Getting rid of the update service virus on WIN-XP has solved my problem.? No annoying pop-up and probably no annoying trying to call home to see if WIN-XP is legal.

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Now even after 24 hours in a cold shop, the homing of Z right after power up does not fail.?? I can tell the oil is bit cold from the sound of the machine but that problem is solved.

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Now I'd like to get back to addressing something that is very annoying.?

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I have the "Charge Pump ON during ESTOP" which keeps my PMDX-126 active and the relay closed that completes the MASTER Switch circuit through several NC ESTOP mushroom buttons and to the MILL power supply.? Loose Charge Pump or open the ESTOP ?circuit and all power that could move something is removed.? Stop MACH and the Charge Pump vanishes and again Power goes away.

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When the Charge Pump is removed all outputs on the PMDX-126 are also disabled which means DB25-Pin1 that is set as Enable1 output also vanishes.? I'm find with the ESTOP and even the Reset button doing that.

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I'm not happy with the OFFLINE button removing the Charge Pump.? I think the OFFLINE but should switch off the list of Enable_x pins in the "Ports & Pins - Outputs" tab.? Since MACH3 is still running that Charge Pump shouldn't go away.? It's not logical that it does.

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And when I have a Servo Motor fault the only way to clear it is to remove the enable and then put it back.? But if the Charge Pump goes away too then so does the high voltage to the servo which then causes a new fault and therefore the fault is impossible to clear.

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So what do I do with MACH3 and the OFFLINE button so it sets the Enable_x outputs OFF but leaves the Charge Pump alone.

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Essentially I want the RESET and OFFLINE operations swapped.? The RED Reset button gives the appearance of an ESTOP but doesn't behave as one.? The OFFLINE behaves as an ESTOP shutting off Enable1 and opening the external ESTOP circuit.

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Thanks

John Dammeyer

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"ELS! Nothing else works as well for your Lathe"

Automation Artisans Inc.

www dot autoartisans dot com

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Hi Dan,

Thanks for the list.? It's a bit newer than the one I was working off.

My idea that Microsoft learned from VIRUS writers and created their own internal hard to get rid of unwanted programs was reinforced today.

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Most of the stuff in your list I'd already done.? So did the rest and it still popped up the balloon that my system as at risk and needed to be updated etc.?? Even though I removed all the checked boxes in the Startup tab and then rebooted they'd come back.? And I'd done everything on yours and my old list.

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I finally unchecked Security Center.?

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In addition to un-checking this box one also has to run the Services tab in settings and actually stop this service or it will likely check the box again as the system shuts down.? All the behaviour of a virus.

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Now the balloon is gone.? The system appears to start up and I can home Z immediately and there doesn't seem to be an error.? The next few days will tell

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Thanks again

John

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I've sent this again since the link to the jpg was way at the bottom of the message and it may not have shown up for everyone.

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I played around a bit more with the stepper motor speeds.? Fine with jogging up to 35 IPM but a standard G-Code move locks the motor in a heartbeat.? Back to 25 IPM and 2 for acceleration.? 厂颈驳丑…

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John

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Oh and if this jpg attachment works here's the list of Bergerda motors.

The one I have that drives the X axis nicely is the 60SM-M0130MAL at 1.27N.m and 3000 RPM max.

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I think what would work for the knee is the 80SM-M0230MAL with 2.4N.m and 3000 RPM along with the 120T:20T belt drive (6:1)

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Maybe I'll just try the smaller one with 6:1 belt.? Time to go shopping.

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John

Oh and if this jpg attachment works here's the list of Bergerda motors.

The one I have that drives the X axis nicely is the 60SM-M0130MAL at 1.27N.m and 3000 RPM max.

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I think what would work for the knee is the 80SM-M0230MAL with 2.4N.m and 3000 RPM along with the 120T:20T belt drive (6:1)

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Maybe I'll just try the smaller one with 6:1 belt.? Time to go shopping.

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John

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I had a KL34H280-45-8B 4.5 N.m. drive but found I couldn't run it very fast. ?I upgraded it to a? KL34H2120-42-8A which static torque is 8.4 N.m.? But it's all about speed isn't it.

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The math with me thinking out loud is as follows:

0.25" per rev of Z Knee motion (or 4 revs per inch)

3:1 reduction with toothed belt.

Gecko microstepping driver which is 2000 steps per rev or (if it were half steps 400 steps per rev).

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So 2000 * 3 * 4 = 24,000 which is what I have in the MACH motor tuning screen.?

And if it were half steps then 400 * 3 * 4 = 4800 steps per inch.

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Max speed is set to 25 IPM.?

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Work that backwards and it's 10kHz step rate.

Ie. 10,000 steps/second is 600,000 steps per minute (300 RPM).

And 600,000 steps per minute divided by 24,000 steps per inch is 25 inches per minute.

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If it were half steps then it's 2000 steps/second and the torque curve puts that at 4.5 N.m which matches the smaller motor and that I couldn't get that moving past about 12 IPM because then torque fell below 4 N.m.

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This is with both the vise and the rotary table sitting on the X table.?

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The torque on the bigger motor falls off almost linearly so it's one half the torque at 4000 steps per second verses torque at 10000. ?

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The AC Servo I have is 1.27 N.m at 3000 RPM with a much higher peak rating and if it were reduced to 300 RPM I'd have 12.7 N.m or 3x what is needed.? I would really just need to add an extra 3.5:1 to bring it down to about 850 RPM which scales axis speed up now to 70 IPM.

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Or get a bigger servo.? One that is about 2.5 N.m at 2500 RPM and change the reduction from 3:1 to 6:1.? (120T pulley and 20T pulley).

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That gives me 104 IPM with torque at the hand crank shaft at 15 N.m compared to the stepper 13.5 N.m at only 25 IPM.

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Assuming I've done the math correctly.

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So if I want the speed for peck drilling…

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John Dammeyer

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Here is a list of things that you want to check with your OS

Dan Mauch

(This file has been updated to exclude the least effective items)

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NOTE: Before doing ANY optimising, run MAch3 first, odds are you dont need to optimise.

?????? and before optimising, use msconfig to shut off all Startup Items, then reboot.

????????????Killing stratup Items fixed 90% of computers having any troubel with MAch3.

????????????Optimising should NEVER be done priot to knowing a problem exists.

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Windows XP Professional System Optimization Guide:

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0. Install Windows in Standard PC Mode

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1. When you see the installation tell you to press F6 (Third Party

SCSI or RAID Drivers) press F5 instead.

2. You will see Press F2 for Automated System Recovery, (DONT press

F2).

3. Right after that you will see a list.

4. Press the UP arrow key to highlight Standard PC.

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When installing, make SURE you install all of the most recent drivers

for your

Hardware. This is vital!

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6. Disable Automatic Updates

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1. Right Click My Computer and select Properties

2. Click Automatic Updates tab.

3. Uncheck Keep my computer updated..

4. Click OK.

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7. Disable Remote Assistance

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1. Right Click My Computer and select Properties

2. Click Remote tab.

3. Uncheck "Allow Remote Assistance Invitations.".

4. Click OK.

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***? NOte ***

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(The following step shoudl not be done unless all else fails. It is usually only necessary

for laptops that vary their frequency badly, and sometimes fails to help. So skip this unless

everythign else fails to fix any trouble )!!!!!!!!!!!!!!!!!!!!!!!!!

9. Set Computer to Standard PC NOT ACPI PC

NOTE: This is only necessary if you wish to remove ACPI AFTER install.

If you followed step 0, you don't need to do this.

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1. Right Click My Computer and select Properties

2. Click Hardware tab.

3. Click Device Manager Button in the middle.

4. Double click "Computer".

5. Right click on Standard ACPI PC and choose Update Driver.

6. Choose "Install the software from a Specific Location (Advanced)"

7. Click Next.

8. Choose "Don't search. I will choose driver to install."

9. Click Next.

10. Choose "Standard PC" from the listing.

11. Click Next.

12. Click OK.

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****

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11. Disable Startup Items in Registry

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1. Click Start button.

2. Click Run.

3. Type MSCONFIG and press [ENTER].

4. Click Startup tab.

5. Uncheck everything

6. Click OK.

7. Exit MSCONFIG.

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12. Disable Startup Program Group Items in Start Menu

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1. Right click Start button and choose Open.

2. Double click Programs.

3. Double click Startup.

4. Delete anything you think you don't need.

5. Close window.

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16. Set Windows Theme to CLASSIC

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1. Right-click on your desktop, and then click Properties.

2. Click on Themes tab

3. Set Themes to Windows Classic

4. Hit OK

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17. Disable Indexing on all NTFS drives

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1. Double click My Computer.

2. Right click on hard drive and choose Properties.

3. On bottom, uncheck "Allow Indexing Service to index this file for

faster searching". 4. Hit OK.

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18. Run diskperf -n

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1. Click the Start Button.

2. Click Run.

3. Type DISKPERF -N and press [ENTER].

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20. Disable MSN Messenger

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1. Double click on the Messenger icon in the system tray to open it.

2. Skip thru the internet and sign up stuff, just cancel it.

3. When Messenger loads go to Tools -> Options then Preferences.

4. Uncheck 'Run this program when windows starts'

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21. Disable Power Management

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1. Right-click on your desktop, and then click Properties.

2. Click on the Screen Saver tab.

3. Set Screensaver to None.

4. Press the Power button near the bottom.

5. Set all options to NEVER shut down automatically!

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22. Disable Wallpaper

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1. Right-click on your desktop, and then click Properties.

2. Click on the Desktop tab.

3. Where it says Background, scroll all the way up and choose None.

4. Click OK.

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23. Disable System Sounds

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1. Click Start Button.

2. Click Settings.

3. Click Control Panel

4. Double click Sounds and Audio Devices.

5. Click Sounds tab.

6. For Sound Scheme, choose "No Sounds".

7. Click OK.

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25. Install Programs

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Do not install any programs you will not use. Only install programs

that you DEPEND on for what you do on your computer. Keeping things

lean and mean will keep your system fast and stable.

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26. Maintain Hard disk

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1. Double click on My Computer.

2. Right click on Hard Disk and choose Properties.

3. Click Tools tab.

4. For Error Checking click Check Now. Do before Defrag!

5. Click Defragment Now, AFTER Error Checking completes.

6. Click OK.

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The little balloon from Microsoft is a real indication.? Other issues might well be noise. ?The DC Servo supply (105VDC) has a big honking line filter.? The 60V stepper motor supply does not and I've been thinking about adding it.? Or more ideally replace the stepper on the knee with a servo (AC or DC) since I have extra STMBL servo drive kits and the one smaller Bergerda.

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Need to look up what the Automation Technologies stepper motor torque falls off to when I'm doing 25 IPM.? That will tell me what I need for continuous torque from a servo.

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I wanted to keep the Stepper Power supply because I may add stepper motors to things like tool changer or perhaps the quill.?

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John

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I went down this morning and switched on the machine.? As soon as Windows was up I ran MACH3.? ??As soon as MACH3 was up I sent it to find the home switches.

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I then sent it to work coordinates zero which is about 4" up from the bottom of the knee travel and mid point for X/Y.? As it started moving up at the exact same instant that the little balloon came up telling me that my windows might be out of date and doesn't have virus protection, the Z axis locked up with noisy rattling.? And of course it lost position.? I left the balloon in place and re-homed. ?Then repeated the goto 0.? At a much higher point it locked it up again.

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After that no matter how many times I tried it worked perfectly.? This was different from the machine reporting an ESTOP event and stopping completely.

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So.? Machine cold?? Z axis binding at 25 ipm?? Or Microsoft running crap in the background that interrupts the GECKO with 60VDC supply to a 1200 oz-in motor using 4:1 belt drive to the mill Knee shaft which is 0.25" per rev.? Conversion is 24,000 with the GECKO 10 micros steps per step.? Ie.? 2000 steps is 0.25" and it needs 3 turns to move 0.25" so that's 6000 steps per 0.25" or 24,000 steps

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Just went down, tried it again booting from scratch.? This time the XY motion, which is DC Servos faulted with a following error at the same time the balloon appeared.? The Z axis moved smoothly at 8 IPM toward the switches and then 20 IPM (I changed it) up to the work coordinates 0 position.

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So I think first thing is to disable completely that test by the OS so the balloon never shows up.? So it doesn't even have the virus icon on the task bar.? This system isn't even on a network.

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More and more I'm suspecting the OS here.? Which also explains why it never shows up with Linux.

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John

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I have a nice little Bergerda AC Servo that I may try.? I just need to cast a new mount for Z.? It's worked really well on the X axis but it may not be big enough for the knee.? Plus the motor shaft is a different size so it's a lot of work.

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You can see how small that motor is compared to the DC Servo with the same torque spec

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John

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