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Messages - BluePinnacle

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241
General Mach Discussion / toolpath display: odd problem
« on: January 19, 2009, 09:09:46 AM »
Hi. Strange one, this. My toolpath display 3D model looks fine, the line-by-line simulation goes nicely from one fixture to the other and the program works perfectly. On the other hand , when I actually run it, the green "done" line appears only over the first fixture (on the left). Pics of the fixtures are here: http://www.machsupport.com/forum/index.php/topic,9956.0.html - the left hand fixture is G56, and the right hand is G55. It starts on the left, chops out a hole, then goes right and does the bolt holes, face relief and edge trim, then returns to the start position on G56 and rewinds. Any ideas? it's not stopping me working but I'd like it to display properly. Ta :)

242
Show"N"Tell ( Your Machines) / Re: Excel Pinnacle vertical mill
« on: January 13, 2009, 12:17:25 PM »
that's a VERY sexy conversion and I'm in considerable envy of the travel speed. I must see if I can snag a faster computer for my rig, mine seems rather limited in terms of the speed of the pulse train it can generate. Well done, great job there :)

243
Show"N"Tell ( Your Machines) / Re: Excel Pinnacle vertical mill
« on: January 13, 2009, 06:17:55 AM »
Hi. Could be that the Yamazen mill is based on the same castings, and the electrical & control systems fitted by different companies. It's fairly common with machine tools, I believe. Does the Yamezen have plastic slide surfaces?

244
Show"N"Tell ( Your Machines) / Re: Excel Pinnacle vertical mill
« on: January 12, 2009, 07:36:24 PM »
Hi. X around 750mm, Y around 400mm, Z around 180mm (set a bit low so i don't knock the coolant pipe off).

More pictures:


Front - with TFT display and hardware control panel. The guards are less than wonderful, really they just prevent coolant going absolutely everywhere ( they constrain it to "nearly everywhere :(  ")


Backside - the white boxes are for contactors, LPT interface boards and other trickery. The RoutOut stepper driver and PC are on the steel framed shelf to the right.


Front hardware control panel for locking out the brake and running the pneumatic drawbar. The spindle can also be disabled and safely reenabled from here, all done with relay logic. The whole thing is completely fail-safe.


Current 2-jig setup making WG5Q flanges for coupling waveguide sections. The twin fixtures enable angles flanges to be made by tilting the first fixture, then finishing off on the second jig.


My lovely twin-jet coolant feed doing its thing. it's such an improvement over the old "gooseneck" feed!


Product! A complete WG5Q flange from 15mm thick 6082 alloy. Complete cycle time is 20 minutes dead, no tool changes.

245
Show"N"Tell ( Your Machines) / Excel Pinnacle vertical mill
« on: December 26, 2008, 08:03:44 PM »

Height - 7 feet, spindle - 4hp, 415v 3ph, 4200 RPM max expanding sheave drive and automatic airbrake, 3x 10 amp stepper drives, routout stepper driver, microstepping to 32,000 steps per inch. Maximum X,Y speed - 1200 mm/minute and of course Mach3 running on an old 950MHz PC with two parallel cards.

Note to self - more pictures required! it's quite a big beast. The first two pictures are of the twin-jet travelling coolant system I made up. I'm cutting large parts on two fixtures with a significant variation in Z offsets, and the static feed was either missing the tool or getting spun off the chuck and vapourising all over the floor.





It works a treat, I'd like a lot more pressure but that'll mean making a new coolant pump as the old one gets tired, bless it. 10-15PSI at the nozzle would be good! The clamp is a giant 85mm hose clamp, and the jets are now angled at 45 and 225 degrees to X so that on normal X or Y oriented cuts the coolant flow is approximately the same.

More photos when I remember! :D


246
Good point - thanks.

It's been ok since then despite wobbly power.

 ???

247
General Mach Discussion / Re: Motor problem
« on: December 12, 2008, 12:31:58 PM »
acceleration values matter too, if the motor can't spool up quick enough it may trip over itself. the motor tuning dialog is useful for determining what's what.

248
Another possibility... our power is not the best. I did have a sag a week ago which forced a reboot; luckily the chargepump board dropped out and I heard the spindle slam to a stop before I'd spotted the lights go down. Everything stopped dead, just like I'd designed it. :D I'll see if the IT lads have a spare UPS anywhere.

Another thought - USB memory sticks make mine go mad, the steppers bang and groan and won't work worth a sht. It's impossible to do anything. Funny business  ???

Edit again! i checked - the stalling at the end of the sub is down to a missing carriage return. Very peculiar, I'd never have thought to check for that. I'd just gone through and deleted any and all unnecessary spaces. I'll make a point of putting in

(leave this line in, mach3 needs a carriage return above here) at the end of my subroutine file. Cheers for the tip :)

249
Hi Jim

Offset tables - Going by what you've said i think we can rule these out. I'd done several parts that day, the usual routine being followed thus:

start computer
reference all axes
jog to approximate start point
fit blanks
load G-code
manually G0 to x100 y130 z10 (nominated start/return point)
run cycle
repeat until hometime

When I started the computer today and did a spindle-off thin-air run, it went to the right places on the fixtures with no surprises, so i can only imagine that my offset tables are robust. I've never zeroed DROs in-flight. Wierdly, it now stops at the end of a subroutine a few steps from the end of the program! arrrgh.

The other possibility you raise is that of reading ahead into a subroutine, I wrote all mine into the same text file. This may be giving it headaches. I'll re-write using seperate text files for subroutines and see if this helps.

There were no orphan spaces in the code btw.

thanks again :)

250
Hi, thanks for the tips so far, I'll check on these.

I didn't check the offset table, but I'll do that today. After the first crash I re-homed the machine and carried on - somebody had stood a part on the keyboard ( !!! ) so i put the spectacular crash down to bad luck and dumbness. The second time I was stood next to it when it halted halfway through a safe move, fed Z down onto the part and stubbed out a brand new 8mm cutter like a freshly finished smoke. I punched the Estop button and halted everything, and the G-code readout on the program run screen was displaying a Z move which is part of a subroutine for boring a 10.2mm hole (feed down, circle, feed down, circle, pullback, rinse-and-repeat). It seems to have jumped there from halfway through a move. Why? This is getting expensive! And it's making me look stupid! I'm not happy! More to the point I've done 40 or so of these parts already with only minor edits for gradually raising feed rates and reducing cycle times. I haven't altered any of the wiring or changed PC settings at all.

I'll investigate and get back on this, thanks again for the suggestions thus far. I'll let you know what I find. The code is pretty beaten-around so there may be blank or orphaned lines in there.

jim - What am I looking for in the offset table? Would its values change for any reason? ta.

more later ... BP

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