motion error while standing still

[Montabelli]

I decided to switch my motion master to torque mode with cam soft, I rewired every thing and have been preparing to check the motors out and see if ever thing is OK, my y axis ran away, so I switched the invert encoder box to off it doesn't do any thing there but give me motion errors, if I clear the fault it just pops another back up, with no motion. I unplugged the encoder pass through cable in case something toward the computer was the problem, no change. suppose my encoders is toast?

I also have a problem connecting to the drive with gd tool. it frequently gives me an error message ready for firmware update.

[Xerxes]

Hi,

Please post the saved GDtool .drc settings so I can check it. I think you may have low value in motion fault threshold. Please set it to 0 to disable it completely (and re-enable if necessary as last step of setup).

Drive goes into FW update mode if certain CMD connector input pins are in certain digital state during drive power up. To avoid this, please ensure that nothing is plugged in CMD connector when configuring.

[Montabelli]

I was able to get a test out of the system and the motor passed. i went ahead and powered up under cam soft and x and z jogged ok, I think i'll have some tuning issues to content with, buy the y would lurch and moe back to position and I got excessive position errors. I think I'll double check all my wiring tomorrow and if that is all ok, I think I'll swap out encoders and try another.


<!DOCTYPE VSD_ML>
<Setup>
<CFG_MOTOR_MODE Current="1" Type="uint16" />
<CFG_RECOVERY_SPEED Current="200" Type="uint16" />
<CFG_DEFAULT_CONTROL_MODE Current="3" Type="uint16" />
<CFG_FERROR_TRIP Current="1000" Type="uint16" />
<CFG_MULTIPLIER Current="50" Type="uint16" />
<CFG_DIVIDER Current="50" Type="uint16" />
<CFG_PULSE_MODE Current="0" Type="uint16" />
<CFG_ABS_IN_OFFSET Current="1638" Type="uint16" />
<CFG_DRIVE_FLAGS Current="8" Type="uint16" />
<CFG_MOTION_FAULT_THRESHOLD Current="2000" Type="uint16" />
<CFG_VEL_I Current="2000" Type="uint16" />
<CFG_POS_P Current="10" Type="uint16" />
<CFG_VEL_P Current="10000" Type="uint16" />
<CFG_AD_VEL_I Current="10158" Type="uint16" />
<CFG_AD_POS_P Current="19988" Type="uint16" />
<CFG_AD_VEL_P Current="10158" Type="uint16" />
<CFG_VEL_FF Current="100" Type="uint16" />
<CFG_ACC_FF Current="10" Type="uint16" />
<CFG_AD_LIM Current="1" Type="uint16" />
<CFG_TORQ_P Current="1000" Type="uint16" />
<CFG_TORQ_I Current="1000" Type="uint16" />
<CFG_TORQUELIMIT_PEAK Current="14000" Type="uint16" />
<CFG_TORQUELIMIT_CONT Current="13000" Type="uint16" />
<CFG_TORQUELIMIT_HOMING Current="2000" Type="uint16" />
<CFG_TORQUELIMIT_FAULT Current="15000" Type="uint16" />
<CFG_ENCODER_PPR Current="2500" Type="uint16" />
<CFG_MOTOR_POLEPAIRS Current="4" Type="uint16" />
<CFG_PHASESEARCH_VOLTAGE_SLOPE Current="1000" Type="uint16" />
<CFG_PHASESEARCH_CURRENT Current="5000" Type="uint16" />
<CFG_THERMAL_TIMECONSTANT Current="900" Type="uint16" />
<CFG_TRAJ_PLANNER_ACCEL Current="50" Type="uint16" />
<CFG_TRAJ_PLANNER_VEL Current="6700" Type="uint16" />
<CFG_TRAJ_PLANNER_HOMING_VEL Current="200" Type="uint16" />
<CFG_TRAJ_PLANNER_HOMING_ACCEL Current="10" Type="uint16" />
<CFG_TRAJ_PLANNER_HOMING_BITS Current="7" Type="uint16" />
<CFG_TRAJ_PLANNER_HOMING_HARD_STOP_THRESHOLD Current="500" Type="uint16" />
<CFG_TRAJ_PLANNER_HOMING_OFFSET_LO Current="0" Type="uint16" />
<CFG_TRAJ_PLANNER_HOMING_OFFSET_HI Current="0" Type="uint16" />
<CFG_ABSPOSITION_HI_LIMIT_HI Current="0" Type="uint16" />
<CFG_ABSPOSITION_HI_LIMIT_LO Current="0" Type="uint16" />
<CFG_ABSPOSITION_LO_LIMIT_HI Current="0" Type="uint16" />
<CFG_ABSPOSITION_LO_LIMIT_LO Current="0" Type="uint16" />
<CFG_TORQUE_LPF_BANDWIDTH Current="3" Type="uint16" />
<CFG_VELOCITY_FERROR_TRIP Current="200" Type="uint16" />
<RUNTIME_CAPTURE_SOURCE Current="0" Type="uint16" />
<RUNTIME_CAPTURE_SOURCE_2 Current="0" Type="uint16" />
<RUNTIME_CAPTURE_TRIGGER Current="0" Type="uint16" />
<RUNTIME_CAPTURE_SAMPLERATE Current="0" Type="uint16" />
<RUNTIME_CAPTURE_BUF_LENGHT Current="2000" Type="uint16" />
<RUNTIME_FAULTBITS Current="64" Type="uint16" />
<RUNTIME_STATUSBITS Current="1077" Type="uint16" />
<RUNTIME_CONTROL_MODE Current="3" Type="uint16" />
<RUNTIME_INPUT_WATCHDOG Current="0" Type="uint16" />
<RUNTIME_BUS_VOLTAGE_SCALE_100V Current="14674" Type="uint16" />
<RUNTIME_CURRENT_SCALE_1A Current="662" Type="uint16" />
<RUNTIME_RETURN_PARAMETER_TYPE Current="0" Type="uint16" />
<RUNTIME_FEATURES1 Current="1599" Type="uint16" />
<RUNTIME_FIRMWARE_VERSION Current="208" Type="uint16" />
<RUNTIME_DEVICE_TYPE Current="270" Type="uint16" />
<RUNTIME_OVERRIDE_COMMUTATION_ANGLE Current="0" Type="uint16" />
<RUNTIME_DEBUGPARAM1 Current="0" Type="uint16" />
<CFG_OPTO_OUT1_SOURCE Current="21" Type="uint16" />
<CFG_OPTO_OUT2_SOURCE Current="24" Type="uint16" />
<CFG_DISABLE_IN_SOURCE Current="2" Type="uint16" />
<CFG_CLEAR_FAULTS_EDGESOURCE Current="3" Type="uint16" />
<CFG_START_HOMING_EDGESOURCE Current="240" Type="uint16" />
<CFG_STAT_USER_BIT_SOURCE Current="240" Type="uint16" />
<CFG_HV_VOLTAGE_LOW_LIMIT Current="1000" Type="uint16" />
<CFG_HV_VOLTAGE_LIMIT Current="15000" Type="uint16" />
</Setup>

[Xerxes]

Thanks!

Before all, try using drive in velocity mode instead of torque. It usually gives more stable operation in overall as drive has more control of motor.

Also try following changes:
-Set AC phasing current to 10000
-Set motion fault treshold to 0
-Try increasing Pos P gain (if using position mode)
-Set accel & vel feedforwards to 0
-Set anti-dither region to 0

[Montabelli]

Yesterday was so much fun... It is always a joy when your electronics decide to give you a lesson in humility whether you need it or not.

the drive I have been using on the y axis was finally giving me an encoder error message, so I swaped out motors and got the same kind of error messages ... 30 encoder counts over 4 poles. I swapped out the drive and the motor tested good but now when I power up the drives, the z starts a slow decent, then a little later the x started doing the same thing. I have never enabled the homing but it appears to be what is going on. I can physically grab the z axis and stop it from moving, so I assueme this is the home to hard stop sequence.

the next question is, if I have a smart motion control card (galil) and smart amplifiers(vsd-xe), should I dumb down the motion card or the amp,

[Montabelli]

I turned off the pid in cam-soft and the war that was going on between the soft ware and the vsd-xe subsided.

[Al_The_Man]

Basically Galil will run with non-intelligent drives with ±10vdc analogue control in the torque mode, the PID loop is then closed back to Galil.
Al.

[Montabelli]

OK, got it sorted out, I think I have 1 bad drive or somehow I messed up the firmware I don't know, but I think i did it when I first was setting up the machine. when I switched the set up to run by analog signal, I manage to reverse the command wires for the analog signal, love that ribbon cable, and that was the cause of the runaways now all axes are under control, a bit more tuning and I think I'll be running again. thanks for the help. I also learned that with the pid segments zeroed out, there is no analog signal from the galil card.

perhaps by the time I'm 112, I'll figure some of this stuff out.

[Montabelli]

Xerxes,
1) I have all the drives in velocity mode, when I have the input from the galil card disconnected so I can run gd tool, the drives are all drifting toward the end of the axis, I can stop them by grabbing the axis and holding it. once I stop the z it will stay, the x and y just keep drifting.
2) since the galil card must have pid settings to produce an analog signal, what would you recommended as the velocity settings to keep the two intelligent systems from fighting each other, currently, the axes will all jog under control but will get in an oscillating mode. I currently have the camsoft settings as low as they can go and I am getting less oscillation, but I haven't started cutting any thing yet so I'm not sure where I might need to change things out to make it work. what would be the lowest settings I( could use in the vsd-xe drives?
3) If there is somehow a problem in the firm ware in my drive that is misbehaving, might I be able to upload the firm ware for the dual dc servo control and see if that makes it work again? I have a lathe that I can use 2 axis control on.

[Xerxes]

I think some problems may be explained by following reason when using AC motor with Hall sensors disabled:
-Gravity pull of axis when not powered
-Axis colliding at travel limit during power-up

If yes, then you will need to wire & enable hall sensors. The hall-sensorless mode may fail if motor cannot move freely in both ways little bit during power on (and will cause tuning issues & follow errors).

1) This is caused by a small analog offset and its typical in analog velocity mode (not only our drives). Smallest voltage measured at command input will cause motor to drift.

2) This is difficult topic of the machine has high stiffness. If not, then both motors may operate almost independently without getting affected by other's operation. In high stiffness machine you may need to reduce gains to make system less stiff to avoid fighting.

3) Drive internally checks firmware integrity, so its very unlikely that it's corrupted. You may try DualDC for DC motors, which is also easier to configure than single axis firmware.