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Spoke too soon! The problem has started again.

Strange, the chain seems to be running fine today. Thanks for all the input!

Here's a .pdf with more information. http://literature.rockwellautomation.com/idc/groups/literature/documents/wp/drives-wp001_-en-p.pdf

The drives are configured as Speed Trim Followers. The master sends its torque signal to the followers who develop a "trim" error by comparing the master torque to their own.

Oh, I see the abrupt drop in current after it spikes up. Here is a screen capture from today before lunch. Red is the infeed motor, and green is the outfeed.http://files.engineering.com/getfile.aspx?folder=abdba186-6cb8-4e3e-aef9-f0edc257290d&file=Motor_Current_12_17_2014.jpg

The current is spiking when the slowdown occurs. My supervisors and mechanics don't think that the sprocket is slipping. We believe that it would be completely catastrophic if that were to happen. We are getting normal square waves on the A,A*, B, and B* lines on both drives, but the Z and Z*...

Should we have only 1 encoder feeding the virtual master? I'm not familiar with the virtual master setup.

Thanks for the responses. I've made some notes and we'll look at these things. @waross, is there any way to mitigate the problem of hoar frost?

So, I've drawn a little diagram of the system (which is why i get earn big money). The process is like this: The machine is a miniaturized blast freezer. Hooks hang from the chain every foot. The chain itself is over 800 feet long, and it can hold some 800 hog carcasses at a time. I'll assume...

Oh, the files are called "Pump...", these are not pump motors, they drive a chain.

So, I guess I can only submit one file at a time. Here is the motor speed for an 8 hour period in the morning. http://files.engineering.com/getfile.aspx?folder=46fe27e7-728e-4ccf-89ed-d7af8fbb7573&file=Pump_Speed_8hr.png Here is a zoomed in version of one of the "spikes" on current...

So, we've installed this fancy new system with a dual motor driven chain, and the damned thing has had problems since day one. It slows down from time to time and interrupts production. We have considered a number of options to cure the problem, for example, we just changed the motors' encoders...