Re: [Emc-users] BeagleBone Image Available

2013-09-05 Thread Paul Lacatus
On 9/3/2013 3:24 AM, Charles Steinkuehler wrote:
 On 9/2/2013 7:14 PM, Kirk Wallace wrote:
 On 09/02/2013 03:38 PM, Charles Steinkuehler wrote:
 I have a new version of the MachineKit image for running LinuxCNC on a
 BeagleBone available:

 Image:
 http://bb-lcnc.blogspot.com/p/machinekit_16.html

 Announcement:
 http://bb-lcnc.blogspot.com/2013/09/new-machinekit-image-available.html

 This is a fairly significant change from the previous versions, as I am
 now building the kernel fully from source (pulling in the required
 Xenomai code from git) and I have switched to the
 unified-build-candidate branch of LinuxCNC (which is going to become 2.6?).

 Anyway, if anyone has an interest in playing with LinuxCNC on the
 BeagleBone give it a whirl and let me know how it works for you.  It
 moves motors for me, but I have made enough changes I'd like as much
 testing as possible.

 Thanks!
 Is there a brain dead install document or a list of things one would
 need to learn to do an installation? The wiki pages look like they were
 last updated in March?
 Which wiki pages?

 My blog page with the image download should have enough to get you going
 if you have some Linux experience and can figure out the device
 representing your SD card reader:

 http://bb-lcnc.blogspot.com/p/machinekit_16.html


Hi,

I bought a BBB card for using on my little MF70 CNC.  I am looking for a 
while on internet but did not  found anything about using a BBB with a 
cape or connection to emulate the parallel port by BBB GPIO. I have seen 
the BeBoPr  or K9 Smorgasboard  that emulates the parallel port but 
there is not an inexpensive solution ? Only some logic  level converters?

Also it will be nice to have a small touch screen to be used with axis , 
some advicez . I am thinking as variant to use a android tablet with an 
x11 server app

Paul

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Re: [Emc-users] Servo motor watts VS torque?

2013-09-05 Thread Dave Caroline
An important spec to look for in any motor is the stall torque to give
an idea of its ability to move a dead load like a machine table that
also has stiction (stationary friction) and any other load on the
table to overcome.

Note power is the product of torque and rpm
the formulas are on
http://www.engineeringtoolbox.com/electrical-motors-hp-torque-rpm-d_1503.html
including some example motor ratings

Use a motor man enough for the job

This is from a user who is about to rebuild the X slide due to
friction problems when static

Dave Caroline


On Thu, Sep 5, 2013 at 5:40 AM, Gregg Eshelman g_ala...@yahoo.com wrote:
 On Wed, 9/4/13, Jack Coats j...@coats.org wrote:

  Subject: Re: [Emc-users] Servo motor watts VS torque?
  To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
  Date: Wednesday, September 4, 2013, 8:18 PM

  From what I have been told, the
  Amps is the 'power', but more volts is the
  'speed' and responsiveness component.

  Watts is Volts times Amps, and is defined as 'power'.

  The 'torque' would be more the 'amps' than power, but
  obviously they are related.

  Does that help?
  --

 What I'm looking for is for each type of motor (AC and BLDC) is You want at 
 least x watts and n amps to at least be in the same range as the old motor. 
 On cncdrives.com I noticed the torque values listed are different for AC and 
 DC motors of the same watts.

 The old motors were 5.8 amp cont, 30 amp peak. Stall torque 3NM cont. Max RPM 
 2400. Max voltage 140 DC.

 I don't know how much the table and saddle weigh, but having had the table 
 and saddle off a slightly smaller Lagun to do long overdue cleaning and nut 
 replacement, I know it's a rather large number of pounds or kilos. There's 
 some videos on youtube of old Anilam Crusader M systems on knee mills, 
 presumably with 140V brush DC motors like these, and they don't appear to be 
 too sprightly.

 Have a look at this. It's a bed mill, it must have some real powerful motors 
 to move that fast. http://www.youtube.com/watch?v=E3AqIZURMbI I don't expect 
 a knee mill to be that fast, but it should be able to be at least somewhat 
 quicker than it was out the factory door 23 years ago, with newer motors and 
 control systems.

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Re: [Emc-users] BeagleBone Image Available

2013-09-05 Thread Michael Haberler

Am 05.09.2013 um 08:28 schrieb Paul Lacatus p...@paul-lacatus.ro:

 On 9/3/2013 3:24 AM, Charles Steinkuehler wrote:
 On 9/2/2013 7:14 PM, Kirk Wallace wrote:
 On 09/02/2013 03:38 PM, Charles Steinkuehler wrote:
 I have a new version of the MachineKit image for running LinuxCNC on a
 BeagleBone available:
 
 Image:
 http://bb-lcnc.blogspot.com/p/machinekit_16.html
 
 Announcement:
 http://bb-lcnc.blogspot.com/2013/09/new-machinekit-image-available.html
 
 This is a fairly significant change from the previous versions, as I am
 now building the kernel fully from source (pulling in the required
 Xenomai code from git) and I have switched to the
 unified-build-candidate branch of LinuxCNC (which is going to become 2.6?).
 
 Anyway, if anyone has an interest in playing with LinuxCNC on the
 BeagleBone give it a whirl and let me know how it works for you.  It
 moves motors for me, but I have made enough changes I'd like as much
 testing as possible.
 
 Thanks!
 Is there a brain dead install document or a list of things one would
 need to learn to do an installation? The wiki pages look like they were
 last updated in March?
 Which wiki pages?
 
 My blog page with the image download should have enough to get you going
 if you have some Linux experience and can figure out the device
 representing your SD card reader:
 
 http://bb-lcnc.blogspot.com/p/machinekit_16.html
 
 
 Hi,
 
 I bought a BBB card for using on my little MF70 CNC.  I am looking for a 
 while on internet but did not  found anything about using a BBB with a 
 cape or connection to emulate the parallel port by BBB GPIO. I have seen 
 the BeBoPr  or K9 Smorgasboard  that emulates the parallel port but 
 there is not an inexpensive solution ? Only some logic  level converters?

that'd be very useful to have, I guess many people could make use of such a cape

I heard Alex Joni thinking aloud about creating one.. Alex? 

next best thing is buying a breakout cape like this: 
http://www.adafruit.com/products/572 and grabbing the soldering iron ;)


- Michael


 
 Also it will be nice to have a small touch screen to be used with axis , 
 some advicez . I am thinking as variant to use a android tablet with an 
 x11 server app
 
 Paul
 
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[Emc-users] Control refit options - best economical servo amp for this application?

2013-09-05 Thread Greg Bentzinger


Hello group;

An old friend contacted me recently about problems he has been having with his 
hobby mill. I say hobby because the man is a top notch surgeon who does mainly 
reconstruction of destroyed hands.

His hobby mill looks to be a late 70's vintage CNC knee mill with a 2 or 3 hp 
Universal 300 qwik switch spindle. The control CRT is long gone and a BW 7 
inch hand held TV is strapped in place using composite RCA video.  I'm guessing 
a Z80A cpu.  The Mill has Baldor servos as follows; 
ModelM-4060-FL-43
Mfg Code 16/190 81633
 
Max Current25A
Torque Stall350 oz inch
Max Speed2500 RPM
Max Volt120 VDC

Baldor servo amps Model  UM3012-100  Part #  990122C-00. These are +/- 10V 
analog with tach velocity feedback.

I measure 100VDC at the power supply capacitor.

This machine came as a 4 axis but he claims the 4th unit was a basket case when 
he received it and he just kept the extra amp mounted as a spare. Recently the 
Y axis had problems so he moved the wiring from that amp to the A axis amp, Now 
the X is giving him fits and he is blaming the amps but I think the control may 
be failing. While I was there he set the home offset, and about 15 minutes 
later that value was missing for X.

What he would like to do is replace the amps and control, re-using servos and 
existing limit switch wiring and power supplies.

I looked at Copley and I didn't see anything that looked close.  AMC looks like 
a good contender with the 25A20I. Any others I should look at? I would like to 
use that tach feedback if possible as this machine may have rather low count 
encoders and I don't want to touch them at all.

I will likely use one of the 5i25 combo's for I/O. I am considering showing him 
touchy but I have not used it myself as yet so it will be alot more extra 
homework for me.

I also want to try and use the baldor amps at first to prove out limits, homing 
etc. I get the feeling that his amps are far out of tune due to him meddling 
with all the trims pots.

I will need lots of help with guessing accelspecs and other initial settings, I 
will likely be very well versed in some areas of using HAL to get things 
functional.

 
Worse yet - it looks like MY mill may have just given up the ghost also, so 
that machine may be inline for a refit too.


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Re: [Emc-users] Control refit options - best economical servo amp for this application?

2013-09-05 Thread Gregg Eshelman
On Thu, 9/5/13, Greg Bentzinger skullwo...@yahoo.com wrote:

 Hello group;
 
 An old friend contacted me recently about problems he has
 been having with his hobby mill. I say hobby because the man
 is a top notch surgeon who does mainly reconstruction of
 destroyed hands.
 
 His hobby mill looks to be a late 70's vintage CNC knee mill
 with a 2 or 3 hp Universal 300 qwik switch spindle. The
 control CRT is long gone and a BW 7 inch hand held TV
 is strapped in place using composite RCA video.  I'm
 guessing a Z80A cpu.  The Mill has Baldor servos as
 follows; 
 ModelM-4060-FL-43
 Mfg Code 16/190 81633
  
 Max Current25A
 Torque Stall350 oz inch
 Max Speed2500 RPM
 Max Volt120 VDC
-

He's in the same boat I'm in. High voltage DC motors and new or new-er amps to 
drive them are hideously expensive. But a surgeon, you say? That usually means 
a person of means. I couldn't get around the cost of replacing one missing old 
amp and then coming up with the hardware to control it - and then always the 
worry that one of the nearly quarter century old amps would go *poof*, just 
like lighting $500 on fire.

If they were under 100 volts there's plenty of amps or drivers on eBay, but get 
over 100 volts and there's not much. (I spent a lot of time on there looking 
for more up to date drives capable of handling 140 volt DC motors.)

He'll be best off buying a new kit of motors and drivers with all the wiring. 
They usually include some cheap Chinese BOB. Use it to get it set up then toss 
it and get compatible gear from Mesa or Pico or one of the other guys who posts 
here. If you can afford it, all new is the best because A. It's supposed to 
work. B. If it doesn't work you can exchange it.

If he does want to pinch a few pennies, there's a seller on eBay going by 
FA-PARTS, selling kits with used drivers and motors, all tested, with all the 
connectors, wiring diagram and software in English, and a cheap Chinese BOB. 
The connectors have been cut off of cables so wiring is up to the buyer. (I'm 
thinking of buying a kit from FA-PARTS but it'll have my investment in the mill 
over $2,000, dagnabit!)

Might be able to part out the old system to recover some of the cost. I've 
brought in about $700 on old Anilam Crusader M pieces and still have some of it 
left. Curiously, no bids on the amps at a starting bid of $100.

My sights (and budget) are set a bit lower. Still looking at options with 
NEMA34 size motors - and going to have to have someone else make plates to 
adapt a NEMA34 mount to a 4 on 75mm bolt circle. That's something your Dr. 
friend can do before his mill goes dead. Settle on what sort of motors to use 
then get adapters made.

If he doesn't want that 4th axis, I'd be happy to take it off his hands. :-)

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Re: [Emc-users] Servo motor watts VS torque?

2013-09-05 Thread andy pugh
On 5 September 2013 05:40, Gregg Eshelman g_ala...@yahoo.com wrote:
 The old motors were 5.8 amp cont, 30 amp peak. Stall torque 3NM cont. Max RPM 
 2400. Max voltage 140 DC
140V * 30A = 4200W
140V * 5.8A = 800W
3Nm * 2400 rpm = 750W

You probably want at least 750W motors, geared to suit any difference
in nominal motor speed.

My small knee mill seems pretty reasonable with 750W brushless servos.
Though I suspect that I am limited by software commutation at that top
speed end.


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Re: [Emc-users] BeagleBone Image Available

2013-09-05 Thread Mark Wendt
On Wed, Sep 4, 2013 at 2:15 PM, Kirk Wallace kwall...@wallacecompany.comwrote:

 On 09/04/2013 09:56 AM, Kirk Wallace wrote:

 ... snip

 I tried AXIS but got:
 http://www.wallacecompany.com/machine_shop/LinuxCNC/Screenshot-3.png

 so I guess AXIS doesn't work with the BBB.

 Now, on to integrating real hardware.

 --
 Kirk Wallace
 http://www.wallacecompany.com/machine_shop/
 http://www.wallacecompany.com/E45/


Kirk,

That's not a LinuxCNC/Axis error, that's an X error.  There should be
something in the X logs that point to the problem.  Look in your home
directory for the .xsession-errors file.  Should say in there what
parameter caused the X window to barf.

Mark
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Re: [Emc-users] BeagleBone Image Available

2013-09-05 Thread Bob Weiss
On Thu, Sep 5, 2013 at 2:55 AM, emc-users-requ...@lists.sourceforge.netwrote:


 I bought a BBB card for using on my little MF70 CNC.  I am looking for a
 while on internet but did not  found anything about using a BBB with a
 cape or connection to emulate the parallel port by BBB GPIO. I have seen
 the BeBoPr  or K9 Smorgasboard  that emulates the parallel port but
 there is not an inexpensive solution ? Only some logic  level converters?

 Also it will be nice to have a small touch screen to be used with axis ,
 some advicez . I am thinking as variant to use a android tablet with an
 x11 server app

 Paul



All of the signals needed (xstep, xdir etc..) are present on the BBB's
GPIO headers at 3.3v level but are very limited to the amount of current
they can drive/source. If are familiar with electronics you could get the
prototype cape and wire up some I/O line drivers to them and connect right
to your stepper drivers and with Charles' MachineKit image be good to go.

The BeBoPr just does the same thing but adds the MOSFET's to control a 3D
printer's heated bed etc...

Also, the abitlity to connect a touch-screen is there as well. I believe
the drivers in linux are availble to read the input from it as well.

It would be nice though if there was such a Parallel Port Breakout type
board pre-made for those that need that option and provided the connectors
ready to be wired up..

Bob
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Re: [Emc-users] Control refit options - best economical servo amp for this application?

2013-09-05 Thread andy pugh
On 5 September 2013 08:11, Greg Bentzinger skullwo...@yahoo.com wrote:

 What he would like to do is replace the amps and control, re-using servos and 
 existing limit switch wiring and power supplies.
...
 I will likely use one of the 5i25 combo's for I/O. I am considering showing 
 him touchy but I have not used it myself as yet so it will be alot more 
 extra homework for me.

For DC servos I would either be looking at second-hand AMC drives from
eBay/ New I would be looking at  Granite Devices, or the properly dumb
drives from Pico or Mesa.

http://pico-systems.com/osc2.5/catalog/product_info.php?cPath=3products_id=26

Mesa 7i29 (note that it handles 2 motors per card):
http://www.mesanet.com/motioncardinfo.html

Neither the Pico or the Mesa card are analogue-input. They both
actually want a PWM signal, and both Pico and Mesa have hardware to
produce that. The 7i29 is a different family to the 5i25, being
50-pin header rather than DB25. This is mainly a wiring issue, as I
understand it, and I think that adapters exist. However unless you are
committed to the 5i25 the 5i20 would be simpler.

I _think_ that the analogue outputs on the 7i77 are generated by a
DAC, so whilst PWM control of Pico amps with a Mesa 5i25 is almost
certainly entirely possible, It isn't just a wiring issue, you would
need a PWM firmware.

-- 
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http://www.ifixit.com/Manifesto

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Re: [Emc-users] BeagleBone Image Available

2013-09-05 Thread andy pugh
On 5 September 2013 10:36, Bob Weiss bweiss0...@gmail.com wrote:

 It would be nice though if there was such a Parallel Port Breakout type
 board pre-made for those that need that option and provided the connectors
 ready to be wired up..

I made one for the Raspberry Pi:
https://picasaweb.google.com/108164504656404380542/CNCUnsorted#5889107885914527378
It cost me $20 for 20 of the PCBs.

There is a magic chip that does bidirectional level shifting, so the
breakout doesn't need to know which pins are inputs and which are
outputs.
http://docs-europe.electrocomponents.com/webdocs/0b4c/0900766b80b4c8d8.pdf

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Re: [Emc-users] Servo motor watts VS torque?

2013-09-05 Thread Gregg Eshelman
On Thu, 9/5/13, andy pugh bodge...@gmail.com wrote:

 Subject: Re: [Emc-users] Servo motor watts VS torque?
 To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
 Date: Thursday, September 5, 2013, 3:19 AM
 
 On 5 September 2013 05:40, Gregg
 Eshelman g_ala...@yahoo.com
 wrote:
  The old motors were 5.8 amp cont, 30 amp peak. Stall
 torque 3NM cont. Max RPM 2400. Max voltage 140 DC
 140V * 30A = 4200W
 140V * 5.8A = 800W
 3Nm * 2400 rpm = 750W
 
 You probably want at least 750W motors, geared to suit any
 difference in nominal motor speed.
 
 My small knee mill seems pretty reasonable with 750W
 brushless servos.
 Though I suspect that I am limited by software commutation
 at that top speed end.
 ---

The Servo Dynamics SDF1525-12 is rated at 120 volts so I assume the motors 
never saw 140 volts. Still nearly 700 Watts.

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Re: [Emc-users] Spindle Lubrication

2013-09-05 Thread Erik Christiansen
On 04.09.13 15:21, andy pugh wrote:
 On 4 September 2013 14:05, Stuart Stevenson stus...@gmail.com wrote:
 
  Oil bath bearings in the bottom of a gearbox are bathed in ALL of the wear
  particles of the gear train - not a good situation.
 
 That's an interesting point.
 
 I guess it is possible that the idea is that the gearbox oil washes
 the bearings

Then it ought to be beneficial to fit a strong magnet on the end of any
drain plug in the head, or drill and tap a hole to allow for one, if
absent. The bearing would provide ample oil agitation for the magnet to
filter the oil, I figure

Erik

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(We go to the polls on Saturday, and that seems to apply here too.)


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Re: [Emc-users] Servo motor watts VS torque?

2013-09-05 Thread Sven Wesley
2013/9/5 Gregg Eshelman g_ala...@yahoo.com

 On Thu, 9/5/13, andy pugh bodge...@gmail.com wrote:

  Subject: Re: [Emc-users] Servo motor watts VS torque?
  To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
  Date: Thursday, September 5, 2013, 3:19 AM

  On 5 September 2013 05:40, Gregg
  Eshelman g_ala...@yahoo.com
  wrote:
   The old motors were 5.8 amp cont, 30 amp peak. Stall
  torque 3NM cont. Max RPM 2400. Max voltage 140 DC
  140V * 30A = 4200W
  140V * 5.8A = 800W
  3Nm * 2400 rpm = 750W

  You probably want at least 750W motors, geared to suit any
  difference in nominal motor speed.

  My small knee mill seems pretty reasonable with 750W
  brushless servos.
  Though I suspect that I am limited by software commutation
  at that top speed end.
  ---

 The Servo Dynamics SDF1525-12 is rated at 120 volts so I assume the motors
 never saw 140 volts. Still nearly 700 Watts.


I don't know what your machine looks like, but I think many people believe
they need much larger servos than actually needed. My steel router has a
gantry weight around 80-90 kg and is driven by small Nidec servos rated at
80 V (really small). I can assure you that my computer is the bottleneck
and if I go from max feed to a complete stop the whole table shakes. It's
all about acceleration, and I can accelerate pretty fast. If I don't
remember wrong I lowered the max_accel value to 2250 from 3000 to be able
to cut with the table jumping around.
This machine has a belt reduction and 5 mm pitch so I have no problem
running alu or steel despite the small motors, it's the spindle that
doesn't take it.

/S
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[Emc-users] Creating Screw Compensation Table

2013-09-05 Thread Russell Brown

I've RTFM and Googled but I can't find an idiot's guide to creating a
lead screw compensation table for Linuxcnc.  Is my googlefu weak or is
there no such thing?

...or do I actually need one at all?


As background (Hello!  and Warning Newbie Alert!) I have a metric
WMD30LV (big brother to the G0704) mill using the standard lead screws
being driven by 7Nm NEMA 34 steppers (oldham couplers), DQ860MA drivers
and a cheapy BOB connected to a parallel port with Linuxcnc 2.5.3 in
control.  The mill has glass scale DRO's on all axis (fitted when I
thought I could resist going CNC...  Pah!  :-)

However, I think I might have a problem with the accuracy of my lead
screws or perception of accuracy and/or something else...  which is why
I'm thinking that a lead screw compensation file might be better than a
crude backlash setting (yes I have backlash and no, I'm not surprised
but I'd like to make chips before embarking on a ballscrew conversion).

If I do:

G90
G0 X0
X50
reset DRO to zero in the X axis
X100

and take a reading from my DRO I get slightly under 50mm shown.

I've tried various microsteppings with the following results on X  Y:

   Micro
   Steps  X-Axis  Y-Axis
   40049.960  49.950
   80049.960  49.930
  100049.970  49.970
  200049.965  49.970
  400049.955  49.970

Max variation:  0.015mm (0.59 thou) in X and 0.04mm (1.57 thou) in Y.

Does that look like lost steps?  or as much accuracy as I'm likely to
see?  (one can get hung up on accuracy reading the various cnc
lists'n'forums and watching the DRO for that +-5 flicker in the third
decimal place :-)

Is this the sort of thing that a screw compensation table is meant to
deal with?  If so, how do I actually measure the numbers for the table?

Are the measurements absolute or relative to the previous move?  How do
I get the reverse or reverse trim numbers?  Sorry for being a thickie.

If I do use a compensation table, ISTR that there's a limit of 256
entries and the table on my mill moves +-300mm.  Is a table entry for
every 2.34mm what I need to generate?

Thanks in advance.


PS - If I do need a compensation table and work out how to generate one
I'll put something on the wiki for future newbies.
-- 
 Regards,
 Russell
 
| Russell Brown  | MAIL: russ...@lls.com PHONE: 01780 471800 |
| Lady Lodge Systems | WWW Work: http://www.lls.com  |
| Peterborough, England  | WWW Play: http://www.ruffle.me.uk |
 

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Re: [Emc-users] BeagleBone Image Available

2013-09-05 Thread Kirk Wallace
On 09/05/2013 02:31 AM, Mark Wendt wrote:
 On Wed, Sep 4, 2013 at 2:15 PM, Kirk Wallace 
 kwall...@wallacecompany.comwrote:

 On 09/04/2013 09:56 AM, Kirk Wallace wrote:

 ... snip

 I tried AXIS but got:
 http://www.wallacecompany.com/machine_shop/LinuxCNC/Screenshot-3.png

 so I guess AXIS doesn't work with the BBB.

 Now, on to integrating real hardware.

 --
 Kirk Wallace
 http://www.wallacecompany.com/machine_shop/
 http://www.wallacecompany.com/E45/


 Kirk,

 That's not a LinuxCNC/Axis error, that's an X error.  There should be
 something in the X logs that point to the problem.  Look in your home
 directory for the .xsession-errors file.  Should say in there what
 parameter caused the X window to barf.

 Mark

... snip

I have some HDMI and USB bits on order, so I can hook up a monitor, 
keyboard, and mouse directly. The X problem will be put lower on on my list.

It would be really nice to collect the nuggets of X wisdom as applied to 
LInuxCNC on the wiki somewhere. I have used xorg.conf to force X to give 
me what I need, but I'm sure there are much better ways to do this. On 
the other hand, rant on the best practices will probably change as 
soon as we get something that works.

-- 
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http://www.wallacecompany.com/machine_shop/
http://www.wallacecompany.com/E45/

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Re: [Emc-users] Servo motor watts VS torque?

2013-09-05 Thread Jon Elson
Gregg Eshelman wrote:

 What I'm looking for is for each type of motor (AC and BLDC) is You want at 
 least x watts and n amps to at least be in the same range as the old motor. 
 On cncdrives.com I noticed the torque values listed are different for AC and 
 DC motors of the same watts.

 The old motors were 5.8 amp cont, 30 amp peak. Stall torque 3NM cont. Max RPM 
 2400. Max voltage 140 DC.
   
Now, there's an important data point missing from your original 
question!  RPM.
So, a motor of so many Watts can be wound for low-speed or high-speed
operation.  Belt drives have a limited ratio they can provide in one stage.
So, a 3:1 or 4:1 reduction is the maximum that is practical in this 
case.  Also,
as the belt reduction increases, the motor's OWN inertia becomes dominant.
That's why many machine tools run the motors 1:1 with massively oversized
motors to get the required torque for acceleration.  But, modern motors,
especially the brushless type, have low enough rotational inertia that a
2:1 ratio will be just fine.

Anyway, you can compute the linear force a ballscrew can exert from
some given motor torque, and then compute how much acceleration in
G's that will give.  That is a good exercise, rather than talking about
motor Watts.

Jon

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Re: [Emc-users] Creating Screw Compensation Table

2013-09-05 Thread andy pugh
On 5 September 2013 19:08, Russell Brown russ...@lls.lls.com wrote:

 Were the 'errors' I showed (~.015mm over a 50mm move) in the right ball
 park for a non-ball-screw benchtop mill driven by steppers?

Not brilliant, but then I doubt that the machine is driven by
super-precision screws.

 Should I expect a commanded 50mm move to travel 0.040mm less than 50mm ?

 Does the variation in actual distance moved indicate missed steps?  (the
 actual move varied with different microsteppings)

You may be missing steps, it is always a possibility with stepper machines.

I don't suppose you have any way to get the DRO feedback into the PC?
Closing the loop might be a fun project.

-- 
atp
If you can't fix it, you don't own it.
http://www.ifixit.com/Manifesto

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Re: [Emc-users] Creating Screw Compensation Table

2013-09-05 Thread Russell Brown
Quoth bodge...@gmail.com.

On 5 September 2013 16:33, Russell Brown russ...@lls.lls.com wrote:

 Is this the sort of thing that a screw compensation table is meant to
 deal with?  If so, how do I actually measure the numbers for the table?

Then just run up the table, G0 X10, note the reading and make a comp
file entry of 10,9.92, and so on to the end of travel, then come back the 
other way, filling in the third column.

OK.  If I do that, given my X backlash of 0.165mm and an assumed feed of
9.92mm for every 10mm commanded, then I end up with a table like:

  00.00 00.00 0.165   (10.085-9.92)
  10.00 09.92 10.085  (20.005-9.92)
  20.00 19.84 20.005  (29.76-9.92+my_backlash)
  30.00 29.76 

Does that look right?

Given 600mm travel on the X-axis, what table intervals make sense?

Or have I misunderstood the question?

Well.  You missed bits...  but it was multi-part :-) 

Were the 'errors' I showed (~.015mm over a 50mm move) in the right ball
park for a non-ball-screw benchtop mill driven by steppers?

Should I expect a commanded 50mm move to travel 0.040mm less than 50mm ?

Does the variation in actual distance moved indicate missed steps?  (the
actual move varied with different microsteppings)

Am I trying to fix something that's 'normal' ?

-- 
 Regards,
 Russell
 
| Russell Brown  | MAIL: russ...@lls.com PHONE: 01780 471800 |
| Lady Lodge Systems | WWW Work: http://www.lls.com  |
| Peterborough, England  | WWW Play: http://www.ruffle.me.uk |
 

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Re: [Emc-users] Control refit options - best economical servo amp for this application?

2013-09-05 Thread Kirk Wallace
On 09/05/2013 02:53 AM, andy pugh wrote:
 On 5 September 2013 08:11, Greg Bentzinger skullwo...@yahoo.com
 wrote:

 What he would like to do is replace the amps and control, re-using
 servos and existing limit switch wiring and power supplies.
 ...
 I will likely use one of the 5i25 combo's for I/O. I am considering
 showing him touchy but I have not used it myself as yet so it
 will be alot more extra homework for me.

 For DC servos I would either be looking at second-hand AMC drives
 from eBay/ New I would be looking at  Granite Devices, or the
 properly dumb drives from Pico or Mesa.


... snip

The Pico/Mesa amps have my vote. You can leverage the intelligence built
into LinuxCNC, instead of trying to arbitrate between LinuxCNC and the
intelligence in the drives. LinuxCNC should have no trouble utilizing
tachometer, rotary encoder, or scale input, and you get to use HALscope
for tuning.

-- 
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http://www.wallacecompany.com/machine_shop/
http://www.wallacecompany.com/E45/

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Re: [Emc-users] Creating Screw Compensation Table

2013-09-05 Thread andy pugh
On 5 September 2013 16:33, Russell Brown russ...@lls.lls.com wrote:

 Is this the sort of thing that a screw compensation table is meant to
 deal with?  If so, how do I actually measure the numbers for the table?

Normally it is quite difficult. But as you have glass scales then it
seems like it ought to be very simple in your case.

http://www.linuxcnc.org/docs/html/config/ini_config.html#_axis_lt_num_gt_section_a_id_sub_axis_section_a

You need to specify a COMP_FILE and COMP_FILE_TYPE in the INI file.

You can choose to specify an absolute or relative file (that's the FILE_TYPE)

I think what you need to do in your case is switch to machine
coordinate view (#, or use the menu if you don't have a #, or Linux
hasn't found it)

Then G0 X0 and manually push the axis to the end of backlash (unless
your config allows you to approach zero from the other side).
First line in the comp file is now 0,0,?

Then just run up the table, G0 X10, note the reading and make a comp
file entry of 10,9.92,
and so on to the end of travel, then come back the other way, filling
in the third column.

Or have I misunderstood the question?

-- 
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http://www.ifixit.com/Manifesto

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Re: [Emc-users] BeagleBone Image Available

2013-09-05 Thread Ron Bean
I still don't see a
benefit in using a BB with a Bridgeport class machine

I tend to assume that a single-board computer like the Beaglebone would 
be more reliable than a desktop PC, just because it has fewer moving 
parts.



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Re: [Emc-users] Servo motor watts VS torque?

2013-09-05 Thread Sven Wesley
 Anyway, you can compute the linear force a ballscrew can exert from
 some given motor torque, and then compute how much acceleration in
 G's that will give.  That is a good exercise, rather than talking about
 motor Watts.

 Jon


...which you can do with my calc sheet posted earlier. :)

/S
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Re: [Emc-users] Control refit options - best economical servo amp for this application?

2013-09-05 Thread Jon Elson
Greg Bentzinger wrote:
 Hello group;

 An old friend contacted me recently about problems he has been having with 
 his hobby mill. I say hobby because the man is a top notch surgeon who does 
 mainly reconstruction of destroyed hands.

 His hobby mill looks to be a late 70's vintage CNC knee mill with a 2 or 3 hp 
 Universal 300 qwik switch spindle. The control CRT is long gone and a BW 7 
 inch hand held TV is strapped in place using composite RCA video.  I'm 
 guessing a Z80A cpu.  The Mill has Baldor servos as follows; 
 ModelM-4060-FL-43
 Mfg Code 16/190 81633
  
 Max Current25A
 Torque Stall350 oz inch
 Max Speed2500 RPM
 Max Volt120 VDC
   
There are a couple of Pico Systems (disclaimer: my company) ways to go 
with this.
We have an analog servo system called the PPMC (Parallel Port Motion 
Control) that
can use analog velocity servo amps such as the Copley or AMC.  Copley DOES
make higher current servo amps, such as the 422.  (180 V, 20 A peak).

The other way is our PWM servo amps and PWM controller.  This is also 
capable
of 120+ V at 20 A peak.

You can look these up at http://pico-systems.com

Jon

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Re: [Emc-users] Creating Screw Compensation Table

2013-09-05 Thread Troy Jacobson
What are the DRO readings vs. commanded position at regular intervals along
the entire length of travel?


On Thu, Sep 5, 2013 at 1:20 PM, andy pugh bodge...@gmail.com wrote:

 On 5 September 2013 19:08, Russell Brown russ...@lls.lls.com wrote:

  Were the 'errors' I showed (~.015mm over a 50mm move) in the right ball
  park for a non-ball-screw benchtop mill driven by steppers?

 Not brilliant, but then I doubt that the machine is driven by
 super-precision screws.

  Should I expect a commanded 50mm move to travel 0.040mm less than 50mm ?
 
  Does the variation in actual distance moved indicate missed steps?  (the
  actual move varied with different microsteppings)

 You may be missing steps, it is always a possibility with stepper machines.

 I don't suppose you have any way to get the DRO feedback into the PC?
 Closing the loop might be a fun project.

 --
 atp
 If you can't fix it, you don't own it.
 http://www.ifixit.com/Manifesto


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Re: [Emc-users] Servo motor watts VS torque?

2013-09-05 Thread Kerry Lynn
On 9/5/13 7:07 AM, Gregg Eshelman wrote:
 On Thu, 9/5/13, andy pugh bodge...@gmail.com wrote:

   Subject: Re: [Emc-users] Servo motor watts VS torque?
   To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
   Date: Thursday, September 5, 2013, 3:19 AM
   
   On 5 September 2013 05:40, Gregg
   Eshelman g_ala...@yahoo.com
   wrote:
The old motors were 5.8 amp cont, 30 amp peak. Stall
   torque 3NM cont. Max RPM 2400. Max voltage 140 DC
   140V * 30A = 4200W
   140V * 5.8A = 800W
   3Nm * 2400 rpm = 750W
   
   You probably want at least 750W motors, geared to suit any
   difference in nominal motor speed.
   
   My small knee mill seems pretty reasonable with 750W
   brushless servos.
   Though I suspect that I am limited by software commutation
   at that top speed end.
   ---

 The Servo Dynamics SDF1525-12 is rated at 120 volts so I assume the motors 
 never saw 140 volts. Still nearly 700 Watts.
Divide watts by 746 to get hp.

Under the heading you get what you pay for, have you looked at the Teknic
Hudson series?  http://www.teknic.com/products/motor_sel.php#

They are available in a variety of stack lengths and windings, and sold 
in the
US by Bearing Engineers: 
http://www.bearingengineers.com/products/product.php?id=223
Bearing Engineers have app specialists who would be happy to talk with you.

No affiliation, just looking into these for one of my projects.
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Re: [Emc-users] Creating Screw Compensation Table

2013-09-05 Thread Stuart Stevenson
If you do bidirectional compensation then backlash does not apply.
I think I would adjust the scale to get the numbers to match as good as
possible. Then the compensation values would be small.



On Thu, Sep 5, 2013 at 1:20 PM, andy pugh bodge...@gmail.com wrote:

 On 5 September 2013 19:08, Russell Brown russ...@lls.lls.com wrote:

  Were the 'errors' I showed (~.015mm over a 50mm move) in the right ball
  park for a non-ball-screw benchtop mill driven by steppers?

 Not brilliant, but then I doubt that the machine is driven by
 super-precision screws.

  Should I expect a commanded 50mm move to travel 0.040mm less than 50mm ?
 
  Does the variation in actual distance moved indicate missed steps?  (the
  actual move varied with different microsteppings)

 You may be missing steps, it is always a possibility with stepper machines.

 I don't suppose you have any way to get the DRO feedback into the PC?
 Closing the loop might be a fun project.

 --
 atp
 If you can't fix it, you don't own it.
 http://www.ifixit.com/Manifesto


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Re: [Emc-users] Servo motor watts VS torque?

2013-09-05 Thread dave
On Thu, 2013-09-05 at 20:19 -0400, Kerry Lynn wrote:
 On 9/5/13 7:07 AM, Gregg Eshelman wrote:
  On Thu, 9/5/13, andy pugh bodge...@gmail.com wrote:
 
Subject: Re: [Emc-users] Servo motor watts VS torque?
To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
Date: Thursday, September 5, 2013, 3:19 AM

On 5 September 2013 05:40, Gregg
Eshelman g_ala...@yahoo.com
wrote:
 The old motors were 5.8 amp cont, 30 amp peak. Stall
torque 3NM cont. Max RPM 2400. Max voltage 140 DC
140V * 30A = 4200W
140V * 5.8A = 800W
3Nm * 2400 rpm = 750W

You probably want at least 750W motors, geared to suit any
difference in nominal motor speed.

My small knee mill seems pretty reasonable with 750W
brushless servos.
Though I suspect that I am limited by software commutation
at that top speed end.
---
 
  The Servo Dynamics SDF1525-12 is rated at 120 volts so I assume the motors 
  never saw 140 volts. Still nearly 700 Watts.
 Divide watts by 746 to get hp.

Before you jump check to see if those amps weren't connected directly to
the line. 

The set I have of SD board amps just like your's that runs directly off
line voltage. 

It is a little hot but those motor are rather responsive at 167 VDC. ;-)

Dave
 
 Under the heading you get what you pay for, have you looked at the Teknic
 Hudson series?  http://www.teknic.com/products/motor_sel.php#
 
 They are available in a variety of stack lengths and windings, and sold 
 in the
 US by Bearing Engineers: 
 http://www.bearingengineers.com/products/product.php?id=223
 Bearing Engineers have app specialists who would be happy to talk with you.
 
 No affiliation, just looking into these for one of my projects.
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Re: [Emc-users] Servo motor watts VS torque?

2013-09-05 Thread Gregg Eshelman
On Thu, 9/5/13, Sven Wesley svenne.d...@gmail.com wrote:

 I don't know what your machine looks like, but I think many
 people believe
 they need much larger servos than actually needed. My steel
 router has a
 gantry weight around 80-90 kg and is driven by small Nidec
 servos rated at 80 V (really small).


That's not even 200 pounds. The table on this mill is 10x50 - 25.4x127 
centimeters, 4 - 10cm at its thickest, of cast iron, plus the saddle. That's a 
lot of weight to move, which I'm not in the least interested in removing unless 
or until it absolutely needs to be.

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Re: [Emc-users] BeagleBone Image Available

2013-09-05 Thread Jon Elson
Ron Bean wrote:
 I still don't see a
 benefit in using a BB with a Bridgeport class machine
 

 I tend to assume that a single-board computer like the Beaglebone would 
 be more reliable than a desktop PC, just because it has fewer moving 
 parts.
   
All Bridgeport mill and Romi lathes made since 1980 (maybe earlier) had
desktop PC motherboards in them.  We have 3 at work like that.

Jon

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Re: [Emc-users] Creating Screw Compensation Table

2013-09-05 Thread Marshland Engineering
 Were the 'errors' I showed (~.015mm over a 50mm move) in the right ball
 park for a non-ball-screw benchtop mill driven by steppers?


This sounds well within then range if normal screws if not better than I 
would have expected.   Another way of looking at this is it is 0.03% error. 
Very small. The trouble with  non-ball-screws is wear from sliding as 
compared balls with rolling. The nuts and screws wear quickly and therefor 
the calibration goes out quite quickly.

Cheers Wallace. 


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[Emc-users] Plasma Table

2013-09-05 Thread Jack Coats
Has anyone done a DIY plasma table, or have suggestions I could find
out about a DIY version?

I am a rookie and just learning, wanting to find out if it could be
practical for a hobby setup.

TIA, Jack

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