IHSS60-36-30 motor tuning/issues

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26 Jul 2022 09:28 #248308 by ddB0515
Hello

I have question regarding motor tuning, did go trough numerous threads how to tune motors but didn't get too much information for it (due to different motor types)

I have same setup for all 3 axis/motors (IHSS60-36-30) (here is INI for one of them)
#******************************************
[AXIS_X]
MAX_VELOCITY = 166.666666667
MAX_ACCELERATION = 1000
MIN_LIMIT = -0.01
MAX_LIMIT = 500

[JOINT_0]
TYPE = LINEAR
HOME = 0.0
FERROR = 10.0
MIN_FERROR = 1.0
MAX_VELOCITY = 166.666666667
MAX_ACCELERATION = 1000.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 180
STEPGEN_MAXACCEL = 1500.000
# these are in nanoseconds
DIRSETUP   = 3000
DIRHOLD    = 3000
STEPLEN    = 3000
STEPSPACE  = 3000
STEP_SCALE = 640.0
# Homing Setup 
MIN_LIMIT = -0.01
MAX_LIMIT = 500
HOME_OFFSET = -0.500
HOME_SEARCH_VEL = -10.000
HOME_LATCH_VEL = 0.500
### HOME_SEARCH_VEL = 0
### HOME_LATCH_VEL = 0
HOME_FINAL_VEL = 0.500
HOME_USE_INDEX = NO
HOME_SEQUENCE = 1
HOME_IGNORE_LIMITS = YES
#******************************************

Motor switches are set to micro stepping 3200 (SW1-4) JMC manual  page 12
SW1  -  OFF
SW2  -  OFF
SW3  -  ON
SW4  -  ON
SW5  -  ON    (this was recommended to be ON)
SW6  -  OFF   (CW/CCW)

I have ordered dial indicator that can do 1inch for testing but till then I' looking how to improve this as much as I can

If you take a look on image
 
This is current values from milled example, RED values are measured via kaliper 
Big circles should be 20mm but measured are 18.88mm
Small circle in left corner should be 10mm but is 8.88mm
And square should be 30mm but it is 28.88mm

Not sure if this is step slipping or something else so any suggestion is more then welcome :)
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26 Jul 2022 13:43 #248324 by tommylight
From what you describe, the tool compensation is on.

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26 Jul 2022 14:34 #248332 by ddB0515
I have checked Gcode and didn't find any G41/42 in so I don't think so that is the case :(

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26 Jul 2022 16:34 #248347 by Todd Zuercher
Backlash?

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26 Jul 2022 16:40 #248350 by ddB0515
Was thinking the same but even if I push hard head in XY direction with dial I have (0.01mm/range 1mm) moves for a max 0.1 so that is not likely that is the problem :(

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26 Jul 2022 16:57 #248352 by tommylight

 
Big circles should be 20mm but measured are 18.88mm
Small circle in left corner should be 10mm but is 8.88mm
And square should be 30mm but it is 28.88mm

Did you check for tool compensation in LinuxCNC and in CAM software.
Screenshot of the path in LinuxCNC? What dimensions does it show there?
Pictures of the cut part?

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26 Jul 2022 17:40 - 26 Jul 2022 17:52 #248356 by scotth
Look at actual tool diameter and compare it to tool diameter in CAM program.
Spindle run out will also cause a size problem.
Last edit: 26 Jul 2022 17:52 by scotth.

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26 Jul 2022 22:35 #248375 by ddB0515
So here is image with all important settingsTool I'm using is 5mm flat mill 3 flute (and is brand new, few cuts so wear is out of questions)I didn't see compensation at all in settings and Gcode there is no G41/42 so that is off also 
Attached milled part 
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29 Jul 2022 12:49 #248618 by GuiHue
I know this sounds a bit wild/ like a longshot, but having measured ALL the dimensions at 1.12mm off, I would questions my metrology (if cutter comp, stock to leave and tooldiameter are ruled out).
Any scaling or ballscrew error in an axis should not result in the same absolute error over different distances. You mentioned that the square is off, are both of by 1.12mm? Some questions for the circles: Are they off the same way across both main axis (xy)?
The attached part looks ok, albeit the spindle trim may be off a bit and the cut shows some vibration.
Do you have a known 10mm reference (and be it an endmill) - does that truly measure around 10.00 with the same caliper? It got tricked by an offset caliper before, hence my question...

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29 Jul 2022 15:29 #248621 by P1-Engineering
Share the settings for the 2d contour.
2d pocket is for roughing out the pocket. Finishing to size should be done with a 2d contour toolpath.
Since the difference is the same everywhere I expect a CAM issue.

Oher question, depth of the pocket, what was the difference there?.

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