====================================================================== SPINDLE SUPERVISOR TUNING DIAGNOSTICS ====================================================================== ── A. RATIO FILTER HEALTH ─────────────────────────────────────────── Closed-loop samples : 116712 Learning enabled : 26155 (22.4%) Blocked — ratio freeze : 69194 (59.3%) Blocked — CVT pulse active : 24859 (21.3%) Blocked — VFD saturated : 22670 (19.4%) Blocked — fb_vel too high : 116712 (100.0%) fb_vel percentiles (gate = 15 RPM/s): p1=139 p5=244 p25=798 p50=1602 p75=2977 p95=4098 p99=4523 Fraction of time below gate: 0.0% *** GATE TOO TIGHT — learning blocked almost entirely *** Suggested OL_STABLE_BAND = 801 (gate would be 2402 RPM/s, above p50) Large ratio step events (|Δratio| > 0.1 in one sample): Count: 495 Time From To Δ fb hz fb_vel freeze Note 146.0 0.971 7.989 7.018 37 37.9 446 0.00 *** CORRUPT 146.0 7.989 8.440 0.451 37 39.9 442 0.00 gate should block 146.0 8.440 8.898 0.458 38 41.9 447 0.00 gate should block 146.0 8.898 9.391 0.492 38 44.2 449 0.00 gate should block 146.0 9.391 9.909 0.518 38 46.5 444 0.00 *** CORRUPT 146.0 9.909 10.464 0.555 37 49.0 445 0.00 *** CORRUPT 146.0 10.464 11.029 0.565 38 51.5 450 0.00 *** CORRUPT 146.0 11.029 11.634 0.605 37 54.2 451 0.00 *** CORRUPT 146.0 11.634 12.276 0.641 37 57.1 448 0.00 *** CORRUPT 146.0 12.276 12.957 0.681 37 60.1 446 0.00 *** CORRUPT 146.0 12.957 13.649 0.692 38 63.2 451 0.00 *** CORRUPT 146.0 13.649 14.390 0.741 37 66.5 452 0.00 *** CORRUPT 146.0 14.390 15.176 0.786 37 70.0 450 0.00 *** CORRUPT 146.7 15.176 15.070 0.106 202 66.0 836 0.00 gate should block 146.7 15.070 14.964 0.105 202 65.6 829 0.00 gate should block ... and 480 more ── B. PI SATURATION MAP ───────────────────────────────────────────── Cmd Gear N AtMax% AtMin% Short% Over% OnTgt% HzMean RatMean ------ ---- ------ ------- ------- ------- ------- ------- ------- -------- 50 BG 11399 0.0 100.0 0.0 0.9 99.1 10.0 5.411 150 BG 23751 0.6 11.0 8.3 65.6 26.1 43.9 10.842 350 HG 27051 0.0 5.7 32.3 47.6 20.1 33.8 3.255 650 HG 31160 10.6 2.3 56.2 38.0 5.8 41.7 2.247 1350 HG 23348 12.7 0.0 40.8 46.3 12.9 45.7 1.355 AtMax%: time at VFD max Hz — CVT increase needed if spindle short Short%: time spindle below cmd by >deadband OnTgt%: time within deadband (goal: >80%) ── B2. EVENT TIMELINE ─────────────────────────────────────────────── Time Type Detail ------- --------- ------------------------------------------------------- 55.4 ▶ START cmd=335 RPM ratio=1.446 59.4 ● CVT-MAN dec dur=1.18s ΔHz=-1.0 ratio=2.369 63.4 ● CVT-MAN dec dur=1.22s ΔHz=+1.1 ratio=2.286 67.6 ● CVT-MAN inc dur=0.25s ΔHz=-0.6 ratio=4.936 71.6 ● CVT-MAN inc dur=0.81s ΔHz=-13.7 ratio=5.933 75.6 ● CVT-MAN dec dur=1.78s ΔHz=+7.2 ratio=1.286 79.6 ● CVT-MAN dec dur=0.14s ΔHz=-0.9 ratio=4.221 82.4 → SPEED 335 → 0 RPM 82.4 → SPEED 0 → 670 RPM 83.6 ● CVT-MAN inc dur=2.21s ΔHz=-2.5 ratio=4.221 87.6 ● CVT-MAN inc dur=0.96s ΔHz=-22.3 ratio=3.096 91.6 ● CVT-MAN dec dur=1.31s ΔHz=+13.6 ratio=1.062 95.6 ● CVT-MAN dec dur=1.01s ΔHz=+7.1 ratio=1.332 99.6 ● CVT-MAN dec dur=0.23s ΔHz=+5.1 ratio=2.030 105.4 → SPEED 670 → 1340 RPM 105.4 ● CVT-MAN inc dur=2.72s ΔHz=+0.0 ratio=2.336 109.4 ● CVT-MAN inc dur=2.72s ΔHz=-18.4 ratio=2.336 113.6 ● CVT-MAN dec dur=0.82s ΔHz=-1.6 ratio=0.754 117.7 ● CVT-MAN dec dur=0.92s ΔHz=+5.5 ratio=0.706 121.7 ● CVT-MAN dec dur=0.10s ΔHz=+1.5 ratio=1.157 128.7 → SPEED 1340 → 670 RPM 128.7 ● CVT-MAN dec dur=1.38s ΔHz=+25.2 ratio=1.003 132.7 ● CVT-MAN inc dur=0.82s ΔHz=-13.8 ratio=2.975 136.9 → SPEED 670 → 0 RPM 136.9 ■ STOP 136.7 ● CVT-MAN dec dur=0.20s ΔHz=-11.3 ratio=0.971 146.0 ▶ START cmd=134 RPM ratio=7.989 146.0 R RATIO 0.971→15.176 (197 steps, range 0.971–15.176) 150.0 ● CVT-MAN inc dur=0.46s ΔHz=-3.7 ratio=13.268 153.0 R RATIO 13.268→14.980 (71 steps, range 6.118–14.980) 154.0 ● CVT-MAN inc dur=0.59s ΔHz=-3.5 ratio=13.856 157.0 R RATIO 13.856→15.083 (97 steps, range 5.793–15.083) 158.0 ● CVT-MAN inc dur=0.87s ΔHz=-7.4 ratio=15.083 161.0 R RATIO 15.083→14.864 (70 steps, range 6.352–14.864) 162.0 ● CVT-MAN inc dur=0.91s ΔHz=-11.8 ratio=15.266 165.0 R RATIO 15.266→15.026 (60 steps, range 5.670–15.026) 166.0 ● CVT-MAN dec dur=1.24s ΔHz=-0.5 ratio=5.640 169.7 → SPEED 134 → 67 RPM 181.1 → SPEED 67 → 0 RPM 181.1 ■ STOP Summary: 2 spindle start(s) 0 auto CVT 24 manual CVT 495 ratio change(s) (11 corrupt) ── C. SPEED SETTLING ──────────────────────────────────────────────── Time From To Settle Note ------ ------ ------ ---------- -------------------- 128.7 1350 650 TIMEOUT >40s *** did not settle 169.7 150 50 0.13s Settled steps : 1 / 2 Settle time : mean=0.13s min=0.13s max=0.13s ── D. CVT PULSE AUDIT ─────────────────────────────────────────────── Total pulses: 24 Stalled (|ΔHz|<1): 3 Wrong direction: 5 Time Dir Cmd Dur ΔHz ΔRatio Hz/sec Result ------ --- ----- ----- ------- -------- ------- ---------- 59.4 dec 335 1.18 -1.51 -0.083 1.3 WRONG 63.4 dec 335 1.22 +3.84 +0.283 3.1 ok 67.6 inc 335 0.25 +11.51 +0.997 45.1 WRONG 71.6 inc 335 0.81 -56.70 -4.647 69.8 ok 75.6 dec 335 1.78 +41.22 +3.480 23.1 ok 79.6 dec 335 0.14 +25.54 +0.000 178.6 ok 83.6 inc 670 2.21 -3.63 -1.125 1.6 ok 87.6 inc 670 0.96 -55.72 -2.034 58.2 ok 91.6 dec 670 1.31 +14.75 +0.270 11.2 ok 95.6 dec 670 1.01 +14.91 +0.698 14.7 ok 99.6 dec 670 0.23 +10.78 +0.333 46.5 ok 105.4 inc 1340 2.72 -3.19 +0.000 1.2 ok 109.4 inc 1340 2.72 -45.05 -1.875 16.6 ok 113.6 dec 1340 0.82 +0.07 -0.038 0.1 STALL 117.7 dec 1340 0.92 +20.28 +0.541 22.0 ok 121.7 dec 1340 0.10 -1.14 -0.147 11.5 WRONG 128.7 dec 670 1.38 +64.35 +1.972 46.7 ok 132.7 inc 670 0.82 -52.03 -2.004 63.3 ok 136.7 dec 670 0.20 -1.29 +7.025 6.6 ok 150.0 inc 134 0.46 +0.78 +0.589 1.7 STALL 154.0 inc 134 0.59 +5.80 +1.227 9.8 WRONG 158.0 inc 134 0.87 +0.71 +0.183 0.8 STALL 162.0 inc 134 0.91 -46.94 -10.327 51.6 ok 166.0 dec 134 1.24 -13.20 -0.230 10.6 WRONG CVT_HZ_PER_SEC (non-stall pulses >0.2s): mean=27.6 min=1.2 max=69.8 Recommended: CVT_HZ_PER_SEC = 27.6 ── E. LIMIT CYCLE DETECTION ───────────────────────────────────────── S350: oscillation detected Duration : 27.0s Error range: 588 RPM Hz range: 57.5 Hz Period : ~0.31s Mean ratio : 3.255 Mean Hz: 33.8 sched_kp : 0.31 i_clamp: 6667 RPM·s LIKELY CAUSE: ratio filter corruption FIX: Check ratio step events in Section A S650: oscillation detected Duration : 23.0s Error range: 1108 RPM Hz range: 59.7 Hz Period : ~1.35s Mean ratio : 2.358 Mean Hz: 43.7 sched_kp : 0.42 i_clamp: 6667 RPM·s LIKELY CAUSE: ratio filter corruption FIX: Check ratio step events in Section A S1350: oscillation detected Duration : 23.3s Error range: 2203 RPM Hz range: 52.6 Hz Period : ~0.17s Mean ratio : 1.355 Mean Hz: 45.7 sched_kp : 0.74 i_clamp: 6667 RPM·s LIKELY CAUSE: ratio filter corruption FIX: Check ratio step events in Section A S650: oscillation detected Duration : 8.2s Error range: 898 RPM Hz range: 67.7 Hz Period : ~1.26s Mean ratio : 1.937 Mean Hz: 36.4 sched_kp : 0.52 i_clamp: 6667 RPM·s LIKELY CAUSE: ratio filter corruption FIX: Check ratio step events in Section A S150: oscillation detected Duration : 23.8s Error range: 466 RPM Hz range: 60.0 Hz Period : ~0.09s Mean ratio : 10.842 Mean Hz: 43.9 sched_kp : 0.09 i_clamp: 6667 RPM·s LIKELY CAUSE: ratio filter corruption FIX: Check ratio step events in Section A S50: oscillation detected Duration : 11.4s Error range: 75 RPM Hz range: 0.0 Hz Mean ratio : 5.411 Mean Hz: 10.0 sched_kp : 0.18 i_clamp: 6667 RPM·s LIKELY CAUSE: VFD saturated at min — ratio too low FIX: RATIO_MIN cap or CVT decrease needed ── F. PARAMETER RECOMMENDATIONS ───────────────────────────────────── OL_STABLE_BAND (current) : 5 → gate = 15 RPM/s fb_vel p50 / p95 : 1602 / 4098 RPM/s Ratio learning active : 22.4% of CL time *** WARNING: ratio learning active only 22% of time Suggested OL_STABLE_BAND = 801 Integrator clamp : ±6667 RPM·s (MAX_I_ERROR=200 / KI=0.030) Peak integrator seen : 9095 RPM·s *** Integrator hitting clamp — anti-windup active High gear ratio range : 0.441 – 6.109 Backgear ratio range : 2.348 – 15.266 Recommended BACKGEAR_RATIO_MIN = 4.23 Peak fb_rpm seen : 2831 RPM ====================================================================== Run with --report calibration for CVT Hz/sec measurement ======================================================================