Does the graph stay like a Z. Well I have just done everything again and hre is what happened.

First went to MDI screen and entered various S values see below.
S1000   0RPM
S1500   417RPM
2000     815
2200     966
2400     1133
2600     1292
2800     1441
3000     4994
S0        0      I should have left things like that, but read on.

Selected spindle calibration
Calibration screen blank, as usual.  P0.25 I1.0 D0.3
Pulses/rev 1,  Control 50 RPM 0, No1 pulley Control ratio  0.0441

select autocalibrate  control 100RPM control ratio1.000

A 45deg yellow line drawn across calib screen. Blue line drawn swooping down and curving to gradually meet 30deg yellow line.
control shows 3000 rpm jumping 1000 to 5000 but spindle on high speed.
Window says successful test-save results  YES
Spindle switched off and Mach rebooted.

Again selected auto-calibate.
Control   RPM
200        0
210       0
240       0
270      0
300      0
330      0
360      0
420      0
450      100
480      102
570      400
lost track, figues increasing too quickly to record.
Saved result after which dro showed control 3000 5010RPM
Clicked 'update PID'  nothing happened.
Going back to main screen Status bar said 'Too fast for pulley - using Max'
Rebooted Mach.
On MDI entered M3,S10 and got immediately top revs
rebooted Mach
On MDI screen M3 S100 1330RPM
s150    5027RPM
S50     5027RPM
S0       5027RPM
M5      0RPM

Thoughts on all this?!
tmsmith

OK, we first need to back up  little. I take it you have multi pulleys. Set the pulley combination that gives a 1:1 ratio. Next what is the top rpm for your motor 3600?.

With the pulleys set to 1:1(same size pulley on both sides) and a top rpm of 3600, you should see 3600RPM at the spindle when s3600 is set. I believe the ratio you see in the pulley setting is for gear box drives like a BP it should be set to 1 for this test. set the low rpm for 100 and the top rpm for 3600.

Now try the recalibrate again.  If all goes well then try the S100 and s3600 it should be close. If it is close then you will need to setup your different pulley settings for mach to follow.

I believe the graph should be faily linear in form. If not we may have to drag Art into this conversation

(;-) TP

HI Vmax, thanks for your continued interest and help. I would love to get this sorted.

Right - I have only a single pair of pulleys so no flexibility there.
Motor speed is 3000revs on the case but that is at 80volts. It is actually being run at 130volts so really I have no idea what its top speed is.
The pulley step down the speed in a 2:1 ratio.
So now I am uncertain. should I set all 4 ratios to the same value.
I also wonder why the pulses per rev which is 1 in the box on the calibration screen cannot be altered when it says a zero should be entered for 1 pulse /rev.
I have still got three of the 4 slots taped over so 1 pulse /rev.

tmsmith

Just had another play around and in the spindle calibrate screen 'control' box appeared   -1.#IND.
I am sure I have seen this before as well.

I wonder if some of my files are corrupt and this is causing my problems.
\anyone know which file controls spindle calibration?

tmsmith

OK the Mrpm@80v=3000, @.026v/rev , then 130v=5000rpm. I am not sure I would run the motor at that speed for long.?? You can always adjust the span voltage on the digispeed to limit the top rpm on the motor

If you have a 2:1 stepdown ratio (largest pulley on the spindle)then at the rated rpm of 3000 then you have a spindle rpm of 1500rpm

you set the pulley speed at 100 low 1500 top at a base of 5.75% that should give you a low speed of 100rpm min and limit you to 1500 top rpm. s100-s1500

Since you only have one pulley ratio  you only need to set 1 pulley setup

First you probably need to download a fresh copy of mach and do an install to clear up any possible problem there. Make sure you save a copy of the xml file as a backup. also if you are using a screenset other than 1024 then back it up also. then reinstall mach. I will find my manual on the speed controller and double check the digispeed manual and the mach manual and we will start from scratch.

YOu can only use 1 pulse per rev with the index option. for multi pulse you have to use the timing option. Lets stick with 1 pulse for now until we get that working ok. YOu really only need the multi pulses if you are going to run the spindle under pid control it gives it more signals per rev to work with. Can be a real pain to set up if you are not familar with pid tuning.
(;-) TP

I spent more time on the problem today but no improvement.
Reinstalled Mach3 v2.076 but that was no cure.

My actual speed reduction is 3000rpm motor to 2000rpm spindle.
At one stage today if I increased the S value the spindle revs went down and then at higher S values they started to climb again!!!.
I tried every combination of settings but no joy.
The actual calibration sequence/result appears to be the problem but other factors are probably effecting that.
For example entering the min(start) revs in the calibration window. Sometimes when the window is opened it shows the last Svalue I had used on the MDI screen.
Other times it showed zero and would not let me alter it. other times it showed -1.#IND.
Sometimes it stepped up the Revs setting at 20Revs per step, other times 50revs per step.
The graphs drawn were variable and at the start the graph was always blank apart from the axis names.
On pressing calibrate a line would be drawn usually coming from some high off scale value on the left and oscillate towards the target line which was sometimes 45deg and other times lower.
Sometimes a stright horizontal line was drawn  at 5000rpm and the figure in the start revs DRO was 5000.

All very frustrating.
Could my high setting of 5000revs be the cause of the revs suddenly taking off above 3000rpm; I will check that tomorrow.

Cheers
tmsmith

Lets try something different. Remove MACH by using the control panel and remove the program entirely(WINDOWS remove program)

. Now do a fresh install and DO NOT RUN SPINDLE CALIBRATION.(;-) Next make sure all the setup has been done according to the Digispeed manual as far a setting up the digispeed in MACH.

 Next setup the spindlepulleys page. Then try the S100 s2000 and see what happens. Remember DO NOT RUN THE SPINDLE CALIBRATION(;-)

(;-) TP

Vmax,
Some success at last

Removed Mach3 via control panel.
Downloaded latest version - 2.0.080 and installed it.
It had retained my .xml file so checked settings OK.
Set pulley #1  100 and 2000, left ratio?? at 1.
No spindle calibration carried out.
Config pins set for index and one untaped slot on spindle disk.

I'll give you the results of using MDI unput.

   S      RPM (indicated)
  300    0
  400    187
  500    503
  600   807
 700    1112
  800   1421
  900   1723
  1000   2026
  1100   2336
  1200   2635
  1300   2935
  1400   3241
  1500   3542
  1600   3837
  1700   4150
  1800   4454
  1900   4730
  2000   5000 +/_10
  400     188

Apart from a dip at s400 these readings lie on a straight line.
Obviously the spindle calibration should bring the slope of the graph to 45 deg.

Thoughts on this success??

Malcolm

Getting there, Look at the spindle setup in mach and see if the PWMbase is set for 50 and min pwm=0

I am assuming here that you are running with PWM control not step/direction???

For some reason the output from the digispeed is not linear. At 500 rpm it is correct and progrssively gets further from control point as commanded speed is increased. The error doubles as the speed doubles??

 How about emailing Peter and send him your notes on this test and see what he says.

Is the forward / reverse control still working?

Vmax,
Yes I am using PWM and M3 M4 still working as they should.

PWMbase is 50 but I have the minPWM set at 10% - I will try that at 0% tomorrow.

Good idea including Peter I will do that.

thanks,
 Malcolm