Re: [Emc-users] Off Topic, Broaching

2007-10-30 Thread Andre' Blanchard

Just found a good video on rotary broaching.
http://www.slatertools.com/video.htm
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Re: [Emc-users] Off Topic, Broaching

2007-10-30 Thread Jon Elson
Kirk Wallace wrote:
 Has CNC changed the way keyways are made? I need to make some keyways
 for my mill conversion, and I have no tooling so far for doing it. Since
 I will may be buying tooling, I want to explore the options in order to
 make the best investment. I actually prefer not having keyways and going
 with set screws on countersinks. Anyone have thoughts on this? Thanks.
 
You can cut keyways on a lathe using the carriage as the power 
source, the X axis to step the feed, and a hand-made shaper 
type tool as the cutter.  You want to shave off a pretty thin 
slice each time as the Z axis usually isn't very strong.  I have 
done this manually on occasion, and even made internal splines
this way.

If keyways were in it before, they probably had a reason.  The 
only really good alternative is taper-lock hubs.  The Bridgeport 
BOSS machines used them, for instance, on the axis drive 
pulleys, and they worked pretty well.  You could actually make 
some taper hubs on your lathe, now that it is mostly working.
It is essentially a collet.  You have two pieces that are bored 
for the shaft on the ID, and tapered on the OD to match a taper 
cut on the ID of the sprocket.  Then, there is a plate that 
allows small bolts to pull the pulley tight onto the collet 
pieces.  You also need a scheme to push the pulley off the 
collet.  Look in Grainger or McMaster-Carr's catalog (on line) 
and see if they have a good picture of these.

Jon

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Re: [Emc-users] Off Topic, Broaching

2007-10-30 Thread Brian Pitt
On Monday 29 October 2007 23:10, Kirk Wallace wrote:
 Has CNC changed the way keyways are made?

I talked with a guy a few weeks ago who has a CNC broaching machine
from the description it sounded like more of a vertical shaper/slotter with an
X-Y-rotary table and uses a single point tool to peck away at the work

Brian

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Re: [Emc-users] Ethernet I/O

2007-10-30 Thread Jon Elson
Rafael Skodlar wrote:
 
 This brings up another option, build an open source EMC controller 
 PCI[e] card with slow, medium and high speed ports that could be used to 
 control buses. Speeds would need to be determined based on what is 
 required for machine world. If build with an FPGA, it would be very 
 flexible and handle a lot of logic and speed and could be programmed for 
 different needs: use with lathe, 3D routers and torch machines, or even 
 run real time functions.
This may be what Paul Corner has been ranting about for some 
time.  Port EMC(your flavor here) to one of the ARM all-in-one 
CPUs, and keep the GUI on a PC.  There are a bunch of details, 
the biggest being how to access the G-code and configuration 
files.  It would probably require more memory than they 
currently fit into such chips as the AT91SAM7X series, I think 
256 K it the max.  There apparently is a substantial speed 
penalty for external memory.  There would need to be some 
process on the PC supporting file serving to the ARM, but I 
suppose NFS would work.  Without all the Linux OS overhead and 
virtual PC nightmares of the current PC architecture, the 70+ 
MIPS of the ARM processors might be sufficient.

Once the file serving question is handled, the only serious 
remaining effort (I think) would be porting rtapi to one of the 
competing ARM RTOS options.

A very interesting idea, but it could be fairly time consuming 
to deal with all the intricacies of such a big porting effort.
It would sure make a NEAT package, and the board could be quite 
cheap.  These ARM microcontrollers are in the $7 - 14 range, 
they need an additional $12 or so of parts to implement 
Ethernet, and maybe under $10 for extra memory.  I would think 
that pat could be done for under $100.  Add an FPGA to do step 
generation or PWM drive and a bunch of I/O connections, and you
are up to maybe $200 for a commercial product.

Jon

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Re: [Emc-users] Off Topic, Broaching

2007-10-30 Thread Gene heskett
On Tuesday 30 October 2007 14:17:43 Jon Elson wrote:
 Kirk Wallace wrote:
  Has CNC changed the way keyways are made? I need to make some keyways
  for my mill conversion, and I have no tooling so far for doing it. Since
  I will may be buying tooling, I want to explore the options in order to
  make the best investment. I actually prefer not having keyways and going
  with set screws on countersinks. Anyone have thoughts on this? Thanks.

 You can cut keyways on a lathe using the carriage as the power
 source, the X axis to step the feed, and a hand-made shaper
 type tool as the cutter.  You want to shave off a pretty thin
 slice each time as the Z axis usually isn't very strong.  I have
 done this manually on occasion, and even made internal splines
 this way.

 If keyways were in it before, they probably had a reason.  The
 only really good alternative is taper-lock hubs.  The Bridgeport
 BOSS machines used them, for instance, on the axis drive
 pulleys, and they worked pretty well.  You could actually make
 some taper hubs on your lathe, now that it is mostly working.
 It is essentially a collet.  You have two pieces that are bored
 for the shaft on the ID, and tapered on the OD to match a taper
 cut on the ID of the sprocket.  Then, there is a plate that
 allows small bolts to pull the pulley tight onto the collet
 pieces.  You also need a scheme to push the pulley off the
 collet.  Look in Grainger or McMaster-Carr's catalog (on line)
 and see if they have a good picture of these.

 Jon

Basically, copy the Browning taper-lock hub idea, it works very well indeed 
for the higher horsepower stuff.  Pix might be available on their web page.  

Its internal collet is keyed for the usual square stock key, but I've seen the 
idea used on go-karts 40 years ago where the individual drive sprockets on 
the axle weren't fitted with a key, so that the firing order of multiple 
engine setups could be set to alternate for 2, or at 120 degrees for 3 
engines.  Even w/o keys, they only slipped if the cart jock didn't tighten 
them in sequence enough times.  These were 5.8 to 6.1 cid 2 stroke engines 
turning up to 17k rpm's, so the shock loads at the lower rpms were pretty 
high on the hubs, and equally high at the 8 to 10 teeth on the engine 
sprockets at the top end, stretching a #35 chain for each engine into junk in 
an evenings racing, at speeds in the neighborhood (both sides of it) of 125 
mph.  Booze  dynamite burners, depending on the track  gearing might have 
hit 150 occasionally.  I burned some booze  castor for a while, but my 
converted bilge pump engine was all run out at about 120.  It was a deflector 
head design,  they are all done at about 8k rpm's.  The torque its rotary 
intake gave just couldn't make up for the rpm loss, but I had fun and went 
through way too much money doing it.

-- 
Cheers. Gene
There are 4 boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order
-Ed Howdershelt (Author)

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Re: [Emc-users] Ethernet I/O

2007-10-30 Thread Jon Elson
Jarl Stefansson wrote:
 I would like to point out that ARM processors aren't the only way to go
 embedded, there are very decent x86 embedded systems available with AMD
 (Geode LX/NX) and VIA (CN/CX/C7/Eden) CPUs.
 
 System based on these can be sourced for less than $100 in bulk and as
 an added benefit none of the code needs to be ported.
 
Unless you are going to put a hard drive on there, you still 
have to problem of where the G-code files come from.
 Perhaps it's time to experiment with building a custom distro to run
 EMC2 or a subset of it on embedded systems booting from flash NAND/NOR.
 
I guess there are special file systems that reduce unneccesary 
writes to the flash memory.  or, you could put all the writable 
files on the system with the GUI.  Do these systems still have 
parallel ports?  I'm guessing these systems still have VGA 
ports, too, so you don't really need a separate system for the GUI.
 Instead of porting the code our time might be better spent optimising
 for x86 which would benefit all users.
 
 My main question is how hard would it be to run EMC in a distributed
 way so that the motion controller could run remotely from the pulse
 generator?
Hmmm, well the MPG could still be connected to the system 
running the RT section of EMC, but I'm not sure that's what you 
are asking here.

Jon

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Re: [Emc-users] Ethernet I/O

2007-10-30 Thread Jon Elson
Rufi wrote:
 hello guys,
  
 I like to point you to our dspMC motion controller 
 www.vitalsystem.com/dspMC http://www.vitalsystem.com/dspMC. 
  
 the board has a blackfin DSP from Analog Devices.  the Blackfin dsp is 
 supported by Gnu/Gcc comipler and a linux port is available at 
 http://blackfin.uclinux.org.
Only $895

Jon

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Re: [Emc-users] Ethernet I/O

2007-10-30 Thread Stephen Wille Padnos
Jarl Stefansson wrote:

I would like to point out that ARM processors aren't the only way to go
embedded, there are very decent x86 embedded systems available with AMD
(Geode LX/NX) and VIA (CN/CX/C7/Eden) CPUs.
  

If you're thinking of the small-footprint PC-like systems, you probably 
need to think again :)  The systems I've seen (and I've looked at a lot 
of them) are all meant for throughput, not latency.  They also have no 
non-PC I/O.  By that I mean that they're usually missing even the 
parallel port (though some have an internal header for it).
We're talking about the controller that actually generates step/dir or 
PWM signals, and the embedded PCs don't have the connections or the 
realtime response to do that.  They're pretty fast little processors, 
and if you want to make a little streaming video box they're great, but 
for the level of realtime performance this project would need, I don't 
think they can do the job.

Of course I'd love to be proven wrong, so if you know of a little 
embedded PC that actually has RT latencies 5-10 usec, please tell us 
about it :)

System based on these can be sourced for less than $100 in bulk and as
an added benefit none of the code needs to be ported.

Perhaps it's time to experiment with building a custom distro to run
EMC2 or a subset of it on embedded systems booting from flash NAND/NOR.
  

This would be excellent.  I have a small system that uses RTAI/HAL, and 
runs from an SSD hard drive.  I managed to get the latencies near 1 
microsecond most of the time, with outliers around 2 us.  This was done 
by using ext2 on the disk, and preventing almost everything from 
loading.  Additionally, since the PC has a core 2 duo in it, I create a 
CPU-hog process, which reduces latency from around 5-6 us to around 
1us.  (I don't know why it works, but this isn't the only system we've 
seen that on)
I would love to have a small distro that just boots up and runs the app 
(EMC2 or some other RT app), and doesn't barf when you shut it down by 
removing power (without doing a shutdown).

Instead of porting the code our time might be better spent optimising
for x86 which would benefit all users.

My main question is how hard would it be to run EMC in a distributed
way so that the motion controller could run remotely from the pulse
generator?
  

I think the easier thing to do is put the motion controller and pulse 
generator on the same board, and let EMC2 run remotely the way it was 
designed - using NML or some other communication method at the CANON level.

- Steve


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Re: [Emc-users] Off Topic, Broaching

2007-10-30 Thread ben lipkowitz
On Mon, 29 Oct 2007, Kirk Wallace wrote:

 I actually prefer not having keyways and going with set screws on 
 countersinks. Anyone have thoughts on this? Thanks.


One trick I came up with is to use a shorter than normal set-screw, and 
put a cylindrical piece of brass or plastic that matches the internal 
diameter of the setscrew threads into the screw hole underneath the 
set-screw. The screw pushes on the cylindrical 'key' allowing use of 
shafts with key slots, and will still shear off the way a key would, but 
probably at a lower torque. You could use a fatter set-screw to get the 
key width up and mill flats on it if you were so inclined...

   -fenn

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Re: [Emc-users] Ethernet I/O

2007-10-30 Thread Peter C. Wallace
 $300, using pluggable terminal strips ;)


Heh, We told Digikey the Avnet price and they came down to ~10.00...

For a parallel port replacement Ethernet, maybe a thing to consider is just a 
single point to point link to the (multi axis) endpoint and some very simple 
master slave protocol. The slave would get a packet, unpack to hardware 
registers, and echo a new packet or return data.

I've been thinking of doing this with a low cost FPGA card like the 7I43. Just 
replace the USB interface with a LM3S8933 or something (Nice because it has a 
built in PHY and IEEE 1588 (no speed demon though))


 - Steve


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Mesa Electronics

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Re: [Emc-users] Ethernet I/O

2007-10-30 Thread Rufi
Jon,

it will be in the $600 range for the emc community. like I said, we will not be 
developing the software so this will allow us to offer the board at a lower 
price.

regards,
Abdul



- Original Message 
From: Jon Elson [EMAIL PROTECTED]
To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
Sent: Tuesday, October 30, 2007 7:53:51 PM
Subject: Re: [Emc-users] Ethernet I/O

Rufi wrote:
 hello guys,
  
 I like to point you to our dspMC motion controller 
 www.vitalsystem.com/dspMC http://www.vitalsystem.com/dspMC. 
  
 the board has a blackfin DSP from Analog Devices.  the Blackfin dsp is 
 supported by Gnu/Gcc comipler and a linux port is available at 
 http://blackfin.uclinux.org.
Only $895

Jon

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Re: [Emc-users] Ethernet I/O

2007-10-30 Thread Javid Butler
Fair enough, although I'm seeing machines that have both an RJ-45 and Wifi, 
which would address the problem.

Javid


- Original Message - 
From: Peter C. Wallace [EMAIL PROTECTED]
To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
Sent: Tuesday, October 30, 2007 8:17 PM
Subject: Re: [Emc-users] Ethernet I/O


 On Tue, 30 Oct 2007, Javid Butler wrote:

 Date: Tue, 30 Oct 2007 19:36:35 -0600
 From: Javid Butler [EMAIL PROTECTED]
 Reply-To: Enhanced Machine Controller (EMC)
 emc-users@lists.sourceforge.net
 To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
 Subject: Re: [Emc-users] Ethernet I/O

 Jon wrote-

 Given all the required overhead to read and write multiple
 packets, it is already pretty close to chewing up a whole
 millisecond, and there's no way it could handle even 5 KHz
 servo update rate.  So, I really don't think CAN is a good
 candidate.

 I agree. The thread started because of concern about the parport going 
 away
 on newer machines, and how to replace it. I have not seen any computers 
 with
 a CAN interface built in, which would defeat the whole purpose. We could
 consider USB, but that has problems as well and met with resistance
 upthread. Ethernet is relatively easy, affordable and available, and as 
 Jon
 mentioned before is isolated.

 Not arguing for CAN, but Ethernet being built-in is not a great advantage
 unless there are 2 channels built in, since real time Ethernet (real time
 meaning fast enough to close a servo loop) will not get along with normal
 Ethernet traffic and a network connection is almost a necessity, requiring 
 a
 add-in card in most cases. Not much different from the parallel port case,
 though faster.


 Peter Wallace

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Re: [Emc-users] Ethernet I/O

2007-10-30 Thread Jon Elson
Stephen Wille Padnos wrote:
 
 Jon Elson wrote:
 
 

 
 I think the flash is actually slower than external memory access.  The 
 datasheet for one of these chips (don't remember which one) said that it 
 was limited to ~55 MHz operating from flash, but 175-200 MHz from RAM.  
 I don't recall if that was internal SRAM or external ram though.  It's 
 definitely prudent to stick high-speed ISRs in RAM though.
 
OK, I have read a LOT more about the unavailable NXP ARM7 chips 
with the 10/100 Ethernet built in, and haven't gotten up to 
speed on the Atmel version.
 
 There would need to be some 
process on the PC supporting file serving to the ARM, but I 
suppose NFS would work.  Without all the Linux OS overhead and 
virtual PC nightmares of the current PC architecture, the 70+ 
MIPS of the ARM processors might be sufficient.
 

 
 You don't need to serve files.  The place to put the break between PC 
 and motion controller is probably CANON/NML, not G-code.  This 
 eliminates the need to send G-code files to the embedded box, and it 
 also makes G-code additions/modifications happen on the PC only (most of 
 the time anyway).
 
Well, this is getting WAY deeper into this than I wanted it 
to get!  I was hoping for a quick hack to basically extend my 
IEEE-1284 protocol through some kind of ethernet encapsulation, 
now we're getting into splitting EMC2 into several pieces 
running on different architectures.  It would certainly be a 
great facility to have, but this way beyond the amount of time I 
have to devote to it.  If I could do some of the hardware level 
stuff, like reworking an Atmel development board to just have 
what we need (like maybe some outboard RAM, Ethernet, parallel
port that could be used for step generation or an interface to 
my controller boards, and the ADC and other features of the 
Atmel chip, I'd sure be interested in working on that.  But, 
when I look at all the areas that might need work, such as 
hooking RTnet (or other RT-Ethernet driver/stack) to HAL, 
getting the same RT-ethernet driver ported to the Atmel chip,
and now sawing EMC2 in half without killing it, just like the 
stage magician, I'm definitely getting overwhelmed.
 
Once the file serving question is handled, the only serious 
remaining effort (I think) would be porting rtapi to one of the 
competing ARM RTOS options.
 

 
 I don't know that the embedded processor needs to run Linux.  That may 
 be an unnecessarily large burden, though it seems simpler because you're 
 then just networking two Linux systems, which works quite nicely.  I 
 suspect, though I don't have any recent experience with it, that ucLinux 
 is pretty RT already, or could be made so pretty easily.
 
There are several Rtos packages for the ARM that are not 
anything near a Linux kernel.  They are much closer to the old 
rt scheduler.
 
A very interesting idea, but it could be fairly time consuming 
to deal with all the intricacies of such a big porting effort.
It would sure make a NEAT package, and the board could be quite 
cheap.  These ARM microcontrollers are in the $7 - 14 range, 
they need an additional $12 or so of parts to implement 
Ethernet, and maybe under $10 for extra memory.  I would think 
that pat could be done for under $100.  Add an FPGA to do step 
generation or PWM drive and a bunch of I/O connections, and you
are up to maybe $200 for a commercial product.
 

 
 $300, using pluggable terminal strips ;)
Yeah, I know!

Jon

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Re: [Emc-users] Ethernet I/O

2007-10-30 Thread Jon Elson
Peter C. Wallace wrote:
$300, using pluggable terminal strips ;)
 
 
 
 Heh, We told Digikey the Avnet price and they came down to ~10.00...
 
 For a parallel port replacement Ethernet, maybe a thing to consider is just a 
 single point to point link to the (multi axis) endpoint and some very simple 
 master slave protocol. The slave would get a packet, unpack to hardware 
 registers, and echo a new packet or return data.
Yes, but it has to have a real time driver module, that's the 
problem.  And, it would require two ethernet ports on the 
system, if you wanted to also be on the local network.
 
 I've been thinking of doing this with a low cost FPGA card like the 7I43. 
 Just 
 replace the USB interface with a LM3S8933 or something (Nice because it has a 
 built in PHY and IEEE 1588 (no speed demon though))
For what I want to do with t, it has to be pretty fast.  I'd 
want to leave the possibility it could run at a 10 KHz servo 
update rate, otherwise it is a step BACK from the parallel port.

Jon

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Re: [Emc-users] Ethernet I/O

2007-10-30 Thread Jon Elson
Peter C. Wallace wrote:
 On Tue, 30 Oct 2007, Javid Butler wrote:
 
 
Date: Tue, 30 Oct 2007 19:36:35 -0600
From: Javid Butler [EMAIL PROTECTED]
Reply-To: Enhanced Machine Controller (EMC)
emc-users@lists.sourceforge.net
To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
Subject: Re: [Emc-users] Ethernet I/O

Jon wrote-


Given all the required overhead to read and write multiple
packets, it is already pretty close to chewing up a whole
millisecond, and there's no way it could handle even 5 KHz
servo update rate.  So, I really don't think CAN is a good
candidate.

I agree. The thread started because of concern about the parport going away
on newer machines, and how to replace it. I have not seen any computers with
a CAN interface built in, which would defeat the whole purpose. We could
consider USB, but that has problems as well and met with resistance
upthread. Ethernet is relatively easy, affordable and available, and as Jon
mentioned before is isolated.
 
 
 Not arguing for CAN, but Ethernet being built-in is not a great advantage 
 unless there are 2 channels built in, since real time Ethernet (real time 
 meaning fast enough to close a servo loop) will not get along with normal 
 Ethernet traffic and a network connection is almost a necessity, requiring a 
 add-in card in most cases. Not much different from the parallel port case, 
 though faster.
RTnet solves this problem by time division multiplexing the 
ethernet, but then you need some other machine to have the dual 
ethernet ports to work as a router.  But, you only need one.

Jon

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Re: [Emc-users] Ethernet I/O

2007-10-30 Thread Rafael Skodlar
Jon Elson wrote:
 Jarl Stefansson wrote:
   
 I would like to point out that ARM processors aren't the only way to go
 embedded, there are very decent x86 embedded systems available with AMD
 (Geode LX/NX) and VIA (CN/CX/C7/Eden) CPUs.

 
As others have pointed out, miniITX and such do not solve the problem 
because there is no appropriate IO available in most of them.

 System based on these can be sourced for less than $100 in bulk and as
 an added benefit none of the code needs to be ported.

 
 Unless you are going to put a hard drive on there, you still 
 have to problem of where the G-code files come from.
   
NFS. You don't need it much, only to copy the files to slave system from 
the server and you can disconnect the network afterwards for security or 
latency reasons.

There are other possibilities to go about this: http://www.emdebian.org, 
http://www.ltsp.org, or http://www.etherboot.org for example. Bootup 
takes only a few seconds so it would be possible to rebuild the whole OS 
and simply reboot the slave system. Other advantages are low initial and 
maintenance costs, one non-RT server could feed a number of diskless EMC 
systems on  the shop floor, etc. Default OS with basic EMC functionality 
could still be stored in EMC system flash memory.

Providing virtual appliances for bootup from the net and testing would 
also be easy with virtualization now being mainstream. Instead of 
generic EMC, a set of preconfigured appliances could be built to help 
new users.

 Perhaps it's time to experiment with building a custom distro to run
 EMC2 or a subset of it on embedded systems booting from flash NAND/NOR.

 
 I guess there are special file systems that reduce unneccesary 
 writes to the flash memory.  or, you could put all the writable 
 files on the system with the GUI.  Do these systems still have 
 parallel ports?  I'm guessing these systems still have VGA 
 ports, too, so you don't really need a separate system for the GUI.
   
 Instead of porting the code our time might be better spent optimising
 for x86 which would benefit all users.

 My main question is how hard would it be to run EMC in a distributed
 way so that the motion controller could run remotely from the pulse
 generator?
 
 Hmmm, well the MPG could still be connected to the system 
 running the RT section of EMC, but I'm not sure that's what you 
 are asking here.

 Jon
   
-- 
Rafael


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