Re: [Emc-users] Homing of rotary axis

2010-05-15 Thread Viesturs Lācis
I had a thought about that and there is one BUT... I am going to use
stepper motor to control the rotary axis and as far as i know there is
only one way to create a closed loop system - EMC outputs PWM signal
and receives encoder data and then there has to be PWM-to-step signal
converter.

Viesturs

2010/5/14 dave dengv...@charter.net:
 Maybe this is the place to use an absolute encoder? Just an off the wall
 thought.

 Dave


 On Fri, 2010-05-14 at 10:59 -0400, Cal Grandy wrote:
 You might consider homing the head prior to energizing the high pressure
 hoses.  Only a sequence control.


 - Original Message -
 From: Viesturs Lacis viesturs.la...@gmail.com
 To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
 Sent: Friday, May 14, 2010 7:35
 Subject: Re: [Emc-users] Homing of rotary axis


 2010/5/14 Andy Pugh a...@andypugh.fsnet.co.uk:
  On 14 May 2010 00:16, sa...@free.fr wrote:
 
 
 
  (Ian, your idea would work fine too, but he asked to minimise the
  amount of movement that his hoses are subjected to)
 

 Yes, the essence is that I do not want the head to tilt those 50
 degrees (which is maximum tilt angle) every time i turn on the
 machine, because it puts a lot of stress to high-pressure tubing
 (water pressure reaches ~4000 bar).

 Ian, thank You for a suggestion on playing with HOME_OFFSET value for
 fine-tuning the home position. I find that in some cases it might be
 easier than adjusting the home switch itself.

  I think it need be nothing more complex than a semi-circular metal disc on
  the rear shaft
  extension of the motor and an optical slot detector.

 Yes, it seems like a pretty simple setup to me too, Thank You for an idea!

 Viesturs

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Re: [Emc-users] Homing of rotary axis

2010-05-15 Thread Stephen Wille Padnos
Viesturs Lācis wrote:
 I had a thought about that and there is one BUT... I am going to use
 stepper motor to control the rotary axis and as far as i know there is
 only one way to create a closed loop system - EMC outputs PWM signal
 and receives encoder data and then there has to be PWM-to-step signal
 converter.

EMC can output whatever you want, it doesn't have to be PWM. The problem 
with closed loop and steppers is that the available torque of a stepper 
decreases with speed, so when the motor falls behind enough for PID to 
try to correct, it's already lost. The stepper has no extra torque to 
give in response to the faster command it gets, unlike a servo.

Closed loop monitoring of a stepper position, using that for following 
error detection, is perfectly reasonable and can be done with EMC2, 
without a hardware PWM-to-step converter.

- Steve


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Re: [Emc-users] Homing of rotary axis

2010-05-15 Thread Andy Pugh
On 15 May 2010 11:56, Viesturs Lācis viesturs.la...@gmail.com wrote:

 I had a thought about that and there is one BUT... I am going to use
 stepper motor to control the rotary axis and as far as i know there is
 only one way to create a closed loop system - EMC outputs PWM signal
 and receives encoder data and then there has to be PWM-to-step signal
 converter.

There are people running closed-loop stepper systems. One way is to
use a velocity-mode stepgen and to pass the output of the PID as a
velocity request. It would also be possible to use a very slow
(possibly integral-only) PID as an added-on offset to a position
command.

You can use an absolute encoder without needing to be closed-loop,
though. You could use a constant term, calculated at boot time as an
offset between current stepgen position and current position as
measured by an encoder and just add that on to the position reguest
before passing it to the stepgen. It would seem a waste to fit an
absolute encoder and then to only use it for a millisecond a day
though.


You can use an absolute encoder without needing to b
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Re: [Emc-users] Homing of rotary axis

2010-05-15 Thread Tom Easterday
On May 15, 2010, at 9:24 AM, Andy Pugh wrote:
 
 There are people running closed-loop stepper systems.

Really?  I keep getting told you can't do it for various reasons.

 One way is to
 use a velocity-mode stepgen and to pass the output of the PID as a
 velocity request. It would also be possible to use a very slow
 (possibly integral-only) PID as an added-on offset to a position
 command.

I would love to see someone's configuration files who has made a closed loop 
with steppers work.

-Tom


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Re: [Emc-users] Homing of rotary axis

2010-05-15 Thread Jon Elson
Viesturs Lācis wrote:
 I had a thought about that and there is one BUT... I am going to use
 stepper motor to control the rotary axis and as far as i know there is
 only one way to create a closed loop system - EMC outputs PWM signal
 and receives encoder data and then there has to be PWM-to-step signal
 converter.

   
The Pico Systems Universal Stepper Controller is a board that generates 
step pulses.
The default is to have it count the step pulses it sends out to keep EMC 
in sync with the steps.
But, by flipping a switch, it can count encoder pulses instead, and 
report that back to EMC.
This selection can be made on an axis-by-axis basis. You can also use a 
software encoder in EMC to read the encoder, but that eats up a lot of 
parallel port bits. But, you could do a 4-axis system with only two 
parallel ports this way, setting the data bits on the 2nd port to input 
mode.

Jon

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Re: [Emc-users] Homing of rotary axis

2010-05-15 Thread Jon Elson
Tom Easterday wrote:
 On May 15, 2010, at 9:24 AM, Andy Pugh wrote:
   
 There are people running closed-loop stepper systems.
 

 Really?  I keep getting told you can't do it for various reasons.
   

 I would love to see someone's configuration files who has made a closed loop 
 with steppers work.
   
The Pico Systems Universal Stepper Controller is a sort of closed loop 
system all the time.  The default method is to count the step pulses 
sent out.  By flipping a switch for each axis, you can set it to read 
the encoder pulses, instead.

So, in fact, EMC doesn't actually even KNOW whether it is physical 
closed-loop or electronic closed-loop!  The only changes in the .ini 
file would be to change the INPUT_SCALE parameter to reflect the encoder 
resolution vs. the step resolution per user unit.

See the configs file directory included in your EMC2 distro under univstep.

Now, the reason you've been told you can't do that is because it 
doesn't PREVENT stalls.  It WILL detect a stalled motor and cause a 
following error stop.  It will also silently fix a single lost step here 
and there caused by setup time violations during direction reversals.
Some machines suffer from this kind of problem.

Jon

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Re: [Emc-users] Homing of rotary axis

2010-05-15 Thread Viesturs Lācis
2010/5/15 Stephen Wille Padnos spad...@sover.net:
 Viesturs Lācis wrote:
 I had a thought about that and there is one BUT... I am going to use
 stepper motor to control the rotary axis and as far as i know there is
 only one way to create a closed loop system - EMC outputs PWM signal
 and receives encoder data and then there has to be PWM-to-step signal
 converter.

 EMC can output whatever you want, it doesn't have to be PWM. The problem
 with closed loop and steppers is that the available torque of a stepper
 decreases with speed, so when the motor falls behind enough for PID to
 try to correct, it's already lost. The stepper has no extra torque to
 give in response to the faster command it gets, unlike a servo.

 Closed loop monitoring of a stepper position, using that for following
 error detection, is perfectly reasonable and can be done with EMC2,
 without a hardware PWM-to-step converter.



Motors will be moving relatively slowly, so loss of torque in high
speeds is not a problem.
I expect that rotary axis will have to hold their existing position
more than do any movement at all and steppers are better in holding
their position than servos without a brake.


2010/5/15 Jon Elson el...@pico-systems.com:
 Tom Easterday wrote:
 On May 15, 2010, at 9:24 AM, Andy Pugh wrote:

 There are people running closed-loop stepper systems.


 Really?  I keep getting told you can't do it for various reasons.


 I would love to see someone's configuration files who has made a closed loop 
 with steppers work.

 The Pico Systems Universal Stepper Controller is a sort of closed loop
 system all the time.  The default method is to count the step pulses
 sent out.  By flipping a switch for each axis, you can set it to read
 the encoder pulses, instead.

 So, in fact, EMC doesn't actually even KNOW whether it is physical
 closed-loop or electronic closed-loop!  The only changes in the .ini
 file would be to change the INPUT_SCALE parameter to reflect the encoder
 resolution vs. the step resolution per user unit.

 See the configs file directory included in your EMC2 distro under univstep.

 Now, the reason you've been told you can't do that is because it
 doesn't PREVENT stalls.  It WILL detect a stalled motor and cause a
 following error stop.  It will also silently fix a single lost step here
 and there caused by setup time violations during direction reversals.
 Some machines suffer from this kind of problem.

 Jon


I (and seems like other EMC users as well) did not know that stepper
motors are used in closed-loop systems. I will try to search for more
information about that Pico Systems Universal Stepper controller.
Thank You for sharing the information?

Then I have one more question - what are the options to use servo
motors and stepper motors together in one machine? I have 3 servos (2
on X axis and 1 on Y axis) and currently I am trying to control servo
drives in step/dir mode, which does not seem very clever idea, besides
movement of axis with old, DOS based control system is smoother
(analog +10V/-10V signal is used) than EMC with step/dir mode
performs. I want to add 3 stepper motors on Z, A and B axis
respectively. I already have stepper drivers and motors, so i could
save some money and as I mentioned - i believe that steppers on rotary
axis are better.

Viesturs

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Re: [Emc-users] Homing of rotary axis

2010-05-15 Thread Stephen Wille Padnos
Viesturs Lācis wrote:
 2010/5/15 Stephen Wille Padnosspad...@sover.net:

 [snip]
 Motors will be moving relatively slowly, so loss of torque in high
 speeds is not a problem.
 I expect that rotary axis will have to hold their existing position
 more than do any movement at all and steppers are better in holding
 their position than servos without a brake.

I guess I should have said that since a stepper never has more torque 
than when it's stopped, it will never have extra torque to catch up if 
it falls behind the expected position or speed.

 2010/5/15 Jon Elsonel...@pico-systems.com:

 Tom Easterday wrote:
  
 On May 15, 2010, at 9:24 AM, Andy Pugh wrote:


 There are people running closed-loop stepper systems.

  
 Really?  I keep getting told you can't do it for various reasons.


 I would love to see someone's configuration files who has made a closed 
 loop with steppers work.


 The Pico Systems Universal Stepper Controller is a sort of closed loop
 system all the time.  The default method is to count the step pulses
 sent out.  By flipping a switch for each axis, you can set it to read
 the encoder pulses, instead.

 So, in fact, EMC doesn't actually even KNOW whether it is physical
 closed-loop or electronic closed-loop!  The only changes in the .ini
 file would be to change the INPUT_SCALE parameter to reflect the encoder
 resolution vs. the step resolution per user unit.

 See the configs file directory included in your EMC2 distro under univstep.

 Now, the reason you've been told you can't do that is because it
 doesn't PREVENT stalls.  It WILL detect a stalled motor and cause a
 following error stop.  It will also silently fix a single lost step here
 and there caused by setup time violations during direction reversals.
 Some machines suffer from this kind of problem.

 Jon

  
 I (and seems like other EMC users as well) did not know that stepper
 motors are used in closed-loop systems. I will try to search for more
 information about that Pico Systems Universal Stepper controller.
 Thank You for sharing the information?

It's not as common to use steppers in true closed loop systems, since 
they can't catch up once they fall behind.  Using a stepper in a system 
that has feedback that is used only for following error detection is a 
different story, and is definitely do-able.
 Then I have one more question - what are the options to use servo
 motors and stepper motors together in one machine?
You can use any kind of motor for any joint on the machine.  You can 
also use more than one type of hardware, so for instance you could have 
a Pico Systems card on one parallel port, use a second parallel port 
directly, and use a PCI plug-in Mesa card, all at once.
 I have 3 servos (2
 on X axis and 1 on Y axis) and currently I am trying to control servo
 drives in step/dir mode, which does not seem very clever idea, besides
 movement of axis with old, DOS based control system is smoother
 (analog +10V/-10V signal is used) than EMC with step/dir mode
 performs. I want to add 3 stepper motors on Z, A and B axis
 respectively. I already have stepper drivers and motors, so i could
 save some money and as I mentioned - i believe that steppers on rotary
 axis are better.

Just mix and match them as you like, EMC doesn't care.

- Steve


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Re: [Emc-users] Homing of rotary axis

2010-05-14 Thread Ian W. Wright
Andy wrote...
 
 I think it would be a perfectly normal looking INI file. 
As for the
 switch arrangement, on the proposed stepper-motor 
arrangement I think
it need be nothing more complex than a semi-circular metal 
disc on the
 rear shaft extension of the motor and an optical slot 
detector.

 (Ian, your idea would work fine too, but he asked to 
minimise the
 amount of movement that his hoses are subjected to)
 

I understand your point about the hoses but, if you are 
thinking of using a central switch, wouldn't this give a 
different tripping point depending on which side of centre 
you approach it from? i.e if it were a slot in a disk, the 
opto would trip on one side of the slot when approaching 
from one side and the other side of the slot when 
approaching from the other direction

Ian

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Re: [Emc-users] Homing of rotary axis

2010-05-14 Thread Andy Pugh
On 14 May 2010 08:08, Ian W. Wright watchma...@talktalk.net wrote:

 I understand your point about the hoses but, if you are
 thinking of using a central switch, wouldn't this give a
 different tripping point depending on which side of centre
 you approach it from? i.e if it were a slot in a disk, the
 opto would trip on one side of the slot when approaching
 from one side and the other side of the slot when
 approaching from the other direction

The idea is to always use the same edge, and for home to always search
in the same direction.
You use a semi-circular disc or a 180 degree cam so that the system
knows which initial direction to move in to find the homing area, then
once it has driven off the cam or sensor it performs a  standard
homing routine.

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Re: [Emc-users] Homing of rotary axis

2010-05-14 Thread Viesturs Lācis
2010/5/14 Andy Pugh a...@andypugh.fsnet.co.uk:
 On 14 May 2010 00:16,  sa...@free.fr wrote:



 (Ian, your idea would work fine too, but he asked to minimise the
 amount of movement that his hoses are subjected to)


Yes, the essence is that I do not want the head to tilt those 50
degrees (which is maximum tilt angle) every time i turn on the
machine, because it puts a lot of stress to high-pressure tubing
(water pressure reaches ~4000 bar).

Ian, thank You for a suggestion on playing with HOME_OFFSET value for
fine-tuning the home position. I find that in some cases it might be
easier than adjusting the home switch itself.

 I think it need be nothing more complex than a semi-circular metal disc on 
 the rear shaft
 extension of the motor and an optical slot detector.

Yes, it seems like a pretty simple setup to me too, Thank You for an idea!

Viesturs

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Re: [Emc-users] Homing of rotary axis

2010-05-14 Thread Stuart Stevenson
Gentlemen,
  Here are two pictures of my cinci. They show the A axis from a wide view
and a close view of the cam and switches.
  The cam is the homing cam. If the cam would be lengthened  to engage the
switch for 1/2 the motion of the A axis then the machine would function per
the explanation provided by John Kasunich.
  As it functions now it is a very short annunciation of 'I am at the home
switch'. The control ignores the home switch after the home cycle.

http://www.mpm1.com:8080/cinci/pictures/cinciAaxiswide.jpg
http://www.mpm1.com:8080/cinci/pictures/cinciAaxisclose.jpg

thanks
Stuart

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Re: [Emc-users] Homing of rotary axis

2010-05-14 Thread Cal Grandy
You might consider homing the head prior to energizing the high pressure 
hoses.  Only a sequence control.


- Original Message - 
From: Viesturs Lacis viesturs.la...@gmail.com
To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
Sent: Friday, May 14, 2010 7:35
Subject: Re: [Emc-users] Homing of rotary axis


2010/5/14 Andy Pugh a...@andypugh.fsnet.co.uk:
 On 14 May 2010 00:16, sa...@free.fr wrote:



 (Ian, your idea would work fine too, but he asked to minimise the
 amount of movement that his hoses are subjected to)


Yes, the essence is that I do not want the head to tilt those 50
degrees (which is maximum tilt angle) every time i turn on the
machine, because it puts a lot of stress to high-pressure tubing
(water pressure reaches ~4000 bar).

Ian, thank You for a suggestion on playing with HOME_OFFSET value for
fine-tuning the home position. I find that in some cases it might be
easier than adjusting the home switch itself.

 I think it need be nothing more complex than a semi-circular metal disc on 
 the rear shaft
 extension of the motor and an optical slot detector.

Yes, it seems like a pretty simple setup to me too, Thank You for an idea!

Viesturs

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Re: [Emc-users] Homing of rotary axis

2010-05-14 Thread dave
Maybe this is the place to use an absolute encoder? Just an off the wall
thought. 

Dave


On Fri, 2010-05-14 at 10:59 -0400, Cal Grandy wrote:
 You might consider homing the head prior to energizing the high pressure 
 hoses.  Only a sequence control.
 
 
 - Original Message - 
 From: Viesturs Lacis viesturs.la...@gmail.com
 To: Enhanced Machine Controller (EMC) emc-users@lists.sourceforge.net
 Sent: Friday, May 14, 2010 7:35
 Subject: Re: [Emc-users] Homing of rotary axis
 
 
 2010/5/14 Andy Pugh a...@andypugh.fsnet.co.uk:
  On 14 May 2010 00:16, sa...@free.fr wrote:
 
 
 
  (Ian, your idea would work fine too, but he asked to minimise the
  amount of movement that his hoses are subjected to)
 
 
 Yes, the essence is that I do not want the head to tilt those 50
 degrees (which is maximum tilt angle) every time i turn on the
 machine, because it puts a lot of stress to high-pressure tubing
 (water pressure reaches ~4000 bar).
 
 Ian, thank You for a suggestion on playing with HOME_OFFSET value for
 fine-tuning the home position. I find that in some cases it might be
 easier than adjusting the home switch itself.
 
  I think it need be nothing more complex than a semi-circular metal disc on 
  the rear shaft
  extension of the motor and an optical slot detector.
 
 Yes, it seems like a pretty simple setup to me too, Thank You for an idea!
 
 Viesturs
 
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Re: [Emc-users] Homing of rotary axis

2010-05-13 Thread Andy Pugh
2010/5/13 Viesturs Lācis viesturs.la...@gmail.com:

 2) homing sensor - i have no idea, how to implement homing sensor on a
 rotary axis so that it is in a middle of the movement range - it seems
 to me that usual homing sensors are not suitable. Please correct me,
 if I am wrong. Or maybe should i use some kind of priximity switch?

The logical way seems to me to have a switch of some sort (mechanical,
optical, proximity) which is on for all positive angles and off
for all negative ones. Then the homing sequence would know which
direction it has to move to find the edge.
Then you have two possible homing sequences:
a) if the switch is on a fast move to off and a slow search to on
b) if the switch is off a fast move to on then a fast move to
off and a slow search to on

However: I don't think this is type of configuration is currently
supported, I think you will tend to get an error along the lines of
home switch set before search move though it might well be worth an
experiment to see if it works. (I don't have a machine here to try it
on)

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Re: [Emc-users] Homing of rotary axis

2010-05-13 Thread John Kasunich


On Thu, 13 May 2010 10:59 +0100, Andy Pugh a...@andypugh.fsnet.co.uk
wrote:
 2010/5/13 Viesturs Lācis viesturs.la...@gmail.com:
 
  2) homing sensor - i have no idea, how to implement homing sensor on a
  rotary axis so that it is in a middle of the movement range - it seems
  to me that usual homing sensors are not suitable. Please correct me,
  if I am wrong. Or maybe should i use some kind of priximity switch?
 
 The logical way seems to me to have a switch of some sort (mechanical,
 optical, proximity) which is on for all positive angles and off
 for all negative ones. Then the homing sequence would know which
 direction it has to move to find the edge.
 Then you have two possible homing sequences:
 a) if the switch is on a fast move to off and a slow search to on
 b) if the switch is off a fast move to on then a fast move to
 off and a slow search to on
 
 However: I don't think this is type of configuration is currently
 supported, I think you will tend to get an error along the lines of
 home switch set before search move though it might well be worth an
 experiment to see if it works. (I don't have a machine here to try it
 on)
 

Actually EMC2 will work just find with such a switch.  It is not quite
exactly what you wrote, instead the process is:

1) If initially on the switch, move in the opposite direction to
normal homing until off

2) Move in the normal homing direction till on

3) Finish the homing process (this might involve one, two, or three
more moves, depending on your configuration).

The usual way to implement a switch that is on for half the travel
is to have a long cam or switch actuator.

John Kasunich

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  jmkasun...@fastmail.fm


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Re: [Emc-users] Homing of rotary axis

2010-05-13 Thread Andy Pugh
On 13 May 2010 12:53, John Kasunich jmkasun...@fastmail.fm wrote:

 Actually EMC2 will work just find with such a switch.

Excellent, I thought it seemed too likely a situation not to be
supported. I think I must have been confusing it with the switch
inactive before start of latch move message.

As you say, easily done with a long cam or a long flag and an opto.

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Re: [Emc-users] Homing of rotary axis

2010-05-13 Thread Viesturs Lācis
2010/5/13 Andy Pugh a...@andypugh.fsnet.co.uk:
 On 13 May 2010 12:53, John Kasunich jmkasun...@fastmail.fm wrote:

 Actually EMC2 will work just find with such a switch.
 The usual way to implement a switch that is on for half the travel
 is to have a long cam or switch actuator.

 Excellent, I thought it seemed too likely a situation not to be
 supported. I think I must have been confusing it with the switch
 inactive before start of latch move message.

 As you say, easily done with a long cam or a long flag and an opto.


Thank You, guys, for suggestions!
I am not sure that I understand, what is meant by a long cam or a
long flag and an opto.

Viesturs

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Re: [Emc-users] Homing of rotary axis

2010-05-13 Thread Stuart Stevenson


 Thank You, guys, for suggestions!
 I am not sure that I understand, what is meant by a long cam or a
 long flag and an opto.


a long cam to hold the switch open/closed for half the travel of the rotary
head



 Viesturs


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Re: [Emc-users] Homing of rotary axis

2010-05-13 Thread Ian W. Wright
Hi Viesturs,

I have just been implementing something a little similar on 
my mill - at least, you can achieve what you want in a 
similar way. I have the mill set up as a normal 3-axis mill 
with home/limit switches at one end of each axis. What I 
wanted to set up now was a configuration where I can use my 
rotary axis on the middle of the table as a 'C' axis, i.e. 
with its spindle parallel to the milling spindle. To make 
setting up the jobs easy, I wanted the milling spindle to 
'Home' to the exact centre of the rotary axis spindle. It 
turns out to be quite easy to do just set the 
HOME_OFFSET to a distance equal to half the axis travel and 
HOME_POSITION to 0.00. In my case, the X and Y axes rapidly 
move to the end of their travel until they hit the home 
switch, back off it then slowly onto the switch again to get 
exact position and finally rapidly move to the central 
position and set the axis display to 0.000 . In your case, 
you could put either a mechanical or optical switch on one 
side of each axis at 50 degrees from centre and set 
HOME_OFFSET to 50 and HOME_POSITION to 0.000 . If the switch 
is a little off the exact position, it doesn't really matter 
as you can easily correct the error by adjusting the 
HOME_OFFSET value until your spindle/torch lies truly vertical.

Ian
__
Ian W. Wright
Sheffield  UK

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Re: [Emc-users] Homing of rotary axis

2010-05-13 Thread saadp


Very interesting discussion.

Does anyone have an example of implementation of a rotary cam-switch (and where
to find one) along with an INI file example?

Sincerely,


Patrice

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Re: [Emc-users] Homing of rotary axis

2010-05-13 Thread Andy Pugh
On 14 May 2010 00:16,  sa...@free.fr wrote:

 Does anyone have an example of implementation of a rotary cam-switch (and 
 where
 to find one) along with an INI file example?

I think it would be a perfectly normal looking INI file. As for the
switch arrangement, on the proposed stepper-motor arrangement I think
it need be nothing more complex than a semi-circular metal disc on the
rear shaft extension of the motor and an optical slot detector.

(Ian, your idea would work fine too, but he asked to minimise the
amount of movement that his hoses are subjected to)

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atp

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