Re: [Emc-users] stepper power supply

2011-12-29 Thread Ed Nisley
On Wed, 2011-12-28 at 12:03 -0500, gene heskett wrote:
 There are hall effect based ammeters

A while back, I mooched a Tek Hall-effect current probe from my buddy
Eks to take some interesting pix:

http://softsolder.com/2011/06/20/stepper-sync-wheel-current-waveform-first-light/
http://softsolder.com/2011/06/27/stepper-motor-winding-current-rise-time/

The winding current stays within a skosh of the setpoint for each
microstep, which the driver determines by applying the sine  cosine of
the microstep (electrical) angle to the overall peak current setpoint.

That may also contribute to the mystical 70% derating factor, because in
full-step mode the driver (well, Allegro drivers, anyway) applies
1/sqrt(2) = 0.71 of the peak current setpoint to *each* winding. That
keeps the overall motor power dissipation the same, but the total
current into both windings is 2*(1/sqrt(2))*peak = 1.4*peak. Perhaps the
person who first stated that factor, back in the dim past, forgot about
the current in the *other* winding?

While I was doing that, I managed to stoke a mechanical resonance that
back-drove the winding current something awful:

http://softsolder.com/2011/09/12/stepper-dynamometer-mechanical-resonance/ 

Keeps me off the streets at night... [grin]

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Re: [Emc-users] stepper power supply

2011-12-30 Thread Ed Nisley
On Thu, 2011-12-29 at 21:14 -0500, gene heskett wrote:
 pointers to the articles

That was a series on transformers  triac triggering, with a resistance
soldering setup as the McGuffin. CC doesn't put articles online (if you
know where to look, go for April/June/August 2008), but I put up some
notes a while ago; start at the first post and rummage through the next
few days:

http://softsolder.com/2010/09/07/resistance-soldering-gizmo-overview/

The transformer notes, complete with a B-H curve, may be most useful:

http://softsolder.com/2010/09/08/resistance-soldering-transformer/

The triac trigger circuitry was *insanely* complex, because I wanted to
show what happens during four-quadrant triggering with sub-cycle
control. In real life, you'd just fire a triac driver for the entire
heating pulse and be done with it.

A while back, Eks forced me to take his homebrew water-cooled pulser
built around a stack of hockey-puck transistors that he'd been using for
EDM. All I need is a bulk supply behind the thing, a bit of Z axis
control, and I could sink dies with the best of 'em... [sigh]

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Re: [Emc-users] stepper power supply

2011-12-30 Thread Ed Nisley
On Fri, 2011-12-30 at 16:33 -0500, Jim Coleman wrote:
 how stable the voltage remains across a range of loads

I really didn't measure that, but I think the core losses are just this
side of terrible. After all, they used core saturation for output power
control, so reducing losses probably wasn't particularly important.

Some handwaving:

It pushed 280 A into a 14 m-ohm load with 4.1 V at the lugs, which made
the winding + terminal resistance 3 to 4 m-ohm. That's higher than I
expected for four parallel #10 wires: 1 m-ohm/ft x 4 ft = 4 m-ohm each,
so you'd expect 1 m-ohm total. Frankly, my measurement accuracy isn't up
to the task and I'm ignoring core losses.

Putting three of those #10 wires in series, rather than parallel, would
give 15 V with maybe 10 m-ohm. You pull 75 A for 1 kW at 13.5 V, so the
voltage would drop a bit under 1 V due to copper resistance. Add or
subtract a turn or two for the right answer.

It might come heartbreakingly close to working.

 any reason this technique couldn't be used for higher voltages

The original secondary had a bazillion turns of fine wire to stuff what,
4 kV or so into the magnetron. The catch would be winding the heavy wire
you need at 1 V/turn: a dozen or so turns would be do-able, but much
beyond that won't fit through the core windows.

You could, I suppose, delaminate the transformer and start all over
again, but that starts to resemble actual work.

Also, the recycled Romex wire I used is, , suboptimal in a
high-current transformer. I'm not sure you (well, I) could feed enamel
(or whatever they use these days) insulation through the core windows
without nicking it; the thick plastic insulation on that Romex gave me
decent results with crude techniques.

But, again, it'd probably come pretty close to working...

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Re: [Emc-users] gEDA / Correcting for workpiece warpage.

2012-01-12 Thread Ed Nisley
On Thu, 2012-01-12 at 17:28 -0500, gene heskett wrote:
 get another armload of 2  1/2 ring binders 

If you can stand to wait for a bit, I'll run off a booklet-sized version
and send it to you. The printer uses bulk ink, I've finally got the
restack orientation down to a reflex, and I have a comb binding machine.
The booklet will be half-letter size, which is about what the old EAGLE
manuals used to be, back in the day. Color, too, if the PDF has any.

A 334 page manual will boil down to 84 letter-size sheets of paper, cut
in half to make 168 half-size sheets, so it'll be maybe 3/4 inch thick.
Thinner than the stack of EMC2 manuals everybody wanted to buy off me at
Cabin Fever a year or so ago...

Send me your mailing address and I'll get one off as soon as the CadSoft
site recovers from the 6.0.0 - 6.1.0 onslaught.

Your payment: keep telling war stories that I can send to our Larval EE
in up Rochester as examples of what she won't learn in the classroom.

Deal?

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Re: [Emc-users] steppers

2012-01-13 Thread Ed Nisley
On Fri, 2012-01-13 at 10:09 -0700, Cathrine Hribar wrote:
 if the steppers are wired in series, like I wired mine, 
 they would require twice as much current 

Having waded through this mess not too long ago, here's what I (think I)
know...

Putting the two halves of a single pole's winding in series doubles the
number of turns, doubles the winding resistance, and increases the
inductance by a factor of four.

Doubling the turns doubles the magnetic flux density in the pole, which
is easier to see with the old-school unit of Ampere-turn instead of the
fancy-pants metric Gauss or Tesla. Because torque is proportional to
magnetic flux, you should get twice the torque for the same current.

Unfortunately, the armature will probably saturate because you're now
running it at twice its design flux, which will kill the torque and
perhaps the motor, too. That's not a desirable outcome, so,
paradoxically, a motor rated at 2.8 A per winding should run at 1.4 A
with two windings in series.

The resistive power losses would double at the same current, but will go
down by a factor of 2 at half that current. If the motor has enough
magnetic headroom, you can reduce the current by 1/sqrt(2) to dissipate
the same amount of power: 2.8 A * 0.707 = 2 A.

The increased inductance increases the overall L/R rise time by a factor
of 4, assuming the external circuit is supplying substantial resistance
(as in antique L/5R DC drives with hulking power resistors). With modern
current-limiting chopper drivers, however, the rise time depends mostly
on the winding's internal resistance, which increases by a factor of 2,
so the net L/R increases by a factor of only 4/2 = 2.

So, with the series-wired windings connected to the same supply voltage,
the current rise time doubles. If you were pushing the motor's upper
speed limit, the torque will fall off because the current reaches the
limit set by the driver much later in each microstep. In the worst case,
it no longer reaches the limit at all.

It's enough to make your (well, my) head spin...

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Re: [Emc-users] eagle-6.1.0 (again)

2012-01-17 Thread Ed Nisley
On Tue, 2012-01-17 at 20:30 -0500, gene heskett wrote:
 If I fix the library, 
 will that fix the schematic when it is next loaded?

Nope, the schematic holds copies of all the components, so that you
can't inadvertently wreck all your circuits with a single library
change.

You must delete all instances of the old part from the schematic,
refresh the library to get the new part, and then re-place all of them.

It's a pain, but it does make a certain kind of sense.

 those manuals were in my mailbox this evening.

Excellent! Now, keep telling the occasional war story...

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Re: [Emc-users] eagle-6.1.0 (again)

2012-01-18 Thread Ed Nisley
On Wed, 2012-01-18 at 00:03 -0500, gene heskett wrote:
 Alright, how about this one?

That'll work! [grin]

And who knows? My Larval Engineer may remember how to poke around inside
the safety covers without dying, in some future day when they
desperately need a fix right *now*...

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Re: [Emc-users] eagle-6.1.0 (again)

2012-01-18 Thread Ed Nisley
On Wed, 2012-01-18 at 13:46 +1100, Erik Christiansen wrote:
 Nope, to update the library info used in an open schematic editor, hit
 Library-Update and select the modified library, or just use
 Library-Update_All. 

That's exactly what I expected to work, but it didn't:

http://softsolder.com/2011/11/13/emc2-logitech-gamepad-trigger-button-name-change/

Of course, that involved a pin name change, rather than a footprint or
wiring change, which may make all the difference.

Mutter...

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Re: [Emc-users] question on gcode parsing

2012-01-21 Thread Ed Nisley
On Sat, 2012-01-21 at 12:44 -0600, Jon Elson wrote:
 Every numeric value is preceded by a letter telling what it is. 

Except in the wonderful world of RepRap, wherein they're now
(contemplating?) dual-extruder G-Code with multiple numeric values
after the E axis to mix / simultaneously extrude multiple materials:

http://reprap.org/wiki/G-code#M160:_Number_of_mixed_materials

The E axis must then absorb a linear distance of filament, plus the
mix fractions for each material.

The RepRap dialect seems to be diverging fairly rapidly from what the
LinuxCNC parser understands; in particular, their myriad M codes look
like a problem.

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Re: [Emc-users] question on gcode parsing

2012-01-21 Thread Ed Nisley
On Sat, 2012-01-21 at 21:27 +0100, Michael Haberler wrote:
 LinuxCNC in the chipmaking corner of the CNC universe.

Which it does exceedingly well!

For a number of reasons, I don't like the Arduino-based motion control
that's common to DIY 3D printers and would vastly prefer LinuxCNC for
the high-performance printer that's on my far back burner. The language
is close enough, right now, but it'd take some effort to make the answer
come out right; which is why I'm spring-loaded to notice discussions
about parsers.

Returning to my lurking niche...

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Re: [Emc-users] Rotary homing.

2012-01-23 Thread Ed Nisley
On Mon, 2012-01-23 at 14:56 -0500, gene heskett wrote:
 by destroying that known position as the homed flags are set. 

Although I *do* have home switches on the Sherline, I also inserted 

[TRAJ]
NO_FORCE_HOMING = 1

So it doesn't enforce the must-home-before-moving rule.

Axis then starts up wherever it shut down, with the previous position in
place, and runs just fine. It doesn't display the homed crosshairs,
but that really doesn't matter.

Ought to work for you...

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Re: [Emc-users] Rotary homing.

2012-01-23 Thread Ed Nisley
On Mon, 2012-01-23 at 22:34 +0200, Viesturs Lācis wrote:
 also tells Axis to remember joint positions on shutdown 

It's a simpleminded XYZA Sherline mill that wouldn't know what to do
with a joint if it saw one...

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Re: [Emc-users] Rotary homing.

2012-01-24 Thread Ed Nisley
On Tue, 2012-01-24 at 00:12 -0500, gene heskett wrote:
 Its doing all moves on the .bot. files 
 in negative X from the reference point 

I'm pretty sure there's a checkbox along the way that reads Mirror X
axis to make that answer come out right without any further attention.

The Eagle gerbv274x CAM file has a mirror option that might do exactly
what you need. Probably applies only to the bottom layer, though.

[*fails to install pcb2gcode due to dependency hell*]

The pcb2gcode man page seems to imply (in --mirror-absolute) that
backside mirroring normally takes place at the middle of the board.

Perhaps you have one or more of:
- the Eagle origin at the wrong spot
- the backside Gerber file exported without mirroring
- the --mirror-absolute option set/unset

I'd expect some option twiddling would solve the problem without resort
to G-Code hackage. After all, you're not the first person to mill the
backside of a PCB with this tool chain!

And you really need an automatic tool height probe switch... really you
do!

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Re: [Emc-users] Rotary homing.

2012-01-25 Thread Ed Nisley
On Tue, 2012-01-24 at 18:04 -0500, gene heskett wrote:
 if I can insert those few lines of code after the M6 T# command. 

If you add:

[EMCIO]
TOOL_CHANGE_AT_G30 = 1

Then M6 will move to the G30 position, which you've cleverly set right
above the probe switch. Admittedly, you must then call the probe
subroutine, but a little sed-fu [grin] should do the trick if pcb2gcode
doesn't have an option buried in there to wrap some user code around the
tool change.

The sourceforge pcb2gcode page has a bullet item:

output can be adjusted for automated height probing, see
http://www.cnczone.com/forums/showthread.php?t=82628

That discussion points to:

http://www.cnczone.com/forums/pcb_milling/82628-cheap_simple_height-probing.html

Which seems to be a generalized planar-surface probe process that's
likely too complex. All you must do is insert a G38.2 probe-and-set
subroutine, because you've already solved the PCB flatness and alignment
problems. Some sed-fu should do the trick.

I vaguely recall reading that stuff while building my hand-hewn G-Code
routines. Mercifully, those didn't have the problem of integrating with
anything else in the known universe...

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Re: [Emc-users] Rotary homing.

2012-01-25 Thread Ed Nisley
On Wed, 2012-01-25 at 22:20 +, andy pugh wrote:
 Even that is potentially optional:

Oh, *wow*... Yet Another Way to confuse myself beyond recognition.

I must put the tool probe switch somewhere more-or-less fixed before I
start invoking that code, but I like what it can do!

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Re: [Emc-users] DIY output driver

2012-01-27 Thread Ed Nisley
On Fri, 2012-01-27 at 12:26 -0500, gene heskett wrote:
 The LM317T is a linear regulator device 
 and could be made adjustable so as to compensate for the wiring and
 switching loss in your controller. 

Judging from Viesturs' description in a later message:

 Nope, I see 2 resistors in series for the middle leg.

The LM317 is probably wired up as a current controller, not a voltage
controller: it's providing a fixed *current* to the laser diode, not
regulating the voltage across the wires.

https://en.wikipedia.org/wiki/File:LM317_1A_ConstCurrent.svg

In that mode, the voltage drop from controller to laser doesn't make
much difference, at least within reasonable limits. What *does* matter
is the voltage supplied to the controller (which sets the compliance it
needs to regulate the laser current) and the current available from the
raw +12 V supply (which must be greater than the laser current).

Tweaking the resistors or substituting a voltage source for the laser
controller will let the magic smoke out of the laser!

The BD139 has a 1.5 A current rating, with a fairly low hFE = 40. That
says it must have 1.0 / 40 = 25 mA of base current to saturate while
carrying 1 A. More base current will be better.

The 4N25 has a current transfer ratio of 20%, which means the LED
current must be 25 / 0.20 = 125 mA. Anything less than that won't
provide enough base drive, so the transistor won't saturate, so the
laser controller won't get enough power, and the transistor will
eventually overheat and die.

However, you can't jam that much current through the 4N25's LED.

At the risk of sounding like an Olde Farte, the easiest way to get this
contraption working is a small mechanical relay: a few tens of mA in
will switch an amp of DC on the output. No voltage drops, no muss, no
fuss.

The optoisolator won't have enough current capacity for the relay, so
you will probably need the driver transistor to power the *relay* from
the digital output. But there's no need for the optoisolator in that
case.

Or, of course, I could be completely wrong...

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Re: [Emc-users] Back to isolcpus=1, again...

2012-01-31 Thread Ed Nisley
On Mon, 2012-01-30 at 23:35 -0500, gene heskett wrote:
 htop shows 2 cpu's with the 2nd one sitting at 0.0% use.

As I understand it, that's the way it should be.

The point of isolating the second CPU / core / whatever is to dedicate
it to the real-time parts of RTAI, thus reducing interrupt latency. The
CPU will sit there, completely idle, most of the time, so that when a
real-time interrupt / task needs work, it can be dispatched immediately.

Pinning AXIS to that idle CPU will definitely make the UI run much
faster, but then the interrupt latency will (uh, should) get much worse,
with the usual horrible effects on software step pulse generation.

At least, that's how I think it works...

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Re: [Emc-users] Back to isolcpus=1, again...

2012-02-01 Thread Ed Nisley
On Wed, 2012-02-01 at 10:59 -0500, Tom Easterday wrote:
 run the latency-test on the idle core AND run glxgears there (using
 taskset to move it too), my latency is very bad.

That makes perfect sense: the video involved in glxgears locks out
interrupts for protracted periods, so running it on the same core as the
real-time handler should dramatically increase interrupt latency.

It seems the AXIS UI is much better behaved, so running it on the
real-time core doesn't affect latency all that much. Of course, running
AXIS on an otherwise idle core will vastly improve overall performance,
but that's not really the point of fencing off that core.

I'd want to study the whole latency thing a lot more closely, with
steppers whining away and the interpreter chewing through G-Code, before
concluding that running *anything* other than real-time tasks on that
core was a Good Idea.

Now, if you had a four-core CPU, you could put the real-time stuff on
one core, AXIS on another, have two left for everything else, and get
wonderful performance... but, then, that's not a cheap Atom box. [grin]

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Re: [Emc-users] US Digital encoders?

2012-02-02 Thread Ed Nisley
On Thu, 2012-02-02 at 09:36 -0500, gene heskett wrote:
 that would require a function generator 

Perhaps gimmicking up a HAL circuit with siggen or freqgen to drive the
stepper, then compare the encoder input with the motor output? You
probably don't need a sine wave, just drive the motor back and forth at
a variable rate: siggen providing a sawtooth wave to freqgen?

Surely it'd be more complex than that, but triggering on one edge of the
motor output and looking at the corresponding encoder edges should be
revealing...

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Re: [Emc-users] US Digital encoders?

2012-02-03 Thread Ed Nisley
On Thu, 2012-02-02 at 22:21 -0500, gene heskett wrote:
 what can he use for an exciting signal?

It seems I'm missing something obvious. I thought the idea was to move
the motor back  forth while comparing the commanded (presumably, the
actual) position with the encoder's (also, presumably, the actual)
position to see if there's any lag / jitter / instability between the
two.

Using freqgen (plus stepgen or whatever the motor might require) to
drive the motor should accomplish the first part. Triggering halscope on
(some part of) the output signal, then displaying both output and input
traces will reveal their relation.

Then use siggen to ramp / sawtooth freqgen and you'll see how the
relation varies with speed  acceleration.

Yes?

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Re: [Emc-users] Need an electronic tech smarter than me

2012-02-20 Thread Ed Nisley
On Mon, 2012-02-20 at 17:42 -0500, gene heskett wrote:
 4. All logic outputs with the slots open 
 are sitting at about 18 millivolts. 

The doc says a high output when the optical path is clear, so
something's definitely wrong...

If that were my board, I'd expect the top-surface ground line running
barely 25 mils from the screw terminal pads to be at least mildly
shorted to all three output pins. Given the weak pullup, that'd hold all
three to ground.

With the power disconnected, are all three outputs isolated from each
other *and* ground? With both polarities of the DMM?

The bottom surface trace from the B terminal along those same pads may
give you a clue. Whip out a magnifier and check that clearance.

If you have a duplicate unsoldered board, check that one out...

Is the board drawing (3 x 25 mA) for the LEDs + maybe (3 x 10 mA) for
the detectors? If the detectors aren't powered up, that's a hint. If
they *are* powered up, then their outputs are shorted to ground.

The datasheet recommends a 100 nF cap between VCC and ground near the
device. That probably doesn't make much difference in a test setup, but
I'd be superstitious and slap one cap in place across the board power
input.

Having just brought up a homebrew PCB, I never cease to be amazed at the
wide variety of things that can go wrong. Like having to scratch off a
tiny un-etched copper filament shorting a IC pin to ground *under* the
IC; it was visible, but just barely, only after I soldered the IC in
place. Before that, it wasn't there. [sigh]

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Re: [Emc-users] Need an electronic tech smarter than me

2012-02-21 Thread Ed Nisley
On Tue, 2012-02-21 at 16:15 +1100, Erik Christiansen wrote:
 But it has banana sockets, so it'll do me.

Murphy also has his way with them, particularly nowadays:

http://softsolder.com/2012/02/08/power-supply-banana-jack-misfit/

Grumble...

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Re: [Emc-users] Need an electronic tech smarter than me

2012-02-21 Thread Ed Nisley
On Tue, 2012-02-21 at 23:37 +1100, Erik Christiansen wrote:
 the last paragraph of the wikipedia entry for banana connector 

Seems to me that's an eBay market opportunity: who could possibly object
to a small envelope with a gift from afar?

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Re: [Emc-users] The future of LinuxCNC mailing lists and bug tracking

2012-02-21 Thread Ed Nisley
On Tue, 2012-02-21 at 10:46 -0600, Jeff Epler wrote:
 approval of a user's initial post will be required. 

My admittedly limited 3-year experience with my Wordpress-based blog
shows that exactly zero spammers have figured out how to post one
meaningful, on-point comment in order to clear the approve-first-comment
bar and then hose the place down with junk.

I have seen a few borderline cases, but right up front I say that I
reject first comments along the lines of Cool post!... and I do.

So my data point says approval should work pretty well.

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Re: [Emc-users] Q re lathe vs axis

2012-03-14 Thread Ed Nisley
On Wed, 2012-03-14 at 11:04 -0400, gene heskett wrote:
 And that man page is as obtuse as any I've seen.

Rather than hammering that out by hand, use the remote desktop built
right into Ubuntu?

On the Ubuntu machine attached to the mill, clicky:

System - Preferences - Remote Desktop

Then select:

Allow other users to view your desktop
Allow other users to control your desktop

Set up the Security section to suit your paranoia.

On the Ubuntu machine attached to your Comfy Chair, clicky:

Applications - Internet - Remote Desktop Viewer

It'll show you a list of what's available on your network, which should
include the milling machine. Clicky to select, feed in a password if you
set it up that way, blow that window up to full screen, and you're
there...

Works for me, anyhow. I do pretty nearly all the setup  fiddling from
the Comfy Chair for both the Sherline  Thing-O-Matic, then drop down to
the Basement Lab to actually start building things.

Not quite so manly as mud-wrestling with X, but ...

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Re: [Emc-users] Q re lathe vs axis

2012-03-15 Thread Ed Nisley
On Wed, 2012-03-14 at 22:23 -0400, gene heskett wrote:
 PClos on this quad core phenom. 

Well, OK, use whatever *PClos* uses for remote desktop sharing... it's
not like PClos is some mutant without all the usual Linux stuff tucked
away under the hood.

 linuxcnc runs just fine from its own keyboard, 
 but not from an ssh login

Which is why I'm recommending you do something *other* than wrestle with
X through SSH: export the whole [mumble] desktop and be done with it.
That's stock technology, designed to Just Work.

Anything Linux-oid with a package manager should have *something* that
speaks VNC to the far end of the network. Set up the milling box to
allow desktop sharing with VNC, set up your desktop box to connect with
a VNC desktop, and you're done.

Modulo, of course, having your network running, which may not be a given
at this point. That, alas, is a real swamp...

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Re: [Emc-users] database Q?

2012-04-03 Thread Ed Nisley
On Mon, 2012-04-02 at 23:12 -0400, gene heskett wrote:
 so if it did do an automatic save

Among the other things I set up with a new OO/LO installation:

Tools - Options - Load/Save General - check Save AutoRecovery
information every and set the timer for 10 minutes

That dramatically improves the chances of recovering *something*,
because if it's turned off, you're stuck with whatever's been manually
saved. That might be nothing at all, as you've discovered.

But, come now, you *know* recording data on a crash-test dummy box is
Bad Technique. Case in point: this past weekend at a robot contest, an
otherwise useless stack of shredded dead trees turned out to be
absolutely vital...

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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread Ed Nisley
On Wed, 2012-05-30 at 19:29 +0200, Roland Jollivet wrote:
 The thing is, what do you do with these parts?

Some examples of stuff I've designed  build  used...

A case for a GPS+voice amateur radio circuit:
http://softsolder.com/2012/04/13/wouxun-kg-uv3d-gps-interface-functional-case/

Adapter to hold a camera on a microscope, a macro lens holder for that
camera, plus an LED ring illuminator for the microscope:
http://softsolder.com/2011/11/14/canon-sx230hs-microscope-and-close-up-macro-adapters/
http://softsolder.com/2011/04/11/microscope-led-ring-illuminator/

Caliper repair part (no finishing required!):
http://softsolder.com/2011/05/27/thing-o-matic-caliper-repair-perfection/

Bike helmet mirror mount (ugly, but better than commercial units):
http://softsolder.com/2011/07/01/helmet-mirror-mount-first-light/
http://softsolder.com/2011/06/29/helmet-mirror-mount-solid-model/

Blinky light mount for my recumbent:
http://softsolder.com/2012/01/03/planet-bike-superflash-tour-easy-mount/

Cookie cutter:
http://softsolder.com/2011/09/07/tux-cookie-cutter/

Fuzz blocker for a Kindle Fire:
http://softsolder.com/2012/04/10/kindle-fire-power-button-protector/

Simple stepper motor mount:
http://softsolder.com/2011/08/23/nema-17-stepper-motor-mount/

And, of course, improve the 3D printer:
http://softsolder.com/2011/04/20/thing-o-matic-x-axis-rod-follower-installed/

Beyond their hand-knitted appearance, the parts are entirely serviceable
for most of the things I do. Of course, that may just mean I do simple
things that don't involve a lot of stress on either the operator or the
user. [grin]

Now, admittedly, those parts emerged after the better part of half a
year of rebuilding to persuade my Thing-O-Matic to work the way they
claimed it would. That's a whole 'nother story...

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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread Ed Nisley
On Fri, 2012-06-01 at 08:44 -0400, gene heskett wrote:
 the bolts are 3/8 but the holes are 7/16

In this case, the bolts were 7/16 and the holes 3/8... [grin]

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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread Ed Nisley
On Fri, 2012-06-01 at 10:10 -0400, Eric Keller wrote:
 anyone that makes things

Unlike folks who use industrial-grade machinery to build exquisite
widgets (you know who you are), mostly, I fix stuff.

Being able to sketch out a solid model and then have it *happen* is
wonderfully liberating. The Sherline CNC mill does great work (I just
made a plug-ugly manual-CNC scabbard for a garden knife yesterday), but
for complex shapes the 3D printer can't be beat.

That radio case was what compelled me to get the printer: I couldn't
imagine carving another case from solid acrylic on the Sherline. It took
a few tries to get the design  sizes right, but now I can build a
second and a third with only a few minutes of finishing  fitting; the
printer can be building a case while I'm making the PCB to go inside.

When we eventually downsize, I know which machine tool is a keeper...

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Re: [Emc-users] OT: and Soapbox: 3D Printer Mods?

2012-06-04 Thread Ed Nisley
On Sun, 2012-06-03 at 21:08 -0400, Dave wrote:
 buy one or two PID controllers.

The slicing software can produce different extrusion temperatures for
different layers (or classes of layers), so the printer needs
programmatic control over *everything*. You may as well integrate all
that in LinuxCNC, where it belongs. The thermal time constants of small
extruders seem to be on the order of tens of seconds, while my hunk o'
steel requires minutes.

The whole extrusion process is strongly nonlinear along many axes, which
is something that's becoming more difficult to ignore as extrusion
speeds increase. With XY speeds under about 30 mm/s, the linear
assumptions work reasonably well. Moving faster than that shows the
limits: oozing from a stopped extruder, nonlinear flow-vs-pressure,
nonlinear flow-vs-acceleration, and (for my printer) unstable mechanical
construction.

The threshold obviously varies with printer design  implementation, but
the high end of of DIY 3D printing has now collided with the low end of
CNC machine control. The limits of the Arduino-class controller
programming model are becoming apparent (at least to me, anyhow).

LinuxCNC could implement a complex extruder model as a HAL component,
with inputs from temperature sensors and motion control, far better than
an Arduino-based controller. Handling multiple extruders with different
material properties would be relatively straightforward in HAL. Doing
all the soon-to-be-required toolchanging, height probing, and platform
leveling in HAL / Classic Ladder makes a lot of sense (again, at least
to me).

Methinks anyone working on such a contraption would receive a visit from
a nattily attired lawyer who would explain his employer's view of the US
patent system...


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Re: [Emc-users] OT: and Soapbox: 3D Printer Mods?

2012-06-04 Thread Ed Nisley
On Mon, 2012-06-04 at 08:44 -0400, Dave wrote:
 Who hold the patents?

The big players that have been doing 3D extrusion since the mid 80s, the
ones with positive cash flow and actual engineering teams. The Wikipedia
article has a list:

https://en.wikipedia.org/wiki/3D_printing#Industrial_uses

Although the earliest patents have expired, a guy at the presentation I
gave to the local ACM chapter mentioned that the reason none of the DIY
printers have an enclosed, temperature-controlled build chamber is
because whoever (Stratasys or 3DS, I don't recall) holds *that* patent
and licenses it with some vigor. I can't cite the number, though, so the
story may be n-th hand hearsay.

To a good first approximation, machine-shop 3D printing technology is a
solved problem at industrial scale (the nanoscale stuff seems blue-sky
handwaving). DIY printers started about 25 years behind the state of the
art and now lags by just under one patent lifetime, where it's likely to
stay. Basement-shop DIY is one thing, building a business around that
tech is entirely another matter.

None of the DIY players amount to pocket lint in the major league. I
expect Makerbot's recent 10 megabuck infusion triggered some talks that
circumscribe their enthusiasm, but I have no actual data.

That said, I'd love to do a LinuxCNC-based printer, starting with
extruder modeling. So many projects, so little time... [grin]

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Re: [Emc-users] OT: and Soapbox: 3D Printer Mods?

2012-06-04 Thread Ed Nisley
On Mon, 2012-06-04 at 11:53 -0600, Jeshua Lacock wrote:
 you are basing this on what?

Rumor, supposition, hearsay, random tales, and watching the slow-motion
destruction of mobile phone innovation through internecine IP warfare.
The fact that a judge had to rule that APIs can't be copyrighted tells
you pretty nearly everything you need to know about the state of the
art.

Given the current attitude toward IP, there's no reason to expect
benevolent behavior from the major players. The only reason we don't see
lawyers catapulting over the parapets seems to be that the minor players
lack enough money to make it worthwhile... [grin]

I've started reading the old 3D printing patents. It's heavy going, but
many of the clever ideas I've had / seen elsewhere seem to be covered.
Verily, there's little new under the sun and, of course, I'm now coated
with a thin layer of precious IP floobydust.

As the saying goes: It's not whether you're paranoid, it's whether
you're paranoid *enough*.

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Re: [Emc-users] OT: and Soapbox: 3D Printer Mods?

2012-06-04 Thread Ed Nisley
On Mon, 2012-06-04 at 18:31 -0600, Jeshua Lacock wrote:
 Also, as far as I know, Makerbot et al have not had 
 much of a legal battle so far.

True, but now that they're doing something over $5 M/yr with substantial
funding, they look more like a target. Again, I know nothing other than
the fundamental truth that money changes *everything*...

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[Emc-users] Mysterious direction-signal changes

2006-11-28 Thread Ed Nisley
AXIS 1.4a0  EMC2 2.0.4 (stock iso + all updates)

This story takes a while to set up...

While cutting out a cam that involves lots of fiddly 
motions, my (mostly stock) Sherline mill gradually forgot 
its origin position and would have, had I not popped the 
Esc key, gnawed its way right through the fixture.

I set up another blank and, dang, the same sort of thing 
happened. A bit different positions, but equally bad.

So I took everything apart, cleaned  lubed  tweaked, made 
a great improvement in the overall mechanical goodness, 
chucked up another blank, and -blap- same story. I hate it 
when that happens.

The failures are similar, but not identical: the XY position 
gradually drifts in off into the +X/-Y quadrant and the Z 
position drifts downward. The final G0 move away from the 
(ruined) blank should be vertically upward, but typically 
goes vertically downward and thunks the fixture.

The AXIS preview looks fine, so the g-code is correct. 
Admittedly, it took a while to get there, but it's OK.

After fiddling with numerous dead ends, I reinstalled the 
whole Ubuntu/EMC thing from scratch. Starting from the 
stepper_xyza base, I set the velocity  acceleration values 
to drive the mill at well under its ratings: 0.25 ips max 
velocity, 1 in/sec^2 max acceleration. This is achingly 
slow, but it eliminates motor dynamics from the problem: I 
can -watch- the motors ramp up to their peak nose-picking 
speed!

This is on a Dell Dimension 4550, 2.4 GHz P4, 1 GB RAM, so I 
set the base period = 25 us. I then added steplen / 
stepspace / dirsetup / dirhold statements to the HAL file 
to put 4 ticks between each edge going to the controller 
box. That eliminates noise and pulse speed from the 
problem.

With a minimum pulse length of 4 ticks, the maximum motor 
step rate should be 8 ticks = 200 us. That's well under 
actual rate required by the max velocity, so it's not 
producing following errors even with the slow pulses.

Now, under manual control with the jog speed dialed back 
to 1 ipm, I have a solid failure. Tapping PgUp and PgDn (or 
the other axes, as well) generally does what I'd expect. 
However, -sometimes- the motors turn (slowly!) the wrong 
way; start correctly, jerk backwards, then run backwards; 
run correctly for a short time and then stall; and so 
forth.

I attached a digital 'scope to the Z axis step  direction 
signals. They're clean digital pulses, good amplitudes, no 
noise worth mentioning. The step signal shows the expected 
ramping-up and ramping-down frequencies at about the right 
rates.

However, the direction signal misbehaves!

Erratically, occasionally, but reproduceably (if I'm 
patient), the direction signal changes while the step 
signal is pulsing. For example, it will change from 1 to 0 
to 1 (high - low - high) while I'm holding down the PgUp 
key (not calling for a direction change). The other axis 
behave similarly.

The changes seem to be in the tens-to-hundreds of 
millisecond range and generally occur at the leading or 
trailing ends of the motion, not in the middle, but that 
may just be my observations so far.

While the direction signal glitches, the step pulses 
continue to ramp up or down, so it seems as though 
something is losing track of which the motion direction for 
a while . The resulting transients whack the motors pretty 
hard; they're obviously not carefully planned direction 
changes!

Note that the parallel port is disconnected from the driver 
box, the spindle motor is off, and this is pure software 
from the PC. Nothing mechanical at all!

This is the most complex part I've made, so the mill was 
running longer and doing more motions than ever before, 
which would cause the misbehavior to add up. However, I 
-think- it's the first part I've done since the most recent 
EMC updates, although I'm ashamed to admit I haven't been 
logging what I've been doing against those changes.

It -definitely- didn't misbehave like this back in the BDI 
days. I -think- the first few EMC2 versions were OK, but I 
can't be sure because it's intermittent enough that I might 
have not noticed slight errors on the simpler parts. It's 
not like I'm doing really high-precision stuff here...

I did manage to make one good cam before the latest updates, 
so it -did- work correctly a week or so ago.

Anyhow, I think I've eliminated all the things that could 
cause the problem outside of the EMC2 code itself, but if 
there's any other information I can provide or debugging I 
can do, I'm willing, because it flat out doesn't work for 
me right now!

Thanks...

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[Emc-users] Axis 2.1.6 jogging always uses inches?

2007-07-09 Thread Ed Nisley
As nearly as I can tell, Axis always jogs in inch units, 
even in G21 mode, even when displaying millimeters.

Fire up Axis, F1  F2 to get started, F5  type G21 for 
metric units, View - Show MM, then F3 to get manual 
controls. Select X axis, pick 0.1 jog increment from the 
list, then click the + button: the displayed X position 
changes by 2.54 mm. Yikes!

Seems like it ought to change by 0.1 mm.

I -think- that means Axis must keep track of the G20/G21 
state and update its stepping value accordingly.

Of course, that might be a whole lot trickier than it 
seems... as is always the case with software!

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Re: [Emc-users] Axis 2.1.6 jogging always uses inches?

2007-07-10 Thread Ed Nisley
 While a better choice in emc 2.1 would have been to treat
 the jog distance as in the currently-displayed coordinate
 system

That would definitely have obeyed the principle of least 
surprise...

 I think the version 2.2 solution will be even better.

Sounds good to me. 

Be sure to include both inch and metric units in the default 
list, so that it's usable for both right out of the box!

Is it in the CVS code these days? Any reason not to use the 
Latest  Greatest version?

Thanks...

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Re: [Emc-users] Cabin Fever presentation

2008-01-03 Thread Ed Nisley
 Gene: Where and when is this Cabin Fever supposed to be?

York, PA. Two weekends and counting:

http://www.cabinfeverexpo.com/

More info should be up shortly; I just sent in a 
description.

 Gene: another emc article in Circuit Cellar?

I write about analog and RF stuff for them, but, hey, 
stepper drive circuitry has lots of analog issues! You'll 
see some of those same pix at Cabin Fever, should that 
influence your decision (one way or the other).

 Seth: I am definitely planning to be there.

OK, at least you and me will have a fine time playing with 
my show-n-tell gadgetry...

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Re: [Emc-users] Cabin Fever presentation

2008-01-14 Thread Ed Nisley
 are you going to video the talk and 
 place the video where we can see it? 

I don't know what the show organizers have on tap, but I 
wasn't planning to immortalize the thing!

I could put up the PDF version of all the slides I'll be 
using (where? suggestions?); it's about 8 MB. Plenty of 
pix, some bullet-item text, but none of the patter. I don't 
know how useful that would be, but I used a Creative 
Commons license and it's good to go.

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Re: [Emc-users] Cabin Fever presentation

2008-01-15 Thread Ed Nisley
 with the 'patter' would be golden.

I briefly considered hitching a Webcam+mic to my laptop, the 
one running the presentation, and recording on the fly.

Then I came to my senses.

If anybody else will be there with audio or video recording 
gear, we'll go for it... but I'll have enough to do, what 
with  simultaneously standing up -and- talking!

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[Emc-users] CNC Presentation Trip Report

2008-01-22 Thread Ed Nisley
About 50 people showed up for my Why CNC? An Introduction 
talk at Cabin Fever Expo, perhaps ten snuck out early, and 
about two dozen hung around afterward for the demo. I think 
a good time was had by all: the presenter wasn't injured 
during the after-game melee.

I made a botch of the demo by not telling my assistant (my 
daughter) which parallel port I used for the motor 
controller, then fumbling around for far too long figuring 
that out. However, the crowd learned how Things Go Wrong 
and that problems can be fixed with the help of some 
friends; my thanks to the guy who noticed that the box 
had -two- parallel ports. After moving the cable, the pace 
of the festivities picked right up.

I don't know who was wielding the video camera, but 
there -is- a recording. Given the dim lighting, I'm 
probably just a blur, so if someone could extract the audio 
track, turn it into an MP3, perhaps add slide-change beeps 
(I think I can do that), and put it next to the PDF of my 
slides, that would be better.

The PDF is at

http://members.localnet.com/~ednisley/CNC%20Introduction.pdf

where it will stay until that account closes in February. If 
anyone has a better spot, feel free to shuffle the file as 
needed.

Our van's mass air flow sensor died on I-81 near Harrisburg 
on Friday night, so I spend Saturday afternoon  Sunday 
morning diagnosing  fixing that, rather than exhibiting my 
toys  yakking with the CNC folks at the show as planned. 
Swapping a MAF sensor in the Advance Auto Parts parking lot 
at 19 degrees with a 20-mph breeze is -not- my idea of a 
good time. The folks at the Toyota dealership confirmed my 
already low opinion of Toyota's personnel, but I heroically 
suppressed my urge to urinate in their Mr. Coffee.

My daughter was enchanted by the craftsmanship on display at 
the Expo and gained an appreciation of what's required to 
produce -perfect- work instead of doing just enough to get 
by. Truly, those engines are jewelry, not machinery!

Thanks to all of you folks for -your- craftsmanship in EMC, 
which made my presentation possible. I hope I showed it in 
a good light and got a few people started on the CNC path.

-- 
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Re: [Emc-users] CNC Presentation Trip Report

2008-01-22 Thread Ed Nisley
 If someone needs it emailed, or zipped

A ZIP file won't be much smaller, alas, because the JPG 
images are so large.

I just generated a version with brutally squashed pictures 
that look pretty grotty, but the file is a mere 1.6 MB:

http://members.localnet.com/~ednisley/CNC%20Introduction%20-%20lowres.pdf

Apply eyedrops and you'll be OK...

At least this one ought to be easier to email!

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Re: [Emc-users] Nisley Presentation at Cabin Fever

2008-01-28 Thread Ed Nisley
 posted your introduction pdf to my site

Thank you!

I haven't been able to track down who did the video 
recording during my talk. Does anyone know? If we can find 
that tape, peel the audio track off, and put it near the 
PDFs, that would be a good addition.

 Why the kid's finger in disrepair?

Fortunately, that's not her finger. The caption on the 
original reads Honey, I told you I'd never take my ring 
off. It's a condition called degloving: the guy caught 
his ring in rotating machinery.

My shop assistant tells me she doesn't like that picture at 
all, not one little bit. I tell her Good. Think about it.

Warning: graphic injury!
http://www.safetycenter.navy.mil/media/posters/posterimages/hand.jpg

They post a new and disturbingly -true- safety situation 
every week:
http://safetycenter.navy.mil/photo/default.htm

-- 
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[Emc-users] Singular realtime delay error

2008-03-03 Thread Ed Nisley
Gene Heskett wrote:

 When starting emc on its own screen, I
 do get a realtime error, just one that never repeats.

That just cropped up here after I updated to 2.2.3. There's 
one realtime error when Axis starts up, then nothing else. 
I run it either locally or through rdc, with the same 
results.

The info in dmesg looks like this:

[  187.772175] I-pipe: Domain RTAI registered.
[  187.772183] RTAI[hal]: magma mounted over 
IPIPE-NOTHREADS 1.3-00.
[  187.772186] RTAI[hal]: compiled with gcc version 4.0.3 
(Ubuntu 4.0.3-1ubuntu5).
[  187.772192] RTAI[hal]: mounted (IPIPE-NOTHREADS, 
IMMEDIATE (INTERNAL IRQs VECTORED), ISOL_CPUS_MASK: 0).
[  187.772194] PIPELINE layers:
[  187.772197] f8bca780 9ac15d93 RTAI 200
[  187.772200] c02d1680 0 Linux 100
[  187.791834] RTAI[malloc]: vmalloced extent f8c3e000, size 
2097152.
[  187.791902] RTAI[malloc]: loaded (global heap 
size=2097152 bytes).
[  187.793705] RTAI[sched_lxrt]: loaded (IMMEDIATE, UP, 
USER/KERNEL SPACE with RTAI TASKs).
[  187.793716] RTAI[sched_lxrt]: hard timer type/freq = 
8254-PIT/1193180(Hz); default timing mode is periodic; 
linear ordering of timed lists.
[  187.793729] RTAI[sched_lxrt]: Linux timer freq = 1000 
(Hz), CPU freq = 2392319000 hz.
[  187.793732] RTAI[sched_lxrt]: timer setup = 2010 ns, 
resched latency = 2689 ns.
[  187.843547] RTAI[math]: loaded.
[  188.027891] config string '0xecf8'
[  190.667837] RTAPI: ERROR: Unexpected realtime delay on 
task 1

Running the latency tests for an hour didn't turn anything 
up, so it looks like a startup glitch.

Suggestions?


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[Emc-users] Netiquette: Trimming Messages

2008-09-10 Thread Ed Nisley
A plaintive note from a lurker...

When you guys hit Reply to fire off a one-liner message, 
could you -please- trim off the 1300-some-odd lines of 
diagnostic trace / dmesg dump / status log that accompanied 
the original note?

I'd appreciate it if folks replying to digest messages would 
do the same, as there's nothing quite like sorting through 
two or three nested digests to find the one-liners.

Ob-EMC: 2.2.6 is working great for me on my hacked Sherline.

Back to lurking.

Thanks...

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[Emc-users] Sherline CNC show-n-tell

2008-11-19 Thread Ed Nisley
I've offered to show off my Sherline CNC setup for a couple  
of folks from the Sherline list who are thinking about 
buying one. After considerable to-and-fro-ing, we've 
settled on this coming Sunday, 24 September. If anybody 
else is interested, c'mon over... I figure you guys all 
know more than I do about EMC, so anybody who shows up can 
keep me straight.

We'll shoot the breeze, see how the CNC thing works, talk 
about EMC  G-code  stuff like that, and play with shiny 
toys. No agenda, no schedule, no sales pitches.

I'm in Poughkeepsie, NY, halfway up the Hudson between NYC 
and Albany, inconveniently located quite far from nearly 
everywhere else. Drop me a note for details.

Show up before noon-ish and you'll get in on some cold-cut 
lunchy things. If you're not out by suppertime, you'll be 
forced to eat something then, too...

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Re: [Emc-users] Sherline CNC show-n-tell

2008-11-20 Thread Ed Nisley
 It is already November for this year.

And you know what? They're going to change the month -again- 
in just a few days. I can't keep up any more!

This coming Sunday is actually 24 November. Right? sigh

I will be home: can't risk going out in this condition.

 And that is a fur piece from Ithaca

A mere 4 hours along the Future I-86. Heck, you could sneak 
out  back before supper and nobody'd notice.

Now, after eight hours on the road, you might be as 
disconnected from reality as I was after returning from 
near Harrisburg PA on Tuesday, through the Pocono Snows. 
Driving always dumbs me right down to room temperature.

Must. Recalibrate. Caffeine. Delivery. System.

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Re: [Emc-users] Sherline CNC show-n-tell

2008-11-20 Thread Ed Nisley
 My 2008 one says this
 Sunday is November 23.

Hey, we live here: just show up some time, OK?

From the back door, the head is on your right, the basement 
door is straight ahead, and the kitchen is on the left. 
What's not to like?

Pay no attention to the doddering fool in the living room 
crouched at the keyboard; he can't help ya nohow.

Right now I'm laying out a solar panel measurement circuit 
board. This story is not going to have a happy ending...

*fumbles for more teabags*

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Re: [Emc-users] Gcode Newbie Question - repetitive par t making

2008-12-16 Thread Ed Nisley
 if Ed will be continuing similar articles in the future

That's the plan!

The Winter 08 column deals with fillets on internal corners: 
using cutter comp and figuring the arc centers for mostly 
right-angle corners. Pretty easy once you see it.

Next up: finding the centers when the sides aren't at right 
angles. Time to haul some trig functions out of the closet, 
blow the dust off, and fire those devils up.

So many topics, so few issues...

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Re: [Emc-users] Gcode Newbie Question - repetitive part

2008-12-17 Thread Ed Nisley
 Once upon a time, I wrote some gcode subroutines

Sure: I'm always interested to find out what I could do 
better!

Or at least differently, as I seem to have a lot of code 
sitting around that makes me wonder what I was thinking at 
the time. Maybe nothing, aye, there's the rub.

Thanks...

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Re: [Emc-users] New cutter compensation algorithm in TRUNK

2009-01-08 Thread Ed Nisley
 The new algorithm handles concave corners

And here I am, halfway through writing the next installment 
of Adventures in Filleting, explaining how to lay an arc 
into a concave corner to avoid gouging. I am crushed, I 
tell you, -crushed- by this horrible news!

big grin

The timing is actually great. I'll add a note along the 
lines of by the time you read this, EMC2 should handle 
concave corners automagically, folks can download the Live 
CD, and everybody lives happily ever after. I love a happy 
ending.

I must do some prep for Cabin Fever (i.e., whack stock into 
bite-sized pieces  collect my toys into one untidy heap), 
but after we're back I'll see how it works. I don't do any 
of that fancy machining stuff, though, so most likely I 
can't contribute any useful checking; if it ran your 
testcase, it'll have no trouble with my parts.

Great improvement... many thanks!

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[Emc-users] Cabin Fever Trip Report

2009-01-21 Thread Ed Nisley
Here's a writeup of my Cabin Fever Expo adventures, with 
Brian's incriminating picture. There's a link to my 
handouts and I'll get more of my code up as examples of 
what (not) to do.

http://softsolder.wordpress.com/2009/01/21/cabin-fever-trip-report/

Cabin Fever's demographics are grim; in a decade most of the 
exhibitors will be gone. EMC may be a way to get more young 
folks into the craft, but we definitely gotta buff up our 
image...

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Re: [Emc-users] Cabin Fever Trip Report

2009-01-22 Thread Ed Nisley
 cut out a pinewood derby car design.
 bring my 3 axis router (kit built) 

Given the Sherline's itsy-bitsy work envelope and 
nose-picking speed, I think carving out -real- Pinewood 
Derby cars on your router would be even better. Bolt a 
block to a plate, clamp the plate to the base, and then let 
the chips fly. How long would such a thing take?

If you were excruciatingly clever, you could mill the axle 
supports, too, perhaps as little stubs faired out from the 
sides. When you're done, unbolt the block, hand the kid a 
finished car (with pre-drilled axle holes?) and a ziplock 
baggie full of wheels, nails, and an EMC sticker or two.

Killer demo, if a bit noisy. We'll all be hoarse anyway.

I could mill out wheels, albeit at a pathetically slow pace, 
by bolting plastic disks to the rotary table and carving 
the tread with nice algorithmic patterns. Haven't thought 
on it much more than that, but it'd likely be the same 
level of complexity as the demo-quality finger rings I keep 
muttering about.

 for people to try installing from the Live CD 
 and running the simulators 

That would exceed the attention span of most folks, but if 
you'd put on a quasi-seminar showing how it's done 
and -then- break to the simulators, that'd be a win. Run 
the talk a few times during the day (with announcements on 
a board in the lobby and over the unintelligible PA system) 
and folks would flock to it.

Sounds like a plan, it does indeed ...

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[Emc-users] Data Point: How Many of Us Are Here?

2009-01-27 Thread Ed Nisley
After I posted the note about my Cabin Fever trip report a 
week ago, that blog entry got a bunch of hits in quick 
succession.

In round numbers, 176 people clicked on that link from an 
actual email, a Web email client, or the many mailing list 
archives scattered around the Web. Dunno how many total 
list subscribers there are, but there's one number.

A simple plot and a few numbers lives here:
http://softsolder.wordpress.com/2009/01/27/hits-from-emc-mailing-list/

As nearly as I can tell, this is a small, but -very- helpful 
group! Thanks to all of you for hauling me along...

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Re: [Emc-users] Either I am a survivor, or he isn't ready for me.

2014-06-07 Thread Ed Nisley
On 06/07/2014 03:24 AM, Gene Heskett wrote:
 I keep telling myself he isn't ready for me yet.

One of my aunts had stroke that knocked her flat out on the kitchen 
floor, but she thought Oh, no, you don't! Dragged herself over to the 
table, pulled the tablecloth off to get her phone, dialed 911, and 
yakked with the EMTs all the way to the hospital.

Some years earlier, she insisted on *watching* while they carved a huge 
tumor out of her belly; evidently, they couldn't use general anethesia 
for some good reason. She's always been about the size of a sparrow, but 
losing 10% of her body weight didn't slow her down at all.

As for you: every morning, the Devil wakes up, checks his status board, 
and says Whew, Gene's still alive!

Now, get back to making chips...

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Re: [Emc-users] integrator manual

2014-07-15 Thread Ed Nisley
 I M does not shows any working sample

Here's how I did it for my little Sherline mill...

Modify the Sherline control box to accept the wiring. This is an example 
for the tool length probe line, but the same thing happened for the home 
switch input:

http://softsolder.com/2010/04/11/sherline-tool-length-probe-adding-a-jack/

Connect the physical home switches to the parallel port pin and define 
the HAL wiring that connects the input pin to the homing signals:

http://softsolder.com/2010/05/11/sherline-cnc-mill-adding-home-switches/

Define the homing parameters that control the motion on all three axes:

http://softsolder.com/2010/05/12/sherline-cnc-mill-defining-home-switches/

That configuration worked back in the 2.4 days and has continued to work 
fine ever since, so it should get you reasonably close to your goal.

Hope that helps ...

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Re: [Emc-users] integrator manual

2014-07-17 Thread Ed Nisley
On 07/16/2014 04:35 PM, a k wrote:
 I did input
 # Read home switch inputs from I/O card.
 net x-home-sw = hm2_[HOSTMOT2](BOARD).0.gpio.026.in
 net y-home-sw = hm2_[HOSTMOT2](BOARD).0.gpio.030.in
 net z-home-sw = hm2_[HOSTMOT2](BOARD).0.gpio.034.in

Did you change the *example* HOSTMOT2 and BOARD strings to match the 
actual hardware in your system?

This *sample* for my hardware shows the commands that dump the names:

http://softsolder.com/2013/06/17/mesa-5i25-7i76-hal-pins/

I believe there's a period (.) missing before the BOARD part of the 
identifier in what you have written. This seems more likely:

hm2_5i25.0.gpio.032.in

However, that's for my system, not yours, and you must modify the 
*examples* to match your actual hardware.

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Re: [Emc-users] uvcvideo vs v4l video

2014-07-25 Thread Ed Nisley
On 07/24/2014 09:06 PM, Gene Heskett wrote:
 the real problem that caused the usb disconnect?

If the dmesg dump says something like:
 hub 1-0:1.0: port 2 disabled by hub (EMI?), re-enabling...

Then I'll lay you long odds it really *is* EMI from your myriad steppers 
and suchlike. Spent quite a while figuring that out, but in my case it 
was an acrylic jacket:

http://softsolder.com/2009/01/28/usb-disconnects-nobody-moves-nobody-gets-hurt/

Now, if that's not what dmesg says, I'd still suspect EMI...

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Re: [Emc-users] G-Code files needed

2011-01-23 Thread Ed Nisley
On Sun, 2011-01-23 at 12:23 -0800, Neil Baylis wrote:
 large or complex g-code files

The programs I've been writing for my Along the G-Code Way columns in
Digital Machinist aren't all that large, but they do exercise some
EMC2-specific language features. The more recent ones will probably be
the most useful.

They're tucked into the ZIP files at:

http://www.digitalmachinist.net/downloads

Which text editor are you targeting?

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Re: [Emc-users] G-Code files needed

2011-01-24 Thread Ed Nisley
On Sun, 2011-01-23 at 15:00 -0800, Neil Baylis wrote:
 If there's demand, I would consider other
 editors as well 

I'll put in a vote for KATE, the KDE editor. It already has G-Code
highlighting, but, lacking EMC2's language features, it's pretty much
useless.

http://kate-editor.org/

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Re: [Emc-users] Multiplexers

2011-02-13 Thread Ed Nisley
On Sun, 2011-02-13 at 07:59 -0600, John Thornton wrote:
 use a multiplexer to get 4 thermocouples into one MAX6675 

Given the microvolt-level signals from a thermocouple, it's not clear
the signal emerging from a multiplexer would bear more than a casual
relation to the actual temperature. With any additional conductors /
connectors in the middle of a run of thermocouple wire, each temperature
gradient adds *another* thermocouple joint with its own voltage to the
mix.

An analog multiplexer adds several solder joints  socket pins, each
with its own temperature gradient, to the input and output signals.
Inside the chip, the signal faces silicon offset  leakage voltages that
are about the same size as the thermocouple signals.

While I'm sure multiplexing thermocouples can be done (nay, has been
done), it's a nontrivial project to get *accurate* measurements out of
the far end. The MAX6675 is actually a pretty good deal, considering
that it goes directly from thermocouple microvolts to Celcius digital
values: think of it as buying engineering expertise.

DIY op-amp circuitry faces similar problems: while it can be done,
*accurately* amplifying microvolt DC signals and stabilizing the result
is a nontrivial project.

If you do use MAX6675 chips in a situation where the thermocouple bead
could contact a live wire, take this problem into account:

http://softsolder.com/2011/02/06/thing-o-matic-mk5-extruder-protecting-the-thermocouple/

Sounds like you've got a fun project, though...

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Re: [Emc-users] Joypad button to tell axis to move?

2011-02-17 Thread Ed Nisley
On Thu, 2011-02-17 at 13:39 -0600, Igor Chudov wrote:
 I would like to use regular joypad buttons

I did that with my Logitech gamepad: the joysticks do gradual motion and
the buttons do on-off motion.

This should get you started:

http://softsolder.com/2010/10/23/logitech-gamepad-as-emc2-pendant-eagle-schematics-for-the-joggy-thing/

I wrote up a somewhat more elaborate version  for Digital Machinist
magazine. You can fetch the files (but not the article itself) from:

http://www.digitalmachinist.net/files/downloads/2010Winter/DM%205.4%
20Nisley.zip

There's a bit of trickery in that version to avoid some race conditions,
but the overall logic is straightforward.

As soon as I got it set up, there was no going back!

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Re: [Emc-users] Temperature Controller with nested PID loops

2011-02-19 Thread Ed Nisley
On Fri, 2011-02-18 at 19:53 -0800, Kirk Wallace wrote:
 I might not have to be the only one that's always right. 

I regard it as my solemn obligation to be one of the two dozen folks who
are (almost) always wrong... after all, without me, how could you
possibly look so good? [grin]

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Re: [Emc-users] Single to Three Phase Rotary Converters

2011-03-14 Thread Ed Nisley
On Mon, 2011-03-14 at 11:00 +, andy pugh wrote:
 which caused some worrying sizzling noises. 

Obviously, your radio isn't turned up nearly loud enough...

(Which helps with car repairs, too.)

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Re: [Emc-users] manual tool change

2011-03-19 Thread Ed Nisley
On Fri, 2011-03-18 at 20:58 -0500, Jon Elson wrote:
 pre-measuring all your tools and entering the 
 length offsets in the tool table,
 so you don't have to touch off at each tool change. 

Or you can add a tool length probe station and have tool length
measurement happen automagically, without interrupting the program.

You *definitely* need something far more rugged on a real milling
machine in an actual machine shop, but the switch itself need not be
more complex than a snap-action button:

http://softsolder.com/2010/12/06/improved-tool-length-probe-switch/

The stability and repeatability are surprisingly good:

http://softsolder.com/2010/12/07/improved-tool-length-probe-switch-repeatability/
 
http://softsolder.com/2011/01/15/improved-sherline-probe-length-switch-repeatability-selah/

When it comes time for a tool change, the G-Code does the G30 / Tx M6
dance and puts up a prompt. My ArmStrong tool changer swings into
action; it finishes by whacking the spacebar to continue. A subroutine
measures the new tool length, adjusts the offset, and the G-Code
continues with a properly adjusted tool.

That doesn't solve the my tool broke and I can't jog manually problem,
but for my simple needs it's *wonderful*: swapping tools is no longer a
major pain.

One gotcha: Axis will occasionally leave the machine in the G59.3
coordinate system (which has absolute machine coordinates) after I
interrupt the program, even if I interrupt it when G54 (which has the
tool  fixture offsets) should be active. This is most likely due to my
misunderstanding of how coordinate systems work, not an intrinsic flaw.

Highly recommended...

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Re: [Emc-users] multiple instances of emc?

2011-04-02 Thread Ed Nisley
On Sat, 2011-04-02 at 15:33 +0100, Steve Blackmore wrote:
 The custom kernel says edit menu.lst - doesn't exist any more

The Grub2 file is /boot/grub/grub.cfg. It looks different, but gets
basically the same treatment as Grub1's menu.lst.

But it's actually worse than that. The grub.cfg file gets rewritten
every time there's a kernel update; there's a warning at the top of the
file to *not* hand-edit it. You're supposed to futz with the
configuration files in (IIRC) /etc/grub that tell Grub2 how to
automagically create grub.cfg as part of the kernel update.

HOWEVER, I've been unable to figure out how to do something special with
the RTAI-modified kernel: there's no way (that I can find) to *not*
regenerate a standard kernel boot line for the RTAI kernel.

So whenever I hand-edit grub.cfg, I add a note to the RTAI menu entry
showing that it's decorated with isolcpus=1. After every kernel update,
that note vanishes: it's time to edit grub.cfg again.

Maybe there's a way to do that automagically, but ... 

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Re: [Emc-users] Monitor and control my CNC through an IP camera ?

2011-04-12 Thread Ed Nisley
On Mon, 2011-04-11 at 09:51 -0700, Kirk Wallace wrote:
 a page on the wiki covering the making of bellows.

For those of us with Sherline mills and no flood coolant, plain old
paper works surprisingly well. You don't form a deep emotional
attachment to it, so throwing it out when it gets really crusty doesn't
hurt at all...

http://softsolder.com/2010/02/26/improved-sherline-way-bellows/

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Re: [Emc-users] Beating Grub2 into submission

2011-04-12 Thread Ed Nisley
On Sat, 2011-04-09 at 21:41 -0400, Kent A. Reed wrote:
 Kudos, brickbats, big yawns, gleeful 
 nitpicking, all willingly accepted, 

Well, here's a heaping double handful of kudos from me!

Your script bottles up a whole bunch of magic that I certainly couldn't
have figured out on my own.

Thanks...

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Re: [Emc-users] Extrusion-based RP

2011-06-11 Thread Ed Nisley
On Sat, 2011-06-11 at 19:17 -0400, Colin K wrote:
 you can make very complex geometries 
 without multiple setups or fixtures 

That's why I got a Thing-O-Matic: create near-net parts that don't need
much finishing. This one came out perfectly:

http://softsolder.com/2011/05/27/thing-o-matic-caliper-repair-perfection/ 

The parts have a rather hand-knitted aspect that doesn't matter for the
things I build. Some close-ups:

http://softsolder.com/2011/04/18/hbp-aluminum-build-plate-abs-film-win/ 

It's handy for cranking out one-off parts on short notice:

http://softsolder.com/2011/06/11/stepper-motor-sync-wheel/

Fortunately, some parts really don't have any accuracy specs:

http://softsolder.com/2011/06/02/thing-o-matic-graduation-day/

Being that sort of bear, I've tweaked / improved / rebuilt / replaced
much of the printer's innards and now have something that works quite
well. Other folks have had zero problems with the stock printer, so much
of what I've done has been along the lines of That doesn't seem quite
right, I'd rather do it this way rather than the rare Dang, it's
busted! Like, for example, my experience with the stock stepper motors:

http://softsolder.com/2011/05/05/thing-o-matic-mbi-stepper-motor-analysis/ 

It now produces good parts almost every time, although you must design
parts with the printer's limitations in mind. The smallest feature will
be a bit under 1 mm, you can put edges anywhere with resolution around
0.05 mm, it doesn't do steep overhangs very well at all, and the objects
must fit in a more-or-less 100 mm cube.

But you can print some truly odd things:

http://softsolder.com/2011/05/02/what-would-barbie-pack/ 

The firmware doesn't apply acceleration limiting, which I regard as a
major limitation on performance and dependability. I'd like to plug the
motrors into EMC2 and whip up some HAL / ladder logic to control the
extruder  temperatures, but I've reached my tinkering limit for a
while.

DIY 3D printing is *definitely* not a plug-and-play experience!

If you have nothing better to do for a while, my blog's Thing-O-Matic
category may be amusing...

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Re: [Emc-users] Extrusion-based RP

2011-06-12 Thread Ed Nisley
On Sat, 2011-06-11 at 23:54 -0700, Mike Payson wrote:
 that is a limitation of the Makerbot firmware. 

As nearly as I can tell, ReplicatorG has become sufficiently
intertwingled with the firmware that it's best to not stray too far from
the beaten path, so I'll continue to use the 2.7 firmware until things
settle down a bit. RepG 24 has 17 different drivers for various
combinations of machines / firmware / configurations and it's not at all
clear what works with what.

I used to like being a beta tester, but I've gotten over it...

 integrated MCU based driver

The problem with that is economics: right now, the hardware cost for the
microcontroller(s) and motherboards has run up against the cost of an
ATX system board. In fact, the MBI retail price for the Ardino /
Motherboard / Extruder Controller exceeds the full-up Atom I'm using
with the Sherline.

There's not all that much horsepower in an 8-bit microcontroller and the
firmware is bumping up against those limits, too. I expect the next
generation will use an ARM or some such, at the economics will
definitely favor a commodity PC and a very cheap analog interface board;
you need pretty much the same stepper drivers for either one.

All the firmware does is eat G-Code and spit out parts; that's exactly
what EMC2 does with my Sherline mill. I think it'd be a whole lot easier
and less expensive to use EMC2 for motion control than to re-invent all
those functions and jam them into an Arduino. Plus, you'd get a much
better user interface, bigger displays, better keyboards, and a much
more stable system for free.

The fact that the computer inside the printer is a PC running EMC2,
instead of a microcontroller running something else, is largely
irrelevant. From the outside, you feed either printer with G-Code from
Skeinforge it produces parts; the advantage of using EMC2 is that
developers can concentrate on improving *printing* rather then
reinventing motion control / UI wheels.

I'd like to do it just to show how it works, but ... not right now.

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Re: [Emc-users] Extrusion-based RP

2011-06-13 Thread Ed Nisley
On Sun, 2011-06-12 at 14:33 -0700, Mike Payson wrote:
 a bit of a Makerbot champion 

The *idea* behind the Thing-O-Matic is great, but the *implementation*,
well, not so much. Plus, all the things on the their wishlist seem to be
done deals with EMC2, but I digress.

 ship it, then sell them an upgrade when they complain.

Which is why I have trouble recommending that anybody buy a
Thing-O-Matic: it costs about $2k by the time you get it gussied up with
everything required to make it work the way they described it late last
year when I bought it. That's ignoring the inconvenient fact that not
everything you'd get actually works the way it should; it's still a shop
project.

 ARM chips are cheaper than an 8-bit ATMega

*pumps fist*

Yes! I had a ten-cent bet with myself that when everybody finally
admitted that an Arduino couldn't handle the load, they'd step up to an
ARM and start from scratch.

 since those same points are true of the RepRap today with
 the host software.

Ah, but look at it a bit differently: A dual-core Foxconn Atom (with
parallel port!) + 1 GB DDR2 + 80 GB SATA is $150 *retail* at Newegg, so
it's under $70 OEM. Add a custom interface board with the stepper
interface and an Arduino-class micro that handles the heaters / fans /
thermocouples for maybe $50 OEM. You get a headless EMC2 system for $120
OEM that runs rings around a de novo ARM, particularly because you don't
have to re-write all that motion control and UI code.

Example: Want a higher-end 3D printer system with touch screens,
keyboards, joysticks, whatever? Would you rather have this:

http://www.makerbot.com/wp-content/uploads/2011/03/Interface_Text.jpg 

Or this:

http://www.linuxcnc.org/docs/2.5/html/gui/touchy.html 

Given that a VGA-resolution 8-inch touch screen costs the same
(admittedly, on eBay) as the MBI kit (modulo shipping), I think you see
where I'm coming from. With EMC2, you just plug it in, load up the HAL
code, and you've got a touch screen interface.

Which printer UI would be an easier sell to the *next* 10,000 customers
who aren't gearheads like us? Attracting their attention might be worth
a hundred bucks right there...

/rant [grin]

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Re: [Emc-users] stepConf configuration | EMC conversion

2011-06-27 Thread Ed Nisley
On Mon, 2011-06-27 at 13:41 -0700, For Sale Sticker wrote:
 'leadscrew pitch' (do I just count the number of threads per inch?)

It's barely possible that the leadscrew will have a multiple-start
thread, making the linear-motion-per-turn higher than you'd expect from
a simple count of the threads-per-inch number.

Turn the leadscrew by hand and count the number of threads that vanish /
appear at the edge of the stage for each turn: mark a thread, then watch
it for one turn. If one thread vanishes / appears, then the leadscrew
doesn't have a multiple-start thread.

If it has a multi-start thread, then the stage will move more than the
threads-per-inch by the number of thread starts.

(The Z axis on my Thing-O-Matic has a four-start leadscrew, so I had to
puzzle through this mess while figuring out the mechanics...)

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Re: [Emc-users] Emc vs modern lcd monitors

2011-08-15 Thread Ed Nisley
On Sat, 2011-08-13 at 08:50 -0400, gene heskett wrote:
 under the vesa driver on an ati x1650 video card

I ran into something like that on a Foxconn dual-core Atom D520 box that
I'm sliding under my Thing-O-Matic: the default video setup sent
1024x768 dots to a 1280x1024 monitor and didn't offer anything better.

The gotcha lay inside the Ubuntu 11.04 monitor settings, wherein
unchecking the Show same thing on both monitors box suddenly revealed
a second monitor! The Atom board has bone-stock Intel graphics with (to
the best of my knowledge) no second video output, but the second monitor
config showed all the myriad resolutions supported by the actual
display.

So I turned off the first monitor, picked 1280x1024 for the second
monitor, the LCD went *blink*, and it's now fine. BTSOOM.

Dunno if that applies to the VESA driver atop an ATI board, but it's
certainly worth checking.

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Re: [Emc-users] NAMES and Flash Drive devices

2009-03-16 Thread Ed Nisley
 Copying to user-provided flash drives instead of handing
 out CDs is a great idea, especially because it makes the
 user participate actively rather than just grab
 reflexively.

Although that's true, I think trying to do anything that 
smacks of system administration while on the show floor is 
doomed to humiliating failure.

Most of the time, flash drives Just Work under Linux, but 
there are a wide variety of flash drives and some require 
specific care  feeding. All of us have the personality flaw 
that requires us to solve problems and there's nothing more 
compelling than Showing Off Our Sysadmin Chops.

The inevitable result is being elbow-deep in the guts of the 
OS, desperately trying to write the victim's USB drive, 
while causing untold collateral damage. Worst case: neither 
his USB drive nor your system are ever quite the same 
afterward -and- you blew half an hour getting there.

Better to keep a stack of CDs under the table and hand one 
out to each interested prospect. While the CD might not be 
readable in his drive, you can fix that up after the fact.

I would not, under any circumstances, use a Windows box for 
USB-drive duplication, as you'd almost certainly propagate 
the malware brought to you by an unsuspecting victim. Case 
in point:

http://www.news.cornell.edu/stories/Oct08/bots.ws.html

Trade-show Exhibitor Rule Number 1: Keep It Simple, Stupid!

Works for me, anyway...

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Re: [Emc-users] Puzzling Interpreter Error

2009-06-10 Thread Ed Nisley
 I narrowed down your program into a very short one:

Well, that's certainly easier to follow!

Thanks for the flensing... grin

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[Emc-users] Speaking of metric

2009-06-12 Thread Ed Nisley
Given that money is power, I propose we measure  report all 
financial changes in decibels.

Hearing The Dow was down 3 dB yesterday wouldn't be very 
disturbing, would it?

Your previously extortionate 20% credit card rate would drop 
to a mere 0.8 dB.

But your CDs would yield 0.08 dB and let's not talk about 
your savings account (remember those?).

OK, enough of this...

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Re: [Emc-users] Cabin Fever Expo, York PA - January 15-17

2010-01-03 Thread Ed Nisley
 ... if anyone will be set up there again this year

I'll bring my little Sherline CNC mill  stack o' 
simpleminded projects again. If the conference room isn't 
full up, I'll do my Why CNC? An Introduction song  dance 
routine, too.

Gotta start printing some handouts pretty quick!

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[Emc-users] Probing and tool-change coordinates

2010-03-28 Thread Ed Nisley
I'm beating a tool-height probe switch into submission and 
want to make sure I'm not misinterpreting what I see; the 
relevant sections of the EMC2 version 2.3 doc are not 
entirely forthcoming.

Here's how I think the pieces work...

The coordinates stored by G30.1 in #5181-#5186 are always in 
native machine units, which are inches for my Sherline's 20-
tpi leadscrews. Thus, to program a Z-axis move to the G30 
height while using metric units, you'd use

G0 Z[#5183 * 25.4]

The tool dimensions stored in the classic tool table file 
are always in native machine units: inches for my machine. 
Thus, the tool lengths used by G43 H- (read from the table) 
will be in inches.

The coordinates stored by G38.2 in #5061-#5069 are in 
whatever units the currently active G20/G21 mode calls for. 
Thus, with G21 metric units active, #5063 has the most 
recently probed Z-axis coordinate in millimeters.

The tool length used by G43.1 K- is also in the current 
G20/G21 units, which will be millimeters when G21 is active.

So, with G21 active, doing a G38.2 probe stores coordinates 
in millimeters, which are exactly what's needed for the 
subsequent G43.1 K-

G43.1 K[#5063 - #_ToolRefZ]

That's the way it seems to work and it makes perfect sense, 
although the collision of units in the G43 family was 
disconcerting.

Do I have all that right?

Now, is there any way for a G-Code (sub)program to determine 
which of G20/G21 is currently in effect? It Would Be Nice If 
the routine could pick its Z traverse level and probing 
speed based on the current units.

Thanks...

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[Emc-users] Tool Table Size Limit?

2010-05-29 Thread Ed Nisley
In Axis 2.4.0, is it true that the tool table can have only 
48-ish entries?

I'm drilling circuit boards from Eagle layouts, using a 
script that extracts all the holes, sorts them by drill 
diameter, then visits each set in nearest-neighbor order.

The problem is that Eagle's part libraries have a 
bewildering variety of hole diameters, which means you can't 
tell which drills you need for any given board, even rounded 
off to the nearest 0.001 inch.

I use Txxx M6 and the Axis manual toolchanger, so my 
changer has access to all the drills  mills in my 
cabinet. I figured I could shotgun the problem by simply 
listing all possible drill sizes from zero on up to about 
half an inch: larger than I'd want to drill with the 
Sherline, anyway.

So I set up a tool table with 501 entries:

T1000   P1000   Z1 D0.000
... snippage ...
T1020   P1020   Z1 D0.020
T1021   P1021   Z1 D0.021
T1022   P1022   Z1 D0.022
T1023   P1023   Z1 D0.023
T1024   P1024   Z1 D0.024
T1025   P1025   Z1 D0.025
... snippage ...
T1500   P1500   Z1 D0.500

The Z values are all 1 because I'm using a tool length probe 
to set the lengths on the fly.

Unfortunately, Axis seems to truncate the tool table to 
about 48 entries. I'd expected that to not be a problem, 
because the doc gives this example:

T9  P9  D23.75000   Z-0.300 ;You have a 
big tool changer

Is there a user-level way to increase the maximum number of 
entries in the tool table?

In practice, I use only a few drill sizes, because as far as 
I'm concerned 0.023 and 0.024 drills are identical. But the 
script doesn't know which drills I favor, so it lists 
everything it needs. I could stuff those sizes in the tool 
table, but a limit of 50 entries is perilously close to how 
many different drill sizes I actually use:  I want to avoid 
having a separate tool table for each job!

Thanks...

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Re: [Emc-users] tool length setting after toolchange

2010-08-11 Thread Ed Nisley
 I got inspiration from these two sites

I ran a quick-and-dirty test on the repeatability of my ugly 
tool length probe switch and discovered that it works 
surprisingly well:

http://softsolder.wordpress.com/2010/04/17/ugliest-tool-
length-probe-switch-repeatability/

Shorter link: http://wp.me/poZKh-15y

A somewhat less hideous version of the probe subroutines 
lies buried in the G-Code accompanying this post:

http://softsolder.wordpress.com/2010/06/15/water-bottle-
spring-cap-repair/

Shorter link: http://wp.me/poZKh-1cI

The trick is to put the G30.1 location far enough above the 
switch to accommodate the longest tool you'll use for that 
job. That's a gotcha I discovered on PCBs requiring both 
carbide drills in a 1/8 collet and twist drills in a Jacobs 
chuck.

I recently got a sack of assorted SMD switches that (seem 
to) have more overtravel, but I'll procrastinate until I 
wreck the ugly one and must replace it.

All in all, a tool length probe station isn't hard to build, 
at least if you're not writing up the project for Digital 
Machinist... [grin]

-- 
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[Emc-users] Speaking of Intel Atom 510 systems

2010-09-10 Thread Ed Nisley
It seems the Intel D510MO board works fine with the new 
10.04 SMP version of EMC2, but one must wrap a box  power 
supply around it, then kludge up a parallel port connector.

Does anyone have an opinion on the $130 (+$5 shipping) 
Foxconn R3-D2 (or similar) barebones system? It has an 
Atom 510, a box with LPT connector on back, and a power 
supply, but needs $45 worth of DDR2/800 from Micron. Under 
$200 if you have a SATA drive in your parts box.

Looks pretty close to plug-and-play with EMC2!

Thanks...

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Re: [Emc-users] Speaking of Intel Atom 510 systems

2010-09-10 Thread Ed Nisley
 Stay away from Foxconn, 
 I went through three motherboards in a row

That's the sort of experience I was looking for...

This is surely the same Foxconn that makes all the fancy 
consumer electronics for all the Big Names, though. Perhaps 
those contracts pay for better reliability?

 Since we had other gear in that box that would need 12 V,

This is for my simple Sherline setup, so plain old 120 VAC 
wall outlet power is just fine. I'd just conjure up a 12 VDC 
supply from the heap, but avoiding an AC-DC-DC conversion 
seems like a Good Thing.

Thanks...

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Re: [Emc-users] Automatic Z-axis touchoff ?

2010-09-22 Thread Ed Nisley
 some G code snippets

A somewhat improved version of the probe length routines are 
down near the bottom of this post:

http://softsolder.com/2010/06/15/water-bottle-spring-cap-
repair/

Shorter link: http://wp.me/poZKh-1cI

I found that using the G59.3 coordinate system for probing 
prevented messing up the G54 coordinates.

However, Bad Things can happen when you interrupt the 
program: it may leave you in G59.3, with the origin far away 
from the touch-off point in G54 that you're expecting to 
use.

I'm still putzing around with the code, but that simple 
pushbutton switch works fine!

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[Emc-users] Eagle-to-HAL converter

2010-10-18 Thread Ed Nisley
Is anybody out there using Martin Schoeneck's Eagle2HAL configuration
program?

http://wiki.linuxcnc.org/emcinfo.pl?Eagle2HAL

I'm writing up my Logitech gamepad Joggy Thing for Digital Machinist and
realized that it's *much* easier to talk about circuit diagrams than
lines of HAL code. I remembered Martin's work and decided that if I was
going to draw schematics, I might as well get the HAL code for free.

An email to the address given on the wiki page seems to have vanished
(no bounce, but no reply after several days). A search for 

martin shoeneck eagle

produces exactly one hit:

http://martin.yaelbz.de/hal-write/

The main URL is essentially blank. Now, Martin may be on vacation,
but ... it sure looks like an orphan project to me.

So far, I've updated his hal-write.ulp script to handle (some of) the
new devices introduced in EMC 2.4.x, added a few devices to
hal-config.lbr, and am slowly figuring out how the whole thing works.

I can take the changes far enough to scratch my itch, which is basically
handling halui / hal_input device configuration. The intricacies of the
schematic he used as a testcase / example / demo are *far* beyond what I
need or can verify!

Has anybody else been tinkering with Eagle2HAL? Any suggestions on what
to do or how to do it?

Thanks...

 
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Re: [Emc-users] Eagle-to-HAL converter

2010-10-19 Thread Ed Nisley
On Tue, 2010-10-19 at 08:57 +0200, Martin Schöneck wrote:
 I only used it for my own configuration 

That's pretty much what I had in mind, too!

I'll take a look at your changes and send you mine; between the two of
us, perhaps we can scratch *both* our itches and make something useful
to somebody else.

More discussion off-list...

Thanks!
 
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[Emc-users] Progress Report: Eagle Schematic to HAL code converter

2010-10-23 Thread Ed Nisley
I tweaked Martin's original Eagle ULP a bit, added some library devices,
then built a schematic to connect my Logitech gamepad Joggy Thing as an
EMC2 pendant.

The grisly details, links to background info, and current files are at:

http://softsolder.com/2010/10/23/logitech-gamepad-as-emc2-pendant-eagle-schematics-for-the-joggy-thing/

Shorter link: http://wp.me/poZKh-1qh

My intent is *not* to make a general do-it-all converter that can eat a
schematic describing an entire machine and spit out a complete HAL file
set, but to have something that can handle specific hardware gadgets
that fit into an existing machine's HAL files. Basically, that's about
all I understand how to do and have the machinery to test.

It's reasonably usable as-is; I'll write up an overview of the pendant
function for my Digital Machinist column.

After some tweaking, adding more library devices, and cleaning up the
internal doc, I'll figure out how to stuff the files back into the wiki.

Suggestions, commentary, and funny stories are welcome...
 
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Re: [Emc-users] Progress Report: Eagle Schematic to HAL code converter

2010-10-24 Thread Ed Nisley
On Sat, 2010-10-23 at 09:41 -0400, Kent A. Reed wrote:
 document existing configurations

That's sort of what pushed me into getting the schematic converter
running: I wanted to tweak my existing Logitech HAL configuration, but
the prospect of figuring out how it worked seemed too painful for words.

Using the loadrt and2 names=winken,blinken,nod option and naming the
nets doesn't help much, because names don't make the interconnections
any more obvious.

Get that reverse-documentation thing running: I'll use it!
 
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Re: [Emc-users] slo-syn drivers

2010-11-13 Thread Ed Nisley
On Sat, 2010-11-13 at 14:38 +1100, Erik Christiansen wrote:
 The easiest way to increase the high-state output voltage, when it's
 only getting to three-and-a-bit volts, is to add a pull-up resistor. 

Be careful: the parallel port's output transistor probably doesn't have
a particularly high output voltage rating. It'll almost certainly work
fine with +5 V, but don't connect +12 V or (shudder) +48 V motor power
supplies.

The problem is not the forward current conducted when the transistor is
on (which will be limited by the external circuit), but the voltage it
must withstand when turned off (which is set by the external supply).
The port pin may also be connected to ESD protection diodes and suchlike
that will react unkindly to higher voltages.

The general idea of an opto-isolator is to turn on an LED with a current
(in the neighborhood of 10 mA) that can come from a low-voltage source
that's switched by a low-voltage transistor like the one in the parallel
port. What happens on the other side of the isolator doesn't affect the
LED side.

A bare optoisolator IC generally contains just the LED, so you must
choose an external series resistor to limit the current to whatever the
LED requires. However, if you're using a packaged optoisolator module,
it probably has an internal resistor that's specified to work with a
particular supply voltage. If that supply is supposed to be +12 V, then
the LED won't get enough current from a +5 V supply.

On the other side of the isolator, the output transistor will be good
for operation at the (much higher) currents and voltages required by the
motor drivers.

Hope that helps a bit...
 
-- 
Ed


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Re: [Emc-users] Correct use of subroutines

2013-05-13 Thread Ed Nisley
On 05/13/2013 02:01 AM, Rafael Skodlar wrote:
 emerging personal 3D printing.

G-Code is largely irrelevant for 3D printing: it's nothing more than an 
intermediate machine language between the slicer and the printer.

The complexity of the motions required to produce a single layer of a 
model prevents anybody from writing or even modifying that code by hand: 
the slicer output is essentially a write-only code blob. A typical 
G-Code file for a small object contains half a megabyte of instructions; 
some of my models exceed 10 MB.

For example, a 6 MB file has 141000 lines of G-Code.

The slicers add short, hand-written G-Code routines to the beginning and 
end of the automatically generated G-Code blob, as well as insert shim 
routines at each layer and tool change. However, those routines perform 
stereotyped functions, such as axis home, nozzle wipe, motor disable, 
and camera trigger, that would be configured and written by the machine 
integrator rather than the machine operator.

In the current DIY 3D printing world, one person may play both of those 
roles, but that era is coming to an end. In any event, unlike a 
subtractive machine tool, you can't pause a 3D printer, hack the G-Code, 
and fire it up again: time, tide, and molten plastic wait for no operator!

To a reasonable approximation, a 3D printer's software stack eats solid 
models and produces plastic shapes, with no human intervention along the 
way. The typical user has no idea what G-Code is and really shouldn't 
get involved at that level: the high level language describes the 
object geometry, not the production method.

-- 
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Re: [Emc-users] Correct use of subroutines

2013-05-13 Thread Ed Nisley
On 05/13/2013 08:43 AM, andy pugh wrote:
 feed it STL rather than G-code

Or, perhaps, an OpenSCAD model in source-code format, although you'd 
really want a better set of primitives that take advantage of arcs and 
suchlike.

STL can't handle multiple colors / materials, has only triangle 
tesselation, and really shouldn't be the basis of further development. 
Just like G-Code, it'll live forever. [grin]

 doesn't let you control things like fill patterns.

The newer, more consumer-oriented UIs have eliminated the myriad knobs 
we enjoy fiddling with, replacing them with a linear scale: fine, 
medium, coarse. It (or the original programmer) then chooses detailed 
settings based on the desired outcome, slices the model accordingly, and 
drives the printer.

The real problem (and it *is* a real problem) then becomes generating 
the model geometry. Based on a very small sample, non-techies have 
trouble with 3D modeling and fancier CAD programs aren't the answer...

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Re: [Emc-users] Easy 3D Re: Correct use of subroutines

2013-05-13 Thread Ed Nisley
On 05/13/2013 06:41 PM, Gregg Eshelman wrote:
 As for sketchup, unless it's seen some massive debugging and improvements,
  it's a very nice utility
  for creating some of the most fouled up 3D geometry

Aye!

But the objects *look* good, so they should print fine. Right? [wince]

I've given up explaining why Sketchup isn't good for solid modeling, but 
I also no longer (try to) advise people who have a totally botched model 
what went wrong. That maximizes the total happiness.

But Sketchup seems to be the least user-hostile program out there for 
folks who want to build things. OpenSCAD definitely isn't the answer 
and traditional CAD/CAM packages aren't for those folks, either.

'Tis a puzzlement.

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Re: [Emc-users] Correct use of subroutines

2013-05-15 Thread Ed Nisley
On 05/14/2013 07:08 PM, Eric Keller wrote:
 cut a hole in the family room floor

My buddy Eks got a spectacular deal on a CNC mill that was too tall for 
his shop doorway: he had to dismount the head. Then, of course, there 
was no clearance for a hoist between head and ceiling, so he drilled a 
hole into the bedroom above the shop, put a plate on the floor, threaded 
a cable through the hole, hauled the hoist into the bedroom, and 
finished the job.

As he put it, Heck, it's just a little hole under the bed. Nobody will 
ever notice it.

He *does* have a wife, but she's used to his, ah, quirks...

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Re: [Emc-users] Correct use of subroutines

2013-05-15 Thread Ed Nisley
On 05/15/2013 10:46 AM, Gene Heskett wrote:
 he'd have to patch it

Oh, he did, and IIRC cut the carpet as a flap that laid down neatly over 
the plug... he's that kind of guy.

But even if had been a hardwood floor, well, he *is* that kind of guy.

 a job fixing them newfangled TV thingies

Which, as nearly as I can tell from here, was a perfect fit!

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Re: [Emc-users] BeagleBone + BeBoPr 3D Printing

2013-06-01 Thread Ed Nisley
On 06/01/2013 12:39 PM, Charles Steinkuehler wrote:
 I particularly like the acceleration control in LinuxCNC.
  It seems smoother than the Arduino code.

At least on the Marlin firmware branch of the RepRap tree, the interrupt 
handler switches from one-step-per-interrupt to two/interrupt at 10 k 
step/s, then to four/interrupt at 20 k step/s, with abrupt step timing 
changes. These pictures show the step pulses to the X axis of my M2 
during the ramp up to 450 mm/s at 5000 mm/s^2:

https://www.dropbox.com/s/llrx2ik6vlq4ne9/X%20Axis%20450%20mm-s%2050%20mm%20-%20100%20us-div%2041.9%20ms%20dly.png
https://www.dropbox.com/s/z4w4mg6wklnhvpm/X%20Axis%20450%20mm-s%2050%20mm%20-%20200%20us-div%2019%20ms%20dly.png

The top trace is the motor winding current, the bottom trace is the Step 
pulse from the Arduino to the driver chip. The pulse clusters on the 
right side show how a single interrupt produces multiple steps, with the 
*average* rate remaining constant. However, speeds over about 112 mm/s 
(on the M2, anyway) have irregularly spaced Step pulses.

I'm getting ready to disconnect the stock RAMBo board and hitch up 
LinuxCNC through a Mesa card and some stepper driver bricks to the M2; I 
think it'll be happier with regular Step pulses!

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Re: [Emc-users] Pendant recommendations

2013-06-02 Thread Ed Nisley
On 06/02/2013 03:16 PM, Dave wrote:
 If you are using a USB joystick as a pendant, which model are you using??

At least for my Sherline, a Logitech Dual-Action gamepad works 
wonderfully well. Here's the initial description:

http://softsolder.com/2010/10/23/logitech-gamepad-as-emc2-pendant-eagle-schematics-for-the-joggy-thing/

It gives direct four-axis control: XY on the left, ZA on the right. The 
buttons along the top provide full-speed rapids and the joysticks go 
down to crawling speeds.

The HAL circuitry detects which joystick axis starts moving and locks 
out all the others, which prevents inadvertent motion along an axis that 
you've already lined up against an edge. The buttons don't have that 
lockout, so you can slew diagonally at high speed when that's appropriate.

More HAL wiring uses two of the four buttons on the cable side as an 
E-stop button: you must push both buttons to trigger the stop. Agreed, 
software should be in the E-stop loop, but this is a Sherline... and I 
haven't ever used those buttons, come to think of it, because shutting 
off the power to the motor driver box works even better.

 How practical are USB joysticks for use as pendants on a milling machine?

Probably not very, at least on a real milling machine that's spraying 
coolants and hot chips and piles of swarf all over. On the other hand, 
gamepads are cheap and easily replaceable, so you don't form a deep 
emotional attachment to them...

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Re: [Emc-users] BeagleBone + BeBoPr 3D Printing

2013-06-02 Thread Ed Nisley
On 06/02/2013 03:50 PM, Karl Schmidt wrote:
 improved surface finish

Not really. The slicing software adjusts the extrusion speed to match 
the XY speed, so the printer lays down a consistent amount of plastic no 
matter what speed you choose.

That's the theory. In practice (and for my setup), higher speeds produce 
worse results. I think part of the problem is that the extruder must 
paste the current molten thread onto the previous layer, which requires 
enough dwell time to melt them firmly together; higher speeds work 
against that, so things don't stick nearly as well.

On the other hand, faster non-printing moves reduce the amount of time 
the printer spends *not* printing, which is generally a Good Thing... 
until something shakes loose.

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Re: [Emc-users] Machinekit LinuxCNC-on-BeagleBone Beta Release

2013-06-15 Thread Ed Nisley
On 06/13/2013 06:12 PM, Charles Buckley wrote:
 1) None of the current GUIs are really good for this,

I've been using http://gcode.ws/ to visualize the actual paths within 
each layer, but that's probably too weird for most folks.

 Keeping the spool sync'd with the filament feed rate

Recently bumped on my priority list: a powered filament feeder that 
automagically maintains the loop feeding the extruder, specifically to 
eliminate the usual feed tube with all the usual problems. The drive 
gear/pulley/wheel ramming filament into the hot end shouldn't also drag 
filament through a long tube!

I think the simplest approach will be a filament position sensor so a 
HAL circuit can run the feed motor as needed to maintain the loop 
height. Those I've seen in the wild can benefit from HAL...

Given a filament position station, I have a notion that would add 
two-axis filament diameter sensing. That can feed into a HAL component 
that would produce the filament area, which could then twiddle the feed 
on the fly.

 PWM to control the heating element.

With control based on actual thermal properties and measurements, rather 
than by-guess-and-by-gosh. I just laid in a stock of DC-DC SSRs for that 
very purpose!

 4) Temperature reading.

Dan Newman wrote some code for the TC4 thermocouple shield that converts 
it to a USB HID hal_input device that I'll be using with my M2 printer:

http://softsolder.com/2013/06/10/tc4server-eagle-hal-device/

 pushing as much of the machining steps into hardware as possible.

I really want to use automagic probing to compensate for platform shape 
 positioning, because there don't seem any cheap, flat, removable 
hotplates out there. Methinks this one is easier to fix in the 
kinematics than in the metal; the shape of the platform changes as it 
heats up and nobody wants to measure a hot platform by hand.

The M2 is rigid enough to do XY axis homing once per session and be done 
with it, but the general case probably requires that on a per-print 
basis along with the platform compensation.

Let many LinuxCNC installations blossom!

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Ed
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Re: [Emc-users] Machinekit LinuxCNC-on-BeagleBone Beta Release

2013-06-15 Thread Ed Nisley
On 06/15/2013 08:43 AM, Viesturs Lācis wrote:
 take a look at probekins,

That's exactly why I'm so enthused about automagic platform probing: 
somebody else wrote the kinematics module! [grin]


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Re: [Emc-users] Machinekit LinuxCNC-on-BeagleBone Beta Release

2013-06-15 Thread Ed Nisley
On 06/15/2013 12:04 PM, Charles Buckley wrote:
 you could treat the spool feed as an
 additional axis whose feed rate is the same as the 4th axis.

I think that would come heartbreakingly close to working, because the 
feed rate depends so much on the effective diameter of the 
gear/pulley/wheel. A teeny difference in hobbing will eventually (i.e., 
over the course of a dozen hours) cause the filament loop to either 
vanish or spill off the table: gotta wrap some feedback around the 
filament coming off the spool.

But it might be close enough. Do a coarse positioning at the start of 
the print to put enough filament in the loop, then run the two motors 
in parallel for a few hours without feedback. That would eliminate the 
need to keep track of the filament while it flops around, which sound 
like a Good Thing.

 measuring the table temp for a heated table bed would also be good.

The TC4 board also has four thermistor inputs... and I now have some 25 
A DC-DC SSRs on hand. [grin]

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Re: [Emc-users] Machinekit LinuxCNC-on-BeagleBone Beta Release

2013-06-15 Thread Ed Nisley
On 06/15/2013 09:01 AM, Viesturs Lācis wrote:
 I have no idea, how difficult that actually might be.

Given the requirement that it match the extruder nozzle height to within 
0.05 mm (more or less) over a wide temperature range, it's a *very* 
tough problem. I think separating the nozzle height measurement from the 
platform probe operation might be the only way to make both of them work 
properly.

I put a simple switch on my much-modified Thing-O-Matic's platform and 
poked it with the extruder nozzle to set the zero height position, but 
that's obviously a poor general solution:

http://softsolder.com/2011/05/18/thing-o-matic-z-minimum-platform-height-switch/

Those platform pictures come from the days of ABS slurry on Planet 
Barbie... [wince]

I think a pogo test pin with a side flag tripping an optical 
interrupter, perhaps through an amplifying lever, might be workable for 
platform probing, but I won't believe it until I run the numbers.

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Ed
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