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IndustryArena Forum > MetalWorking Machines > Fadal > Fadal bad arc finish
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  1. #1

    Fadal bad arc finish

    Hi friends
    I have two fadal 4020 and many problems
    All of arcs very jerky and i think bad finish
    And angles have stair step finish
    On manual of fadal wirten this problem for motor
    AXIS AMPLIFIER
    COMPENSATION
    SETTING
    And
    CHECK SIN/COS
    SIGNALS USING
    SERVICE TOOL ST48.
    ADJUST IF VARIANCE
    > 0.001V

    But how adjust sin/cos output from clock card?!!
    I checked all 3 axis resolver and tach and very clean
    I check all 3 amplifiers and balance and signal gain adjusted
    I check comp and cl complete cw( not multi turn pot)
    Checked 5vdc & 12v is good
    Checked big blue capacitor and 125vdc output for motor drives
    Adjusted master clock feedrate with r6 pot
    What is the way clock card sin/cos output setting?!!!
    All 3 cuopling is ok and ballscrew rebuild
    Gib belts is ok
    But when interpolating x&y axis bad moving axis and
    I think not sync
    ??

    Please helps
    Thx:

  2. #2
    Join Date
    Sep 2004
    Posts
    148

    Re: Fadal bad arc finish

    Quote Originally Posted by Mhook View Post
    Hi friends
    I have two fadal 4020 and many problems
    All of arcs very jerky and i think bad finish
    And angles have stair step finish
    On manual of fadal wirten this problem for motor
    AXIS AMPLIFIER
    COMPENSATION
    SETTING
    And
    CHECK SIN/COS
    SIGNALS USING
    SERVICE TOOL ST48.
    ADJUST IF VARIANCE
    > 0.001V
    But how adjust sin/cos output from clock card?!!
    I checked all 3 axis resolver and tach and very clean
    I check all 3 amplifiers and balance and signal gain adjusted
    I check comp and cl complete cw( not multi turn pot)
    Checked 5vdc & 12v is good
    Checked big blue capacitor and 125vdc output for motor drives
    Adjusted master clock feedrate with r6 pot
    What is the way clock card sin/cos output setting?!!!
    All 3 cuopling is ok and ballscrew rebuild
    Gib belts is ok
    But when interpolating x&y axis bad moving axis and
    I think not sync
    ??
    Please helps
    Thx:
    Hi Mhook

    I had the same issue
    I had to adjust the clock card to get the correct 72 seconds +1.5/-0.0, after which I had to adjust the following error to 595. That didn't improve the finish.

    I would say it's 95% likely you have a bad resolver(s)

    The resolvers on the X and Y axis were bad, the bearings in the X-axis allowed very large amounts of radial and axial play. I bought some small bearings from McMaster and made housing disks to replace the bearings of the resolvers. That fixed the issue. I bought 2 new resolvers off ebay, which I will replace the fixed resolvers with.

    Pull the resolvers off and check the bearings.

  3. #3
    hi triumph 406
    thanks for your time
    I replace 3 resolver
    also i check 1.75 vac on axis controller cards its fine
    i check resolver bearing very smooth turning and resolver bearing is good
    by the way i replaced with new resolvers on x&y&z motors
    but my problem not solved
    i checked ac ripples on power supply 5,-12,12 and under .02 vac
    i think this problem for droping output voltage on amplifiers
    or bad comp
    and clock card sincos output signal
    all of 15 years with fanuc ,siemens,mitsubishi,heidenhain working i never have problem for arc machining but with
    fadal control i have only problem problem and problems on arcs

  4. #4
    tach feedback
    x 3.4
    y 3.35
    z 3.9
    for 500 rpm on motors

  5. #5
    Join Date
    Sep 2004
    Posts
    148

    Re: Fadal bad arc finish

    Mhook
    sounds like there may be some mechanical issues

    Is it getting adequate lubrication to the ways?
    Gibs correctly adjusted?
    Machine level?

  6. #6
    Hi
    Yes
    Gib adjusted with pulbar .007 mm and ballscrew
    Free moving by hand
    Machine table is level
    All 3 axis bl under 5 value
    Lubrication is ok
    Box way always lubricating

  7. #7
    Join Date
    Jan 2004
    Posts
    3154

    Re: Fadal bad arc finish

    it could be the program.
    Maybe your other controls have built in "short segment smoothing".
    www.integratedmechanical.ca

  8. #8
    Join Date
    Apr 2016
    Posts
    74

    Re: Fadal bad arc finish

    try this, run it at a 45 deg. angle and watch the numbers next to the x and y, they should be the same and a low number.
    if not the servos are not tuned correctly, we usually bring a service tech to fix that, but it fixed the problem your describing.

  9. #9
    Hi JMORLAN
    I dont trying 45deg
    But certainy i check that
    Already i checked following error on 302 & .735 vdc all 3 axis
    425 & 1.04 vdc and 595 & 1.44 vdc on all 3 axis
    But didnt improve arc finish
    I try 45 deg and i tell you
    Thx

  10. #10
    Join Date
    Sep 2004
    Posts
    148

    Re: Fadal bad arc finish

    Quote Originally Posted by Mhook View Post
    Hi JMORLAN
    I dont trying 45deg
    But certainy i check that
    Already i checked following error on 302 & .735 vdc all 3 axis
    425 & 1.04 vdc and 595 & 1.44 vdc on all 3 axis
    But didnt improve arc finish
    I try 45 deg and i tell you
    Thx
    Mhook

    In one of the online Fadal manuals (can't remember which) there's a procedure for setting the following error. For a 4020 it goes from along a diagonal line, I think it was X-10,Y-10,Z-10 TO X10,Y10,Z10 at 100ipm. You run this and set the following error to 595

  11. #11
    Thx triumph 406
    I usually type TA,2 and Service programs upload
    From eprom to memory
    next run program number 5811
    For adjust following error

  12. #12
    CHECK SIN/COS
    SIGNALS USING
    SERVICE TOOL ST48.
    ADJUST IF VARIANCE
    > 0.001V
    Adjust clock card ?!!!

  13. #13
    Join Date
    Sep 2004
    Posts
    148

    Re: Fadal bad arc finish

    Quote Originally Posted by Mhook View Post
    Jmorlan
    I checked 45 deg and all of numbers on display identical x&y
    When i remove power supply and check with oscilloscope on -12 vdc
    ac ripple = .35 vac
    Does it ok?!
    I thinks capacitors destroyed
    Please help
    Thx
    A bad capacitor will be visible, usually swelling of the body or cap

  14. #14
    Join Date
    Apr 2016
    Posts
    74

    Re: Fadal bad arc finish

    This might be something to try, that has caused us issues in the past, have you checked your bellville washers? put a indicator on the toolholder in the spindle and use a pry bar and see if you can move the toolholder, if you can, you need to replace those. your not getting
    any drawbar pull. just a shot..............

  15. #15
    Join Date
    Sep 2004
    Posts
    148

    Re: Fadal bad arc finish

    bad electrolytic capacitors will be visible, either swelling of the body, or swelling of the end of the capacitor.

  16. #16
    CHECK SIN/COS
    SIGNALS USING
    SERVICE TOOL ST48.
    ADJUST IF VARIANCE
    > 0.001V
    Adjust clock card is my dream

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