I finally gave up. I have spend hours and hours trying to find out why my motor stall. I even contacted the manufacture of the drives and motors with no success. I replaced all wires,motors, drives, added ferrite cores,.... There is almost nothing I have not tested.
I am convinced it has nothing to do with the Rio software. But the tang vs parallel port makes the difference. The signal after the BOB comes out with less noise when I run it from the parallel port as when I have the tang connected. I don't know why and I don't know why my DM332T don't make an issue either way, but the Microkinetics does.
I will order a new drive, but that opens up a new can of worms and I may upgrade directly to servo drives...
The attached control circuit will disable the spindle and servos of the machine if an Estop push button (PB) is pressed or change tool is requested. The arrangement is combination of both software and external hardwired circuit.
To stop any movement of the machine, the approach uses estop and reset pins of the halui component and redundant hardwired external circuit to disable any movement of the machine. The interface between the software and the hardwired circuit is done through digital I/O (2 or 3 inputs and two outputs).
Operation of this system is follows:
If an Estop PB is activated or tool change is requested machine will go into an Estop state.
If only Estop is activated, operator is required to press push button reset to enable spindle and servos
If tool change is requested, operator is required to change the tool, press tool changed PB (either hardwired or UI) and press reset PB to reset the estop and continue operation. (I know operators don’t like to press two buttons sequentially in certain order, but for their hands and fingers sake the extra mental challenge makes it worthwhile, I think!.
On the left side of the sheet is the electrical schematic. Showing use 5 relays. If you decide to use this circuit you need to determine the number of contacts normally open and normally closed before ordering the relays. The MCR contacts connection to servos and VFD are hardware dependent (if you need help with this part of the diagram ask)
On the right side is a postgui block diagram reflecting net listing of hal file see below.
# signal/wire connected Pins
#--+
+
net estop.activate.sig halui.estop.activate and2.1.in1 flipflop.0.out
net estop.is-activated.sig halui.estop.is-activated and2.0.in1 flipflop.0.reset hm2-7i92.0.7i77.0.0.output-00
net estop.reset.sig halui.estop.reset and2.0.out
net external.reset and2.0.in0 hm2-7i92.0.7i77.0.0.input-01
net external=estop flipflop.0.set hm2-7i92.0.7i77.0.0.input-00
net t.prepare.loop iocontrol.0.tool-prepared iocontrol.0.tool-prepare
net t.xch.done hal_manualtoolchange.changed iocontrol.0.tool-changed
net tool-changed or2.0.in0
net tool-xch.request hal_manualtoolchange.change iocontrol.0.tool-change hm2-7i92.0.7i77.0.0.output-01
net tool.changed or2.0.out and2.1.in0
net tool.changed.button hal_manualtoolchange.change_button and2.1.out
net tool.number hal_manualtoolchange.number iocontrol.0.tool-prep-number
net ui.tool.change.pb or2.0.in1
