Reset kflop board

[Tarasevih]

Hi Tom.
I just can't get this to work.
I think the board is being reset.
During a tool change, the program freezes and after a while reports a connection error.

During milling, an error appears at different times and stops work.

Regards,
Taras.

[TomKerekes]

Hi Taras,

During a tool change, the program freezes and after a while reports a connection error.

What is your Tool Change doing?

During milling, an error appears at different times and stops work.

It is indicating the axes are disabled. Are they? Run KMotion.exe and when the error occurs check for any messages on the Console Screen.

[Tarasevih]

Hi Tom.
I found the reasons why the automatic tool changer did not work.
The problem occurred when the chip brush lowering valve was turned on.
I installed freewheeling diodes in parallel with all valve windings and the problem disappeared.
However, the problem with stopping during milling is still relevant.
Tomorrow I'll try to look at the console after stopping.

Regards,
Taras.

[Tarasevih]

I want to show what I'm working on.
Here's a video of the problem.
https://www.youtube.com/watch?v=0Q77vpXCm3Y

[Tarasevih]

Hi Tom.
Unfortunately, the problem is not so easy to catch.
It’s a pity that the program does not have any quality control for the USB connection.
The branched reset line also haunts me.
It is impossible to track the reason why processing stops. Perhaps due to the reset line or due to data loss via USB?
It’s bad that there are no tools for finding and debugging situations like mine.

[Tarasevih]

Hi Tom.
I'm trying to fix the problem but it's no use.
The system simply turns off during milling at different times and stops functioning without any visible errors.

This happens with the spindle on.
Nothing is reported to the console, it just stops and that’s it.
I have already done so much that I don’t know what to do next.
You don't answer me either Tom.


Regards,
Taras.

[TomKerekes]

It doesn't seem to be an issue with USB or "turning off" or there would be a disconnect message.

Instead it says "Axis Disabled". Are the Axes disabled? Check with the KMotion Axis Screen. Do you have anything that would disable the axes?

Please post your Initialization C Program and Home Programs.

What Version are you using?

[Tarasevih]

Hi Tom.
The problem turned out to be the EMI filter.
After replacing the filter, the stops disappeared.
The only thing that remains unclear is why the program did not produce any errors but simply stopped citing a G code error?
Regards,
Taras.

[TomKerekes]

Hi Taras,

The reported error was "Axis Disabled". The GCode stopped because an Axis was disabled. That's why I asked you to post those things.

[Tarasevih]

Hi Tom.
initialization file

Code: Select all

#include "KMotionDef.h"

#define AXISX 0
#define AXISYA 1
#define AXISYB 2
#define AXISZ 3

#define MPG_INPUT_AXIS 7    // Axis used to read hardware encoder (not necessarily the encoder channel)// Ось, используемая для чтения аппаратного энкодера (не обязательно канала энкодера)

#define TAU0  0.01			// smoothness factor (Low Pass Time constant seconds for MoveExp)// коэффициент гладкости (постоянная времени низкого прохода в секундах для MoveExp)
#define TAU1 0.015			// smoothness factor (Low Pass Time constant seconds for pre filter 1)// коэффициент гладкости (постоянная времени прохождения нижних частот в секундах для предварительного фильтра 1)
#define TAU2 0.015			// smoothness factor (Low Pass Time constant seconds for pre filter 2)// коэффициент гладкости (постоянная времени прохождения нижних частот в секундах для предварительного фильтра 2)
#define FINAL_TIME 1.0		// Set final dest after this amount of time with no change// Устанавливаем конечную цель по истечении этого времени без изменений

#define ENABLE_MPG 1050       // Switch/Button used to enable MPG Motion// Переключатель/кнопка, используемая для включения MPG Motion
#define FACTOR1 28
#define FACTOR10 30
#define FACTOR100 32

#define SELECTX 16
#define SELECTY 18
#define SELECTZ 29
#define SELECTA 30
#define Estop 7
#define MPG_Estop 31
#define Spindle_CW 27
#define Estop_Bit 1030
void ServiceMPG(void);

int main() 
{
	double T0, LastX=0, LastY=0, LastZ=0, LastA=0, Tau;
	
	KStepPresent=FALSE;      // enable KSTEP input multiplexing
	FPGA(KAN_TRIG_REG)=0;  	// Mux PWM0 to JP7 Pin5 IO 44 for KSTEP 

	FPGA(STEP_PULSE_LENGTH_ADD) = 63 + 0x80;  // set polarity and pulse length to 4us
	
	ch0->InputMode=NO_INPUT_MODE;
	ch0->OutputMode=STEP_DIR_MODE;
	ch0->Vel=26660;
	ch0->Accel=150000;
	ch0->Jerk=4e+06;
	ch0->P=0;
	ch0->I=0.01;
	ch0->D=0;
	ch0->FFAccel=0;
	ch0->FFVel=0;
	ch0->MaxI=200;
	ch0->MaxErr=1e+06;
	ch0->MaxOutput=200;
	ch0->DeadBandGain=1;
	ch0->DeadBandRange=0;
	ch0->InputChan0=0;
	ch0->InputChan1=0;
	ch0->OutputChan0=0;
	ch0->OutputChan1=0;
	ch0->MasterAxis=-1;
	ch0->LimitSwitchOptions=0x110;
	ch0->LimitSwitchNegBit=0;
	ch0->LimitSwitchPosBit=0;
	ch0->SoftLimitPos=1e+30;
	ch0->SoftLimitNeg=-1e+30;
	ch0->InputGain0=1;
	ch0->InputGain1=1;
	ch0->InputOffset0=0;
	ch0->InputOffset1=0;
	ch0->OutputGain=-1;
	ch0->OutputOffset=0;
	ch0->SlaveGain=1;
	ch0->BacklashMode=BACKLASH_OFF;
	ch0->BacklashAmount=0;
	ch0->BacklashRate=0;
	ch0->invDistPerCycle=1;
	ch0->Lead=0;
	ch0->MaxFollowingError=1000000000;
	ch0->StepperAmplitude=20;

	ch0->iir[0].B0=1;
	ch0->iir[0].B1=0;
	ch0->iir[0].B2=0;
	ch0->iir[0].A1=0;
	ch0->iir[0].A2=0;

	ch0->iir[1].B0=1;
	ch0->iir[1].B1=0;
	ch0->iir[1].B2=0;
	ch0->iir[1].A1=0;
	ch0->iir[1].A2=0;

	ch0->iir[2].B0=0.000769;
	ch0->iir[2].B1=0.001538;
	ch0->iir[2].B2=0.000769;
	ch0->iir[2].A1=1.92076;
	ch0->iir[2].A2=-0.923833;
    EnableAxisDest(0,0);

	ch1->InputMode=NO_INPUT_MODE;
	ch1->OutputMode=STEP_DIR_MODE;
	ch1->Vel=26660;
	ch1->Accel=150000;
	ch1->Jerk=4e+06;
	ch1->P=0;
	ch1->I=0.01;
	ch1->D=0;
	ch1->FFAccel=0;
	ch1->FFVel=0;
	ch1->MaxI=200;
	ch1->MaxErr=1e+06;
	ch1->MaxOutput=200;
	ch1->DeadBandGain=1;
	ch1->DeadBandRange=0;
	ch1->InputChan0=0;
	ch1->InputChan1=0;
	ch1->OutputChan0=1;
	ch1->OutputChan1=0;
	ch1->MasterAxis=-1;
	ch1->LimitSwitchOptions=0x110;
	ch1->LimitSwitchNegBit=0;
	ch1->LimitSwitchPosBit=0;
	ch1->SoftLimitPos=1e+30;
	ch1->SoftLimitNeg=-1e+30;
	ch1->InputGain0=1;
	ch1->InputGain1=1;
	ch1->InputOffset0=0;
	ch1->InputOffset1=0;
	ch1->OutputGain=-1;
	ch1->OutputOffset=0;
	ch1->SlaveGain=1;
	ch1->BacklashMode=BACKLASH_OFF;
	ch1->BacklashAmount=0;
	ch1->BacklashRate=0;
	ch1->invDistPerCycle=1;
	ch1->Lead=0;
	ch1->MaxFollowingError=1000000000;
	ch1->StepperAmplitude=20;

	ch1->iir[0].B0=1;
	ch1->iir[0].B1=0;
	ch1->iir[0].B2=0;
	ch1->iir[0].A1=0;
	ch1->iir[0].A2=0;

	ch1->iir[1].B0=1;
	ch1->iir[1].B1=0;
	ch1->iir[1].B2=0;
	ch1->iir[1].A1=0;
	ch1->iir[1].A2=0;

	ch1->iir[2].B0=0.000769;
	ch1->iir[2].B1=0.001538;
	ch1->iir[2].B2=0.000769;
	ch1->iir[2].A1=1.92076;
	ch1->iir[2].A2=-0.923833;
    EnableAxisDest(1,0);

	ch2->InputMode=NO_INPUT_MODE;
	ch2->OutputMode=STEP_DIR_MODE;
	ch2->Vel=26660;
	ch2->Accel=150000;
	ch2->Jerk=4e+06;
	ch2->P=0;
	ch2->I=0.01;
	ch2->D=0;
	ch2->FFAccel=0;
	ch2->FFVel=0;
	ch2->MaxI=200;
	ch2->MaxErr=1e+06;
	ch2->MaxOutput=200;
	ch2->DeadBandGain=1;
	ch2->DeadBandRange=0;
	ch2->InputChan0=0;
	ch2->InputChan1=0;
	ch2->OutputChan0=2;
	ch2->OutputChan1=0;
	ch2->MasterAxis=1;
	ch2->LimitSwitchOptions=0x110;
	ch2->LimitSwitchNegBit=0;
	ch2->LimitSwitchPosBit=0;
	ch2->SoftLimitPos=1e+30;
	ch2->SoftLimitNeg=-1e+30;
	ch2->InputGain0=1;
	ch2->InputGain1=1;
	ch2->InputOffset0=0;
	ch2->InputOffset1=0;
	ch2->OutputGain=1;
	ch2->OutputOffset=0;
	ch2->SlaveGain=1;
	ch2->BacklashMode=BACKLASH_OFF;
	ch2->BacklashAmount=0;
	ch2->BacklashRate=0;
	ch2->invDistPerCycle=1;
	ch2->Lead=0;
	ch2->MaxFollowingError=1000000000;
	ch2->StepperAmplitude=20;

	ch2->iir[0].B0=1;
	ch2->iir[0].B1=0;
	ch2->iir[0].B2=0;
	ch2->iir[0].A1=0;
	ch2->iir[0].A2=0;

	ch2->iir[1].B0=1;
	ch2->iir[1].B1=0;
	ch2->iir[1].B2=0;
	ch2->iir[1].A1=0;
	ch2->iir[1].A2=0;

	ch2->iir[2].B0=1;
	ch2->iir[2].B1=0;
	ch2->iir[2].B2=0;
	ch2->iir[2].A1=0;
	ch2->iir[2].A2=0;
	EnableAxisDest(2,0);
	
	ch3->InputMode=NO_INPUT_MODE;
	ch3->OutputMode=STEP_DIR_MODE;
	ch3->Vel=20000;
	ch3->Accel=150000;
	ch3->Jerk=4e+06;
	ch3->P=0;
	ch3->I=0.01;
	ch3->D=0;
	ch3->FFAccel=0;
	ch3->FFVel=0;
	ch3->MaxI=200;
	ch3->MaxErr=1e+06;
	ch3->MaxOutput=200;
	ch3->DeadBandGain=1;
	ch3->DeadBandRange=0;
	ch3->InputChan0=0;
	ch3->InputChan1=0;
	ch3->OutputChan0=3;
	ch3->OutputChan1=0;
	ch3->MasterAxis=-1;
	ch3->LimitSwitchOptions=0x110;
	ch3->LimitSwitchNegBit=0;
	ch3->LimitSwitchPosBit=0;
	ch3->SoftLimitPos=1e+30;
	ch3->SoftLimitNeg=-1e+30;
	ch3->InputGain0=1;
	ch3->InputGain1=1;
	ch3->InputOffset0=0;
	ch3->InputOffset1=0;
	ch3->OutputGain=-1;
	ch3->OutputOffset=0;
	ch3->SlaveGain=1;
	ch3->BacklashMode=BACKLASH_OFF;
	ch3->BacklashAmount=0;
	ch3->BacklashRate=0;
	ch3->invDistPerCycle=1;
	ch3->Lead=0;
	ch3->MaxFollowingError=1000000000;
	ch3->StepperAmplitude=20;

	ch3->iir[0].B0=1;
	ch3->iir[0].B1=0;
	ch3->iir[0].B2=0;
	ch3->iir[0].A1=0;
	ch3->iir[0].A2=0;

	ch3->iir[1].B0=1;
	ch3->iir[1].B1=0;
	ch3->iir[1].B2=0;
	ch3->iir[1].A1=0;
	ch3->iir[1].A2=0;

	ch3->iir[2].B0=0.000769;
	ch3->iir[2].B1=0.001538;
	ch3->iir[2].B2=0.000769;
	ch3->iir[2].A1=1.92076;
	ch3->iir[2].A2=-0.923833;
	EnableAxisDest(3,0);
	
	DefineCoordSystem(0,1,3,-1);
	
//  Add a small amount of Coordinated Motion Path smoothing if desired
//	Tau = 0.001;  // seconds for Low Pass Filter Time Constant
//	KLP = exp(-TIMEBASE/Tau);
	KLP=0; // force to 0 to disable
//	printf("Tau=%f KLP=%f\n",Tau,KLP);
	SetBitDirection(Spindle_CW,1);            //настроим как выход 
	SetBitDirection(17,1);                    //настроим как выход 
	SetBitDirection(33,1);                    //настроим как выход 
	SetBitDirection(19,1);                    //Управление щеткой настроим как выход 
	SetBitDirection(21,1);                    //Управление замком держателя инструментов настроим как выход 
	SetBitDirection(23,1);                    //Управление пневатикой датчика поиска меток настроим как выход 
	ClearBit(ENABLE_MPG);
	ClearBit(Spindle_CW);
	ClearBit(23);                             //Поднимем датчик поиска меток
	ClearBit(21);                             //Закроем замок держателя инструмента
	ClearBit(1055);                           //Отменим готовность датчика к поиску метки
	ClearBit(19);                             //Поднимем щетку 
	ClearBit(1040);                           //Выключим режим New Tool
	ClearBit(1041);                           //Потушим бит освобождения шпинделя
	ClearBit(1024);                           //выключим светодиод оси Х 
	ClearBit(1026);                           //выключим светодиод оси Y 
	ClearBit(1025);                           //выключим светодиод оси Z
	ClearBit(1027);                           //сбросим флаг занято
    
	 chan[0].SoftLimitPos = 6e+09; 
     chan[0].SoftLimitNeg = -6e+09; 
     chan[1].SoftLimitPos = 6e+09; 
     chan[1].SoftLimitNeg = -6e+09; 
     chan[2].SoftLimitPos = 6e+09; 
     chan[2].SoftLimitNeg = -6e+09; 
     chan[3].SoftLimitPos = 6e+09; 
     chan[3].SoftLimitNeg = -6e+09;
	for (;;) // loop forever
	{
		WaitNextTimeSlice();
		
		if (!ReadBit(Estop) || !ReadBit(MPG_Estop))  //!chan[AXISX].Enable || !chan[AXISYA].Enable || !chan[AXISYB].Enable || !chan[AXISZ].Enable ||
		{
			SetBit(Estop_Bit);
			ClearBit(ENABLE_MPG);
			ClearBit(Spindle_CW);
			ClearBit(23);        //Поднимем датчик поиска меток
			ClearBit(1055);      //Отменим готовность датчика к поиску метки
			ClearBit(19);        //Поднимем щетку 
			ClearBit(1040);      //Выключим режим New Tool
			ClearBit(1041);      //Потушим бит освобождения шпинделя
			if (ch0->Enable)DisableAxis(0);
			if (ch1->Enable)DisableAxis(1);
			if (ch2->Enable)DisableAxis(2);
			if (ch3->Enable)DisableAxis(3);	
		}
		else ClearBit(Estop_Bit);
		/*
		if (!ReadBit(Estop) || !ReadBit(MPG_Estop))
		{
			SetBit(Estop_Bit);
			ClearBit(ENABLE_MPG);
			ClearBit(Spindle_CW);
			ClearBit(23);
			if (ch0->Enable)DisableAxis(0);
			if (ch1->Enable)DisableAxis(1);
			if (ch2->Enable)DisableAxis(2);
			if (ch3->Enable)DisableAxis(3);		
		}
		if (ReadBit(Estop) || ReadBit(MPG_Estop))ClearBit(Estop_Bit);
		*/
		
	    if (ReadBit(ENABLE_MPG))ServiceMPG();
	}

    return 0;
}
void ServiceMPG(void)
{
	static int Pos, FirstTime = TRUE;
	static int InMotion = FALSE, Axis,Axis_old, LastAxis = -1;
	static double LastChangeTime = 0, Target, Factor = 0,Factor_old;
	static double Target1, Target2, K1, K2, K1M, K2M;

	int Change1, NewPos;

	if (FirstTime)
	{
		Pos = chan[MPG_INPUT_AXIS].Position;
		K1 = exp(-2 * TIMEBASE / TAU1);	// filter coefficients// коэффициенты фильтра
		K2 = exp(-2 * TIMEBASE / TAU2);
		K1M = 1.0 - K1;
		K2M = 1.0 - K2;
		FirstTime = FALSE;
	}

	NewPos = chan[MPG_INPUT_AXIS].Position;
	Change1 = NewPos - Pos;
	Pos = NewPos;

	if ( !ReadBit(ENABLE_MPG) || JOB_ACTIVE)	// if not button pressed or Job Active ignore the encoder.
		Change1 = 0;
	
	if (ReadBit(FACTOR1))		// is X1 selected?
		Factor = 1;
	else if (ReadBit(FACTOR10))	// is X10 selected?
		Factor = 10;
	else if (ReadBit(FACTOR100))	// is X100 selected?
		Factor = 20;
	else
		Factor = 0.0;
  
	if (ReadBit(SELECTX))		// is x selected?
		Axis = 0;
	else if (ReadBit(SELECTY))	// is y selected?
		Axis = 1;
	else if (ReadBit(SELECTZ))	// is z selected?
		Axis = 3;
	else if (ReadBit(SELECTA))	// is A selected?
		Axis = 4;
    
	// Feedhold fully stopped ??// Feedhold полностью остановлен ??
	if (CS0_StoppingState == 4 && InMotion)
	{
		Change1 = 0;			// ignore any MPG change// игнорируем любые изменения MPG
		Jog(LastAxis, 0);
		InMotion = FALSE;
	}

	// check if the Axis just changed or we have been // проверяем, изменилась ли ось только что или мы были
	// converging to the target for a long time// долго приближаемся к цели
	if (Axis != LastAxis || (InMotion && Time_sec() > LastChangeTime + FINAL_TIME))
	{
		if (InMotion)
			Move(LastAxis, Target1);	//finalize any motion//завершаем любое движение

		LastAxis = Axis;
		InMotion = FALSE;
	}

	if (Change1)				// did we move?// мы переехали?
	{
		if (!InMotion)
			Target = Target1 = Target2 = chan[Axis].Dest;
		Target1 += Change1 * Factor;
		LastChangeTime = Time_sec();
		InMotion = TRUE;
	}

	if (InMotion)				// If moving// Если двигаться
	{
		if (Target1 > chan[LastAxis].SoftLimitPos)
			Target1 = chan[LastAxis].SoftLimitPos;
		if (Target1 < chan[LastAxis].SoftLimitNeg)
			Target1 = chan[LastAxis].SoftLimitNeg;
		Target2 = Target2 * K1 + Target1 * K1M;
		Target = Target * K2 + Target2 * K2M;
		MoveExp(Axis, Target, TAU0);
	}
}

Regards,
Taras.