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Hello EtherCAT gurus,

After generous help from OncedLoved and AI we have reached the end of our troubleshooting patience trying to resolve the strange behavior of my new closed loop VDF (Cumark 15 KW) connected to LinuxCNC via EtherCAT (non- CiA402).

Current Condition:

• The VFD is properly set up for the spindle (motor parameters and encoder) and it runs perfectly using the keypad.
• The drive successfully enters OP mode when LinuXCNC starts up and the PDOs are displayed in halshow (see attached screenshot and xml)
• In halshow, when I set Ref 1 (motor speed) to 500 and ControlWord to 2178 (decimal for hex 0x0882 = Start Command), the spindle instantly runs to 500rpm as expected.
• After a few seconds the motor speed changes to 2178 rpm! As if the motor reference value is the decimal start command value. This can happen from 10-90 seconds after the spindle is turned on.
• Then I set ControlWord to 2177 (decimal for hex 0x0881 = Stop Command), and the spindle unreliably either:
  • Turns off after a delay of 30 to 120 seconds, or
  • the motor speed changes to 2177 rpm after a similar delay range, and then turn off after and additional delay range.
• As a result, the spindle eventually turns off but not instantly.
• Actual values Act1 and Act2 are either displaying the wrong value or there is also a delay.
• This strange behaviour happens when controlling the VFD from TwinCAT as well. So I am guessing that something in the drive is not setup correctly.

Questions:

1. What is causing this inconsistent delay behaviour?
2. Anyone experienced in custom EtherCAT configurations (non-CiA402)?
3. How do I convert decimal values transmitted from the VFD  to legible Drive Status Word: (vfd manual page 59 section 6.05)

Attached is:

1. ethercat-conf.xml (just testing the VFD - slave 0)
2. generic ini and hal files for testing
3. spreadsheet of VFD ethercat relating settings and PDO mapping
4. Link to vdf and ethercat card pdf manuals, and xml from Cumark.
5. screenshot of the lcec hal pins when spindle off and on
6. Pictures of the machine frame build and spindle for your interest

It would be great to get this running and I am sure others would find this useful otherwise I would switch for Modbus or analog (not ideal).

Your expertise in this nuanced topic would be greatly appreciated!


Background about the Build in case you are interested:
CNC milling machining for my business in designing and building scientific instrumentation. The frame is made out mineral casting by Muller (Germany). The travel is 600mm X x 500mm Y x 350mm Z. It has 23 23-bit absolute encoders, AC Servos driven by EL8 Leadshine drives. It has a DECI 24K rpm, 15 kw continuous, 18 kw peak HSK 63f liquid cooled direct drive spindle controlled by a CUMARK closed loop VFD hopefully via ethercat.

To check, in halcmd:

sets b-index-enable true

and watch b-index-enable in halshow

Then move the axis past an index mark

b-index-enable should go false when the index is detected

hello,I've managed to set my PID.I've mounted an encoder directly on my machine B axis. My encoder is of the phase type A+,A-;B+,B-;Z+,Z-.the feedback is correct on my axis position. However, it's impossible to detect my Z0. I have a 7i96s and I've connected my two Z+,Z- wires to pins 13 & 14 of TB2 on my card. My .hal file is correctly configured for homing with this Z phase. I've tested 5 encoders of the same type. but I can't find the Z pulse.Is there a trick? Can anyone help me? Thanks

The modal/active gcodes personally I find them to be more/less the same. I dont really find it any more readable than linuxcnc. They are both just a jumble of g and m codes with F S H T at the end. I just takes more space with coloums instead of rows

this is crazy!! after applying your parameters, my ping went down from 1.xx to 0.3xx

Thx so much.

 

I want to use an ATC spindle with a rack tool changer. I was struggling to find some ready-made script I could use and perhaps modify that would fullfill this goal. Is anyone aware of an existing implementation that was tested/proven by some people that does this? I was able to find some carousel tool changer scripts/designs, but I explicitly need a simple rack solution since the machine is a router with 1m length I can use for holding plenty of tools.

Megnetic are cheaper but more dust tolerant, just like rotary encoders.
Pros are price and dust/ contamimation tolerance, unless you get them full of steel shavings they will work.
Optical, glass scales will fail sooner than magnetic if you install them within fine dust presence area.
Big con is magnetic field sensitivity. Use of magnetic holders for coolant/air nozzles may shift your readings.
My(£100 motor and driver) magnetic encoder servo motors suffer so bad(plastic encoder covers) can make them rotate 3°(0.1mm axis move witn 10mm pitch screws) by putting magnetic indicator base next to them. Running spindle makes z motor 120mm away move the axis up/down 0.02-0.05mm and with right spindle speed it would start oscillating into oercurrent error. swapped the motor to optical encoder(£40 extra) and it all went away...