230-00CE

Check mechanical components

Inspect ball screws, linear guides, and coupling mechanisms for debris, damage, or binding. Look for chips, coolant buildup, or worn components.

Ensure machine is in safe state and locked out before inspection

Manual axis movement test

Use Manual Operation mode to jog each coupled axis individually at low feed rates (F100-200) and observe for irregular movement or resistance.

Compare movement smoothness between the coupled axes - any difference indicates mechanical issues

Lubrication check

Verify automatic lubrication system operation and manually lubricate linear guides and ball screws if necessary according to machine manual.

Check lubrication parameter MP7500 for proper cycle timing

Backlash verification

Check backlash compensation values in MP1410-1419 for each coupled axis and verify mechanical backlash hasn't increased due to wear.

Check servo drive status

Navigate to Diagnosis->Servo and examine drive status, current consumption, and error flags for both coupled axes. Look for asymmetric current draw.

Compare following error values between coupled axes during movement

Encoder signal verification

Check encoder signals in Diagnosis->Position menu. Verify clean square wave signals and proper interpolation for both position and velocity feedback.

Encoder contamination can cause intermittent position errors

Motor temperature check

Monitor motor temperatures via MP1060 thermal monitoring. Overheated motors will have reduced torque output causing position lag.

Servo parameter comparison

Compare servo parameters MP1420-1499 between coupled axes to ensure identical tuning. Pay special attention to velocity feedforward MP1442 and position loop gain MP1460.

Review maxPosDiff setting

Access Service menu->CfgAxisCoupling and check maxPosDiff value. Typical values range from 0.01-0.1mm depending on mechanical precision requirements.

Start with 0.05mm and adjust based on actual system performance

Verify coupling configuration

Confirm correct axis assignment in CfgAxisCoupling->coupledAxis parameters and ensure master/slave relationship is properly defined.

Test with relaxed limits

Temporarily increase maxPosDiff by 50% and test axis movement to determine if alarm clears, indicating configuration issue rather than mechanical problem.

Only use relaxed limits for diagnostic purposes, restore proper values after testing

Synchronization check

Perform axis coupling synchronization procedure from Service menu to establish proper reference relationship between coupled axes.

Analyze cutting parameters

Review current program cutting speeds, feeds, and depths of cut. Check if alarm occurs during specific machining operations or tool changes.

Monitor servo current during cutting to identify load spikes

Tool condition inspection

Examine cutting tools for wear, damage, or improper geometry that could cause uneven cutting forces across the coupled axis system.

Workpiece setup verification

Check workpiece clamping and setup for proper support and balance. Uneven clamping can create asymmetric loads during machining.

Improper workpiece support can cause dangerous vibrations and tool breakage

Feed rate optimization

Reduce rapid traverse rates (MP1010) and acceleration values (MP1420) temporarily to determine if high dynamics are causing the position difference.