Dynomotion

Group: DynoMotion Message: 14155 From: daveymahomh600e Date: 11/22/2016
Subject: Axis Faulting Causing Gcode Error
Hi Tom,
One of my machines has started giving a gcode fault due to a disabled axis. The axis is an open loop step/direction one which feeds a C6 card for speed control of a VFD. The M3, M5 and S commands use the CSS Spindle Using Jogs programs and I can't seem to find why the axis would disable.

Here are the settings for the axis...

    ch4->InputMode=NO_INPUT_MODE;
    ch4->OutputMode=STEP_DIR_MODE;
    ch4->Vel=40000000;
    ch4->Accel=400000;
    ch4->Jerk=4e+006;
    ch4->P=0.2;
    ch4->I=0;
    ch4->D=0;
    ch4->FFAccel=0;
    ch4->FFVel=0;
    ch4->MaxI=200;
    ch4->MaxErr=20000;
    ch4->MaxOutput=200;
    ch4->DeadBandGain=1;
    ch4->DeadBandRange=0;
    ch4->InputChan0=4;
    ch4->InputChan1=1;
    ch4->OutputChan0=14;
    ch4->OutputChan1=1;
    ch4->MasterAxis=-1;
    ch4->LimitSwitchOptions=0x100;
    ch4->LimitSwitchNegBit=0;
    ch4->LimitSwitchPosBit=0;
    ch4->SoftLimitPos=1e+009;
    ch4->SoftLimitNeg=-1e+009;
    ch4->InputGain0=1;
    ch4->InputGain1=1;
    ch4->InputOffset0=0;
    ch4->InputOffset1=0;
    ch4->OutputGain=1;
    ch4->OutputOffset=0;
    ch4->SlaveGain=1;
    ch4->BacklashMode=BACKLASH_OFF;
    ch4->BacklashAmount=0;
    ch4->BacklashRate=0;
    ch4->invDistPerCycle=1;
    ch4->Lead=0;
    ch4->MaxFollowingError=10000000;
    ch4->StepperAmplitude=250;

    ch4->iir[0].B0=1;
    ch4->iir[0].B1=0;
    ch4->iir[0].B2=0;
    ch4->iir[0].A1=0;
    ch4->iir[0].A2=0;

    ch4->iir[1].B0=1;
    ch4->iir[1].B1=0;
    ch4->iir[1].B2=0;
    ch4->iir[1].A1=0;
    ch4->iir[1].A2=0;

    ch4->iir[2].B0=1;
    ch4->iir[2].B1=0;
    ch4->iir[2].B2=0;
    ch4->iir[2].A1=0;
    ch4->iir[2].A2=0;

Is it possible that because this axis only moves in 1 direction that the movement over several hundred parts is putting the soft limits at the max? The only thing in the console window that looked like it might be an error was Result=0. I couldn't find this reference in any of the CSS programs.

Thanks in advance,
David.
Group: DynoMotion Message: 14158 From: Tom Kerekes Date: 11/22/2016
Subject: Re: Axis Faulting Causing Gcode Error

Hi David,

Your soft limits are set of 1 billion counts could you be moving that far.  Consider setting to 1e30 and -1e30 instead.

Normally that would send a Soft Limit Error and feed hold to a stop and not disable axes.

Which axes are disabled?

I assume this is the axis configuration for your Spindle?

What are your spindle programs doing?

You might search all your programs (and included files) for the word "Result"

Regards
TK


On 11/22/2016 1:24 PM, david.m.stevenson@... [DynoMotion] wrote:
 

Hi Tom,
One of my machines has started giving a gcode fault due to a disabled axis. The axis is an open loop step/direction one which feeds a C6 card for speed control of a VFD. The M3, M5 and S commands use the CSS Spindle Using Jogs programs and I can't seem to find why the axis would disable.

Here are the settings for the axis...

    ch4->InputMode=NO_INPUT_MODE;
    ch4->OutputMode=STEP_DIR_MODE;
    ch4->Vel=40000000;
    ch4->Accel=400000;
    ch4->Jerk=4e+006;
    ch4->P=0.2;
    ch4->I=0;
    ch4->D=0;
    ch4->FFAccel=0;
    ch4->FFVel=0;
    ch4->MaxI=200;
    ch4->MaxErr=20000;
    ch4->MaxOutput=200;
    ch4->DeadBandGain=1;
    ch4->DeadBandRange=0;
    ch4->InputChan0=4;
    ch4->InputChan1=1;
    ch4->OutputChan0=14;
    ch4->OutputChan1=1;
    ch4->MasterAxis=-1;
    ch4->LimitSwitchOptions=0x100;
    ch4->LimitSwitchNegBit=0;
    ch4->LimitSwitchPosBit=0;
    ch4->SoftLimitPos=1e+009;
    ch4->SoftLimitNeg=-1e+009;
    ch4->InputGain0=1;
    ch4->InputGain1=1;
    ch4->InputOffset0=0;
    ch4->InputOffset1=0;
    ch4->OutputGain=1;
    ch4->OutputOffset=0;
    ch4->SlaveGain=1;
    ch4->BacklashMode=BACKLASH_OFF;
    ch4->BacklashAmount=0;
    ch4->BacklashRate=0;
    ch4->invDistPerCycle=1;
    ch4->Lead=0;
    ch4->MaxFollowingError=10000000;
    ch4->StepperAmplitude=250;

    ch4->iir[0].B0=1;
    ch4->iir[0].B1=0;
    ch4->iir[0].B2=0;
    ch4->iir[0].A1=0;
    ch4->iir[0].A2=0;

    ch4->iir[1].B0=1;
    ch4->iir[1].B1=0;
    ch4->iir[1].B2=0;
    ch4->iir[1].A1=0;
    ch4->iir[1].A2=0;

    ch4->iir[2].B0=1;
    ch4->iir[2].B1=0;
    ch4->iir[2].B2=0;
    ch4->iir[2].A1=0;
    ch4->iir[2].A2=0;

Is it possible that because this axis only moves in 1 direction that the movement over several hundred parts is putting the soft limits at the max? The only thing in the console window that looked like it might be an error was Result=0. I couldn't find this reference in any of the CSS programs.

Thanks in advance,
David.
Group: DynoMotion Message: 14159 From: David Stevenson Date: 11/22/2016
Subject: Re: Axis Faulting Causing Gcode Error

Hi Tom,

The customer told me they ran 500 parts, but I haven't yet done the math on the counts for that size run.

I was told the disabled axis is the one I sent the config for (4) and this is the spindle axis (via C6 0-10V and VFD).

The spindle programs are as per the CSS SpindleUsingJogs examples... M3 runs OnCW.c, M5 runs OffJog.c and S runs SpindleJog.c . The error occurs near the M3 command I'm told.

Thanks,

David.


On 11/22/2016 4:42 PM, Tom Kerekes tk@... [DynoMotion] wrote:
 

Hi David,

Your soft limits are set of 1 billion counts could you be moving that far.  Consider setting to 1e30 and -1e30 instead.

Normally that would send a Soft Limit Error and feed hold to a stop and not disable axes.

Which axes are disabled?

I assume this is the axis configuration for your Spindle?

What are your spindle programs doing?

You might search all your programs (and included files) for the word "Result"

Regards
TK


On 11/22/2016 1:24 PM, david.m.stevenson@... [DynoMotion] wrote:
 

Hi Tom,
One of my machines has started giving a gcode fault due to a disabled axis. The axis is an open loop step/direction one which feeds a C6 card for speed control of a VFD. The M3, M5 and S commands use the CSS Spindle Using Jogs programs and I can't seem to find why the axis would disable.

Here are the settings for the axis...

    ch4->InputMode=NO_INPUT_MODE;
    ch4->OutputMode=STEP_DIR_MODE;
    ch4->Vel=40000000;
    ch4->Accel=400000;
    ch4->Jerk=4e+006;
    ch4->P=0.2;
    ch4->I=0;
    ch4->D=0;
    ch4->FFAccel=0;
    ch4->FFVel=0;
    ch4->MaxI=200;
    ch4->MaxErr=20000;
    ch4->MaxOutput=200;
    ch4->DeadBandGain=1;
    ch4->DeadBandRange=0;
    ch4->InputChan0=4;
    ch4->InputChan1=1;
    ch4->OutputChan0=14;
    ch4->OutputChan1=1;
    ch4->MasterAxis=-1;
    ch4->LimitSwitchOptions=0x100;
    ch4->LimitSwitchNegBit=0;
    ch4->LimitSwitchPosBit=0;
    ch4->SoftLimitPos=1e+009;
    ch4->SoftLimitNeg=-1e+009;
    ch4->InputGain0=1;
    ch4->InputGain1=1;
    ch4->InputOffset0=0;
    ch4->InputOffset1=0;
    ch4->OutputGain=1;
    ch4->OutputOffset=0;
    ch4->SlaveGain=1;
    ch4->BacklashMode=BACKLASH_OFF;
    ch4->BacklashAmount=0;
    ch4->BacklashRate=0;
    ch4->invDistPerCycle=1;
    ch4->Lead=0;
    ch4->MaxFollowingError=10000000;
    ch4->StepperAmplitude=250;

    ch4->iir[0].B0=1;
    ch4->iir[0].B1=0;
    ch4->iir[0].B2=0;
    ch4->iir[0].A1=0;
    ch4->iir[0].A2=0;

    ch4->iir[1].B0=1;
    ch4->iir[1].B1=0;
    ch4->iir[1].B2=0;
    ch4->iir[1].A1=0;
    ch4->iir[1].A2=0;

    ch4->iir[2].B0=1;
    ch4->iir[2].B1=0;
    ch4->iir[2].B2=0;
    ch4->iir[2].A1=0;
    ch4->iir[2].A2=0;

Is it possible that because this axis only moves in 1 direction that the movement over several hundred parts is putting the soft limits at the max? The only thing in the console window that looked like it might be an error was Result=0. I couldn't find this reference in any of the CSS programs.

Thanks in advance,
David.






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