Re: [Emc-users] Weird EMC2 tuning issue (direction reverses intermittently)

2009-07-07 Thread Glenn R. Edwards
Yes, I had a stepper system run backwards when pushed too hard.  I believe
it was a combination of accel and start frequency being too aggressive.
However, the backwards motion was NOT smooth or at commanded speed- slow and
noisy is what I remember.  Jeffrey did not report, though, that his
backwards motion was anything but normal except direction-wise.  So, I'm
thinking this isn't the case here.

Glenn

-Original Message-
From: emc-users-boun...@lists.sourceforge.net
[mailto:emc-users-boun...@lists.sourceforge.net] On Behalf Of Gene Heskett
Sent: Tuesday, July 07, 2009 7:30 AM
To: Enhanced Machine Controller (EMC)
Subject: Re: [Emc-users] Weird EMC2 tuning issue (direction reverses
intermittently)

On Tuesday 07 July 2009, Andy Pugh wrote:
2009/7/5 Jeffrey Pease jpe...@peasej.com:
 One mysterious issue I've seen that I'm trying to figure out is that 
 very, very rarely, a movement command to the milling machine will 
 make an axis move the correct distance in the INCORRECT direction.

Is there any possibility that this is a mechanical problem with the 
motors? I am wondering if they can get into some form or resonance when 
pushing the step rate too far, such that they start stepping backwards?
Note that I don't even know if this is possible/

Yes it is, particularly when using a driver that can't microstep. Resonance
can build up to the point where its actually turning backwards due to the
magnetic spring action, and it could find it easier to keep on turning
backwards, having overshot the center.  I have not personally observed that
in my machine however, cuz if it skips a step, mine just locks in place and
sings.  Dampers will help to squash this, allowing considerably higher
speeds.  
The dampers should take the form of loosely coupled weights that can slip
and therefore absorb the resonance motions.  Mine are built from a steel
spool with one flange removable and adjustable, with alternating layers of
sheet rubber whose center holes are a drag fit on the spool hub, and large
fender washers that are free to turn on the spool hub.  The removable flange
is adjusted so that the stack of washers/rubber is snug but can be turned in
place when the motors are powered up  locked.  This works well for
microstepping drivers such as the xylotex I use, allowing about 2x speed
increases but probably needs a more mathematically based design for stuff
running at half or full step.

They can be see at http://gene.homelinux.net:85/gene/emc

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Re: [Emc-users] 5 axis compensation kinematics

2009-06-25 Thread Glenn R. Edwards
Stuart,

In your axis compensation plan, do you assume that the axes are perfectly
straight and not bowed?  Such as table sag at the end of travels.

Glenn

-Original Message-
From: emc-users-boun...@lists.sourceforge.net
[mailto:emc-users-boun...@lists.sourceforge.net] On Behalf Of Stuart
Stevenson
Sent: Thursday, June 25, 2009 7:46 AM
To: EMC2-Users-List
Subject: [Emc-users] 5 axis compensation kinematics

Gentlemen,
   I have the kinematics file on the cinci. I am running the emc-dev
(trunk) from the git download.
   The machine is running and looking/moving as expected.
   Measuring and adjusting is the next task. I will assume the X axis is the
perfect axis/joint combination and comp everything to the X axis and the
table top.
   My plan is to: (in this order)
  comp the Y axis to X
  comp the Y axis to Z (table top)
  comp the Z axis to X
  comp the Z axis to Y
  comp the parallelism of the A and X axes
  comp the parallelism of the B and Y axes
  comp the construction errors of the AB head (the spindle centerline
does not project exactly through either the A or B axes centerliines of
rotation having some fun now (sweet) thanks (many thanks to the developers
for this incredible EMC software) this sow's ear is looking like a denim
(not quite silk) purse.
Stuart

ps - axis jog would be especially nice for this :)
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Re: [Emc-users] Roles in the manufacturing chain (was Metriks)

2009-06-13 Thread Glenn R. Edwards
Doug,

There are well-defined drafting standards such as ANSI Y14.5M-1994 used
mostly in the USA.  No doubt CNC has changed the landscape; imported solid
models defining the part geometry (through the CAD to CAM to CNC pipeline)
and drawings used mostly as inspection tools.  Still, a good machinist will
always make a better part and a good engineer will always design one,
compared to their untrained/unskilled/sloppy brethren, no matter what tools
they use.  And, I find abundance of the good type wherever I go, still to
this day.  I've been at it for 25+ years

Glenn

-Original Message-
From: emc-users-boun...@lists.sourceforge.net
[mailto:emc-users-boun...@lists.sourceforge.net] On Behalf Of Douglas
Pollard
Sent: Saturday, June 13, 2009 9:20 AM
To: Enhanced Machine Controller (EMC)
Subject: Re: [Emc-users] Roles in the manufacturing chain (was Metriks)

Jon Elson wrote:
 Andy Pugh wrote:
   
 Most of the dimensions for the general geometry were +/- 0.2mm except 
 for the flexural element, which was 0.2mm +/- 0.05mm dimensioned from 
 a face with a stacked-up positional tolerance of about 0.4mm.
 The machinist set up his CNC mill to the centre value of each 
 tolerance starting from a part edge and pressed go. When the 
 program finished the flexural element was not even there.

 Who was at fault? I argued that the wider tolerances elsewhere in the 
 geometry were specifically so that they could get the flexure right, 
 they said You always work to mid-tolerance, and the drawing should 
 assume that
   
 
 Well, if the drawing showed metal to be there, and there was no metal 
 in that position, then the part did not match the drawing.  How can 
 they argue with that?

 Now, if the dimensions were in some way wrong, so you cut one side, 
 flip it, cut the other side and there's nothing left, because the 
 drawing instructs them to mill more than half the thickness from both 
 sides, that's an inconsistent drawing, and should have been caught 
 before machining, but the drawing is wrong.

 If the problem was due to tolerance stackup or the relief of stresses 
 in the stock as material was removed, and competent machinist SHOULD 
 have been aware of the problem just from examining the drawing.  If 
 tolerance stackup, then a fixture should have been made so the part 
 could have been machined with fewer setups (preferably just one or 
 two).  If part warpage, then the whole machining process was flawed, 
 either due to wrong material selection, wrong approach, wrong 
 fixturing or whatever.

 Some shops would be offended if you tell them how to machine a part, 
 they OUGHT to know better how to do it with their machines and 
 materials.  But any shop that complains that the part doesn't match 
 the drawing and it is YOUR fault for making it hard to machine 
 sounds like a bunch of idiots.  Button pushers, not machininsts.  Ie, 
 they went straight from  a drawing, to CAD, to CAM, with no 
 understanding of materials and machining processes.  If they 
 complained about this, it is actually FUNNY, because they were 
 revealing their own ignorance in a VERY embarrassing way!

 Jon

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I may be all wet, but it seems to me there aren't any standards much
now. Mostly mayhem in machining.
At one time there was Henry Ford and his people writing automotive
standards and they were an authority.  Seems like professors are doing the
same thing in teaching,  in a lot of areas  but there seems little agreement
between them. I guess this is because we are in transition in manufacturing.

The fact that there is misunderstanding over you drawing is proof of 
that.  I believe mechanical design is mostly bedlam for now.   More and 
more it doesn't matter though  the machine just follows the codes given it.
It has no knowledge of making a part it is simply following code.
Doug


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Re: [Emc-users] EMC in South West UK

2009-04-03 Thread Glenn R. Edwards
Yup, Palo Alto.

Glenn 

-Original Message-
From: emc-users-boun...@lists.sourceforge.net
[mailto:emc-users-boun...@lists.sourceforge.net] On Behalf Of Rafael Skodlar
Sent: Friday, April 03, 2009 12:33 PM
To: Enhanced Machine Controller (EMC)
Subject: Re: [Emc-users] EMC in South West UK

Eric H. Johnson wrote:
 Peter,
 
 Er, you mean like this?
 http://www.frappr.com/emc2/
 

that was pointed to me earlier on IRC but the map part was broken
unfortunately. I too am interested to get in touch with local users to
exchange experience and possibly mutual support.

SF (south) bay area anybody?

 :)
 
 Regards,
 Eric
 
 
 Hello community,
 I think Aaron had a great idea. How about a world map showing the 
 places where EMC addicts are so we could visit each other and profit 
 from their experiences? I guess it would be quite around the world 
 with the center of gravity in the US.
 

--
Rafael


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Re: [Emc-users] matching servo motor to axis

2009-01-23 Thread Glenn R. Edwards
Hi Dave,

Here's one from Galil, a pretty trusted supplier of motion systems.  Of
course, using one of these usually leads you to a motor the vendor
recommends, but you can look at the specs and then buy one similar from
anyone.

http://www.galilmc.com/learning/motorsizer.php

Glenn

-Original Message-
From: emc-users-boun...@lists.sourceforge.net
[mailto:emc-users-boun...@lists.sourceforge.net] On Behalf Of Dave Engvall
Sent: Friday, January 23, 2009 3:57 PM
To: Enhanced Machine Controller (EMC)
Subject: [Emc-users] matching servo motor to axis

Hi all,

Does anyone know of a good worksheet for working thru the design parameters
for a servo drive.

eg. given:
  servo motor of a given torque and speed; gear reduction ball screw dia and
pitch desired accel and velocity weight of the axis coeff of friction for
the slides and probably things I've not thought of.

With a good set of specs it ought to be possible to calculate ...   
yes this will work ... or it is beyond
the given parameters.

TIA

Dave



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Re: [Emc-users] [OT] MFG.com

2009-01-21 Thread Glenn R. Edwards
Hi Kirk,

My reply is from a user's viewpoint, meaning as a purchaser of machined
parts.  Mfg.com is simple to use and at no cost for consumer.  I use it from
time to time to source simple parts that I want made cheaply.  I think this
is a common use of mfg.com so there is a lot of price pressure on suppliers.

My only complaint is finding suppliers for my RFQ's- there are so many at
mfg.com and I do not want to send out hundreds and then deal with hundreds
of returns.  Mfg.com's system of pre-selecting suppliers could be better.

Glenn

-Original Message-
From: emc-users-boun...@lists.sourceforge.net
[mailto:emc-users-boun...@lists.sourceforge.net] On Behalf Of Kirk Wallace
Sent: Tuesday, January 20, 2009 2:18 PM
To: Enhanced Machine Controller (EMC)
Subject: [Emc-users] [OT] MFG.com

Has anyone used MFG.com to get jobs to run on your CNC's? I'm trying to
figure out if I should make the effort to get up to speed with it.
Thanks.

Kirk
http://www.wallacecompany.com/machine_shop/




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Re: [Emc-users] CNC Newbie Questions.

2008-12-11 Thread Glenn R. Edwards
Luke,

Here are some links, mostly of CNC Router machines- many capable of
non-ferrous metal work.  You say you want to do wood which I think moves you
away from CNC Milling machines because of limited working area in the
horizontal plane.

http://campbelldesigns.net/index.php
http://solsylva.com/
http://www.mechmate.com/
http://www.multicam.com/eng/index.html
http://www.rolanddga.com/asd/default.asp
http://www.shopbottools.com/
http://www.techno-isel.com/CNC_Routers/index.htm
http://www.cncrouter.com/index.htm
http://www.fireballcnc.com/

I'm sure others will respond.  Good luck.

Glenn

-Original Message-
From: emc-users-boun...@lists.sourceforge.net
[mailto:emc-users-boun...@lists.sourceforge.net] On Behalf Of Luke Scharf
Sent: Thursday, December 11, 2008 8:50 AM
To: Enhanced Machine Controller (EMC)
Subject: [Emc-users] CNC Newbie Questions.

I'm a guy who spends a fair bit of time building stuff in my garage.

I started reading about the CarveWright machine, and it sounds like it could
be useful.  But I'm a longtime Linux user, and I'd prefer an open-source and
modifiable solution.  Also, I'd like to be able to work with materials that
are harder than just wood -- like steel.  Also, I'm concerned that the
sandpaper belts that the CarveWright uses to move the material forward and
backward may not produce as consistent of a result as, say, clamping the
material to the plate.

Also, I see that EMC2 is used with a lot of homebrew style mills.  
That's wonderful and I'd love to get into that -- but, at the moment, I have
a lot of projects in mind -- from wood carving to the occasional
adapter-plate.  So, I'd like to spend more time building stuff than
tinkering with a CNC machine.  I'm quite capable of building a kit,
soldering, and all of that -- but if I do that, I'd rather build a
well-supported popular design.  Or just buy a reasonably priced commercial
unit.

My questions are:

* What kind of a desktop mill (for a hobbyist-sized workload) would
  you all recommend for me?
* Any recommendations for CAD software?
* Are there any FAQs that I should review to get myself up to speed
  on the small-scale CNC technologies?


Thanks!
-Luke



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Re: [Emc-users] Pissed off of EMC2 and 7i43

2008-11-16 Thread Glenn R. Edwards
Mr Acosta,

I've had enough.  Perhaps its from seeing the 'P' word time and time again
in the subject line: it's sophomoric, insulting and reflects badly on the
originator, you.  Or perhaps it's your insistence on blaming others.  There
is not a manufacturer in the world with perfect documentation and there is
not a manufacturer in the world that will guarantee its system will work for
you, perfectly out of the box.  That's your job, if I am to assume you are
the responsible engineer at your company, to make the technical decisions in
a timely manner to assure success.  You had several months to make this
work, your words, and where were the intermediate milestones that would have
alerted you to a lack of progress?  Be a professional (and an adult), learn
from your mistakes and move on.

I, for one, know that the team developing EMC2 is extremely talented and
very, very supportive of this community.

Glenn

-Original Message-
From: [EMAIL PROTECTED]
[mailto:[EMAIL PROTECTED] On Behalf Of Richard Acosta
Sent: Saturday, November 15, 2008 8:27 AM
To: Enhanced Machine Controller (EMC)
Subject: Re: [Emc-users] Pissed off of EMC2 and 7i43

El 09/11/08 18:55, noel escribió:
 Richard,
 I'm a happy and satisfied Mesanet customer.
 I use a 5i20, 7i33 and 7i37.  with the 'stock' and 'proven' EMC2 
 configurations.
 I have stayed away from the 7i43 until the EMC2 driver and 
 configurations are thoroughly worked out
Hi Noel, i don't doubt you're right and i think there must be some (or a lot
of) people using the same hardware that i'm.

To everyone else: I asked for help here on this group and despite the good
will and help of the people i could'nt make it work, which has led me to
loose time, money and a very important work.
I choose EMC because of the freedom part, and 7i43 because emc2 claims it
work.
Then i read manuals and help wich made me think it was all working, and then
i decided to choose this board.
If at any place i would have read that the board is not working completely i
could have choose another option, but i didn't find it.

Those who was trying to help me asked for my config files, wich i had make
by reading plus test and error since there is no clear sample, but i can't
keep losing time on investigating, i had to make this work more than a
couple months ago, and i lost a very important work because of this, plus
time, plus money.
I think it would be so much easier if you provide those files, or at least
some clear paths to use the appropriate configs.

I'll give it a last try, since it seems Ted Hyde has it working, and he has
a VIA chipset plus the same card (400k) than i.
Thanks everyone for your patience, but anyway think that i have lost this
job because the lack of clear info.
Again thanks.


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Re: [Emc-users] Free 3D CADs on Linux WAS: BRL-CAD

2008-11-04 Thread Glenn R. Edwards
...snip...

Dave,

 I think I've go that software on my EMC machine right now.  
I'd forgotten all about it.  Wonder if it'll read AutoCAD dwg files?  
Hmmm, may have to play around with it.

Mark

I've gotten the impression that AutoCad will go after anyone who tries to
write a dwg reader.

--
Cheers, Gene

..snip...

SolidWorks publishes a 2D software application called DWGEditor and it
reads/writes dwg files along with dxf.  While not absolute proof against the
above statement, I am not sure AutoDesk is aggressive against dwg editors:
they are putting their muscle behind Inventor.  BTW: DWGEditor is equivalent
to AutoCAD LT and every SolidWorks license gets three, free DWGEditor
licenses.  So, ask a friend for one as it is pretty good, though only for
Windoz.  (I am not a SolidWorks employee or consultant, just a licensee who
has already given away my three DWGEditors ;^)

Glenn


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Re: [Emc-users] sherline 4400 cnc config for large pen type objects

2008-09-24 Thread Glenn R. Edwards
Here's a website of similar vein which might have some pointers for you...
http://www.computersculpture.com/ 

Glenn 

-Original Message-
From: [EMAIL PROTECTED]
[mailto:[EMAIL PROTECTED] On Behalf Of l.collier
hyams
Sent: Wednesday, September 24, 2008 7:40 PM
To: emc-users@lists.sourceforge.net
Subject: [Emc-users] sherline 4400 cnc config for large pen type objects

I'm a new emc user and have yet to develop a good technique or system for
machining objects that best resemble oversized writing pens. I teach digital
art, animation, music and sculpture and know my way around unix, irix,
linux, all the win os and all of the mac os. I'm thinking of doing much of
the design work in Google Sketch or even BobCad and have looked at a number
of other packages. The starting points may be obvious for the group, but
it's pretty new on my end. Any pointers?

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Re: [Emc-users] A little OT: Need advice on cable

2008-09-10 Thread Glenn R. Edwards
Hi Ed,

I have used a high-flex ribbon cable to great success.  Others have
mentioned flex circuits which are great but can cost you with tooling.
Digi-key should have it, or Google...

Glenn 

-Original Message-
From: [EMAIL PROTECTED]
[mailto:[EMAIL PROTECTED] On Behalf Of Ed
Sent: Wednesday, September 10, 2008 11:24 AM
To: Enhanced Machine Controller (EMC)
Subject: [Emc-users] A little OT: Need advice on cable

I am finally getting to work on my Hardinge CHNC and would like to repleace
the old cables that run to the back side of the cross slide. 
These cables run in a track something like an Igus(sp) so they get flexed
constantly. The cables would be for encoder, limit and home switches,turret
position, and small air solenoids. Can anyone recommend a type of cable for
this purpose? Preferably from Digikey? Thanks in 
advance.   Ed.

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Re: [Emc-users] Harmonic gear and EMC2. ????

2008-05-22 Thread Glenn R. Edwards
Aram,
What is the total travel distance of the grinding table?
Glenn 

-Original Message-
From: [EMAIL PROTECTED]
[mailto:[EMAIL PROTECTED] On Behalf Of
[EMAIL PROTECTED]
Sent: Thursday, May 22, 2008 6:59 PM
To: Enhanced Machine Controller (EMC)
Cc: emc-users@lists.sourceforge.net
Subject: [Emc-users] Harmonic gear and EMC2. 

I am building CNC tool grinder.
The feed for tool grinder should be from 0.00025 to 0.001 of the inch per
minute.
The servo motor must perform at this feed perfect to make a good grinding
job.
I will use direct drive and my ball screw has 5  pitch per inch.
So talking in degrees, 5 times 360 = 1800 degrees of revolution of motor to
get 1 inch for linear motion.

To get 1 inch need turn 1800degrees/minute of motor.
To get 0.00025 need  0.45 degrees/minute of motor.
Is this too slow?
I think so.
The one solution is to take high end controller and large AC servo motor and
that is expensive.

Jon Elson said about harmonic drive. I found here www.harmonicdrive.net That
gear can reduce up to 1 to 160. If I will put two side by side, it gives to
me 25600 to 1 reduction.
So 0.45degrees/minute times 25600 equal 11520degrees/minute, or 32
revolution per minute.
32 revolution per minute is good range to any AC servomotor and with 8192
pulse per revolution drive and EMC2 will have enough pulses to be accurate.

All harmonic drives have 0 backlash. One piece for NEMA34 cost $1500 and per
axis it is $3500 with special plates etc.

5 axis is $17, 500 is to gears a lone to make good CNC tool grinder.
I think it is very good idea!
Instead of making electronics part and programming more complicated ( and
not all can understand that part - I can not for sure) it is much better use
mechanical gear reducer and use less expensive and more robust drives and
software.

I am correct?
Aram




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Re: [Emc-users] Thread Milling

2008-05-21 Thread Glenn R. Edwards
Jon,
I hope it doesn't appear as though I am jostling you for the final word,
however you pointed out a major difference between us hobbyists and
professionals.  A professional must deliver a part in spec 100% of the time
( six sigma- don't get me started...) no matter if the part was cut in the
cold morning or during a hot afternoon, if the part was mounted at the
center of the table or if mounted near the edge, if the machine was being
run by your best operator or the guy you hired yesterday.

A tap can wear, but so can a thread mill cutter and probably faster.
However, thread milling introduces two additional tolerances that tapping
does not.  Each of those tolerances can (and eventually will) produce an
unacceptable thread.  A loose fitting thread can have a LOT less pull-out
strength than a properly formed thread.  And, you might not be aware of a
loose thread unless you have a GO NO-GO gage.  In my day job, I want tapped
holes from the machine shop (In fact, I am getting quite accustomed to
roll-tapping and the superior strength thread it produces).  During the
weekend, I will enjoy making my own threaded holes with a thread mill.

Glenn

-Original Message-
From: [EMAIL PROTECTED]
[mailto:[EMAIL PROTECTED] On Behalf Of Jon Elson
Sent: Wednesday, May 21, 2008 9:51 AM
To: Enhanced Machine Controller (EMC)
Subject: Re: [Emc-users] Thread Milling

Glenn R. Edwards wrote:
 
 Other issues with thread milling: 1)The thread mill tool will not 
 follow the pre-drilled hole as will a tap.  2)Getting the correct 
 pitch diameter from a thread mill is a trial and error routine.
I don't think so.  I bought a single-row 1/4 thread mill from Micro-100.  I
wrote a program to create the G-code, and after trying one pass in air, I
drilled a hole and let it run.  It produced a thread as close as I could
tell identical to a tap.
I didn't have a real certified go/no-go gauge, but a threaded part felt the
same in the hole.  I was very impressed.  I had bought the thing because I
had a job coming up that needed an NSEF thread, and I was worried about
getting a tap for that. 
Then a sale flier on special taps crossed my desk, and I was able to get the
right tap at a very reasonable price.  So, I've only done one job where I
needed to thread an off-size hole at a wierd angle.  But, it produces a
thread with very predictable pitch diameter.

Jon

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Re: [Emc-users] Z-Axis Drifting Problem

2008-05-17 Thread Glenn R. Edwards
Focusing on possible mechanical sources: A Z-axis not capable of lifting the
spindle at max slew, but sized well enough to drive the spindle down, would
behave in this manner.

Glenn 

-Original Message-
From: [EMAIL PROTECTED]
[mailto:[EMAIL PROTECTED] On Behalf Of Jeff Epler
Sent: Saturday, May 17, 2008 3:17 PM
To: Enhanced Machine Controller (EMC)
Subject: Re: [Emc-users] Z-Axis Drifting Problem

On Sat, May 17, 2008 at 02:33:04PM -0500, Ray Henry wrote:
 I can't see how electrical interference would cause bad counting in 
 one direction only but you might make certain your encoder cables are 
 grounded at the drive end only.

I agree this sounds a bit strange, but I've seen this on two occasions.
Once the encoder sensor was physically dirty, and in the other case there
was electrical noise due to (iirc) bad grounding.  In both these cases, the
position error was consistently biased in one particular direction.

You're right to suggest not dismissing electrical interference in this case.

Jeff

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Re: [Emc-users] How to set certain AXIS settings to defaults?

2008-03-27 Thread Glenn R. Edwards
Jon,

Are you implying that you manually, or otherwise, get the table to within
one encoder revolution of home and then do a homing sequence with EMC?

Glenn

-Original Message-
From: [EMAIL PROTECTED]
[mailto:[EMAIL PROTECTED] On Behalf Of Jon Elson
Sent: Wednesday, March 26, 2008 10:51 AM
To: Enhanced Machine Controller (EMC)
Subject: Re: [Emc-users] How to set certain AXIS settings to defaults?

Gary Fixler wrote:
 One of the reasons I often drill a useless hole someplace at the
 start of the
 project, and write my code with that as the 0,0,0 point.  That makes
 getting
 back to within a couple thou a bit easier.
 
 
 That's a great idea. I would love an absolute positioning system - 
 something that was always the same for the mill, at least between full 
 strip-downs, and rebuilds.
 
Well, it depends on how your homing system works.  I have index pulses on my
encoders, and home to those pulses.  I get quite repeatable homing that way.
In theory, I could shut down one day, fire it up the next day, home the
axes, and be right on the same alignment to the vise jaw or whatever.

Jon

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Re: [Emc-users] How do I calculate leadscrew push/pull forces?

2008-03-17 Thread Glenn R. Edwards
And,

Don't forget screw pitch, or lead. Pitch is also a big determinate of screw
efficiency.

Glenn 

-Original Message-
From: [EMAIL PROTECTED]
[mailto:[EMAIL PROTECTED] On Behalf Of John Kasunich
Sent: Sunday, March 16, 2008 7:57 PM
To: Enhanced Machine Controller (EMC)
Subject: Re: [Emc-users] How do I calculate leadscrew push/pull forces?

Stephen Wille Padnos wrote:

 The leadscrew diameter isn't important for the force calculation.
 
 The motor can output 200 ounces force at a one inch radius, as you 
 said.  For one revolution, the 200 ounces of force is applied over 
 2*pi inches of travel, but produces 0.2 inches of table motion.  Just
divide:
 200 * (2*pi*r) / (0.2) = force in ounces =2000*pi, or about 6280 
 ounces force (close enough to 400 pounds).
 
 The units are ounces * (inches) / (inches), which is ounces since the 
 lengths cancel out.
 

Actually the diameter does matter, at least for acme screws.  The
calculation that Steven did is correct if you neglect friction.  For
ballscrews, with 90% or better efficiency, you can almost neglect friction.
Not so for acme screws - the majority of the torque at the motor is from
friction.

Here is the counter-intuitive part - a smaller diameter screw of the same
pitch will be MORE efficient.

Assume you have 100 lbs pushing on the nut.  Steven's formula above can be
used in reverse to calculate the torque on the screw from the nut.
For a 100 lb load, and a 0.200 screw pitch, that torque is 100 lbs = 1600
oz, times (0.2/(2*pi)) = 50.95 oz*in (call it 51).

But now you need to add the torque due to friction.  The force is equal to
the load times the friction coefficient, so it will depend on the material
of the nut and screw.  Google says the coefficient for a lubricated bronze
nut on a steel screw is about 0.16.  That means our 100 lb load will result
in 16 pounds (256 ounces) of tangential friction force.

That force is at the radius of the screw, where screw and nut meet.  If the
screw is 5/8 inch in diameter, its radius is 0.312 inches, and the friction
needs 256oz * 0.312in = 80 oz-in of torque to overcome it.

So you need 80 oz*in to overcome friction, and 51 oz*in to move the load for
a total of 131 oz*in.  (You'll want a motor that can deliver at LEAST twice
that amount at your maximum desired speed, for insurance against lost
steps.)

Now switch to a 2 diameter screw.  Now the 256 oz friction force acts at a
radius of 1 inch, and you need 256 oz*in of torque to overcome it.
Add the 51 oz*in that actually moves the load, and you get 307 oz*in.

Now you see why we like ballscrews so much.

Regards,

John Kasunich




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Re: [Emc-users] Running EMC2 from another, local app

2008-03-12 Thread Glenn R. Edwards
Thanks Eric,

That did the trick.  And my apologies to the group for posting the same
question twice.  I got nervous first thing in the morning when I did not see
my post from the night before.

Glenn

-Original Message-
From: [EMAIL PROTECTED]
[mailto:[EMAIL PROTECTED] On Behalf Of Eric H.
Johnson
Sent: Tuesday, March 11, 2008 8:58 AM
To: 'Enhanced Machine Controller (EMC)'
Subject: Re: [Emc-users] Running EMC2 from another, local app

Glenn,

Do you have the following in one of the hal files for the configuration you
are running:
loadusr emcrsh

If you do not include that, then you will get the indicated error since the
application to respond to your telnet session is not running.

I don't recall whether the latest thing I have run is v2.2.2 or v2.2.3, but
I just downloaded the latest version a couple of weeks back, and it was
working then. I will try it tonight and make sure it is working. I also know
that Chris is about to release a new version, but I have not seen that it
has actually been released yet.

I need to add some online documentation for that utility, it is still mainly
within the c source files.

Regards,
Eric

Awhile back, EMC2 v2.1.1, I was successful in commanding EMC2 from a
terminal window using commands such as 'telnet localhost 5007' and
'axis-remote'.  'Telnet' opens a variety of commands to EMC2 (through
emcrsh) and 'axis-remote' allows shutdown (and a just few others).  Now,
with v2.2.3, telnet is not working.  Here is what I get (I first start 'emc'
in another terminal):
 
~$ telnet localhost 5007
Trying 127.0.0.1...
telnet: Unable to connect to remote host: Connection refused ~$
 
I have searched wiki and linuxcnc for 'telnet' and 'emcrsh', but to no
avail.  Also, I thought, AXIS communicates with EMC2 via telnet?  Any help
is appreciated.
 


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[Emc-users] Running EMC2 from another, local app

2008-03-11 Thread Glenn R. Edwards
Hi all,
 
Awhile back, EMC2 v2.1.1, I was successful in commanding EMC2 from a
terminal window using commands such as 'telnet localhost 5007' and
'axis-remote'.  'Telnet' opens a variety of commands to EMC2 (through
emcrsh) and 'axis-remote' allows shutdown (and a just few others).  Now,
with v2.2.3, telnet is not working.  Here is what I get (I first start 'emc'
in another terminal):
 
~$ telnet localhost 5007
Trying 127.0.0.1...
telnet: Unable to connect to remote host: Connection refused
~$
 
I have searched wiki and linuxcnc for 'telnet' and 'emcrsh', but to no
avail.  Also, I thought, AXIS communicates with EMC2 via telnet?  Any help
is appreciated.
 
Thanks,
Glenn



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[Emc-users] Running EMC2 from another, local application

2008-03-11 Thread Glenn R. Edwards
Hi all,
 
Awhile back, EMC2 v2.1.1, I was successful in commanding EMC2 from a
terminal window using commands such as 'telnet localhost 5007' and
'axis-remote'.  'Telnet' opens a variety of commands to EMC2 (through
emcrsh) and 'axis-remote' allows shutdown (and a just few others).  Now,
with v2.2.3, telnet is not working.  Here is what I get (I first start 'emc'
in another terminal):
 
~$ telnet localhost 5007
Trying 127.0.0.1...
telnet: Unable to connect to remote host: Connection refused
~$
 
I have searched wiki and linuxcnc for 'telnet' and 'emcrsh', but to no
avail.  Also, I thought, AXIS communicates with EMC2 via telnet?  Any help
is appreciated.
 
Thanks,
Glenn
 
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Re: [Emc-users] LInuxCNC laptops

2008-03-03 Thread Glenn R. Edwards
Hi Marcin, et al:
 
I have two laptops running Linux and EMC2.  One is a Dell 5000e and the
other a Dell M50.  Both were high-end laptops at the time of purchase, both
have standard parports and both are running strong today (the 5000e is eight
years old).  I am not a Dell junkie; my latest laptop is an HP/Compaq nw9440
which is the best engineered laptop I have yet encountered.  To finish my
background cv: the laptops are driving a small, desktop CNC (Taig) Mill- NOT
heavy metal, by any metric.
 
Here are some URL's I found useful for running Linux on a laptop:
http://www.linux-laptop.net/
https://help.ubuntu.com/community/WindowsDualBoot
http://tuxmobil.org/distribution_linux_laptop_mandrake.html
http://www.astro.umd.edu/~teuben/linux/laptop/dell5000.html
 
Things to watch for:
Graphics drivers (laptops come with video chipsets, not real video cards,
and can misbehave)
Power management (I always have trouble with waking up in Linux- so never
sleep ;-)
 
Good luck,
Glenn

  _  

From: [EMAIL PROTECTED]
[mailto:[EMAIL PROTECTED] On Behalf Of Marcin
Jakubowski
Sent: Monday, March 03, 2008 5:44 PM
To: Enhanced Machine Controller (EMC)
Subject: Re: [Emc-users] LInuxCNC laptops


Thanks for the responses on EMC laptops. But surely there must be at least
one specific laptop that does work? Is there any success story out there at
ALL for a working laptop?

Marcin


On Mon, Mar 3, 2008 at 3:33 PM, Jason Cox [EMAIL PROTECTED] wrote:


Only problem is that Printer ports are not addressed the same on PCMCIA
cards and with EMC2 we talk direct to the address and not via a driver.
I dont think this solution would work.
Jason


On Mon, 2008-03-03 at 15:07 -0600, Jack wrote:
 In general, laptops are not a good idea.  Many of the inexpensive ones
 are doing away with 'legacy' ports.
 I would suggest, whatever you get, get one with a PCCard slot, and get
 a PCCard that has a printer port on it.
 Actually, I would want two of the cards, just in case one gets
 fried :(

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[Emc-users] Steppers and INI file

2007-03-01 Thread Glenn R. Edwards
I am running a four-axis mini-type mill with a xylotec board and stepper
motors throughout.  Everything runs fine (pretty much) except for the
4th axis which is an angular axis.  All the linear axes have the same
settings in the INI file and are mechanically the same.

 

I have noticed that when I do a fast-move command with all axes going,
such as G0 X50 Y30 Z20 A90 (from home), the angular axis will move
faster than when I do a single axis move such as G0 A90.  And I noticed
that a G0 command behaves like a G1 command in that all the axes arrive
at the same time.  For example, in the multi-axis move listed above, I
would expect a trapezoid move profile (the axes with shorter distances
arrive first) but I am getting a straight-line move profile from home to
the end-point.  Any suggestions or comments?

 

Best regards,

-- --

Glenn 

 

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Re: [Emc-users] Steppers and INI file

2007-03-01 Thread Glenn R. Edwards
Thanks Chris.

The G0 answer makes sense.

I am running EMC 2.1.1

I'll post the INI file as soon as I get it off the machine.

Best regards,
-- --
Glenn

On Thu, Mar 01, 2007 at 04:04:16PM -0800, Glenn R. Edwards wrote:
 
 I have noticed that when I do a fast-move command with all axes going,
 such as G0 X50 Y30 Z20 A90 (from home), the angular axis will move
 faster than when I do a single axis move such as G0 A90.  

Please post your ini (attach it here, or use www.pastebin.ca and
include just a link here) and also say which version of EMC you are
running.  

 And I noticed
 that a G0 command behaves like a G1 command in that all the axes
arrive
 at the same time.  For example, in the multi-axis move listed above, I
 would expect a trapezoid move profile (the axes with shorter distances
 arrive first) but I am getting a straight-line move profile from home
to
 the end-point.  Any suggestions or comments?

This is the correct behavior; the axes should start and stop together,
according to the rs274ngc spec:

http://www.linuxcnc.org/handbook/RS274NGC_3/RS274NGC_32a.html#1012110

Since you would have to wait for the slowest axis (making the longest
move) anyway, this costs you no extra time, and a straight move is a
lot less surprising in a lot of situations.

Chris


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Re: [Emc-users] M0 vs Cycle start button

2007-02-26 Thread Glenn R. Edwards
I am interested in getting manual tool change to work and I have
followed the below instructions.  When I issue an M6 T1, the machine
does not move the 4th axis (angular: C) to the position set in the ini
file: TOOL_CHANGE_POSITION = 4 5 10 90.  Any suggestions?  Thanks!

Best regards,
-- --
Glenn 


-Original Message-
From: [EMAIL PROTECTED]
[mailto:[EMAIL PROTECTED] On Behalf Of Patrick
Giasson
Sent: Sunday, February 25, 2007 6:37 AM
To: Enhanced Machine Controller (EMC)
Subject: Re: [Emc-users] M0 vs Cycle start button

Thank you, it works with axis, which will be fine with me. If others are

looking for a solution to this problem, don't forget that you need the 
following line too:

linkpp iocontrol.0.tool-prepare iocontrol.0.tool-prepared


with the other 5 below.


Thanks again


Patrick


Jeff Epler wrote:
 For emc2.1 systems with manual tool change, I recommend using
 'hal_manualtoolchange'.  This is demonstrated in the 'sim/axis'
 configuration.  When you issue a tool change g-code like 'M6 T1', the
 machine goes to a location defined in the INI, then a dialog appears
on
 the screen with a button for you to press when the new tool is in
place.
 Then the machine returns to the previous location and continues with
the
 file.  The HAL lines for this are:
 loadusr -W hal_manualtoolchange

 # in case they were linked already
 unlinkp iocontrol.0.tool-change
 unlinkp iocontrol.0.tool-changed

 linkpp hal_manualtoolchange.change iocontrol.0.tool-change 
 linkpp hal_manualtoolchange.changed iocontrol.0.tool-changed
 linkpp hal_manualtoolchange.number iocontrol.0.tool-prep-number

 You can specify the location to move to in the ini file:
 [EMCIO]
 TOOL_CHANGE_POSITION = 0 0 2

 If you prefer to use only tkemc, then the button you are looking for
is
 the one marked Resume, in the center just above the program listing.

 Jeff



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Re: [Emc-users] Command-line interface to EMC2

2007-02-08 Thread Glenn R. Edwards
While EMC is processing a file, how do I get its status.  I am looking
for Busy, Done, etc.  EMCRSH and AXIS-REMOTE do not seem to have any
appropriate commands, unless I am overlooking something.

Best regards,
-- --
Glenn 


-Original Message-
From: [EMAIL PROTECTED]
[mailto:[EMAIL PROTECTED] On Behalf Of Eric H.
Johnson
Sent: Wednesday, February 07, 2007 11:03 AM
To: 'Enhanced Machine Controller (EMC)'
Subject: Re: [Emc-users] Command-line interface to EMC2

Jeff,

It should be noted however that if AXIS, or any other user interface
opens a
program file, that issuing:

get program

To emcrsh will (ok should, I know it works with tkemc) return the
current
open program.

Regards,
Eric

 It's possible that 'open' is working, but axis isn't doing 
 what you expect.  If another UI (including emcrsh) opens a 
 file, AXIS doesn't automatically load that file in its 
 preview.  If you want to open a file in AXIS to preview, you 
 can use the script 'axis-remote' to do it.



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Get stuff done quickly with pre-integrated technology to make your job easier.
Download IBM WebSphere Application Server v.1.0.1 based on Apache Geronimo
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[Emc-users] Command-line interface to EMC2

2006-12-29 Thread Glenn R. Edwards
Dear fellow EMC users and developers,

 

Several months ago I asked a question about remote control of EMC.  I
received many excellent responses - thank you all.

 

As the system architecture progresses, it has become clear (or clearer)
that what I need is the ability run EMC2 from within a Python shell
program (or supervisory program) running on the same computer as EMC2.
The shell program will start/stop EMC2 (not necessary, but
nice-to-have), deliver an  *.ngc  file to EMC2 and have EMC2 execute
that file (necessary) and get status reports from EMC2 (necessary).

 

I have researched emcsh and emcsvr , but have come to dead-ends on both
topics.  Does anyone have any ideas on where to start my research?
Thanks!  I sense that I am just emulating a GUI (or precluding the use
of one), of which there are many excellent ones that have been developed
for EMC2.

 

Best regards,

-- --

Glenn Edwards

 

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