On Wednesday 29 November 2006 21:54, 
[EMAIL PROTECTED] wrote:
> So we can review it, can you paste your ini file and
> you hal file(s) on www.pastebin.ca, and post a link

http://pastebin.ca/262379
http://pastebin.ca/262384

> Please make sure your following error limits are set to
> well under a half a turn of the motor. Usually you can set
> the limit to maybe a 50th of a turn. 

Bingo!

The current limits are 1.0 & 0.010, which doesn't match 
either of the two original stepper ini files. Looks like an 
obvious brain cramp on my part. I don't know what, if 
anything, I was thinking. I'll tighten those up before 
doing anything further.

The Sherline is 0.050 per turn, so max and min should be, 
say, 0.001 and 0.0002? Seems awfully tight, given what's in 
the original stepper_xyza.ini file: 0.050 and 0.010.

I evidently have two unrelated problems: the direction 
glitch and a hole in my foot. Dang that footgun!

> Does it seem to happen more on one axis or another?

Nope, it seems equally distributed. The cam is symmetric 
across the Y axis and the largest drift is toward -Y, which 
is what I'd expect from lots of fiddly Y-axis motions with 
an occasionally low direction signal. The other axes also 
drift in the "low direction signal" direction.

The most glaring error, however, happens when the final G0 Z 
upward jog that's supposed to clear the clamps goes the 
wrong way and gnaws into the fixture at full speed...

> so far I've only seen it happen at the start of the very
> first jog, and the step pulses issued (including the
> "glitchy" one) seem to occur only at low speeds

I've also seen incorrect motion at the end of a move, but I 
have absolutely no hard evidence to back that up. It looks 
like a really abrupt halt or reverse jerk, so the glitch 
could be longer than a few step pulses and happen well 
before the actual end of the step pulse sequence.

That could just be my bogus FERROR settings at work, so 
unless / until I can present some solid evidence, 
concentrating on the leading edge makes perfect sense.

> I understand that you've observed the signals with a real
> scope, which tends to rule out the drives and cabling.

Yup, it's there at the parallel port output pins and has 
nothing to do with the machinery. One less thing to worry 
about, if that's any consolation.

Verily, there's nothing like a good new problem to take your 
mind off all your old problems...

-- 
Ed

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