Re: [Emc-users] 5-axis table-table kinematics: G54 offsets

2011-12-28 Thread Andrew
2011/12/28 Rudy du Preez r...@asmsa.co.za

 It is in groups.yahoo.com under group SA-CNC-CLUB in photos.


I tried searching
Sorry, no matches were found for SA CNC CLUB

Andrew
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Re: [Emc-users] 5-axis table-table kinematics: G54 offsets

2011-12-28 Thread Viesturs Lācis
2011/12/28 Rudy du Preez r...@asmsa.co.za:
 In a recent posting I did say where photo's of my machine and an impeller
 cut with it can be looked at.

 It is in groups.yahoo.com under group SA-CNC-CLUB in photos. This is the
 discussion group for our local CNC club (South Africa), which I started
 about 2 years ago (SA-CNC-CLUB) and has about 40 members.

Ok, You did mention the Yahoo group. AFAIK only group members can view
posted pictures.
But I was not able to check that for sure, because I did not find the
group, see this link:
http://groups.yahoo.com/search?query=sa-cnc-clubsort=relevance

 I have not been able to find a way to post photos to this forum.

Yes, e-mail attachments are not encouraged, it is better to post
pictures somewhere with a public access, like Google's Picasa. I guess
that pastebin.com also accepts pictures.

 Lets focus a little on the process of going from world coordinates to joint
 coordinates. Starting from a toolpoint position in part or world coordinates
 xyz and unit tool vector ijk, these have to be transformed to joint
 coordinates XYZAC, with C the rotation angle of the top rotary table and A
 the rotation angle of the rotary table on which the top rotary table sits.
 The rotary axis of the A table is along the X-axis of the machine. X sits on
 Y which sits on Z (look at my pictures if necessary).

Ok, I finally understood, how the joints are alligned in Your machine.

 The world coordinates I supply to EMC is the original xyz and the two angles
 A and C which have been computed in the CAM post-processor from ijk by:

 A = -arccos(k) and C =  arctan2(i,j)

 Some adjustment of C is necessary to go beyond -180 deg and +180 deg.

 This is transformed by the inversekins:

 J0 = cos(C)*x - sin(C)*y
 j1 = sin(C)*cos(A)*x + cos(C)*cos(A)*y - sin(A)*z
 j2 = sin(C)*sin(A)*x + cos(C)*sin(A)*y + cos(A)*z
 j3 = A
 j4 = b (not used)
 j5 = C

 This is a working process for me so far as you can see from the photo of the
 impeller produced.

Ok, I need You to expand on this in more details.
Where are these formulas used?
1) In postprocessor of Your CAM program?
2) In Your custom kinematics module?
3) Somewhere else?



 If I use a G55 transformation of say G55 x10 y10, then EMC seems to add
 these values to x and y before it sends it to inversekins. The world
 coordinate origin is shifted to the new position. That seems fine. G55 is
 set by a G10 L2 P2 command.

 If I use a G55 of say G55 c45 nothing happens. It would have worked for me
 if EMC also added 45 to the value of C before it passes it on to
 inversekins. Practically I would only want to shift the C-axis when cutting
 parts like impellers with a number of blades. The GCODE for only one blade
 is the provided.

Does EMC produce correct blade with the g-code for a single blade with
trivkins module?
If yes, can You check, if this approach is working (again - with
trivkins module):

1) Save the blade's g-code in a separate file with the name o100.ngc;
in that file define subroutine, just like the example You already
provided:
 o100 sub
 G0 x25 y0
 G1 x30 f200
 G1 y5
 G1 x25
 G1 y0
 o100 endsub

2) Create another file, which will call subroutines for each blade and
rotate the top rotary table:
a) place the tool in part's coordinate origin either by jogging or by
a move in machine's coordinates, because I suspect that part's origin
will be in the center of C joint and since You should know the
location of C joint in machine coordinates, You can easily get there
with (X,Y, Z numbers are random):
G53 G0 X123 Y 123 Z123 A0 C0

b) zero G54 coordinates and select them:
G10 L2 P1 x0 y0 z0 a0 c0
G54 G0 x0 y0 C0

c) call subroutine, produce the blade and rotate the C for 51.43:
o100 call
G0 X0 Y0 Z0 A0 C51.43

d) zero G54 again and do the next blade:
G10 L2 P1 X0 Y0 Z0 A0 C0
o100 call

e) I apologize beforehand for any mistakes in this code, as I myself
actually have never used subroutines.


 I could also have passed on the ijk values as abc values to the inversekins.
 It would then have to work out the AC values, but there is quite a bit of
 checking and adjustment to C to be done. I am not sure if EMC could then
 pass on transformations.

What is that You want to achieve with this?
I feel pretty confident about my math skill and what I feel about Your
formulas is that You are trying to implement things that I do not see
that You need.
You are adding the compensating moves along X, Y and Z so that tool
stays at the same point of the part, when A or C joints are rotated.
Actually that is very useful thing, because then parts that require
complex 5-axis machining can be programmed a lot more easily,
sometimes even by hand. Anyway, that would almost eliminate need for
CAM postprocessor. That is very nice and extremely useful, but since
You never mentioned that this is Your goal, I do not understand, why
are You spending Your effort on this.

Viesturs

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Re: [Emc-users] SA-CNC-CLUB

2011-12-28 Thread Rudy du Preez
The full link to the group is:

tech.groups.yahoo.com/group/sa-cnc-club

You may have to register to be able to access the photos. Sign on - you can
always de-register afterwards.

Rudy


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Re: [Emc-users] 5-axis table-table kinematics: G54 offsets

2011-12-28 Thread Andy Pugh


On 28 Dec 2011, at 05:52, Rudy du Preez r...@asmsa.co.za wrote:

 If I use a G55 of say G55 c45 nothing happens.
...
 I hope the problem is now clearer and look forward to some response

Yes, I now understand that you want to pass a tool XYZAC to the G code and have 
EMC2 convert the A and C to movements in joints 3 and 5. 

I am assuming that when you say g55 c45 that is a shorthand for g10 L2 C45 / 
g55? I am fairly sure that an axis word on the same line an a G55 is simply 
interpreted as a movement, and will be fast or slow dependent on whether G1 or 
G0 is active. 

I think the complication in your case is that you want to index explicitly in 
joint 5 not in World C to move from vane to vane, the G55 offset can only ever 
be in tool angle. I think that your vane-to-vane indexing will need to be an 
extra pin input into your kinematics routine. 
(or alternatively an offset component in the HAL between the position-command 
and the stepgen or pid. )


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Re: [Emc-users] 5-axis table-table kinematics: G54 offsets

2011-12-28 Thread Rudy du Preez
I have found a way to do rotational  shifts of the C-axis using XYZACkins. I
use the B-axis for that and just program G0 Bxx at the start of each blade
of the impeller, where xx is the absolute position of each blade; ie 0, 90,
180, 270 for 4 blades.

The B position is available and free to use in the kinematics program. I use
it and subtract it from the given C value coming from EMC in the inversekins
and use the joint[4] value and add to the joint[5] value in the forwardkins.

It may not be the most elegant way, but it works and I now only have to
supply Gcode for one blade in a subroutine.

I would not be able to have EMC do it beforehand with a G54 to G59 command,
since I need the unshifted C-value from EMC as well as the shift value (in
my case now B).

The machine is now a 6-axis machine XYZABC with the B axis just used for
rotational shifts of C! I suppose there are also other ways to do it such as
using G43.1 instead of a B-axis.

Thanks everybody for the discussions and help on this. It always amazes me
how flexible  EMC2 is. Marvelous!

Rudy


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[Emc-users] stepper power supply

2011-12-28 Thread kqt4at5v
I have a 40v 10amp power supply from Probotix
I asked this question of supp...@probotix.com

 I have used your 40 volt 10 amp power supply for over a year with 3 of your 
 yellow motors (3 ammps each)
 I just added a 4th driver to my controller with the intent of adding a 4th 3 
 amp motor for a rotary table
 How is the 10 amp power supply going to handle 4 - 3 amp motors
 Am i looking for trouble

I got this response

 The 40V 10Amp power supply is more than capable of handling all 4 drivers 
 running the 3 amp motors. The formula breaks down like this: 3A x 4 x 60% = 
 7.2 amps
 This would be what your draw would be on the power supply.

Would someone elaborate on this just a bit
I am not questioning their response I just do not understand it

Richard


ps - I tend to bring many non-emc related questions to this list
If there is a more appropriate place please point me to it



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Re: [Emc-users] stepper power supply

2011-12-28 Thread Dave Caroline
I assume all my steppers are using all the amps I want them to, which
would be 12A if I was using 4 steppers at 3A ea.

But probotix is probably assuming some reduction in current while
stationary this can lead to loss of position when powered down to a
lower current (it may be a requirement if insufficient heatsink is
provided).

This may be ok for some operations but not all.

Dave Caroline

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Re: [Emc-users] stepper power supply

2011-12-28 Thread Andy Pugh


On 28 Dec 2011, at 15:52, kqt4a...@gmail.com wrote:

 Would someone elaborate on this just a bit
 I am not questioning their response I just do not understand it

I suspect that the 60% might be a diversity factor. 

www.wikipedia.org/wiki/Diversity_factor

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Re: [Emc-users] stepper power supply

2011-12-28 Thread gene heskett
On Wednesday, December 28, 2011 11:21:24 AM kqt4a...@gmail.com did opine:

 I have a 40v 10amp power supply from Probotix
 I asked this question of supp...@probotix.com
 
  I have used your 40 volt 10 amp power supply for over a year with 3 of
  your yellow motors (3 ammps each) I just added a 4th driver to my
  controller with the intent of adding a 4th 3 amp motor for a rotary
  table How is the 10 amp power supply going to handle 4 - 3 amp motors
  Am i looking for trouble
 
 I got this response
 
  The 40V 10Amp power supply is more than capable of handling all 4
  drivers running the 3 amp motors. The formula breaks down like this:
  3A x 4 x 60% = 7.2 amps This would be what your draw would be on the
  power supply.
 
 Would someone elaborate on this just a bit
 I am not questioning their response I just do not understand it
 
 Richard
 
Each motor may have a 3 amp current flowing, but due to the current 
regulation of the chopper in the driver, with its free-wheeling diodes 
effect, much of that 3 amp current is circulating current between the motor 
and its driver, with, when the motor is stationary, only perhaps 400 
milliamps actually coming from the supply when averaged. Enough to make up 
for the resistive heating losses in the motor and driver.

Steppers working hard at higher rpms will draw more, but in the real world 
all 4 motors will never be running full speed continuously.  If you could 
put a meter into the line and measure it (not recommended because the 
inductance of the meter will mess with the chopper waveforms back and forth 
into the supplies output filter capacitor, and that could destroy a driver 
package from overvoltage spikes on its supply input) I would doubt very 
seriously that you would ever see more than 4-6 amps to run all 4 motors at 
a good clip.

There are hall effect based ammeters that could measure the current this 
current without the inductive effects, but they are above the range of 
everyone having one in his tool kit, purely laboratory instruments that in 
60+ years of troubleshooting electronics, I have never felt crippled by not 
having one of them in my kit.  As the folks here have taught me quite a few 
times, the cat has more than 9 lives because there are usually more than 9 
ways to skin him.  One can often get answers for this sort of problems from 
the display of an oscilloscope if you know how to read what it is telling 
you.

IOW you should be fine.
 
 ps - I tend to bring many non-emc related questions to this list
 If there is a more appropriate place please point me to it

While this could be OT for this list, it is not OT for quite a few of us 
here.  I am more than happy to teach a wee bit about electronic subjects 
where I have some BTDT experience with them.  Trying to pay back for some 
of the help that the real machinists here have given me over the years.  
Backscratching as it were. It is mutually pleasurable. :)

Cheers, Gene
-- 
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 soap, ballot, jury, and ammo. Please use in that order.
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My web page: http://coyoteden.dyndns-free.com:85/gene
Well, O.K.  I'll compromise with my principles because of EXISTENTIAL 
DESPAIR!

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[Emc-users] Live CD

2011-12-28 Thread Tim James
I have downloaded and burnt the Live CD 10.04.

It has worked on one desktop I tried but not on another or my laptop.

I only have the laptop with me at the moment so I would like to install Ubuntu 
and EMC to find out more in conjunction with reading all the EMC manuals I have 
printed out.

The laptop is a Panansonic Toughbook CF29,Windows XP,Pentium 4,756Mb ram.

From the users emails over the last few days I tried the ctrl/alt/f1and have 
experimented with the f6 boot options.

The laptop appears to boot to a certain point and then the screen goes blank 
and then 'hangs' with the power off button being the only option.

If I delete splash-- and replace it with vga=771 then the display remains on  
and the laptop 'hangs' on pulseaudio configured for per-user sessions line.

I have tried some of the other f6 suggestions but not all as yet (I will wear 
the power button out soon).

I don't know if I can add the options  sequentially to the boot line or only 
use one at a time.

Does anybody have any suggestions rather than me working through all the f6 
options without really knowing which maybe causing the boot problem ?

Tim


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Re: [Emc-users] stepper power supply

2011-12-28 Thread Dave Caroline
chopped 3A means 3A AVERAGE the peak is much higher

Dave Caroline

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Re: [Emc-users] stepper power supply

2011-12-28 Thread Viesturs Lācis
2011/12/28  kqt4a...@gmail.com:

 I got this response

 The 40V 10Amp power supply is more than capable of handling all 4 drivers 
 running the 3 amp motors. The formula breaks down like this: 3A x 4 x 60% = 
 7.2 amps
 This would be what your draw would be on the power supply.

 Would someone elaborate on this just a bit
 I am not questioning their response I just do not understand it

When stepper motor is moving, current in the windings is turned on and
off, it fluctuates from 0 to 3A and back, so overall current does not
reach 3A, but is somewhere inbetween. There are stepper drives, that
are doing this also when motor is not moving, probably their drives
are doing this.

BTW I used Gecko drives for one of my machines. Their manual says that
drive will draw 67% of motor winding current from the power supply. If
motors are set (with DIP switches or resistor) for 3A, it will draw
~2A from power supply.

Viesturs

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Re: [Emc-users] stepper power supply

2011-12-28 Thread gene heskett
On Wednesday, December 28, 2011 12:05:13 PM Dave Caroline did opine:

 I assume all my steppers are using all the amps I want them to, which
 would be 12A if I was using 4 steppers at 3A ea.

Not so Dave.  For modern chopper stabilized current controlling drivers, 
the power supply is only supplying the resistance and eddy current losses 
in the motor and driver.  Worst case for really old motors with lossy iron 
might be 50% of the nameplate current that actually comes from the supply 
_once_ the current setting has been reached at initial power-up.
 
 But probotix is probably assuming some reduction in current while
 stationary this can lead to loss of position when powered down to a
 lower current (it may be a requirement if insufficient heatsink is
 provided).
 
I have been amazed at how cool my motors run on the MM-542 drivers, and 
equally amazed at the torque it takes to turn them a full step when powered 
down to 50% current when idle.  Yes, I _can_ turn them but they will not 
get moved by accident...  Brushing an arm or belly against the resonance 
damper while hand changing tooling sure isn't going to do it.

 This may be ok for some operations but not all.
 
 Dave Caroline

Cheers, Gene
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We'll know that rock is dead when you have to get a degree to work in it.

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Re: [Emc-users] stepper power supply

2011-12-28 Thread gene heskett
On Wednesday, December 28, 2011 12:20:36 PM Andy Pugh did opine:

 On 28 Dec 2011, at 15:52, kqt4a...@gmail.com wrote:
  Would someone elaborate on this just a bit
  I am not questioning their response I just do not understand it
 
 I suspect that the 60% might be a diversity factor.
 
 www.wikipedia.org/wiki/Diversity_factor
 
From that article and its assumptions, I believe is where the term SWAG 
came from?  ;-)


Cheers, Gene
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 soap, ballot, jury, and ammo. Please use in that order.
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Re: [Emc-users] Live CD

2011-12-28 Thread gene heskett
On Wednesday, December 28, 2011 12:24:02 PM Tim James did opine:

 I have downloaded and burnt the Live CD 10.04.
 
 It has worked on one desktop I tried but not on another or my laptop.
 
 I only have the laptop with me at the moment so I would like to install
 Ubuntu and EMC to find out more in conjunction with reading all the EMC
 manuals I have printed out.
 
 The laptop is a Panansonic Toughbook CF29,Windows XP,Pentium 4,756Mb
 ram.
 
No knowledge of that one.

 From the users emails over the last few days I tried the ctrl/alt/f1and
 have experimented with the f6 boot options.
 
 The laptop appears to boot to a certain point and then the screen goes
 blank and then 'hangs' with the power off button being the only option.
 
 If I delete splash-- and replace it with vga=771 then the display
 remains on  and the laptop 'hangs' on pulseaudio configured for
 per-user sessions line.

Someone needs to tell you how to skip pulse, I believe it can be done but 
I've never had to get out that big a hammer.
 
 I have tried some of the other f6 suggestions but not all as yet (I will
 wear the power button out soon).

:)  There are pretty durable, my old hp dv-5120-us has a lot of use, still 
fine.
 
 I don't know if I can add the options  sequentially to the boot line or
 only use one at a time.
 
Generally you can use a whole bunch of the options, that buffer is at least 
a full kilobyte.

 Does anybody have any suggestions rather than me working through all the
 f6 options without really knowing which maybe causing the boot problem
 ?
 
 Tim
 
 
 Sent from my BlackBerry® wireless device
 
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Cheers, Gene
-- 
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 soap, ballot, jury, and ammo. Please use in that order.
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My web page: http://coyoteden.dyndns-free.com:85/gene
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confidence.
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Re: [Emc-users] Live CD

2011-12-28 Thread Schooner
Hi

Download the 8.04 cdimage and install that.

If you want a newer version of EMC you can install that onto 8.04.

A lot of things have changed from version 9.10 of Ubuntu onwards, that 
do not make it ideal for older hardware.

I have 8.04 running happily on 2 P4 desktops in the workshop, with a RIP 
build of EMC 2.6.

http://www.linuxcnc.org/hardy/ubuntu-8.04-desktop-emc2-aj13-i386.iso

regards






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Re: [Emc-users] Live CD

2011-12-28 Thread Rafael Skodlar
On 12/28/2011 09:06 AM, Tim James wrote:
 I have downloaded and burnt the Live CD 10.04.

 It has worked on one desktop I tried but not on another or my
 laptop.

 I only have the laptop with me at the moment so I would like to
 install Ubuntu and EMC to find out more in conjunction with reading
 all the EMC manuals I have printed out.

 The laptop is a Panansonic Toughbook CF29,Windows XP,Pentium 4,756Mb
 ram.

what's more important to know is which chipset video and CPU are in there.


 From the users emails over the last few days I tried the
 ctrl/alt/f1and have experimented with the f6 boot options.

 The laptop appears to boot to a certain point and then the screen
 goes blank and then 'hangs' with the power off button being the only
 option.

 If I delete splash-- and replace it with vga=771 then the display
 remains on  and the laptop 'hangs' on pulseaudio configured for
 per-user sessions line.

 I have tried some of the other f6 suggestions but not all as yet (I
 will wear the power button out soon).

 I don't know if I can add the options  sequentially to the boot line
 or only use one at a time.

 Does anybody have any suggestions rather than me working through all
 the f6 options without really knowing which maybe causing the boot
 problem ?

 Tim

First try to see if you can install it in text mode only. Next would be 
Ubuntu 11.x to see if it works better or you could try perhaps kubuntu 
version. If not then try a different distribution altogether. I would 
try debian as ubuntu is based on it.

One other option is to try virtual installation inside XP to see if that 
works. RT will not work of course, but you can still test basic EMC 
functionality. Installing virtualbox from Oracle takes only a few minutes.

-- 
Rafael

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Re: [Emc-users] stepper power supply

2011-12-28 Thread Dave Caroline
The reason they state 67% is because they are not getting the full
torque from the motor
They are not fully powering both windings and there is an assumption that
the motors are not all in the same phase so some windings are partially powered.
for full step and full power you power both windings fully.


see half step and microstep sections
http://en.wikipedia.org/wiki/Stepper_motor

Dave Caroline

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Re: [Emc-users] stepper power supply

2011-12-28 Thread kqt4at5v
Well I guess if y'all are going to explain it like that then even I can 
understand it :)

Thanks
Richard

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[Emc-users] Hal comp.

2011-12-28 Thread Spiderdab
Hi all, I need to compare if a value is  or  of another, i think i may
use the comp realtime component, but i can't find how to use that.

is there an example you know about?

thanks, Davide.


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Re: [Emc-users] Hal comp.

2011-12-28 Thread Spiderdab
Il giorno gio, 29/12/2011 alle 00.35 +0100, Spiderdab ha scritto:
 Hi all, I need to compare if a value is  or  of another, i think i may
 use the comp realtime component, but i can't find how to use that.
 
 is there an example you know about?
 
 thanks, Davide.
Sorry, i 've found the solution looking at new pins.
comp.0.out is true when in1in0 and false when in1=in0.

thanks!


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Re: [Emc-users] stepper power supply

2011-12-28 Thread Steve Stallings
Sorry, but a different opinion here

Gecko publishes the 67% number based on
real world experience with a large number
of motors and power supplies tested.

The reality of calculating the current
needed is daunting. First you start by
looking at power, which is what is really
being delivered. The Gecko drivers are
modern chopping drivers which behave
somewhat like a switching power supply.
They convert a high voltage moderate
current into a lower voltage at a
higher, but regulated, current to drive 
the motor. For the same driver and motor 
the current drawn from the power supply 
will be different (lower current) for a 
higher voltage power supply than for a 
lower voltage one. Indeed, I have seen
drivers overheat simply because the
power supply voltage was too low. This 
is a natural result of the driver delivering 
a mostly constant amount of power, but
having to draw more current to do so. 
Heating in the driver is dominated by
I squared R when the MOSFETs are fully
turned on, and twice the current results
in four times the heat losses.

Things get complicated because the
power required is the sum of:

1) mechanical power delivered by the motor
2) mechanical losses within the motor 
   (bearing and air drag)
3) resistive losses ( I squared R )
4) hystersis losses in the iron (this
   is often the main cause of motor heating)
5) efficiency of the driver itself

Modeling all of the above is a lot of
work, even if you do have accurate data
to start from.

Gecko has stated that the 67% is the most
you are going to need assuming you have
selected a reasonable power supply voltage
and are driving the motor to deliver its
maximum mechanical power output.

The fact that most machines only move two
axes at a time for most operations will
mean that the mechanical part of the power
is less, but the other factors are not
much effected by the mechanical power
output.

I generally tell my customers that 50%
is good enough for typical machines, 67%
will provide for anything you can ever
hope to achieve, and anything more is
purely for bragging rights.

Regards,
Steve Stallings
PMDX



 -Original Message-
 From: Dave Caroline [mailto:dave.thearchiv...@gmail.com] 
 Sent: Wednesday, December 28, 2011 1:27 PM
 To: Enhanced Machine Controller (EMC)
 Subject: Re: [Emc-users] stepper power supply
 
 The reason they state 67% is because they are not getting the full
 torque from the motor
 They are not fully powering both windings and there is an 
 assumption that
 the motors are not all in the same phase so some windings are 
 partially powered.
 for full step and full power you power both windings fully.
 
 
 see half step and microstep sections
 http://en.wikipedia.org/wiki/Stepper_motor
 
 Dave Caroline
 
 --
 
 Ridiculously easy VDI. With Citrix VDI-in-a-Box, you don't 
 need a complex
 infrastructure or vast IT resources to deliver seamless, 
 secure access to
 virtual desktops. With this all-in-one solution, easily 
 deploy virtual 
 desktops for less than the cost of PCs and save 60% on VDI 
 infrastructure 
 costs. Try it free! http://p.sf.net/sfu/Citrix-VDIinabox
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 Emc-users@lists.sourceforge.net
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Re: [Emc-users] stepper power supply

2011-12-28 Thread gene heskett
On Wednesday, December 28, 2011 10:10:54 PM Steve Stallings did opine:

 Sorry, but a different opinion here
 
 Gecko publishes the 67% number based on
 real world experience with a large number
 of motors and power supplies tested.
 
 The reality of calculating the current
 needed is daunting. First you start by
 looking at power, which is what is really
 being delivered. The Gecko drivers are
 modern chopping drivers which behave
 somewhat like a switching power supply.
 They convert a high voltage moderate
 current into a lower voltage at a
 higher, but regulated, current to drive
 the motor. For the same driver and motor
 the current drawn from the power supply
 will be different (lower current) for a
 higher voltage power supply than for a
 lower voltage one. Indeed, I have seen
 drivers overheat simply because the
 power supply voltage was too low. This
 is a natural result of the driver delivering
 a mostly constant amount of power, but
 having to draw more current to do so.
 Heating in the driver is dominated by
 I squared R when the MOSFETs are fully
 turned on, and twice the current results
 in four times the heat losses.

Another effect of a miss-match between power supply and driver is often 
overlooked, and that is the I*r loss in the mosfet as it is turning off 
this higher current during the 10-100 nanoseconds it takes to turn it off.  
Because more current was flowing, there are more charge carriers that must 
be cleared away and this loads the mosfets (hexfets) driver stage and slows 
in down.  What this translates to in the real world is that a 48 volt 
driver, running on 24 volts will probably need to get rid of about 4.5 to 5 
times as much heat as the *4 doesn't take this switching time difference 
into account.

OTOH, I think we are getting closer all the time, thanks to the push for 
ever more efficient computer psu's, which has led to the development of 
ever faster switching transition times AND ever lower on resistances.  I 
believe I benefited much from that effect when I blew the hexfet in my 
micromills motor controller.  I looked up and printed out tha data sheet on 
that device, picked up a dead psu I'd had laying around for a couple years, 
checked the hexfets in it, and found that except for the gate capacitance 
going up by about 150%, every other specification was anywhere from 2 to 
10x better.  So I put it in, and watched it with an IR thermometer while 
the motor was being run at about 75% of full rpms for around an hour.  I 
could not find a single part that was more than 15F above the background 
room temp and the hexfet itself was only warmed maybe 3F.  So I put it back 
together and its still fairly well sealed inside a shack project box, about 
a 3.5x5.8x7 black plastic thing, sharing room with your PMDX-106.  It does 
warm some but more than 15F of ambient.  Running nicely for at least 2 
years now.

 
 Things get complicated because the
 power required is the sum of:
 
 1) mechanical power delivered by the motor
 2) mechanical losses within the motor
(bearing and air drag)
 3) resistive losses ( I squared R )
 4) hystersis losses in the iron (this
is often the main cause of motor heating)
 5) efficiency of the driver itself
 
 Modeling all of the above is a lot of
 work, even if you do have accurate data
 to start from.
 
 Gecko has stated that the 67% is the most
 you are going to need assuming you have
 selected a reasonable power supply voltage
 and are driving the motor to deliver its
 maximum mechanical power output.
 
 The fact that most machines only move two
 axes at a time for most operations will
 mean that the mechanical part of the power
 is less, but the other factors are not
 much effected by the mechanical power
 output.
 
 I generally tell my customers that 50%
 is good enough for typical machines, 67%
 will provide for anything you can ever
 hope to achieve, and anything more is
 purely for bragging rights.

Such a statement covers it quite well Steve.

 Regards,
 Steve Stallings
 PMDX

Cheers, Gene
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