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| Thought Process | Action Taken | Result |
|---|---|---|
| Is there the ability to communicate with the motor and limit switches? | Accessed the IMS Motor Controls Screen to check communication with the motor. Please see Understanding the AUX screens to know more about IMS Screen Parameters. | The IMS Motor Controls Screen was greyed out, indicating a lack of all communication with the motor. |
Is it unable to communicate due to the lack of power? | Rechecked the connections to the port as well as the motor protection board. The IMS Motor Controls Screen Parameters were reconfirmed. | -While checking the different connections, it was noticed that the designated Port # on the IMS Control Screen, did not match the physical port. Both the power and communications cable were moved to the correct port. IMPORTANT: Always notify and seek approval from the POC Controls prior to changing the port #. |
| After establishing communication, are both limits responding when depressed? | At this point, actuator movement was not necessary, since testing purposes only involved operation of the limit switches. Please see Limit Switch Selection for Mechatronics in L2SI (or the Bane of the Baumer) for more information regarding limit switches as well as the designated length of travel for a stage. Independently pressed each limit switch(both the upper and lower limits), while checking the IMS Motor Controls Screen to read any feedback. Motor feedback can be found under the "Log Messages" section. | No, only the upper limit was working. Feedback message appeared as "Upper limit hit." One operating limit switch indicated that communication was established, ruling out potential issues upstream from the motor protection board. |
| Are cables for the lower limit switch correctly terminated? | The newly terminated cables as well as the soldering associated with the lower limit were inspected. Power supplied to the lower limit switch was checked. This was done by using a multimeter to check if a complete circuit was established on the Molex connections. Tip: Always check the reliability and proper calibration of any device being used for diagnostic purposes. In this case, the multimeter should be checked for continuity prior to use. | Continuity of the lower limit was confirmed, indicating proper termination and soldering. |
| Is the lower limit switch wired correctly? | 2 people independently checked the wiring of the limit switch setup example from CXI. | Inconsistencies with wiring of the lower limit switch were discovered. After rewiring the lower limit switch, according to the CXI motor setup used as reference, both lower limit switches were operational. Feedback message under the IMS Motor Controls Screen showed "Both limits hit" when the physically limits were depressed. |
CXI Parker Brake Issues
Case 2: Controls reported motor/hardware issues involving a stalled motor. MM-09 located on the DG2 stand consisted of a motor, coupling, linear encoder and a parker brake. Parker brakes require ~24V delivered in order to disengage/release the brake. Prior to exploring hardware issues, controls power cycled the following: motor, moxa, & ioc. The following errors: mcode stall,
Image 2. CXI-DG2-MMS-09 motor setup of the linear encoder with a Parker brake.
Thought Process | Action Taken | |
Ability to communicate? | Yes, the ” Stall code detected error” and “Mcode Not Running” message appears on the IMS Motor Control. | Removed the motor completely and observed free rotation of the shaft. Although a signal showed motor movement, encoder movement was not observed. |
Is enough power being delivered to the Parker Brake? | Unsure, since it was possible that 24V was not being supplied to release the brake. | Connected an external power supply source in order to independently release the brake. Continued receiving the same error.
Image 3. Parker brake connecter used to connect to external power supply source. |
Is it a coupling issue? | Possibly, since the stall error indicated slipping. | Threading on the top screw of the coupling was stripped. A longer screw with more threading was used. Encoder movement was observable after the screw replacement.
Image 4. 4 caps were removed to expose the holes in order to access the 2 adjacent set screws on the coupling. |
