave it in SVC mode or switch to standard V/Hz mode ?



Looks like i have usable power from 300 to 3000rpm, 10 to 100Hz
Stopping from 3000rpm in 1s pretty impressive too

1048

General Mach Discussion / Re: Bridgeport Knee Mill Conversion?

« on: October 05, 2016, 08:53:42 AM »

Its a supplier i have used in the day-job for some years and is very helpful/knowledgable so i will go with the advice for now.

Gotta love the far-east wiring colours

1049

General Mach Discussion / Re: Bridgeport Knee Mill Conversion?

« on: October 05, 2016, 08:23:25 AM »

Just had a chat with the supplier and he recommends not fitting an input filter as the Bosch inverter I have already has a good internal filter filter to the input, that is unless there is proof of interference on other components.

Also, peak demand for my motor/drive setup in a balls-to-wall full-load situation would be 22.5A on the supply, above that level the inverter will start reducing speed, prolonged heavy draw will trigger a shutdown - the point at which this happens can be adjusted with the settings.

Now, question is, can a Bridgeport actually USE 3Hp at the spindle without snapping something

1050

General Mach Discussion / Re: Bridgeport Knee Mill Conversion?

« on: October 05, 2016, 07:32:29 AM »

Thanks, will have a look for a filter, do have one but is only 14A so will have to come out.


Yes UK