well
none of us was right.
I sent the necessary pulse signal for 1 full turn of the ballscrew to every axis which has servo installed, checked the settings and made measurements with precision 1micron marcator and tesa indicators;
drivers received exactly 10000pulses(4x2500) for 1 full turn, received and actual encoder pulses are same(10000), so nothing wrong with the pulse signals or signal generators,
measured the 25mm(X axis), 10mm(Y axis) and 5mm(Zth axis) ballscrew pitches, they are exactly 25.001mm, 10mm and 5.001mm, i assume 1micron is the measuring error of the dial indicator, so nothing wrong with the ballscrews,
before measured backlash is still there and its not the problem,
i made many measurements again with +1mm, +2mm, +3mm, +4mm, +5mm, +10mm and +25mm command set, it is still repeating that odd positioning error in most of the time, but in couple times it made the exact positioning within 1-2microns for the whole 1 set in every axis.
without a hope i tried to adjust the count per unit value with the wizard and of course it didnt fix anything.
i still dont know why i am reading this positioning error in the dial indicators, when every axis commanded to go 500mm and return back to 0 all of them returns back the exact point within couple of microns.
before this error presented itself i was making a test cut which has couple of circles, tilted square and rectangles on it, weird thing is this; for the rectangle(35mmx25mm) machine made it within 20microns, it was 35.02 in the X and 25.01 in the Y direction. But according to the measurements i am reading it should have done that cut with 50-60 micron error. The rectangle and squares was ok but the circles were not true circles, they were reflecting the errors i am measuring and +60micron wrong.
I am gonna make the same test cut again, after tuning the servos and aligning the ballscrews within 10micron to guideways.
I wonder what u guys read on the dial indicator when u move one of the axis of your machines +1mm for example?
Regards,
Hakan