I just recently started using soft limits, maybe someone will find the  
following observations relevant to this topic:

I am using emc2 on a Sherline with steppers, mm screws, and no limit  
or home switches. I used to always set up the ini file with the soft  
limits well beyond the machine travel to effectively negate soft  
limits as discussed in other posts on this topic. I used home to set  
the machine zero to equal the part zero for each set-up. This mean't  
that I was free to send the machine right to the end of its travel,  
which doesn't do much damage on one of these little machines but does  
cause it to completely loose its position on the stalled axis.

After playing with offset coordinate systems a bit I decided to change  
the way I do things and set the Sherline up to use soft limits. I jog  
the machine to a reference mark at one end of the useful limit of  
travel, home the axis (no switch, current position is set as home, in  
my case equal to zero). The position doesn't need to be extremely  
precise if all I am looking for is to keep the machine inside its  
mechanical limits. If I want to be able to shut down the machine and  
restart it at exactly the same home position I can use the reference  
marks to get the screw within one turn of the desired home position  
and the handwheel dials to get it back to the same position. It's a  
bit fiddly, but does work for my purposes.

I did need to set the soft limits just outside the desired limits to  
allow me to jog the machine right up to the desired limits. Instead of  
setting X MIN to 0 and X MAX to 330, I set X MIN to -1 and X MAX to  
331. Otherwise I couldn't quite jog up to the soft limits. A move in  
MDI would go right up to the limits with no complaints.

I ran into in interesting quirk in Axis that didn't show up in Tkemc.  
With home set to 0.0 and the minimum axis limit set to 0.0, as soon as  
I homed all three axes the x axis would show as beyond limits. At that  
point I was stuck. Neither the jog keys nor MDI would move any axis.  
This is when I learned that override limits doesn't apply to soft  
limits. All I could do is restart EMC. Setting the soft limits 1 mm  
outside the desired range also eliminated this issue.

Carl Helquist


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