File Corruption During Network Transfer

[noahwass]

My company computer (hooked up to our internal network;no homegroup) has just had a fresh install of Windows 7 Pro 64-bit. I went through the process of mapping network drives and had a problem when it came to connecting to IP addresses and folders in the format of '\\server\shared folder'. Turned out that I had to change a security setting. Following the instructions on this site, I was able to resolve that issue.

These network locations are CNC machines and the files that I am placing on the machines contain CNC code (G&M code and X, Y, Z values for 3D machining). Basically, G&M code cannot have multiple X, Y or Z values on the same line (it wouldn't make sense to go to two X locations in the same move). When I transfer CNC files from a network location (all of our files are stored on a server) to the CNC machine, they occasionally get corrupted where part of one file is contained in another file.

I have tried transferring one at a time and in bulk, both with the same result.

Does anyone have any insight into this problem? I am going to continue exploring potential fixes and will post updates as I find things. Any help would be appreciated.

 

[noahwass]

UPDATE

I tried turning off Remote Differential Compression to see if there was some data loss during the transfer, but this did not help.

Still searching!

 

[WebMattR]

If it's possible, could you copy one of the files from the server to your machine, and then try transferring it to the CNC Machine?

 

[noahwass]

Good suggestion. I moved one of the files that I had attempted previously onto my desktop and then transferred it to the CNC machine. Fail. I then wanted to make sure that I was actually overwriting the file on the CNC machine during transfer, so I renamed the file on my desktop and tried again. Fail. I put the original file from the server on to a thumb drive and loaded the file from the thumb drive on to the CNC machine (it has a USB slot for doing this) and that went well. The CNC file loaded fine and was verified on the CNC machine as being a good file.

It has something to do with Win7 communicating to the CNC machine over the network. Something is happening during that interaction that I know very little about!

 

[noahwass]

UPDATE

I have tried this same CNC file on multiple CNC machines with different version operating systems (all same brand: Haas) with the same result. I have also tried from a different PC running Windows 7 with the same negative result.

Still searching!

 

[WebMattR]

So, what do you think at this point? It sounds to me like a network issue. What networking hardware is between you and the CNC machine?

 

[noahwass]

It's definitely a network issue. The pieces of hardware that are between my PC and the CNC machine are:

MyPC -> two or three switches -> modem on CNC machine.

I realize that this is not as specific as you would like. I just spoke with an IT person here and we were talking about ways that we could trace the route of the file over the network or just hooking my PC straight to the CNC machine to rule out any hardware in between.

The file that I have been transferring always increases in size once it has been placed on the CNC machine. Information is not being lost; rather gained.

 

[WebMattR]

Do you travel through a router, or anything else, or is it all internal switches?

Also, the file size increase may be due to the CNC machine uncompressing it, or things like that. I would suggest start by connecting to a switch as close to the CNC machine as possible (maybe directly into the modem), and see if it works. If it does, trace your way back to the next switch, and repeat until you're sitting at your desk, or have isolated the problem.

I'll bet you a billion confederate dollars that the problem lies with the device that's doing the digital to analog conversion for your CNC's modem. Intuition is telling me that it needs to be either rebooted or replaced.

 

[noahwass]

WebMattR,

I have a request in to the IT department to look at the network hardware.

A possible related issue has popped up. I have been using my computer for CAD work again and the software has a network license that it loses on a regular basis, which did not happen when I had WinXP installed two weeks ago. This could be related to the switches that are being used and not related to the CNC network hardware...or it could be it's own little problem! I did call the CAD software company and they told me to look at our internal network, FWIW.

 

[WebMattR]

Well keep us up to date, and I'll help you as best as I'm able.

 

[Generalchaos]

We are having the same problem. Windows 7 Pro 64bit machine hooked to a Haas milling machine through a router. The network connection to the Haas is slow and files sent to the machine grow in size after being sent. Sections of previous G code files get chopped up and inserted into the sent file. I'm wondering if its a Windows 7 thing, because I still have my old 32bit XP machine hooked up to the same network and it sends to the Haas just fine with no data growth.

Local Haas guys are baffled. Had them over twice to look into it and upgrade the floppy driver. Made no difference.

 

[WebMattR]

Have you tried the steps I've suggested to the other person?

 

[Generalchaos]

I did try your suggestions and no difference. I did what noahwass suggested and plugged the 150' cat5 cable from the Haas machine right into the Win7 machine. Same thing. Slow to connect, and files grow on transfer to the Haas. So this eliminates the router and switch as problems. So we're down to ethernet adapter in Haas, or some Win7 issue since the XP machine works. Any further ideas?

USB thumb drive transfer works fine.

 

[WebMattR]

I'll think on it, and hope someone else jumps in, but for now I'm a little stumped, I'm afraid.

 

[Generalchaos]

Well I made it work by NOT dropping the cutting programs into the Haas but by creating a shared folder, and having the Haas "pull" the files down. Works well so far. Drag and drop to the machine would be slightly easier, but oh well maybe it will work itself out as more shops switch to Windows 7.

 

[WebMattR]

Interesting. I wonder what the difference is. Sorry I didn't have an answer for you, but at least you've given me the knowledge to help those who come by with similar troubles.

 

[noahwass]

I just wanted to update this thread and mention that I was able to move a small 4KB NC program to the machine uncorrupted. A larger 1,478KB file still corrupts when it gets transferred. It's unlikely and unreasonable to suggest or assume that anyone can create smaller NC programs and move them to their machines, but if you have short, simple toolpaths, you can most likely transfer them with no hassles.

WebMattR, would it be safe to assume that network hardware can be ruled out if this smaller program is making it through with no problems?

 

[Generalchaos]

Solved my problem (so far)

Hi Guys

Solved my problem as of middle of last week so far.

Instead of mapping the drive of the Haas mill I just address it by its IP address. We had a conflicting IP address which we sorted out, and I had the driver on the Haas upgraded from 12 to 13.009 which is the latest driver for that model and year of control.

I am now dragging and dropping from my desktop into the drive of the Haas machine, and have had no corruption of files.

Its only been a week but anything from a few kb to 1.8 meg has worked.

 

[noahwass]

Our IT guys finally got around to looking into our file transfer problem and verified that it is a problem between Windows 7 and Haas' operating system/firmware/driver. We were able to transfer files using WinMend File Copy and the IT guy was able to transfer files using basic DOS commands at the DOS level. Anything else gave us corrupted files.

From here, I'm going to call Haas and make sure that they're aware of this and see if upgrading the machine OS to the most recent OS/firmware/driver will do help as it may have in Generalchaos' case.