Re: [Emc-users] jerk discussion

2013-12-17 Thread Gene Heskett
On Tuesday 17 December 2013 06:17:55 Gregg Eshelman did opine:

 On 12/16/2013 12:05 PM, Gene Heskett wrote:
  Greetings all;
 
 clip
 
  Shorter, even only a 4 tap setup could be of help and might be worth
  exploring just for SG, concept checking to see if I know what I'm
  going on about. ;-)  It might even be worth doing a digital sine
  squared search on google for ideas.
  
  Cheers, Gene
 
 I wonder if this is anything like that?
 http://www.youtube.com/watch?v=2SozZ7af3wg
 
No, no resemblance to my idea, and TBT that driver would be dangerous 
unless its feedback does go into LCNC so LCNC knows it is not where LCNC 
told it to be.  Cute demo yes but could you trust 9 of them to stay within 
a thou of the programmed path?  Scary.

Cheers, Gene
-- 
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 soap, ballot, jury, and ammo. Please use in that order.
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Re: [Emc-users] jerk discussion

2013-12-17 Thread Bertho Stultiens
On 12/17/2013 12:23 PM, Gene Heskett wrote:
 I wonder if this is anything like that?
 http://www.youtube.com/watch?v=2SozZ7af3wg

 No, no resemblance to my idea, and TBT that driver would be dangerous 
 unless its feedback does go into LCNC so LCNC knows it is not where LCNC 
 told it to be.  Cute demo yes but could you trust 9 of them to stay within 
 a thou of the programmed path?  Scary.

But that is the point; if you do not have feedback, then you will never
be able to ensure that you are anywhere on the programmed path. No
matter what driver you use. If one axis is slowed down externally, then
all others need to be adjusted too.

The real problem is, if the slowing force is reduced, who is controlling
the axis' (re-)acceleration? If the HW driver is (partly) autonomous,
then your controlling SW will always lag behind and create a larger path
deviation than if the SW has full control. I.e. reactionary vs.
actionary control.


-- 
Greetings Bertho

(disclaimers are disclaimed)

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[Emc-users] Number of available variables

2013-12-17 Thread Bertho Stultiens
Hi,

Is there a reason, other than the RS274 standard, why there are only
5000 numbered variables available?

I am trying to create a compiling backend to gcmc and the maximum
complexity of the program will depend on the available storage. The
gcode interpreter has enough Turing completeness to calculate anything,
but the available memory size is a limiting factor.

Wouldn't it be trivial to support numbered variables to any number N?

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Re: [Emc-users] Number of available variables

2013-12-17 Thread andy pugh
On 17 December 2013 14:09, Bertho Stultiens ber...@vagrearg.org wrote:


 I am trying to create a compiling backend to gcmc and the maximum
 complexity of the program will depend on the available storage.


You could use named variables instead.

-- 
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Re: [Emc-users] Number of available variables

2013-12-17 Thread Bertho Stultiens
On 12/17/2013 03:33 PM, andy pugh wrote:
 I am trying to create a compiling backend to gcmc and the maximum
 complexity of the program will depend on the available storage.
 You could use named variables instead.

Not for indirect addressing. A lot of the memory needs to be addressed
using #[var] or #[#123] constructs and the target is always a numerical
variable.

Unless you know of a way to store strings in variables and dereference them.

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Re: [Emc-users] jerk discussion

2013-12-17 Thread Gene Heskett
On Tuesday 17 December 2013 07:26:20 Bertho Stultiens did opine:

 On 12/17/2013 12:23 PM, Gene Heskett wrote:
  I wonder if this is anything like that?
  http://www.youtube.com/watch?v=2SozZ7af3wg
  
  No, no resemblance to my idea, and TBT that driver would be dangerous
  unless its feedback does go into LCNC so LCNC knows it is not where
  LCNC told it to be.  Cute demo yes but could you trust 9 of them to
  stay within a thou of the programmed path?  Scary.
 
 But that is the point; if you do not have feedback, then you will never
 be able to ensure that you are anywhere on the programmed path. No
 matter what driver you use. If one axis is slowed down externally, then
 all others need to be adjusted too.
 
 The real problem is, if the slowing force is reduced, who is controlling
 the axis' (re-)acceleration? If the HW driver is (partly) autonomous,
 then your controlling SW will always lag behind and create a larger path
 deviation than if the SW has full control. I.e. reactionary vs.
 actionary control.

Absolutely, that driver, even though its driving steppers MUST be treated 
like a servo, where if it hasn't the hangy downs to get there, the rest of 
the machine is slowed to match and the path tolerance maintained.

Then the question turns into a which costs more question.  And the fact 
that few if any of them are being used, at least on this list  worldview, 
pretty well answers that.  If there were a distinct price advantage over 
servo's, you can bet your sweet we'd have been discussing and using them 
already.  I've a limited info path, these two lists and haven't heard of 
them till now.

Jon's foray into using encoders on steppers for feedback quite some time 
ago seems to have well defined the problems.

Cheers, Gene
-- 
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 soap, ballot, jury, and ammo. Please use in that order.
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Re: [Emc-users] Slow G code

2013-12-17 Thread sam sokolik
Here is a crappy video showing the difference (first run is current TP - 
second run is Roberts hard work)

https://www.youtube.com/watch?v=oUajH5BCOUQfeature=youtu.be

spiral is made up of short line segments.  The current tp has to be able 
to stop by the end of the next segment so it peaks at about 110ipm.  The 
new TP can look 40 segments ahead.  (that will be a configurable in the 
future..) and peaks at about 410ipm.

Current status as I understand it.

Read ahead works if segment transitions are
-Line-Line
-Tangent line-arc, arc-line
-Tangent arc-arc

Darn impressive.
Great work Robert!
sam



On 12/16/2013 12:43 PM, Kent A. Reed wrote:
 On 12/16/2013 01:02 PM, John Alexander Stewart wrote:
 It's been a while since I wrote SLERPing code, but the project I wrote it
 for used Quaternions, which I don't think LinuxCNC uses?? Quaternions
 certainly made a lot of the internal maths easier. (code was in the
 FreeWRL VRML/X3D browser)

 *Does*  LinuxCNC use Quaternions?
 Well, that depends on your meaning of the word use. If you look at the
 libnml/posemath/ routines you'll see a lot of internal usage of
 quarternions for the reason you name but most calls to the routines from
 the rest of LinuxCNC consist of customary and usual representations.
 What representations? Well, consider this snippet from posemath.h

 -
 /* translation types */
 struct PM_CARTESIAN;/* Cart */
 struct PM_SPHERICAL;/* Sph */
 struct PM_CYLINDRICAL;/* Cyl */

 /* rotation types */
 struct PM_ROTATION_VECTOR;/* Rot */
 struct PM_ROTATION_MATRIX;/* Mat */
 struct PM_QUATERNION;/* Quat */
 struct PM_EULER_ZYZ;/* Zyz */
 struct PM_EULER_ZYX;/* Zyx */
 struct PM_RPY;/* Rpy */

 /* pose types */
 struct PM_POSE;/* Pose */
 struct PM_HOMOGENEOUS;/* Hom */
 -

 You can browse the source code itself but it's faster to read the nearly
 15-year old document
 http://www.isd.mel.nist.gov/projects/rcslib/posemath_examples.html


 Regards,
 Kent
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Re: [Emc-users] Limiting Jerk

2013-12-17 Thread Charles Steinkuehler
On 12/16/2013 11:27 AM, Robert Ellenberg wrote:

 That's an interesting use of the term jerk, certainly. The circular-arc
 blend method limits cornering acceleration as well, so you don't need a
 separate spec for that. If they're using a trapezoidal velocity profile,
 there will still be large kinematic jerks, though. Whether you need
 jerk-limiting will probably depend on how stiff your machine is relative to
 the max acceleration, and how much damping your structure and joints
 provide. It would certainly be useful feedback for me if you tried out the
 circular arc branch (linked below if you're curious).
 
 https://github.com/robEllenberg/linuxcnc-mirror/tree/circular-blend-arc-alpha
 
 One issue I can see with running a 3D printer is that A-axis moves have to
 fall back to stock blends (i.e. parabolic). It's something I'd like to
 address in a future release, though there's more work to be done on that
 front.

I'd be willing to test your branch, but pretty much every single move is
going to include X+Y+A.  There are some positioning moves that just
involve X/Y or Z, but all the 'interesting' moves include A.

You do blend over three axis (XYZ), right?  Is there an easy way to
blend over XYA and leave Z as the odd-man out?

If not, I'm not sure testing would really be that interesting, other
than to prove the code properly falls back to the stock blending.

-- 
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char...@steinkuehler.net



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[Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread John Alexander Stewart
Hello all;

2014 sees me finishing up my lathe conversion to CNC. (Emco Compact-8).

I'm a bit confused about spindle sensors, and I do see a few different
designs.

Question - if you had to do it again, what would YOU do for a modern
spindle encoder?

(trying to learn from those who have gone before me, wish me luck!)

PS - I'm tempted to just go for the CNC4PC Index Pulse Card, but maybe
there are better alternatives out there.

Thanks;
John A. Stewart.
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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread andy pugh
On 17 December 2013 23:32, John Alexander Stewart ivatt...@gmail.comwrote:

 Question - if you had to do it again, what would YOU do for a modern
 spindle encoder?


 I am on the 3rd iteration of spindle encoder on my lathe, so feel well
qualified opinionate.

iteration 1 was a laser-printed target wrapped round the spindle shaft and
viewed by reflective optos. It worked, but not all that well.
iteration 2 was a custom made aluminium target and the same reflective
optos:
https://picasaweb.google.com/lh/photo/_hlZumHKbsbV7YoKPcEmOdMTjNZETYmyPJy0liipFm0?feat=directlink
This worked, but had a tendency to drift.
iteration 3 is a cheap rotary encoder from eBay driven by 1:1 gearing on
the spindle shaft. This works perfectly. But I have gear-making facilities.

(Cheap eBay encoder, though not the one I used):
http://www.ebay.co.uk/itm/40mm-Outer-Diameter-Incremental-Type-Photoelectric-Encoder-Rotary-Encoder-/281099904847
At that price, if you can find a way to drive it, it isn't worth trying to
make anything.

I would guess that the lathe has no gears on the spindle to use gear-tooth
detectors on?

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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread Gene Heskett
On Tuesday 17 December 2013 18:55:04 John Alexander Stewart did opine:

 Hello all;
 
 2014 sees me finishing up my lathe conversion to CNC. (Emco Compact-8).
 
 I'm a bit confused about spindle sensors, and I do see a few different
 designs.
 
 Question - if you had to do it again, what would YOU do for a modern
 spindle encoder?
 
 (trying to learn from those who have gone before me, wish me luck!)
 
 PS - I'm tempted to just go for the CNC4PC Index Pulse Card, but maybe
 there are better alternatives out there.
 
 Thanks;
 John A. Stewart.

John:  You need finer grained control than an index generator will ever 
allow if you ever intend to use the G33.1 or G76 thread cutting on the 
lathe, and once I had that working, I don't know why I ever considered not 
doing it.  How big is the back end of the enco spindle?  It can't be a 
whole lot bigger than any of the 7x models.  I have the code to carve a 50 
slot, 200 'edge' wheel with index to fit my 7x, and it wouldn't take long 
to edit to change the size of the center spindle hole a wee bit to make it 
fit the enco.  That encoder's pix is at the

lathe-stf/lathe-pix/Spindle-encoder-final.JPG

link off my web page in the sig.  I can dig up the code that carved that 
wheel, and the pcb above it, with the caveat that the pots you see in that 
pix, which fine tune the britness of the led's in the interruptors, are an 
after the make fix, smoothing the noise in the encoders velocity output 
considerably, if you would like to follow that path.

Along that same vein, I love CNC4PC's C1G interface, but do not recommend 
CNC4PC's C41 spindle controller, its too slow, some non-linear, and needs 
mods to make it faster, lots faster when you are using LCNC to control the 
spindle speed in real time.  Had I any clue to the rocks in the path to 
make that work well, I would have just bought a PMDX-106 in the first 
place.  I have one of those on my toy milling machine but not under servo 
control, just open loop, which works great, but of course I can't do rigid 
tapping very handily with that.

I don't know if the listserver will pass the gcode for the encoder wheel or 
not, but its attached. 10.4K.

Cheers, Gene
-- 
There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order.
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Genes Web page http://geneslinuxbox.net:6309/gene

Blend until smooth.
A pen in the hand of this president is far more
dangerous than 200 million guns in the hands of
 law-abiding citizens.
( spindle-encoder.ngc )
( by Lawrence Glaister VE7IT )
( Sept 15 2007 )
( lerman - thankyou for named variables and owords very cool )
( Cut from arborite stock with 0.049 endmill. )
( This encoder ring mounts on the lathe spindle drive pulley. )
( Ring encoder provides A,B,Z phases using 3 H21TLB slot sensors. )
( The H21TLB sensor use 5v and can directly drive parallel port pins. )
( The sensor apeture is 0.035, so I used double that for the slot length )
( to allow for some runout on mounting the ring. )
( The main constraint is that the main track opto has to be able to physically )
( read the inner track... reaching over the outer index track )
( To preview what it will look like, set _endmill_dia = 0.0 below. )
( With a high speed spindle you may be able to cut to depth in 1 pass. )
( Edited to make a much smaller wheel with fewer slots by Gene Heskett )

(==)
(= Subroutines )
( cuts a circle at request diameter around x,y to requested depth )
o100 sub
  (Subroutine to do a circle)
  ( P1=X center P2=Y center P3-diameter P4=depth P5=feedrate )
  g0 z#_safe_Z
  g0 x[#1-[#3* 0.5]] y#2
  g0 z#4
  g2 F[#5/1.5] x[#1-[#3/2]] y#2 i[#3/2] j0
  g0 z#_safe_Z
o100 endsub

(==)
(=== Define Constants/Variables ===)
#_restartZ = -0.0210

#_endmill_dia = 0.03125 		  	  (  endmill diameter )
#_endmill_rad = [#_endmill_dia * 0.50]   ( endmill radius )
#_duty_cycle	= .30 ( adjust for 50% at output )
#_safe_Z = 0.050	  ( safe Z height )
#_zstart = 0.0015	(run down to there fast, then ramp into slot)
#_feedrate = 2.7		  ( cutting feedrate )
S2500 (spindle speed)
( define characteristics of encoder and index tracks )
#_main_track_dia = 2.2765	  ( diameter of main signal track )
#_index_track_dia = [#_main_track_dia - 0.155] ( diameter of index track )
( May 30, 14:14 GH fix this to compensate for bit radii, needs 1.044 ID hole )
#_inside_cutout = [1.0500 - #_endmill_dia] ( diameter of interior cutout = inside of pulley)
#_outside_cutout = 2.431	  ( diameter of exterior cutout ~= enough space for tracks)
(#_encoder_cycles = 39)	  	  ( number of slots to cut * 4 == 156 edges or about 2.30769230769 degree resolution)
#_encoder_cycles = 50
#_slotlen = 0.100   ( 

Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread Cecil Thomas
Andy,
This one has no index.  How did you generate your index pulse?
Cecil


Andy Pugh wrote:

(Cheap eBay encoder, though not the one I used):
http://www.ebay.co.uk/itm/40mm-Outer-Diameter-Incremental-Type-Photoelectric-Encoder-Rotary-Encoder-/281099904847
At that price, if you can find a way to drive it, it isn't worth trying to
make anything.
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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread andy pugh
On 18 December 2013 00:21, Cecil Thomas wctho...@chartertn.net wrote:

 Andy,
 This one has no index.  How did you generate your index pulse?


I hadn't noticed that, I can't read Chinese.

That might not be the end of the world, as it could be geared to the
spindle at a more convenient ratio than 1:1 and the index could be taken
from a separate flag on the spindle.

But finding one nearly as cheap with index would be better.

Sorry for the duff lead.

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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread dave
On Tue, 2013-12-17 at 18:32 -0500, John Alexander Stewart wrote:
 Hello all;
 
 2014 sees me finishing up my lathe conversion to CNC. (Emco Compact-8).
 
 I'm a bit confused about spindle sensors, and I do see a few different
 designs.
 
 Question - if you had to do it again, what would YOU do for a modern
 spindle encoder?
 
 (trying to learn from those who have gone before me, wish me luck!)
 
 PS - I'm tempted to just go for the CNC4PC Index Pulse Card, but maybe
 there are better alternatives out there.
 
 Thanks;
 John A. Stewart.
Hi John, 
Indeed I hope 2014 does see an operating cnc lathe in my shop. I ripped
out all the mechanical stuff and started on a cnc implementation of a
Jet 12 x 40. 
For the spindle I did something dumb which I will need to fix. Used a
360 cpr Koyo encoder but geared it (in a moment of dullness) 2:1 so
index pulses are not unique in angular index. Duh! I geared this with a
couple of timing pulley and a timing belt. I just need to make room for
1:1 so I can use the index without hassle. Yes, I know I could divide by
2 but the KISS principle is overpowering. 

If anyone has a really neat idea for getting the Z ballscrew aligned
with the Z axis I'm all ears.

I hope everyone has time with family over the holidays but also has time
to work on THEIR pet projects.  Good Grief! Winter solstice is Sat. As
the frog said, time fun when you are having flies.

Dave 



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[Emc-users] Servo Following Error

2013-12-17 Thread Jeshua Lacock

Greetings,

I dusted off my CNC machine which required a bit of TLC.

The system is now perfectly stable and all axis work using both Manual Control 
and MDI. Shortly after I try to run gcode it stops with most often a following 
error or sometimes something is silently throwing the estop.

I am using Pico's universal stepper controller with their gecko interface.

Please see a plot of the axis that is causing the following error on my test 
gcode:

http://3dtopo.com/z-servo-plot.png

I am really stumped, any advice would be greatly appreciated!


Thanks,

Jeshua Lacock
Founder/Engineer
3DTOPO Incorporated
http://3DTOPO.com
Phone: 208.462.4171


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Re: [Emc-users] Servo Following Error

2013-12-17 Thread Peter C. Wallace
On Tue, 17 Dec 2013, Jeshua Lacock wrote:

 Date: Tue, 17 Dec 2013 18:09:18 -0700
 From: Jeshua Lacock jes...@3dtopo.com
 Reply-To: Enhanced Machine Controller (EMC)
 emc-users@lists.sourceforge.net
 To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
 Subject: [Emc-users] Servo Following Error
 

 Greetings,

 I dusted off my CNC machine which required a bit of TLC.

 The system is now perfectly stable and all axis work using both Manual 
 Control and MDI. Shortly after I try to run gcode it stops with most often a 
 following error or sometimes something is silently throwing the estop.

 I am using Pico's universal stepper controller with their gecko interface.

 Please see a plot of the axis that is causing the following error on my test 
 gcode:

   http://3dtopo.com/z-servo-plot.png

 I am really stumped, any advice would be greatly appreciated!



maybe out of velocity headroom?




 Thanks,

 Jeshua Lacock
 Founder/Engineer
 3DTOPO Incorporated
 http://3DTOPO.com
 Phone: 208.462.4171


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 organizations don't have a clear picture of how application performance
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Mesa Electronics

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Re: [Emc-users] Servo Following Error

2013-12-17 Thread Jeshua Lacock

On Dec 17, 2013, at 6:49 PM, Peter C. Wallace p...@mesanet.com wrote:

 maybe out of velocity headroom?

Hi Peter,

Thanks, but I have the speed and acceleration way down for now. It used to work 
much much faster….


Thanks again,

Jeshua Lacock
Founder/Engineer
3DTOPO Incorporated
http://3DTOPO.com
Phone: 208.462.4171


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Re: [Emc-users] Servo Following Error

2013-12-17 Thread Jeshua Lacock

p.s.

It still can go plenty fast (200+ ipm) using manual control or MDI...

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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread Gene Heskett
On Tuesday 17 December 2013 20:51:20 dave did opine:

 On Tue, 2013-12-17 at 18:32 -0500, John Alexander Stewart wrote:
  Hello all;
  
  2014 sees me finishing up my lathe conversion to CNC. (Emco
  Compact-8).
  
  I'm a bit confused about spindle sensors, and I do see a few
  different designs.
  
  Question - if you had to do it again, what would YOU do for a modern
  spindle encoder?
  
  (trying to learn from those who have gone before me, wish me luck!)
  
  PS - I'm tempted to just go for the CNC4PC Index Pulse Card, but maybe
  there are better alternatives out there.
  
  Thanks;
  John A. Stewart.
 
 Hi John,
 Indeed I hope 2014 does see an operating cnc lathe in my shop. I ripped
 out all the mechanical stuff and started on a cnc implementation of a
 Jet 12 x 40.
 For the spindle I did something dumb which I will need to fix. Used a
 360 cpr Koyo encoder but geared it (in a moment of dullness) 2:1 so
 index pulses are not unique in angular index. Duh! I geared this with a
 couple of timing pulley and a timing belt. I just need to make room for
 1:1 so I can use the index without hassle. Yes, I know I could divide by
 2 but the KISS principle is overpowering.
 
 If anyone has a really neat idea for getting the Z ballscrew aligned
 with the Z axis I'm all ears.

I bolted up, loosely, the right end bearing, ran it up against the left 
bearing and adjusted the nut on the face of the carriage apron to hold the 
far end loosely in the correct position.  Then ran the carriage to the 
right and tightened up the right end bearing where it fell.  Then went back 
to the left, re-centered the nut in the apron, went back to the right and 
let that carrier move ever so slightly.  My guess is that it is within a 
thou right now.  No detectable bind.

 I hope everyone has time with family over the holidays but also has time
 to work on THEIR pet projects.  Good Grief! Winter solstice is Sat. As
 the frog said, time fun when you are having flies.
 
 Dave
 
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Cheers, Gene
-- 
There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order.
-Ed Howdershelt (Author)
Genes Web page http://geneslinuxbox.net:6309/gene

Every morning, I get up and look through the 'Forbes' list of the
richest people in America.  If I'm not there, I go to work
-- Robert Orben
A pen in the hand of this president is far more
dangerous than 200 million guns in the hands of
 law-abiding citizens.

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Re: [Emc-users] Servo Following Error

2013-12-17 Thread Peter C. Wallace
On Tue, 17 Dec 2013, Jeshua Lacock wrote:

 Date: Tue, 17 Dec 2013 18:57:25 -0700
 From: Jeshua Lacock jes...@3dtopo.com
 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] Servo Following Error
 

 p.s.

 It still can go plenty fast (200+ ipm) using manual control or MDI...

If my math is right it looks like it blew up at 200 IPM
(d/dt pos ~4 so ~4 IPS or 240 IPM)

Does the error happen in the same place if you run the program again?



 --
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Mesa Electronics

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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread dave
On Tue, 2013-12-17 at 20:59 -0500, Gene Heskett wrote:
 On Tuesday 17 December 2013 20:51:20 dave did opine:
 
  On Tue, 2013-12-17 at 18:32 -0500, John Alexander Stewart wrote:
   Hello all;
   
   2014 sees me finishing up my lathe conversion to CNC. (Emco
   Compact-8).
   
   I'm a bit confused about spindle sensors, and I do see a few
   different designs.
   
   Question - if you had to do it again, what would YOU do for a modern
   spindle encoder?
   
   (trying to learn from those who have gone before me, wish me luck!)
   
   PS - I'm tempted to just go for the CNC4PC Index Pulse Card, but maybe
   there are better alternatives out there.
   
   Thanks;
   John A. Stewart.
  
  Hi John,
  Indeed I hope 2014 does see an operating cnc lathe in my shop. I ripped
  out all the mechanical stuff and started on a cnc implementation of a
  Jet 12 x 40.
  For the spindle I did something dumb which I will need to fix. Used a
  360 cpr Koyo encoder but geared it (in a moment of dullness) 2:1 so
  index pulses are not unique in angular index. Duh! I geared this with a
  couple of timing pulley and a timing belt. I just need to make room for
  1:1 so I can use the index without hassle. Yes, I know I could divide by
  2 but the KISS principle is overpowering.
  
  If anyone has a really neat idea for getting the Z ballscrew aligned
  with the Z axis I'm all ears.
 
 I bolted up, loosely, the right end bearing, ran it up against the left 
 bearing and adjusted the nut on the face of the carriage apron to hold the 
 far end loosely in the correct position.  Then ran the carriage to the 
 right and tightened up the right end bearing where it fell.  Then went back 
 to the left, re-centered the nut in the apron, went back to the right and 
 let that carrier move ever so slightly.  My guess is that it is within a 
 thou right now.  No detectable bind.
 
  I hope everyone has time with family over the holidays but also has time
  to work on THEIR pet projects.  Good Grief! Winter solstice is Sat. As
  the frog said, time fun when you are having flies.
  
  Dave

That makes sense, I've just been mentally fighting it. Tnx. 

Dave
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   https://lists.sourceforge.net/lists/listinfo/emc-users
  
  
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 Cheers, Gene
 -- 
 There are four boxes to be used in defense of liberty:
  soap, ballot, jury, and ammo. Please use in that order.
 -Ed Howdershelt (Author)
 Genes Web page http://geneslinuxbox.net:6309/gene
 
 Every morning, I get up and look through the 'Forbes' list of the
 richest people in America.  If I'm not there, I go to work
   -- Robert Orben
 A pen in the hand of this president is far more
 dangerous than 200 million guns in the hands of
  law-abiding citizens.
 
 --
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 affects their revenue. With AppDynamics, you get 100% visibility into your 
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Re: [Emc-users] Servo Following Error

2013-12-17 Thread Jeshua Lacock

On Dec 17, 2013, at 7:17 PM, Peter C. Wallace p...@mesanet.com wrote:

 On Tue, 17 Dec 2013, Jeshua Lacock wrote:
 
 Date: Tue, 17 Dec 2013 18:57:25 -0700
 From: Jeshua Lacock jes...@3dtopo.com
 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] Servo Following Error
 
 
 p.s.
 
 It still can go plenty fast (200+ ipm) using manual control or MDI...
 
 If my math is right it looks like it blew up at 200 IPM
 (d/dt pos ~4 so ~4 IPS or 240 IPM)
 
 Does the error happen in the same place if you run the program again?

Hi Peter,

It looks like Max Velocity was at the default max (912 in/min) for that test, 
but I confirmed it does the same thing with max velocity set way low like 16 
in/min.

Interesting it would go that fast though because currently the limits I have 
set for testing in the config file are far lower than that. E.g. that 
MAX_VELOCITY for that drive is currently set to 30.5 and PID_MAX_VEL is set to 
30.65.

It does seem to stop on the same gcode line for any given gcode file.


Best,

Jeshua Lacock
Founder/Engineer
3DTOPO Incorporated
http://3DTOPO.com
Phone: 208.462.4171


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Re: [Emc-users] Servo Following Error

2013-12-17 Thread Peter C. Wallace
On Tue, 17 Dec 2013, Jeshua Lacock wrote:

 Date: Tue, 17 Dec 2013 19:29:46 -0700
 From: Jeshua Lacock jes...@3dtopo.com
 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] Servo Following Error
 

 On Dec 17, 2013, at 7:17 PM, Peter C. Wallace p...@mesanet.com wrote:

 On Tue, 17 Dec 2013, Jeshua Lacock wrote:

 Date: Tue, 17 Dec 2013 18:57:25 -0700
 From: Jeshua Lacock jes...@3dtopo.com
 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] Servo Following Error


 p.s.

 It still can go plenty fast (200+ ipm) using manual control or MDI...

 If my math is right it looks like it blew up at 200 IPM
 (d/dt pos ~4 so ~4 IPS or 240 IPM)

 Does the error happen in the same place if you run the program again?

 Hi Peter,

 It looks like Max Velocity was at the default max (912 in/min) for that test, 
 but I confirmed it does the same thing with max velocity set way low like 16 
 in/min.

 Interesting it would go that fast though because currently the limits I have 
 set for testing in the config file are far lower than that. E.g. that 
 MAX_VELOCITY for that drive is currently set to 30.5 and PID_MAX_VEL is set 
 to 30.65.

 It does seem to stop on the same gcode line for any given gcode file.

can you add a plot of the commanded velocity?



 Best,

 Jeshua Lacock
 Founder/Engineer
 3DTOPO Incorporated
 http://3DTOPO.com
 Phone: 208.462.4171


 --
 Rapidly troubleshoot problems before they affect your business. Most IT
 organizations don't have a clear picture of how application performance
 affects their revenue. With AppDynamics, you get 100% visibility into your
 Java,.NET,  PHP application. Start your 15-day FREE TRIAL of AppDynamics Pro!
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Mesa Electronics

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()_() signature to help him gain world domination.


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Re: [Emc-users] Servo Following Error

2013-12-17 Thread Jeshua Lacock

On Dec 17, 2013, at 7:33 PM, Peter C. Wallace p...@mesanet.com wrote:

 On Tue, 17 Dec 2013, Jeshua Lacock wrote:
 
 Date: Tue, 17 Dec 2013 19:29:46 -0700
 From: Jeshua Lacock jes...@3dtopo.com
 
 On Dec 17, 2013, at 7:17 PM, Peter C. Wallace p...@mesanet.com wrote:
 
 On Tue, 17 Dec 2013, Jeshua Lacock wrote:
 
 Date: Tue, 17 Dec 2013 18:57:25 -0700
 From: Jeshua Lacock jes...@3dtopo.com
 
 p.s.
 
 It still can go plenty fast (200+ ipm) using manual control or MDI...
 
 If my math is right it looks like it blew up at 200 IPM
 (d/dt pos ~4 so ~4 IPS or 240 IPM)
 
 Does the error happen in the same place if you run the program again?
 
 It looks like Max Velocity was at the default max (912 in/min) for that 
 test, but I confirmed it does the same thing with max velocity set way low 
 like 16 in/min.
 
 Interesting it would go that fast though because currently the limits I have 
 set for testing in the config file are far lower than that. E.g. that 
 MAX_VELOCITY for that drive is currently set to 30.5 and PID_MAX_VEL is set 
 to 30.65.
 
 It does seem to stop on the same gcode line for any given gcode file.
 
 can you add a plot of the commanded velocity?

Sure thing, please see:

http://3dtopo.com/z-servo-plot2.png

It is now the 4th channel (purple).

You can also see my LinuxCNC window and the line it stops at for this file.


Best,

Jeshua Lacock
Founder/Engineer
3DTOPO Incorporated
http://3DTOPO.com
Phone: 208.462.4171


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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread Gene Heskett
On Tuesday 17 December 2013 21:22:48 dave did opine:

 On Tue, 2013-12-17 at 20:59 -0500, Gene Heskett wrote:
  On Tuesday 17 December 2013 20:51:20 dave did opine:
   On Tue, 2013-12-17 at 18:32 -0500, John Alexander Stewart wrote:
Hello all;

2014 sees me finishing up my lathe conversion to CNC. (Emco
Compact-8).

I'm a bit confused about spindle sensors, and I do see a few
different designs.

Question - if you had to do it again, what would YOU do for a
modern spindle encoder?

(trying to learn from those who have gone before me, wish me
luck!)

PS - I'm tempted to just go for the CNC4PC Index Pulse Card, but
maybe there are better alternatives out there.

Thanks;
John A. Stewart.
   
   Hi John,
   Indeed I hope 2014 does see an operating cnc lathe in my shop. I
   ripped out all the mechanical stuff and started on a cnc
   implementation of a Jet 12 x 40.
   For the spindle I did something dumb which I will need to fix. Used
   a 360 cpr Koyo encoder but geared it (in a moment of dullness) 2:1
   so index pulses are not unique in angular index. Duh! I geared this
   with a couple of timing pulley and a timing belt. I just need to
   make room for 1:1 so I can use the index without hassle. Yes, I
   know I could divide by 2 but the KISS principle is overpowering.
   
   If anyone has a really neat idea for getting the Z ballscrew aligned
   with the Z axis I'm all ears.
  
  I bolted up, loosely, the right end bearing, ran it up against the
  left bearing and adjusted the nut on the face of the carriage apron
  to hold the far end loosely in the correct position.  Then ran the
  carriage to the right and tightened up the right end bearing where it
  fell.  Then went back to the left, re-centered the nut in the apron,
  went back to the right and let that carrier move ever so slightly. 
  My guess is that it is within a thou right now.  No detectable bind.
  
   I hope everyone has time with family over the holidays but also has
   time to work on THEIR pet projects.  Good Grief! Winter solstice is
   Sat. As the frog said, time fun when you are having flies.
   
   Dave
 
 That makes sense, I've just been mentally fighting it. Tnx.
 
 Dave
 
As an ex bro-in-law once remarked:  Its good enough for the girls I go 
with.  He had a rather dry sense of humor about injustices though.  He 
enlisted back in the day, finished growing up into a 225 lb 6'3 man but 
was given a medical when they found he had chorea.  Can home, bought an old 
neighborhood bar, and had been running it quietly for about 18 months when 
the city building inspector came in one night and said he was out of code, 
no back fire exit  he was going to padlock the place.  Roger protested 
that the bar had been there, getting along with its neighbors for something 
like 30 years, why the sudden, and unannounced enforcement activity the guy 
couldn't even produce the city code that defined it.  Roger by then knew 
the layout in the alley back of the building and suggested, pointing at a 
fairly clear spot on the back wall, saying there might be a good place 
for a new door.

The guy agreed, so Roger picked him up and used him to make a new doorway 
in that 40 yo brick wall.  Then he called the cops, whom he was on good 
terms with, told them to come and take out the trash.  They did, charges 
were never filed.  Roger framed in the hole and hung a cheap steel door in 
it the next day so he was legal again.

He was funny about abused kids, married the first 2 times just to file and 
take the child away from an unfit mother in the divorce a few months later.  
Got married to an RN then, who was supplying the money to build them a 
house for all 3 kids, cash  carry.  Rogers sweat equity.

Most bar owners have to make an attitude adjustment occasionally, but 
Roger said 4 or 5 years later after he had sold it, making a good profit, 
that after that, he never had to do it again, just a look under a raised 
eyebrow was all it took.  But chorea and scoliosis was taking him down 
fast, by then I was 1 taller than he was.  I have no idea if he still 
survives, would be about 63 now.  I haven't checked since his older sis, my 
ex bitch, left in late '85.  Cheaper that way.

Cheers, Gene
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Re: [Emc-users] Servo Following Error

2013-12-17 Thread Jon Elson
On 12/17/2013 07:09 PM, Jeshua Lacock wrote:
 Greetings,

 I dusted off my CNC machine which required a bit of TLC.

 The system is now perfectly stable and all axis work using both Manual 
 Control and MDI. Shortly after I try to run gcode it stops with most often a 
 following error or sometimes something is silently throwing the estop.

 I am using Pico's universal stepper controller with their gecko interface.

 Please see a plot of the axis that is causing the following error on my test 
 gcode:

   http://3dtopo.com/z-servo-plot.png

 I am really stumped, any advice would be greatly appreciated!




Ah, you say the Gecko interface.  So, you probably are using
brush servo motors and the Gecko 320 step-servo drive.
It may just be running out of dynamic range.  What is your
power supply voltage?  I see in the delta plot that the velocity
is ramping up to 5 units, meaning 5 encoder counts/servo
period, or typically 5000 counts/second.  Taking a wild 
assumption
of 500 cycle/rev encoders, that would be 2.5 revs/second or
150 RPM, which doesn't sound very fast.  But, if they are
500 count/rev encoders, that would be 600 RPM.  Depending
on the motor and the supply voltage, that could be as fast as
it can go.

Also, there are parameters in the .ini file such as
MAX_VELOCITY
PID_MAX_VEL
OUTPUT_SCALE

OUTPUT_SCALE is a **divider**, so larger numbers reduce the
output command to the step generator.  Generally, it is left at
1.0 (or -1.0 to reverse direction).
MAX_VELOCITY and PID_MAX_VEL are in user units per SECOND.
PID_MAX_VEL should be slightly higher than MAX_VELOCITY to
give the PID calculation a little headroom for acceleration.
Make sure these ini file settings are sufficient for your 
machine.

It looks from your plot that the move is about .4 per second,
or 24 IPM.  Figure out how many RPM you need to move at that
speed, then work backwards from supply voltage and motor
ratings to see if the voltage can give that speed.

Feel free to contact me if the above hints don't point you
to the solution.

Jon
Jon

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Re: [Emc-users] Servo Following Error

2013-12-17 Thread Jon Elson
On 12/17/2013 08:29 PM, Jeshua Lacock wrote:


 It looks like Max Velocity was at the default max (912 in/min) for that test, 
 but I confirmed it does the same thing with max velocity set way low like 16 
 in/min.
Turning MAX_VELOCITY down in the INI file will make it 
worse.  OR,
do you mean turning it down in the GUI (Axis?)  Depending on 
LinuxCNC
version, the GUI max velocity slider may not limit your
rapid\feed (G0) moves!  So, make sure you can move at the 
desired
speeds in G1 first.  If it only fails in G0, then it is most 
likely that
you have set excessive velocities in your [TRAJ] section.
 Interesting it would go that fast though because currently the limits I have 
 set for testing in the config file are far lower than that. E.g. that 
 MAX_VELOCITY for that drive is currently set to 30.5 and PID_MAX_VEL is set 
 to 30.65.
My reading of the plot is about one vertical unit at .2 
(200m) in half
a second, or .4 per second = 24 IPM.  That's a rough guess 
by eye.
Also, the error trace is very suspicious!  It hums along at 
a very small
error (~.0005 or less) for the entire move, then suddenly 
surges to
.010 or so when it trips the following error limit.  The 
only thing I can
figure is that the next command is for a MUCH higher velocity,
which the motion hardware cannot perform.

 It does seem to stop on the same gcode line for any given gcode file.

That is also quite bizarre, if true.  If the same line of 
the G-code file
tells it to do something different, it would be odd for that 
to cause
a fault.

Jon

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Re: [Emc-users] Servo Following Error

2013-12-17 Thread Jeshua Lacock

On Dec 17, 2013, at 8:26 PM, Jon Elson el...@pico-systems.com wrote:

 n 12/17/2013 08:29 PM, Jeshua Lacock wrote:
 
 
 It looks like Max Velocity was at the default max (912 in/min) for that 
 test, but I confirmed it does the same thing with max velocity set way low 
 like 16 in/min.
 Turning MAX_VELOCITY down in the INI file will make it 
 worse.  OR,
 do you mean turning it down in the GUI (Axis?)  Depending on 
 LinuxCNC
 version, the GUI max velocity slider may not limit your
 rapid\feed (G0) moves!  So, make sure you can move at the 
 desired
 speeds in G1 first.  If it only fails in G0, then it is most 
 likely that
 you have set excessive velocities in your [TRAJ] section.
 Interesting it would go that fast though because currently the limits I have 
 set for testing in the config file are far lower than that. E.g. that 
 MAX_VELOCITY for that drive is currently set to 30.5 and PID_MAX_VEL is set 
 to 30.65.
 My reading of the plot is about one vertical unit at .2 
 (200m) in half
 a second, or .4 per second = 24 IPM.  That's a rough guess 
 by eye.
 Also, the error trace is very suspicious!  It hums along at 
 a very small
 error (~.0005 or less) for the entire move, then suddenly 
 surges to
 .010 or so when it trips the following error limit.  The 
 only thing I can
 figure is that the next command is for a MUCH higher velocity,
 which the motion hardware cannot perform.
 
 It does seem to stop on the same gcode line for any given gcode file.
 
 That is also quite bizarre, if true.  If the same line of 
 the G-code file
 tells it to do something different, it would be odd for that 
 to cause
 a fault.

OK - thanks everyone for their help!

I actually just plugged the power supply directly into the wall instead of 
through a SSR controlled by the USC.

Must be some sort of interference?



Best,

Jeshua Lacock
Founder/Engineer
3DTOPO Incorporated
http://3DTOPO.com
Phone: 208.462.4171


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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread John Alexander Stewart
Hi Andy;

Thank you for the response - I have seen your little 7x lathe cnc
conversion on a few places - well done.

I'll readily admit to being a bit newby in encoders.

The Compact-8 does have a 40 tooth gear on the spindle. Right now spindle
pulley is off, because was doing some measurements on it for someone in
Britain who specializes in threading clutches - he needed a Compact-8 to
measure.

Was thinking that, while it was off, I could make up a large disk with
holes for the encoder.  Would it be better to read off the 40 tooth gear on
the spindle??  To me, in my novice state, I'd think that was not as good,
but...

With the ebay rotary encoder -  I can mount that and drive it either via a
timing belt, or simple gear - I have a set or three of change wheels for
the lathe, and I'm sure one could be put into use.

Hmmm - I'm going to look at these rotary encoders more. I'd think that I'd
still need a timing pulse though.

Thank you - John A. Stewart.
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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread John Alexander Stewart
Hi Gene - by:

John:  You need finer grained control than an index generator will ever
 allow if you ever intend to use the G33.1 or G76 thread cutting on the
 lathe, and once I had that working, I don't know why I ever considered not
 doing it.



I presume you mean the one pulse per rev that Mach users seem to be stuck
with.

Code for encoder wheel came through, by the way. I did measure the spindle
diameter (not by lathe right now) so can not comment on how well it'll fit
with your GCode.

The Emco (Austrian, Enco is Asian) will be running with a 3 phase motor and
inverter - already here, just waiting to be installed. The inverter takes
0-10v for the spindle - so that's good.

This is all interesting! Thank you - John A. Stewart
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Re: [Emc-users] Slow G code

2013-12-17 Thread Todd Zuercher
Looking forward to trying this out.

- Original Message -
From: sam sokolik sa...@empirescreen.com
To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
Sent: Tuesday, December 17, 2013 3:10:46 PM
Subject: Re: [Emc-users] Slow G code

Here is a crappy video showing the difference (first run is current TP - 
second run is Roberts hard work)

https://www.youtube.com/watch?v=oUajH5BCOUQfeature=youtu.be

spiral is made up of short line segments.  The current tp has to be able 
to stop by the end of the next segment so it peaks at about 110ipm.  The 
new TP can look 40 segments ahead.  (that will be a configurable in the 
future..) and peaks at about 410ipm.

Current status as I understand it.

Read ahead works if segment transitions are
-Line-Line
-Tangent line-arc, arc-line
-Tangent arc-arc

Darn impressive.
Great work Robert!
sam



On 12/16/2013 12:43 PM, Kent A. Reed wrote:
 On 12/16/2013 01:02 PM, John Alexander Stewart wrote:
 It's been a while since I wrote SLERPing code, but the project I wrote it
 for used Quaternions, which I don't think LinuxCNC uses?? Quaternions
 certainly made a lot of the internal maths easier. (code was in the
 FreeWRL VRML/X3D browser)

 *Does*  LinuxCNC use Quaternions?
 Well, that depends on your meaning of the word use. If you look at the
 libnml/posemath/ routines you'll see a lot of internal usage of
 quarternions for the reason you name but most calls to the routines from
 the rest of LinuxCNC consist of customary and usual representations.
 What representations? Well, consider this snippet from posemath.h

 -
 /* translation types */
 struct PM_CARTESIAN;/* Cart */
 struct PM_SPHERICAL;/* Sph */
 struct PM_CYLINDRICAL;/* Cyl */

 /* rotation types */
 struct PM_ROTATION_VECTOR;/* Rot */
 struct PM_ROTATION_MATRIX;/* Mat */
 struct PM_QUATERNION;/* Quat */
 struct PM_EULER_ZYZ;/* Zyz */
 struct PM_EULER_ZYX;/* Zyx */
 struct PM_RPY;/* Rpy */

 /* pose types */
 struct PM_POSE;/* Pose */
 struct PM_HOMOGENEOUS;/* Hom */
 -

 You can browse the source code itself but it's faster to read the nearly
 15-year old document
 http://www.isd.mel.nist.gov/projects/rcslib/posemath_examples.html


 Regards,
 Kent
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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread Gregg Eshelman
I wonder if the pickup from a Pertronix Ignitor electronic ignition 
retrofit for vehicles with breaker points ignition would work to read 
pulses from a gear?

In the ignition kit it's used to read the very low amplitude breaker 
points cam on the distributor shaft. Gear teeth ought to provide a much 
sharper, more distinct pulse.

To make an index, either break off a tooth or fill in a gap with ferrous 
metal. Using a missing tooth for index would be ideal if your spindle 
gear already has a broken off tooth.

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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread dave
On Tue, 2013-12-17 at 22:37 -0500, John Alexander Stewart wrote:
 Hi Andy;
 
 Thank you for the response - I have seen your little 7x lathe cnc
 conversion on a few places - well done.
 
 I'll readily admit to being a bit newby in encoders.
 
 The Compact-8 does have a 40 tooth gear on the spindle. Right now spindle
 pulley is off, because was doing some measurements on it for someone in
 Britain who specializes in threading clutches - he needed a Compact-8 to
 measure.
 
 Was thinking that, while it was off, I could make up a large disk with
 holes for the encoder.  Would it be better to read off the 40 tooth gear on
 the spindle??  To me, in my novice state, I'd think that was not as good,
 but...
 
 With the ebay rotary encoder -  I can mount that and drive it either via a
 timing belt, or simple gear - I have a set or three of change wheels for
 the lathe, and I'm sure one could be put into use.
 
 Hmmm - I'm going to look at these rotary encoders more. I'd think that I'd
 still need a timing pulse though.
 
 Thank you - John A. Stewart.

You might want to take a look at what Jon Elson did on his BP, this of
course assumes the gear is steel. 

Dave
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Re: [Emc-users] Servo Following Error

2013-12-17 Thread Jon Elson
On 12/17/2013 08:50 PM, Jeshua Lacock wrote:
 On Dec 17, 2013, at 7:33 PM, Peter C. Wallacep...@mesanet.com  wrote:

 can you add a plot of the commanded velocity?

 Sure thing, please see:

 http://3dtopo.com/z-servo-plot2.png

 It is now the 4th channel (purple).


No, that is MEASURED velocity from the encoder.  I think the
COMMANDED velocity will be quite instructive, but I'm
not sure there  is a hal signal that displays that.

But, you are running version 2.5.3, and I think that version may
not obey the GUI velocity limits on G0 moves, which I 
clearly see
in your screenshot.  So, you might change those few G0's
at the beginning of your G-code programs to G1 and see if
that prevents the problem.  If so, then you may need to turn
down the MAX_VELOCITY in the [TRAJ] section of your .ini
file.  Or, possibly, the velocity is fine but the 
MAX_ACCELERATION
value is too high.

Jon


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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread Cecil Thomas

I used the black dummy CD or DVD (cant remember which) that comes 
in a new stack of disks to make my encoder disk.
I cut 20 equally spaced notches about .15 inch deep and made one of 
them about .45 deep for the index.  I used TTL output optical 
interrupters to read the disk with 2 for quadrature and one for 
index.  The disk is very easy to cut and it runs true without 
worrying about it wobbling.  I cut mine on my cnc'd Millrite with a 
cnc rotary table but you could easily lay out and file the notches in 
less time than it took me to write the code and set up the table on the mill.
I mounted the interrupters on very thin little aluminum plates and 
held them onto the machine with supermagnets. When I had confirmed 
the timing of A and B for quadrature and made sure the index wasn't 
picking up the shallow notches I put a couple of drops of superglue 
on the edge of the aluminum plate.  When it had set I removed the 
magnets and drilled the plates for mounting screws with complete 
assurance that they would be rigidly mounted in the right place.

I used this technique on the spindle of a Jet 9 x 20 and also on my 
Monarch 10EE.  They are both very happy.

Cecil

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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread Jon Elson
On 12/17/2013 09:37 PM, John Alexander Stewart wrote:
 The Compact-8 does have a 40 tooth gear on the spindle. Right now spindle
 pulley is off, because was doing some measurements on it for someone in
 Britain who specializes in threading clutches - he needed a Compact-8 to
 measure.

 Was thinking that, while it was off, I could make up a large disk with
 holes for the encoder.  Would it be better to read off the 40 tooth gear on
 the spindle??  To me, in my novice state, I'd think that was not as good,
 but...


If the gear is steel, you could use the trick I used:
http://pico-systems.com/bridge_spindle.html

The gear teeth on the Bridgeport are probably larger than
on your lathe, but those Avago sensors detect the PASSAGE
of the tooth across the face of the sensor, and are supposed
to be able to detect fairly small teeth.  You need 3 sensors,
but together they cost less than a most encoders.

A 40-tooth gear would give you 160 counts/rev, which should be
fine for threading.  I do fine on my Bridgeport with 324 
counts/rev.

Jon

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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread Cecil Thomas

I was a little concerned that 20 teeth (80 quadrature) wouldn't be 
enough resolution.  After cutting a couple of 0-80 and 00-90 screws 
on both the machines and testing with commercial nuts and examining 
the thread geometry under the microscope I no longer have any 
reservations about 80 quadrature not being good enough.
If I can consistently cut 90 tpi in multiple passes and leave a 
thread that is perfect in form and pitch then I think it will do fine 
for the typical 40 tpi to 8 tpi that one normally is required to cut.

By the way the threads are cut in about 20 passes so the resolution 
and repeatability have been thoroughly tested.  If you wonder why it 
takes so many passes you have probably never actually held a 00-90 
screw in your hand.  The diameter is .043 so the radius is 
.0215.  How deep a cut do you think you can take on that little 
sucker even with a tool that's as sharp as it is humanly possible to 
make it.  I know when the tool is dull because it just pushes the 
little fellow away and breaks it off as it climbs up on the tool.   I 
am sure I could cut a 000-120 thread but I don't have a nut to test it with.

If on the other hand I was using the spindle as a servo driven axis I 
would probably want more slots.

By the way I am thinking seriously about repurposing my HF 7 x 10 
lathe as a CNC tool and cutter grinder for the single lip engraving 
tools I use which are in the neighborhood of 20 degree included angle 
with a tip of 4 to 15 thousandths.  I previously had it set up as a 
cnc lathe with a very large brushed servo driving the spindle and 
controlled as the A axis.  It worked well enough but the top speed 
was limited by LCNC's ability to produce steps fast enough to use the 
motors top speed.
The encoder on the servo was 500 lines so the resolution was far 
better than I ever needed and it would work happily at ridiculously 
slow speeds e.g. 1 to 10 RPM as would be used for a the work holder 
for a cutter grinder.
With a grinding wheel on the cross slide I could produce the tool tip 
geometry and relief just like the big boys.

I robbed the x and z servos from it to install on the Jet 9 x 20 and 
used the spindle servo as the z axis servo on the 10EE.  I guess I'll 
have to go servo hunting again.

Cecil

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Re: [Emc-users] Lathe spindle encoder, Mesa 7i76.

2013-12-17 Thread Gene Heskett
On Wednesday 18 December 2013 01:16:47 John Alexander Stewart did opine:

 Hi Gene - by:
 
 John:  You need finer grained control than an index generator will ever
 
  allow if you ever intend to use the G33.1 or G76 thread cutting on the
  lathe, and once I had that working, I don't know why I ever considered
  not doing it.
 
 I presume you mean the one pulse per rev that Mach users seem to be
 stuck with.

Yes, poor things.
 
 Code for encoder wheel came through, by the way. I did measure the
 spindle diameter (not by lathe right now) so can not comment on how
 well it'll fit with your GCode.
 
 The Emco (Austrian, Enco is Asian) will be running with a 3 phase motor
 and inverter - already here, just waiting to be installed. The inverter
 takes 0-10v for the spindle - so that's good.

Whereas I took the cheap way out and bought a 1.5hp treadmill motor off 
fleabay, controller and all  $100 bill.  But 2 things wrong with the 
controller, starting with its being an scr model so it hummed to beat the 
band at medium speeds, plus I blew two of the darned things with accidental 
shorts while first assembling it.  In the end I wound up buying a hexfet 
based controller, 25 amp rated from Empire in Wisconsin, around $150, runs 
dead silent and has almost 300% the capacity this motor needs.

Then because the motor is bigger, it of course wouldn't fit in the pocket 
under the bed where the 200 watter was.  So I made a jackshaft assembly 
that sat in the old motors position, using a new but same teeth timing 
pulley in the same location as the OEM motor would have held it, but used a 
3 poly-groove pulley on the other end that the 1 pulley on the new motor 
drove, so I had a 3/1 step down to the original backgear equipt head.  The 
tread mill motor can easily muster up 10+ grand at  about 9.5 volts into 
the controller, so I am presently setup for about 2k max revs at the 
spindle nose, with enough torque to turn the house around.  Max volts from 
the pwm converter is about 8 volts so even at that speed, the servo speed 
control is very strong.

Where before I was out of torque pulling a 3 thou by 2 thou chip off a 
piece of 3/4 cold roll in a 4 chuck it now has a much better built 5 4 
jaw, and I can now pull a 10x10 chip off of a 2 diameter piece of steel.  
At speeds that have the inserts edge itself dull red.  The other half of 
that is the strength of the gears in the head, particularly the hub 
keyways, so I expect to be looking for better gears if I make a habit of 
that big a cut too often. :(

By the time I was done, with a suitable suicide braking setup to be able to 
run the g33.1 in peck cycle, I expect I have the cost of your 3 phase motor 
and its inverter in it.  And my .hal file is over 1200 lines!  The hand 
made box on the rear of the lathe to contain all that just kept growing, 
but its not in the way so its a shrug, it keeps the swarf out of the 
electrics.  That motor is very quiet, all you can hear at 10k shaft revs is 
the air from the fan cast as part of the pulley.  The Z stepper setup is 
far noisier as it has the clearances of a 2/1 spur gear stepdown to drive 
the 16x5mm ball screw.  Thats a major clatter maker as both gears are from 
a metal gear change gear kit.  Someday I'll put a much quieter timing belt 
setup on it, but the gears are what I had on hand, just needed bore 
machining for some home made taperlock hubs.

 This is all interesting! Thank you - John A. Stewart
 
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Cheers, Gene
-- 
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 soap, ballot, jury, and ammo. Please use in that order.
-Ed Howdershelt (Author)
Genes Web page http://geneslinuxbox.net:6309/gene

Tact is the art of making a point without making an enemy.
A pen in the hand of this president is far more
dangerous than 200 million guns in the hands of
 law-abiding citizens.

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Rapidly troubleshoot problems before they affect your business. Most IT 
organizations don't have a clear picture of how application performance 
affects their revenue. With AppDynamics, you get 100% visibility into your 
Java,.NET,  PHP application. Start your 15-day FREE TRIAL of AppDynamics Pro!
http://pubads.g.doubleclick.net/gampad/clk?id=84349831iu=/4140/ostg.clktrk
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