Re: [Emc-users] DRO Input?

2008-02-01 Thread davenull

> Message: 9
> Date: Thu, 31 Jan 2008 13:36:51 -0800
> From: Dave Engvall <[EMAIL PROTECTED]>
> Subject: Re: [Emc-users] DRO input?

>
> Hi Dave,
>
> It all depends on what you want to do. If you just want manual
> position then the glass scales will do your job.
>
> However, if you ever intend to control the axes then encoders mounted
> on the end of the ball screws would be my choice. USdigital or
> Automation Direct (Koyo) encoders are reasonably priced and should do
> the job.


With respect to you all, I know about encoders, and I know any CNC control
software is going to need positional input many, many times per second.

but... sticking an encoder on an axis is not measuring the position of
anything except the leadscrew, it takes no account whatsoever of backlash,
uneven wear or pitch errors.

To a certain extent you can map out backlash and areas of wear on a
leadscrew, but leadscrew pitch errors are going to be tough.

The DRO is, quite differently, measuring the *actual* X Y Z position, if
the DRO says you are 100.000 mm from point A then you can take it to the
bank.

My leadscrews are ten turns to the inch, I can compensate for backlash etc
manually, second nature, and even with less than theoretically perfect
accuracy I can still trust feeding a leadscrew in a few thou and know and
measure that the error on that movement is very small.

We appear to be confusing two things.

Encoding leadscrew rotational angles and feeding this back to the human
brain or CNC software, and factoring in mental or electronic fudge tables
for backlash and wear, can give us fairly good accuracy of MOVEMENT.

A DRO with proper glass scales gives us fairly good accuracy of POSITION.

5 times a second is *plenty* for an accurate positional measurement system
to update an accurate movement system, and produce a system with true
accuracy.

While leadscrew encoders and a copy of emc and no stepper or servo motors
will indeed give me a system that will display X Y Z co-ordinates on a
screen, the accuracy of these readings is going to be just as suspect as
it is sans emc and encoders, only the DRO and pukka glass scales will give
true positional accuracy.

As someone who couldn't code "hello world" (except maybe in BASIC) writing
the code isn't an option, so unless emc has this facility on the roadmap
then being free as in beer isn't enough.

Many thanks to all, hopefully there is some more meat in this subject yet.

end



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Re: [Emc-users] DRO Input?

2008-02-01 Thread Chris Morley

Dave.

I would say all the advice given to you is sort of a shot in the dark- until 
you tell us your intentions with your equipment. Of course what you do with the 
advice is up to you.
  As far EMC and serial input from a DRO goes - there is no driver currently to 
do what you ask, but it could be written. One would need some information about 
the DRO  first.
 Another idea is you could feed the scales output to EMC then Get EMC to output 
a signal to your DRO (assuming the scales output square wave signals)
The question is why?

Cheers
Chris Morley  

> Date: Fri, 1 Feb 2008 10:07:32 +
> From: [EMAIL PROTECTED]
> To: emc-users@lists.sourceforge.net
> Subject: Re: [Emc-users] DRO Input?
> 
> 
>> Message: 9
>> Date: Thu, 31 Jan 2008 13:36:51 -0800
>> From: Dave Engvall 
>> Subject: Re: [Emc-users] DRO input?
> 
>>
>> Hi Dave,
>>
>> It all depends on what you want to do. If you just want manual
>> position then the glass scales will do your job.
>>
>> However, if you ever intend to control the axes then encoders mounted
>> on the end of the ball screws would be my choice. USdigital or
>> Automation Direct (Koyo) encoders are reasonably priced and should do
>> the job.
> 
> 
> With respect to you all, I know about encoders, and I know any CNC control
> software is going to need positional input many, many times per second.
> 
> but... sticking an encoder on an axis is not measuring the position of
> anything except the leadscrew, it takes no account whatsoever of backlash,
> uneven wear or pitch errors.
> 
> To a certain extent you can map out backlash and areas of wear on a
> leadscrew, but leadscrew pitch errors are going to be tough.
> 
> The DRO is, quite differently, measuring the *actual* X Y Z position, if
> the DRO says you are 100.000 mm from point A then you can take it to the
> bank.
> 
> My leadscrews are ten turns to the inch, I can compensate for backlash etc
> manually, second nature, and even with less than theoretically perfect
> accuracy I can still trust feeding a leadscrew in a few thou and know and
> measure that the error on that movement is very small.
> 
> We appear to be confusing two things.
> 
> Encoding leadscrew rotational angles and feeding this back to the human
> brain or CNC software, and factoring in mental or electronic fudge tables
> for backlash and wear, can give us fairly good accuracy of MOVEMENT.
> 
> A DRO with proper glass scales gives us fairly good accuracy of POSITION.
> 
> 5 times a second is *plenty* for an accurate positional measurement system
> to update an accurate movement system, and produce a system with true
> accuracy.
> 
> While leadscrew encoders and a copy of emc and no stepper or servo motors
> will indeed give me a system that will display X Y Z co-ordinates on a
> screen, the accuracy of these readings is going to be just as suspect as
> it is sans emc and encoders, only the DRO and pukka glass scales will give
> true positional accuracy.
> 
> As someone who couldn't code "hello world" (except maybe in BASIC) writing
> the code isn't an option, so unless emc has this facility on the roadmap
> then being free as in beer isn't enough.
> 
> Many thanks to all, hopefully there is some more meat in this subject yet.
> 
> end
> 
> 
> 
> -
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Re: [Emc-users] DRO Input?

2008-02-01 Thread RogerN
Would it be difficult to update the actual position with the position 
from the linear encoders?  The DRO position would just stomp on the 
actual position.  Hopefully most of the time the error would be small 
and it would require real time DRO position... or perhaps only assign 
the DRO value when the axis is moving very slow or stopped.

- Original Message - 
From: <[EMAIL PROTECTED]>
To: 
Sent: Friday, February 01, 2008 4:07 AM
Subject: Re: [Emc-users] DRO Input?


>
>> Message: 9
>> Date: Thu, 31 Jan 2008 13:36:51 -0800
>> From: Dave Engvall <[EMAIL PROTECTED]>
>> Subject: Re: [Emc-users] DRO input?
>
>>
>> Hi Dave,
>>
>> It all depends on what you want to do. If you just want manual
>> position then the glass scales will do your job.
>>
>> However, if you ever intend to control the axes then encoders mounted
>> on the end of the ball screws would be my choice. USdigital or
>> Automation Direct (Koyo) encoders are reasonably priced and should do
>> the job.
>
>
> With respect to you all, I know about encoders, and I know any CNC 
> control
> software is going to need positional input many, many times per 
> second.
>
> but... sticking an encoder on an axis is not measuring the position of
> anything except the leadscrew, it takes no account whatsoever of 
> backlash,
> uneven wear or pitch errors.
>
> To a certain extent you can map out backlash and areas of wear on a
> leadscrew, but leadscrew pitch errors are going to be tough.
>
> The DRO is, quite differently, measuring the *actual* X Y Z position, 
> if
> the DRO says you are 100.000 mm from point A then you can take it to 
> the
> bank.
>
> My leadscrews are ten turns to the inch, I can compensate for backlash 
> etc
> manually, second nature, and even with less than theoretically perfect
> accuracy I can still trust feeding a leadscrew in a few thou and know 
> and
> measure that the error on that movement is very small.
>
> We appear to be confusing two things.
>
> Encoding leadscrew rotational angles and feeding this back to the 
> human
> brain or CNC software, and factoring in mental or electronic fudge 
> tables
> for backlash and wear, can give us fairly good accuracy of MOVEMENT.
>
> A DRO with proper glass scales gives us fairly good accuracy of 
> POSITION.
>
> 5 times a second is *plenty* for an accurate positional measurement 
> system
> to update an accurate movement system, and produce a system with true
> accuracy.
>
> While leadscrew encoders and a copy of emc and no stepper or servo 
> motors
> will indeed give me a system that will display X Y Z co-ordinates on a
> screen, the accuracy of these readings is going to be just as suspect 
> as
> it is sans emc and encoders, only the DRO and pukka glass scales will 
> give
> true positional accuracy.
>
> As someone who couldn't code "hello world" (except maybe in BASIC) 
> writing
> the code isn't an option, so unless emc has this facility on the 
> roadmap
> then being free as in beer isn't enough.
>
> Many thanks to all, hopefully there is some more meat in this subject 
> yet.
>
> end
>
>
>
> -
> This SF.net email is sponsored by: Microsoft
> Defy all challenges. Microsoft(R) Visual Studio 2008.
> http://clk.atdmt.com/MRT/go/vse012070mrt/direct/01/
> ___
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> Emc-users@lists.sourceforge.net
> https://lists.sourceforge.net/lists/listinfo/emc-users 


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Re: [Emc-users] Emc-users DRO input?

2008-02-01 Thread John Thornton
That is how my DRO's work that I built for my mill and lathe.

http://www.shumatech.com/

John
On 31 Jan 2008 at 18:04, [EMAIL PROTECTED] wrote:

> Another thought, is there any value in having an RS-232 connection
> with serial calipers or micrometers?



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Re: [Emc-users] DRO input?

2008-02-01 Thread John Thornton
That would depend on the accuracy of your scales... .4" precision 
(.001mm)is 
not cheap...

In my case mine are not nearly that accurate...

I guess it depends on how much accuracy is needed and the future of the machine.

EMC does have screw mapping...

John

On 1 Feb 2008 at 4:04, [EMAIL PROTECTED] wrote:

> The DRO is, quite differently, measuring the *actual* X Y Z position,
> if the DRO says you are 100.000 mm from point A then you can take it
> to the bank.





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Re: [Emc-users] Emc-users DRO input?

2008-02-01 Thread Kirk Wallace
On Fri, 2008-02-01 at 06:03 -0600, John Thornton wrote:
> That is how my DRO's work that I built for my mill and lathe.
> 
> http://www.shumatech.com/
> 
> John
> On 31 Jan 2008 at 18:04, [EMAIL PROTECTED] wrote:
> 
> > Another thought, is there any value in having an RS-232 connection
> > with serial calipers or micrometers?

That's a nice setup DRO system and website you have. I was fishing for a
reason to have a serial micrometer connected to EMC for a reason other
than as motion feed back or axis position. For instance, to automate
offset adjustments, or something like Will Ferrell said in Old School,
"Maybe she's wearing something I haven't even thought of yet."

-- 
Kirk Wallace (California, USA
http://www.wallacecompany.com/machine_shop/ 
Hardinge HNC lathe,
Bridgeport mill conversion, doing XY now,
Zubal lathe conversion pending)


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Re: [Emc-users] DRO input?

2008-02-01 Thread Jon Elson
Dave Engvall wrote:
> 
> Yep! Wilson machine bought a 50' x 4' CMM at a Boeing auction. Got it  
> cheap and spent a million moving it and
> getting it set up again.  And that was only a few miles.
Holy COW!  a 50 FOOT CMM?  There must only be 2 or 3 in the 
entire US that big.  (I can understand why Boeing would need 
such a machine.)

Jon

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Re: [Emc-users] DRO Input?

2008-02-01 Thread Jon Elson
[EMAIL PROTECTED] wrote:

> but... sticking an encoder on an axis is not measuring the position of
> anything except the leadscrew, it takes no account whatsoever of backlash,
> uneven wear or pitch errors.
> 
> To a certain extent you can map out backlash and areas of wear on a
> leadscrew, but leadscrew pitch errors are going to be tough.
> 
You can "map" backlash, but you can't FIX it in software. 
Backlash means the table position is NOT fully constrained.
EMC2 already has the capability to fix pitch irregularity, you 
just need to do the tedious measurement with gage blocks once 
and enter the data.

> 5 times a second is *plenty* for an accurate positional measurement system
> to update an accurate movement system, and produce a system with true
> accuracy.
> 
Not when the machine is moving at 60 IPM, doing a climb-mill cut.

Jon

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Re: [Emc-users] DRO Input?

2008-02-01 Thread Jon Elson
RogerN wrote:
> Would it be difficult to update the actual position with the position 
> from the linear encoders?  The DRO position would just stomp on the 
> actual position.  Hopefully most of the time the error would be small 
> and it would require real time DRO position... or perhaps only assign 
> the DRO value when the axis is moving very slow or stopped.
How about when moving at 60 IPM?  What is the time delay in the 
DRO software?  I've seen a number of good DROs that have 
SIGNIFICANT delays in the update, and settle once you slow down.
If the serial output from the DRO box has a 1/4 second delay, 
and the servo is running at 1000 updates a second, you can only 
re-sync when you KNOW the machine is dead still.  A true servo 
is NEVER dead-still, it is always bouncing between adjacent 
encoder counts.

Jon

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Re: [Emc-users] DRO Input?

2008-02-01 Thread Jon Elson
RogerN wrote:
> Would it be difficult to update the actual position with the position 
> from the linear encoders?  The DRO position would just stomp on the 
> actual position.  Hopefully most of the time the error would be small 
> and it would require real time DRO position... or perhaps only assign 
> the DRO value when the axis is moving very slow or stopped.
How about when moving at 60 IPM?  What is the time delay in the 
DRO software?  I've seen a number of good DROs that have 
SIGNIFICANT delays in the update, and settle once you slow down.
If the serial output from the DRO box has a 1/4 second delay, 
and the servo is running at 1000 updates a second, you can only 
re-sync when you KNOW the machine is dead still.  A true servo 
is NEVER dead-still, it is always bouncing between adjacent 
encoder counts.

Jon

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Re: [Emc-users] DRO input?

2008-02-01 Thread jcombs
>>
>> Yep! Wilson machine bought a 50' x 4' CMM at a Boeing auction. Got it
>> cheap and spent a million moving it and
>> getting it set up again.  And that was only a few miles.
>Holy COW!  a 50 FOOT CMM?  There must only be 2 or 3 in the
>entire US that big.  (I can understand why Boeing would need
>such a machine.)


50 foot at .0001 / Inch  resolution would almost be at the limit for a 32
bit unsigned integer!  I could see some
really strange software bugs begin to show up. (Signed vs unsigned
integers).  Would a double precision
float handle that?

Yikes!

0xD693A400 - or something like that.

Jim Combs



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Re: [Emc-users] DRO Input?

2008-02-01 Thread Anders Blix
I have a different idea.

Why not tap in to the signal from the encoders themselves? If this is glass
scales with proper quadrature output it should be simple to read this
signals by a cheap card? There is nothing that says the quadrature signals
can't be read by both EMC and the DRO main unit. 

I plan to do this myself. I also bought a far eastern DRO with glass scales
and hope to be able to tap in to the signals being transmitted by the
scales. I have a Universal Stepper Card with quadrature inputs. 
At the same time it is quite nice to have the DRO for manual milling.

Does anyone have a good reason for not doing this? I should possibly use
optoisolators though, right?

Anders 

> -Original Message-
> From: [EMAIL PROTECTED] [mailto:emc-users-
> [EMAIL PROTECTED] On Behalf Of Chris Morley
> Sent: 1. februar 2008 12:02
> To: Enhanced Machine Controller (EMC)
> Subject: Re: [Emc-users] DRO Input?
> 
> 
> Dave.
> 
> I would say all the advice given to you is sort of a shot in the dark-
> until you tell us your intentions with your equipment. Of course what you
> do with the advice is up to you.
>   As far EMC and serial input from a DRO goes - there is no driver
> currently to do what you ask, but it could be written. One would need some
> information about the DRO  first.
>  Another idea is you could feed the scales output to EMC then Get EMC to
> output a signal to your DRO (assuming the scales output square wave
> signals)
> The question is why?
> 
> Cheers
> Chris Morley
> 
> > Date: Fri, 1 Feb 2008 10:07:32 +
> > From: [EMAIL PROTECTED]
> > To: emc-users@lists.sourceforge.net
> > Subject: Re: [Emc-users] DRO Input?
> >
> >
> >> Message: 9
> >> Date: Thu, 31 Jan 2008 13:36:51 -0800
> >> From: Dave Engvall
> >> Subject: Re: [Emc-users] DRO input?
> >
> >>
> >> Hi Dave,
> >>
> >> It all depends on what you want to do. If you just want manual
> >> position then the glass scales will do your job.
> >>
> >> However, if you ever intend to control the axes then encoders mounted
> >> on the end of the ball screws would be my choice. USdigital or
> >> Automation Direct (Koyo) encoders are reasonably priced and should do
> >> the job.
> >
> >
> > With respect to you all, I know about encoders, and I know any CNC
> control
> > software is going to need positional input many, many times per second.
> >
> > but... sticking an encoder on an axis is not measuring the position of
> > anything except the leadscrew, it takes no account whatsoever of
> backlash,
> > uneven wear or pitch errors.
> >
> > To a certain extent you can map out backlash and areas of wear on a
> > leadscrew, but leadscrew pitch errors are going to be tough.
> >
> > The DRO is, quite differently, measuring the *actual* X Y Z position, if
> > the DRO says you are 100.000 mm from point A then you can take it to the
> > bank.
> >
> > My leadscrews are ten turns to the inch, I can compensate for backlash
> etc
> > manually, second nature, and even with less than theoretically perfect
> > accuracy I can still trust feeding a leadscrew in a few thou and know
> and
> > measure that the error on that movement is very small.
> >
> > We appear to be confusing two things.
> >
> > Encoding leadscrew rotational angles and feeding this back to the human
> > brain or CNC software, and factoring in mental or electronic fudge
> tables
> > for backlash and wear, can give us fairly good accuracy of MOVEMENT.
> >
> > A DRO with proper glass scales gives us fairly good accuracy of
> POSITION.
> >
> > 5 times a second is *plenty* for an accurate positional measurement
> system
> > to update an accurate movement system, and produce a system with true
> > accuracy.
> >
> > While leadscrew encoders and a copy of emc and no stepper or servo
> motors
> > will indeed give me a system that will display X Y Z co-ordinates on a
> > screen, the accuracy of these readings is going to be just as suspect as
> > it is sans emc and encoders, only the DRO and pukka glass scales will
> give
> > true positional accuracy.
> >
> > As someone who couldn't code "hello world" (except maybe in BASIC)
> writing
> > the code isn't an option, so unless emc has this facility on the roadmap
> > then being free as in beer isn't enough.
> >
> > Many thanks to all, hopefully there is some more meat in this subject
> yet.
> >
> > end
> >
> >
> >
> > 
> -
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> > Defy all challenges. Microsoft(R) Visual Studio 2008.
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Re: [Emc-users] DRO Input?

2008-02-01 Thread Kirk Wallace
On Fri, 2008-02-01 at 23:19 +0100, Anders Blix wrote:
> I have a different idea.
> 
> Why not tap in to the signal from the encoders themselves? If this is glass
> scales with proper quadrature output it should be simple to read this
> signals by a cheap card? There is nothing that says the quadrature signals
> can't be read by both EMC and the DRO main unit. 
> 
> I plan to do this myself. I also bought a far eastern DRO with glass scales
> and hope to be able to tap in to the signals being transmitted by the
> scales. I have a Universal Stepper Card with quadrature inputs. 
> At the same time it is quite nice to have the DRO for manual milling.
> 
> Does anyone have a good reason for not doing this? I should possibly use
> optoisolators though, right?
> 
> Anders 

I don't see why you need the DRO unit. EMC makes for a good DRO as well
as a motion controller and desert topping. See here:

http://www.wallacecompany.com/machine_shop/EMC2/dro_vfd/

You can change between EMC and EMC/DRO by running the appropriate file.

-- 
Kirk Wallace (California, USA
http://www.wallacecompany.com/machine_shop/ 
Hardinge HNC lathe,
Bridgeport mill conversion, doing XY now,
Zubal lathe conversion pending)


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[Emc-users] Serial DAC Done (Almost)

2008-02-01 Thread Kirk Wallace
I have just successfully tested my serial DAC with my VFD's and KBIC.
It's kind of strange to see it work with the KBIC, since it is floating
at about 70 Volts AC, but it works fine. See here:

http://www.wallacecompany.com/machine_shop/EMC2/serial_dac/

If anyone is interested, I can make a parts list, layout a real board
and have boards etched and silk-screened.

At least three parallel port pins are needed. The Clock and Data pins
can run to multiple serial devices. A Load pin is needed for each
device.

I did a breadboard of the serial ADC, which is working, and an H-bridge
to be used as a DC motor reverser on the KBIC, and so far it's also
working well.

-- 
Kirk Wallace (California, USA
http://www.wallacecompany.com/machine_shop/ 
Hardinge HNC lathe,
Bridgeport mill conversion, doing XY now,
Zubal lathe conversion pending)


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Re: [Emc-users] DRO input?

2008-02-01 Thread Jon Elson
[EMAIL PROTECTED] wrote:
>>>Yep! Wilson machine bought a 50' x 4' CMM at a Boeing auction. Got it
>>>cheap and spent a million moving it and
>>>getting it set up again.  And that was only a few miles.
>>
>>Holy COW!  a 50 FOOT CMM?  There must only be 2 or 3 in the
>>entire US that big.  (I can understand why Boeing would need
>>such a machine.)
> 
> 
> 
> 50 foot at .0001 / Inch  resolution would almost be at the limit for a 32
> bit unsigned integer!  I could see some
> really strange software bugs begin to show up. (Signed vs unsigned
> integers).  Would a double precision
> float handle that?
That's a good point.  I vaguely seem to recall the OLD EMC(1) 
overflowed the 32-bit raw encoder count into a double float.
The current version just goes to a 32-bit signed value (unless 
this has been changed recently).  I was wondering if that would 
ever be a problem.

Hmm, calculating it, I get 50 * 12 * 1 = 6 million, which is
not anywhere near 4 billion, or even +/- 2 billion, which is 
what the numerical limits of a 32-bit integer are.

I calculate that 2^31 / ( 1 * 12) = 17896.xxx FEET, which 
sounds like it is a lot less of a problem.

Jon

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Re: [Emc-users] DRO input?

2008-02-01 Thread Dave Engvall


On Feb 1, 2008, at 8:12 PM, Jon Elson wrote:


[EMAIL PROTECTED] wrote:
Yep! Wilson machine bought a 50' x 4' CMM at a Boeing auction.  
Got it

cheap and spent a million moving it and
getting it set up again.  And that was only a few miles.


Holy COW!  a 50 FOOT CMM?  There must only be 2 or 3 in the
entire US that big.  (I can understand why Boeing would need
such a machine.)




50 foot at .0001 / Inch  resolution would almost be at the limit  
for a 32

bit unsigned integer!  I could see some
really strange software bugs begin to show up. (Signed vs unsigned
integers).  Would a double precision
float handle that?

That's a good point.  I vaguely seem to recall the OLD EMC(1)
overflowed the 32-bit raw encoder count into a double float.
The current version just goes to a 32-bit signed value (unless
this has been changed recently).  I was wondering if that would
ever be a problem.

Hmm, calculating it, I get 50 * 12 * 1 = 6 million, which is
not anywhere near 4 billion, or even +/- 2 billion, which is
what the numerical limits of a 32-bit integer are.

I calculate that 2^31 / ( 1 * 12) = 17896.xxx FEET, which
sounds like it is a lot less of a problem.


Putting a face on it  with a bit of arithmetic always helps.

Dave


Jon

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