On Sat, 5 Nov 2011, Viesturs L?cis wrote: > Date: Sat, 5 Nov 2011 14:09:35 +0200 > From: "[UTF-8] Viesturs L?cis" <[email protected]> > Reply-To: "Enhanced Machine Controller (EMC)" > <[email protected]> > To: "Enhanced Machine Controller (EMC)" <[email protected]> > Subject: Re: [Emc-users] Dust-proof case? > > 2011/11/5 Slavko Kocjancic <[email protected]>: >> Hello... >> >> I think the 1'st thing is to check what is wrong. Not to do something to >> eliminate problem but not know what problem it is. > > Yes, that is exactly my question - is there anything I can do to > diagnose the cause of problem? > >> If EMC doesn't crash then motherboard isn't problem (CPU/RAM/ROM/S,N >> bridges...) so try to check where is problem. It can be somewhere betwen >> CPU bus (aka whatewer card you use for IO) throu motor driver board. >> Just I don't understand how you are can continue work on next piece >> after crash without rehoming? Do you have servo or stepper. In case of >> stepper there should be position loss so rehoming is mandatory. (Or you >> just tolerate absolute error as you touchof coordinate to part >> machined?) If that's true then jou maybe just have missconfigured >> configuration. Eg you measure latency and got for example 10us and you >> conclude that is it. But sometime some events thermal recalibration of >> HDD for example can cause little longer latency and jou hit the problem. >> And this occour in random time not periodic. Just put that pc with >> intensive work to measure latency for few hours to werify. If you have >> servo then EMI can be problem. (for stepper to but less possible as >> machine run long time without trouble). > > Here is some data about the machine: > 4 MotionKing stepper drives with Mesa 7i43 for step generation. > PC is dual-core Intel Pentium CPU with 1GB memory, no idea about motherboard. > EMC version is 2.4.6 running on Lucid. > > These are the symptoms: > 1) EMC won't start running a file, when a PLC (currently controls > pneumatics, it will be removed eventually) sends a signal to do so. > In HAL file I have: > > net deb-in debounce.0.0.in <= > hm2_[HOSTMOT2](BOARD).0.gpio.034.in_not > net oneshot-in debounce.0.0.out => oneshot.0.in > net oneshot-out oneshot.0.out => and2.0.in0 > > setp debounce.0.delay 5 > > setp oneshot.0.rising 1 > setp oneshot.0.retriggerable 1 > setp oneshot.0.width 5 > > net ready pyvcp.ready => and2.0.in1 > net start and2.0.out => halui.mode.auto halui.program.run > > Incoming signal from PLC is filtered through debounce and routed into > oneshot to watch for rising edge. > There is pyvcp button "Ready for work" for operator to enable EMC > following PLC commands. > > I have been watching these pins in "Show HAL Config": > hm2_[HOSTMOT2](BOARD).0.gpio.034.in_not > and2.0.out > halui.program.run > halui.program.is-running > halui.mode.auto > halui.mode.is-auto > > What I have observed: > There are cases, when EMC does not run a file, when PLC sends a signal > to do so - I can see that on GPIO pin and and2.0 output pin. > The thing is that pins that request changing to auto mode and running > a file are "true", but EMC does nothing. Resetting the GPIO pin > usually solves the situation. So EMC does behave unusually. > Blowing out the dust from all the cases - PC, monitor and the box with > Mesa card and stepper drives. EMC behaved correctly for ~30 minutes > and then this behavior started to repeat once in ~10 minutes.
Sounds more like a thermal problem rather than dust, maybe a marginal level somewhere. But the Bit that EMC does not react seems really strange If its related to spindle noise, installing a line filter or ferrite bead an the spindle motor wires should make a big difference Also the debounce of 5 mS (assuming 1 mS servo thread) seems pretty fast for a mechanical relay output (if thats what the PLC outputs) > > 2) One of the spindles takes a wrong path. > The work process is that operator places the material in fixture and > presses "Start" button - pneumatic cylinders hold it in place and > spindles conduct a movement, shaping both ends of material. Cylinders > release the material, operator takes the part out and puts the next > part in and presses "Start" again. > And then repeat this for hundreds of times. > > I have 2 joints hardcoded to X and other 2 joints hardcoded to Y in > kinematics module. > > The error is that sometimes one of the spindles (not the same spindle > all the times) moves less than needed along X thus ruining part. The > differene is ~1mm. > > Most surprising is that after such a wrong move next part is correct. > The thing is that deviance of 0.1 mm can already be seen on the part > due to the shape of the tool and the shape of the cut. > > I have a suspicion that this might be something connected with Mesa > card and magnetic field from VFD and also spindle motors, because > there is CRT monitor ~0,5m from spindle motor and the picture gets > creeped. It is good as soon as motor is turned off and gets creepy as > soon as it is turned on. The pattern of creepiness changes as the > motor moves. > > If there was a noise in step/dir signals, then the error should > remain. But the thing is that in all the cases it recovers and next > part is totally fine. > > The pattern for this error was something like this: > No error for first 40-50 minutes. > One part ruined. > Fine for 5-10 minutes. > One part ruined. > Fine for ~20 parts. > One part ruined. > Fine for 6 parts. > One part ruined. > Fine for 4 parts. > One part ruined. > Fine for 10-15 parts. > One part ruined. > Then I lost the track. > > Confirmed by supervisor - the tendency is that all these errors (and > they say that there are other errors that I was not able to observe > during 3 hours I was there) get worse and worse as the machine is > working. So if one shift (7 hours) somehow can work, then the night > shift comes in and in the morning there is almost nothing done. > Let the machine rest for few hours and then it can work for a while. > > > So is there anything I can do to diagnose the problem? > > Viesturs > > ------------------------------------------------------------------------------ > RSA(R) Conference 2012 > Save $700 by Nov 18 > Register now > http://p.sf.net/sfu/rsa-sfdev2dev1 > _______________________________________________ > Emc-users mailing list > [email protected] > https://lists.sourceforge.net/lists/listinfo/emc-users > Peter Wallace Mesa Electronics (\__/) (='.'=) This is Bunny. Copy and paste bunny into your (")_(") signature to help him gain world domination. ------------------------------------------------------------------------------ RSA(R) Conference 2012 Save $700 by Nov 18 Register now http://p.sf.net/sfu/rsa-sfdev2dev1 _______________________________________________ Emc-users mailing list [email protected] https://lists.sourceforge.net/lists/listinfo/emc-users
