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  1. #161
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    I got home and the Y axis wouldn't even jog over and back without error. The Z and X passes the cycle 50 test.

    I poked around and noticed that I had knocked the ground off off the motor PS. Hooked it up, all axis passed the cycle50 test.

    I did a test cut (air) of the Aztec center test file and for the first time ever everything returned to zero after the job.

    Running more test now, but is it really possible that the reload did in fact fixed it and the missin ground caused the confusion?

    I for one am hoping so at the moment.

    More later.

    BobL.

  2. #162
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    Ok, two more test runs and those were off. This time the Z ended up above zero after the jobs and it used to end up below it. It was off a fair ammount, but not as much as it was before, but at this point I don't know what means something and what doesn't.

    Looks like I'll probably be moving things to the (as yet to be built) new control box and go from there.

    BobL.

  3. #163
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    Bob,
    I have not been getting updates to this thread. :-(
    Things sure have be causing you to go in a circle.
    With any luck soon you will sort it out.
    Other than good thoughts all I can offer is to divide and conquer.
    You have too many variables right now IMHO.
    Try separating the electronics from the machine or the motion controller from the system.

    You have too many levels of possible problems.
    Sounds like you are still missing motion.

    Something really simple like setting the motors up on bench with some flags and see if you have the problem there.

    I will try to stay tuned better.

    Dave

  4. #164
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    Control Box II

    I reached the same conclusion that Dave pointed out, which is that I had too much going on. The clincher was that I was spending way too much time doinking with a control box that was not permanent.

    I scrambled to come up with something using the resources available and came up with the idea to use a pair of used PC cases. One the Power Side housing the power supply, contactor, etc. The other one for the logic boards.

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    My first thought was to use a piece of plywood as a panel between them. This would make mounting everything easy and provide support to the stripped cases. For electical isolatioin between the two sides I veneered the plywood with aluminum flashing.

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    I quickly decided this would not allow me as much access as I wanted and I just didn't like it. So I just pushed the two stripped PC cases together and called it a Case The front panel is a kick plate used for protecting doors and picked up at the big box store. Both panels came from one kick plate and I resused the original mounitng holes. That is my Super PID poking though. I decided to mount it on the power side rather than the logic side.

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    The right side with the Power Supply will be mounted to the base. Access will only be available by removing the side panel.

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    On the logic side easy access can be gained by simply removing the side panel. Plus the case itself can be easily removed for full access. Part of the rear of the case is left behind and is where the cables will enter.

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    So anyhow, what do ya'll think of this plan? Thanks for looking.

    BobL.

  5. #165
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    Bob,
    That looks great.
    I think the ability to remove the case and not have to remove cables is a good idea. It will speed up install and debugging.
    I hope you slay the dragon soon.
    Dave

  6. #166
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    Thanks Dave. Yeah, I think it will work out alright as long as I can get everything in on the back wall.

    I am working towards getting movement before adding too many things. Should make trouble shooting much easier if necessary, but I'm hoping this will not require trouble shooting

    Edit: It's a little hard to see but the Eth. Smooth Stepper is mounted to the PMDX board, so it's in there already.

    BobL.

  7. #167
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    I am glad your Ethernet SS is working for you.
    I doubt I will buy another SS product after my experience. :-(

  8. #168
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    More Progress :)

    I've been under the weather this weekend but I did go out and take some pictures of where I'm at. Some of these may not look much different than the last ones but a lot of work was done.

    The other pics were mock-ups so I could figure out what kind of structure I needed. I re-purposed parts of the original case to make the mount for the front panel. The case on that side still slips off easily. So these are final config pics on the way towards the day I start wiring.

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    I made mounting space for another pair of gekos. When and if I can ever get to the fourth axis stage I will go with gekos for ease and simplicity.

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    I think this case is gonna work out pretty good. I wanted a lot of access and this case provides it without having to remove any wires, connectors or the front panel.

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    BobL.

  9. #169
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    Bob,
    That is looking very nice. It looks like you are making great progress. I like the way you have taken into account ongoing modification and maintenance.
    Looking forward to seeing some wires connected soon. ;-)
    Dave

  10. #170
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    Thanks Dave. I appreciate you posting just to know someone is reading this.

    I don't know whether to do just the bare minimum wiring to get some movement so I can see if the problem still exists or not. After everything I've been through I sure would like some confirmation the direction I'm going is Forward !

    Still lots of things to do before I start final wiring. Mounted another terminal strip for 5 and 12 volt feed through from the power side and (crudely) mounted the RJ-45 panel jack for the Smooth Stepper.

    I need to finish the mounting of the Super-PID and mount the Power Supplies.

    On the plus side I don't think there is much in the way of design considerations to slow me down. Those are done and hopefully will pan out and the rest of the control box assembly will be smooth.

    BobL.

  11. #171
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    Bob,
    I guess its how confident you are in your solution working? ;-)
    I would approach this very systematically since you had issues before and work step by step verifying that things work bit buy bit. Its a fairly complex system and you need to identify the root cause of your failure and ensure it is resolved.
    Peel the onion.
    Dave

  12. #172
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    If it were me, I'd set up one axis at a time and verify that it's working correctly before going any further.
    Gerry

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  13. #173
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    Quote Originally Posted by dfmiller View Post
    Bob,
    I guess its how confident you are in your solution working? ;-)
    Its a fairly complex system and you need to identify the root cause of your failure and ensure it is resolved.
    Peel the onion.
    Dave
    I don't know about how confident I am about the 'solution working', but I am confident I am removing lots of potential for problems and will end up with a much cleaner install, and a smaller parts count. I will have to hope it's enough.


    Quote Originally Posted by ger21 View Post
    If it were me, I'd set up one axis at a time and verify that it's working correctly before going any further.

    As I am running the Geko's via motherboard and ribbon cable arrangement I assume it's OK to run the Geko's without motors attached?

    BobL.

  14. #174
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    Bob,
    You might want to check the manual but I believe you can run without a motor. The big issue I think is connecting or disconnecting a motor when powered up.
    I like Gerrys suggestion
    Dave

  15. #175
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    Almost ready to start wiring

    I got a rare weekend in the shop and am making good progress. I thought I would already be wiring by now, but it was one detail after another that needed to be taken care of.

    Unless I'm missing something I am really stoked about this case setup. It is going together really slick and easy. It just sort of fell together. I think the level of access will be a bonus.

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    The SuperPID speed control is safe behind a lexan window cut into the front panel. The power switch is mounted so the front panel pops off easily. It was very easy to mount some captive nuts for the front panels. There is a piece of angle aluminum at the top used for a heatsink for the SuperPID. It is not touching anything other then the heat sink tab on the SPID.

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    I found a piece of DIN rail to mount the contactor to. I want to order some breakers/fuses to mount on there if I can figure out which ones to order. Some of those ordering pages get mighty confusing when you've never brought this stuff before.

    I mounted a cable carrier purchased from surplus. There's a place local that has all kinds of stuff. A lot of the pieces parts for this case came from there. I'd fill a small paper bag with items and he'd give a price for the lot. You never know what your going to find in this place.

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    The logic side should look great compared to the rats nest of the old one. The RJ-45 connector on the back will feed the Ethernet Smooth Stepper mounted to the PMDX-126. Ribbon cables feed it to the PMDX and power the ESS. Ribbon cable to the 4 main Gekos. That's alot of wiring NOT needing to be done. The terminal blocks will provide power to the PMDX board and the other one will provide DC voltages to the logic ( along with whatever else needs to be routed to the other side.

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    Thanks for looking.
    Feedback welcome.

    BobL.

  16. #176
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    Stil haven't stareted wiring yet, but...

    .. I have cleaned a few things up. I was originally planning on putting the AC for the router on the bottom rear panel on the power side. That's why I originally cut that panel seperate. Anyhow, I decided that with the cable carrier why not put the power outlet to the router where it would work better, so I went to the local H/W store and bought an outlet and installed it.

    Also, since I realized I never posted a pic showing that the logic side is easily removeed I posted a pic showing the full level of access to things.

    Also, I am thinking of re-making the cable support, if I can find that piece of left orver rod around here.

    One more thing, Killian's is tasting goooooood !!

    Comments welcome,


    BobL.

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  17. #177
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    Bob,
    That is looking very nice. I like how you have separated things.
    It will work better once you put some wires in ;-)
    Dave

  18. #178
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    Some wiring done

    Not too many pics today.

    I went ahead and made another cable support bar to provide a little more room where the cables route.

    The wiring shown in the pics provides the ethernet connection to the ESS which supplies the equivalent of 2 PC Parallel Ports to the PMDX via short ribbon cables. The PMDX feeds the 4 main Gekos with another ribbon cable. The Geko motor outputs are fed to the rear panel along with cable for 4 Limit/Home switches. That's actually quite a bit.

    I need to supply 120 VAC to the PMDX, terminal block in place, and route the 50VDC to the Geko motherboard.

    AND, the case still slips on easily

    BobL.

    P.S. Cables are run for two additional Gekos and I've got room for 6 more connectors on the bck panel .

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  19. #179
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    Very nice Bob.
    All your planning is coming together.
    Dave

  20. #180
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    Thanks Dave. Hopefully it will work too

    BobL.

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