I'll try to make a better model tomorrow, but maybe the attached shows the gist of it better in cross section. The desired end result is a rectangular pocket. The result is as shown with the undercuts. The tops of both walls are in the right spots and of the correct thickness. The +Y wall is fine all the way down, the -Y wall is not. The end mill was a YG1 E5G98910 (3/8" diameter, 2-1/8" LBS, and 1/2" LOC, with a 0.345" shank, so it is possible for it to make some degree of undercut without rubbing). I'll see if I can measure how extreme the undercuts are tomorrow.
Cutting an internal pocket, climb cuts. The original material was a solid piece.
Possible multiple axes have errors, but I'm not seeing evidence of it. The one dimension in X I can measure is correct and shows no signs of misalignment between Z passes.
I agree this smells like a hardware issue- if so, it'll probably be a bear to track down. The motors are ClearPath servos, driven in quadrature mode. I believe the signals are 5V from the Mesa board, but would have to double check that. If there's some kind of encoder error, it's internal to the motor.
The cables are as provided from Teknic: motor -> cable -> soldered joint to circular connector -> connector -> soldered joint on other end of connector -> ferrule to 7i76E screw terminal. X and Y cables do run adjacent to one another (and power cables) for a few feet, and they're not shielded- though Teknic also sells 55' unshielded cables, so one might infer they don't believe it's important.
What's really hanging me up is that it seems to return to the correct place in +Y, despite apparently cutting incorrectly a variable amount in -Y.
Either way, I'll double check nothing is mechanically loose tomorrow (that would be the nicest answer) and put a scope on the Y axis signals while jogging X around, see what kind of cross-talk I get. I already got LinuxCNC 2.9.3 installed.
ETA: Mechanics appear fine- I can lean/pull on the Y axis and it'll move maybe 0.001", then springs back when I release it. Leadscrew retention nut appears tight.
Hey guys. I wonder if someone could assist me in nutting a problem in my configuration. I know the layout of the config has more than one problem, and i plan to learn better how to fix this myself, however as long as i have the axis' dialled in and the servo spindle controlled through the software i am a-ok with not having spindle orientation and extras setup until I better understand the Hal configurations.
I have been running Probe Basic as a 3 axis stepper driven mill configuration, 3 homing switches for a year using the standard mill motor spindle and that has worked fine. I have just installed a Servo Motor to drive the spindle and now for some reason I am getting a joint following error when homing any axis.
I have had the servo spindle working in a test file, (both Axis and probe basic GUIs),but when combined together in the previously working Probe Basic config I have issues.
I have a feeling it might be something that is related to the post-gui file, as in an attempt to chase errors I was getting I have consolidated a not task that was conflicting, and I have reached to end of my limited knowledge.
I am working regularly to better understand the control flow within linuxcnc, but for now, if i was just able to get a minimal running configuration sorted I could at least use the machine whilst i gain that better knowledge.
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
