5i25+7i76 Spindle and Encoder Setup

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29 Sep 2013 18:27 #39344 by Bad_German
Hi, I've been stuck on this for a wile and cannot get the lathe spindle and encoder working correctly.

1. The spindle analogue output (0-10V) works with Sxxx M3 command but not with a M4, CCW.
The enable and direction optocoupler outputs work, I just don't get any analogue output on SPINDLE OUT pin with an M4 command.

2. I have no feedback from the encoder, it is a 360ppr + index, non-quadrature encoder which I don't know how to setup.
PNCConf has already set "setp hm2_5i25.0.encoder.00.counter-mode 1", and I can't figure out what to change, to show the speed in the PYVCP.
In halscope "spindle-vel-fb" is also always zero.

Can you please point me in the right direction, to fix these 2 problems?

My Setup:
meas 5i25+7i76
Linuxcnc 2.5.3
Spindle Control: 0-10V, direction, enable
Encoder: 5V 360ppr (channel A) + index.


Hall:
# Generated by PNCconf at Sun Sep 29 12:26:37 2013
# If you make changes to this file, they will be
# overwritten when you run PNCconf again

loadrt trivkins
loadrt [EMCMOT]EMCMOT servo_period_nsec=[EMCMOT]SERVO_PERIOD num_joints=[TRAJ]AXES
loadrt probe_parport
loadrt hostmot2
loadrt hm2_pci config=" num_encoders=1 num_pwmgens=0 num_3pwmgens=0 num_stepgens=2 sserial_port_0=00xxxxxx " 
setp     hm2_5i25.0.watchdog.timeout_ns 10000000
loadrt hal_parport cfg="0x0378 out"
loadrt pid names=pid.s
loadrt abs names=abs.spindle
loadrt lowpass names=lowpass.spindle
loadrt scale names=scale.spindle

addf parport.0.read servo-thread
addf parport.0.write servo-thread
addf hm2_5i25.0.read servo-thread
addf motion-command-handler servo-thread
addf motion-controller servo-thread
addf pid.s.do-pid-calcs                 servo-thread
addf abs.spindle                 servo-thread
addf scale.spindle                 servo-thread
addf lowpass.spindle             servo-thread
addf hm2_5i25.0.write         servo-thread
addf hm2_5i25.0.pet_watchdog  servo-thread

# external output signals



# --- MACHINE-IS-ENABLED ---
net machine-is-enabled parport.0.pin-01-out

# --- COOLANT-FLOOD ---
net coolant-flood parport.0.pin-09-out

# external input signals


# --- MIN-X ---
net min-x     <=  hm2_5i25.0.7i76.0.0.input-00-not

# --- MIN-Z ---
net min-z     <=  hm2_5i25.0.7i76.0.0.input-01-not

# --- MAX-HOME-X ---
net max-home-x     <=  hm2_5i25.0.7i76.0.0.input-02-not

# --- MAX-HOME-Z ---
net max-home-z     <=  hm2_5i25.0.7i76.0.0.input-03-not


# --- ESTOP-EXT ---
net estop-ext     <= parport.0.pin-15-in-not

#*******************
#  AXIS X
#*******************

# Step Gen signals/setup

setp   hm2_5i25.0.stepgen.00.dirsetup        [AXIS_0]DIRSETUP
setp   hm2_5i25.0.stepgen.00.dirhold         [AXIS_0]DIRHOLD
setp   hm2_5i25.0.stepgen.00.steplen         [AXIS_0]STEPLEN
setp   hm2_5i25.0.stepgen.00.stepspace       [AXIS_0]STEPSPACE
setp   hm2_5i25.0.stepgen.00.position-scale  [AXIS_0]STEP_SCALE
setp   hm2_5i25.0.stepgen.00.step_type        0
setp   hm2_5i25.0.stepgen.00.control-type     0
setp   hm2_5i25.0.stepgen.00.maxaccel         62.5
setp   hm2_5i25.0.stepgen.00.maxvel           16.7

net x-pos-fb     axis.0.motor-pos-fb   <=  hm2_5i25.0.stepgen.00.position-fb
net x-pos-cmd    axis.0.motor-pos-cmd  =>  hm2_5i25.0.stepgen.00.position-cmd
net x-enable     axis.0.amp-enable-out =>  hm2_5i25.0.stepgen.00.enable

# ---setup home / limit switch signals---

net max-home-x     =>  axis.0.home-sw-in
net min-x     =>  axis.0.neg-lim-sw-in
net max-home-x     =>  axis.0.pos-lim-sw-in

#*******************
#  AXIS Z
#*******************

# Step Gen signals/setup

setp   hm2_5i25.0.stepgen.01.dirsetup        [AXIS_2]DIRSETUP
setp   hm2_5i25.0.stepgen.01.dirhold         [AXIS_2]DIRHOLD
setp   hm2_5i25.0.stepgen.01.steplen         [AXIS_2]STEPLEN
setp   hm2_5i25.0.stepgen.01.stepspace       [AXIS_2]STEPSPACE
setp   hm2_5i25.0.stepgen.01.position-scale  [AXIS_2]STEP_SCALE
setp   hm2_5i25.0.stepgen.01.step_type        0
setp   hm2_5i25.0.stepgen.01.control-type     0
setp   hm2_5i25.0.stepgen.01.maxaccel         62.5
setp   hm2_5i25.0.stepgen.01.maxvel           16.7

net z-pos-fb     axis.2.motor-pos-fb   <=  hm2_5i25.0.stepgen.01.position-fb
net z-pos-cmd    axis.2.motor-pos-cmd  =>  hm2_5i25.0.stepgen.01.position-cmd
net z-enable     axis.2.amp-enable-out =>  hm2_5i25.0.stepgen.01.enable

# ---setup home / limit switch signals---

net max-home-z     =>  axis.2.home-sw-in
net min-z     =>  axis.2.neg-lim-sw-in
net max-home-z     =>  axis.2.pos-lim-sw-in

#*******************
#  SPINDLE S
#*******************

# ---digital potentionmeter output signals/setup---

setp   hm2_5i25.0.7i76.0.0.spinout-minlim    [SPINDLE_9]OUTPUT_MIN_LIMIT
setp   hm2_5i25.0.7i76.0.0.spinout-maxlim    [SPINDLE_9]OUTPUT_MAX_LIMIT
setp   hm2_5i25.0.7i76.0.0.spinout-scalemax  [SPINDLE_9]OUTPUT_SCALE

net spindle-vel-cmd     => hm2_5i25.0.7i76.0.0.spinout
net machine-is-enabled      => hm2_5i25.0.7i76.0.0.spinena
net spindle-ccw         => hm2_5i25.0.7i76.0.0.spindir

# ---Encoder feedback signals/setup---

setp    hm2_5i25.0.encoder.00.counter-mode 1
setp    hm2_5i25.0.encoder.00.filter 1
setp    hm2_5i25.0.encoder.00.index-invert 0
setp    hm2_5i25.0.encoder.00.index-mask 0
setp    hm2_5i25.0.encoder.00.index-mask-invert 0
setp    hm2_5i25.0.encoder.00.scale  [SPINDLE_9]ENCODER_SCALE

net spindle-revs              <=  hm2_5i25.0.encoder.00.position
net spindle-vel-fb            <=  hm2_5i25.0.encoder.00.velocity
net spindle-index-enable     <=>  hm2_5i25.0.encoder.00.index-enable

# ---setup spindle control signals---

net spindle-vel-cmd-rps    <=  motion.spindle-speed-out-rps
net spindle-vel-cmd        <=  motion.spindle-speed-out
net spindle-on             <=  motion.spindle-on
net spindle-cw             <=  motion.spindle-forward
net spindle-ccw            <=  motion.spindle-reverse
net spindle-brake          <=  motion.spindle-brake
net spindle-revs           =>  motion.spindle-revs
net spindle-at-speed       =>  motion.spindle-at-speed
net spindle-vel-fb         =>  motion.spindle-speed-in
net spindle-index-enable  <=>  motion.spindle-index-enable

# ---Setup spindle at speed signals---

sets spindle-at-speed true

#  Use ACTUAL spindle velocity from spindle encoder
#  spindle-velocity bounces around so we filter it with lowpass
#  spindle-velocity is signed so we use absolute component to remove sign
#  ACTUAL velocity is in RPS not RPM so we scale it.

setp     scale.spindle.gain 60
setp     lowpass.spindle.gain 1.000000
net spindle-vel-fb        =>   lowpass.spindle.in
net spindle-fb-filtered-rps    lowpass.spindle.out      =>   abs.spindle.in
net spindle-fb-filtered-abs-rps    abs.spindle.out      =>   scale.spindle.in
net spindle-fb-filtered-abs-rpm    scale.spindle.out

#******************************
# connect miscellaneous signals
#******************************

#  ---HALUI signals---

net joint-select-a        halui.joint.0.select
net x-is-homed            halui.joint.0.is-homed
net jog-x-pos             halui.jog.0.plus
net jog-x-neg             halui.jog.0.minus
net jog-x-analog          halui.jog.0.analog
net joint-select-c        halui.joint.2.select
net z-is-homed            halui.joint.2.is-homed
net jog-z-pos             halui.jog.2.plus
net jog-z-neg             halui.jog.2.minus
net jog-z-analog          halui.jog.2.analog
net jog-selected-pos      halui.jog.selected.plus
net jog-selected-neg      halui.jog.selected.minus
net spindle-manual-cw     halui.spindle.forward
net spindle-manual-ccw    halui.spindle.reverse
net spindle-manual-stop   halui.spindle.stop
net machine-is-on         halui.machine.is-on
net jog-speed             halui.jog-speed 
net MDI-mode              halui.mode.is-mdi

#  ---coolant signals---

net coolant-mist      <=  iocontrol.0.coolant-mist
net coolant-flood     <=  iocontrol.0.coolant-flood

#  ---probe signal---

net probe-in     =>  motion.probe-input

#  ---motion control signals---

net in-position               <=  motion.in-position
net machine-is-enabled        <=  motion.motion-enabled

#  ---digital in / out signals---

#  ---estop signals---

net estop-out     <=  iocontrol.0.user-enable-out
net estop-ext     =>  iocontrol.0.emc-enable-in

#  ---toolchange signals for custom tool changer---

net tool-number             <=  iocontrol.0.tool-prep-number
net tool-change-request     <=  iocontrol.0.tool-change
net tool-change-confirmed   =>  iocontrol.0.tool-changed
net tool-prepare-request    <=  iocontrol.0.tool-prepare
net tool-prepare-confirmed  =>  iocontrol.0.tool-prepared

Ini:
# Generated by PNCconf at Sun Sep 29 12:26:37 2013
# If you make changes to this file, they will be
# overwritten when you run PNCconf again

[EMC]
MACHINE = EMCO-Turn120
DEBUG = 0

[DISPLAY]
DISPLAY = axis
POSITION_OFFSET = RELATIVE
POSITION_FEEDBACK = ACTUAL
MAX_FEED_OVERRIDE = 2.000000
MAX_SPINDLE_OVERRIDE = 1.000000
MIN_SPINDLE_OVERRIDE = 0.500000
INTRO_GRAPHIC = linuxcnc.gif
INTRO_TIME = 5
PROGRAM_PREFIX = /home/stephan/linuxcnc/nc_files
PYVCP = pyvcp-panel.xml
INCREMENTS = 5mm 1mm .5mm .1mm .05mm .01mm .005mm
LATHE = 1
POSITION_OFFSET = RELATIVE
POSITION_FEEDBACK = ACTUAL
DEFAULT_LINEAR_VELOCITY = 10.000000
MAX_LINEAR_VELOCITY = 13.333333
MIN_LINEAR_VELOCITY = 0.010000
DEFAULT_ANGULAR_VELOCITY = 0.250000
MAX_ANGULAR_VELOCITY = 1.000000
MIN_ANGULAR_VELOCITY = 0.010000
EDITOR = gedit
GEOMETRY = xz

[FILTER]
PROGRAM_EXTENSION = .png,.gif,.jpg Greyscale Depth Image
PROGRAM_EXTENSION = .py Python Script
png = image-to-gcode
gif = image-to-gcode
jpg = image-to-gcode
py = python

[TASK]
TASK = milltask
CYCLE_TIME = 0.010

[RS274NGC]
PARAMETER_FILE = linuxcnc.var

[EMCMOT]
EMCMOT = motmod
COMM_TIMEOUT = 1.0
COMM_WAIT = 0.010
SERVO_PERIOD = 1000000

[HOSTMOT2]
# **** This is for info only ****
# DRIVER0=hm2_pci
# BOARD0=5i25

[HAL]
HALUI = halui
HALFILE = EMCO-Turn120.hal
HALFILE = custom.hal
POSTGUI_HALFILE = postgui_call_list.hal
SHUTDOWN = shutdown.hal

[HALUI]

[TRAJ]
AXES = 3
COORDINATES = X Z
LINEAR_UNITS = mm
ANGULAR_UNITS = degree
CYCLE_TIME = 0.010
DEFAULT_VELOCITY = 1.33
MAX_LINEAR_VELOCITY = 13.33
NO_FORCE_HOMING = 1

[EMCIO]
EMCIO = io
CYCLE_TIME = 0.100
TOOL_TABLE = tool.tbl

#********************
# Axis X
#********************
[AXIS_0]
TYPE = LINEAR
HOME = 0.0
FERROR = 0.005
MIN_FERROR = 0.0005
MAX_VELOCITY = 13.3333333333
MAX_ACCELERATION = 50.0
# these are in nanoseconds
DIRSETUP   = 5000
DIRHOLD    = 5000
STEPLEN    = 2500
STEPSPACE  = 2500
STEP_SCALE = -1280.0
MIN_LIMIT = -0.2
MAX_LIMIT = 50.0
HOME_OFFSET = 0.000000
HOME_SEARCH_VEL = -6.666667
HOME_LATCH_VEL = 3.333333
HOME_FINAL_VEL = 0.333333
HOME_USE_INDEX = NO
HOME_IGNORE_LIMITS = YES
HOME_SEQUENCE = 1

#********************
# Axis Z
#********************
[AXIS_2]
TYPE = LINEAR
HOME = 0.0
FERROR = 0.005
MIN_FERROR = 0.0005
MAX_VELOCITY = 13.3333333333
MAX_ACCELERATION = 50.0
# these are in nanoseconds
DIRSETUP   = 5000
DIRHOLD    = 5000
STEPLEN    = 2500
STEPSPACE  = 2500
STEP_SCALE = -1280.0
MIN_LIMIT = -134.0
MAX_LIMIT = 0.2
HOME_OFFSET = 0.000000
HOME_SEARCH_VEL = 6.666667
HOME_LATCH_VEL = -3.333333
HOME_FINAL_VEL = 0.333333
HOME_USE_INDEX = NO
HOME_IGNORE_LIMITS = YES
HOME_SEQUENCE = 0

#********************
# Spindle 
#********************
[SPINDLE_9]
ENCODER_SCALE = 1440.0
OUTPUT_SCALE = 2000.0
OUTPUT_MIN_LIMIT = 0.0
OUTPUT_MAX_LIMIT = 2000.0
Attachments:

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29 Sep 2013 20:47 - 29 Sep 2013 21:01 #39346 by cmorley
I see you have set:
min output limit of the spindle to 0
max limit to 2000
ans scale to 2000

That means you can have a range of 0 to 2000.
Notice how there is no negative range - negative is reverse rotation.

set min limit to -2000

oh wait you can't have negative voltage...so don't change it
I think you need to add an abs component to make sure the voltage is always positive.

you would need to change:
loadrt abs names=abs.spindle
to:
loadrt abs names=abs.spindle,abs,spindle_output

add line
addf abs.spindle_output servo-thread
after line
addf abs.spindle servo-thread

it needs to go between:
net spindle-vel-cmd => hm2_5i25.0.7i76.0.0.spinout
so change it to:
net spindle-vel-cmd => abs.spindle_output.in
net spindle-vel-cmd-abs abs.spindle_output => hm2_5i25.0.7i76.0.0.spinout

I've not tested this but that should do it.
looking at the encoder part ....

Chris M
Last edit: 29 Sep 2013 21:01 by cmorley.

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29 Sep 2013 21:17 #39348 by cmorley
I don't see anything obviously wrong with the encoder HAL file.
Please check wiring, if the encoder is producing signals and that you are connected to encoder 0

Chris M
The following user(s) said Thank You: Bad_German

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29 Sep 2013 21:51 #39349 by PCW
Also for the encoder to work in count mode you must connect the encoder output
to the 'A' input on the 7I76 and jumper the 7I76 encoder input for TTL type signals

Its probably arguable that motion should have both a signed spindle
velocity pin (as it does now) and a unsigned spindle speed pin
(since it already has the direction signals) To avoid the common
requirement of the absolute component here.
The following user(s) said Thank You: Bad_German

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30 Sep 2013 02:23 #39367 by Bad_German
Thanks for the help guy's, you're awesome,
both parts are working now.

fixed two typos, just for future reference...
Replace: loadrt abs names=abs.spindle 
with:
loadrt abs names=abs.spindle,abs.spindle_output

add:
addf abs.spindle_output servo-thread

replace: net spindle-vel-cmd     => hm2_5i25.0.7i76.0.0.spinout  
with:
net spindle-vel-cmd => abs.spindle_output.in
net spindle-vel-cmd-abs abs.spindle_output.out => hm2_5i25.0.7i76.0.0.spinout

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30 Sep 2013 02:59 #39369 by cmorley

Also for the encoder to work in count mode you must connect the encoder output
to the 'A' input on the 7I76 and jumper the 7I76 encoder input for TTL type signals

Its probably arguable that motion should have both a signed spindle
velocity pin (as it does now) and a unsigned spindle speed pin
(since it already has the direction signals) To avoid the common
requirement of the absolute component here.


Yes I agree - working on a patch now.
It would be nice if hostmot has encoder/resolver velocity as an absolute as well.
its common to filter and absolute it for spindle readout display...

Chris M

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15 Dec 2013 20:49 #41625 by Mr_Mayhem
Hi Chris,

Linuxcnc 2.5.0, live cd installed on hd running on older dell. I have the same Meas cards, the 5i25 with the 7i76 daughter card, as above. I have been trying for several days to get Pncconf to configure my spindle via variable voltage output from 7i76 TB4. I want to use the analog 10v variable voltage output on 7i76 TB4 to vary the voltage to my spindle VFD in the usual manner. I don't think I have a problem with the physical connections. My issue is errors in Pncconf.

I do NOT have an encoder for the spindle, it is a chinese 1500 watt water cooled spindle controlled by VFD, simple er11 collett.

For testing I have a digital voltmeter hooked up to the output pin TB4 Pin 2 on the actual 7i76 card, with 13 volts to pin 3 and common to pin 1. So I should see the meter change in relation to commands, but no results with this so far.

My main question has become, can I do this spindle control config in Pncconf (I get errors on "Apply") or do I have to type in the settings manually? Should I simply copy the spindle and abs related lines from the above example?

It would be nice to see Pncconf work the way it should for my no-encoder spindle setup, without resorting to the hal file editing. If I need to manually edit, no problem, but hey, this is a very nice piece of software with a minor issue that can be fixed. I will put in the time and test any fixes you need for this hardware setup.

So far, my attempts in Pncconf pops errors when I get to the final step and hit "Apply". Maybe I am doing it all wrong. To activate the spindle output, I was using the "5i25 firmware: 7i76x1", Tab "Smart Serial 0", sub-tab "7i76 Mode 9 I/O Card", and set the first drop-down item function to "Spindle Output". I click "Foward" to the end and click "Apply" and the error below pops. I do see a Spindle screen and maybe my settings there are screwy, but I have gotten the error for various settings there.

The error says
" PNCconf encountered an error. The following information may be useful in troubleshooting:
Traceback (most recent call last):
File "/usr/bin/pncconf", line 8104, in on_complete_finish
self.data.save()
File "/usr/bin/pncconf", line 3337, in save
self.write_inifile(base)
File "/usr/bin/pncconf", line 1557, in write_inifile
self.write_one_axis(file,9,"s","null",all_homes)
File "/usr/bin/pncconf" line 1618, in write_one_axis
If "analog" in pwmpinname or potoutput:
TypeError: argument type 'NoneType' is not iterable

That's it.

Thanks in advance, Chris. That Pncconf is one complex app. Let me know what can be done, and if you need me to test a fix, no problem. I am not a linux guru, but I can follow directions. If I fix this manually, is the code above appropriate for my no-encoder spindle control, or if not what do I need to change or add? Generally, I want 10 volts to make the spindle do top speed of 24,000 RPM, and zero volts to be zero rpm, with tweaking to follow of course to match reality better.

Thanks in Advance. I am impressed with Linuxcnc and Pncconf, and I am willing to help test new fixes for the 5i25 / 7i76 boards.

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16 Dec 2013 03:33 #41631 by cmorley
Hey Mr_Mayhem

I see you said you are using 2.5.0 from the live CD. Did you update to 2.5.3?

I tried setting the spindle with no encoder and I get no error. (2.5.3)
What I am saying is I think this is fixed on the newer version.

It is unfortunate that we don't upgrade the image on the CD.

Thanks for the informative bug report and if there are still problems please let me know.
Also as it sounds you are new to using Pncconf , any other suggestions are welcome.

Chris M

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16 Dec 2013 12:42 #41637 by Mr_Mayhem
Thanks, I did the upgrade from Linuxcnc 2.5.0 to 2.5.3, walked through pncconf settings to add the spindle on the TB4 output subtab, and it now works. With this new version of Linuxcnc, The 3rd subtab under smart serial 0 tab is now labeled "7i76 Analog Output TB4", whereas under 2.5.0 it did not use the word Analog or mention TB anything.

I had a little challenge to get updated because my box is offline.
For benefit of others, what follows is the procedure I followed to update Linuxcnc 2.5.0 (as installed from live cd) to the latest 2.5.3 version.

I went here, the official home of the binaries I suppose:
buildbot.linuxcnc.org/dists/lucid/v2.5_branch-rt/binary-i386/

and downloaded the very last file on that list, which was
linuxcnc_2.5.3.78.g5901d68_i386.deb

there are also debs containing updated doc files.
like
linuxcnc-doc-en_2.5.3.78.g5901d68_all.deb

Good idea to grab that too.
Copy to usb dongle memory device.
paste into the home directory on the target Linuxcnc computer.

and install the update simply by right-clicking the deb file and left clicking "Open with GDebi Package Manager" and installing from there. I got confused because some of the debs were document files, and I was like why did it not update after seeing the same version number. But the real update deb worked fine. This was
linuxcnc_2.5.3.78.g5901d68_i386.deb
for me, but make sure you grab the most recent one appropriate for your system.
After running the installs for the app and the docs, reboot I suppose and check the version numbers. Just run Axis and examine the splash screen at the beginning or click help/about to see the version number.

There is my first lame docmentation attempt for Linuxcnc.

Thanks Chris for your help.

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20 Jan 2015 23:42 #55210 by PCW
The 7I76 potentiometer circuit draws approximately 8 mA. If this is too much of a load for the controller,
external 10 or 12VDC must be supplied. This power source needs to be isolated when used with low cost speed controllers
A 12VDC wall adapter is a possible source.

To set the 7I76 I/O section into mode 2 you change the sserial_port_0=000xxx
token in the hal file to sserial_port_0=200xxx

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