We have an 1100MX with rigid tapping and tool changer and have an issue where everything works well, tools are indexed correctly for the tool changer but as soon as we perform a rigid tapping feature. the spindle loses it’s encoder position. We then have to go through the dance of setting TC M19. Then everyting works well until the next rigid tapping step.
Toolpaths are created on Fusion360 and we have tried both G84 and G33.1 and neither resolve the issue. Any thoughts on what is happening and how we can correct this? As mentioned earlier, the tool changer works perfectly every time so it isn’t like the encoder is flaky. Only happens after a tapping operation.
Check the belt tension. I could be way off but I saw this hours ago and I waited but nothing yet. I’m probably wrong but it’s worth a try. Are you taping on high or low belt?
Have you verified that the encoder is correctly positioned? I would also check to make sure that the wiring isn’t pinched or otherwise damaged and that there is no debris or other contaminants on the magnetic ring.
Keep in mind that positioning for a tool change is a simple “goto here” context while tapping is a more dynamic process of monitoring location in realtime in order to sync up the spindle speed and Z position. It’s entirely possible that you have a fault somewhere that doesn’t affect the tool change position but does impact reading position elsewhere in the spindle’s orientation.
Yeah, nothing is pinched. It’s not random, it’s only after a tapping operation. The spindle encoder is used also for positioning the tool holder for the tool changer. Have never had an issue with tool changes so it’s at least able to position for that operation but I do understand that tapping is a somewhat different use of the encoder. Thanks for the info. I’ll dig a bit deeper.
We are doing everything on high speed. This is with very small taps M2 and M4 in aluminum so don’t think there is any belt slip but I’ll check jus tin case. Thanks!
Have you tried a tapping cycle without any material in the vise? That would tell you if spindle load has any impact on the issue, regardless of belt tension. Though based on M2 and M4 taps in aluminum I wouldn’t expect that to be a thing.
The failure happens when it makes the tool change after tapping. We can move the tapping step to the end but when it is time to store the tool, we get the error. No matter where in the process the tapping step is, it always happens after rigid tapping when changing or storing the tool.
Also worth noting is that this will happen if you set up a tapping operation using conversational programming so it isn’t something in Fusion360. We will be running some more product in a couple days and will disconnect the tool setter to see if that is causing noise issues, we will also set up a simple tapping operation and perform it in the air to see if engaging material is causing the issue.
Thanks again to all who are trying to help. It is appreciated!