Its just about time to stop thinking about this one and start pulling stuff out and putting stuff in. Ive had a few dramas with a five axis router Ive been upgrading. One of the drives seems to be putting out lots of noise on its simulated encoder output. Baldor reckon there is nothing wrong with it but I can put another drive in its place with all the same wiring and the problem goes away. Thats what got me to upgrade my DSPMC, but that only helped to hide the problem, not fix it. Thats the problem with upgrading machine tools. One little thing can be hard to track down, it gobbles time and no one gets paid in the meantime.
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