Weird Z in post

[TERRYH]

We are using X9 first off, and we have 2 machines that have a X,Y,Z and a W (bridge) we do not program the W live it is set at a set point by the operator and the spindle has 17" of travel from where ever the W is set. So when we program stuff we have to watch the total travel and keep it under the 17"

  I did a tall part that was not able to be programmed all at once because top to bottom exceeded the 17" total, so I had to do the taller right side with a safe Z of 22 and do half of the part, then they drop the W and set safe Z below high point at Z14. and run lower half to keep under the 17" travel. With that being said I hope it is understandable, I had several programs posted with a safe Z of 14 for lower side but however 2 out of them at the end of the program went to safe Z of 14 then went above that one to Z17. and the other to Z16. over traveling our machine.  The bad thing is these to machines are old SNK's that used to have a tracer table, and do not have a soft over travel limit switch. Luckily it did not hurt the machine. All of my setting were correct, and I even had another guy check out my settings, and we cannot find out any reason for the additional move being added to make it go above the safe Z I had set, and why just those 2 programs out of a half dozen or so with the same settings. Kind of scratching my head on this, any ideas on what could have caused this, and is there any way to stop it from happening again shy of physically visually checking the post after it is posted? Thanks for any and all help in advance, just hope I explained it well enough to understand.  

[billb]

Are you using incremental Reference points and do you have the Arc filter (or Smoothing) enabled?  I investigated a bug, recently, where that combination led to an extra move.

[TERRYH]

No incremental everything was set to absolute, and will have to look into other stuff.  

[jlw™]

I program a W axis machine with mcam and use a misc real to set w positions.

 

I also use ref points. is it possible you some how set a ref point?

[TERRYH]

no the guys at the machine run the spindle up so it is above the part and can get the safe z I tell them then that's where they set the W to in the G54  and it stays there only the spindle moves up and down. but in MC I could se the rapid move in Z after it went to the Z14 I had set. and like I said it was only in the 2 programs out of 6 for that part, and I did another part almost a mirror of it and it never did it once. went exactly where I had it set. It's confusing the hell out of me and even though all my setting was correct and even had another guy check them the CNC supervisor got pissed and acted like it was my fault that I missed something.