Debugging joint amplifier fault

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28 Mar 2024 13:15 - 28 Mar 2024 13:28 #296999 by knipknap
My machine (Kinematics XYYZ with 4 servos) has been running without a problem for months, but today I started getting "joint 2 amplifier fault". It happens quite quickly after starting any job now. Joint 2 is one of my dual Y axis joints.
I have not found any docs about what this error means. Any hint on where I should start debugging? I have not made any changes on the hardware nor software.
 
Last edit: 28 Mar 2024 13:28 by knipknap.

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28 Mar 2024 14:34 - 28 Mar 2024 14:35 #297002 by knipknap
Turns out my joint 1 servo (not the one that is named in the error) is not working anymore, leading to joint 2 having trouble moving the gantry.

Checked the cabling of the non-working servo, all good. That leaves the servo (JMC with integrated driver) or the interface card (MESA 7176e) as a potential source of the problem.
Last edit: 28 Mar 2024 14:35 by knipknap.

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28 Mar 2024 16:04 - 28 Mar 2024 16:31 #297010 by knipknap
It gets more puzzling:
  • If a swap the two Y axis motors, they both work - if I swap them back, only one works. Repeatedly tried with the same result. In any case, both clearly have power, because if I try to move the non-working one manually, it tries to move back  . I am confused. Could this be servo tuning related?
  • In addition, on my destroyed workpiece I see that there was a large following error on the X axis, not just on Y.
I don't see a common denominator. Except for the MESA card, but it seems to me it would be a strange failure mode, too.
Last edit: 28 Mar 2024 16:31 by knipknap.

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28 Mar 2024 17:12 #297013 by PCW
Replied by PCW on topic Debugging joint amplifier fault
Did you swap the motor connections at the 7I76E or the motor?

If differential signalling is used and you have either:

A bad cable
A bad 7I76E step output
A bad motor driver step input

You can get flaky behavior if just one on the differential
signals is working.

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28 Mar 2024 17:23 #297014 by knipknap
I swapped them at the motor side. I also made sure to check every wire with a beeper while moving the cable around, all wires seem fine. But I only checked the non-moving motor wires, not the other ones... maybe I'll check them all.

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28 Mar 2024 18:50 #297021 by knipknap
I just checked both channels with an oscilloscope:
  • Once with the servos disconnected.
  • Once with the servos connected, such that one doesn't work.
Each time, I measured both channels directly on the servo connector.

When disconnected, channel 1 looks like this:
 

When connected, the pulses are way lower:
 

As a control, I also measured on channel 2 (when connected):
 

I also measured directly on the MESA connector in disconnected state, but both look the same in that case.
So I guess this means that there is a problem with the driver of the JMC...
Attachments:

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28 Mar 2024 19:13 #297023 by PCW
Replied by PCW on topic Debugging joint amplifier fault
A lower signal is expected especially with a differential inputs that typically
have 100 Ohm termination.

Did you check both  STEP+ and STEP- (assuming you have differential connections)
 

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28 Mar 2024 19:15 #297024 by knipknap
Lower yes, but why the large difference between both servos?

The above measurements are between step+ and step-.

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28 Mar 2024 19:38 #297027 by PCW
Replied by PCW on topic Debugging joint amplifier fault
So the large swing difference is traceable to just one drive? (and not one step/dir output)?

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28 Mar 2024 19:52 #297030 by knipknap
Good question. The bad motor on the good channel is also pulled down a lot, but only to 3.7V instead of 2.4V.

The specs of the servo say they tolerate a signal voltage between 5V and 24V, so both is well below that.

I am really not sure who is at fault here; the MESA because it cannot provide enough power, or the driver because it pulls too much power.

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