The notes for the FI command recommend that for high accuracy, the speed during the search should be 500 counts/sec or less. So depending on what resolution the spindle encoder has, this is going to restrict the spindle speed to what? 30rpm for a 1000 count encoder?
I suppose that less accuracy would be acceptable, if the inaccuracy were repeatable at a given rpm.
Al, what are you currently using to rotate the spindle encoder on the test bench? I'm thinking if you had something like a drill motor, that you could run some sort of a mandrel (and the encoder on the outboard end of that), around which you could wrap paper, and use a pen for a tool to scribe lines on the paper. This will give you some frame of reference from which to tell if the tool is tracking the exact same path every repeat. You don't even need to program anything more than the same path to repeat over and over, at least for a start.
Then you've got to get the rpm up and see where it goes from there.
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