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Fly Cut Error

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Fly Cut error

The Fly Cut error usually appears in the two types of situations described below.

Scenario 1: Missed cut

In regular cutting, the program determines the laser firing position from the tool path, whereas in Fly Cut the laser firing depends on both the tool path and the pulse signal from the encoder.

If the encoder pulse signal has incorrect values or polarity, the laser firing during Fly Cut will be incorrect, which can lead to missed cut segments or the laser firing during travel moves.

Troubleshooting:

Run the Encoder Analyze test in CypCut: File → Diagnosis Tool → Card Monitor. Check the result, determine which of the cases below matches your situation, and follow the instructions.

Case 1. The received pulse has polarity opposite to the command pulse.

In the image below, the feedback pulse (−4987) from the Y axis is opposite to the command pulse (+4987). You need to change the pulse polarity in the CypCut Machine Config Tool.

  • Check or uncheck the encoder direction option to change pulse polarity. For the Y axis change axis2/3; for the X axis change axis1. This change does not affect motor rotation direction.
  • Save the settings, run the test in CypCut Card Monitor again, and confirm the result is correct.

Note: if after changing the encoder direction setting in the machine config the encoder analysis result stays the same (pulse polarity still opposite), inspect the soldering of the C15-pin connector and the signal contact of the C62 cable to make sure they are intact.

Case 2. The number of received pulses does not match the command pulses.

  1. Check the pulse output per motor revolution setting in the servo drive — it must match the pulse setting in CypCut Machine Config Tool.
  2. Inspect the soldering of the signal contact of the C15-pin connector and the integrity of the signal contact of the C62 cable.
  3. If the problem persists, replace the BMC control card and check whether the encoder analysis result is correct.

Case 3. No pulses from the encoder.

  1. Inspect the soldering of the signal contact of the C15-pin connector and the integrity of the signal contact of the C62 cable.
  2. If the problem persists, replace the BMC control card and check whether pulses from the encoder are received.

Scenario 2: Laser firing during travel moves

Another form of the Fly Cut error is the laser firing during travel moves, as shown in the image below.

Troubleshooting:

Step 1. Open Card Monitor in CypCut: File → Diagnosis Tool. Enable the output of the PWM+/− signal (if configured) and confirm that the PWM output is grey.

Step 2. Measure the voltage on the P+/− signal contact.

Measure the voltage on the P+/− signal contact and record the reading. This step checks whether the laser leakage is caused by a false signal from interference originating in the laser source.

If the measured value is not zero, disconnect the signal cable from P+ and P−, and measure the voltage again.

  • If the voltage drops to zero after disconnecting the cable, do the following:
    1. Verify that the laser source is properly grounded.
    2. Replace the modulation cable with a cable that has better shielding.
    3. If the problem persists, connect a 1000 Ω resistor between P+ and P− in parallel.
  • If the voltage is still not zero after disconnecting the cable, contact FSCUT technical support.
  • If the measured value is zero, the laser is firing without a command signal from the controller. In that case contact the laser source supplier for diagnosis.