> And that would mean that direction is changed one step later. Which is
fine, because the next direction change would also be done one step later
and thus overall distance of travel still is the same.
> How do I invert a step pin in HAL? I did not see anything in "stepgen"
> section in hostmot2 doc page. Or is it done by treating it as a gpio pin
with the invert_output parameter (with finding out particular pin number
that corresponds to particular step pin)?

Yes, the relevant lines in each section for me look something like:

setp   hm2_5i25.0.gpio.006.invert_output true

> I would like to thank everybody for the ideas, my current to-do list looks
like this:
> 0) update LinuxCNC to 2.7.something to use new tp (will provide smoother
execution as the g-code consists of small g1 moves);
> 1) try inverted step pin;
> 2) recheck steplen, stepspace, dirsetup and dirhold parameters and
increase them, if possible;

When going through my testing for this the first time I cranked all 4
settings up to 10,000 - the problem still occurred. After I tried inverting
the output I slowly stepped them back down - for my G540 I settled on
700/700/2000/2000.

I can run with lower timings than that, but am more prone to losing steps on
heavy cuts, as they are I stall my spindle before I overload the steppers.
Losing steps is thankfully rare now.

> 3) recheck maxaccel values and do a test with considerably lower values;
> 4) if the issue is still there - use dial indicator to actually measure
exact error, torture the machine a little more and then post here again :))
>
> Viesturs

Another option that may be possible is putting a temporary encoder on the z
axis motor - even running it open loop you should be able to find out if a
discrepancy is still occurring after each change.

Ben


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