Doing some thread milling and I keep on getting a motor over load error.

its a 40 20 fadal I was using the end of the table so figured something maybe tight , changed offset to the center of the table just to see if there was a bind still same error. tried 10 inchs a min to 40 inchs a min and everything in between same problem.

what is really weird it only shuts off on the y- or y+ never the x- or x + ie front of the part or back of the part not on the right or left side of the part.
I did make one complete part had my feed rate at 150% ( it had kicked off before and after that one time).

also when it gets the error it may go 10 revolutions or 2 revolutions

I don't get the problem doing anything else and I am feeding on other parts at 50-60 inchs a min not circular interpitaion(sp) but it does use all three axis's at once.

Any Ideas


Edit : this is the error msg. per documentation
12 MOTOR OVERLOAD. STEP COMMAND CHECKSUM ERROR
This message appears after the completion of a move. At the end of a move, the
number of pulses required to complete that move is checked against the number of
pulses taken by the axis controller. If the checksum is not corrected then the
operation is stopped and this message is displayed.

I know that Fadals, depending on the vintage, have a very hard time with helical interpolation.

Fadal was saying it could be a mathmatical error(anomily) and said to change the pitch try a slower feed rate changed the pitch/feed rate same problem,
changed the minor of the thread to 3.0 instead of 2.21875 and it worked 3 times, went and changed the minor back to 2.2 and it dies. havent tried it back at 3.0 yet. Waiting on Fadal to call back. I emailed them the program.

Also yesterday and today on turning the power on I got a darn memory error and it says to erase all programs which I cant do cause I got over 7megs in there ( gotta download them first, lots of programs)
first time I powered up I got an A5A5 error, then just a bit ago I shut it off and got a hexidecmal error msg.
now I am wondering if that might have something to do with it as well.

Machines been rock solid from day one, not to mention I can run any program and it makes parts moving all 3 axis's at the same time 100+ inches a min, just thread millng is kicking my butt. just for one part too ;)

The early Fadal controls have a 24-bit radius limitation and small arc angle issues. If your program contains arc statements that have a radius larger than 8388 mm or arc segments that are less than 0.035 mili-radians you could be in for a big surprise.

I have seen Fadal’s run HUGE arcs right thru the middle of the part, and I have seen them totally ignore the arc statement and proceed to cut from the start point of the circle to the end point of the circle.

These conditions become very severe when using “Curve Fitting” or thread milling do to the nature of the arc generation.

The math problem is in the Fadal, but can be avoided by adjusting the parameters in the CAD system for arc generation once you know what the limitation is. The first step is to see if this condition exists in your NC file.

If you would like to catch these errors before they end up on your part, go to www.vegacnc.com and download the DATA-View utility. The demo will allow you to view your file and if these conditions are present….. you’ll see the flags.

had some time again and dicked with this on some thread milling it just wont thread mill anything.

it also gives me a #12 error on the z axis sometimes when running a g18 go3 code,however when I reset the machine it will run the program for a week or so so the error is intermittent unless its thread milling then it is always the x axis #12 error

took the mem card out like Neal said do a reboot same thing to see if its a memory card.

someone mentioned that it might be gain? change from high to med?
also mentioned to put a ground rod into the ground or a water pipe.
this weekend I will have some time to dick with it so if you have any ideas I would appreciate them.

have you cheked tha ballscrews backlash??

No I didnt it was a completely rebuilt machine when I bought it. but I will check it out thanks