want to get feet wet... looking for recommendations

[mistermikev]

15 minutes ago, MiKro said:

Here are the steps for auto step calcs in MAch3.

 

jeeze... spoon feeding me - love it!!  thank you so much.

[curtisa]

5 hours ago, mistermikev said:

so... with your cnc... 20 questions... did you have usb or parallel? 

Initially I used parallel, but I'm now using ethernet with an external step/dir pulse management card.

 

5 hours ago, mistermikev said:

what controller board did you have?

Whatever came with the original CNC3020, probably not too dissimilar to yours. I think TB56-somethingsomething gets mentioned fairly regularly with regards to these cheap generic CNCs. Actually, that's another thing to investigate - check that your step/dir pulse lengths are configured sufficiently long enough in Mach3 to allow each motor to fully advance between steps correctly. That can also be an indicator of lost steps when under load. 

 

[mistermikev]

37 minutes ago, curtisa said:

Initially I used parallel, but I'm now using ethernet with an external step/dir pulse management card.

 

Whatever came with the original CNC3020, probably not too dissimilar to yours. I think TB56-somethingsomething gets mentioned fairly regularly with regards to these cheap generic CNCs. Actually, that's another thing to investigate - check that your step/dir pulse lengths are configured sufficiently long enough in Mach3 to allow each motor to fully advance between steps correctly. That can also be an indicator of lost steps when under load. 

 

thank you for the reply sir.

interesting... seems a common thread among those that know what they are doing that they have ethernet card.  

if I understand... you are talking about calibrating steps as mikro was mentioning earlier?  Setting my steps as it were?  I did calib my x and y axis tonight... y was off a bit (.125ish) but fixing it did not correct my issue.  tomorrow morning I was thinking I would try running it w/o my spindle plugged in.  I am aware that the spindle is typical source for interference with other axis (if there is going to be any... should be there anyway).  

 

looking for the wire connectors... I've found the typical aviation connectors the setup is using now... but have not located a connector like what is on my spindle... if anyone has a source that'd be great.  it looks like it might just be a bigger version of the aviation connectors that the rest use.

[curtisa]

I think we're talking about two different kinds of 'calibration'. Mikro's talking about checking the number of steps required to get an axis to move a known distance. I'm talking about satisfying the minimum requirements of the hardware in order to guarantee correct motor performance; that each pulse generated by the software is correctly adjusted for timing and spacing to make sure that the motor advances a step without losing pace.

[mistermikev]

Just now, curtisa said:

I think we're talking about two different kinds of 'calibration'. Mikro's talking about checking the number of steps required to get an axis to move a known distance. I'm talking about satisfying the minimum requirements of the hardware in order to guarantee correct motor performance; that each pulse generated by the software is correctly adjusted for timing and spacing to make sure that the motor advances a step without losing pace.

can you elab afa how a simpleton like me might accomplish?

[curtisa]

The hardware you're using to drive the stepper motors will have some kind of minimum specs for the incoming step/direction signals to satisfy in order for the motors to reliably rotate from step to step. If you're lucky your drivers will specify these minimum parameters in the datasheet. Something like this:

Each driver accepts two signals to define the motor's motion - the step and direction signal lines. The step signal controls the rotation of the motor; every pulse that appears on the step line advances the motor around by one increment. The more pulses the further around the motor will rotate. Steps coming in more frequently translates to the motor turning much quicker. The direction signal controls whether the motor rotates clockwise or anticlockwise when the step signal is pulsed. If the direction signal is 'on' the motor may rotate clockwise, and if 'off' it will rotate the other way. The above table highlights some minimum timing requirements for each of the two signals:

1. The step signal when it pulses 'on' must be on for a minimum time in order to be reliably registered by the driver as a step command (labelled as 'Pulse duration, STEP high' in the table = 1.9 microseconds). Anything shorter than this specification of 1.9usec may result in the driver not seeing the pulse and a steps can be lost.
2. The step signal when it pulses 'off' again must be off for a minimum time before the next pulse comes along ('Pulse duration, STEP low = 1.9usec). Anything shorter than 1.9usec may result in the driver not seeing the subsequent pulse and a steps can be lost.
3. The direction signal needs some time after being turned on (rotation = clockwise) or off (rotation = anticlockwise) before any subsequent steps commence on the step line (Setup time, command before STEP rising = 650 nanoseconds). Anything shorter than this specification of 650 nsec may result in steps being lost.
4. The direction signal needs some time to remain in its last stable state before changing again if you want to make the motor begin rotating in the opposite direction (Hold time, command after STEP rising = 650nsec). Anything shorter than this specification of 650 nsec may result in steps being lost.

The above parameters should be configurable in Mach3 for each axis/motor (I'd be surprised if you can't), but I'm basing this solely off LinuxCNC which does allow the user to configure this kind of driver information. Ideally the software should be configured with timing information no lower than the above values, but for reliability you'd probably use values 2x of those presented in the table above. Naturally, if your driver has different data use that instead - you may be able to pop the cover off the top of the CNC interface box and see if you can locate the driver ICs and do a search for a datasheet on Google based on the IC part code.

Probably a bit more info than you really needed...

[mistermikev]

3 hours ago, curtisa said:

The hardware you're using to drive the stepper motors will have some kind of minimum specs for the incoming step/direction signals to satisfy in order for the motors to reliably rotate from step to step. If you're lucky your drivers will specify these minimum parameters in the datasheet. Something like this:

Each driver accepts two signals to define the motor's motion - the step and direction signal lines. The step signal controls the rotation of the motor; every pulse that appears on the step line advances the motor around by one increment. The more pulses the further around the motor will rotate. Steps coming in more frequently translates to the motor turning much quicker. The direction signal controls whether the motor rotates clockwise or anticlockwise when the step signal is pulsed. If the direction signal is 'on' the motor may rotate clockwise, and if 'off' it will rotate the other way. The above table highlights some minimum timing requirements for each of the two signals:

1. The step signal when it pulses 'on' must be on for a minimum time in order to be reliably registered by the driver as a step command (labelled as 'Pulse duration, STEP high' in the table = 1.9 microseconds). Anything shorter than this specification of 1.9usec may result in the driver not seeing the pulse and a steps can be lost.
2. The step signal when it pulses 'off' again must be off for a minimum time before the next pulse comes along ('Pulse duration, STEP low = 1.9usec). Anything shorter than 1.9usec may result in the driver not seeing the subsequent pulse and a steps can be lost.
3. The direction signal needs some time after being turned on (rotation = clockwise) or off (rotation = anticlockwise) before any subsequent steps commence on the step line (Setup time, command before STEP rising = 650 nanoseconds). Anything shorter than this specification of 650 nsec may result in steps being lost.
4. The direction signal needs some time to remain in its last stable state before changing again if you want to make the motor begin rotating in the opposite direction (Hold time, command after STEP rising = 650nsec). Anything shorter than this specification of 650 nsec may result in steps being lost.

The above parameters should be configurable in Mach3 for each axis/motor (I'd be surprised if you can't), but I'm basing this solely off LinuxCNC which does allow the user to configure this kind of driver information. Ideally the software should be configured with timing information no lower than the above values, but for reliability you'd probably use values 2x of those presented in the table above. Naturally, if your driver has different data use that instead - you may be able to pop the cover off the top of the CNC interface box and see if you can locate the driver ICs and do a search for a datasheet on Google based on the IC part code.

Probably a bit more info than you really needed...

wow, that's a big bite.... need to chew chew chew.  well, feels like the term step is getting used in more than one meaning... but in this one - I have read that the step setting in mach3 for my drivers is 320.  pretty interesting stuff.  I will be taking the ctrl box apart this weekend and know what the drivers are... will see if I can find the datasheet.  thank you very much for the info!!

[mistermikev]

well for the record... just trying to keep wacking the mole over here... 

tried running without my spindle - nothing changed.

altered my accel and velocity... ran slower but nothing changed.  

so we can cross those two things off the list.

[MiKro]

5 hours ago, mistermikev said:

wow, that's a big bite.... need to chew chew chew.  well, feels like the term step is getting used in more than one meaning... but in this one - I have read that the step setting in mach3 for my drivers is 320.  pretty interesting stuff.  I will be taking the ctrl box apart this weekend and know what the drivers are... will see if I can find the datasheet.  thank you very much for the info!!

What Andrew is referring to is here in Mach3.

 

[mistermikev]

 

1 minute ago, MiKro said:

What Andrew is referring to is here in Mach3.

 

interesting... my steps are 320, velocity 1500 and accel 400!  good to know this is where I will look when I figure out what drivers/motors I have.  thanks again for the info!!

[MiKro]

40 minutes ago, mistermikev said:

 

interesting... my steps are 320, velocity 1500 and accel 400!  good to know this is where I will look when I figure out what drivers/motors I have.  thanks again for the info!!

The steps and velocity I show are what ever they are in mach3 upon install, This is just Mach3 installed on my main PC for processing Screenshots. Not my actual working control PC. LOl

MK

[mistermikev]

9 minutes ago, MiKro said:

The steps and velocity I show are what ever they are in mach3 upon install, This is just Mach3 installed on my main PC for processing Screenshots. Not my actual working control PC. LOl

MK

oh, well... that's reassuring cause i thought mine might be WAY off!! lol

[curtisa]

Have you tried running the troublesome routine in a CAM simulator to see if the creeping axis is occurring in the code rather than in your machine? I use Camotics to proof stuff before committing it to the workpiece:

https://camotics.org

[mistermikev]

1 hour ago, curtisa said:

Have you tried running the troublesome routine in a CAM simulator to see if the creeping axis is occurring in the code rather than in your machine? I use Camotics to proof stuff before committing it to the workpiece:

https://camotics.org

I didn't realize such a thing existed... then again I did run someone else's version of the toolpath... which is just a shape cut to a pocket... and had similar but opposite problems... but this is an invaluable resource... will try it tonight!!

[mistermikev]

6 hours ago, curtisa said:

Have you tried running the troublesome routine in a CAM simulator to see if the creeping axis is occurring in the code rather than in your machine? I use Camotics to proof stuff before committing it to the workpiece:

https://camotics.org

idk how... but must have never sent my reply.  gonna try this nao - good call!!

[mistermikev]

well..... not the code.  ran perfect and as expected.  that said... an invaluable resource so thank you for that.  

the thing that stuck me about my tests this morning... the code runs the exact sm way every time I run it.  it's def not a mech issue because you'd think there would be some variation... but each pass it shifts the shape the width of the bit to the right... and after running my x axis is shifted the width of the bit minus stepover times however many passes I've made to the right.  

anywho... I need to do some work on this control box... but if I'm putting the effort into it... I can't help but think I'd be better off just investing in building a new control box that in theory I could transport to a new machine down the road (something that could handle a neck thru bass w/o tiling).  Every story on cnczone that ends with someone getting a gekko g540 seems to have a happy ending... and there are countless stories of folks putting all sorts of effort into trying to diagnose/fix the chinese controller.  

think on it for a while...

[curtisa]

3 minutes ago, mistermikev said:

the code runs the exact sm way every time I run it.  it's def not a mech issue because you'd think there would be some variation... but each pass it shifts the shape the width of the bit to the right...

Then it's looking more likely that there's some subtle difference in the way the code is being executed, rather than an issue with the driver hardware, electrical installation or mechanical foibles with the machine.

Shifting the toolpath to one side by the width of the bit is interesting. Incorrectly defined cutter compensation perhaps? That could also explain why your code provided by the other user runs fine on their machine but does oddball things on yours (cutter compensation based on any tool tables you have set up in Mach3 would be particular to the end user, rather than something universal within the Gcode).

Care to share your routine? 

[mistermikev]

well... right now aspire puts out just 'tool 1' every time... I've split my job into each toolpath and really only run one (or occassionally two) common tools at the sm time... and it is always a 1/4" bit.  what I'm getting at is - afa mach3 is concerned it is seeing that sm bit (at least I think so) for each job.  it is successful in other cases.

share my routine - ok, not sure if I know 100% what you want but... basically take some vectors in aspire.. right now I'm importing bitmaps that came from photoshop, then doing a bitmap trace to get vectors in aspire.  then I use the aspire command to smooth this out eliminating points. make a toolpath setting depth and picking a tool, output that to text file with mach3 post processor, transfer via usb strick... everything I do is based around centerline - that's just how I'm comfy... so take a piece of wood, mark out with pencil my ctr... find center with a 60deg engraving bit, then jog the machine to one end of ctr line, then jog to other end to ensure bit is on that line at either end... then lock the piece down with clamps.  run my program to do rear bolt holes... put in nylon bolts and slide the workpiece in... lock down, drill front bolt holes... put nylon bolts in front, lock down, then from there I just keep finding center each time I run something.  find center and cut shape of gtr, find ctr cut shape of pickup, find center cut knob holes, then find ctr and cut neck pocket.  (I am aware I could simply tell mach3 to find home but starting out and making sure as I go since first real proj)  all prior steps used the sm 1/4 bit setup in aspire.  sm feed and such as that is all setup on the tool profile altho I did change it after.

[curtisa]

I just meant, 'do want me to have a look at your Gcode file?'

[mistermikev]

hehe, really overshot the mark on that one... sure, yes abso-motherfricken-lutely:

( Step07__CT5StringBody_V2.08_Top_NeckPocket{AngledWorkpiece}_spiralPath )
( File created: Saturday November 21 2020 - 02:05 PM)
( for Mach2/3 from Vectric )
( Material Size)
( X= 15.900, Y= 20.400, Z= 2.250)
()
(Toolpaths used in this file:)
(NeckPocket-AngledWorkpiece)
(Tools used in this file: )
(1 = End Mill MV {0.25 inch})
N100G00G20G17G90G40G49G80
N110G70G91.1
N120T1M06
N130 (Tool: End Mill MV {0.25 inch})
N140G00G43Z0.8000H1
N150S12000M03
N160(Toolpath:- NeckPocket-AngledWorkpiece)
N170()
N180G94
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%
 

[curtisa]

So you're finding that it starts off and does one spiral clearing pattern from the inside out, and when it returns to do the next spiral pattern at the next depth down it attempts to start again shifted right, and so on and so on?

[curtisa]

Some thoughts on the code. I don't know if they have an impact but they stand out to my eyes:

1. The Gcode doesn't define a coordinate offset system. I'd expect there to be either a G53 (machine absolute) or G54 (user defined) mentioned in the header somewhere, but there isn't anything. Not saying it indicates a problem, but it looks odd. It opens fine on LinuxCNC as it is and looks OK on the backplot.
2. On line N110 the command G70 is issued to tell Mach3 to use inches as the units of movement. On line N100 G20 is also issued to tell Mach3 to use inches. The Mach3 Gcode reference suggests that G20 should be used in preference to G70. Can't imagine it makes any difference if essentially the same command (although may be is issued twice
3. On Line N100 G90 is issued to tell Mach3 to switch to absolute positioning mode. On line N110 G91.1 is issued which tells Mach3 to use incremental mode for arc movements. As your Gcode doesn't use arc moves anyway (no lines prefixed with G2 or G3), you'd think that requesting mixed modes of positioning would be handled OK by Mach3 and it would just ignore the G91.1 command, but who knows?
4. On line N140 G43 is used to initiate a tool length compensation of 0.8". This shouldn't affect the positioning of the X axis (it changes the apparent position of the Z axis while cutting to compensate for the amount of 'stick-out' the tool has below the collet), but is largely redundant in your case as I don't believe you can insert the cutting tool into the collet of the spindle at a predefined, repeatable length every time.
5. Your programmed feed rates for the bulk of the cutting moves is 80 inches per minute. If I'm reading your earlier comment about the stepper motor settings you have a maximum feed rate in Mach 3 of 1500 (I assume this is mm/min?). 80 IPM is 2032 mm/min, which is faster than your maximum axis speed in Mach3. Mach3 should just limit the maximum speed while the Gcode is running to 1500mm/min if asked to do more than this, but maybe something odd happens in Mach3 when the axis velocity limit is reached while running?
6. At the end of each spiral clearing pattern the program pulls the cutter up 0.2" above the surface and does a rapid (G00) move back to the start of the spiral and starts again. Maybe the X axis is over-travelling while doing this return move? Try lowering your acceleration speed in Mach3 for the X axis and see if that changes things.  

Do you have another Gcode for something similar that you know works reliably to compare with? Maybe a pickup cavity?

[mistermikev]

13 hours ago, curtisa said:

So you're finding that it starts off and does one spiral clearing pattern from the inside out, and when it returns to do the next spiral pattern at the next depth down it attempts to start again shifted right, and so on and so on?

no... I don't even finish the first pass.  I start it and the second cycle I can see that instead of 'moving further out' to the west... it just keeps hitting the centerline... but does keep moving east with each circle around.  If I stop it after 3-5 passes - my x is now out of alignment by .25" or so.

very much appreciate the fine detail... I've looked over this code and am not fully versed in gcode yet but I get the gist and your play by play has learned me a few things so thanks for that.

the reason it's issuing the arch code is that the post processor I'm using is the 'arc' version from aspire for mach3.  just trying to keep it simple by using the sm thing at all times so I used this post processor as it is the recommended one.

I'm guessing that is also why it sets up the positioning as such, but I can try a dif post processor to see if it changes anything.

my mach3 machine is setup to use inches... tho I'm not sure what units the 1500 is in... I can tell you that reducing from 100 to 80 did make a difference in speed.  Further dif at 70 and then 40.  none of this changed how the tool ran.

#6 - again, I didn't even complete a full pass on my testing... if I run for 3-5 circles around the axis it ends up being out almost immediately.  the fact that is does NOT do this when running a horizontal pickup cavity... suggests to me it is loosing the fine detail of the angle. 

further... when I watch mach3 execute lines... it does seem to 'jump down'.  originally I thought this must be that it's executing the lines in between so fast that it just looks like it's jumping... but the more I look the more I think that this is actually the 'skipping steps' that this model is so infamous for. 

I tried to just guess at how to execute mach3 code line by line via the interface to see if that would fix things... but I guess I need to read up on how to do that as my first guess didn't quite do it.

thank you again for the detailed help!  very much appreciate it!!

[curtisa]

3 hours ago, mistermikev said:

no... I don't even finish the first pass.  I start it and the second cycle I can see that instead of 'moving further out' to the west... it just keeps hitting the centerline... but does keep moving east with each circle around.

So instead of doing this:

It's doing this?:

Ie, the machine doesn't want to go to any position where the X coordinates are less than zero and the motion gets 'clipped'?

[mistermikev]

1 hour ago, curtisa said:

So instead of doing this:

It's doing this?:

Ie, the machine doesn't want to go to any position where the X coordinates are less than zero and the motion gets 'clipped'?

yes, that's it in a nutshell.