MESA 5-Axis - Axis-3 Following Error

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Askjerry
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26 Jul 2018 06:54 - 26 Jul 2018 06:56 #114858 by Askjerry

MESA 5-Axis - Axis-3 Following Error was created by Askjerry

I used the PNC Wizard to create a functional XYZA mill... the A/B table that I have spins the A-Axis on command.
I reconfigured it again, this time pointing the A-Axis at the connection for the B-Axis... using A-Axis commands, the B-Axis moves just fine.

I configured the XYZA again, pointing to the correct A-Axis hardware and terminal on the MESA, tested it, and it works.

Next I went into the INI file and made the following changes...

FROM
[TRAJ]
AXES = 4
COORDINATES = X Y Z A

TO
[TRAJ]
AXES = 5
COORDINATES = X Y Z A B

Then I did a copy of the A-Axis and modified it for B-Axis...
#********************
# Axis B
#********************
[AXIS_4]
TYPE = ANGULAR
HOME = 0.0
FERROR = 0.005
MIN_FERROR = 0.0005
MAX_VELOCITY = 166.666666667
MAX_ACCELERATION = 250.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 208.3
STEPGEN_MAXACCEL = 500.0
# these are in nanoseconds
DIRSETUP = 6000
DIRHOLD = 6000
STEPLEN = 6000
STEPSPACE = 6000
STEP_SCALE = 26.6667
BACKLASH = 0.05
MIN_LIMIT = -9999.0
MAX_LIMIT = 9999.0
HOME_OFFSET = 0.0

That was all the changes to the INI... onto the HAL...

It already has 5 STEPGEN available...
loadrt hm2_pci config=" num_encoders=1 num_pwmgens=0 num_3pwmgens=0 num_stepgens=5 sserial_port_0=00xxx "

I manually added a B-Axis by cloning the A-Axis and changing "a" to "b" and [AXIS_3] to [AXIS_4].
And all references to stepgen.03 were changed to stepgen.04 as needed.

Then I went in and did the same in the next section... creating "B" from "A"...
net joint-select-d halui.joint.3.select
net a-is-homed halui.joint.3.is-homed
net jog-a-pos halui.jog.3.plus
net jog-a-neg halui.jog.3.minus
net jog-a-analog halui.jog.3.analog

net joint-select-e halui.joint.4.select
net b-is-homed halui.joint.4.is-homed
net jog-b-pos halui.jog.4.plus
net jog-b-neg halui.jog.4.minus
net jog-b-analog halui.jog.4.analog

I saved it all... started the machine... clicked on HOME for each axis... and it shows X-Y-Z-A-B very nicely...
If I enter G1 A90 F1000 the A-Axis moves 90 degrees. (Yeay)
If I enter G1 B90 F1000 the machine stops and proclames JOINT 03 FOLLOWING ERROR.

What is going on? I can't seem to resolve it. Once I get this running... I should be able to wire up my actual (HUGE) mill with the new MESA card and convert the monster into a 5-Axis. But for right now I'm stumped.

Can anyone help???
Jerry

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Last edit: 26 Jul 2018 06:56 by Askjerry. Reason: Corrective

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rodw
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26 Jul 2018 07:51 #114859 by rodw

Replied by rodw on topic MESA 5-Axis - Axis-3 Following Error

Jerry, Others might have better advice but when I was setting up my machine, I found increasing these beyond the recommendation often stopped the following errors. You are using backlash so maybe thats the problem.

# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 208.3
STEPGEN_MAXACCEL = 500.0

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tommylight
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26 Jul 2018 07:54 #114860 by tommylight

Replied by tommylight on topic MESA 5-Axis - Axis-3 Following Error

Ini file has some issues, namely the f_error and min_f_error are set for inches while everything else is in mm.
Hal file :
net a-home-sw => axis.3.home-sw-in
net a-neg-limit => axis.3.neg-lim-sw-in
net a-pos-limit => axis.3.pos-lim-sw-in

you have the same for A and B axis. Needs to be changed accordingly.

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Askjerry
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27 Jul 2018 00:05 #114921 by Askjerry

Replied by Askjerry on topic MESA 5-Axis - Axis-3 Following Error

Tommylight: the "in" you see is pointing to a switch INPUT... has nothing to do with measurement systems.

If I do this... the A-Axis moves and the B-Axis fails.

#*******************
#  AXIS A
#*******************

# Step Gen signals/setup

#setp   hm2_5i25.0.stepgen.04.dirsetup         [AXIS_3]DIRSETUP
#setp   hm2_5i25.0.stepgen.04.dirhold          [AXIS_3]DIRHOLD
#setp   hm2_5i25.0.stepgen.04.steplen          [AXIS_3]STEPLEN
#setp   hm2_5i25.0.stepgen.04.stepspace        [AXIS_3]STEPSPACE
#setp   hm2_5i25.0.stepgen.04.position-scale   [AXIS_3]STEP_SCALE
#setp   hm2_5i25.0.stepgen.04.step_type        0
#setp   hm2_5i25.0.stepgen.04.control-type     0
#setp   hm2_5i25.0.stepgen.04.maxaccel         [AXIS_3]STEPGEN_MAXACCEL
#setp   hm2_5i25.0.stepgen.04.maxvel           [AXIS_3]STEPGEN_MAXVEL

net a-pos-fb     axis.4.motor-pos-fb   <=  hm2_5i25.0.stepgen.04.position-fb
net a-pos-cmd    axis.4.motor-pos-cmd  =>  hm2_5i25.0.stepgen.04.position-cmd
net a-enable     axis.4.amp-enable-out =>  hm2_5i25.0.stepgen.04.enable
#========================================================================================================
#*******************
#  AXIS B
#*******************

# Step Gen signals/setup

setp   hm2_5i25.0.stepgen.03.dirsetup         [AXIS_4]DIRSETUP
setp   hm2_5i25.0.stepgen.03.dirhold          [AXIS_4]DIRHOLD
setp   hm2_5i25.0.stepgen.03.steplen          [AXIS_4]STEPLEN
setp   hm2_5i25.0.stepgen.03.stepspace        [AXIS_4]STEPSPACE
setp   hm2_5i25.0.stepgen.03.position-scale   [AXIS_4]STEP_SCALE
setp   hm2_5i25.0.stepgen.03.step_type        0
setp   hm2_5i25.0.stepgen.03.control-type     0
setp   hm2_5i25.0.stepgen.03.maxaccel         [AXIS_4]STEPGEN_MAXACCEL
setp   hm2_5i25.0.stepgen.03.maxvel           [AXIS_4]STEPGEN_MAXVEL

net b-pos-fb     axis.3.motor-pos-fb   <=  hm2_5i25.0.stepgen.03.position-fb
net b-pos-cmd    axis.3.motor-pos-cmd  =>  hm2_5i25.0.stepgen.03.position-cmd
net b-enable     axis.3.amp-enable-out =>  hm2_5i25.0.stepgen.03.enable
#========================================================================================================

If I make a simple change... it reverses which gen is used... and the A-Axis now fails.

#*******************
#  AXIS A
#*******************

# Step Gen signals/setup

#setp   hm2_5i25.0.stepgen.03.dirsetup         [AXIS_3]DIRSETUP
#setp   hm2_5i25.0.stepgen.03.dirhold          [AXIS_3]DIRHOLD
#setp   hm2_5i25.0.stepgen.03.steplen          [AXIS_3]STEPLEN
#setp   hm2_5i25.0.stepgen.03.stepspace        [AXIS_3]STEPSPACE
#setp   hm2_5i25.0.stepgen.03.position-scale   [AXIS_3]STEP_SCALE
#setp   hm2_5i25.0.stepgen.03.step_type        0
#setp   hm2_5i25.0.stepgen.03.control-type     0
#setp   hm2_5i25.0.stepgen.03.maxaccel         [AXIS_3]STEPGEN_MAXACCEL
#setp   hm2_5i25.0.stepgen.03.maxvel           [AXIS_3]STEPGEN_MAXVEL

net a-pos-fb     axis.3.motor-pos-fb   <=  hm2_5i25.0.stepgen.03.position-fb
net a-pos-cmd    axis.3.motor-pos-cmd  =>  hm2_5i25.0.stepgen.03.position-cmd
net a-enable     axis.3.amp-enable-out =>  hm2_5i25.0.stepgen.03.enable
#========================================================================================================
#*******************
#  AXIS B
#*******************

# Step Gen signals/setup

setp   hm2_5i25.0.stepgen.04.dirsetup         [AXIS_4]DIRSETUP
setp   hm2_5i25.0.stepgen.04.dirhold          [AXIS_4]DIRHOLD
setp   hm2_5i25.0.stepgen.04.steplen          [AXIS_4]STEPLEN
setp   hm2_5i25.0.stepgen.04.stepspace        [AXIS_4]STEPSPACE
setp   hm2_5i25.0.stepgen.04.position-scale   [AXIS_4]STEP_SCALE
setp   hm2_5i25.0.stepgen.04.step_type        0
setp   hm2_5i25.0.stepgen.04.control-type     0
setp   hm2_5i25.0.stepgen.04.maxaccel         [AXIS_4]STEPGEN_MAXACCEL
setp   hm2_5i25.0.stepgen.04.maxvel           [AXIS_4]STEPGEN_MAXVEL

net b-pos-fb     axis.4.motor-pos-fb   <=  hm2_5i25.0.stepgen.04.position-fb
net b-pos-cmd    axis.4.motor-pos-cmd  =>  hm2_5i25.0.stepgen.04.position-cmd
net b-enable     axis.4.amp-enable-out =>  hm2_5i25.0.stepgen.04.enable
#========================================================================================================

So the failure is staying with stepgen_04 for some reason.
But I literally cloned B from A in the HAL...

Then I did the same thing with the INI... and dropped the speed significantly.

#========================================================================================================
#********************
# Axis A
#********************
[AXIS_3]
TYPE = ANGULAR
HOME = 0.0
FERROR = 0.05
MIN_FERROR = 0.5
MAX_VELOCITY = 90
MAX_ACCELERATION = 10
STEPGEN_MAXVEL = 210
STEPGEN_MAXACCEL = 500.0
DIRSETUP   = 9000
DIRHOLD    = 9000
STEPLEN    = 9000
STEPSPACE  = 9000
STEP_SCALE = 26.6667
MIN_LIMIT = -130.0
MAX_LIMIT =  130.0
HOME_OFFSET = 0.0
#========================================================================================================
#********************
# Axis B
#********************
[AXIS_4]
TYPE = ANGULAR
HOME = 0.0
FERROR = 0.05
MIN_FERROR = 0.5
MAX_VELOCITY = 90
MAX_ACCELERATION = 10
STEPGEN_MAXVEL = 210
STEPGEN_MAXACCEL = 500.0
DIRSETUP   = 9000
DIRHOLD    = 9000
STEPLEN    = 9000
STEPSPACE  = 9000
STEP_SCALE = 26.6667
MIN_LIMIT = -9999
MAX_LIMIT =  9999
HOME_OFFSET = 0.0
#========================================================================================================

Does somebody out there have a WORKING 5-AXIS that i can look at the file? This is driving me nuts!!!

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PCW
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27 Jul 2018 00:40 #114924 by PCW

Replied by PCW on topic MESA 5-Axis - Axis-3 Following Error

A couple things:
1 You have ferror and min_ferror reversed
2.Stepgen_maxaccel should only be 1.25X max_acceleration
3. The PID based stepgens (what pncconf generates) are more accurate and
robust WRT host jitter

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Askjerry
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27 Jul 2018 05:29 #114931 by Askjerry

Replied by Askjerry on topic MESA 5-Axis - Axis-3 Following Error

I started another PNCCONFIG session and only really concentrated on the A-Axis settings.

Then I went to the INI file from that session and coppied the A-Axis section under the {AXIS_3] heading... I pasted it into the A-Axis section of the code above, then pasted the same code under the [AXIS_4] section.

I figured... why not? Might actually work.

And it did.

So yeay!
Jerry

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tommylight
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27 Jul 2018 05:49 #114932 by tommylight

Replied by tommylight on topic MESA 5-Axis - Axis-3 Following Error

Askjerry wrote:
Tommylight: the "in" you see is pointing to a switch INPUT... has nothing to do with measurement systems.

Does somebody out there have a WORKING 5-AXIS that i can look at the file? This is driving me nuts!!!

@Askjerry,
Please do read the posts before you insist on always being right.
F_error is very important, but you still chose to ignore it.

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Askjerry
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27 Jul 2018 12:49 - 28 Jul 2018 05:12 #114943 by Askjerry

Replied by Askjerry on topic MESA 5-Axis - Axis-3 Following Error

No sir, I didn't ignore that section of it... that is why I used the PNCCONFIG to regenerate those sections... then copy that newly created output to the existing configuration. The only thing that I stated was an incorrect assumption was the switch input setup that has "in" as part of the configuration... had to do with "inches", the "switch-in" is just indicating an input.

As for the F_Error, you were quite correct... swapping that out fixed the issue... then I was able to continue to tweak the file to get a bit more speed. It's still not finished... just proof that it is operational. (No card or PC failure.)

As a side note... I pulled up the existing INI file for my MONSTER mill figuring that since it already has steppers, and since they are operating well... I could pull the timing from the INI file there and replace it in the INI file here for the X, Y, Z axis. It seems to have worked... but I won't really know for sure until I rewire the whole machine, replacing the parallel port for the MESA.

I honestly do appreciate your assistance.

Jerry

Last edit: 28 Jul 2018 05:12 by Askjerry.

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MESA 5-Axis - Axis-3 Following Error

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