2009/10/22 Jon Elson <[email protected]>:

> Good hypothesis and data taking!  So, it seems the problem is the
> encoder counter sees
> a zero velocity between actual encoder counts, and tells the slaved axis
> to stop NOW!  Then a
> count comes in, and it says MOVE NOW!  Yes, I can see this is a definite
> problem.

 I am not sure that this is the full story anyway. The oscillations
are typically nothing like encoder frequency (say 200Hz) but nearer 5
Hz.
Also note that G33 et-al are position-mode not velocity-mode.

The simple solution might be for stepconf to always connect to
position-interpolated rather than just position. With a good encoder
this seems to work fine in most cases as long as the axis
accelleration is adequate.

There might be an argument for using a more sophisticated PID type
controller, but the correct P. I and D would almost certainly be
strong functions of spindle speed. Add to that the complication that
you are trying to control to position but are limited by velocity and
acceleration and it becomes difficult to think about, let alone work
out how it should be coded.

An alternative might be to keep things much as they are, but to have a
parameter in the G-code for how much "run up" it has. It then becomes
a somewhat simpler trajectory planner issue to get to the thread start
at the right speed next time the index comes round on the unloaded
spindle and only  then to enter the current position-feedback mode to
stay on-pitch and allow for spindle velocity changes.
I think that might actually be the essence of how Chris' patch works,
though that just waits to get a better spindle speed estimate I think.

-- 
atp

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