Acopos Encoder error

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1

We are getting this issue in one of the acopos axis.

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getting the flicker in the position feedback.

  1. Tried configuring the axis again.
  1. swapped the axes in the same drive but still getting the issue in the same axis.
  2. Tried swapping the same axis with the next drive axis but still the issue is with the same axis.

So concluding this as not an hardware error. Any idea what might be the error…??

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These are the Drive, Axis, Encoder info.

Thanks in advance.

2

Hi @harshagowda0707 ,
Could please upload SystemDump?
You are using SafeMOTION, so what about the enable of the drive?
Is your safety application running?

In Ax test window you can check in the ax structure below:

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I’m positive you see the cause of the problem in the Safety logger.
Ciao
Valerio

3

Hi there,

a flickering position is quite normal and nothing to worry about. Once you switch on the controller, it should stop flickering.
What’s more of interest is that you marked the case of “an error”, but did not show the actual error you get - you can switch the view with the traffic light button in the watch view of the test window - the traffic light in the command section acknowledges an error.

Plus what Valerio said :slight_smile:

Best regards

4

I am able to do the control on and do the axis home abut still the error bit is triggering and, in the description, also not able to find anything related to these issues in the safety logs and in the diag section which Valerio mentioned

5

Hi @harshagowda0707 ,
if (with simulation disabled) you can power on (the enable input is true) and home the axis (no issue with encoder) next step will be trace the set and actual position (+ lag error) when you command a movement.

It would be interesting to see the scaling pars too:

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Ciao
Valerio

6

Hello there,

once more you failed to provide any relevant information regarding “the error bit”. I asked you which exact error you are getting and even told you how to get to it.
I am leaving this one to Valerio since it seems to be of no use to invest my time here.

Good luck :slight_smile:

7

Hi @michael_w

Sorry for the late reply, I tried what you told previously but unfortunately, I did not get any errors in the error window which could lead this investigation.
Let me know if you need anything else.

Thanks for understanding.

8

Hi @valerio.manenti

Problem Statement

  • A single ACOPOS P3 axis shows extreme fluctuations in its velocity value (monitor.s in NC Manager).
  • The velocity occasionally drops into underflow, which continuously triggers errors.
  • As a result, the affected axis cannot be commissioned.

Key Observations

  • The system contains many axes (32 in identical configuration), and only one is affected.
  • The issue appears to be software-related, not hardware-related.
  • The strongest indicator:
    • Renaming the axis causes the problem to move to another axis.
    • Reverting the name moves the issue back.

:right_arrow: This strongly suggests that the problem is tied to software logic, configuration mapping, or internal handling of axis identifiers, rather than physical components.

:test_tube: Tests Performed

1. Hardware Tests (all indicate no defect)

The team systematically swapped or modified all relevant hardware components:

  • Motor swap (with known good motor) → no change
  • Switching ACOPOS P3 channels (1 ↔ 2) → no change; hardware worked fine under different axis reference
  • Replacing ACOPOS P3 unit + motor cable → no change
  • Changing node number (e.g., ST32 → ST111) → no change
  • Swapping node numbers between drive combinations → no change; hardware worked elsewhere
  • Manually moving the axis → position updates correctly, but issue remains

:white_check_mark: Conclusion:
All tests confirm hardware is functioning correctly and not the root cause.

2. Software & Configuration Tests

Parameter & Configuration Checks

  • Compared all parameters (including safety) with working axes → no differences found
  • Ran the axis in standard simulation → no effect
  • Checked and adjusted bus cycle times → no effect
  • Updated firmware (ACOPOS + motor objects) → no effect
  • Reduced system load (removed 8 axes) → no effect

Critical Test: Axis Renaming

  • Renaming axis (e.g., gAx1 → gX1) →
    • Problem moves to a different, previously working axis
  • Renaming again → no further movement
  • Restoring original name → problem returns to original axis

:white_check_mark: Conclusion:

  • The issue is strongly correlated with axis naming / reference mapping.
  • Suggests a hidden dependency or corruption tied to axis identifiers.

3. Upgrade Attempt

  • Attempted upgrade to ACP10 v5.31.3 → blocked
  • Reason: Arnc0man library remains at incompatible version (V3.13) and cannot be upgraded with current package

:brain: Overall Diagnostic Conclusion

From all evidence in the email:

  • :cross_mark: Not a hardware issue
  • :cross_mark: Not caused by physical wiring, motor, or drive
  • :cross_mark: Not due to configuration differences or bus timing
  • :white_check_mark: Highly likely a software issue related to axis mapping, naming, or internal data handling

Additionally, the team suspects:

  • Something in the system may be incorrectly accessing or corrupting the motor speed value internally.
9

Hi @harshagowda0707 ,
I read your comment 4 times, twice before I drunk my Italian coffee and twice after that and I have the same thought : Unfortunately I don’t know how I can help you,
we asked additional information and you didn’t provide them + now I see you report an additional issue with Arnc0man library.

You created this post 14 days ago, you deserve an answer, so I recommend to call our Support in India.

Ciao
Valerio

10

@harshagowda0707

you should see an error text message after pressing this button:

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