Problem- Angle Test???

[mniadna]

When I run the angle test from the manual on my 4020, my indicator fluctuates about .0005" along the entire length of the parallel. It is fairly constant, almost pulse, like. I can't adjust it out using the sig 2 pot. This causes minor surface finish irregularities when I make interpolated cuts. My machine will cut super smooth in X or Y alone. The machine has all new support bearings, turcite, gibs. Everything is adjusted properly. Anyone have more insight into this?

Thanks,

[Delw]

if its new it just needs to wear in a tad) gibs and turcite), make sure your getting plenty of oil on the turcite/
the only other thing you can do ( if your drives are tuned perfectly) is reconnect all the drive boards and all connections. sometimes they get a tad corroded(sp)

[Neal]

Is this an AC or DC servo machine? If it is DC you might check the motor brushes and the Tach. Clean the commutator with a clean pencil eraser and then re-tune the loop gain to 595 for the DC servos.

Neal

[mniadna]

Neal,
It is a DC machine. Y is the only motor that isn't freshly rebuilt. I was sort of thinking it could be that motor, but it will cut nice in a straight y move...
Question on the loop gain... I have metric screws and the 1010-4 cards. In another post, I was told 595. In the manual that came with my machine, it says 595, but doesn't specify metric screws. In my service program from TA,2 it says 302 for metric screws. In the newer manual I downloaded it says 302 for metric screws. What is the correct setting? It cuts fine either way. It thumps less when it is set to 595, though.

Thanks,

[alex gitzel]

The dc motors with metric screws are tuned to 302 and 595 for inch screws,program this and test(m49 g1 g8 g90 x-5.y-5.z-5.f150. x0y0z0 m99p2).the clock card should be tuned for speed,and the sine/cosine should also be tuned.if the motors are ok.I would dig in to the motors first if you are cutting a circle flats in line with x+y that is backlash issues.If there are bumps along the rest of the arc that is motor/resolver related,most commonly the resolver.pull the resolvers off are see if there is any bearing play on them,if one is questionable swap it with z axis if that does not work swap the entire motor,if you are not doing any small rigid tapping the z performance is not that important anyway.you may also want to swap amps around.also make sure the machine is level+square.

[Neal]

The DC motors should be tuned to 595 and NOT 302. I know some manuals say deifferent. They are wrong. The smaller the follwing error number the shaper the motor is. A weak motor or amplifier can adversley react too tight a gain setting.

Neal

[Delw]

if you tune your metric screws to 595 let me know if it will rapid at 100% I am betting it wont as mine didnt. once I tuned them back to 302 I had 100% rapid again.

I will say the machine ran much smoother at 595 no thumping or bumping when running the other direction. it holds size and finish is perfect at 302 just a tad noisier.

if you do tune them at the 595 please let me know if your rapid works at 100%

Delw

[mniadna]

Delw,
You are correct. The machine will not rapid at 100%. It will make it about 5 inches at 100%, then cut back to 50%

[Delw]

What year machine do you have? mine makes it a few inchs than kicks out the servos like you pushed the "E" stop button.
Mines a 95 with a -5 system in it, I have the same 1010-4 cards.
3 new resolvers one new motor and the tachs are cleaned and one is replaced.

I been thinking about upgrading the software here fairly quickly to see if that helps

Just out of curiosity can you do a g02 or g03 and move a z move on the same line? Helical interpulation? mine cuts out giveing a motor overload #12 error( think its the #12)

Delw

[mniadna]

Mine is a 1994. I'm not sure what you mean by "-5 system"... Nope. My machine keeps running. It just kicks the rapid down to 50%. All I did to test this was jog to the negative end of X and run G0X19. My machine also does helical interpolation fine. I don't have many run hours on the machine, since I got it together, but I have cut several pockets spiraling in. This uses the same type code. I have 2 rebuilt servos and am working on the 3rd now. I just put a new resolver on Y and ordered one for X today(trying to fix my interpolation blips). It never errored out with the old servos and resolvers. I started doing the motors because one had bearing noise, and another was eating brushes. My Z servo tach only puts out 6V@1000rpm and everything still works fine. I bought a new tach for that motor, because I read somewhere that it had to be within 10% of 7V, but never installed it, because 6V seems to be okay. Isn't Error #12 resolver related?

[Delw]

Originally Posted by mniadna Mine is a 1994. I'm not sure what you mean by "-5 system"... Nope. My machine keeps running. It just kicks the rapid down to 50%. All I did to test this was jog to the negative end of X and run G0X19. My machine also does helical interpolation fine. I don't have many run hours on the machine, since I got it together, but I have cut several pockets spiraling in. This uses the same type code. I have 2 rebuilt servos and am working on the 3rd now. I just put a new resolver on Y and ordered one for X today(trying to fix my interpolation blips). It never errored out with the old servos and resolvers. I started doing the motors because one had bearing noise, and another was eating brushes. My Z servo tach only puts out 6V@1000rpm and everything still works fine. I bought a new tach for that motor, because I read somewhere that it had to be within 10% of 7V, but never installed it, because 6V seems to be okay. Isn't Error #12 resolver related?

Motor overload #12 is a checksum error.
-5 system from the way I understand it is the newer version of the motherboard and cpu ?

do you know what software your boards are running?
That rapid kicking down to 50% is pretty wild. Mine just dies LOL
if you dont mind I would like to hook up on the phone or email someday and compare notes on parameters
I havent checked the voltage on the tach, but what I do know about them is if they get dirty they really play with the finish, acroloc (using gettys motors) was extreamly bad for this. I noticed mine was bad when I was tuning the drive as I couldnt keep the numbers from flucuation less than 30-40 points on the one axis. the othere were with in a few points.


Delw

[mniadna]

My CPU board has a -4 on it. The chip on my axis card says:
ELE- 0179
V90.8P

Send me a PM and I give you my email addy.