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Going to try to get it going with some Optical sensors.
One of the pockets has a double flag to include the homing, all other pockets only 1 flag to detect the index position.

Printer is churning them out at the moment, should be able to test if it works over the weekend.

 

Just wait a second after the motor starts before reading RPM from encoder.

This would not work with rigid tapping (the OP's question)

Edited original post
But it happens in any subroutine, in simple nor complex.
It can be like this -

G91                                ; relative
G38.2 Z-164 F1000                ; quick find

---

HERE IT STOP

---

G1 Z3.0 F10000                    ; retreat by 3mm
G1 Z-2.0 F10000                    ; move toward 2mm
G38.2 Z-1 F5                    ; slow find
G1 Z1 F10000          

If I change G1 to G0, it never stops. But that not possible everywhere.

I have the same issue. Sometimes (every other day) I start a probing routine. It probes the first touch, hangs(seemingly), then I need to press 'stop' and start again. Then it works. I've always thought that it was my probe that was a bit iffy.

Is there a way to have a higher degree of logging than starting linuxcnc from the terminal. Would be interesting to see what the last command is that dosent complete, if any.

might be a good idea to attach the subroutine in question.