Suddenly spindle servo stopped and now only turns in one direction

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30 Jul 2022 09:42 #248666 by anton610
Hello,
I'm using a JMC 1000w Servo motor as a spindle servo with the JASD15002-20B controller from JMC for a year now.
It runs up to max rpm and down to 50rpm (Milling, rigid tapping, ...) without a problem

shop.cnc-technics.de/Integrated-Servo-Mo...-36.html?language=de

A few days ago while a milling job the servo stopped suddenly. Maybe overload or something else, i don't know. 
After that the servo only turns on (run) when i run the spindle with 2500 rpm in linuxcnc, in the reverse direction the servo doesn't turn.


I can run the servo directly (manual) on the controller with every rpm, in normal or reverse direction.

Can that be a linuxcnc or a mesa card problem?
I didin't changed any parameter in linuxcnc.

Many thanks!
BR Anton

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30 Jul 2022 15:00 #248672 by PCW
How are the spindle speed and direction controlled?

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30 Jul 2022 15:37 - 30 Jul 2022 15:41 #248679 by anton610
Hello,
thanks for the reply.

The spindle is controlled throu pos and dir of the mesa card.
I have a belt drive with 1:1,64 ratio
here is my Spindle section .ini:


[SPINDLE_0]
MAX_VELOCITY = 8000
# MAX_VEL = Umdrehungen geteilt durch 60 8235/60 = 137.254901 (8235U ist die Übersetung bei 5000U 56 Zähne zu 34 Zähnen)
MAX_ACCELERATION = 2000
# 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 = 10000
STEPGEN_MAXACCEL = 2500
P = 5000.0
I = 0.0
D = 0.0
FF0 = 0.0
FF1 = 1.0
FF2 = 0.0
BIAS = 0.0
DEADBAND = 0.0
MAX_OUTPUT = 500
# these are in nanoseconds
DIRSETUP   = 500
DIRHOLD    = 500
STEPLEN    = 500
STEPSPACE  = 500
STEP_SCALE = 6071.428571428571
# STEP_SCALE = 10000 (Encoderzahl pro Umdrehung) / Übersetzung (56Z zu 34Z = 1,647058823529412)

#---Encoder etc einrichten für orient----
OUTPUT_SCALE    = 101.1904761904762
#Berechnung: 10000/60 (Stepscale)Encoderimpulse pro Umdrehung durch 60 = Impulse pro Sek
ENCODER_SCALE   = 6071.428571428571
ACCELERATION    = 2000
MAX_ERROR        = 0.2
OFF_DELAY       = 1.5


I can controll the speed also throu the gmocappy Spindle speed beam but the spindle starts only at approx 2500rpm then i can go down with the beam % to nearly 1 rpm but the spindle speed on gmocappy shows ~2100.
Rotate in reverse is not possible.

the strange thing is, that before the milling job everything worked flawless.

Many thanks!
BR
Anton

 
Last edit: 30 Jul 2022 15:41 by anton610.

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30 Jul 2022 19:20 #248689 by PCW
Those PID settings look fairly crazy to me...

Can you post the hal file?

Is encoder feedback being used?

For a normal velocity mode step/dir driven spindle (open loop) I would expect
PID values of all 0 except FF0=1 (and a low P value)

Also you might try doubling the step times, 500 ns is quite short for most hardware
The following user(s) said Thank You: anton610

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30 Jul 2022 21:37 #248695 by anton610
Hello Peter,
thanks!

Here is my hal file.

Yes i use encoder feedback for rigit tapping (index with sensor on the spindle)

BR
Anton
Attachments:

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30 Jul 2022 23:59 #248703 by PCW
OK so that's a complex spindle configuration with position mode for spindle orientation

So if this did work and nothing has changed settings wise, it might
be a good ides to verify the step/dir signals. SInce you say the spindle
will not run in reverse, I would verify that the DIR signal from the 7I76E
is valid at the drive connector.

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31 Jul 2022 07:23 #248708 by tommylight
I would check the drive firts, it all points to the drive stopping due to power surge or overload and reseting settings.

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31 Jul 2022 15:37 #248736 by PCW
Yeah, I also had that feeling (that perhaps drive settings were lost somehow)

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31 Jul 2022 19:04 #248745 by anton610
Hello, Thanks for the inputs!

now I'm a little bit nearer the finish.

I also think that the drive settings are gone. Before i get 1rpm - 8000rpm with the setting in the .ini above.

Now when i go up with the step times (850) the servo is working, but i get an error message:
maxvel is too big for current step timings & position-scale, clipping to max possible
and i didn't get the max speed out of the motor. Only approx. 3500rpm

Thanks!

best regards
Anton
 

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31 Jul 2022 19:36 #248746 by andypugh

Now when i go up with the step times (850) the servo is working, but i get an error message:
maxvel is too big for current step timings & position-scale, clipping to max possible

That's LinuxCNC settings, not drive settings, though. 

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