Size error in X on TL1

[Radian Racing]

Have I seen a thread somewhere about this?
My TL1 (which has been working very hard since new but is only 4 months old) now has something seriously wrong in X Travel.
This morning for no reason on same program as last night it started off with oversize 0.5mm ..... massive error.

I reset the tools and this program is just using two tools cutting and threading.

Then halfway through the day size changes suddenly to cutting undersize by 0.5 mm. Surely toolwear cannot cause undersize cutting. Must be a problem on X travel something loose.

I called Haas they will come look tommorrow since surely something must be wrong. Is there any feedback here on such problem so I can look like I know something tommorrow when the Haas rep is here.?

[CNCRim]

the proximity switch might be loose, but most of the time the X drive servo acting up and need to replace.

[Radian Racing]

Haas Rep came out. Checked mechanical with clock. Did agree there is a problem. Checked ball screw nut. replaced the input card (suppose reading of the encoder). Declared problem solved.

I did make a few parts....on size again but proof would come on Monday when we start to run 100 parts again.

however I have a problem with open loop contorl philosophy on this machine.
Have seen before and also the other day again that moving from IPS to machine can induce a condition where you have indication that the axis are running (digits are counting) but the axis are not moving. This tells me that the Haas control actually thinks that the axis is moving based on the command issued but does not actually measure it.

If the only way in which the axis position display could be changing would be by direct reading of the actual axis position directly from the encoder then this problem could never appear. For me this is a sure cause of problems.

The control must issue commands to move axis and then stop the move based upon actual feedback from encoder and not on assumption how far the axis would have moved. Also I want to see my position display as the direct value from encoder and not some predicted value. Exactly like in the common old DRO where what I see is what I really have and not what is calculated.