Re: [Emc-users] My runaway A axis problem.

2008-04-16 Thread Erik Christiansen
On Wed, Apr 16, 2008 at 10:38:40PM -0400, Gene Heskett wrote:
> So I need the silver cyanide, a small loop of silver wire I can place
> around it for the sacrificial silver, and a few volts and amps to do
> the plating.  Both are made out of pure un-obtainium out here in the
> hills of WV.

A quick google confirmed my rusty recollection that last century we
tended to use silver nitrate. It's much less toxic, but turns the skin
black wherever it touches. I found that wears off when the skin does.

e.g:
http://www.google.com.au/search?q=silver+plating+nitrate&ie=utf-8&oe=utf-8&rls=org.mozilla:en-GB:official&client=firefox-a&safe=images

IIRC, Ag goes well onto copper. It may go fine onto clean brass, I expect,
but iron needed Cu on it first, I seem to recall. (If you want it to
stay on. ;-)

I think the cyanide solution was for gold plating, and we used a
titanium anode, to avoid polluting the solution. (Which was consumed.)

hth,
Erik

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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread Jon Elson
Kirk Wallace wrote:
> 
> The IA and IB sink the LED's on two optocoupler inputs each. The high
> side of the LED's is driven by the Q and /Q quadrature signals. I am
> guessing this forms a NAND function or an Inhibit? I wonder if the
> inhibits are needed to prevent shoot-through? If that is the case I will
> need to be very careful not to allow shoot-through. Here are some
> pictures of one of the drives.
> 
> http://www.wallacecompany.com/machine_shop/Shizuoka/1-1a.jpg
> http://www.wallacecompany.com/machine_shop/Shizuoka/2-1a.jpg
> 
> I am wondering if this is just a simple H-bridge with current limit? If
> anyone has more information on this drive, I would appreciate hearing
> it.
> 

It seems to have a LOT of parts for an H-bridge, and you 
mentioned before "common" wires on the motors.  So, it sounds 
like a very typical current-limiting unipolar drive.  It would 
need 4 transistors for the unipolar phases, and then more stuff 
for the current regulator(s).  I see 4 copies of some circuitry 
at the bottom of your first picture, so I'm guessing the bottom 
4 transistors are those phase drivers.  There are 7 big diodes, 
too.  I can't quite explain the whole topology from the pics, 
but a dual H-bridge would not use the motor center taps, and 
would need 8 identical power transistors.  You have 6 identical 
TO-218 units, and 2 TO-220s and one more (different) TO-218.

Yes, it seems reasonable they need to turn off one transistor 
before turning on the opposing one.  It wouldn't actually cause 
"shoot through", but an equally rough situation due to the 
center-tapped transformer action of the motor winding.  If those 
transistors are Darlingtons (quite likely) then they can take a 
LONG time to turn off, in the several microseconds range.

Jon

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Re: [Emc-users] My runaway A axis problem.

2008-04-16 Thread Gene Heskett
On Wednesday 16 April 2008, John Kasunich wrote:
>Gene Heskett wrote:
>> I didn't time it John, but that sounds about right.  I was up to my buns
>> in a different pool of alligators, the inner filament contact for a final
>> tube in a tv transmitter & had left it running itself while I went looking
>> for some silver braze rod.  The only thing I have is some pretty old
>> nickle-silver rod whose flux has worn off from laying around.  I have it
>> mostly fixed, but need to locate some chemistry for silver plating the
>> repair.  Suggestions anyone?
>
>Depends on the shape of the part, but if its something simple that you
>can rub vigorously with a damp cloth you might try Cool Amp.  It's a
>powder that is usually used for field plating of high current busbars.
>
>http://www.cool-amp.com/cool-amp.html
>
>I've used it with some success.  Takes a bit of elbow grease, so it
>won't be suitable for complex or fragile shapes.  Really intended just
>for busbars and such.  But it is hard to beat for simple and easy.
>Clean the copper, rub the powder on with a damp cloth, rinse with water,
>done.
>
>John Kasunich
>
This piece is a brass concoction, crookedly screwed onto a piece of 5/16"
copper rod, about 1.5" long, about 3/4" OD, bored to 1/2" and turned to have a 
side view of -/\, but with the bottom of those slashes cut away by the 
1/2" bore, then a dozen or so slits cut so that there are about a dozen 
fingers that in turn plug into the center bottom connector of the high power 
tube, and are supposed to fit tight enough so that this connector can be 
inserted, and it has enough outward force from the fingers that the about 10 
pound tube can then be picked up by the connector rod.

This one had apparently had a problem at some time in the past before Dave and 
I came on the scene, and whoever worked on it before did not replace the 
internal tru-arc snap rings that help supply the high contact pressures 
needed to put 200+ amps though the connection reliably.  I've cleaned the 
burnt stuff off, and cut it down to clean bare brass, put the snap rings back 
in, and now need to sit the end of it in about 1/2" of silver cyanide & move 
silver in about a dimes volume, onto the repaired contacts.  So I need the 
silver cyanide, a small loop of silver wire I can place around it for the 
sacrificial silver, and a few volts and amps to do the plating.  Both are 
made out of pure un-obtainium out here in the hills of WV.

Hopefully McMaster-Carr has that in small qty's.  Off to check that right now.

-- 
Cheers, Gene
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
I object to intellect without discipline;  I object to power without
constructive purpose.
-- Spock, "The Squire of Gothos", stardate 2124.5

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Re: [Emc-users] Installation of emc2.2

2008-04-16 Thread Jon Elson
Craig Muller wrote:
> Hi All
> 
>  
> 
> I Previously had emc installed via the BDI I have recently tried to 
> upgrade to emc2,2 . I downloaded the ISO and cut it to a disc seemingly 
> without a hiccup. I can boot my machine using the live cd however when I 
> try to install the software the installation hangs at step 3 (Keyboard 
> layout) does any one have any I deas how to solve this?
make sure you have enough video memory on your video card.  I 
think you need 4 MB.  If you have on the motherboard video, you 
may need to add a plug-in video card.  You need at least 2-3 GB 
of hard drive and 256 MB of main memory.  If you disk is 
partitioned from the BDI, that may be confusing this install. 
You might have to do a custom install and delete all partitions, 
or do some tinkering if you want to save files on the system.

Jon

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Re: [Emc-users] My runaway A axis problem.

2008-04-16 Thread John Kasunich
Gene Heskett wrote:

> 
> I didn't time it John, but that sounds about right.  I was up to my buns in a 
> different pool of alligators, the inner filament contact for a final tube in 
> a tv transmitter & had left it running itself while I went looking for some 
> silver braze rod.  The only thing I have is some pretty old nickle-silver rod 
> whose flux has worn off from laying around.  I have it mostly fixed, but need 
> to locate some chemistry for silver plating the repair.  Suggestions anyone?
> 

Depends on the shape of the part, but if its something simple that you
can rub vigorously with a damp cloth you might try Cool Amp.  It's a
powder that is usually used for field plating of high current busbars.

http://www.cool-amp.com/cool-amp.html

I've used it with some success.  Takes a bit of elbow grease, so it
won't be suitable for complex or fragile shapes.  Really intended just
for busbars and such.  But it is hard to beat for simple and easy.
Clean the copper, rub the powder on with a damp cloth, rinse with water,
done.

John Kasunich

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Re: [Emc-users] My runaway A axis problem.

2008-04-16 Thread Gene Heskett
On Wednesday 16 April 2008, John Kasunich wrote:
>Gene Heskett wrote:
>> Greetings guys;
>>
>> I edited the ini file and slowed the A axis down to 10%, or maxvel=7.2,
>> with corresponding slowdowns in the accel's too.  and I added another 9 in
>> front of its limits so it can now turn 99,999 degrees.
>>
>> Then I re-figured the cut for a .003" per A revolution, giving 61,200
>> degrees of A motion and fired off the cut at f0.008 with g93 active, which
>> worked rather well, but took several hours as the A table was turning
>> rather leasurely.
>>
>> When I get the time, I'll play with that some more & see if I can make any
>> sense out of it.  What I was getting last night sure was off the wall.
>
>F.008 in inverse time mode means 1/0.008 = 125 minutes.  It should have
>taken 2 hours and 5 minutes.
>
>Regards,
>
>John Kasunich

I didn't time it John, but that sounds about right.  I was up to my buns in a 
different pool of alligators, the inner filament contact for a final tube in 
a tv transmitter & had left it running itself while I went looking for some 
silver braze rod.  The only thing I have is some pretty old nickle-silver rod 
whose flux has worn off from laying around.  I have it mostly fixed, but need 
to locate some chemistry for silver plating the repair.  Suggestions anyone?

-- 
Cheers, Gene
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
There's a way out of any cage.
-- Captain Christopher Pike, "The Menagerie" ("The Cage"),
   stardate unknown.

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Re: [Emc-users] My runaway A axis problem.

2008-04-16 Thread John Kasunich
Gene Heskett wrote:
> Greetings guys;
> 
> I edited the ini file and slowed the A axis down to 10%, or maxvel=7.2, with 
> corresponding slowdowns in the accel's too.  and I added another 9 in front 
> of its limits so it can now turn 99,999 degrees.
> 
> Then I re-figured the cut for a .003" per A revolution, giving 61,200 degrees 
> of A motion and fired off the cut at f0.008 with g93 active, which worked 
> rather well, but took several hours as the A table was turning rather 
> leasurely.
> 
> When I get the time, I'll play with that some more & see if I can make any 
> sense out of it.  What I was getting last night sure was off the wall.
> 
F.008 in inverse time mode means 1/0.008 = 125 minutes.  It should have
taken 2 hours and 5 minutes.

Regards,

John Kasunich


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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread John Kasunich
Kirk Wallace wrote:
> On Wed, 2008-04-16 at 16:14 -0700, Kirk Wallace wrote:
>> On Tue, 2008-04-15 at 20:42 -0700, Kirk Wallace wrote:
>> ... snip 
> 
>> I am wondering if this is just a simple H-bridge with current limit? If
>> anyone has more information on this drive, I would appreciate hearing
>> it.
> 
> Looking more closely at the driver, reveals it has three MC1455 (NE555
> compatible) timer/oscillators and an unknown FUA3302. The oscillators
> must be doing some sort of power conversion. I was wondering why there
> seemed to be allot of extra transistors and why the motors buzzed even
> at rest. I need to some more poking around with the scope or voltmeter.
> 

It sure looks like a unipolar drive to me.  They are probably doing
half-stepping, which would give you the counts per inch that you think
you have.

Power is applied to the two center taps, thru two of the transistors
which probably act as choppers to control the current.  The other four
transistors connect the ends of the windings to ground.  If you call the
windings 1 and 2, and the two ends of each winding A and B, half
stepping would be something like so:

1A only
1A and 2A
2A only
2A and 1B
1B only
1B and 2B
2B only
2B and 1A
repeat

That is one full electrical cycle, four full steps, eight half-steps.

It might be enlightening to trace out as much of the power circuit as
possible and post it, if you are interested in reverse engineering the
drive.  I've done a little power electronics, and I'd be happy to take a
look and see what I can figure out.

Regards,

John Kasunich



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Re: [Emc-users] Vital System Error

2008-04-16 Thread Eric H. Johnson
Glenn,

The VTI configuration is for the Vigilant Technologies Inc (Vigilant
Products) board. I believe you will find the Vital systems configuration
under "motenc".

Regards,
Eric


I have loaded my box with Ubuntu and EMC2 following the instructions
provided on the download page. 

I was able to get into the Sim config with no problems.

I have a Vital Systems Motenc-lite board and when I pick the VTI config, I
get the following error.

 

Debug file information:

insmod: error inserting
'/usr/realtime-2.6.15-magma/modules/emc2/hal_vti.ko': -1 No such device

vti_motion.hal:5: exit value: 1

vti_motion.hal:5: insmod failed, returned -1



PID TTY STAT TIME COMMAND

Stopping realtime threads

Unloading hal components

 

 

I looked for the obvious, but I am a total EMC2 and Linux noob, can someone
point me in the right direction?



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[Emc-users] My runaway A axis problem.

2008-04-16 Thread Gene Heskett
Greetings guys;

I edited the ini file and slowed the A axis down to 10%, or maxvel=7.2, with 
corresponding slowdowns in the accel's too.  and I added another 9 in front 
of its limits so it can now turn 99,999 degrees.

Then I re-figured the cut for a .003" per A revolution, giving 61,200 degrees 
of A motion and fired off the cut at f0.008 with g93 active, which worked 
rather well, but took several hours as the A table was turning rather 
leasurely.

When I get the time, I'll play with that some more & see if I can make any 
sense out of it.  What I was getting last night sure was off the wall.

-- 
Cheers, Gene
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
In just seven days, I can make you a man!
-- The Rocky Horror Picture Show

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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread Kirk Wallace
On Wed, 2008-04-16 at 16:14 -0700, Kirk Wallace wrote:
> On Tue, 2008-04-15 at 20:42 -0700, Kirk Wallace wrote:
> ... snip 

> I am wondering if this is just a simple H-bridge with current limit? If
> anyone has more information on this drive, I would appreciate hearing
> it.

Looking more closely at the driver, reveals it has three MC1455 (NE555
compatible) timer/oscillators and an unknown FUA3302. The oscillators
must be doing some sort of power conversion. I was wondering why there
seemed to be allot of extra transistors and why the motors buzzed even
at rest. I need to some more poking around with the scope or voltmeter.

-- 
Kirk Wallace (California, USA
http://www.wallacecompany.com/machine_shop/ 
Hardinge HNC lathe,
Bridgeport mill conversion, doing XY now,
Zubal lathe conversion pending
Craftsman AA 109 restoration
Shizuoka ST-N/Bandit CNC)


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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread Kirk Wallace
On Wed, 2008-04-16 at 16:07 -0500, sam sokolik wrote:
> If you actually have access to all 4 coils - then I would use types 9
> or 10.  This would be half stepping and give you 2000 steps per inch.
> (.0005 per step) 200*2*5.
> 
> at a normal base period of 5 - you could get (without using
> doublestep) 300ipm easy.  Not that your machine would actually do
> that.
> 
> sam

Thanks Sam. I believe my motors have a common on two pairs of coils. I
think like this:

1  C  2
|  |  |
 WW WW

 MM MM
|  |  |
3  C  4

I don't know the options for wiring this configuration, but the Gecko
documentation indicates that you can series or parallel the coils for a
four wire configuration. I get the feeling that currently, my four coils
are driven separately. The plan so far, is to just reproduce the present
wave forms, so I won't need to know what I am doing. I'll just look like
it.

-- 
Kirk Wallace (California, USA
http://www.wallacecompany.com/machine_shop/ 
Hardinge HNC lathe,
Bridgeport mill conversion, doing XY now,
Zubal lathe conversion pending
Craftsman AA 109 restoration
Shizuoka ST-N/Bandit CNC)


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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread Kirk Wallace
On Tue, 2008-04-15 at 20:42 -0700, Kirk Wallace wrote:
... snip 
> The drives have four inputs that appear
> to take in steps as quadrature signals plus their complements; QB,
> QA, /QB, /QA.
> 
> QB  ___|```|___|```|_
> QA  _|```|___|```|___
> /QB ```|___|```|___|`
> /QA `|___|```|___|```

I scoped out the driver IO and got this:

QB ___|```|___|```|_ 
QA  _|```|___|```|___
/QB ```|___|```|___|`
/QA `|___|```|___|```
IB  __||__||__||__||_
IA  ||__||__||__||__|

The IA and IB sink the LED's on two optocoupler inputs each. The high
side of the LED's is driven by the Q and /Q quadrature signals. I am
guessing this forms a NAND function or an Inhibit? I wonder if the
inhibits are needed to prevent shoot-through? If that is the case I will
need to be very careful not to allow shoot-through. Here are some
pictures of one of the drives.

http://www.wallacecompany.com/machine_shop/Shizuoka/1-1a.jpg
http://www.wallacecompany.com/machine_shop/Shizuoka/2-1a.jpg

I am wondering if this is just a simple H-bridge with current limit? If
anyone has more information on this drive, I would appreciate hearing
it.

-- 
Kirk Wallace (California, USA
http://www.wallacecompany.com/machine_shop/ 
Hardinge HNC lathe,
Bridgeport mill conversion, doing XY now,
Zubal lathe conversion pending
Craftsman AA 109 restoration
Shizuoka ST-N/Bandit CNC)


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[Emc-users] Vital System Error

2008-04-16 Thread Glenn Stewart
Hello,

I have loaded my box with Ubuntu and EMC2 following the instructions
provided on the download page. 

I was able to get into the Sim config with no problems.

I have a Vital Systems Motenc-lite board and when I pick the VTI config, I
get the following error.

 

Debug file information:

insmod: error inserting
'/usr/realtime-2.6.15-magma/modules/emc2/hal_vti.ko': -1 No such device

vti_motion.hal:5: exit value: 1

vti_motion.hal:5: insmod failed, returned -1



PID TTY STAT TIME COMMAND

Stopping realtime threads

Unloading hal components

 

 

I looked for the obvious, but I am a total EMC2 and Linux noob, can someone
point me in the right direction?

Thanks

Glenn Stewart

 

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Re: [Emc-users] Installation of emc2.2

2008-04-16 Thread Chris Radek
On Wed, Apr 16, 2008 at 09:11:48PM +0200, Craig Muller wrote:
>  
> Hi All
>  
> I Previously had emc installed via the BDI I have recently tried to
> upgrade to emc2,2 . I downloaded the ISO and cut it to a disc seemingly
> without a hiccup. I can boot my machine using the live cd however when I
> try to install the software the installation hangs at step 3 (Keyboard
> layout) does any one have any I deas how to solve this?

It's a little hard to guess with only this information.  Many problems
are caused by a bad download and/or a bad CD burn.  Did you verify the
md5sum of the iso download and then also verify the CD (at the initial
menu when you booted from it)?


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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread sam sokolik
If you actually have access to all 4 coils - then I would use types 9 or 
10.  This would be half stepping and give you 2000 steps per inch. 
(.0005 per step) 200*2*5.


at a normal base period of 5 - you could get (without using 
doublestep) 300ipm easy.  Not that your machine would actually do that.


sam

Kirk Wallace wrote:

On Wed, 2008-04-16 at 12:27 -0400, John Kasunich wrote:
  

Kirk Wallace wrote:


Thanks for your reply, Erik. I was wondering if there was a way to
figure out the steps per revolution with the motors disconnected, but
it's probably not important, because I can adjust settings after I get
the motors working. Although, it would be nice to know to figure out
what pulse rate I would need for my planned rapid of 100 inches per
minute (with 5 rev. per inch screws).

  
Small steppers (as in printers, etc) tend to come in all flavors.  But 
once you get into the kind of motors that are used on larger machines, 
200 step per rev is the huge majority.  In your shoes, I would assume 
200 until proven otherwise.


Regards,

John Kasunich



Thanks John and Jon. While I was using the machine, it seemed I could
dial in a least a half thousandth on the axis dials and the motors are
directly coupled. There is .2" per rev. so at least 400 half thousandths
or steps per rev. I must be missing something about steppers.

So for 200 steps/rev:

100 inches/minute x 1 minute/60 seconds = 1.6667 inches/second
x 1 rev./.2 inches = 8. rev./second (500 RPM)
x 200 steps/rev. = 1666 steps/second

That seems a little low. It is well within parport frequency, though.

Stepgen type eight seems to be what I need. I assume that for a
direction change phase C and D sift two periods or a half wave? I could
use an inverter chip to create phase B and D from type 2 but I don't
mind using two more pins. I guess that could change.

I found that the controller ground was +12 Volts relative to my scope
probe, so I rigged up an optocoupler and it works well. Now, with
another opto, I can scope out the driver IO.

  
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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread Kirk Wallace
On Wed, 2008-04-16 at 12:27 -0400, John Kasunich wrote:
> Kirk Wallace wrote:
> > 
> > Thanks for your reply, Erik. I was wondering if there was a way to
> > figure out the steps per revolution with the motors disconnected, but
> > it's probably not important, because I can adjust settings after I get
> > the motors working. Although, it would be nice to know to figure out
> > what pulse rate I would need for my planned rapid of 100 inches per
> > minute (with 5 rev. per inch screws).
> > 
> 
> Small steppers (as in printers, etc) tend to come in all flavors.  But 
> once you get into the kind of motors that are used on larger machines, 
> 200 step per rev is the huge majority.  In your shoes, I would assume 
> 200 until proven otherwise.
> 
> Regards,
> 
> John Kasunich

Thanks John and Jon. While I was using the machine, it seemed I could
dial in a least a half thousandth on the axis dials and the motors are
directly coupled. There is .2" per rev. so at least 400 half thousandths
or steps per rev. I must be missing something about steppers.

So for 200 steps/rev:

100 inches/minute x 1 minute/60 seconds = 1.6667 inches/second
x 1 rev./.2 inches = 8. rev./second (500 RPM)
x 200 steps/rev. = 1666 steps/second

That seems a little low. It is well within parport frequency, though.

Stepgen type eight seems to be what I need. I assume that for a
direction change phase C and D sift two periods or a half wave? I could
use an inverter chip to create phase B and D from type 2 but I don't
mind using two more pins. I guess that could change.

I found that the controller ground was +12 Volts relative to my scope
probe, so I rigged up an optocoupler and it works well. Now, with
another opto, I can scope out the driver IO.

-- 
Kirk Wallace (California, USA
http://www.wallacecompany.com/machine_shop/ 
Hardinge HNC lathe,
Bridgeport mill conversion, doing XY now,
Zubal lathe conversion pending
Craftsman AA 109 restoration
Shizuoka ST-N/Bandit CNC)


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[Emc-users] Installation of emc2.2

2008-04-16 Thread Craig Muller
 
Hi All
 
I Previously had emc installed via the BDI I have recently tried to
upgrade to emc2,2 . I downloaded the ISO and cut it to a disc seemingly
without a hiccup. I can boot my machine using the live cd however when I
try to install the software the installation hangs at step 3 (Keyboard
layout) does any one have any I deas how to solve this?
 
 
 
Best regards
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Re: [Emc-users] brushless motors

2008-04-16 Thread Peter C. Wallace
On Wed, 16 Apr 2008, Jon Elson wrote:

> Date: Wed, 16 Apr 2008 12:17:10 -0500
> From: Jon Elson <[EMAIL PROTECTED]>
> Reply-To: "Enhanced Machine Controller (EMC)"
> 
> To: "Enhanced Machine Controller (EMC)" 
> Subject: Re: [Emc-users] brushless motors
> 
> Peter C. Wallace wrote:
>
>> Also you mentioned that you had some cogging. Is the resonance something that
>> happens statically or only when moving at certain velocities? Is it possible
>> that you have some non-linearity or even hysteresis in you drive - torque
>> curve?
>>
> The first large motor I tried this on has probably been dropped,
> or is just a horribly-built motor.  This motor works MUCH
> better, and after a little tuneup of the commutation encoder it
> runs with very little vibration.
>> To get our 3 phase driver to work well, we first had to first fix the VQ -> 
>> IQ
>> nonlinearitys as best we could before closing the current loop. It was really
>> lumpy at first...
> This motor runs quite well, there is just a slight hum at one
> narrow speed band.  I assume that is when the 6-step commutation
> frequency matches the motor's natural frequency.  It is never
> "lumpy" at all.  I still would like to get more P gain without
> instability, but I suspect it is impossible without solving the
> current vs. voltage drive question.  Getting the absolute
> current out of the power stage isn't so hard, as it already has
> current sense resistors for limit purposes.  But, turning that
> current into a SIGNED value indicating the correct sign of power
> flow is tougher.
>
> Jon
>


Our low power voltage mode 3 phase drivers have always worked smoothly
(sine wave drive mode) but as soon as we used a IGBT module, the dead zones 
are so large that they play havoc with the open loop current waveforms, 
requiring some rather fussy software fixes.

MOSFETS really spoil you...

We've been testing with a bunch of shall we say 'motors of questionable 
provenance' also. Just managed to melt the encoder on one by running it into 
the dynamometer (just a big DC motor with a load) with the wrong startup angle 
so what looked like IQ was really mostly ID, lots of current and heat, not 
much go (like a stepper :-)


Peter

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Re: [Emc-users] brushless motors

2008-04-16 Thread Jon Elson
Kenneth Lerman wrote:
> Jon,
> 
> I've tried to use combination drill/taps with my Tapmatic tapping head with 
> similar breaking results. The problem seems to be that the tapping head 
> allows for sideways float to that the tap will self align with an existing 
> hole. That works great when you are manually positioning a part on a drill 
> press. It did not work well with the drill/tap on the same drill press.
> 
> For now, I just drill all the holes and then make a separate pass with a 
> tap.
Well, I do batches of servo amp mounting plates with 12 
holes/plate, all 4-40.  When I get everything all set up right, 
I can do the whole batch on one tap, and sometimes a tap works 
for several batches over time before something goes wrong.  I 
usually break the tap on the first hole or two.  Yes, I think 
the radial slop in the tap holder is the problem.  I want to try 
doing this on my minimill (which has a spindle encoder) and 
without the huge Procunier tapping head in the stack, the tap 
will be just an inch or two below the spindle.  That should let 
the tap go in straight and without wander.

Jon

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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread Jon Elson
Kirk Wallace wrote:
> I am losing patience with the Bandit on my Shizuoka mill, so I am
> thinking of converting to EMC2 sooner than later. I would like to save
> the stepper drivers but they look like they might have a proprietary
> integration with the controller. The drives have four inputs that appear
> to take in steps as quadrature signals plus their complements; QB,
> QA, /QB, /QA.
EMC2 can produce these signals.  You can generate quadrature 
outputs and then produce the complements with inverter chips.
That still uses only 2 pins/axis.  Or, you can make it produce 
wave drive, and get smoother operation with wave drive, at the 
cost of going to 4 pins/axis.
> 
> QB  ___|```|___|```|_
> QA  _|```|___|```|___
> /QB ```|___|```|___|`
> /QA `|___|```|___|```
> 
> ... Darn, I just realized this will only work for the parallel port,
> which is too slow.
Why is the par. port too slow?
  I guess, I need new step/direction drivers plus a
> hardware clock generator. Unless someone knows of a clock generator with
> quadrature outputs.
> 
> For a stepper driver, what do I need to consider to make the best
> integration with EMC2? 
> 
> My current drivers have a 45 V supply, 8 Amp limit, and 6 wires of which
> two are labeled "common". The motors are not labeled and I don't know
> how to determine the steps per revolution.

Almost without a doubt, 200 full steps/rev.

Jon

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Re: [Emc-users] brushless motors

2008-04-16 Thread Jon Elson
Peter C. Wallace wrote:

> Also you mentioned that you had some cogging. Is the resonance something that 
> happens statically or only when moving at certain velocities? Is it possible 
> that you have some non-linearity or even hysteresis in you drive - torque 
> curve?
> 
The first large motor I tried this on has probably been dropped, 
or is just a horribly-built motor.  This motor works MUCH 
better, and after a little tuneup of the commutation encoder it 
runs with very little vibration.
> To get our 3 phase driver to work well, we first had to first fix the VQ -> IQ
> nonlinearitys as best we could before closing the current loop. It was really 
> lumpy at first...
This motor runs quite well, there is just a slight hum at one 
narrow speed band.  I assume that is when the 6-step commutation 
frequency matches the motor's natural frequency.  It is never 
"lumpy" at all.  I still would like to get more P gain without 
instability, but I suspect it is impossible without solving the 
current vs. voltage drive question.  Getting the absolute 
current out of the power stage isn't so hard, as it already has 
current sense resistors for limit purposes.  But, turning that 
current into a SIGNED value indicating the correct sign of power 
flow is tougher.

Jon

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Re: [Emc-users] brushless motors

2008-04-16 Thread Jon Elson
John Kasunich wrote:
> Jon Elson wrote:
> 
>>Peter C. Wallace wrote:
>>
>>>If you are just driving a bare motor, try raising your sampling rate...
>>
>>Geez, the resonance seems to be about 40 Hz, my sampling rate is 
>>already 1 KHz, 25 X higher.  But, yes, I can go to at least 5 
>>KHz and see what happens.
>>
>>Jon
>>
> 
> 
> Do you have current feedback or a current loop?  (I doubt it.)
No.  This is an absolute bare-bones drive.  Measuring current
is fairly easy on a brush drive, and I've done that before. 
But, I don't even know how to measure the current on a 3-phase 
motor.  My brush solution was to put a current sense resistor in 
series with the output right after one half-bridge (before the 
output filter) and read it with an Analog Devices AD620 
instrumentation amp.  This works amazingly well reading 100 mV 
drop off a resistor while the common-mode is a 70 V 100 KHz 
square wave!  But, I really don't see how to do that and 
decipher four-quadrant motor current from the motor lines.  The 
problem then is you need to get the current reading into an 
equation, while EMC is already putting out a digital PWM signal.
I only have a 36 macrocell CPLD on the brushless servo amp board
and 4000-series CMOS on the brush model, so DSP computations are 
out of the question.
   If you
> control current, you more-or-less eliminate one pole from the system
> response.
Yes, maybe this whole PWM idea has a fundamental flaw, 
especially with larger motors.  But, now I've backed myself into 
a corner, building a whole product line around a possibly flawed 
concept.

Jon

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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread Kirk Wallace
On Wed, 2008-04-16 at 07:00 -0500, Andre' Blanchard wrote:
... snip
> Step direction to quadrature conversion can be done, not all that much of a 
> circuit needed really.
> http://www.cnczone.com/forums/showthread.php?t=12066
> 
> __
> Andre' B.  Clear Lake, Wi.

I tried to see what the driver inputs were by using my oscilloscope, but
the signals are referenced to a floating ground, what I got was allot of
noise. I could use two channels to get a differential between the signal
and its ground, but I only have two channels, so I could not compare the
timing of two signals. So far my guess about the signals is based on
noisy traces and reverse engineering a small bit of the controller
output circuit. I suppose I could continue to trace the circuit to see
what signals are up the line. I just realized, I could probably get by
the scope problem by probing the far side of the optocouplers in the
driver or setup my own optocouplers referenced to the scope ground. I
guess this is going to take a little more effort on my part.

-- 
Kirk Wallace (California, USA
http://www.wallacecompany.com/machine_shop/ 
Hardinge HNC lathe,
Bridgeport mill conversion, doing XY now,
Zubal lathe conversion pending
Craftsman AA 109 restoration
Shizuoka ST-N/Bandit CNC)


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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread John Kasunich
Kirk Wallace wrote:
> 
> Thanks for your reply, Erik. I was wondering if there was a way to
> figure out the steps per revolution with the motors disconnected, but
> it's probably not important, because I can adjust settings after I get
> the motors working. Although, it would be nice to know to figure out
> what pulse rate I would need for my planned rapid of 100 inches per
> minute (with 5 rev. per inch screws).
> 

Small steppers (as in printers, etc) tend to come in all flavors.  But 
once you get into the kind of motors that are used on larger machines, 
200 step per rev is the huge majority.  In your shoes, I would assume 
200 until proven otherwise.

Regards,

John Kasunich


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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread Kirk Wallace
On Wed, 2008-04-16 at 05:38 -0500, RogerN wrote:
> If I remember correctly, the Quadrature signals will let the control 
> step a motor twice as fast as step and direction.  It might be worth a 
> try before replacing your drives.
> 
> Roger Neal
> [EMAIL PROTECTED]

Good point, Roger.

-- 
Kirk Wallace (California, USA
http://www.wallacecompany.com/machine_shop/ 
Hardinge HNC lathe,
Bridgeport mill conversion, doing XY now,
Zubal lathe conversion pending
Craftsman AA 109 restoration
Shizuoka ST-N/Bandit CNC)


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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread Kirk Wallace
On Wed, 2008-04-16 at 17:23 +1000, Erik Christiansen wrote:
> On Tue, Apr 15, 2008 at 08:42:44PM -0700, Kirk Wallace wrote:
> > The motors are not labeled and I don't know
> > how to determine the steps per revolution.
> 
> ...
> 
> > I suppose I can add an index disk and sensor.
> 
> Is that perhaps a simple way to determine the steps per revolution?
> (Count the steps fed to the motor, and observe how often the index
> occurs.)
> 
> (Can't offer much on the other questions. :-)
> 
> Erik

Thanks for your reply, Erik. I was wondering if there was a way to
figure out the steps per revolution with the motors disconnected, but
it's probably not important, because I can adjust settings after I get
the motors working. Although, it would be nice to know to figure out
what pulse rate I would need for my planned rapid of 100 inches per
minute (with 5 rev. per inch screws).

-- 
Kirk Wallace (California, USA
http://www.wallacecompany.com/machine_shop/ 
Hardinge HNC lathe,
Bridgeport mill conversion, doing XY now,
Zubal lathe conversion pending
Craftsman AA 109 restoration
Shizuoka ST-N/Bandit CNC)


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Re: [Emc-users] brushless motors

2008-04-16 Thread Kenneth Lerman
Jon,

I've tried to use combination drill/taps with my Tapmatic tapping head with 
similar breaking results. The problem seems to be that the tapping head 
allows for sideways float to that the tap will self align with an existing 
hole. That works great when you are manually positioning a part on a drill 
press. It did not work well with the drill/tap on the same drill press.

For now, I just drill all the holes and then make a separate pass with a 
tap.

Ken


- Original Message - 
From: "Jon Elson" <[EMAIL PROTECTED]>
To: "Enhanced Machine Controller (EMC)" 
Sent: Tuesday, April 15, 2008 9:38 PM
Subject: Re: [Emc-users] brushless motors


> Chris Radek wrote:
>> On Tue, Apr 15, 2008 at 11:40:59AM -0500, Jon Elson wrote:
>>
>>
>>>Another topic...  I want to try some rigid tapping a la the
>>>Mazak on my portable mill and bring that to the Workshop.
>>>Is there a sample G-code program or a program that creates the
>>>G-code for that cycle?  I'm thinking of hooking my spindle motor
>>>to another servo amp.  Since the servo box only has a 50 V power
>>>supply, I'll lose some RPM but I think that will be OK.
>>
>>
>> It's very easy:
>>
>> G20 G90
>> S250 M3 (spindle nice and slow)
>> G0 X0 Y0 Z0.1 (0.1" above a previously drilled #7 hole)
>> G33.1 Z-0.6 K0.05 (Tap 1/4-20, 1/2" deep)
>> M2
> OK, cool!  I've been drilling/tapping holes with these "thread
> drills", that have a point just like a drill bit, and the rear
> section is a tap.  I started around 300 RPM, and recently have
> been doing it at 1200 RPM.  The problem is my Procunier tapping
> head is such a HUGE contraption that I have the point of the tap
> about 8" from the machine spindle.  I think if the drill point
> wanders just a little before biting, the hole goes in crooked
> and can break the tap.  It gets trickier because the drill can't
> feed at the tap feed rate, so I have to do a slow feed of about
> .001 - .002" per rev until the drill is through, then accelerate
> to the tap rate.  I will have to try this out as soon as I get
> a few things fixed up on the machine.
>
> Thanks,
>
> Jon
>
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Re: [Emc-users] new to CNC

2008-04-16 Thread Andrea Montefusco
John Thornton wrote:
> There are some G-Code generators for simple things over at the EMC wiki 
> site...

http://wiki.linuxcnc.org/cgi-bin/emcinfo.pl?Simple_EMC_G-Code_Generators

useful for simpler works without fireup the whole thing (CAD, CAM).

For a (embrionic) open source CAM give a look at

http://gcam.js.cx/index.php/Main_Page

but, again, no DXF conversion here.

Until now, I use CamBam on the same (Window$) machine where CAD is runnig.

Regards

   *am*

-
Andrea Montefuscoandrew at montefusco.com
tel: +393356992791 fax: +390623318709
-

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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread Andre' Blanchard
At 10:42 PM 4/15/2008, you wrote:
>I am losing patience with the Bandit on my Shizuoka mill, so I am
>thinking of converting to EMC2 sooner than later. I would like to save
>the stepper drivers but they look like they might have a proprietary
>integration with the controller. The drives have four inputs that appear
>to take in steps as quadrature signals plus their complements; QB,
>QA, /QB, /QA.
>
>QB  ___|```|___|```|_
>QA  _|```|___|```|___
>/QB ```|___|```|___|`
>/QA `|___|```|___|```
>
>... Darn, I just realized this will only work for the parallel port,
>which is too slow. I guess, I need new step/direction drivers plus a
>hardware clock generator. Unless someone knows of a clock generator with
>quadrature outputs.
>
>For a stepper driver, what do I need to consider to make the best
>integration with EMC2?
>
>My current drivers have a 45 V supply, 8 Amp limit, and 6 wires of which
>two are labeled "common". The motors are not labeled and I don't know
>how to determine the steps per revolution.
>
>I seem to recall the Geckos had a non-adjustable I in its PID tuning?
>
>I want to use limit and home switches, but I am used to homing on an
>encoder index and I won't have an index. It seems that a switch alone
>would not be accurate enough. I suppose I can add an index disk and
>sensor. On the other hand, this is only important if you don't want to
>touch off after powering up?
>
>It's time to hit the books, but any advise is appreciated.


Step direction to quadrature conversion can be done, not all that much of a 
circuit needed really.
http://www.cnczone.com/forums/showthread.php?t=12066

__
Andre' B.  Clear Lake, Wi.



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Re: [Emc-users] best cnc tool-holder system

2008-04-16 Thread Ron Ginger
I also use the Tormach system and like it a lot. My Jet knee mill was 
converted to move the table instead of the quill for Z. That leaves the 
quill free for hand drilling, but also lets me make a real quick switch 
on the tool holder. I installed the drawbar with a short but stiff 
spring under its head. I made a small bridge over the top of the 
drawbar. To change tools I just use the quill handle and lift the quill 
until the top of the drawbar hits the bridge, then a slight more and the 
collet opens to drop the tool holder. One hand on the quill handle one 
hand to grab the tool holder. No wrench or power drawbar need.

Its worked great for me.

ron ginger

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Re: [Emc-users] new to CNC

2008-04-16 Thread John Thornton
There are some G-Code generators for simple things over at the EMC wiki site...

John

On 15 Apr 2008 at 14:04, Marc Koch wrote:

> 
> Hi,
> 
> I'm following this very interesting group for a while now. In the
> meantime I build a plywood router and I played around with the
> hobbyCNC board connected to an old laptop running EMC2.
> 
> I've two questions so far:
> - What do you use in the Linux world to convert from DXF to G-Code? I
> found CamBam very nice in the Windows world.
> 
> - How to change pulse width generated?
> 
> Thx
> Marc
> 
> between -00-00 and -99-99 



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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread RogerN
If I remember correctly, the Quadrature signals will let the control 
step a motor twice as fast as step and direction.  It might be worth a 
try before replacing your drives.

Roger Neal
[EMAIL PROTECTED]

- Original Message - 
From: "Kirk Wallace" <[EMAIL PROTECTED]>
To: "Enhanced Machine Controller (EMC)" 

Sent: Tuesday, April 15, 2008 10:42 PM
Subject: [Emc-users] Bandit Steppers


>I am losing patience with the Bandit on my Shizuoka mill, so I am
> thinking of converting to EMC2 sooner than later. I would like to save
> the stepper drivers but they look like they might have a proprietary
> integration with the controller. The drives have four inputs that 
> appear
> to take in steps as quadrature signals plus their complements; QB,
> QA, /QB, /QA.
>
> QB  ___|```|___|```|_
> QA  _|```|___|```|___
> /QB ```|___|```|___|`
> /QA `|___|```|___|```
>
> ... Darn, I just realized this will only work for the parallel port,
> which is too slow. I guess, I need new step/direction drivers plus a
> hardware clock generator. Unless someone knows of a clock generator 
> with
> quadrature outputs.
>
> For a stepper driver, what do I need to consider to make the best
> integration with EMC2?
>
> My current drivers have a 45 V supply, 8 Amp limit, and 6 wires of 
> which
> two are labeled "common". The motors are not labeled and I don't know
> how to determine the steps per revolution.
>
> I seem to recall the Geckos had a non-adjustable I in its PID tuning?
>
> I want to use limit and home switches, but I am used to homing on an
> encoder index and I won't have an index. It seems that a switch alone
> would not be accurate enough. I suppose I can add an index disk and
> sensor. On the other hand, this is only important if you don't want to
> touch off after powering up?
>
> It's time to hit the books, but any advise is appreciated.
>
> -- 
> Kirk Wallace (California, USA
> http://www.wallacecompany.com/machine_shop/
> Hardinge HNC lathe,
> Bridgeport mill conversion, doing XY now,
> Zubal lathe conversion pending
> Craftsman AA 109 restoration
> Shizuoka ST-N/Bandit CNC)
>
>
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Re: [Emc-users] Bandit Steppers

2008-04-16 Thread Erik Christiansen
On Tue, Apr 15, 2008 at 08:42:44PM -0700, Kirk Wallace wrote:
> The motors are not labeled and I don't know
> how to determine the steps per revolution.

...

> I suppose I can add an index disk and sensor.

Is that perhaps a simple way to determine the steps per revolution?
(Count the steps fed to the motor, and observe how often the index
occurs.)

(Can't offer much on the other questions. :-)

Erik

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