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Hi Friends, 

I am pulling my hair out trying to determine how many steps it take for my angular C axis to make one full revolution. I recently had to redesign the tangential cutting head so while I had it off the machine I wanted to tune it as much as possible with the tools i had available  (scale, min max jog speed, etc) 

So i set out to determine how many steps it would take the motor to rotate the output shaft one full revolution. After a few days of doing what I thought was simple calculations to little to no success I tried to go bottom up. That is, hard coding the number of steps and adjusting based on behavior. this took like 5 minutes to get it pretty close.. However, its not perfect and I'd like it to be close i don't understand why it is the number it is. I don't think i understand the 'Pulse/rev' table on the driver. 

The bottom up number i got for steps per revolution was around 540. 

Current settings:
Pulse/rev (dip switches) 1600
Motor Step Angle 1.8
Pulley Ratio :3.12

No matter how i combine those numbers i cannot seem to get anywhere close to the 540, the number that actually produces somewhat close to a full revolution. 

Any help or explanation is greatly appreciated. My end goal is a precise calculated steps per revolution. 

Ps. i am ignoring that this is a servo motor and capable of closed loop control, not sure if this logic holds but i would like it the be as close to correct as possible then use the PID controls to correct error and not lean on it due to sloppy setup work. 

If its just a flash issue, ( normal Ethernet comms  are reliable )
It may possibly be a a compatibility issue or perhaps signal
integrity or some other flash EEPROM connection issue.

In all honesty if the kernel gives no issues I wouldn't bother upgrading, from memory there isn't much of a difference in performance.

The first issue I run into is that my gear track is 5 TPI The shaft diameter to the motor is 18mm does anyone build gears with metric bores and imperial gear pitch? buy a 5/8 bore pinion chuck it up in the lathe and bore it out to 18mm? hand file to broach out the keyway? a 20 T pinion should get me to about 600 ipm if my calculations are correct. which is honestly to fast but I am worried a 10t will not have enough contact and skip or slop.

I have a spindle that has motor pulley belt pulley
after has a geartrain with 2 positions-speeds.
I want to mount encoder to second pulley shaft before geartrain.
Iam confused how to set ini file values
max_speed min_speed encoder_scale output_scale etc